Shop Manual: Dump Truck
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robing8m8cueva8obispCEBM033900
Shop
Manual
980E-5
DUMP TRUCK
SERIAL NUMBERS 980E-5 A50137 – A50138
ENGINE 16V190
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright November 2021
Printed in U.S.A.
Komatsu America Corp.
CEN00064-00
DUMP TRUCK 1SHOP MANUAL
980E
Machine model Serial number
980E-5 A50137, A50138
00 Index and foreword
Index
Composition of shop manual ................................................................................................................................ 2
Table of contents................................................................................................................................................... 4
1
CEN00064-00 00 Index and foreword
Composition of shop manual
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
: New module (to be filed additionally) : Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tab No. with No. indicated next
to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accordingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs CEBM033900
00 Index and foreword
Index CEN00064-00
Foreword, safety and general information CEN00051-01
01 Specification
Specification and technical data CEN01030-00
10 Structure, function and maintenance standard
Steering circuit CEN10062-02
Hoist circuit CEN10067-01
Brake circuits CEN10068-02
Electrical system, 24 volt CEN10107-00
Automatic lubrication (auto lube) system CEN10080-00
20 Standard value table
Standard service value table CEN20012-00
30 Testing and adjusting
Steering, brake cooling and hoist hydraulic system CEN30071-05
Brake system CEN30072-04
Accumulators and suspensions CEN30098-11
Electrical systems CEN30102-02
Interface module 2 (IM2) CEN30125-00
KOMTRAX Plus II CEN30091-00
Payload meter IV CEN30070-03
Komatsu Wireless Bridge (KWB) CEN30101-00
KomVision CEN30105-02
Cab air conditioning CEN30029-01
Automatic lubrication (auto lube) system CEN30129-00
2
00 Index and foreword CEN00064-00
40 Troubleshooting
Fuse, diode and relay locations CEN40199-01
Troubleshooting by failure code, Part 1 CEN40178-01
Troubleshooting by failure code, Part 2 CEN40179-01
Troubleshooting by failure code, Part 3 CEN40180-02
Troubleshooting by failure code, Part 4 CEN40181-03
Troubleshooting by failure code, Part 5 CEN40182-00
Steering system CEN40104-05
KomVision CEN40200-01
Automatic lubrication (auto lube) system CEN40202-00
Electronic fan clutch CEN40256-00
50 Disassembly and assembly
Service tools CEN50046-05
Wheels, spindles and rear axle CEN50107-01
Brake system CEN50023-02
Steering system CEN50045-00
Suspensions CEN50049-01
Hoist circuit CEN50110-00
Body and structures CEN50105-00
Operator cab CEN50108-00
Power module CEN50138-00
90 Diagrams and drawings
Hydraulic circuit diagrams CEN90014-03
Electrical circuit diagrams CEN90033-01
3
CEN00064-00 00 Index and foreword
Table of contents
00 Index and foreword
Index CEN00064-00
Composition of shop manual.....................................................................................................2
Table of contents .......................................................................................................................4
Foreword, safety and general information CEN00051-01
Foreword ...................................................................................................................................4
How to read the shop manual ...................................................................................................5
General safety ...........................................................................................................................7
Precautions before operating the truck ...................................................................................10
Precautions while operating the truck .....................................................................................12
Working near batteries ............................................................................................................15
Precautions before performing service....................................................................................17
Precautions while performing service......................................................................................20
Tires ........................................................................................................................................22
Precautions for performing repairs ..........................................................................................25
Precautions for welding on the truck .......................................................................................26
Control cabinet capacitor discharge system............................................................................27
Handling electrical equipment and hydraulic components ......................................................29
Standard tightening torques ....................................................................................................37
Conversion tables....................................................................................................................43
01 Specification
Specification and technical data CEN01030-00
Specification drawing ................................................................................................................3
Specifications ............................................................................................................................4
Weight table ..............................................................................................................................6
Fuel, coolant and lubricants ......................................................................................................7
10 Structure and functions
Steering circuit CEN10062-02
Steering circuit operation...........................................................................................................2
Steering circuit components ......................................................................................................7
Steering/brake pump operation .................................................................................................9
Flow amplifier operation ..........................................................................................................12
Hoist circuit CEN10067-01
Hoist circuit operation................................................................................................................3
Hoist circuit components ...........................................................................................................4
Hoist pilot valve operation .........................................................................................................8
Brake circuits CEN10068-02
General information...................................................................................................................3
Service brake circuit operation ..................................................................................................4
Secondary braking ....................................................................................................................7
Automatic brake application (Auto apply)..................................................................................7
4
00 Index and foreword CEN00064-00
Parking brake circuit operation.................................................................................................. 8
Wheel brake lock circuit operation ............................................................................................ 9
Brake warning circuit operation................................................................................................. 9
Electrical system, 24 volt CEN10107-00
Battery supply system ............................................................................................................... 3
Isolation box .............................................................................................................................. 4
Engine starting system with prelube ......................................................................................... 5
Auxiliary control cabinet components........................................................................................ 6
Body-up switch.......................................................................................................................... 9
Hoist limit switch........................................................................................................................ 9
Automatic lubrication (auto lube) system CEN10080-00
General information................................................................................................................... 3
System operation ...................................................................................................................... 4
20 Standard value table
Standard value table CEN20012-00
Standard value table for truck ................................................................................................... 3
30 Testing and adjusting
Steering, hoist, brake cooling and auxiliaryhydraulic system CEN30071-05
Hydraulic system bleeddown procedure ................................................................................... 3
Hydraulic system vacuum procedure ........................................................................................ 5
General information on system checkout.................................................................................. 5
Hydraulic system checkout procedures .................................................................................... 6
Hydraulic system checkout data sheet.................................................................................... 17
High altitude steering pump adjustment.................................................................................. 20
Toe-in adjustment.................................................................................................................... 21
Measuring steering pin joint wear ........................................................................................... 22
Hoist cylinder leakage test ...................................................................................................... 25
Steering cylinder leakage test .................................................................................................25
Brake system CEN30072-04
General information on system checkout.................................................................................. 3
Brake system checkout procedures .......................................................................................... 3
Brake system checkout data sheet ......................................................................................... 15
Brake piston leakage test........................................................................................................ 23
Brake seal pressure test ......................................................................................................... 23
Oil separator seal pressure test .............................................................................................. 23
Wet disc brake bleeding procedure......................................................................................... 24
Parking brake bleeding procedure .......................................................................................... 25
Service brake disc wear inspection......................................................................................... 26
Parking brake disc wear inspection......................................................................................... 27
Brake valve bench test and adjustment .................................................................................. 28
Dual relay valve bench test and adjustment ........................................................................... 31
Accumulators and suspensions CEN30098-11
Accumulator charging and storage ........................................................................................... 3
Bladder accumulator charging procedure ................................................................................. 4
5
CEN00064-00 00 Index and foreword
Piston accumulator charging procedure....................................................................................8
Piston accumulator storage..................................................................................................... 11
Piston accumulator leak testing............................................................................................... 11
Checking for improper suspension charge..............................................................................12
Suspension oiling and charging procedures ...........................................................................13
Suspension pressure test........................................................................................................22
Electrical systems CEN30102-02
General information on system checkout ..................................................................................3
Truck shutdown procedure ........................................................................................................4
AC drive system ........................................................................................................................5
Electrical system checkout procedures .....................................................................................6
Electrical checkout sheet.........................................................................................................12
Interface module 2 (IM2) CEN30125-00
Required tools ...........................................................................................................................3
Programming the IM2................................................................................................................3
Interface module checkout procedures .....................................................................................5
IM checkout sheet ...................................................................................................................10
KOMTRAX Plus II CEN30091-01
Required software and tools......................................................................................................3
Ethernet connection to KOMTRAX Plus II controller.................................................................3
KOMTRAX Plus II configuration ................................................................................................5
GPS connection test..................................................................................................................7
Iridium satellite system opening ................................................................................................9
Data download over ethernet connection for KOMTRAX Plus II initialization .........................12
Payload meter IV CEN30070-03
Payload meter IV software and tools.........................................................................................3
Payload meter IV system configuration.....................................................................................3
Payload meter IV software installation ......................................................................................5
Payload meter IV checkout procedure ......................................................................................6
PLM IV system checkout data sheet .......................................................................................12
Downloading PLM IV data and possible errors .......................................................................13
Komatsu wireless bridge (KWB) CEN30101-00
General information...................................................................................................................3
Required software and tools......................................................................................................3
Configuring the Bullet wireless radio .........................................................................................4
Installing the Bullet wireless radio .............................................................................................7
Configuring the NanoStation access point ................................................................................8
Testing the connection............................................................................................................. 11
Changing a service computer’s IP address .............................................................................12
KomVision CEN30105-02
Requirements ............................................................................................................................3
Initial setup ................................................................................................................................3
Checkout data sheet ...............................................................................................................10
Calibration sheets....................................................................................................................15
Camera calibration procedures ...............................................................................................22
Radar setting procedure..........................................................................................................32
6
00 Index and foreword CEN00064-00
Cab air conditioning CEN30029-01
General information................................................................................................................... 3
Service tools and equipment..................................................................................................... 4
Detecting leaks.......................................................................................................................... 7
System performance test .......................................................................................................... 8
Checking system oil .................................................................................................................. 9
System flushing....................................................................................................................... 10
Installing the manifold gauge set............................................................................................. 11
Recovering and recycling refrigerant ...................................................................................... 12
Evacuating the air conditioning system................................................................................... 14
Charging the air conditioning system ...................................................................................... 15
Automatic lubrication (auto lube) system CEN30129-00
Priming the system.................................................................................................................... 3
Checkout procedure.................................................................................................................. 4
Adjusting the lubrication cycle timing ........................................................................................ 5
40 Troubleshooting
Fuse, diode and relay locations CEN40199-01
Vehicle Electrical Center (VEC-89) ........................................................................................... 2
Vehicle Electrical Center (VEC-90) ........................................................................................... 4
Vehicle Electrical Center (VEC-91) ........................................................................................... 6
Vehicle Electrical Center (VEC-92) ........................................................................................... 8
Rear Terminal Mini-fuse and Relay (RTMR3) ........................................................................... 9
Rear Terminal Mini-fuse and Relay (RTMR4) ......................................................................... 10
Circuit breakers ....................................................................................................................... 10
Troubleshooting by fault code, part 1 CEN40178-01
Fault Code A001 ....................................................................................................................... 4
Fault Code A002 ....................................................................................................................... 5
Fault Code A003 ....................................................................................................................... 6
Fault Code A004 ....................................................................................................................... 7
Fault Code A005 ....................................................................................................................... 8
Fault Code A006 ....................................................................................................................... 9
Fault Code A007 ..................................................................................................................... 10
Fault Code A008 ..................................................................................................................... 11
Fault Code A011...................................................................................................................... 12
Fault Code A013 ..................................................................................................................... 13
Fault Code A014 ..................................................................................................................... 14
Fault Code A016 ..................................................................................................................... 15
Fault Code A017 ..................................................................................................................... 16
Fault Code A018 ..................................................................................................................... 17
Fault Code A019 ..................................................................................................................... 18
Fault Code A022 ..................................................................................................................... 19
Fault Code A101 ..................................................................................................................... 20
Fault Code A103 ..................................................................................................................... 21
Fault Code A104 ..................................................................................................................... 22
Fault Code A105 ..................................................................................................................... 23
7
CEN00064-00 00 Index and foreword
Fault Code A109......................................................................................................................24
Fault Code A111 ......................................................................................................................25
Fault Code A115......................................................................................................................27
Fault Code A117......................................................................................................................28
Fault Code A118: Brake pressure is low while in brake lock ...................................................30
Fault Code A123: GE has generated a reduced retarding caution..........................................32
Fault Code A124: GE has generated a no propel / no retard or system not running input......33
Fault Code A125: GE has generated a no propel warning......................................................36
Fault Code A126: Oil level in the hydraulic tank is low............................................................37
Fault Code A127: IM-furnished +5 volt output for sensors is low ............................................38
Fault Code A128: IM-furnished +5 volt output for sensors is high...........................................39
Fault Code A139: Low fuel warning.........................................................................................40
Troubleshooting by fault code, part 2 CEN40179-01
Fault Code A145: Hydraulic oil temp sensors cause engine rpm advance to level 1................4
Fault Code A146: Hydraulic oil temp sensors cause engine rpm advance to level 2................6
Fault Code A152: Starter failure ................................................................................................8
Fault Code A153: Battery voltage is low with the truck in operation........................................10
Fault Code A154: Battery charging voltage is excessive ........................................................13
Fault Code A155: Battery charging voltage is low...................................................................14
Fault Code A158: Fuel level sensor open or shorted high; false low fuel level indicated........16
Fault Code A166: Left rear hydraulic oil temperature sensor is low ........................................18
Fault Code A167: Right rear hydraulic oil temperature sensor is low......................................20
Fault Code A168: Left front hydraulic oil temperature sensor is low .......................................22
Fault Code A169: Right front hydraulic oil temperature sensor is low.....................................24
Fault Code A170: Left rear hydraulic oil temperature sensor is high.......................................26
Fault Code A171: Right rear hydraulic oil temperature sensor is high ....................................27
Fault Code A172: Left front hydraulic oil temperature sensor is high......................................28
Fault Code A173: Right front hydraulic oil temperature sensor is high ...................................29
Fault Code A184: The J1939 data link is not connected .........................................................30
Fault Code A190: The auto lube control has detected an incomplete lube cycle ....................32
Fault Code A193: Hydraulic Tank Oil Temperature is high ......................................................34
Fault Code A194: Left front hydraulic oil temperature is high..................................................35
Fault Code A195: Right front hydraulic oil temperature is high ...............................................36
Fault Code A196: Left rear hydraulic oil temperature is high ..................................................37
Fault Code A197: Right rear hydraulic oil temperature is high ................................................38
Fault Code A198: Hoist Pressure 1 Sensor is high .................................................................39
Fault Code A199: Hoist Pressure 2 Sensor is high .................................................................40
Fault Code A200: Steering Pressure Sensor High ..................................................................41
Fault Code A201: Brake Pressure Sensor High ......................................................................42
Fault Code A202: Hoist Pressure 1 Sensor Low .....................................................................44
Fault Code A203: Hoist Pressure 2 Sensor Low .....................................................................46
Fault Code A204: Steering Pressure Sensor Low...................................................................48
Fault Code A205: Brake Pressure Sensor Low.......................................................................50
Fault Code A206: Ambient Temperature Sensor High.............................................................52
Fault Code A207: Ambient Temperature Sensor Low .............................................................53
Fault Code A213: Parking brake should have applied; detected as not having applied..........54
8
00 Index and foreword CEN00064-00
Fault Code A214: Parking brake should have released; detected as not having released ..... 60
Fault Code A215: Brake auto apply valve circuit is defective.................................................. 66
Fault Code A216: Open or short to ground detected in parking brake command valve circuit70
Fault Code A223: Excessive engine cranking occurred or jump start attempted .................... 74
Fault Code A230: Parking brake has been requested while truck still moving........................ 76
Fault Code A231: The body is up while traveling or intending to travel................................... 80
Fault Code A233: Drive system CAN/RPC Control Link not connected.................................. 84
Fault Code A235: Steering accumulator is in the process of being bled down ....................... 88
Fault Code A236: The steering accumulator has not properly bled after 90 seconds............. 90
Fault Code A237: The CAN/RPC connection to the display is open ....................................... 92
Fault Code A240: The keyswitch input to the Interface Module is open ................................. 93
Fault Code A242: The fuel level gauge in the display panel is defective ................................ 94
Fault Code A243: The engine coolant temp gauge in the display panel is defective ..............95
Fault Code A244: The drive system temp gauge in the dash display panel is defective......... 96
Fault Code A245: The hydraulic oil temp gauge in the display panel is defective................... 97
Fault Code A246: PLM reports truck overload ........................................................................ 98
Troubleshooting by fault code, part 3 CEN40180-02
Fault Code A247: Low steering pressure warning .................................................................... 4
Fault Code A248: Status module within the dash display panel is defective ............................ 7
Fault Code A249: Red warning lamp in the display panel is shorted ........................................ 9
Fault Code A250: Battery voltage is low with the truck parked ............................................... 11
Fault Code A251: Sonalert circuit is open or shorted to ground.............................................. 15
Fault Code A252: Start enable output circuit is either open or shorted to ground................... 17
Fault Code A253: Steering bleed circuit is not open while running ......................................... 19
Fault Code A256: Red warning lamp in the display panel is open .......................................... 21
Fault Code A257: Payload CAN/RPC is not connected .......................................................... 23
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective ................ 24
Fault Code A260: Parking brake failure .................................................................................. 25
Fault Code A261: Low brake accumulator pressure warning.................................................. 27
Fault Code A262: Steering bleed valve circuit open during shutdown .................................... 31
Fault Code A264: Parking brake relay circuit is defective ....................................................... 34
Fault Code A265: Service brake failure................................................................................... 37
Fault Code A266: Shift lever was not in park while attempting to crank engine...................... 39
Fault Code A267: Parking brake was not set while attempting to crank engine ..................... 41
Fault Code A268: Secondary engine shutdown while cranking .............................................. 43
Fault Code A270: Brake lock switch power supply is not on when required ........................... 45
Fault Code A272: Brake lock switch power supply is not off when required ........................... 48
Fault Code A273: Hoist filter or steering filter pressure switch circuit fault detected............... 51
Fault Code A274: A brake setting fault has been detected ..................................................... 52
Fault Code A275: A starter has been detected as engaged without a cranking attempt......... 55
Fault Code A277: Parking brake applied while loading........................................................... 57
Fault Code A278: Service brake applied while loading ........................................................... 59
Fault Code A279: Low Steering Pressure Switch bad ............................................................ 61
Fault Code A280: Steering accumulator bleed down switch is defective ................................ 63
Fault Code A281: Brake lock degrade switch is defective ...................................................... 65
Fault Code A282: Excessive cranking counts or jump starts without the engine running ....... 67
9
CEN00064-00 00 Index and foreword
Fault Code A283: Engine shutdown delay aborted; parking brake not set..............................69
Fault Code A284: Engine shutdown delay aborted; secondary shutdown switch operated ....73
Fault Code A285: The parking brake was not set when the keyswitch was turned off............77
Fault Code A286: A fault was detected in the shutdown delay relay circuit.............................79
Fault Code A292: Shutdown delay relay stays on after latched key switch circuit is off .........81
Troubleshooting by fault code, part 4 CEN40181-03
Fault Code A303: Shift lever is defective...................................................................................4
Fault Code A304: Auto lube grease level fault ..........................................................................6
Fault Code A305: Auto lube circuit is defective ........................................................................7
Fault Code A307: Both GE inverters are disabled.....................................................................8
Fault Code A309: No brakes applied when expected .............................................................10
Fault Code A310: Low fuel warning.........................................................................................12
Fault Code A311: Brake lock switch is on when it should not be ............................................14
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings ...........16
Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings...........17
Fault Code A315: DCDC converter 12 volt circuit is low .........................................................18
Fault Code A316: Starter engagement has been attempted with engine running...................20
Fault Code A317: Operation of brake auto apply circuit without a detected response............22
Fault Code A318: Unexpected power loss to interface module...............................................24
Fault Code A328: Drive system not powered up .....................................................................25
Fault Code A332: Seat belt not buckled ..................................................................................26
Fault Code A333: The hydraulic ladder controller has declared a ladder fault ........................28
Fault Code A334: Shift lever not in park when propel was either not ready or at rest.............30
Fault Code A335: Manual/Auto Apply Pressure Fault .............................................................32
Fault Code A337: Engine Air Filter Circuit Fault ......................................................................33
Fault Code A338: Engine Air Filter Fault .................................................................................34
Fault Code A339: The DEF level gauge in the display panel is defective ...............................35
Fault Code A340: The shifter controller has declared a fault ..................................................36
Fault Code A341: The shifter control circuit is defective .........................................................37
Fault Code A342: The Accessory Pump Filter Switch has actuated .......................................39
Fault Code A343: Truck speed is limited by GE ......................................................................40
Fault Code A344: GE has posted a No Retarding fault...........................................................41
Fault Code A345: Engine speed limited by GE .......................................................................42
Fault Code A346: Delayed Shut Down by GE.........................................................................43
Fault Code A347: Operator Override of GE is active ..............................................................44
Fault Code A348: GE has disabled load box operation...........................................................45
Fault Code A349: GE has limited load box operation..............................................................46
Fault Code A350: Overload on output 1B................................................................................47
Fault Code A351: Overload on output 1E................................................................................49
Fault Code A352: Overload on output 1H ...............................................................................51
Fault Code A353: Overload on output 1J ................................................................................53
Fault Code A354: Overload on output 1K................................................................................55
Fault Code A355: Overload on output 1L ................................................................................56
Fault Code A356: Overload on output 1M ...............................................................................57
Fault Code A357: Overload on output 1N ...............................................................................59
Fault Code A358: Overload on output 1P................................................................................61
10
00 Index and foreword CEN00064-00
Fault Code A359: Overload on output 1R ............................................................................... 63
Fault Code A360: Overload on output 1S ............................................................................... 65
Fault Code A361: Overload on output 1T................................................................................ 66
Fault Code A362: Overload on output 1U ............................................................................... 67
Fault Code A363: Overload on output 1X ............................................................................... 68
Fault Code A364: Overload on output 1Y ............................................................................... 69
Fault Code A365: Overload on output 1Z................................................................................ 70
Fault Code A366: Axle box cooling fault.................................................................................. 71
Troubleshooting by fault code, part 5 CEN40182-00
Fault Code A400: Tire 1 (Front Left) High Pressure RED ......................................................... 4
Fault Code A401: Tire 1 (Front Left) High Pressure AMBER .................................................... 5
Fault Code A402: Tire 1 (Front Left) Low Pressure RED .......................................................... 6
Fault Code A403: Tire 1 (Front Left) Low Pressure AMBER ..................................................... 7
Fault Code A404: Tire 1 (Front Left) No Data / Sensor Failure / Not Connected ...................... 8
Fault Code A405: Tire 1 (Front Left) High Temperature RED.................................................... 9
Fault Code A406: Tire 1 (Front Left) High Temperature AMBER............................................. 10
Fault Code A407: Tire 1 (Front Left) Bad Value Sensor Error / Not Connected ...................... 11
Fault Code A408: Tire 2 (Front Right) High Pressure RED..................................................... 12
Fault Code A409: Tire 2 (Front Right) High Pressure AMBER................................................ 13
Fault Code A410: Tire 2 (Front Right) Low Pressure RED...................................................... 14
Fault Code A411: Tire 2 (Front Right) Low Pressure AMBER ................................................. 15
Fault Code A412: Tire 2 (Front Right) No Data / Sensor Failure / Not Connected.................. 16
Fault Code A413: Tire 2 (Front Right) High Temperature RED ............................................... 17
Fault Code A414: Tire 2 (Front Right) High Temperature AMBER .......................................... 18
Fault Code A415: Tire 2 (Front Right) Bad Value Sensor Error / Not Connected.................... 19
Fault Code A416: Tire 3 (Rear Left Outboard) High Pressure RED........................................ 20
Fault Code A417: Tire 3 (Rear Left Outboard) High Pressure AMBER................................... 21
Fault Code A418: Tire 3 (Rear Left Outboard) Low Pressure RED......................................... 22
Fault Code A419: Tire 3 (Rear Left Outboard) Low Pressure AMBER.................................... 23
Fault Code A420: Tire 3 (Rear Left Outboard) No Data / Sensor Failure / Not Connected..... 24
Fault Code A421: Tire 3 (Rear Left Outboard) High Temperature RED .................................. 25
Fault Code A422: Tire 3 (Rear Left Outboard) High Temperature AMBER ............................. 26
Fault Code A423: Tire 3 (Rear Left Outboard) Bad Value Sensor Error / Not Connected....... 27
Fault Code A424: Tire 4 (Rear Left Inboard) High Pressure RED...........................................28
Fault Code A425: Tire 4 (Rear Left Inboard) High Pressure AMBER...................................... 29
Fault Code A426: Tire 4 (Rear Left Inboard) Low Pressure RED ...........................................30
Fault Code A427: Tire 4 (Rear Left Inboard) Low Pressure AMBER ...................................... 31
Fault Code A428: Tire 4 (Rear Left Inboard) No Data / Sensor Failure / Not Connected ....... 32
Fault Code A429: Tire 4 (Rear Left Inboard) High Temperature RED ..................................... 33
Fault Code A430: Tire 4 (Rear Left Inboard) High Temperature AMBER ................................ 34
Fault Code A431: Tire 4 (Rear Left Inboard) Bad Value Sensor Error / Not Connected ......... 35
Fault Code A432: Tire 5 (Rear Right Inboard) High Pressure RED ........................................ 36
Fault Code A433: Tire 5 (Rear Right Inboard) High Pressure AMBER ................................... 37
Fault Code A434: Tire 5 (Rear Right Inboard) Low Pressure RED ......................................... 38
Fault Code A435: Tire 5 (Rear Right Inboard) Low Pressure AMBER .................................... 39
Fault Code A436: Tire 5 (Rear Right Inboard) No Data / Sensor Failure / Not Connected ..... 40
11
CEN00064-00 00 Index and foreword
Fault Code A437: Tire 5 (Rear Right Inboard) High Temperature RED...................................41
Fault Code A438: Tire 5 (Rear Right Inboard) High Temperature AMBER..............................42
Fault Code A439: Tire 5 (Rear Right Inboard) Bad Value Sensor Error / Not Connected .......43
Fault Code A440: Tire 6 (Rear Right Outboard) High Pressure RED......................................44
Fault Code A441: Tire 6 (Rear Right Outboard) High Pressure AMBER.................................45
Fault Code A442: Tire 6 (Rear Right Outboard) Low Pressure RED ......................................46
Fault Code A443: Tire 6 (Rear Right Outboard) Low Pressure AMBER .................................47
Fault Code A444: Tire 6 (Rear Right Outboard) No Data / Sensor Failure / Not Connected ..48
Fault Code A445: Tire 6 (Rear Right Outboard) High Temperature RED ................................49
Fault Code A446: Tire 6 (Rear Right Outboard) High Temperature AMBER ...........................50
Fault Code A447: Tire 6 (Rear Right Outboard) Bad Value Sensor Error / Not Connected ....51
Steering system CEN40104-05
Steering circuit troubleshooting chart ........................................................................................3
Steering circuit troubleshooting guidelines................................................................................5
Basic hydraulic system checks..................................................................................................6
System leakage check ..............................................................................................................7
Steering pump troubleshooting guide........................................................................................9
Pump pressure control checks ................................................................................................12
KomVision CEN40200-01
KomVision fault codes...............................................................................................................3
Automatic lubrication (auto lube) system CEN40202-00
Autolube troubleshooting chart..................................................................................................3
Electronic fan clutch CEN40256-00
Electronic fan clutch troubleshooting.........................................................................................3
50 Disassembly and assembly
Service tools CEN50046-05
Special tool group......................................................................................................................3
Additional service tools..............................................................................................................4
KomVision calibration tools .......................................................................................................4
Locally made tools.....................................................................................................................4
Wheels, spindles and rear axle CEN50107-01
General precautions for tires and rims ......................................................................................3
Rim components .......................................................................................................................4
Wheel stud maintenance...........................................................................................................5
Removal and installation of front wheel.....................................................................................6
Removal and installation of rear wheel .....................................................................................8
Rim and tire service................................................................................................................. 11
Removal and installation of front wheel hub and spindle ........................................................25
Disassembly and assembly of front wheel hub and spindle....................................................32
Hub floating ring seal assembly and installation .....................................................................49
Removal and installation of rear axle ......................................................................................56
Removal and installation of anti-sway bar...............................................................................59
Removal and installation of pivot pin.......................................................................................62
Pivot eye and bearing service .................................................................................................64
Removal and installation of wheel motor.................................................................................66
12
00 Index and foreword CEN00064-00
Removal and installation of rear brake assembly ................................................................... 73
Brake system CEN50023-02
Removal and installation of brake valve.................................................................................... 3
Disassembly and assembly of brake valve/pedal assembly ..................................................... 5
Removal and installation of dual relay valve ............................................................................. 8
Removal and installation of brake manifold ............................................................................ 11
Disassembly and assembly of brake manifold ........................................................................ 12
Removal and installation of piston brake accumulator............................................................ 13
Disassembly and assembly of piston brake accumulator ....................................................... 15
Disassembly and assembly of front wheel brake .................................................................... 19
Disassembly and assembly of rear wheel brake..................................................................... 25
Brake floating ring seal assembly and installation .................................................................. 33
Removal and installation of parking brake .............................................................................. 40
Disassembly and assembly of parking brake.......................................................................... 42
Steering system CEN50045-00
Removal and installation of steering control unit....................................................................... 3
Disassembly and assembly of steering control unit .................................................................. 5
Removal and installation of steering column........................................................................... 10
Removal and installation of steering wheel............................................................................. 12
Removal and installation of bleeddown manifold .................................................................... 13
Removal and installation of flow amplifier ............................................................................... 15
Removal and installation of steering cylinders and tie rod ...................................................... 16
Disassembly and assembly of steering cylinders.................................................................... 18
Removal and installation of steering/brake pump ................................................................... 21
Removal and installation of piston steering accumulator ........................................................23
Disassembly and assembly of piston steering accumulator.................................................... 25
Suspensions CEN50049-01
Removal and installation of front suspension............................................................................ 3
Disassembly and assembly of front suspension ..................................................................... 11
Removal and installation of rear suspension .......................................................................... 16
Disassembly and assembly of rear suspension ...................................................................... 20
Hoist circuit CEN50110-00
Removal and installation of hoist pump .................................................................................... 3
Disassembly and assembly of hoist pump ................................................................................ 8
Removal and installation of hoist valve ................................................................................... 17
Disassembly and assembly of hoist valve............................................................................... 19
Overcenter manifold service ................................................................................................... 27
Removal and installation of hoist pilot valve ........................................................................... 28
Disassembly and assembly of hoist pilot valve ....................................................................... 31
Removal and installation of hoist cylinders ............................................................................. 33
Disassembly and assembly of hoist cylinders......................................................................... 36
Body and structures CEN50105-00
Removal and installation of dump body .................................................................................... 3
Removal and installation of body pads ..................................................................................... 6
Removal and installation of diagonal ladder/hood and grille assembly..................................... 8
Removal and installation of RH deck ...................................................................................... 10
13
CEN00064-00 00 Index and foreword
Removal and installation of LH deck .......................................................................................12
Removal and installation of fuel tank.......................................................................................14
Removal and installation of fuel gauge sender .......................................................................16
Removal and installation of hydraulic tank ..............................................................................17
Removal and installation of hydraulic tank strainers ...............................................................19
Operator cab CEN50108-00
Removal and installation of operator cab ..................................................................................3
Removal and installation of cab door ........................................................................................6
Disassembly and assembly of cab door....................................................................................8
Adjustment of cab door ...........................................................................................................16
Removal and installation of side window glass .......................................................................18
Removal and installation of windshield and rear window glass...............................................21
Removal and installation of windshield wiper components .....................................................22
Removal and installation of cab seats.....................................................................................24
Removal and installation of seat belts.....................................................................................26
Power module CEN50138-00
Removal and installation of power module................................................................................3
Removal and installation of alternator .....................................................................................18
Engine / alternator attachment checkout data sheet ...............................................................29
Additional engine measurements ............................................................................................31
Removal and installation of the cooling module ......................................................................35
Repairing the radiator..............................................................................................................40
Removal and installation of engine .........................................................................................43
90 Diagrams and drawings
Hydraulic circuit diagrams CEN90014-03
Steering, hoist and brake cooling hydraulic circuit schematic .............................. 58B-60-21400
Brake hydraulic circuit schematic ......................................................................... 58F-60-00841
Auxiliary system hydraulic circuit schematic ........................................................ 58E-60-01680
Electrical circuit diagrams CEN90033-01
Electrical circuit diagram ...................................................................................... 58B-06-05901
HVAC circuit diagram ........................................................................................... 58B-06-06830
14
00 Index and foreword CEN00064-00
NOTES
15
CEN00064-00 00 Index and foreword
980E Dump truck
Form No. CEN00064-00
16
CEN00051-01
DUMP TRUCK 1SHOP MANUAL
980E
Machine model Serial number
980E-5 A50137, A50138
00 Index and foreword
Foreword, safety and general information
Foreword............................................................................................................................................................... 4
How to read the shop manual ............................................................................................................................... 5
General safety....................................................................................................................................................... 7
Precautions before operating the truck ............................................................................................................... 10
Precautions while operating the truck ................................................................................................................. 12
Working near batteries ........................................................................................................................................ 15
Precautions before performing service ............................................................................................................... 17
Precautions while performing service ................................................................................................................. 20
Tires .................................................................................................................................................................... 22
Precautions for performing repairs...................................................................................................................... 25
Precautions for welding on the truck................................................................................................................... 26
Control cabinet capacitor discharge system ....................................................................................................... 27
Handling electrical equipment and hydraulic components .................................................................................. 29
Standard tightening torques ................................................................................................................................ 37
Conversion tables ............................................................................................................................................... 43
1
CEN00051-01 00 Index and foreword
This material is proprietary to Komatsu America
Corp (KAC), and is not to be reproduced, used, or
disclosed except in accordance with written autho-
rization from KAC.
It is the policy of the Company to improve products
whenever it is possible and practical to do so. The
Company reserves the right to make changes or
add improvements at any time without incurring
any obligation to install such changes on products
sold previously.
Because of continuous research and development,
periodic revisions may be made to this publication.
Customers should contact their local Komatsu dis-
tributor for information on the latest revision.
Unsafe use of this machine may cause serious injury or death. Operators and maintenance person-
nel must read and understand this manual before operating or maintaining this machine.
This manual should be kept in or near the machine for reference, and periodically reviewed by all
personnel who will come into contact with it.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust, some of its constituents, and certain vehicle components contain or emit
chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals and related accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and birth defects or other reproductive harm. Wash
hands after handling.
CALIFORNIA
Proposition 65 Warning
Mercury and mercury compounds are known to the State of California to cause developmental prob-
lems. This machine may be equipped with optional HID lamps which contain mercury. There is no
risk of exposure unless the lamps are broken. However, the lamps must be reused, recycled or prop-
erly disposed of in accordance with Local, State and Federal Laws at the end of their useful lives.
2
00 Index and foreword CEN00051-01
NON-OEM PARTS IN CRITICAL SYSTEMS
For safety reasons, Komatsu America Corp. strongly recommends against the use
of non-OEM replacement parts in critical systems of all Komatsu equipment. Critical
systems include but are not limited to steering, braking and operator safety sys-
tems.
Replacement parts manufactured and supplied by unauthorized sources may not be
designed, manufactured or assembled to Komatsu's design specifications; accord-
ingly, use of such parts may compromise the safe operation of Komatsu products
and place the operator and others in danger should the part fail.
Komatsu is also aware of repair companies that will rework or modify an OEM part
for reuse in critical systems. Komatsu does not generally authorize such repairs or
modifications for the same reasons as noted above.
Use of non-OEM parts places full responsibility for the safe performance of the
Komatsu product on the supplier and user. Komatsu will not in any case accept
responsibility for the failure or performance of non-OEM parts in its products,
including any damages or personal injury resulting from such use.
3
CEN00051-01 00 Index and foreword
Foreword A product identification plate is located on the frame in
front of the right side front wheel. It designates the
This manual is written for use by the operator and/or
Truck Model Number, Product Identification Number
the service technician. It is designed to help these
(vehicle serial number), and Maximum GVW (Gross
persons to become fully knowledgeable of the truck
Vehicle Weight) rating.
and all of its systems in order to keep it operating
safely and efficiently. All operators and maintenance The KOMATSU truck model designation consists of
personnel should read and understand the information three numbers and one letter (i.e. 960E).
in this manual before operating the truck or performing The three numbers represent the basic truck
maintenance and/or operational checks on the truck. model.
All safety notices, warnings, and cautions should be
The letter “E” designates an Electrical wheel
understood and followed when operating the truck or
motor drive system.
performing repairs on the truck.
The Product Identification Number (vehicle serial
The first section covers component descriptions, truck
number) contains information which identifies several
specifications and safe work practices, as well as other
characteristics of this unit. For a more detailed
general information. The major portion of the manual
explanation, refer to the Operation and Maintenance
pertains to disassembly, service and reassembly. Each
Manual.
major serviceable area is dealt with individually. For
example, the disassembly, service and reassembly of The Gross Vehicle Weight (GVW) is what determines
the radiator group is discussed as a unit. The same is the load on the drive train, frame, tires, and other
true of the engine and engine accessories, and so on components. The vehicle design and application
through the entire mechanical detail of the truck. guidelines are sensitive to the maximum GVW.
Disassembly should be carried only as far as GVW is total weight: empty vehicle weight + fuel &
necessary to accomplish needed repairs. lubricants + payload.
The illustrations used in this manual are typical of the To determine the allowable payload, fill all lubricants to
component shown and may not be an exact the proper level and fill the fuel tank of an empty truck
reproduction of what is found on the truck. (which includes all accessories, body liners, tailgates,
etc.), and then weigh the truck. Record this value and
This manual shows dimensioning of U.S. standard and
subtract it from the GVW. The result is the allowable
metric (SI) units throughout. All references to “right,”
payload.
“left,” “front,” or “rear” are made with respect to the
operator's normal seated position unless specifically NOTE: Accumulations of mud, frozen material, etc,
stated otherwise. become part of the GVW and reduces the allowable
When assembly instructions are provided without payload. To maximize payload and to keep from
references to specific torque values, standard torque exceeding the maximum GVW rating, these
values should be used. Standard torque values are accumulations should be removed as often as
shown in torque charts later in this section. Specific practical.
torques, when provided in the text, are in bold face Exceeding the allowable payload will reduce the
type, such as 135 N·m (100 ft lb). All torque expected life of truck components.
specifications have ±10% tolerance unless otherwise
specified.
4
00 Index and foreword CEN00051-01
How to read the shop manual
• Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
• Materials and specifications are subject to change without notice.
• Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The
structure and function sub-section explains the structure and function of each component. It serves not
only to give an understanding of the structure, but also serves as reference material for troubleshooting.
The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgment criteria for testing, adjusting,
and troubleshooting. This standard value table is used to check the standard values in testing and adjust-
ing and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgment criteria for testing and adjusting are
explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by
failure modes.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and weight of
components are also explained.
90. Diagrams and drawings
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Revision and distribution
Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-
date information before you start any work.
5
CEN00051-01 00 Index and foreword
Symbols
This “ALERT” symbol is used with the signal words,
“DANGER”, “WARNING”, and “CAUTION” in this
manual to alert the reader to hazards arising from
improper operating and maintenance practices.
“DANGER” identifies a specific potential hazard WHICH WILL
RESULT IN EITHER INJURY OR DEATH if proper precautions
are not taken.
“WARNING” identifies a specific potential hazard WHICH MAY
RESULT IN EITHER INJURY OR DEATH if proper precautions
are not taken.
“CAUTION” is used for general reminders of proper safety
practices OR to direct the reader’s attention to avoid unsafe
or improper practices which may result in damage to the
equipment.
6
00 Index and foreword CEN00051-01
General safety Fire extinguisher and first aid kit
Safety records from most organizations will show that • Make sure that fire extinguishers are accessible
the greatest percentage of accidents are caused by and proper usage techniques are known.
unsafe acts performed by people. The remainder are • Provide a first aid kit at the storage point.
caused by unsafe mechanical or physical conditions.
Report all unsafe conditions to the proper authority. • Know what to do in the event of a fire.
The following safety rules are provided as a guide for • Keep the phone numbers of persons you should
the operator. However, local conditions and regulations contact in case of an emergency on hand.
may add many more to this list.
Read and follow all safety precautions. Failure to
do so may result in serious injury or death.
Safety rules Clothing and personal items
• Only trained and authorized personnel may • Avoid loose clothing, jewelry, and loose long hair.
operate and maintain the truck. They can catch on controls or in moving parts and
• Follow all safety rules, precautions and instructions cause serious injury or death. Also, never wear oily
when operating or performing maintenance on the clothes as they are flammable.
truck. • Wear a hard hat, safety glasses, safety shoes,
• Follow the local safety statutes and laws when mask and gloves when operating or maintaining a
working with electrical components. truck. Always wear safety goggles, hard hat and
heavy gloves if your job involves scattering metal
• When working with another operator or a person chips or minute materials, particularly when driving
on work site traffic duty, make sure that all pins with a hammer or when cleaning air cleaner
personnel understand all hand signals that are to elements with compressed air. Also, ensure that
be used. the work area is free from other personnel during
such tasks.
Safety features
• Make sure that all guards and covers are in their
proper position. Have any damaged guards and
covers repaired.
• Learn the proper use of safety features such as
safety locks, safety pins, and seat belts. Use these
safety features properly.
• Never remove any safety features. Always keep
them in good operating condition.
• Improper use of safety features could result in
serious bodily injury or death.
• Check the seat belt fabric, buckle and hardware for
damage or wear. Replace any worn or damaged
parts immediately.
• The seat belts must be replaced 5 years after seat
belt manufacture, or after every 3 years of use,
whichever comes first.
7
CEN00051-01 00 Index and foreword
Leaving the operator seat Fire prevention for fuel and oil
When preparing to leave the operator's seat, do not • Fuel, oil, and antifreeze can be ignited by a flame.
touch any control lever that is not locked. To prevent Fuel is extremely flammable and can be
accidental operations from occurring, always perform hazardous. Keep flames away from flammable
the following: fluids.
• Move the directional control lever to PARK. Do not • Keep oil and fuel in a designated location and do
use the wheel brake lock when the engine will not allow unauthorized persons to enter.
be turned off. • When refueling, stop the engine and do not smoke.
• Lower the dump body to the frame. • Refueling and oiling should be done in well
• Stop the engine. When exiting the truck, always ventilated areas.
lock compartments and take the keys with you. If • Tighten all fuel and oil tank caps securely.
the truck should suddenly move or move in an
unexpected way, this may result in serious bodily
injury or death.
Mounting and dismounting
• Use the handrails and steps when getting on or off
the truck.
• Never jump on or off the truck. Never climb on or
off a truck while it is moving.
• When climbing on or off a truck, face the truck and
use the hand-hold and steps.
• Never hold any control levers when getting on or
off a truck.
• Always maintain three-point contact with the hand-
holds and steps to ensure that you support
yourself.
• When bringing tools into the operator's
compartment, always pass them by hand or pull
them up by rope.
• If there is any oil, grease, or mud on the hand-
holds or steps, wipe them clean immediately.
Always keep these components clean. Repair any
damage and tighten any loose bolts.
8
00 Index and foreword CEN00051-01
Precautions with high temperature fluids Prevention of injury by work equipment
Immediately after truck operation, engine coolant, Never enter or put your hand, arm or any other part of
engine oil, and hydraulic oil are at high temperatures your body between movable parts such as the dump
and are pressurized. If the cap is removed, the fluids body, chassis or cylinders. If the work equipment is
are drained, the filters are replaced, etc., there is operated, clearances will change and may lead to
danger of serious burns. Allow heat and pressure to serious bodily injury or death.
dissipate before performing such tasks and follow
proper procedures as outlined in the service manual.
Unauthorized modification
Any modification made to this vehicle without
authorization from Komatsu America Corp. can
possibly create hazards.
Before making any modification, consult the authorized
regional Komatsu America Corp. distributor. Komatsu
will not be responsible for any injury or damage caused
by any unauthorized modification.
To prevent hot coolant from spraying:
1. Stop the engine.
Precautions when using ROPS
2. Wait for the coolant temperature to decrease.
3. Depress the pressure release button on the cap The ROPS is intended to protect the operator if the
to vent cooling system pressure. truck should roll over. It is designed not only to support
the load of the truck, but also to absorb the energy of
4. Turn the radiator cap slowly to release the the impact.
pressure before removing.
• The Rollover Protection Structure (ROPS) must be
To prevent hot engine oil spray: properly installed before the truck is operated.
1. Stop the engine. • ROPS installed on equipment manufactured and
2. Wait for the oil temperature to cool down. designed by Komatsu America Corp. fulfills all of
the regulations and standards for all countries. If it
3. Turn the cap slowly to release the pressure is modified or repaired without authorization from
before removing the cap. Komatsu, or if it is damaged when the truck rolls
over, the strength of the structure will be
compromised and will not be able to fulfill its
intended purpose. Optimum strength of the
Asbestos dust hazard prevention structure can only be achieved if it is repaired or
Asbestos dust is hazardous to your health when modified as specified by Komatsu.
inhaled. If you handle materials containing asbestos • When modifying or repairing the ROPS, always
fibers, follow the guidelines below: consult your nearest Komatsu distributor.
• Never use compressed air for cleaning.
• Use water for cleaning to control dust.
• Operate the truck or perform tasks with the wind to
your back whenever possible.
• Use an approved respirator when necessary.
9
CEN00051-01 00 Index and foreword
Precautions for attachments Precautions before operating the truck
• When installing and using optional equipment, Safety is thinking ahead. Prevention is the best safety
read the instruction manual for the attachment and program. Prevent a potential accident by knowing the
the information related to attachments in this employer's safety requirements and all necessary job
manual. site regulations. In addition, know the proper use and
• Do not use attachments that are not authorized by care of all the safety equipment on the truck. Only
Komatsu America Corp. or the authorized regional qualified operators or technicians should attempt to
Komatsu distributor. Use of unauthorized operate or maintain a Komatsu machine.
attachments could create a safety problem and
adversely affect the proper operation and useful Safe practices start before the operator gets to the
life of the truck. equipment.
• Any injuries, accidents, and product failures Safety at the worksite
resulting from the use of unauthorized attachments
will not be the responsibility of Komatsu America • When walking to and from a truck, maintain a safe
Corp. or the authorized regional Komatsu distance from all machines even when the operator
distributor. is visible.
• Before starting the engine, thoroughly check the
area for any unusual conditions that could be
Precautions for starting the truck dangerous.
Start the engine from the operator seat only. Never • Examine the road surface at the job site and
attempt to start the engine by shorting across the determine the best and safest method of
cranking motor terminals. This may cause a fire, operation.
serious injury or death to anyone in truck’s path. • Choose an area where the ground is as horizontal
and firm as possible before performing the
operation.
• If you need to operate on or near a public road,
protect pedestrians and cars by designating a
person for work site traffic duty or by installing
fences around the work site.
• The operator must personally check the work area,
the roads to be used, and the existence of
obstacles before starting operations.
• Always determine the travel roads at the work site
and maintain them so that it is always safe for the
machines to travel.
• If travel through wet areas is necessary, check the
depth and flow of water before crossing the
shallow parts. Never drive through water that
exceeds the permissible water depth.
10
00 Index and foreword CEN00051-01
Fire prevention Mirrors, windows and lights
• Remove wood chips, leaves, paper, and other • Remove any dirt from the surface of the
flammable items that have accumulated in the windshield, cab windows, mirrors and lights. Good
engine compartment. Failure to do so could result visibility may prevent an accident.
in a fire.
• Adjust the rear view mirror to a position where the
• Check the fuel, lubrication, and hydraulic systems operator can see best from the operator's seat. If
for leaks. Repair any leaks. Clean any excess oil, any glass or light is broken, replace it with a new
fuel or other flammable fluids, and dispose of them part.
properly.
• Make sure that the headlights, work lights, and
• Make sure that a fire extinguisher is present and in taillights are in proper working order. Make sure
proper working condition. that the truck is equipped with the proper work
lamps that are needed for the operating conditions.
• Do not operate the truck near open flames.
In operator cab (before starting the engine)
• Do not leave tools or spare parts lying around. Do
not allow trash to accumulate in the cab of the
truck. Keep all unauthorized reading material out
of the truck cab.
• Keep the cab floor, controls, steps and handrails
free of oil, grease, snow and excess dirt.
Ventilation in enclosed areas • Read and understand the contents of this manual.
Pay special attention to the sections pertaining to
If it is necessary to start the engine within an enclosed safety and operating instructions. Become
area, provide adequate ventilation. Inhaling exhaust thoroughly acquainted with all gauges, instruments
fumes from the engine can kill. and controls before attempting operation of the
truck.
• Read and understand the WARNING and
CAUTION decals in the operator's cab.
• Make sure that the steering wheel, horn, controls
and pedals are free of any oil, grease or mud.
• Check the operation of the windshield wiper,
condition of wiper blades, and the washer fluid
reservoir level.
• Be familiar with all steering and brake system
Preparing for operation controls, warning devices, road speeds and
loading capabilities before operating the truck.
• Always mount and dismount while facing the truck.
Never attempt to mount or dismount the truck while Seat Belts
it is in motion. Always use handrails and ladders
when mounting or dismounting the truck. • On both driver and passenger seats, check the
seat belt fabric, buckle, all belt retractors and
• Check the deck areas for debris, loose hardware hardware for damage or wear. Replace any worn
and tools. Check for people and objects that might or damaged parts immediately.
be in the area.
• Even if there are no signs of damage, replace both
• Become familiar with and use all protective driver and passenger seat belts 5 years after seat
equipment devices on the truck and ensure that belt manufacture, or every 3 years after start of
these items (anti-skid material, grab bars, seat use, whichever comes first. The passenger seat
belts, etc.) are securely in place. belt date of manufacture label is sewn into the seat
belt near the buckle. The driver seat belt date of
manufacture label is sewn into the shoulder
harness belt, near the retractor end.
11
CEN00051-01 00 Index and foreword
Precautions while operating the truck
When starting the engine
• Never attempt to start the engine by shorting
across cranking motor terminals. This may cause a
fire, or serious injury or death to anyone in truck’s The tire and rim assembly may explode if
path. subjected to excessive heat. Personnel should
move to a remote or protected location if sensing
• Never start the engine if a warning tag has been excessively hot brakes, smelling burning rubber or
attached to the controls.
observing evidence of fire near the tire and wheel
• When starting the engine, sound the horn as an area.
alert.
If the truck must be approached to extinguish a
• Start and operate the truck only while seated in the fire, those personnel should do so only while
operator’s seat. facing the tread area of the tire (front or back)
• Do not allow any unauthorized persons in the unless protected by using large heavy equipment
operator's compartment or any other place on the as a shield. Stay at least 15 m (50 ft) from the tread
truck. of the tire.
General truck operation In the event of fire in the tire and wheel area
(including brake fires), stay away from the truck
• Wear the seat belt at all times. for at least 8 hours or until the tire and wheel are
• Only authorized persons are allowed to ride in the cool.
truck. Riders must be in the cab and belted in the • Keep serviceable fire fighting equipment on hand.
passenger seat. Report empty extinguishers for replacement or
• Do not allow anyone to ride on the decks or steps refilling.
of the truck. • Always place the directional control lever in the
• Do not allow anyone to get on or off the truck while PARK position when the truck is parked and
it is in motion. unattended. Do not leave the truck unattended
while the engine is running.
• Do not move the truck in or out of a building
without a signal person present. NOTE: DO NOT use wheel brake lock when parking
the truck.
• Know and obey the hand signal communications
between operator and spotter. When other • Park the truck a safe distance away from other
machines and personnel are present, the operator vehicles as determined by the supervisor.
should move in and out of buildings, loading areas,
• Stay alert at all times! In the event of an
and through traffic under the direction of a signal
emergency, be prepared to react quickly and avoid
person. Courtesy at all times is a safety
accidents. If an emergency arises, know where to
precaution.
get prompt assistance.
• Immediately report any adverse conditions at the
haul road, pit or dump area that may cause an
operating hazard.
Ensuring good visibility
• Check for flat tires periodically during a shift. If the
truck has been operating on a “flat”, do not park • When working in dark places, install work lamps
the truck inside a building until the tire cools. If the and head lamps. Set up extra lighting in the work
tire must be changed, do not stand in front of the area if necessary.
rim and locking ring when inflating a tire mounted • Discontinue operations if visibility is poor, such as
on the truck. Observers should not be permitted in in mist, snow, or rain. Wait for the weather to
the area and should be kept away from the side of improve to allow the operation to be performed
such tires. safely.
12
00 Index and foreword CEN00051-01
Traveling Traveling on slopes
• When traveling on rough ground, travel at low • Traveling on slopes could result in the truck tipping
speeds. When changing direction, avoid turning over or slipping.
suddenly.
• Do not change direction on slopes. To ensure
• Lower the dump body and set the dump lever to safety, drive to level ground before turning.
the FLOAT position before traveling.
• Do not travel up and down on grass, fallen leaves,
• If the engine stops while the truck is in motion, or wet steel plates. These materials may make the
secondary steering and braking enable the truck to truck slip on even the slightest slope. Avoid
be steered and stopped. A fixed amount of reserve traveling sideways, and always keep travel speed
oil provides temporary steering and braking to low.
briefly allow the truck to travel to a safe area. Apply
• When traveling downhill, use the retarder to reduce
the brakes immediately and stop the truck as
speed. Do not turn the steering wheel suddenly.
quickly and safely as possible off of the haul road,
Do not use the foot brake except in an emergency.
if possible.
• If the engine should stop on a slope, apply the
service brakes fully and stop the truck. Move the
directional control lever to PARK after the truck has
Traveling in reverse
stopped.
Before operating the truck:
• Sound the horn to warn people in the area. Make
sure that the back-up horn also works properly. Operating on snow or ice
• Check for personnel near the truck. Be particularly • When working on snowy or icy roads, there is
careful to check behind the truck. danger that the truck may slip to the side on even
the slightest slope. Always travel slowly and avoid
• When necessary, designate a person to watch the sudden starting, turning, or stopping in these
area near the truck and signal the operator. This is conditions.
particularly necessary when traveling in reverse.
• Be extremely careful when clearing snow. The
• When operating in areas that may be hazardous or road shoulder and other objects are buried in the
have poor visibility, designate a person to direct snow and cannot be seen.
work site traffic.
• Do not allow any one to enter the line of travel of
the truck. This rule must be strictly observed even Avoid damage to dump body
with machines equipped with a back-up horn or
rear view mirror. Always be extremely cautious when working in tunnels,
on bridges, under electric cables, or when entering a
parking place or any other place where there are
height limits. The dump body must be completely
lowered before driving the truck.
13
CEN00051-01 00 Index and foreword
Driving near high voltage cables Working on loose ground
Driving near high voltage cables can cause electric • Avoid operating the truck near cliffs, overhangs
shock. Always maintain safe distances between the and deep ditches. If these areas collapse, the truck
truck and the high voltage cable as listed below. could fall or tip over and result in serious injury or
Voltage Minimum Safety Distance death. Remember that ground surfaces in these
areas may be weakened after heavy rain or
6.6 kV 3m 10 ft. blasting.
33.0 kV 4m 14 ft.
• Freshly laid soil and the soil near ditches is loose.
66.0 kV 5m 17 ft. It can collapse under the weight or vibration of the
154.0 kV 8m 27 ft. truck. Avoid these areas whenever possible.
275.0 kV 10 m 33 ft. Parking the truck
• Choose a flat, level surface to park the truck. If the
The following actions are effective in preventing
truck has to be parked on a slope, put blocks
accidents while working near high voltages: behind all the wheels to prevent truck movement.
• Wear shoes with rubber or leather soles. • Do not activate the wheel brake lock when the
• Use a signalman to give warning if the truck parking brake is activated. Bleed down of hydraulic
approaches an electric cable. pressure may occur, causing the truck to roll away.
• If the work equipment touches an electric cable, • When parking on public roads, provide fences and
the operator should not leave the cab. signs, such as flags or lights, on the truck to warn
pedestrians and other vehicles. Make sure that the
• When performing operations near high voltage truck, flags or lights do not obstruct traffic.
cables, do not allow anyone to approach the truck.
• Lower the dump body fully, move the directional
• Check with the electrical maintenance department control lever to PARK, stop the engine and lock
about the voltage of the cables before starting everything. Always take the key with you.
operations.
Towing
When dumping
Improper towing methods may lead to serious
• Before starting the dumping operation, make sure personal injury and/or damage. For towing methods,
that there are no persons or objects behind the refer to the Operation & Maintenance Manual.
truck.
• Use a towing device with ample strength for the
• Stop the truck in the desired location. Check again
weight of this truck.
for persons or objects behind the truck. Give the
determined signal, then slowly operate the dump • Towing vehicle must have adequate pulling and
body. If necessary, use blocks for the wheels or braking capacity to both move and stop the towed
position a flagman. truck under all conditions, including towing on a
grade.
• When dumping on slopes, truck stability is poor
and there is danger of tipping over. Always use • Inspect towing components, such as tow bars and
extreme care when performing such operations. couplings, for any signs of damage. Never use
damaged or worn components to tow a disabled
• Never travel with the dump body raised.
vehicle.
When loading • Keep a safe distance from the trucks and towing
apparatus while towing a vehicle.
• Make sure that the surrounding area is safe. Stop
the truck in the correct loading position, then load • When connecting a truck that is to be towed, do
the body uniformly. not allow anyone to go between the tow vehicle
and the disabled vehicle.
• Do not leave the operator seat during the loading
operation. • Set the coupling of the truck being towed in a
straight line with the towing portion of the tow
truck, and secure it in position.
14
00 Index and foreword CEN00051-01
Working near batteries • Batteries generate hydrogen gas. Hydrogen gas is
very explosive and can easily be ignited with a
Battery hazard prevention small spark or flame.
• Battery electrolyte contains sulfuric acid, which can • Before working with batteries, stop the engine and
quickly burn the skin and eat holes in clothing. If turn the key switch to the OFF position.
you spill acid on yourself, immediately flush the • Avoid short-circuiting the battery terminals through
area with water.
accidental contact with metallic objects, such as
• Battery acid can cause blindness if splashed into tools, across the terminals.
your eyes. If acid gets into your eyes, flush them • When removing or installing batteries, check which
immediately with large quantities of water and see
is the positive (+) terminal and the negative (-)
a doctor at once. terminal.
• If you accidentally drink acid, drink a large quantity • Tighten battery caps securely.
of water, milk, beaten eggs or vegetable oil. Call a
doctor or poison prevention center immediately. • Tighten the battery terminals securely. Loose
terminals can generate sparks and lead to an
• Always wear safety glasses or goggles when
explosion.
working with batteries.
15
CEN00051-01 00 Index and foreword
Starting with jumper cables • If any tool touches between the positive (+)
terminal and the chassis, it will cause sparks.
• Always wear safety glasses or goggles when Always use caution when using tools near the
starting the machine with jumper cables. battery.
• While jump starting with another machine, DO
NOT allow the two machines to touch.
• Ensure the parking brake is applied on both Jump starting with receptacles
machines. • Always wear safety glasses or goggles when
• Ensure the size of the jumper cables and clips are starting the machine with jumper cables.
suitable for the battery size. Inspect the cables and • While jump starting with another machine, DO
clips for any damage or corrosion. NOT allow the two machines to touch.
• Ensure the key switch and both battery disconnect • Ensure the parking brake is applied on both
switches on the disabled machine are in the OFF machines.
position.
• Inspect the cables and connectors for any damage
• Connect the batteries in parallel: positive to or corrosion.
positive and negative to negative.
• Ensure the key switch and both battery disconnect
• Connect the positive (24VDC +) cable from the switches on the disabled machine are in the OFF
good machine to the (24VDC +) on the disabled position.
machine first.
• Connect the jumper cable to the receptacle on the
• Then connect the ground cable on the good good machine to the receptacle on the disabled
machine to the frame of the disabled machine, as machine.
far away as possible from the batteries. This will
prevent a spark from possibly starting a battery • Allow time for the batteries to charge.
fire.
NOTE: The batteries will charge even with the battery
• Allow time for the batteries to charge. disconnect switches are in the OFF position.
NOTE: The batteries will charge even with the battery • If starting with a jumper cable, perform the
disconnect switches are in the OFF position. operation with two people. One person in the cab
of the disabled machine, the other person working
• If starting with a jumper cable, perform the with the jumper cables.
operation with two people. One person in the cab
of the disabled machine, the other person working • If the batteries are low, DO NOT attempt starting
with the jumper cables. the machine with only one set of jumper cables
installed. Install the second set of jumper cables in
• If the batteries are low, DO NOT attempt starting the same way as already described.
the machine with only one set of jumper cables
installed. Install the second set of jumper cables in • Turn the battery disconnect switches to the ON
the same way as already described. position and attempt starting.
• Turn the battery disconnect switches to the ON • For jumper cable removal, disconnect the cables
position and attempt starting. from each machine.
• For jumper cable removal, disconnect the ground If any tool touches between the positive (+) terminal
or negative (-) cable first, then the (24VDC +) and the chassis, it will cause sparks. Always use
cable last. caution when using tools near the battery.
INCORRECT
16
00 Index and foreword CEN00051-01
Precautions before performing service Proper tools
Warning tag Only use tools that are suited to the task. Using
damaged, low quality, faulty or makeshift tools could
Starting the engine or operating the controls while cause personal injury.
other personnel are performing maintenance on the
truck can lead to serious injury and/or death. Always
attach the warning tag to the control lever in the
operator cab to alert others that you are working on the
truck. Attach additional warning tags around the truck
as necessary.
These tags are available from your Komatsu
distributor. Warning tag part number: 09963-A1640
Use of Tie-Off Anchor During Maintenance and
Repair
While working at heights
during assembly, mainte-
nance or repair of the haul
truck, workers should
wear an appropriate fall
protection harness and
attach it to a tie-off anchor
or tie-off point.
Komatsu anchor (58B-98-75190) is available for use
with fall protection harnesses. Carefully read and
understand the harness maker’s instructions before
using any fall protection harness.
NOTE: The anchor must not be used for lifting.
Stopping the engine
• Before performing inspections or maintenance,
stop the truck on firm flat ground, lower the dump
body, move the directional control lever to PARK,
and stop the engine.
• If the engine must be run during service, such as
when cleaning the radiator, the directional control
lever must be in PARK. Always perform this work
with two people. One person must sit in the
operator's seat to stop the engine if necessary.
During these situations, never move any controls
that are not related to the task at hand.
• When servicing the truck, do not to touch any
moving parts. Never wear loose clothing or jewelry.
• Put wheel blocks under the wheels to prevent truck
movement.
• When performing service with the dump body
raised, place the dump lever in the HOLD position
and apply the lock (if equipped). Install the body-up
safety sling securely.
17
CEN00051-01 00 Index and foreword
Securing the dump body
To avoid serious personal injury or death, the
body retention sling must be installed whenever
personnel are required to perform maintenance on
the truck while the dump body in the raised
position.
The Komatsu body-up safety sling can only be
used with a Komatsu body. Non-OEM body may
not accommodate the Komatsu body-up safety
sling. The end user must ensure that a proper
cable/sling is used.
1. To hold the dump body in the up position, raise
the body to its maximum height.
2. Install two shackles (2, Figure 00-1) and body
retention sling (3) between rear body ear (1) and
the axle housing.
3. Secure the shackle pins with cotter pins.
4. Move the hoist lever to the FLOAT position to FIGURE 00-1. BODY RETENTION SLING
slowly lower the body until the cable is supporting INSTALLATION
the full weight of the body. Then move the hoist 1. Rear Body Ear 3. Body Retention
lever to the HOLD position. 2. Shackle & Pin Sling
5. After service work is completed, return the sling
to the stored position.
18
00 Index and foreword CEN00051-01
Jack point locations Proper jack point locations must be used. The jacks at
locations (3, Figure 00-2) must be located on the
When a truck is being stored for any period of time or
frame rails.
being secured for maintenance work, portable jack
stands or permanent jack stands may be used. If a tow bumper reinforcement group is installed, it is
acceptable to place jack stands under tow hooks at
The jack stands must be adequately rated for the size
locations (4). However, do not position jacks outside of
of the truck. Ensure that the jack stands are on a solid
the tow hooks.
and level surface.
4 4
3 3
2 2
1 1
85201
FIGURE 00-2. JACK POINT LOCATIONS
(Bottom View)
1. Under Rear Suspensions 4. Under Tow Hooks
2. Under Front Suspensions (if equipped)
3. Under Torque Tube
19
CEN00051-01 00 Index and foreword
Precautions while performing service Working under the truck
NOTE: Only authorized personnel should service and • Always lower all movable work equipment to the
repair the truck. ground or to their lowest position before
performing service or repairs under the truck.
Keep the truck clean • Always block the tires of the truck securely.
• Spilled oil, grease, scattered tools, etc, can cause • Never work under the truck if the truck is poorly
you to slip or trip. Always keep your truck clean supported.
and tidy.
• If water gets into the electrical system, there is
danger that the truck may move unexpectedly and/
or damage to components may occur. Do not use
water or steam to clean any sensors, connectors
or the inside of the operator's compartment.
• Use extreme care when washing the electrical
control cabinet. Do not allow water to enter the
control cabinet around the doors or vents. Do not Rotating fan and belts
allow any water to enter the cooling air inlet duct Stay away from all rotating parts such as the radiator
above the electrical control cabinet. If water enters fan and fan belts. Serious bodily injury may result from
the control cabinet through any opening or crevice, direct or indirect contact with rotating parts and flying
major damage to the electrical components is
objects.
possible.
• Never spray water into the rear wheel electric
motor covers. Damage to the wheel motor
armatures may occur.
• Do not spray water into the retarding grids. Excess
water in the retarding grids can cause a ground
fault, which will prevent propulsion.
Adding fuel or oil
• Spilled fuel and oil may cause slipping. Always
clean up spills immediately.
• Always add fuel and oil in a well-ventilated area.
• When refueling, stop the engine and do not smoke.
• Tighten the cap of the fuel and oil fillers securely.
• Never use fuel to wash parts.
Attachments
Use of lighting
Place attachments that have been removed from the
truck in a safe place and manner to prevent them from When checking fuel, oil, coolant or battery electrolyte,
falling. always use lighting with anti-explosion specifications. If
such lighting equipment is not used, there is danger of
an explosion.
20
00 Index and foreword CEN00051-01
Radiator coolant level Handling high pressure hoses
If it is necessary to add coolant to the radiator, stop the • Do not bend high pressure hoses or hit them with
engine and allow the engine and radiator to cool down hard objects. Do not use any bent or cracked
before adding the coolant. Depress the pressure piping, tubes or hoses. They may burst during use.
release button on the cap to vent cooling system • Always repair any loose or broken hoses. If fuel or
pressure. Slowly loosen the cap to relieve any oil leaks, it may result in a fire.
remaining pressure.
Precautions when performing maintenance near
high temperature or high pressure
Immediately after stopping operation, engine coolant
and operating oils are at high temperature and under
high pressure. If the cap is removed, the oil or water is
drained, or the filters are replaced under these
conditions, it may result in burns or other injury. Wait
for the temperature to cool and pressure to subside
before performing the inspection and/or maintenance
Precautions with the battery as outlined in the shop manual.
When repairing the electrical system or performing
electrical welding, remove the negative (-) terminal of
the battery to stop the flow of current.
Waste materials
• Never dump oil into a sewer system, river, etc.
• Always put oil drained from your truck in
appropriate containers. Never drain oil directly
Precautions with high pressure oil onto the ground.
• Work equipment circuits are always under • Obey appropriate laws and regulations when
pressure. Do not add oil, drain oil or perform disposing of harmful objects such as oil, fuel,
maintenance or inspections before completely coolant, solvent, filters and batteries.
releasing the internal pressure.
• The machine may be equipped with optional high
• Small, high-pressure pin hole leaks are extremely intensity discharge lamps which contain mercury.
dangerous. A jet of high-pressure oil can pierce the These lamps must be reused, recycled or properly
skin and eyes. Always wear safety glasses and disposed of in accordance with applicable local,
thick gloves. Use a piece of cardboard or a sheet state and federal laws.
of wood to check for oil leakage.
• If you are hit by a jet of high-pressure oil, consult a
doctor immediately for medical attention.
21
CEN00051-01 00 Index and foreword
Tires
Inspection
The truck tires must be inspected and tire pressure
must be checked with an accurate pressure gauge
before each work shift and during tire rotations. Tire When inflating and deflating tires, always use a
pressure will vary according to manufacturer and local safety cage. Never inflate a tire until the lock ring
working conditions. Consult the tire manufacturer for is securely in place. DO NOT stand in front of or
recommended tire pressure. over the lock ring during inflation procedures.
Never over inflate a tire. Refer to tire manufac-
Ensure that the valve caps are securely applied to the turer’s recommendations.
valve stems. The caps protect the valves from dirt
build up and damage. DO NOT bleed air from tires that
are hot due to truck operation. Under such circum-
stances, it is normal for pressure to increase in the tire
due to expansion.
A bent or damaged rim which does not support the
bead properly may cause abnormal strain on the tire,
resulting in tire damage. If a tire becomes deeply cut, it
must be removed and repaired. Neglected cuts cause
many tire problems. Water, sand, dirt and other foreign
materials can get into the tire through a cut, eventually
FIGURE 00-3. SAFETY CAGE 84825
causing tread or ply separation.
Rim components that are deformed, bent, cracked,
worn, corroded, or damaged must be clearly labeled to
indicate their condition before they are discarded.
Maintenance
Rim and tire maintenance can be hazardous unless the Always keep personnel away from a wheel and tire
correct procedures are followed by trained personnel. assembly when it is being removed, installed,
Tires that are improperly maintained or under/over- deflated or inflated. Personnel must always be out-
inflated can overheat and burst due to excessive pres- side the range of the “hazardous trajectory”. Exer-
sure. Improper inflation can also result in cuts in the tire cise extreme caution as the trajectory may widen.
caused by sharp stones. Both of these conditions can
lead to tire damage, serious personal injury, or even
death. To safely maintain a tire: Hazardous
Trajectory
• Before a tire is removed from a truck, the valve
core must be partially removed to allow deflation.
Then the tire/rim assembly can be removed.
• After the tire/rim assembly is installed on the truck,
inflate the tires to their specified pressure.
Abnormal heat is generated, particularly when the
inflation pressure is too low.
NOTE: Any tire inflation pressures and permissible
speeds given in this manual are general values. The
actual values may differ, depending on the type of tire
and the specific operating conditions. For details, Hazardous
consult the tire manufacturer. Trajectory
84860
Ensure that appropriate personal protective equipment
FIGURE 00-4. HAZARDOUS TRAJECTORY
is worn when servicing tires and rims.
22
00 Index and foreword CEN00051-01
Storage
Tires must be stored indoors, if possible, in a cool, dry,
dark, draft-free location. If stored outdoors, cover tires
with a tarpaulin to keep out dirt, water and other for-
DO NOT weld or apply heat on the rim assembly eign materials. Erect a fence around the tires and put
with the tire mounted on the rim. Remaining gases up “No Entry” signs and other warning signs that even
inside the tire may ignite causing explosion of tire young children can understand. Long exposure to the
and rim. sun will cause ozone cracks. Avoid contact with oil,
grease and other petroleum products.
If a brake or wheel motor has experienced a fire,
Tires must be stored vertically. Stand the tire on level
DO NOT go near the tire until the tire has cooled.
ground and block it securely so that it cannot roll or fall
over. If tires must be laid on their sides for a short
period, avoid distortion by stacking no more than three
When the tires become overheated, a flammable gas
tires on top of one another.
is produced inside the tire which can ignite. It is partic-
ularly dangerous if the tires become overheated while If the tire falls over, flee the area quickly. The tires for
the tires are pressurized. If the gas generated inside dump trucks are extremely heavy, and the impact from
the tire ignites, the internal pressure will suddenly rise, a significant fall could lead to an explosive separation
and the tire will explode, resulting in danger and/or of rim components. Never attempt to hold or support
death to personnel in the area. Explosions differ from the tire. Attempting to hold or support a tire may lead
punctures or tire bursts because the destructive force to serious injury.
of the explosion is extremely large. Therefore, the fol-
lowing operations are strictly prohibited when the tire is
pressurized:
• Welding the rim
• Welding near the wheel or tire.
• Smoking or creating open
flames
Mounted tires stored as spares must be inflated to
minimum inflation pressure necessary to keep the tire
beads properly seated. Maximum inflation pressure of
the stored tire should never exceed 15% of the tire’s
normal cold inflation pressure.
Before storing used tires, clean the tires thoroughly
and inspect for damage. Repair as necessary. When a
truck is placed in storage, it must be blocked up to
remove the weight from the tires. If a stored truck can-
not be blocked up, check the air pressure of the tires
and inspect the tires twice a month for proper inflation
pressure.
23
CEN00051-01 00 Index and foreword
Handling
Ensure that the tire handling equipment is capable
of lifting and maneuvering the load.
Due to the size and weight of the tire and rim assem-
blies, special handling equipment, such as a modified
fork lift called a “tire handler”, as shown in Figure 00-6,
is desirable. Consult local tire vendors for sources of
equipment designed especially to remove, repair, and
install large off-highway truck tires.
Handling of tires and rims must only be done by per-
sonnel who have received training and accreditation
based on instruction from a qualified work supervisor.
There are several types of tools that are used for tire
and rim handling. Ensure that the personnel have a
proper understanding of how to use the tools properly.
When moving tires and rims, be careful to avoid acci-
dental drops or falls that could injure others in the
vicinity.
Regarding dual tire assemblies: DO NOT operate
the truck with a single tire on a dual tire assembly. The
FIGURE 00-6. TYPICAL TIRE HANDLER
load capacity of the tire and rim will be drastically
reduced and may result in damage.
24
00 Index and foreword CEN00051-01
Precautions for performing repairs Engine shutdown procedure after AC drive system
failure
NOTE: Only qualified maintenance personnel who
understand the systems being repaired should attempt If the AC drive system is operating normally when the
repairs. Only a qualified operator should move the engine is shut down, the system should be safe to
truck under its own power in the repair facility or during service. However, in the event of a drive system failure,
road testing after repairs are complete. performing the following procedure before any
maintenance activities will ensure that no hazardous
• Many components on the Komatsu truck are large
and heavy. Ensure that lifting equipment (hoists, voltages are present in the AC drive system.
slings, chains, and lifting eyes) are of adequate 1. Before shutting down the engine, verify the status
capacity to handle the load. of all the drive system warnings and faults.
• Do not work under a suspended load. Do not work If any of the drive system warning lights or faults
under a raised body unless body retention sling, remain active, do not attempt to open any
props or pins are in place to hold the body in the cabinets, disconnect any cables, or reach inside
raised position. the retarding grid or control cabinet without a
• Do not repair the truck while the engine is running, trained drive system technician present. Only
except when adjustments can only be made under qualified personnel who are specifically trained
such conditions. Keep a safe distance from moving for servicing the AC drive system should perform
parts. drive system service.
• When servicing any air conditioning system with 2. If all drive system warning lights and faults are
refrigerant, wear a face shield and cold resistant off, follow the normal engine shutdown
gloves for protection against freezing. Follow all procedure.
current regulations for handling and recycling
refrigerants. Refer to Testing and adjusting section 3. After the engine has been stopped for at least
Cab air conditioning. five minutes, inspect the DC link voltage lights on
the exterior of the main control cabinet.
• Follow package directions carefully when using
cleaning solvents. a. If all lights are off, it is safe to work on the con-
trol cabinet, retarding grid, wheel motors,
• If an auxiliary battery assist is needed, refer to
"Starting with jumper cables" or "Jump starting with alternator and related power cables. Proceed
receptacles" earlier in this section. to Step 5.
• If the truck must be towed, use a rigid tow bar. b. If any lights continue to be illuminated after fol-
Check the truck frame for a decal recommending lowing the above procedure, a fault has
special towing precautions. Also refer to the towing occurred. Leave all cabinet doors in place. Do
instructions in the Operation & Maintenance not touch the retarding grid elements. Do not
Manual. disconnect any power cables or use them as
• Relieve hydraulic pressure before disconnecting hand or foot holds. Notify your Komatsu ser-
any lines or hoses. Hydraulic oil escaping under vice representative immediately.
pressure can have sufficient force to enter a 4. Locate the generator field contactor (GF) switch
person's body by penetrating the skin, resulting in in the main control cabinet. Place the switch in
serious injury and possibly death. the CUTOUT position. This will prevent the
• After adjustments or repairs, replace all shields, alternator from re-energizing and creating system
screens and clamps. voltage until the switch is returned to its former
position.
5. Leave the drive system in the rest mode until the
truck is to be moved.
25
CEN00051-01 00 Index and foreword
Precautions for welding on the truck • Do not weld on the rear of the control cabinet!
The metal panels on the back of the cabinet are
NOTE: Before welding or repairing an AC drive truck, part of capacitors and cannot be heated.
notify a Komatsu service representative. Only qualified
personnel, specifically trained for servicing the AC • Do not weld on the retarding grid exhaust
drive system, should perform this service. louvers! They are made of stainless steel. Some
power cable panels throughout the truck are also
If it is necessary to perform welding on the truck made of aluminum or stainless steel. They must be
without the field engineer present, the following repaired with the same material or the power
procedures and precautions must be followed to cables may be damaged.
ensure that the truck is safe for maintenance personnel • Power cables must be cleated in wood or other
to work on and to reduce the chance for damage to non-ferrous materials. Do not repair cable cleats
equipment. by encircling the power cables with metal clamps
or hardware. Always inspect power cable
• Before opening any cabinets or touching a
insulation before servicing the cables and returning
retarding grid element or a power cable, the engine
the truck to service. Discard cables with broken
must be shutdown and any red drive system
insulation.
warning lights must not be illuminated.
• Power cables and wiring harnesses should be
• Always disconnect the positive and negative
protected from weld spatter and heat.
battery cables of the truck before doing any
welding on the unit. Failure to do so may seriously • Always fasten the welding machine ground (-) lead
damage the battery and electrical equipment. to the piece being welded. The grounding clamp
Disconnect the battery charging alternator lead must be attached as near as possible to the weld
wire and isolate the electronic control components area.
before making welding repairs. (It is not necessary
to disconnect or remove any control circuit cards • Always avoid laying welding cables over or near
on electric drive dump trucks or any of the AID the vehicle electrical harnesses. Welding voltage
circuit control cards.) could be induced into the electrical harness and
cause damage to components.
• Always fasten the welding machine ground (-) lead
to the piece being welded. The grounding clamp • Before doing any welding on the truck, disconnect
must be attached as near as possible to the weld the battery charging alternator lead wire and
area. Never allow welding current to pass through isolate electronic control components.
ball bearings, roller bearings, suspensions or • Also, always disconnect the negative and positive
hydraulic cylinders. Always avoid laying welding battery cables of the vehicle. Failure to do so may
cables over or near the vehicle electrical seriously damage the battery and electrical
harnesses. Welding voltage could be induced into equipment.
the electrical harness and possibly cause damage
to components. • Never allow welding current to pass through ball
bearings, roller bearings, suspensions or hydraulic
• Drain, clean, and ventilate fuel tanks and hydraulic cylinders.
tanks before making any welding repairs on the
tanks.
• Before welding on the truck, disconnect all
electrical harnesses from the modules and
controllers inside the auxiliary control cabinet
behind the operator cab.
26
00 Index and foreword CEN00051-01
Control cabinet capacitor discharge system The main control cabinet is equipped with two sets of
DC link voltage lights on the exterior of the cabinet.
One set is for the primary DC link and the other is for
the secondary DC link. The DC link voltage lights,
when off, indicate to service personnel that the drive
system is safe to work on.
However, certain drive system failures can result in a
Hazardous voltages are present in this equipment.
condition where one or more capacitors can remain in
Ensure that the control power switch is in the OFF
a charged state even though the DC link voltage lights
position and that the generator field contactor (GF)
are off.
switch is in the CUTOUT position before
attempting any work on the drive system Because a danger can still exist when the DC link
components. Check that DC link voltage light are voltage lights are off, it is necessary to manually
not illuminated. discharge the capacitors before touching or servicing
drive system components. Only authorized service
Use measurement and protective equipment rated
personnel are allowed to service the drive system.
for 2000 VDC minimum to verify that no voltage is
present before touching any terminal. Refer to the GE shop manual for safety rules and pro-
cedures regarding the servicing of the drive system.
Verify functionality of the measurement equipment
Adhere to the proper procedures for disabling, check-
using site-approved procedures both before and
ing and discharging the drive system.
after performing control group measurements.
Verify functionality of the measurement equipment
using site-approved procedures both before and
after performing control group measurements.
Failure to observe these precautions may result in
death or serious personal injury.
27
CEN00051-01 00 Index and foreword
1 2
4
86939
FIGURE 00-7. MAIN CONTROL CABINET
1. Control Power Switch 3. Primary DC Link Voltage Lights
2. Generator Field Contactor (GF) Switch 4. Secondary DC Link Voltage Lights
28
00 Index and foreword CEN00051-01
Handling electrical equipment and hydraulic
components
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality
of repairs. For this purpose, it provides information on handling electrical equipment and handling hydraulic equip-
ment (particularly gear oil and hydraulic oil).
Points to remember when handling electrical equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fitted
in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of rain,
water, heat, or vibration. Furthermore, during
inspection and repair operations, they are fre-
quently removed and installed again, so they are
likely to suffer deformation or damage. For this
reason, it is necessary to be extremely careful
when handling wiring harnesses.
2. Main failures occurring in wiring harness
• Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not properly
inserted into the female connector, or because
one or both of the connectors is deformed or the
position is not correctly aligned, or because there
is corrosion or oxidization of the contact surfaces.
The corroded or oxidized contact surfaces may
become shiny again (and contact may become
normal) by connecting and disconnecting the
connector about 10 times.
• Defective crimping or soldering of connectors
The pins of the male and female connectors are
in contact at the crimped terminal or soldered
portion, but if there is excessive force brought to
bear on the wiring, the plating at the joint will peel
and cause improper connection or breakage.
29
CEN00051-01 00 Index and foreword
• Disconnections in wiring
If the wiring is held and the connectors are pulled
apart, or components are lifted with a crane with
the wiring still connected, or a heavy object hits
the wiring, the crimping of the connector may
separate, or the soldering may be damaged, or
the wiring may be broken.
• High-pressure water entering connector
The connector is designed to make it difficult for
water to enter (drip-proof structure), but if high-
pressure water is sprayed directly on the connec-
tor, water may enter the connector, depending on
the direction of the water jet. Accordingly, take
care not to splash water over the connector. The
connector is designed to prevent water from
entering, but at the same time, if water does
enter, it is difficult for it to be drained. Therefore, if
water should get into the connector, the pins will
be short-circuited by the water, so if any water
gets in, immediately dry the connector or take
other appropriate action before passing electricity
through it.
• Oil or dirt stuck to connector
If oil or grease are stuck to the connector and an
oil film is formed on the mating surface between
the male and female pins, the oil will not let the
electricity pass, so there will be defective contact.
If there is oil or grease stuck to the connector,
wipe it off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact restorer.
• When wiping the mating portion of the con-
nector, be careful not to use excessive
force or deform the pins.
• If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the com-
pressed air completely before cleaning with
compressed air.
30
00 Index and foreword CEN00051-01
3. Removing, installing, and drying connectors
and wiring harnesses
• Disconnecting connectors
a. When disconnecting the connectors, hold the
connectors. For connectors held by a screw,
loosen the screw fully, then hold the male and
female connectors in each hand and pull
apart. For connectors which have a lock stop-
per, press down the stopper with your thumb
and pull the connectors apart. Never pull with
one hand.
b. Both of the connector and clip have stoppers,
which are engaged with each other when the
connector is installed.
When removing a connector from a clip, pull the
connector in a parallel direction to the clip for
removing stoppers. If the connector is twisted up
and down or to the left or right, the housing may
break.
c. After removing any connector, cover it with a
vinyl bag to prevent any dust, dirt, oil, or water
from getting in the connector portion. If the
machine is left disassembled for a long time, it
is particularly easy for improper contact to
occur, so always cover the connector.
31
CEN00051-01 00 Index and foreword
• Connecting connectors
a. Check that there is no oil, dirt, or water stuck
to the connector pins (mating portion). Check
that there is no deformation, defective contact,
corrosion, or damage to the connector pins.
Check that there is no damage or breakage to
the outside of the connector.
• If there is any oil, water, or dirt stuck to the
connector, wipe it off with a dry cloth. If any
water has got inside the connector, warm
the inside of the wiring with a dryer, but be
careful not to make it too hot as this will
cause short circuits.
• If there is any damage or breakage,
replace the connector.
b. Fix the connector securely. Align the position
of the connector correctly, and then insert it
securely. For connectors with the lock stopper,
push in the connector until the stopper clicks
into position.
• Correct any protrusion of the boot and any
misalignment of the wiring harness.
• For connectors fitted with boots, correct
any protrusion of the boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct
position.
• If the connector cannot be corrected easily,
remove the clamp and adjust the position.
• If the connector clamp has been removed,
be sure to return it to its original position.
Check also that there are no loose clamps.
32
00 Index and foreword CEN00051-01
• Heavy duty wire connector (DT 8-pole, 12-pole)
a. For disconnection, press both sides of locks
(a) and (b) while pulling out female connector
(2).
b. For connection, push in female connector (2)
horizontally until the lock clicks.
Since locks (a) and (b) may not be set com-
pletely, push in female connector (2) while mov-
ing it up and down until the locks are set normally.
• Right half of figure: Lock (a) is pulled down
(not set completely) and lock (b) is set
completely.
1. Male connector a. Lock
2. Female connector b. Lock
• Drying wiring harness
If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high pressure water
or steam directly on the wiring harness. If water
gets directly on the connector, perform the follow-
ing procedure.
a. Disconnect the connector and wipe off the
water with a dry cloth. If the connector is
blown dry with compressed air, there is the
risk that oil in the air may cause defective con-
tact, so remove all oil and water from the com-
pressed air before blowing with air.
b. If water gets inside the connector, use a dryer
to dry the inside of the connector. Hot air from
the dryer can be used, but regulate the time
that the hot air is used in order not to make the
connector or related parts too hot, as this will
cause deformation or damage to the connec-
tor.
c. After drying, leave the wiring harness discon-
nected and carry out a continuity test to check
for any short circuits between pins caused by
water.
d. After completely drying the connector, blow it
with contact restorer and reassemble.
33
CEN00051-01 00 Index and foreword
4. Handling controllers
The controllers contain a microcomputer and
electronic control circuits. These control all of the
electronic circuits on the machine, so be
extremely careful when handling the controllers.
• Do not place objects on top of the controllers.
• Cover the controller connectors with tape or a
vinyl bag. Never touch the connector contacts
with your hand.
• During rainy weather, do not leave a controller in
a place where it is exposed to rain.
• Do not place a controller on oil, water, or soil, or
in any hot place, even for a short time. Place it on
a suitable dry stand.
• When carrying out arc welding on the body,
disconnect all wiring harness connectors that are
connected to the controllers. Fit an arc welding
ground close to the welding point.
5. When troubleshooting electric circuits
1) Always turn the power OFF before discon-
necting or connecting any connectors.
2) Before troubleshooting, ensure that all the
related connectors are properly inserted. Dis-
connect and connect the related connectors
several times to check.
3) Always connect any disconnected the con-
nectors before proceeding to the next step. If
the power is turned ON while the connectors
are still disconnected, unnecessary fault
codes will be generated.
4) When troubleshooting circuits (measuring the
voltage, resistance, continuity, or current),
move the related wiring and connectors sev-
eral times and check that there is no change
in the reading of the tester. If there is any
change, there is probably defective contact in
that circuit.
34
00 Index and foreword CEN00051-01
Points to remember when handling hydraulic
equipment
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.
Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the
field
If disassembly or maintenance work is carried out
on hydraulic equipment in the field, there is dan-
ger of dust entering the equipment. It is also diffi-
cult to check the performance after repairs, so it
is desirable to use unit exchange. Disassembly
and maintenance of hydraulic equipment should
be carried out in a specially prepared dustproof
workshop, and the performance should be
checked with special test equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with a
rag, there is danger of dirt entering or of the sur-
rounding area being made dirty by leaking oil so
never do this. Do not simply drain oil out onto the
ground, but collect it and ask the customer to dis-
pose of it, or take it back with you for disposal.
4. Do not let any dirt or dust get in during
refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt
that has collected during storage, so this is an
even more effective method.
35
CEN00051-01 00 Index and foreword
5. Change hydraulic oil when the temperature is
high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be drained
out easily from the circuit together with the oil, so
it is best to change the oil when it is still warm.
When changing the oil, as much as possible of
the old hydraulic oil must be drained from the
hydraulic tank. If any old oil is left, the contami-
nants and sludge in it will mix with the new oil and
will shorten the life of the hydraulic oil.
6. Flushing operations
After disassembly and assembly, or changing the
oil, use flushing oil to remove the contaminants,
sludge, and old oil from the hydraulic circuit. Nor-
mally, flushing is carried out twice: primary flush-
ing is carried out with flushing oil, and secondary
flushing is carried out with the specified hydraulic
oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
carry out oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit. The oil
cleaning equipment is used to remove the ultra
fine particles (about 3 microns) that the filter built
in the hydraulic equipment cannot remove, so it is
an extremely effective device.
36
00 Index and foreword CEN00051-01
Standard tightening torques If special friction-reducing lubricants are used with the
standard torque values listed in this chapter, excessive
This manual provides dual dimensioning for many
stress and possible breakage of the fasteners may
specifications. Metric units are specified first, with U.S.
result.
standard units in parentheses. When torque values are
not specified in the assembly instructions contained in When the torque tables specify “lubricated threads” for
this manual, use the standard torque value for the the standard torque values listed, these standard
hardware being used. Standard value torque tables torque values are to be used with simple lithium base
are contained in this chapter for metric and SAE chassis grease (multi-purpose EP NLGI) or a rust
hardware. preventive grease (see below) on the threads and
seats unless specified otherwise.
This truck is assembled with both metric and SAE
(U.S.) hardware. Reference the correct table when NOTE: Ensure that the threads of fasteners and
determining the proper torque value. tapped holes are free of burrs and other imperfections
before assembling.
Suggested sources for rust preventive grease
References throughout the manual to standard NOTE: This list represents the current engineering
torques or other standard values will be to one of approved sources for use in Komatsu manufacture. It
the following tables. Do not use standard values to is not exclusive. Other products may meet the same
replace specific torque values in assembly specifications of this list.
instructions. • American Anti-Rust Grease #3-X from Standard
For values not shown in any of the charts or tables, Oil Company (also American Oil Co.)
standard conversion factors for most commonly used • Gulf NoRust #3 from Gulf Oil Company.
measurements are provided in the following tables. • Mobilarma 355, Product No. 66705 from Mobil Oil
Corporation.
• Rust Ban 326 from Humble Oil Company.
Effect of special lubricants on fasteners and • Rustolene B Grease from Sinclair Oil Co.
standard torque values
• Rust Preventive Grease - Code 312 from the
The Komatsu engineering department does not Southwest Grease and Oil Company.
recommend the use of special friction-reducing
lubricants, such as Copper Coat, Never-Seez®, and
other similar products, on the threads of standard
fasteners where standard torque values are applied.
The use of special friction-reducing lubricants will
significantly alter the clamping force being applied to
fasteners during the tightening process.
37
CEN00051-01 00 Index and foreword
SAE grade 5 and grade 8 hex head capscrew and In the following table under “Capscrew Size”, the first
nut assemblies number represents the shank diameter (in.). The
second number represents threads per inch.
The following specifications apply to required
assembly torques for all grade 5 and grade 8 Example: 7/16 - 20
capscrews.
7/16 = shank diameter (7/16 inch [0.438 inch])
NOTE: Torques are calculated to give a clamping force 20 = threads per inch
of approximately 75% of proof load. The maximum
torque tolerance shall be within ±10% of the torque
value shown.
Table 3: Standard tightening torques for
SAE hex head capscrew and nut assembly with lubricated threads
Torque - Torque - Torque - Torque -
Thread Grade 5 Grade 8 Thread Grade 5 Grade 8
Size Size
ft lb kg·m N·m ft lb kg·m N·m ft lb kg·m N·m ft lb kg·m N·m
1/4-20 7 0.97 9.5 10 1.38 13.6 3/4-16 235 32.5 319 335 46.3 454
1/4-28 8 1.11 10.8 11 1.52 14.9 7/8-9 350 48.4 475 500 69.2 678
5/16-18 15 2.07 20.3 21 2.90 28 7/8-14 375 51.9 508 530 73.3 719
5/16-24 16 2.21 22 22 3.04 30 1.0-8 525 72.6 712 750 103.7 1017
3/8-16 25 3.46 34 35 4.84 47 1.0-12 560 77.4 759 790 109.3 1071
3/8-24 30 4.15 41 40 5.5 54 1.0-14 570 78.8 773 800 110.6 1085
7/16-14 40 5.5 54 58 8.0 79 1 1/8-7 650 89.9 881 1050 145 1424
7/16-20 45 6.2 61 62 8.57 84 1 1/8-12 700 96.8 949 1140 158 1546
1/2-13 65 9 88 90 12.4 122 1 1/4-7 910 125.9 1234 1480 205 2007
1/2-20 70 9.7 95 95 13.1 129 1 1/4-12 975 134.8 1322 1580 219 2142
9/16-12 90 12.4 122 125 17.3 169 1 3/8-6 1200 166 1627 1940 268 2630
9/16-18 95 13.1 129 135 18.7 183 1 3/8-12 1310 181 1776 2120 293 2874
5/8-11 125 17.3 169 175 24.2 237 1 1/2-6 1580 219 2142 2560 354 3471
5/8-18 135 18.7 183 190 26.2 258 1 1/2-12 1700 235 2305 2770 383 3756
3/4-10 220 30.4 298 310 42.8 420
1 ft lb = 0.138 kgm = 1.356 Nm
38
00 Index and foreword CEN00051-01
SAE grade 9 capscrews Class 10.9 capscrews and class 10 nuts
The following specifications apply to required The following specifications apply to required
tightening torques for SAE hex head and 12-point, assembly torques for all metric class 10.9 finished
grade 9 (170,000 psi minimum tensile) capscrews. hexagon head capscrews and class 10 nuts.
NOTE: Torques are calculated to give a clamping force NOTE: Torques are calculated to give a clamping force
of approximately 75% of proof load. The maximum of approximately 75% of proof load. The maximum
torque tolerance shall be within ±10% of the torque torque tolerance shall be within ±10% of the torque
value shown. value shown.
In the following table under “Capscrew Size”, the first In the following table under “Capscrew Size”, the first
number represents the shank diameter (mm). The sec- number represents the shank diameter (mm). The
ond number represents thread pitch in millimeters. second number represents thread pitch in millimeters.
Example: 1/2 - 13 Example: M20 x 2.25
1/2 = shank diameter (1/2 inch [0.500 inch]) M20 = shank diameter (20 mm)
13 = threads per inch 2.25 = thread pitch in millimeters
Table 4: Standard tightening torques for SAE Table 5: Standard tightening torques for
hex head and 12-point, grade 9 capscrews with metric class 10.9 capscrews and class 10 nuts with
lubricated threads lubricated threads
Capscrew Torque Torque Torque Capscrew Torque Torque Torque
size* N·m ft lb kg·m size* N·m ft lb kg·m
1/4 - 20 12 16 1.7 M6 x1 12 9 1.22
5/16 - 18 24 33 3.3 M8 x 1.25 30 22 3.06
3/8 - 16 42 57 5.8 M10 x 1.5 55 40 5.61
7/16 - 14 70 95 9.7 M12 x 1.75 95 70 9.69
1/2 - 13 105 142 14.5 M14 x 2 155 114 15.81
9/16 - 12 150 203 20.7 M16 x 2 240 177 24.48
5/8 - 11 205 278 28.3 M20 x 2.25 465 343 47.43
3/4 - 10 360 488 49.7 M24 x 3 800 590 81.6
7/8 - 9 575 780 79.4 M30 x 3.5 1600 1180 163.2
1-8 860 1166 119 M36 x 4 2750 2028 280.5
1 - 12 915 1240 126
1 1/8 - 7 1230 1670 170
1 1/8 - 12 1330 1800 184
1 1/4 - 7 1715 2325 237
1 1/4 - 12 1840 2495 254
1 3/8 - 6 2270 3080 313
1 3/8 - 12 2475 3355 342
1 1/2 - 6 2980 4040 411
1 1/2 - 12 3225 4375 445
39
CEN00051-01 00 Index and foreword
Standard tightening torques for fittings
Table 7: Torques for O-ring boss fittings
Tube
Table 6: Torques for JIC 37° swivel nuts Size Threads Torque Torque
size
(with or without O-ring seals) code UNF-2B ft lb N·m
(O.D.)
Tube –2 0.125 0.312–24 4±2 6±3
Size Threads Torque Torque
size
code UNF-2B ft lb N·m –3 0.188 0.375–24 5±2 7±3
(O.D.)
–2 0.125 0.312–24 4±1 5±1 –4 0.250 0.438–20 8±3 11 ± 4
–3 0.188 0.375–24 8±3 11 ± 4 –5 0.312 0.500–20 10 ± 3 13 ± 4
–4 0.250 0.438–20 12 ± 3 16 ± 4 –6 0.375 0.562–18 13 ± 3 18 ± 4
–5 0.312 0.500–20 15 ± 3 20 ± 4 –8 0.500 0.750–16 24 ± 5 33 ± 7
–6 0.375 0.562–18 18 ± 5 24 ± 7 – 10 0.625 0.875–14 32 ± 5 43 ± 7
–8 0.500 0.750–16 30 ± 5 41 ± 7 – 12 0.750 1.062–12 48 ± 5 65 ± 7
– 10 0.625 0.875–14 40 ± 5 54 ± 7 – 14 0.875 1.188–12 54 ± 5 73 ± 7
– 12 0.750 1.062–12 55 ± 5 74 ± 7 – 16 1.000 1.312–12 72 ± 5 98 ± 7
– 14 0.875 1.188–12 65 ± 5 88 ± 7 – 20 1.250 1.625–12 80 ± 5 108 ± 7
– 16 1.000 1.312–12 80 ± 5 108 ± 7 – 24 1.500 1.875–12 80 ± 5 108 ± 7
– 20 1.250 1.625–12 100 ± 10 136 ± 14 – 32 2.000 2.500–12 96 ± 10 130 ± 14
– 24 1.500 1.875–12 120 ± 10 162 ± 14
– 32 2.000 2.500–12 230 ± 20 311 ± 27
40
00 Index and foreword CEN00051-01
Table 8: Torques for O-ring face seal fittings
Table 9: Torques for flared tube and hose fittings
Tube
Size Threads Torque Torque
size Nut Width
code UNF-2B ft lb N·m Torque Torque Torque
(O.D.) Thread Across
N·m ft lb kg·m
Diameter Flat
–4 0.250 0.438–20 11 ± 1 15 ± 1 (± 10%) (± 10%) (± 10%)
(mm) (mm)
–6 0.375 0.562–18 18 ± 2 24 ± 3
14 19 25 18 2.5
–8 0.500 0.750–16 35 ± 4 47 ± 5
18 24 50 36 5
– 10 0.625 0.875–14 51 ± 5 70 ± 8
22 27 80 58 8
– 12 0.750 1.062–12 71 ± 7 96 ± 9
24 32 140 101 14
– 16 1.000 1.312–12 98 ± 6 133 ± 8
30 36 175 130 18
– 20 1.250 1.625–12 132 ± 7 179 ± 9
33 41 195 145 20
– 24 1.500 1.875–12 165 ± 15 224 ± 20
36 46 245 180 25
42 55 295 215 30
Table 10: Torques for pipe thread fittings
Torque with Torque with Torque without Torque without
Size Pipe thread
sealant sealant sealant sealant
code size
ft lb N·m ft lb N·m
–2 0.125–27 15 ± 3 20 ± 4 20 ± 5 27 ± 7
–4 0.250–18 20 ± 5 27 ± 7 25 ± 5 34 ± 7
–6 0.375–18 25 ± 5 34 ± 7 35 ± 5 47 ± 7
–8 0.500–14 35 ± 5 47 ± 7 45 ± 5 61 ± 7
– 12 0.750–14 45 ± 5 61 ± 7 55 ± 5 74 ± 7
– 16 1.000-11.50 55 ± 5 74 ± 7 65 ± 5 88 ± 7
– 20 1.250–11.50 70 ± 5 95 ± 7 80 ± 5 108 ± 7
– 24 1.500–11.50 80 ± 5 108 ± 7 95 ± 10 129 ± 14
– 32 2.000–11.50 95 ± 10 129 ± 14 120 ± 10 162 ± 14
41
CEN00051-01 00 Index and foreword
Standard tightening torques for clamps
Table 12: Torques for split flange clamp bolts
Capscrew Width
Table 11: Torque for T-bolt type Torque Torque Torque
Thread Across
hose clamp (SAE J1508 type TB) N·m ft lb kg·m
Diameter Flat
(± 10%) (± 10%) (± 10%)
Band Thread Torque Torque (mm) (mm)
Width Size in. lb N·m
10 14 66 48 6.7
19.05 mm 0.25–28
75 ± 5 8.5 ± 0.6 12 17 112 83 11.5
(0.75 in.) UNF
16 22 279 206 28.5
42
00 Index and foreword CEN00051-01
Conversion tables
Common conversion multipliers
Table 13: English to metric Table 14: Metric to English
Multiply Multiply
From To From To
by by
inch (in.) millimeter (mm) 25.40 millimeter (mm) inch (in.) 0.0394
inch (in.) centimeter (cm) 2.54 centimeter (cm) inch (in.) 0.3937
foot (ft) meter (m) 0.3048 meter (m) foot (ft) 3.2808
yard (yd) meter (m) 0.914 meter (m) yard (yd) 1.0936
mile (mi) kilometer (km) 1.61 kilometer (km) mile (mi) 0.6210
square centimeter square centimeter
square inch (in.2) 6.45 square inch (in.2) 0.1550
(cm2) (cm2)
square centimeter square centimeter
square foot (ft2) 929 square foot (ft2) 0.001
(cm2) (cm2)
cubic centimeter cubic centimeter
cubic inch (in.3) 16.39 cubic inch (in.3) 0.061
(cm3) (cm3)
cubic inch (in.3) liter (l) 0.016 liter (l) cubic inch (in.3) 61.02
cubic foot (ft3) cubic meter (m3) 0.028 cubic meter (m3) cubic foot (ft3) 35.314
3
cubic foot (ft ) liter (l) 28.317 liter (l) cubic foot (ft3) 0.0353
ounce (oz) gram (g) 28.350 gram (g) ounce (oz) 0.0353
fluid ounce (fl oz) milliliter (ml) 29.573 milliliter (ml) fluid ounce (fl oz) 0.0338
pound (lb) - mass kilogram (kg) 0.454 kilogram (kg) pound (lb) - mass 2.2046
pound (lb) - force Newton (N) 4.448 Newton (N) pound (lb) - force 0.2248
inch pound (in lb) Newton meter (N·m) 0.113 Newton meter (N·m) inch pound (in lb) 8.85
foot pound (ft lb) Newton meter (N·m) 1.356 Newton meter (N·m) foot pound (ft lb) 0.7376
foot pound (ft lb) kilogram meter (kgm) 0.138 kilogram meter (kgm) foot pound (ft lb) 7.2329
pounds/square inch pounds/square inch
kilopascal (kPa) 6.895 kilopascal (kPa) 0.1450
(psi) (psi)
pounds/square inch pounds/square inch
megapascal (MPa) 0.007 megapascal (MPa) 145.038
(psi) (psi)
pounds/square inch kilograms/square kilograms/square pounds/square inch
0.0704 14.2231
(psi) centimeter (kg/cm2) centimeter (kg/cm2) (psi)
short ton kilogram (kg) 907.2 kilogram (kg) short ton 0.0011
short ton metric ton 0.0907 metric ton short ton 1.1023
quart (qt) liter (l) 0.946 liter (l) quart (qt) 1.0567
U.S gallon (gal) liter (l) 3.785 liter (l) U.S gallon (gal) 0.2642
horsepower (HP) kilowatt (kw) 0.745 kilowatt (kw) horsepower (HP) 1.3410
43
CEN00051-01 00 Index and foreword
Table 15: Metric to metric
Multiply
From To
by
Newton meter (N·m) kilogram meter (kgm) 0.102
kilogram meter (kgm) Newton meter (N·m) 9.807
kilograms/square
kilopascal (kPa) 98.068
centimeter (kg/cm2)
kilograms/square
kilopascal (kPa) 0.01
centimeter (kg/cm2)
44
00 Index and foreword CEN00051-01
Temperature conversion table
When converting from Fahrenheit (°F) to Centigrade (°C), consider the center (boldface) column to be a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
When converting from Centigrade (°C) to Fahrenheit (°F), consider the center (boldface) column to be a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
45
CEN00051-01 00 Index and foreword
980E Dump truck
Form No. CEN00051-01
46
CEN01030-00
DUMP TRUCK 1SHOP MANUAL
980E
Machine model Serial number
980E-5 A50137, A50138
01 Specification
Specification and technical data
Specification drawing ............................................................................................................................................ 3
Specifications ........................................................................................................................................................ 4
Weight table .......................................................................................................................................................... 6
Fuel, coolant and lubricants .................................................................................................................................. 7
1
CEN01030-00 01 Specification
NOTES
2
01 Specification CEN01030-00
Specification drawing
10.0 m 32’10”
15.0 m
49’3”
1.8
1
1.88mm 5’10”
5’10”
5.8 m 19’
9.1 m 29’10”
13.90 m 45’7”
7.09 m
23’3”
8.0 m
26’4”
4.9 m
16’1”
2.17 m
7’1” 1.65
1.22
1.22 m 1.22 m
m
4’0” 4’0”
5’5”
4’0”
4.60 m 15’1” 6.65 m 21’10” 5.33 m 17’6” 6.5 m 21’4”
8.0 m 26’4”
16.56 m 54’4”
9.6 m 31’6”
87393
3
CEN01030-00 01 Specification
Specifications
Specification Value
Empty 272 156 kg (600,000 lb)
Nominal load 362 874 kg (800,000 lb)
Gross total 635 030 kg (1,400,000 lb)
Weight
front 135 699 kg (299,165 lb)
distribution
Empty
Weight
rear 129 620 kg (285,763 lb)
front 219 980 kg (484,972 lb)
Loaded
rear 415 050 kg (915,028 lb)
Struck 191 m3 (250 yd3)
Dump body capacity
Performance
Heaped (2:1) 250 m3 (327 yd3)
Max. travel speed 64.4 kph (40 mph)
Gradeability 23.7% at stall
Min. turning diameter 32 m (105 ft)
Dumping angle 45°
Overall length 15.72 m (51 ft 7 in)
Dimensions
Overall width 9.6 m (31 ft 6 in)
Overall height 8 m (26 ft 4 in)
Wheel base 9.1 m (29 ft 10 in)
Ground clearance (empty) 1.22 m (4 ft)
Model KOMATSU SDA16V190
4-cycle, water-cooled, direct injection,
Type
with turbocharger, aftercooler and intercooler
No. of cylinders - Bore x stroke 16 - 190 mm x 210 mm (7.48 in. x 8.27 in.)
Piston displacement 95 L (25.1 gal)
Engine
Rated output 3 281 kW (4,400 hp) at 1,800 rpm
Max. torque 17 406 N·m (12,838 ft lb)
Min. fuel consumption 0.330 lb/hp-hr
Cranking motor 24V, 7.5 kW X 3 units
Battery charging alternator 24V, 275A X 1 unit
Batteries 12V, 1400 CCA, 8D type X 6 units
Motorized wheels AC induction traction motors
AC Drive System
Standard gear ratio 35.02:1
Continuous dynamic retarding 4 476 kW (6,000 hp)
4
01 Specification CEN01030-00
Specification Value
Steering
System
Type Fully hydraulic
Front axle Sliding pillar
Suspension
Suspension method
Rear axle Hydro-pneumatic
Size 59/80 R63
Min. tire pressure 600 kPa (87 psi)
Tires
Front wheel 116 mm (4.6 in.)
Tread (standard tire)
Rear wheel 116 mm (4.6 in.)
Service brakes (front and rear) Multiple wet disc
System
Brake
Parking brake Multiple dry disc
Type Pressure compensated piston pump
Steering/brake pump Delivery
Hydraulic
246 liters/min (65 gpm)
pumps
at 1900 rpm
Type Tandem gear pump
Hoist/brake cooling
pump Delivery
931 liters/min (246 gpm)
at 1900 rpm
Hydraulic systems
Type 3-stage piston
1st stage - 384.2 mm x 945.9 mm
(15.13 in x 37.24 in)
Hoist cylinder 2nd stage - 320.7 mm x 945.9 mm
Bore x stroke
Cylinders
(12.63 in x 37.24 in)
3rd stage - 257.1 mm x 945.9 mm
(10.12 in x 37.24 in)
Piston, double acting
Type
with accumulator assist
Steering cylinder
190.5 mm x 665.7 mm
Bore x stroke
(7.50 in x 26.21 in)
5
CEN01030-00 01 Specification
Weight table
NOTE: This weight table is a guide for use when transporting or handling a component.
Component Approximate Weight
Power module (with sub-frame) 21 773 kg (48,000 lb)
Engine assembly (with oil) 14 061 kg (31,000 lb)
Main traction alternator 6 124 kg (13,500 lb)
Radiator assembly (Radiator & Fan Drive) 3 311 kg (7,300 lb)
Fuel tank assembly 2 177 kg (4,800 lb)
Hydraulic tank assembly (no hydraulic fluid) 816 kg (1,800 lb)
Front suspension cylinder assembly (with oil) 4 363 kg (9,619 lb)
Rear suspension cylinder assembly (with oil) 1 015 kg (2,238 lb)
Hoist cylinder assembly 1 175 kg (2,590 lb)
Steering cylinder assembly 260 kg (573 lb)
Tie rod 383 kg (845 lb)
Bleeddown manifold 170 kg (375 lb)
Pump/hoist valve module (without driveshaft) 765 kg (1,686 lb)
Hoist pump 136 kg (300 lb)
Steering/brake pump 102 kg (225 lb)
Hoist valve 189 kg (417 lb)
Overcenter valve manifold 94 kg (207 lb)
Spindle, hub and brake assembly 6 681 kg (14,728 lb)
Front spindle and hub 3 957 kg (8,724 lb)
Steering arm 352 kg (776 lb)
Front brake assembly 1 687 kg (3,719 lb)
Anti-sway bar 160 kg (353 lb)
Axle housing 7 750 kg (17,100 lb)
Wheel motor assembly 24 000 kg (52,900 lb)
Electric wheel motor 6 135 (13,520 lb)
Transmission/rear brake assembly 17 465 kg (38,500 lb)
Parking brake 173 kg (381 lb)
Final frame structure 31 978 kg (70,500 lb)
Battery box assembly 467 kg (1,030 lb)
Alternator blower air duct 136 kg (300 lb)
Wheel motor blower air duct 181 kg (400 lb)
Cab assembly 2 540 kg (5,600 lb)
Hydraulic brake cabinet 272 kg (600 lb)
Main electrical control cabinet 3 176 kg (7,000 lb)
Auxiliary control cabinet 465 kg (1,025 lb)
Retarding grid 2 600 kg (5,735 lb)
Right deck 1 304 kg (2,875 lb)
Left deck 1043 kg (2,300 lb)
Center deck 1622 kg (3,575 lb)
6
01 Specification CEN01030-00
Fuel, coolant and lubricants
Reservoir Fluid type Recommended fluids Service Capacity
See engine manufacturer’s 500 L (132 gal)
Engine crankcase Engine oil
service manual. including oil filters
Hydraulic tank Hydraulic oil C-4 type (SAE 10W) 1 325 L (350 gal)
Front suspension 148.4 L (39.2 gal)
Suspension oil with See "Suspension cylinder oil and
friction modifier nitrogen specifications".
Rear suspension 61.7 L (16.3 gal)
Grease fittings Multi-purpose extreme
NLGI No. 2 41 kg (90 lb)
Auto lube tank pressure grease
Heavy duty synthetic See drive system manufacturer’s 98 L (26 gal)
Wheel motor
gear oil service manual. per wheel motor
See engine manufacturer’s
Cooling system Coolant 992 L (262 gal)
service manual.
See engine manufacturer’s
Fuel tank Diesel fuel 5 300 L (1,400 gal)
service manual.
7
CEN01030-00 01 Specification
Suspension cylinder oil and nitrogen specifications
HYDRAIR® II oil specifications
Ambient Temperature
Part No. Approved Sources
Range
Mobilfluid 424 Sunfleet TH Universal Tractor Fluid
VJ3911 Mobil DTE 15M Chevron Tractor Hydraulic Fluid
(need to add Texaco TDH Oil Conoco Power Tran III Fluid Petro
6% of AK3761) AMOCO ULTIMATE Motor Oil Canada Duratran Fluid
-34.5°C & above 5W-30 Shell Canada Donax TDL
(-30°F & above) AK4063 Suspension Oil (premixed with 5 gallon container
AK4064 6% Friction Modifier) 55 gallon container
Petro Canada Super Arctic
VJ5925 Emery 2811, SG-CD,
Motor Oil, 0W-30
(need to add 5W-30
Conoco High Performance
6% of AK3761) Mobil Delvac I, 5W-40
Synthetic Motor Oil, 5W-30
-48.5°C & above
AK4065 Suspension Oil (premixed with 5 gallon container
(-55°F & above)
AK4066 6% Friction Modifier) 55 gallon container
NOTE: VJ3911 and VJ5925 oils are not compatible and must not be mixed in a suspension.VJ3911 and
VJ5925 oils are supplied in 5 gallon (19 Liter) cans.
Friction modifier mixing instructions
Friction modifier
(94% suspension oil, 6% friction modifier)
Part number Amount of suspension oil Amount of friction modifier to add
AK3761 1 gallon of suspension oil add 7.7 oz.
(5 Gallon container of 5 gallons of suspension oil add 38.4 oz.
100% Friction Modifier) 55 gallons of suspension oil add 3.3 gal.
Nitrogen gas (N2) specifications
Property Value
Nitrogen gas used in HYDRAIR® II Nitrogen 99.9% Minimum
Suspension Cylinders must meet or Water 32 PPM Maximum
exceed CGA specification G-10.1 for Dew Point -55°C (-68°F) Maximum
Type 1, Grade F Nitrogen Gas
Oxygen 0.1% Maximum
8
01 Specification CEN01030-00
NOTES
9
CEN01030-00 01 Specification
980E Dump truck
Form No. CEN01030-00
10
CEN10062-02
DUMP TRUCK 1SHOP MANUAL
980E
Machine model Serial number
980E-4 A40003 and up
980E-4AT A40003 and up
980E-5 A50005 and up
980E-5AT A50005 and up
10 Structure and functions
Steering circuit
Steering circuit operation ...................................................................................................................................... 2
Steering circuit components.................................................................................................................................. 7
Steering/brake pump operation............................................................................................................................. 9
Flow amplifier operation...................................................................................................................................... 12
1
CEN10062-02 10 Structure and functions
Steering circuit operation Two nitrogen precharged steering accumulators (3,
Steering/brake pump (8, Figure 10-1) supplies oil to Figure 10-1) are mounted on the left frame rail behind
bleeddown manifold (5) after passing through high the front tire. They provide an oil supply that is
pressure filter (9). This oil supply is then distributed to sufficient to allow the operator to steer the truck off the
the various circuits. haul road and park in a safe area if a loss of steering
circuit oil occurs. Steering accumulator bleeddown
The bleeddown manifold performs many functions, solenoid (2, Figure 10-3) is electrically activated to
including distribution of the steering circuit oil supply to bleed the pressurized hydraulic oil from inside the
steering accumulators (3), flow amplifier (4) and accumulators back to the hydraulic tank whenever the
steering cylinders (1). Oil is also provided to the brake engine start switch is turned to the OFF position.
circuit and the auxiliary system manifold. Approximately 90 seconds is required for the
NOTE: The hoist pilot circuit passes through the accumulator to bleed down fully.
bleeddown manifold, but is not supplied by the The bleeddown manifold and steering accumulators
steering/brake pump. It is supplied by the hoist pump. supply oil to flow amplifier (4, Figure 10-1). The flow
Oil pressure from the bleeddown manifold is routed amplifier directs oil flow to the appropriate ports on the
back to the steering/brake pump and sensed by “ACC” steering cylinders as determined by inputs from the
port (7, Figure 10-6) on the unloader valve located on steering control unit (as the operator steers the truck).
the steering/brake pump. The unloader valve regulates Oil entering the steering control unit is blocked until the
the system pressure between 22 065 kPa (3,200 psi) steering wheel is turned in a desired direction. The
and 24 130 kPa (3,500 psi). Steering system pressure steering control unit then directs oil to the flow
switch (10, Figure 10-3) on the bleeddown manifold amplifier, which in turn provides a high volume of oil to
activates a warning if the steering system pressure steering cylinders (1, Figure 10-1). Hydraulic oil at the
drops below 15 858 kPa (2,300 psi). Pressure switch opposite ends of the steering cylinders flows back
(1, Figure 10-3) confirms that hydraulic pressure is through the flow amplifier and bleeddown manifold to
fully relieved at the completion of the bleeddown cycle. hydraulic tank (6).
Auxiliary system pressure switch (18, Figure 10-3) Oil flow to the brake apply circuit flows through a check
controls a solenoid valve in the auxiliary system valve, preventing loss of oil in the brake circuit if a loss
manifold. When the steering system pressure is above of oil occurs in the steering circuit. Refer to Section 10,
18,960 kPa (2,750 psi), the switch sends a signal Structure and functions, Brake circuit for more
current to the solenoid valve to open. When the information.
steering system pressure drops below 17,580 kPa
(2,550 psi), the signal current is removed, causing the
solenoid valve to close, and all steering/brake pump NOTE: Refer to Section 90, Diagrams and drawings,
supply returns to the steering and brake circuits. Steering, hoist and brake cooling hydraulic circuit
schematic for more details on the hydraulic circuit
operation.
2
10 Structure and functions CEN10062-02
5
2
8 86994
FIGURE 10-1. STEERING CIRCUIT COMPONENTS - TYPICAL
1. Steering Cylinders 6. Hydraulic Tank
2. Steering Cylinder Manifold 7. Steering/Brake Pump
3. Steering Accumulators (Piston Type) 8. High Pressure Filter
4. Flow Amplifier 9. Hoist Pump
5. Steering Bleeddown Manifold
3
CEN10062-02 10 Structure and functions
5
6
8
3 4
10 11 12
7
9
1
13
16
15 14
86244
FIGURE 10-2. BLEEDDOWN MANIFOLD PIPING
1. Supply To Flow Amplifier 9. Supply From Pump
2. Return From Flow Amplifier 10. Return From Hoist Pilot Valve
3. To Front Steering Accumulator 11. Hoist Pilot Valve, Power Down
4. To Rear Steering Accumulator 12. Hoist Pilot Valve, Power Up
5. Supply Port (Quick Disconnect) 13. Feedback Pressure to Unloader Valve
6. Return Port (Quick Disconnect) 14. To Hoist Valve, Power Up
7. To Auxiliary Hydraulic System 15. To Hoist Valve, Power Down
8. Return to Tank 16. To Brake System
4
10 Structure and functions CEN10062-02
5
6
2
15
3 4
18
10
8
17
16
14
13 12 11
9 86243
FIGURE 10-3. BLEEDDOWN MANIFOLD COMPONENTS
1. Steering Bleeddown Pressure Switch 10. Steering System Pressure Switch
2. Steering Accumulator Bleeddown Solenoid 11. Test Port (TP2)
3. Relief Valve - 4 100 kPa (600 psi) 12. Check Valve
4. Relief Valve - 27 500 kPa (4,000 psi) 13. Check Valve
5. Pilot Operated Check Valve 14. Check Valve
6. Hoist Up Limit Solenoid 15. Test Port (TP3)
7. Pilot Operated Check Valve 16. Check Valve
8. Inlet Check Valve 17. Check Valve
9. KOMTRAX Plus Steering Pressure Sensor 18. Auxiliary System Pressure Switch
5
CEN10062-02 10 Structure and functions
18 11 19 20 10 21 22 23 12 24 39 25 15
8 1
TP2 TP4 TP3
9
TP1
26
38
16
4 13
37
27
36
17 14
TP9
6 2
35 28
TP10
TP8 TP7 TP6 TP5
7 34 33 32 34 31 3 5 29 87540
FIGURE 10-4. BLEEDDOWN MANIFOLD SCHEMATIC
1. Pressure Switch (Bleeddown) 21. Pantograph (plugged)
2. Steering Accumulator Bleeddown Solenoid 22. Radiator Shutters (plugged)
3. Relief Valve - 4 100 kPa (600 psi) 23. Spare Pressure (plugged)
4. Relief Valve - 27 500 kPa (4,000 psi) 24. Brake Circuit Supply
5. Pilot Operated Check Valve 25. Steering Accumulator (ACC2)
6. Hoist Up Limit Solenoid 26. Supply to Flow Amplifier
7. Pilot Operated Check Valve 27. Supply Port (Quick Disconnect)
8. Inlet Check Valve 28. Return From Flow Amplifier
9. Komtrax Steering Pressure Sensor (TP1) 29. Return Port (Quick Disconnect)
10. Steering System Pressure Switch 30. Spare Return (plugged)
11. Test Port (TP2) 31. Lube (plugged)
12. Check Valve 32. Hoist Pilot Return
13. Check Valve 33. Hoist Pilot Power Down
14. Check Valve 34. Hoist Pilot Power Up
15. Test Port (TP3) 35. Tank Return
16. Check Valve 36. Hoist Power Up
17. Check Valve 37. Hoist Power Down
18. Steering Accumulator (ACC1) 38. Inlet (from Steering/Brake Pump)
19. APU (to Auxiliary System Manifold) 39. Spare Brake (plugged)
20. Pressure Feedback (to Steering/Brake Pump)
6
10 Structure and functions CEN10062-02
Steering circuit components Steering accumulators
Steering control unit Two piston type steering accumulators (3, Figure 10-1)
are mounted on the left side of the truck. Each
Steering control unit (1, Figure 10-5) is mounted inside accumulator has a capacity of 62 liters (16.5 gallons),
the cab and is directly coupled to the lower end of the and each is precharged to 9 650 kPa (1,400 psi) with
steering column. The steering control unit incorporates pure dry nitrogen.
a rotary meter which ensures that the oil volume
supplied to the steering cylinders is proportional to the Oil entering the accumulators compresses the piston
rotation of the steering wheel. The steering control unit against the nitrogen. The nitrogen pressure increases
is a closed circuit system. directly with steering circuit pressure. When steering
circuit pressure reaches 24 305 kPa (3,525 psi), the
Operation of the steering control unit is both manual unloader valve will unload the pump. The
and hydraulic in effect. This component incorporates a accumulators will contain a quantity of oil, under
hydraulic control valve. Steering effort applied to the pressure and held by check valves in the bleeddown
steering wheel by the operator actuates the valve, manifold, that will be available for steering the truck.
which in turn directs hydraulic oil through flow amplifier When system pressure drops to 22 065 kPa (3,200
valve (2) to the steering cylinders to provide the psi), the pump output will again increase to refill the
operator with power steering. accumulators and increase the steering system
pressure. The accumulators also provide oil for a
limited period of time to be used in case the steering/
1 brake pump becomes inoperative.
2 A pressure switch located in the top of each
T accumulator monitors the precharge pressure when
L LS the engine start switch is turned ON before the engine
P
R is started. If the nitrogen pressure drops below 7 600
kPa (1,100 psi), a warning is activated. A latching
LS
circuit prevents the warning from turning off when the
T engine is started and steering system pressure
L
compresses the remaining nitrogen in the
L P accumulator.
R 86257
FIGURE 10-5. STEERING CONTROL UNIT / Do not operate the truck with a precharge pressure
FLOW AMPLIFIER VALVE CIRCUIT of less than 7 600 kPa (1,100 psi) in the
1. Steering Control Unit “T”: Tank Port accumulator. Low nitrogen pressure may not
2. Flow Amplifier Valve “L”: Left Steer Port provide an adequate supply of steering system oil
“P”: Pressure Supply Port in some emergency conditions.
“R”: Right Steer Port
“LS”: Load Sense Port If the low precharge warning remains active, wait
approximately three minutes after the steering
accumulators are completely depressurized to
High pressure filter check the accumulator precharge pressure and
High pressure filter (9, Figure 10-1), located on the recharge the accumulator, if necessary.
back of the fuel tank, filters oil for the steering and
brake apply circuits.
If the filter element becomes restricted, a warning is
activated at 241 kPa (35 psi) differential. Oil will start to
bypass the element when the pressure differential
exceeds 345 kPa (50 psi).
7
CEN10062-02 10 Structure and functions
Bleeddown manifold Quick disconnect ports
Bleeddown manifold (5, Figure 10-1) is located on the Two quick disconnect ports on the bleeddown
outside of the left frame rail just behind the manifold allow service personnel to connect an
accumulators. external hydraulic supply to allow operation of the
The bleeddown manifold receives oil from the steering/ truck steering and service brakes if the steering/brake
brake pump through a high pressure filter and directs pump or engine is not operational.
oil to the steering accumulators, flow amplifier, brake The external supply is connected to port (5, Figure 10-
apply circuit, and the auxiliary system. The manifold 2) and the return is connected to port (6) on top of the
also provides hoist circuit control when the body is bleeddown manifold. This feature should only be used
raised. for an emergency to allow operation of the truck to
return to the shop for service or to move the truck out
Relief valve (4, Figure 10-3) limits the hydraulic supply
of haul road traffic.
pressure to the steering and brake circuits to 27 500
kPa (4,000 psi). Relief valve (3) provides maximum
Flow amplifier
pressure protection of 4 100 kPa (600 psi) for the oil
returning to the hydraulic tank. Flow amplifier (4, Figure 10-1), located on the left
frame rail in front of the accumulators, provides the
NOTE: The relief valves, steering accumulator steering circuit with the high volume of oil required for
bleeddown solenoid, and hoist up limit solenoid are the steering cylinders.
factory preset and cannot be individually rebuilt.
The flow amplifier uses the amount of flow from the
Steering accumulator bleeddown solenoid steering control unit to determine a proportional
amount of flow to send from the bleeddown manifold to
Each time the engine start switch is turned OFF with
the steering cylinders.
the truck stopped, steering accumulator bleeddown
solenoid (2, Figure 10-3) is energized. When the
solenoid is energized, all hydraulic steering pressure
(including the accumulators) is bled back to the
hydraulic tank. Brake pressure, however, will not
bleeddown due to internal check valves in the brake
manifold and bleeddown manifold.
After approximately 90 seconds, the solenoid will de-
energize to close the return port to the hydraulic tank.
By this time, all the oil in the accumulators should be
returned to the hydraulic tank. At startup, the steering
circuit and brake circuit will be charged. Steering
system pressure switch (10, Figure 10-3) will activate
a low steering pressure warning until steering pressure
reaches 15 858 kPa (2,300 psi).
If steering pressure falls below 15 858 kPa (2,300 psi)
during operation, the low steering pressure warning
will be activated until pressure returns to normal.
8
10 Structure and functions CEN10062-02
Steering/brake pump operation
The steering/brake pump is mounted on the rear of the
hoist pump. The driveshaft mates with an internally 1
splined coupling inside the hoist pump when the pump
is bolted in place.
The steering/brake pump is piston-type pump with an
unloader valve. The pump-mounted unloader valve
maintains system pressure between 22 065 kPa
(3,200 psi) and 24 305 kPa (3,525 psi).
Oil flow from the pump is routed through a high
pressure filter, then to the bleeddown manifold, where
the flow is directed to the steering circuit and to the
brake apply circuit components located in the
hydraulic brake cabinet.
3 4 2
High altitude operation
Stroke adjuster (9, Figure 10-6) is set at the factory to
provide maximum pump flow so adjustment is not
normally required. If the truck is operated at high 5
altitude locations of 3 050 meters (10,000 feet) or
more above sea level, it may be necessary to readjust
the stroke control to reduce pump flow to prevent
pump cavitation under certain conditions. If the truck is
operating at high altitude and problems occur, consult 10
your Komatsu service representative for adjustment
procedures.
6
9 8 7 86808
FIGURE 10-6. PUMP ASSEMBLY
1. Outlet (to Filter) 6. GPA Test Port
2. GP4 Test Port 7. GP2 Test Port
3. ACC Port 8. Unloader Adjuster
4. Case Drain 9. Stroke Adjuster
5. Inlet (from Tank) 10. Driveshaft
9
CEN10062-02 10 Structure and functions
FIGURE 10-7. STEERING PUMP PRESSURE CONTROL SCHEMATIC
1. 4-Way Valve 4. Case Drain 6. GP4 Port
2. Unloader Control Block 5. GP2 Port 7. GPA Test Port
3. “ACC” Port
Neutral position
Neutral position (Figure 10-8) results when control
piston (1) centers swashblock (4). The swashblock
angle is zero and the swashblock face is parallel to the
splined housing face. Therefore, no inward or outward
motion of pistons (3) exists as the piston shoes rotate
around the swashblock face. The lack of inward and
outward motion results in no fluid being displaced from
the piston bores to the crescents in the valve plate
and, subsequently, no delivery from pump ports.
FIGURE 10-8. PUMP IN NEUTRAL POSITION
1. Control Piston 3. Piston
2. Splined Housing 4. Swashblock
10
10 Structure and functions CEN10062-02
Full pump volume Half pump volume
Control piston (1, Figure 10-9) controls the angle of The position of control piston (1, Figure 10-10) is near
swashblock (4). When the control piston moves to the the center of its travel. Swashblock (4) is not angled as
full right position, the pump is at maximum pumping steeply as before. Therefore, the pistons have a
capacity. shorter stroke. As the piston stroke gets shorter, the
The driveshaft turns splined housing (2), which pump output also decreases.
contains pistons (3). When the housing is rotated, the
pistons move in and out of their bores and the piston
shoes “ride” against the angled swashblock.
As the cylinder rotates, the individual piston bores are
connected alternately to the left (port “A”) and right
(port “B”) crescent shaped ports in the valve plate.
While connected to left side (suction) port “A”, each
piston moves outward, drawing oil from port “A” into
the piston bore until its outermost stoke is reached. At
that point, the piston bore passes from the left
crescent port to the right crescent port.
While rotating across the right side crescent, each
piston moves downward on the angled swashblock
face. Thus, each piston is forced inward. Each piston
displaces fluid through the right side crescent to port
“B” until its innermost stroke is reached. At that point, FIGURE 10-10. HALF PUMP VOLUME
the piston bore again passes from the right to the left 1. Control Piston 3. Piston
side crescent and the operating cycle is repeated. 2. Splined Housing 4. Swashblock
FIGURE 10-9. FULL PUMP VOLUME
1. Control Piston 3. Piston
2. Splined Housing 4. Swashblock
11
CEN10062-02 10 Structure and functions
Flow amplifier operation
No steer
Refer to Figure 10-11.
High pressure oil from the steering pump and steering
accumulators is available through the bleeddown
manifold to the “HP” port on the flow amplifier.
Upon entering the priority valve, the oil goes past the
spool to the closed amplifier valve and also out port “P”
through a hose to port “P” on the steering control unit.
In the steering control unit, the oil goes to a closed
area in the control.
As pressure builds up in these two areas, oil passes
through orifices in the end of the priority valve and
builds pressure on the end of the valve and port PP.
When pressure reaches approximately 1 600 kPa (232
psi), the spool moves, compressing its spring and
closing off oil supply through area “A”, resulting in high
pressure at “PP” but only 1 600 kPa (232 psi) at the
amplifier spool and steering control unit.
12
10 Structure and functions CEN10062-02
FIGURE 10-11. FLOW AMPLIFIER - NO STEER
13
CEN10062-02 10 Structure and functions
Steering left This combined oil going to the center area “Q” of the
Refer to Figure 10-12. directional valve passes out port “CL” of the flow
amplifier and travels to the steering cylinders to steer
When the operator turns the steering wheel to the left, the front wheels to the left. As the cylinders move, oil is
the steering control unit is opened to allow oil coming forced to return out the opposite ends, enter port “CR”
in port “P” to pass to the gerotor section of the control of the flow amplifier, pass through the directional valve
unit to turn the rotor. Oil in the other side of the gerotor to area “M”, pass through return check valve “N”, and
flows through other passages in the control unit valve exit port “HT” to the hydraulic reservoir.
and out steering control unit port “L”. This oil enters
port “L” of the flow amplifier and goes to a closed area At the steering control unit, when the operator turned
“B” in the directional valve. the steering wheel, supply oil from port “P” was also
delivered through the control unit valve to port “LS”.
As pressure in area “B” builds, it also passes into the This oil enters the flow amplifier through its “LS” port
spool through orifice “C” to the spring area on the end and builds pressure in the spring area of the priority
of the directional valve. The pressure then moves the valve. This additional force on the spring end of the
spool compressing the springs on the opposite end. priority valve causes area “A” to open and allow the
This movement allows the oil entering area “B” to pass necessary flow and pressure to pass through the flow
through the directional valve to area “D” of the amplifier to operate the steering cylinders.
amplifier valve, through holes in sleeve “E” to a
passage between sleeve “E” and valve “F”, and The flow amplifier includes a relief valve in the priority
through hole “G” in sleeve “E”, where it initially is valve spring area that is used to control maximum
blocked by the valve body. steering working pressure to 20 685 kPa (3,000 psi),
even though supply pressure coming in to port “HP” is
As pressure builds up in this area, oil also flows from higher. When 20 685 kPa (3,000 psi) is obtained, the
area “D”, around the outside of sleeve “E”, around pin relief valve prevents the “LS” pressure from
“H”, through orifice “J” to build pressure on the end of increasing, thereby allowing the priority valve to
the amplifier valve, and opens hole “G” just enough to compress the spring enough to close off area “A”.
allow the flow of oil coming from the steering control
unit to pass to the control area of the directional valve.
At the same time, the movement of sleeve “E” opened
the holes near the spring end to allow the oil from the
priority valve to flow into the center of sleeve “E”.
This oil now inside sleeve “E” pushes valve “F” against
its spring to give the oil access to a series of holes “K”
that are in the same plane as hole “G”. The passage of
oil through holes “K” past the valve body is metered by
holes “K” being opened the same proportion as hole
“G”. The number of holes “K” (7) in sleeve “E”
determine the amount of additional oil that is added to
the steering control unit oil passing through hole “G”.
14
10 Structure and functions CEN10062-02
86868
FIGURE 10-12. FLOW AMPLIFIER - STEERING LEFT
15
CEN10062-02 10 Structure and functions
Steering right
Refer to Figure 10-13.
There are only a few differences between steering left
and steering right. When the operator turns the
steering wheel right, oil is supplied out ports “R” and
“LS” of the steering control unit.
The oil enters the flow amplifier assembly at port “R”
and shifts the directional valve the opposite direction.
The oil flows through the amplifier valve in exactly the
same way. The combined oil from the amplifier valve
passes through the center area “Q” of the directional
valve to port “CR”, where it goes to the opposite ends
of the steering cylinders to turn the wheels to the right.
The returning oil comes back through port “CL” to go to
the tank. The “LS” oil operates exactly the same as
steering left.
16
10 Structure and functions CEN10062-02
86867
FIGURE 10-13. FLOW AMPLIFIER - STEERING RIGHT
17
CEN10062-02 10 Structure and functions
No steer, external shock load
Refer to Figure 10-14.
When the operator is not turning the steering wheel,
the steering control unit valve supply is closed. The
directional valve remains centered by its springs, thus
closing the passages to ports “CL” and “CR”. This
creates a hydraulic lock on the steering cylinders to
prevent their movement.
If the tires hit an obstruction that causes a large shock
load, forcing the wheels to the left, increased pressure
will occur in the ends of the cylinders connected to port
“CR”. The shock and suction relief valve inside the
flow amplifier at port “CR” will open at its adjusted
setting of 24 000 kPa (3,480 psi) and allow oil to
escape from the pressurized ends of the cylinders,
preventing a higher pressure.
As the cylinders are allowed to move, the other ends
will have less than atmospheric pressure on port “CL”.
This low pressure permits oil that is escaping through
the “CR” port relief valve to flow through the check
valve portion of the shock and suction relief valve
connected to port “CL”. The oil then flows to the low
pressure ends of the cylinders to keep the cylinders
full of oil and prevent cavitation. A shock load in the
opposite direction merely reverses the above
procedure.
18
10 Structure and functions CEN10062-02
86869
FIGURE 10-14. FLOW AMPLIFIER - NO STEER, EXTERNAL SHOCK LOAD
19
CEN10062-02 10 Structure and functions
980E Dump truck
Form No. CEN10062-02
20
CEN10067-01
DUMP TRUCK 1SHOP MANUAL
980E
Machine model Serial number
980E-4 A40003 and up
980E-5 A50005 and up
10 Structure and functions
Hoist circuit
Hoist circuit operation ........................................................................................................................................... 3
Hoist circuit components ....................................................................................................................................... 4
Hoist pilot valve operation..................................................................................................................................... 8
1
CEN10067-01 10 Structure and functions
NOTES
2
10 Structure and functions CEN10067-01
Hoist circuit operation The hoist valve directs oil to hoist cylinders (10) for
raising and lowering of the dump body. Hoist valve
Hydraulic oil is supplied by a hydraulic tank (1, Figure
functions are controlled by the operator through the
10-1) located on the left frame rail. Hydraulic oil is
hoist control lever that is connected to hoist pilot valve
routed to hoist pump (2). A second pump, coupled to
(4) located in the hydraulic brake cabinet. Hoist limit
the rear of the hoist pump, supplies oil for the steering
solenoid (5), located in the bleeddown manifold, shifts
and brake systems. The pumps are driven by an
the hoist valve out of POWER UP before the hoist
accessory drive at the end of the traction alternator.
cylinders extend to their maximum physical limit.
Hoist pump output is directed to a pair of high pressure
When the hoist valve is in the HOLD or FLOAT
filters (3) mounted on the back of the fuel tank.
position, hoist circuit oil flows to the front and rear
Hydraulic oil from the hoist filters is directed to hoist
service brakes, cooling the wet disc brakes during
valve (7), which is mounted above the pumps.
truck operation.
FIGURE 10-1. HOIST CIRCUIT SCHEMATIC
1. Hydraulic Tank 6. Pilot Operated Check Valve 11. Quick Disconnect
2. Hoist Pump 7. Hoist Valve 12. Overcenter Manifold
3. High Pressure Filter 8. Brake Cooling Oil Supply (Front) 13. Check Valve
4. Hoist Pilot Valve 9. Brake Cooling Oil Supply (Rear) 14. Counterbalance Valve
5. Hoist Limit Solenoid 10. Hoist Cylinder 15. Bleeddown Manifold
3
CEN10067-01 10 Structure and functions
Hoist circuit components A smaller piston type, pressure compensated pump,
rated at 250 l/m (66 gpm) at 1,900 rpm, is coupled to
Hydraulic tank the hoist pump. It supplies oil to the steering system
The hydraulic tank supplies hydraulic oil for the hoist, and brake apply system.
steering and brake circuits. The hydraulic tank is Hoist pressure is limited to 18 960 kPa (2,750 psi) by
located on the left frame rail in front of the rear wheels. internal relief valves located in the hoist control valve
Type C-4 hydraulic oil is recommended for use in the inlet sections.
hydraulic system. Oil used in the hoist circuit flows
through 100 mesh wire suction strainers to the inlet High pressure filters
hoses of the pump. Air drawn into the tank during
Hoist pump output oil is directed to the high pressure
operation is filtered by air filters located on the top of
filters mounted on the inboard side of the fuel tank.
the hydraulic tank. The oil level can be checked
The filter assemblies are equipped with a bypass valve
visually at sight glasses located on the face of the
which permits oil flow if the filter element becomes
hydraulic tank.
excessively restricted. Flow restriction through the
Hoist pump filter element is sensed by an indicator switch which
will activate a warning in the cab to indicate that filter
Hoist pump (6, Figure 10-2) is a tandem, gear type service is required when the restriction reaches
pump driven by a driveshaft on the end of the traction approximately 241 kPa (35 psi). Actual filter bypass
alternator. The pump has a total output of 931 L/m will start to occur when the filter element restriction
(246 gpm) at 1,900 rpm and 18 960 kPa (2,750 psi). reaches approximately 345 kPa (50 psi).
1
2 3
6 86246
FIGURE 10-2. PUMP MODULE
1. Hoist Valve 4. Quick Disconnects
2. Counterbalance Valve 5. Steering/Brake Pump
3. Overcenter Manifold 6. Hoist Pump
4
10 Structure and functions CEN10067-01
Hoist valve Inlet sections
Hoist valve (1, Figure 10-2) is mounted on a modular Each of the front and rear inlet sections of the hoist
assembly containing the hoist valve, overcenter valve contains of the following components:
manifold, and both hydraulic pumps. This assembly is • Flow control valve and main relief valve
bolted to brackets attached to the frame rails behind
the main alternator. The hoist valve is a split spool • Secondary low pressure relief valve
design. The term “split spool” describes the spool • Anti-void check valve
section of the valve.
• Load check valve
The hoist valve precisely follows the differential The flow control portion of the flow control and main
pressure input signals generated by the hoist pilot relief valves allow pump flow to be diverted to the
valve when the operator moves the hoist control lever service brake cooling circuit unless the body is being
while raising and lowering the dump body. raised or lowered. The relief portion of this valve is
direct-acting and has the capacity to limit the
maximum working pressure at full pump flow.
The secondary low pressure relief valve is located
between the low pressure core and the outlet to the
brake cooling circuit. It provides pressure relief if
pressure spikes occur in the low pressure passage
area.
The load check allows free flow from the inlet to the
high pressure core and prevents flow from the high
pressure core to the inlet.
The anti-void check valve allows free flow from the low
pressure core to the high pressure core and prevents
flow from the high pressure core to the low pressure
core.
Tank ports (front) spool section
The primary low pressure valves are located in the
front spool section of the hoist valve. These valves
maintain back pressure on the low pressure passage
FIGURE 10-3. HOIST VALVE and direct the hoist cylinder return oil back to the
hydraulic tank.
1. Inlet Section 4. Inlet Section
2. Work Ports Spool 5. Inlet Port
Section 6. Outlet Port
3. Tank Ports Spool 7. Spool Section Cover
Section 8. Separator Plate
5
CEN10067-01 10 Structure and functions
Work ports (rear) spool section Hoist pilot valve
The rear spool section of the hoist valve consists of the Hoist pilot valve (1, Figure 10-4) is mounted in the
following components: hydraulic brake cabinet behind the operator cab. The
hoist pilot valve spool is spring centered to the neutral
• Pilot ports
position and is controlled directly by the operator
• Main spools through a lever mounted on the console between the
• Work ports operator and passenger seat. A cable connects the
cab mounted lever to the hoist pilot valve in the
• Check poppets hydraulic components cabinet.
The pilot ports are located in the spool section cover. When the operator moves the hoist control lever, the
These ports provide connections for a pilot line to the pilot valve spool moves and directs pilot flow to the
hoist pilot valve. Each work port has a corresponding appropriate pilot port on the hoist valve. The pilot flow
pilot port. causes the main spool to direct oil flow to the hoist
The work ports provide for a line connection between cylinders.
the spool section and the hoist cylinders. One main The hoist pilot valve is equipped with a one-way load
spool for each work port is spring biased on both ends. check valve which allows free flow from the center
This blocks the work port from the high and low passage to bridge core and prevents reverse flow. The
pressure cores when there is no flow through the spool valve also contains power down relief valve (2), which
cross-holes. limits the power down pressure to 10 400 kPa (1,500
When there is flow through the pilot ports to the psi).
spools, a positive differential pressure occurs at the
top of the spool, overcomes the bottom spring bias
and causes the spool to shift, connecting the work port
to the high pressure core.
When there is flow from the main valve work port to
the pilot port through the cross-holes, a positive
differential pressure at the bottom of the spool occurs,
overcoming the top spring bias and the spool will shift
to connect the work port to the low pressure core.
The check poppets located in the spool section permit
free flow from the work port to the pilot port and restrict
flow from the pilot port to the work port. These check
poppets control spool response and spool movements
during void conditions.
FIGURE 10-4. HOIST PILOT VALVE
1. Hoist Pilot Valve 4. To Hoist Valve
2. Power Down Relief (Rod End)
Valve 5. To Hoist Valve
3. Supply Port (Base End)
6. Return to Tank
6
10 Structure and functions CEN10067-01
NOTE: The pilot valve/hoist valve hydraulic circuit is
routed through the bleeddown manifold located on the
left frame rail. The hoist limit solenoid and pilot
operated check valve described below are contained
in the manifold. Refer to Structure, functions and
maintenance standard section Steering circuit for
more information about the bleeddown manifold.
1
Hoist limit solenoid
Hoist limit solenoid (5, Figure 10-5), located in the 2
bleeddown manifold, is used in the hydraulic circuit to
prevent maximum hoist cylinder extension.
The 3-way valve solenoid valve is controlled by a
proximity switch (hoist limit switch) located near the
body pivot and the right rear suspension upper mount.
When the body is nearly fully raised, the body
activates the magnetic proximity switch, signaling the
solenoid to open the “raise” pilot line to the tank, and 86247
close the “raise” pilot line to the hoist valve, thus
FIGURE 10-5. BLEEDDOWN MANIFOLD
stopping further oil flow to the hoist cylinders.
1. Hoist Limit Solenoid 2. Pilot operated
Pilot operated check valve check valve
Pilot operated check valve (6, Figure 10-5), located in
the bleeddown manifold, is opened by power down
pilot pressure to allow oil in the raise port to bypass the
hoist limit solenoid for initial power down operation
Overcenter manifold
while the solenoid is activated by the hoist limit switch.
Overcenter manifold (3, Figure 10-2) contains
counterbalance valve (2), which controls the pressure
of the cushion of oil in the annulus area of the hoist
cylinder when the body approaches the maximum
dump angle. The counterbalance valve limits the
maximum pressure buildup by relieving pressure in
excess of 20 700 kPa (3,000 psi), preventing possible
seal damage.
Quick disconnect fittings (4) allow dumping of the load
in a disabled truck by connecting jumper hoses to the
hydraulic system of an operational truck.
7
CEN10067-01 10 Structure and functions
Hoist pilot valve operation Float position with body down
Refer to Figure 10-6 through Figure 10-10 for oil flow Refer to Figure 10-6.
paths during the following hoist circuit conditions:
Figure 10-6 shows the position of the hoist pilot valve
• Float (with body down) when the truck body is resting on the frame. However,
• Power up the hoist valve internal valves and spools will be in the
position shown in Figure 10-8.
• Hold
Oil from the hoist pump enters the inlet sections of the
• Power down hoist valve in supply port (11), passes through load
• Float check valve (18), and stops at closed high pressure
passage (19) at rod end spool (7) and head end spool
(8).
Pressure builds to approximately 414 kPa (60 psi) on
the pilot of flow control valve (2), causing the valve to
compress the spring and open, which allows the oil to
flow through brake cooling circuit port (23) to the
service brakes for brake disc cooling and eventually
back to the tank. Between brake cooling circuit port
(23) and the brakes or heat exchanger, the cooling
supply tee’s to orificed regulator valves. If supply
pressure attempts to increase above 240 kPa (35 psi),
the regulator valve opens and dumps to the hydraulic
tank.
Oil also flows out of pilot supply port (12) of the hoist
valve to pilot supply port (12) of the hoist pilot valve,
through the hoist pilot valve spool, and out through
tank return port (10) to the hydraulic tank. This oil flow
is limited by orifices in the inlet sections of the hoist
valve and, therefore, has no pressure buildup.
8
10 Structure and functions CEN10067-01
84748
FIGURE 10-6. FLOAT POSITION (BODY DOWN)
1. Hoist Relief Valve (2,750 psi) 9. Head End Work Port 17. Anti-Void Check Valve
2. Flow Control Valve 10. Tank Return Port 18. Load Check Valve
3. Secondary Low Pressure 11. Supply Port 19. High Pressure Passage
Valve (250 psi) 12. Pilot Supply Port 20. Low Pressure Passage
4. Counterbalance Valve 13. Hoist Limit Solenoid 21. Pilot Operated Check Valve
5. Rod End Work Port 14. Raise Pilot Port 22. Primary Low Pressure Relief
6. Hoist Cylinders 15. Down Pilot Port Valve (26 psi)
7. Rod End Spool 16. Power Down Relief Valve 23. Brake Cooling Circuit Port
8. Head End Spool (1,500 psi) 24. Overcenter Manifold
9
CEN10067-01 10 Structure and functions
Power up operation No pressure is present on the top of rod end spool (7).
Cylinder return pressure passes through the check-
Figure 10-7.
poppet in the bottom of rod end spool (7) to build
The hoist pilot valve spool is moved to the power up pressure under the spool, which moves the spool
position when the operator moves the lever rearward upward, thus compressing the top spring. This
in the cab. The pilot supply oil coming in pilot supply movement allows the returning cylinder oil to flow into
port (12) of the hoist pilot valve is prevented from low pressure passage (20) to primary low pressure
returning to the hydraulic tank. Instead, the oil is relief valve (22). Approximately 179 kPa (26 psi)
directed out raise pilot port (14), through hoist limit causes this relief valve to open, allowing the oil to flow
solenoid (13) in the bleeddown manifold, and into raise through tank return port (10) to the hydraulic tank.
pilot port (14) of the hoist valve.
If the load passing over the tail of the body during
From there it goes to the top of head end spool (8) and dumping causes the body to raise faster than the oil is
builds pressure on the end of the spool, causing the being supplied by the pump, the return oil from the
spool to move down and compress the bottom spring, annulus area of hoist cylinders (6) that is passing
thus connecting high pressure passage (19) to head through the counterbalance valve in overcenter
end work port (9). Working oil flow in the high pressure manifold (24) controls how fast the hoist cylinders can
passage is now allowed to flow through head end extend due to the external force of the load. The speed
spool (8) and out head end work port (9) to extend is controlled by counterbalance valve.
hoist cylinders (6).
During the normal raise process, the raise pilot
Even though a small amount of oil flows through the pressure supplied to the counterbalance valve will
check poppet in the top of head end spool (8), open the cylinder return ports fully whenever the raise
pressure at raise pilot ports (14) increases to slightly pressure is above 4 600 kPa (666 psi). As the load
higher pressure than the required hoist cylinder shifts toward the tail of the body, the raise pressure
pressure. As a result, the pressure in pilot supply ports decreases. As it drops below 4 600 kPa (666 psi), the
(12) also increases, causing back pressure to occur in counterbalance valve starts restricting oil flow, causing
the spring area of flow control valve (2). This a back pressure to the annulus area. If the raise
overcomes the pilot pressure on the other end of the pressure were to drop to 0, return pressure would
flow control valve, causing it to close and direct the increase to 20 700 kPa (3,000 psi) maximum.
incoming pump oil through head end spool (8) and to
When the operator releases the hoist control lever, the
hoist cylinders (6) to extend them. At this time, oil flow
valves change to the HOLD position. If the body rises
to the brake cooling circuit is stopped.
to the position that activates the hoist limit switch,
If, at any time, the resistance to the flow of the pump located above the right rear suspension, before the
oil coming into the inlet section causes the pressure to operator releases the lever, hoist limit solenoid (13) is
increase to 18 960 kPa (2,750 psi), the pilot pressure energized. The solenoid valve closes raise pilot port
against hoist relief valve (1) causes it to open and (14) on the hoist and releases the hoist pilot valve
allow oil to flow through brake cooling circuit port (23) raise pilot pressure at port (14) to the tank, allowing
and to return to the hydraulic tank. head end spool (8) to center and shut off the supply of
oil to the hoist cylinders. This prevents maximum
As the hoist cylinders extend, oil in the annulus area of
extension of the hoist cylinders.
all three stages must exit sequentially from the
cylinders. Initially, rod end spool (7) ports are closed.
As the returning oil entering rod end work port (5)
builds low pressure, it flows through the check-poppet
in the top of the spool, through down pilot ports (15),
through the pilot valve spool, through tank return port
(10) of the pilot valve, to the bleeddown manifold and
to the hydraulic tank.
10
10 Structure and functions CEN10067-01
84236
FIGURE 10-7. POWER UP POSITION
1. Hoist Relief Valve (2,750 psi) 9. Head End Work Port 17. Anti-Void Check Valve
2. Flow Control Valve 10. Tank Return Port 18. Load Check Valve
3. Secondary Low Pressure 11. Supply Port 19. High Pressure Passage
Valve (250 psi) 12. Pilot Supply Port 20. Low Pressure Passage
4. Counterbalance Valve 13. Hoist Limit Solenoid 21. Pilot Operated Check Valve
5. Rod End Work Port 14. Raise Pilot Port 22. Primary Low Pressure Relief
6. Hoist Cylinders 15. Down Pilot Port Valve (26 psi)
7. Rod End Spool 16. Power Down Relief Valve 23. Brake Cooling Circuit Port
8. Head End Spool (1,500 psi) 24. Overcenter Manifold
11
CEN10067-01 10 Structure and functions
Hold operation
Refer to Figure 10-8.
The pilot valve spool is positioned to allow the pilot
supply oil entering pilot supply port (12) to return to the
hydraulic tank through head end work port (10). Pilot
supply pressure in pilot supply ports (12) then
decreases to no pressure, allowing flow control valve
(2) to open and route the incoming pump oil through
brake cooling circuit port (23) and back to the hydraulic
tank.
Both raise pilot port (14) and down pilot port (15) in the
pilot valve are closed by the pilot valve spool. In this
condition, pressure is equalized on each end of each
rod end spool (7) and head end spool (8), allowing the
springs to center the spools and close all ports to trap
the oil in hoist cylinders (6) and hold the body in its
current position.
12
10 Structure and functions CEN10067-01
84237
FIGURE 10-8. HOLD POSITION
1. Hoist Relief Valve (2,750 psi) 9. Head End Work Port 17. Anti-Void Check Valve
2. Flow Control Valve 10. Tank Return Port 18. Load Check Valve
3. Secondary Low Pressure 11. Supply Port 19. High Pressure Passage
Valve (250 psi) 12. Pilot Supply Port 20. Low Pressure Passage
4. Counterbalance Valve 13. Hoist Limit Solenoid 21. Pilot Operated Check Valve
5. Rod End Work Port 14. Raise Pilot Port 22. Primary Low Pressure Relief
6. Hoist Cylinders 15. Down Pilot Port Valve (26 psi)
7. Rod End Spool 16. Power Down Relief Valve 23. Brake Cooling Circuit Port
8. Head End Spool (1,500 psi) 24. Overcenter Manifold
13
CEN10067-01 10 Structure and functions
Power down operation
Refer to Figure 10-9.
When the operator moves the hoist control lever to
lower the body, the hoist pilot valve is positioned to
direct the oil in pilot supply ports (12) through down
pilot ports (15) to the top of rod end spool (7).
Pilot pressure increases to move the spool down,
compressing the bottom spring. Movement of the
spool connects high pressure passage (19) to the rod
end (annulus area) of the hoist cylinders. At the same
time, flow control valve (2) is forced to close as pilot
pressure increases, thus directing the incoming pump
oil to the hoist cylinders through rod end spool (7) and
the check valve in the overcenter manifold rather than
back to the hydraulic tank. Oil flow to the brake cooling
circuit ceases when the flow control valve closes.
If the body is at the maximum up position, the hoist
limit switch has the hoist up limit solenoid activated,
therefore closing raise pilot port (14) on the hoist
valve. Power down pilot pressure in ports (15) pushes
open pilot operated check valve (21), located in the
bleeddown manifold, so the pilot pressure in ports (14)
is open to the tank through the pilot valve spool.
As oil attempts to return from the head end of the hoist
cylinders, it initially encounters closed head end spool
(8). Pressure increases on the bottom end of the
spool, causing it to move upward. This allows the
returning oil to enter low pressure passage (20), build
up 179 kPa (26 psi) to open primary low pressure relief
valve (22) and exit the hoist valve through tank return
port (10) to the hydraulic tank.
As the dump body descends and the hoist limit
solenoid is no longer activated, pilot operated check
valve (21) is no longer necessary.
14
10 Structure and functions CEN10067-01
84238
FIGURE 10-9. POWER DOWN POSITION
1. Hoist Relief Valve (2,750 psi) 9. Head End Work Port 17. Anti-Void Check Valve
2. Flow Control Valve 10. Tank Return Port 18. Load Check Valve
3. Secondary Low Pressure 11. Supply Port 19. High Pressure Passage
Valve (250 psi) 12. Pilot Supply Port 20. Low Pressure Passage
4. Counterbalance Valve 13. Hoist Limit Solenoid 21. Pilot Operated Check Valve
5. Rod End Work Port 14. Raise Pilot Port 22. Primary Low Pressure Relief
6. Hoist Cylinders 15. Down Pilot Port Valve (26 psi)
7. Rod End Spool 16. Power Down Relief Valve 23. Brake Cooling Circuit Port
8. Head End Spool (1,500 psi) 24. Overcenter Manifold
15
CEN10067-01 10 Structure and functions
Float operation
Refer to Figure 10-10.
When the operator releases the hoist control lever as
the body travels down, the hoist pilot valve spool
returns to the FLOAT position. In this position, all ports
(10), (12), (14), and (15) are common with each other.
Therefore, the pilot supply oil is returning to the
hydraulic tank with no pressure buildup, thus allowing
flow control valve (2) to remain open to allow the pump
oil to flow through brake cooling circuit port (23) and
eventually return to the hydraulic tank.
With no blockage of either raise pilot port (14) or down
pilot port (15) in the pilot valve, there is no pressure on
the top of either main spool. The oil returning from the
head end of hoist cylinders (6) builds pressure on the
bottom of head end spool (8) exactly like in POWER
DOWN, allowing the returning oil to transfer to low
pressure passage (20). The back pressure in the low
pressure passage, created by primary low pressure
relief valve (22), causes pressure under rod end spool
(7) and moves the spool upward. This connects the
low pressure passage to the rod end of the hoist
cylinders.
The 179 kPa (26 psi) in low pressure passage (20)
causes oil to flow to the rod end of hoist cylinders (6) to
keep them full of oil as they retract. When the body
reaches the frame and there is no more oil flow from
the cylinders, the main spools center themselves and
close the cylinder ports and the high and low pressure
passages.
16
10 Structure and functions CEN10067-01
84235
FIGURE 10-10. FLOAT POSITION
1. Hoist Relief Valve (2,750 psi) 9. Head End Work Port 17. Anti-Void Check Valve
2. Flow Control Valve 10. Tank Return Port 18. Load Check Valve
3. Secondary Low Pressure 11. Supply Port 19. High Pressure Passage
Valve (250 psi) 12. Pilot Supply Port 20. Low Pressure Passage
4. Counterbalance Valve 13. Hoist Limit Solenoid 21. Pilot Operated Check Valve
5. Rod End Work Port 14. Raise Pilot Port 22. Primary Low Pressure Relief
6. Hoist Cylinders 15. Down Pilot Port Valve (26 psi)
7. Rod End Spool 16. Power Down Relief Valve 23. Brake Cooling Circuit Port
8. Head End Spool (1,500 psi) 24. Overcenter Manifold
17
CEN10067-01 10 Structure and functions
980E Dump truck
Form No. CEN10067-01
18
CEN10068-02
DUMP TRUCK 1SHOP MANUAL
980E
Machine model Serial number
980E-4 A40003 and up
980E-5 A50005 and up
10 Structure and functions
Brake circuits
General information .............................................................................................................................................. 3
Service brake circuit operation.............................................................................................................................. 4
Secondary braking ................................................................................................................................................ 7
Automatic brake application (Auto apply) ............................................................................................................. 7
Parking brake circuit operation ............................................................................................................................. 8
Wheel brake lock circuit operation ........................................................................................................................ 9
Brake warning circuit operation............................................................................................................................. 9
1
CEN10068-02 10 Structure and functions
NOTES
2
10 Structure and functions CEN10068-02
General information The brake system consists of several major valve
components:
The truck is equipped with an all-hydraulic actuated
wet disc service brake system. The brake system • The dual circuit brake valve is attached to service
utilizes Type C-4 hydraulic oil provided by the brake/ brake/retarder pedal (1, Figure 10-1) in the
steering pump from the main hydraulic tank for brake operator cab.
application. Brake disc cooling during truck operation
• The two piston type accumulators are mounted on
is provided by the hoist pump through the hoist valve.
the frame rail behind the right front tire. See Figure
A disc type parking brake, located in the rear axle
10-2.
housing, is attached to each wheel motor. The
fundamental function of the brake system is to provide • The brake manifold, the dual relay valve for the
an operator with the necessary control for stopping the front brakes, and the electrical components are
truck in either a slow modulating fashion or in as short located in the hydraulic brake cabinet behind the
a distance as reasonably possible. cab. See Figure 10-3 or (Figure 10-4).
Outlined below are the functions that Komatsu • The dual relay valve for the rear brakes is located
recommends for safe truck operation: on the left side of the rear axle housing. See Figure
10-7.
• Warn the operator as soon as practical of a serious
or potentially serious loss of brake pressure so that Brake manifold (1, Figure 10-3) or (Figure 10-4)
proper action can be taken to stop the truck before contains dual circuit isolation check valves, brake
the secondary system is exhausted of its power. accumulator bleeddown valves, and valves for the
brake lock, parking brake and automatic apply
• Provide secondary brake circuits so that any single
functions. All of these components are screw-in
failure leaves the truck with sufficient stopping
cartridge type valves.
power.
There are two independent means of brake actuation
• Automatically apply the service brakes if low
provided for the operator: the service brake/retarder
pressure warnings are ignored and pressures
pedal and the wheel brake lock switch. Additionally,
continue to decrease.
the brakes will apply automatically if the brake system
• Provide a wheel brake lock to relieve the operator supply pressure drops below a predetermined value.
from holding the brake pedal while at the dump or
NOTE: The following brake circuit descriptions should
shovel.
be used in conjunction with the hydraulic brake system
• Provide a spring-applied, hydraulically released schematic located in the Diagrams and drawings
parking brake for holding (not stopping) the truck section.
during periods other than loading or dumping.
• The brake system should be easy to diagnose and
service.
3
CEN10068-02 10 Structure and functions
Service brake circuit operation Brake accumulators have two functions: storing
energy for reserve braking in the event of a failure and
This portion of the system provides the operator with
providing rapid oil flow for good brake response.
the precise control that is necessary to modulate
(feather) brake pressure to slowly stop the truck or Depressing the brake pedal also actuates stop light
develop full brake effort to stop as quickly as possible. pressure switch (4, Figure 10-3) or (Figure 10-4) which
The heart of this circuit is the foot-operated, dual in turn activates the brake light on top of the cab, the
circuit brake valve. This valve enables the operator to stop/tail lights on the rear axle housing and the
control the relatively high pressure energy within the propulsion interlock.
brake accumulators directed to the brakes. There are
two valves in the dual circuit brake valve. One supplies
pressure to dual relay valve (3, Figure 10-3) or (Figure
10-4) in the hydraulic brake cabinet to provide apply
pressure for the front brakes. The other supplies
pressure to a dual relay valve located in the rear axle
housing to provide apply pressure for the rear brakes.
As service brake/retarder pedal (1, Figure 10-1) is
depressed, each valve within the dual circuit brake 2 1
valve simultaneously delivers fluid from its respective
accumulator to the dual relay valves, which deliver
fluid to the wheel brakes at a pressure proportional to
both pedal position and force. The farther the pedal is
depressed, the higher the brake force, which gives the FRO
operator a very positive feel of control. NT
2
1
86249
FIGURE 10-2. BRAKE ACCUMULATORS
1. Front Brake Accumulator
86231
2. Rear Brake Accumulator
FIGURE 10-1. OPERATOR CAB PEDALS
1. Service Brake/Retarder Pedal
2. Accelerator Pedal NOTE: For an internal view of the brake valve, refer to
Figure 10-8.
4
10 Structure and functions CEN10068-02
4
5
DETAIL A
1 A
2
86250
FIGURE 10-3. HYDRAULIC BRAKE CABINET - BRAKE CIRCUIT COMPONENTS
(EARLIER MODELS)
1. Brake Manifold 4. Stop Light Pressure Switch
2. Brake Lock Shuttle Valve 5. Brake Lock Degradation Switch
3. Dual Relay Valve (Front Brakes)
5
CEN10068-02 10 Structure and functions
4 5
2 1
DETAIL A
88334
FIGURE 10-4. HYDRAULIC BRAKE CABINET - BRAKE CIRCUIT COMPONENTS
(LATER MODELS)
1. Brake Manifold 4. Stop Light Pressure Switch
2. Brake Lock Shuttle Valve 5. Brake Lock Degradation Switch
3. Dual Relay Valve (Front Brakes)
6
10 Structure and functions CEN10068-02
Secondary braking Automatic brake application (Auto apply)
The purpose of the secondary braking system is to Auto apply is a non-operator controlled feature of the
stop the truck in the event of any single brake system service brake system that hydraulically applies the
failure. If any single service brake system were to fail, service brakes by using the brake treadle valve. This
the truck can be safely stopped by using the remaining feature uses auto apply sequence valve (2, Figure 10-
functioning portions of the service brake system and 5) located in the brake manifold, which senses the
retarder. lowest brake accumulator pressure. This valve will
automatically shift if the low brake system pressure
This is accomplished by dividing the service brake
warning has been activated at 12 750 kPa (1,850 psi)
system into two separate circuits, each with its own
and the brake system pressure drops below 11 400
isolation check valve and accumulator. The check
kPa (1,650 psi). When the valve shifts, hydraulic
valves are used to isolate each circuit from each other.
pressure will be applied to an internal piston that is
Each check valve allows each circuit to retain
incorporated into the brake treadle valve. This
pressurized oil and energy in case the other circuit
pressure moves the piston to depress the treadle valve
experiences a failure or a failure occurs in the supply
which, in turn, applies pressure to the dual relay valves
of pressurized oil from the steering system.
and applies all of the service brakes.
The accumulators of each brake circuit are located
after the check valves and perform two functions:
• Provides a source of pressurized oil and rapid flow 8 7
for good brake application response.
• Provides a stored energy that can be used for
secondary braking.
The pressure of both brake circuits is monitored by low
brake pressure switch (8, Figure 10-5). If the pressure
in one circuit falls below 12 750 kPa (1,850 psi), the
low brake pressure warning will be activated. When
this warning is activated, a message will be displayed
and an alarm will sound to inform the operator that the
truck must be stopped by using the secondary brake 6
system as soon as practical. The operator will stop the
truck using the normal brake system controls (brake 1 2 3 4 5 86251
treadle valve). If the brake treadle valve is
FIGURE 10-5. BRAKE MANIFOLD
nonfunctional, the brake lock and the retarder would
be used to stop the truck. 1. Rear Brake Accumulator Bleeddown Valve
2. Automatic Apply Sequence Valve
Sensing the lower brake accumulator circuit pressure
3. Front Brake Accumulator Bleeddown Valve
ensures two to four full brake applications after the low
4. Parking Brake Solenoid Valve
brake pressure warning activates and before auto
5. Brake Lock Solenoid Valve
apply activates. This allows the operator the
6. Pressure Reducing Valve
opportunity to safely stop the truck after the warning
7. Parking Brake Pressure Switch
occurs.
8. Low Brake Pressure Switch
7
CEN10068-02 10 Structure and functions
Parking brake circuit operation If a loss of supply pressure occurs with the directional
control lever in F, R, or N, the parking brake solenoid
Parking brakes (1, Figure 10-6) are spring applied and
will still be energized. The supply circuit that lost
hydraulically released. Whenever the parking brake
pressure is still open to the parking brake pistons. To
solenoid is de-energized, the spring in the solenoid
prevent parking brake pressure oil from returning to
valve will shift the spool, diverting oil pressure from the
the supply circuit, a check valve in the parking brake
parking brakes to direct the oil back to the hydraulic
circuit traps the oil, holding the parking brake in the
tank.
released position.
Normal operation (key switch ON, engine on) NOTE: Normal internal leakage in the parking brake
• Directional control lever in PARK solenoid may allow leakage of the trapped oil to return
Brake lock solenoid (5, Figure 10-5) is energized, to tank and eventually allow parking brake application.
causing the rear service brakes to apply. After one If 24 volt power to the parking brake solenoid is
second, parking brake solenoid (4) is de- interrupted, the parking brake will apply at any truck
energized. The oil pressure in the parking brake speed. The spring in the solenoid will cause it to shift,
lines returns to tank and the springs in the parking opening a path for the oil pressure in the parking brake
brake apply the brake. Parking brake pressure line to return to tank, and the springs in the parking
switch (7) closes, completing a path to ground and brake will apply the brake. Parking brake pressure
illuminating the parking brake indicator light on the switch (7) will close, completing a path to ground,
dash panel. After a 1/2 second, the brake lock illuminating the parking brake indicator light on the
solenoid is de-energized, causing the rear service dash panel and interrupting propulsion.
brakes to release.
• Directional control lever in F, R, or N
The parking brake solenoid is energized. The oil 1
flow is routed from parking brake solenoid valve (4)
to the parking brake pistons for release. The
parking brake circuit is protected against
accidental application by monitoring a wheel motor
speed sensor to determine the truck ground
speed. The parking brake will not apply until the
truck is virtually stopped. This eliminates parking
brake damage and will extend brake adjustment
intervals. If the key switch is turned OFF, the
parking brake will not apply until the truck speed is
less than 0.5 kph (1/3 mph).
2
86253
FIGURE 10-6. PARKING BRAKE LOCATION
1. Parking Brake
2. Wheel Motor
8
10 Structure and functions CEN10068-02
Wheel brake lock circuit operation Brake warning circuit operation
The primary function of the wheel brake lock is to The brake warning circuit will activate a low brake
provide a means for the operator to hold the truck pressure warning message, a red warning light and an
while at the shovel or dump. The brake lock only audible alarm in the operator cab to alert the operator
applies the rear service brakes. It may also provide to low brake pressures. Several electrical sensors, a
a secondary means of stopping the truck in the event relay and delay timer are used to detect brake system
of a brake valve malfunction. problems.
During normal operations, the wheel brake lock will • Brake warning relay
function only when: When the wheel brake lock switch is ON, the brake
warning relay is energized and switches the
• the control power is ON,
electrical connection from the terminal to brake
• the key switch is ON, lock degradation switch (5, Figure 10-3) or (Figure
10-4). When the wheel brake lock switch is OFF,
• and the parking brake is not activated (directional
the relay is de-energized and switches the
control lever is not in PARK).
connection from the brake lock degradation switch
If the wheel brake lock is applied while the truck is to the terminal.
moving, the brake lock function will remain applied
• System supply pressure switch
after the truck is stopped regardless of the conditions
The system supply pressure switch is located on
stated above (except the control power must be ON for
the pump pressure sensing manifold. When
the wheel brake lock to function). The operator must
system supply pressure drops below 15 800 kPa
deactivate the wheel brake lock.
(2,300 psi), the low brake pressure warning will
When the wheel brake lock switch on the dash panel is activate.
activated, brake lock solenoid valve (5, Figure 10-5)
• Low brake pressure switch
and pressure reducing valve (6) will apply
Low brake pressure switch (8, Figure 10-5) is
unmodulated pressure oil at 13 800 kPa (2,000 psi) to
located on the brake manifold in the hydraulic
fully actuate the rear brakes. Shuttle valve (2, Figure
brake cabinet. When the brake accumulator with
10-3) in the rear brake line provides the independence
the lower pressure falls below 12 700 kPa (1,850
from the brake valve for brake application.
psi), the low brake pressure warning will activate.
• Brake lock degradation switch
Brake lock degradation switch (5, Figure 10-3) or
(Figure 10-4) is located on a junction manifold in
1 the hydraulic brake cabinet. When the wheel brake
lock switch is ON, brake lock solenoid (5, Figure
10-5) and the brake warning relay are energized.
The brake warning relay switches the electrical
connection from the terminal to the brake lock
degradation switch. If the brake lock apply
pressure is less than 6 900 kPa (1,000 psi), a path
to ground will be completed and the low brake
pressure warning will activate.
86252
FIGURE 10-7. REAR AXLE
1. Dual Relay Valve (Rear Brakes)
9
CEN10068-02 10 Structure and functions
FIGURE 10-8. BRAKE VALVE
1. Actuator Cap
2. Adjustment Collar
3. Nut
4. Actuator Plunger
5. Wiper Seal
6. Poly-Pak Seal Assembly
7. Glyde Ring Assembly
8. Regulator Springs (B1)
9. Plunger Return Spring
10. Spring Seat
11. Spool Return Spring (B1)
12. Regulator Sleeve (B1)
13. Regulator Spool (B1)
14. Reaction Plunger (B1)
15. Base Plate
16. Reaction Plunger (B2)
17. Regulator Sleeve (B2)
18. Regulator Spool (B2)
19. Spool Return Spring (B2)
20. Regulator Springs (B2)
21. Staging Seat
A. Adjustment Collar Maximum
Pressure Contact Area
B. Automatic Apply Piston Area
C. PX Port
D. Tank Port
E. Reactionary Pressure Area
F. Brake Apply Port
G. Orifice
H. Supply Port
Note:
B1 - Rear Brakes
B2 - Front Brakes
10
10 Structure and functions CEN10068-02
NOTES
11
CEN10068-02 10 Structure and functions
980E Dump truck
Form No. CEN10068-02
12
CEN10107-00
DUMP TRUCK 1SHOP MANUAL
980E
Machine model Serial number
980E-5 A50137, A50138
10 Structure and functions
Electrical system, 24 volt
Battery supply system........................................................................................................................................... 3
Isolation box.......................................................................................................................................................... 4
Engine starting system with prelube ..................................................................................................................... 5
Auxiliary control cabinet components ................................................................................................................... 6
Body-up switch...................................................................................................................................................... 9
Hoist limit switch ................................................................................................................................................... 9
1
CEN10107-00 10 Structure and functions
NOTES
2
10 Structure and functions CEN10107-00
Battery supply system 24VDC auxiliary battery receptacles
Batteries Two auxiliary battery receptacles (5) are provided to
attach battery charger leads for charging the batteries.
The truck uses a 24VDC electrical system to supply These receptacles can also be used for connecting
power for the engine starting circuits and most non- external batteries to aid engine starting during cold
propulsion related electrical components. The 24VDC weather.
electrical circuit is supplied by six heavy duty, type 8D,
12-volt storage batteries (1, Figure 10-1) located in the When external batteries are used, they should be of
battery box on the platform in front of the radiator. The the same type (8D) as the batteries that are installed
batteries are of the lead-acid type, each containing six on the truck. Two pairs of batteries should be used.
2-volt cells. Each pair should be connected in series to provide
24VDC, with one pair connected to each receptacle.
While the engine is off, power is supplied by the
batteries. During engine cranking, power is supplied
by the batteries. When the engine is running, however,
power is supplied by a high capacity alternator that is
driven by the engine.
During operation, the batteries function as an
electrochemical device that converts chemical energy
into the electrical energy that is required for operating
the accessories when the engine is off.
1 1 1 1 1 1 3 2
4 5
88887
FIGURE 10-1. BATTERY BOX COMPONENTS
1. Batteries 4. Fuses (battery charging alternator and
2. 24VDC Bus Bar auxiliary control cabinet)
3. Negative Bus Bar 5. Auxiliary Battery Receptacles
3
CEN10107-00 10 Structure and functions
Isolation box Propel lockout lever
Ground level shutdown switch Propel lockout lever (6) provides a convenient method
for disconnecting the drive system while the engine is
Ground level shutdown switch (1, Figure 10-2) is a in operation. This ensures that the truck will remain
push-pull type switch located on top of the isolation stationary without the need to check the generator field
box. This switch provides a means to shut off the truck contact (GF) switch in the main control cabinet. When
in an emergency. Push the button inward to stop the the propel lockout lever is in the OFF position, the
engine and disable keyswitch power. drive system is locked out and the truck will not propel.
When the propel lockout lever is in the ON position,
Battery disconnect switches the drive system is active and the truck can be driven.
The battery disconnect switches provide a convenient
method of disconnecting the truck’s batteries from the System busy light
24V electrical circuits without having to remove any If green LED light (4) is illuminated, do not turn off
battery cables. master disconnect switch (8). 24V electrical system
When starter disconnect switch (7) is in the OFF components are still in operation.
position, only the cranking motor battery circuit is
LED lights
open, preventing engine startup while still allowing
battery power to the 24VDC control system circuits. LED lights (5) provide a positive, visual indicator when
When master disconnect switch (8) is in the OFF a switch is in the ON position. LED lights (3) provide a
position, the entire 24VDC system circuit is positive, visual indicator when a switch is in the OFF
disconnected. position.
NOTE: Both switches are shown in the OFF position in
Figure 10-2.
1 2 3 4 5 3 5 3
8
7 6 5
KPET00342
FIGURE 10-2. ISOLATION BOX COMPONENTS
1. Ground Level Shutdown Switch 4. System Busy Light 7. Starter Disconnect Switch
2. Access Ladder Light Switch 5. LED Lights (on) 8. Master Disconnect Switch
3. LED Lights (off) 6. Propel Lockout Lever
4
10 Structure and functions CEN10107-00
Engine starting system with prelube NOTE: The oil supply line has a check valve installed
The engine includes an engine prelubrication system between the prelube pump and the engine. The check
designed to reduce wear due to dry starts. valve prevents the passage of oil from the engine back
through the prelube pump to the oil pan after the
The prelube system automatically, safely and quickly engine is started. Check valve leakage back to the
fills the engine oil filters and all oil passages prior to prelube pump will cause extensive damage to the
cranking at each engine startup. The system also pump.
prevents startup if no oil is present in the engine.
NOTE: There will be a short but noticeable delay
between the time that the key switch is moved to the 1
START position and the time that the cranking motors
actuate.
Prelube operation
The prelube system is activated when the operator
turns the key switch and holds it in the START
position. This allows the current to flow to prelube
solenoid (3, Figure 10-3). When this prelube solenoid 2
is activated, current flows through the fusible link to the
prelube motor, driving prelube pump (1), but does not
allow the cranking motors to engage the cranking 3
87913
motor pinion gears at this time. The prelube pump
supplies oil from the engine oil pan to fill the engine oil FIGURE 10-3. ENGINE PRELUBE SYSTEM
filters and oil passages prior to cranking.
1. Engine Prelube Pump 3. Engine Prelube
When the pressure in the engine cam oil rifle reaches 2. Engine Prelube Relay Solenoid
62 kPa (9 psi), the engine prelube oil pressure switch
and dedicated lube pressure switch supply signal
current to the engine start relays. When the engine
start relays are activated, current is provided to the
solenoids of both cranking motors (1, Figure 10-4).
The cranking motors will then be activated and the
pinion gears will be engaged into the flywheel ring
gear. Normal cranking will now occur with sufficient
lubrication to protect the engine bearings and other
components.
5
CEN10107-00 10 Structure and functions
Cranking operation Auxiliary control cabinet components
After the operator turns the key switch and holds it in The auxiliary control cabinet houses various
the START position and the engine prelube system fills components for the 24VDC circuits and terminal strips
the engine oil filters and all oil passages, the engine that connect these components with the rest of the
start relays provide current to the solenoids of both truck. Refer to the electrical schematics in Section 90,
cranking motors (1, Figure 10-4). Diagrams and drawings for additional information.
When the solenoid coils are energized, the plunger is
pulled in, moving the cranking motor drive assembly
forward in the nose housing to engage the engine
1
flywheel ring gear. The main solenoid contacts also
close to provide current to the motor armature and
cranking takes place.
When the engine starts, an overrunning clutch in the
cranking motor drive assembly protects the armature
from excessive speed until the key switch is released. 2
When the key switch is released, a return spring
causes the drive pinion to disengage.
After the engine is running, the dedicated lube
pressure switch senses the engine oil pressure and
opens the electrical circuit to prevent actuation of the
cranking motor(s) after the engine has started. 3
4
5
1
6 7 86763
FIGURE 10-5. AUXILIARY CONTROL CABINET
24VDC COMPONENTS - LH WALL
1 1. Interface Module (IM)
2. Payload Meter IV Controller
3. Payload Meter IV Communication Module
4. Ethernet Switch
5. Diagnostic Connectors (PLMIV, IM, GE)
88886 6. Oil Reserve System Power Relay
7. Oil Reserve System Heated Hose Power Relay
FIGURE 10-4. ENGINE STARTING SYSTEM
1. Cranking Motors 2. Engine Prelube Pump
6
10 Structure and functions CEN10107-00
VEC blocks
VEC blocks (1), (2), (3) and (4, Figure 10-6) contain
replaceable relays, diodes and fuses that are mounted
on a plug-in connector for easy replacement. The
diodes are used to control the flow of current in a 2 1
circuit as required. The fuses protect various circuits
on the truck. Spare fuses are provided in the VEC
blocks. The relays switch on/off circuits that require
control logic.
Refer to Troubleshooting section, Fuse and circuit
3
breaker locations for a list of diode, fuse and relay
functions. 4
NOTE: Before replacing a fuse, determine the cause
of failure. Repair as necessary. Always replace a fuse
6
with one of the same specified amperage. Never
replace with one of greater amperage.
24VDC to 12VDC converter 7
24VDC to 12VDC converter (5) is used to convert the 5
24 volt battery system voltage to 12 volts for various
truck components such as the radio, power windows,
12V auxiliary power receptacles in the cab, ethernet 8
switch, Komvision radars and optional wireless
access.
Circuit breakers
The 24VDC to 12VDC converter output circuits are
protected by 50 amp circuit breaker (6).
9 10
86762
The DEF tank line heater circuits are protected by 70
amp circuit breaker (7). FIGURE 10-6. AUXILIARY CONTROL CABINET
24VDC COMPONENTS - RH WALL
Engine service light timer
1. VEC Block 89 6. Circuit Breaker(50A)
Timer (8) will turn off the engine service lights after two 2. VEC Block 90 7. Circuit Breaker (70A)
hours of operation. 3. VEC Block 91 8. Engine Service Light
4. VEC Block 92 Timer
Ground terminals
5. 24V-12V Converter 9. Ground Terminals
Ground terminals (9) provide a ground location for 10. 24VDC Power
many circuits and are a convenient test point during
troubleshooting procedures.
NOTE: The cover for Item 10 has been removed
24VDC power terminals for clarity.
24VDC power terminals (10) distribute 24VDC battery
voltage and are a convenient test point for measuring
battery voltage during troubleshooting procedures.
7
CEN10107-00 10 Structure and functions
Relays
Relays (1, Figure 10-7) are used to switch heavy loads
on various electrical circuits. These relays are rated at
24V, 75 amps.
• Low Mounted Low Beam Headlights
• High Mounted Low Beam Headlights 1
• Rear Backup Light
• Ladder/Deck Light
• Horn
• Keyswitch/Control Power
• High Beam Headlights
• Key Switch Power
• 12V Power
Terminal boards 2
Terminal boards (2) provide an easy access point for
troubleshooting the various electrical circuits
throughout the truck.
86941
FIGURE 10-7. AUXILIARY CONTROL CABINET
24VDC COMPONENTS - REAR WALL
1. Relays 2. Terminal Boards
8
10 Structure and functions CEN10107-00
Body-up switch Hoist limit switch
Body-up switch (1, Figure 10-8) is located inside the Hoist limit switch (1, Figure 10-9) is located inside the
right frame rail near the front of the body. It must be right frame rail above the rear suspension, near the
adjusted to specifications to ensure that the proper body pivot pin. The hoist limit switch is designed to
electrical signal is obtained when the body is raised or stop the hoist cylinders before they reach full
lowered. The body-up switch is designed to prevent extension, preventing possible damage to the dump
propulsion in REVERSE when the dump body is not body or hoist cylinders.
resting on the frame rails. The switch also prevents
When the hoist cylinders are approximately 152 mm (6
forward propulsion with the body up unless the
in.) from maximum stroke and the body pivots on the
override button is depressed and held.
pins, magnet assembly (3) on bracket (4) moves close
When the body is resting on the frame, magnet enough to magnetically-operated hoist limit switch (1)
assembly (3) on bracket (4) causes the electrical to close the electrical contacts. When the contacts
contacts in the magnetically-operated switch to close. close, an electrical signal is sent to the hoist limit
When the body is raised, the bracket and magnet solenoid valve to prevent further oil flow to the hoist
assembly move away from the switch, opening the cylinders.
contacts. The electrical signal is sent to the control
system and the body-up relay.
Dimension "A"................................45 mm (1.77 in.)
The switch must be properly adjusted at all times.
Improper adjustment or loose mounting capscrews Dimension "B".............................83.1 mm (3.27 in.)
may cause false signals or damage to the switch
assembly.
Dimension "A"................................ 45 mm (1.77 in.)
Dimension "B"............................. 32.3 mm (1.27 in.)
FIGURE 10-9. HOIST LIMIT SWITCH
1. Hoist Limit Switch 3. Magnet Assembly
2. Switch Mounting Plate 4. Actuator Arm
FIGURE 10-8. BODY-UP SWITCH
1. Body Up Switch 3. Magnet Assembly
2. Switch Mounting Bracket 4. Bracket
9
CEN10107-00 10 Structure and functions
980E Dump truck
Form No. CEN10107-00
10
CEN10080-00
DUMP TRUCK 1SHOP MANUAL
730E
830E
930E
980E
Machine model Serial number
730E-10 A50002 and up
830E-5 A50005 and up
830E-5AT A50005 and up
930E-5 A40004 and up
930E-5AT A40004 and up
980E-5 A50005 and up
980E-5AT A50005 and up
10 Structure and functions
Automatic lubrication (auto lube) system
General information .............................................................................................................................................. 3
System operation .................................................................................................................................................. 4
1
CEN10080-00 10 Structure and functions
NOTES
2
10 Structure and functions CEN10080-00
General information
The automatic lubrication (auto lube) system is a
5 6 7
pressurized lubricant delivery system which delivers a
controlled amount of lubricant to designated lube
points such as:
• steering cylinder pins
• tie rod pins 4 8
• body pivot pin
• hoist cylinder pins 9
• rear suspension pins
• sway bar pins
10
The system is controlled by logic in the interface
module (IM), which signals a solenoid valve to operate 3
a hydraulic motor powered grease pump. The solenoid
valve is equipped with a manual override switch that,
when actuated, activates the pump when power is not 2
being supplied to the motor.
Hydraulic oil for pump operation is supplied through
the auxiliary hydraulic system. Grease pump (5, Figure 1 87506
10-1) is driven by the rotary motion of hydraulic motor
FIGURE 30-1. AUTO LUBE PUMP AND
(9), which is then converted to reciprocating motion
RESERVOIR COMPONENTS
through an eccentric crank mechanism. The pump is a
positive displacement, double-acting type as grease 1. Reservoir 6. Hydraulic Oil Supply
output occurs on both the up and the down stroke. 2. Main Grease Supply 7. Pump Control
Line Manifold
Integrated pump control manifold (7) is incorporated
3. Relief Valve 8. Hydraulic Oil Return
with the motor to control input flow and pressure.
4. Vent Valve 9. Hydraulic Motor
Relief valve (3) in vent valve (4) protects the pump
5. Grease Pump 10. Grease Filter
from high pressures. The relief valve is set at 27 580
kPa (4,000 psi). A pressure gauge can be installed in
the plugged port on top of the manifold to check the
hydraulic oil pressure to the inlet of the hydraulic
motor. Normal stall pressure is 2 415 - 2 585 kPa (350
- 375 psi).
When the grease supply is replenished through the
service center, the grease passes through grease filter
(10) to remove contaminants before it flows into
reservoir (1). A bypass indicator on the filter alerts
service personnel when the filter requires
replacement.
3
CEN10080-00 10 Structure and functions
System operation
During truck operation, the lubrication cycle logic in the 3 4
interface module (IM) will energize the system at a
preset time interval. The IM provides a path to ground
to energize solenoid valve (3, Figure 10-2), allowing
hydraulic oil from the auxiliary hydraulic system to flow
to hydraulic motor (1) and initiate a pumping cycle. 5
The hydraulic oil is directed through pressure reducing
valve (2) and flow control valve (5) located in pump
control manifold (4) before entering the hydraulic
motor. The high hydraulic oil pressure from the
auxiliary hydraulic system is reduced to a suitable
2
operating pressure by the pressure reducing valve.
The flow control valve controls the amount of oil flow to
the hydraulic motor.
NOTE: The flow control valve has been factory
adjusted and the setting should not be disturbed.
With oil flowing into the hydraulic motor, the grease
pump will operate, pumping grease from the reservoir
to the injectors, through a check valve, and to vent
valve (4, Figure 10-1). With the vent valve closed, the 1
pump continues to operate until maximum grease 87507
pressure is achieved. During this period, the injectors FIGURE 30-2. HYDRAULIC MOTOR AND
will meter the appropriate amount of grease to each MANIFOLD COMPONENTS
lubrication point.
1. Hydraulic Motor
2. Pressure Reducing Valve
3. Solenoid Valve with Manual Override Switch
4. Pump Control Manifold
5. Flow Control Valve
4
10 Structure and functions CEN10080-00
NOTE: Each injector services only one lube point. In
case of pump malfunction, each injector is equipped
with a covered grease zerk (4, Figure 10-3) to allow
the use of external lubricating equipment.
When grease pressure reaches the setting of pressure
switch (6, Figure 10-3) on the rear axle housing, the
switch contacts will close, sending a signal to the IM
that the pressure setting has been reached. This 5
removes power from the hydraulic motor, which stops
pump operation. The IM will complete a 120 second
ON cycle. 3 4
After the hydraulic motor stops, hydraulic pressure in
the pump control manifold drops and the vent valve
will open, releasing the grease pressure in the lines to 3
injector banks (1). When this occurs, the injectors are
then able to recharge for the next lubrication cycle.
The system will remain at rest until the IM initiates the
next lubrication cycle.
During the normal lubrication cycle, if grease pressure
fails to reach 13 790 kPa (2,000 psi) at pressure
switch (6), fault code A190 - Auto Lube Fault will be 2 1
logged.
FRONT INJECTORS
2 1 REAR INJECTORS 87508
FIGURE 30-3. GREASE INJECTORS
1. Injector Bank 4. Injector Grease Zerk
2. Main Supply Line 5. Injector
3. Secondary Supply Line 6. Pressure Switch
5
CEN10080-00 10 Structure and functions
730E Dump truck
830E Dump truck
930E Dump truck
980E Dump truck
Form No. CEN10080-00
6
CEN20012-00
DUMP TRUCK 1SHOP MANUAL
980E
Machine model Serial number
980E-5 A50137, A50138
20 Standard value table
Standard value table
Standard value table for truck ............................................................................................................................... 3
1
CEN20012-00 20 Standard value table
NOTES
2
20 Standard value table CEN20012-00
Standard value table for truck
Truck model 980E-5
Measurement
Check item Unit Standard value
conditions
• Flat dry road surface
0% grade 64
• Engine coolant
(empty) temperature within (40)
Travel speed
operating range
Maximum speed in 12% grade • Travel resistance: 2.0% kph
forward gear uphill (mph)
(empty) • Standard tires
12% grade
uphill
(loaded)
• Engine coolant
temperature within
Rated operating range 1,800
Engine speed
Idle rpm 750
Max. overspeed 1,880
Stationary steering • Flat dry road surface
91 ± 2.0
effort
Operating
• Steering wheel speed: (20.45 ± 0.45)
force
(If stationary steering is 30 rpm N
impossible, measure (lb)
Max. 115
steering effort at low • Engine low idle
(25.8)
speed.)
Steering wheel
• Engine stopped
Dimension
• Dimension on periphery of
Play grip Degrees 5
• Until front wheel starts
moving
• Lock to lock
Number of
rotations
Number of
Rotation range 4.5 ± 0.5
rotations
3
CEN20012-00 20 Standard value table
Truck model 980E-5
Measurement
Check item Unit Standard value
conditions
• Point at • Starting to 29.3 + 13.0/-0
Operating 150 mm depress N (6.6 + 2.9/-0)
force (6 in.) from (lb)
• Full 58.7 + 0/-13.3
fulcrum of
Accelerator pedal pedal (13.2 + 0/-3.0)
• Starting to
mm 45 ± 5
Stroke depress
(in.) (1.8 ± 0.2)
to Full
• Retarding 44.5 ± 4.0
Operating N (10.0 ± 0.9)
force • Braking (lb) 300.5 ± 189.5
Brake pedal (67.55 ± 42.6)
• Retarding 17.5 ± 1.0
Stroke Degrees
• Braking 17.5 ± 1.0
Operating • Measuring point: N Max. 29.4
Directional control force Center of grip (lb) (Max. 6.61)
lever
Operating force and stroke
mm 24.5 ± 2
Stroke
(in.) (0.96 ± 0.08)
• Measuring • Initial Max. 35.3
Float to point: (Max. 7.94)
Raise Center of
• Full Max. 24.5
grip
(Max. 5.51)
Must return smoothly when
Raise to
engine speed is at high
Hold
idle.
• Initial Max. 35.3
Operating Hold to N (Max. 7.94)
force Raise • Full (lb) Max. 24.5
Hoist lever
(Max. 5.51)
• Initial Max. 35.3
Hold to (Max. 7.94)
Lower • Full Max. 24.5
(Max. 5.51)
Must return smoothly when
Lower to
engine speed is at high
Float
idle.
Raise to • Measuring point:
Hold Center of grip mm 44.8 ± 1.9
Stroke
Hold to (in.) (1.76 ± 0.08
Lower
4
20 Standard value table CEN20012-00
Truck model 980E-5
Measurement
Check item Unit Standard value
conditions
• Flat dry road surface 228.6 ± 10
Standard
(9.0 ± 0.8)
Dimension
Installed Front • Body unloaded
Suspension cylinder
length mm Oil 165.1 ± 10
(exposed (in.) Sands (6.5 ± 0.8)
rod) 212.3 ± 10
Rear
(8.36 ± 0.4)
3 047
Pressure
Nitrogen Front
kPa (442)
gas
(psi) 1 455
pressure Rear
(211)
Accumulator
Front and • Atmospheric temperature):
Pressure
Nitrogen rear service 21 °C (70 °F)
kPa 9 653 ± 70
gas brakes (psi) {1,400 ± 10}
pressure
Steering
• With maximum allowed
Stop slope angle
payload (120%)
• Machine can hold on
Braking capacity specified grade % Max. 15
Parking brake
• Engine running
Oil pressure
kPa 22 753 ± 1 378
Release pressure
(psi) (3,300 ± 200)
Operating • At full stroke
Service brakes
Oil pressure
pressure
Front and
kPa 16 545 ± 517
rear service • Charge accumulator and
Brake oil operate brake first time (psi) (2,400 ± 75)
brakes
pressure
• At full stroke
Air pressure
• Machine unloaded
kPa 600 + 100/-0
Tire
59/80 R63
(psi) (87 + 14/-0)
5
CEN20012-00 20 Standard value table
Truck model 980E-5
Measurement
Check item Unit Standard value
conditions
At rated • Oil temperature:
20 600 ± 500
speed 50 – 80 °C
(122 – 176 °F) (2,987 ± 72)
Steering
(1,900 rpm)
valve
Relief oil
pressure At low idle
(750 rpm) 18 600 ± 500
[Reference (2,697 ± 72)
value]
Cut-in pressure • Oil temperature: 24 300
Counterbalance Steering pump
(unload) 45 – 55 °C (3525)
unloader
(113 – 131 °F)
Oil pressure
Cut-out pressure • High idle 22 240 ± 172
(reload) kPa (3,225 ± 25)
(psi)
• Oil temperature:
50 – 80 °C
(122 – 176 °F)
valve
20 685 ± 690
• Engine speed: (3,000 ± 100)
1,900 rpm (rated speed)
Relief pressure
Hoist valve
18 960 ± 690
(2,750 ± 100)
Empty • Oil temperature: 24 ± 2
50 – 80 °C
Lifting (122 – 176 °F)
speed Loaded 26 ± 2
• Engine speed:
Body
Time
1,900 rpm (rated speed) seconds
Power • Oil temperature:
50 – 80 °C 13 ± 1
Lowering down
speed (122 – 176 °F)
Float 16 ± 2
• Engine speed: 780 rpm
6
20 Standard value table CEN20012-00
NOTES
7
CEN20012-00 20 Standard value table
980E Dump truck
Form No. CEN20012-00
8
CEN30071-05
DUMP TRUCK 1SHOP MANUAL
980E
Machine model Serial number
980E-4 A40003 and up
980E-5 A50005 and up
30 Testing and adjusting
Steering, hoist, brake cooling and auxiliary
hydraulic system
Hydraulic system bleeddown procedure ............................................................................................................... 3
Hydraulic system vacuum procedure.................................................................................................................... 5
General information on system checkout.............................................................................................................. 5
Hydraulic system checkout procedures ................................................................................................................ 6
Hydraulic system checkout data sheet ............................................................................................................... 17
High altitude steering pump adjustment.............................................................................................................. 20
Toe-in adjustment................................................................................................................................................ 21
Measuring steering pin joint wear ....................................................................................................................... 22
Hoist cylinder leakage test .................................................................................................................................. 25
Steering cylinder leakage test ............................................................................................................................. 25
1
CEN30071-05 30 Testing and adjusting
NOTES
2
30 Testing and adjusting CEN30071-05
Hydraulic system bleeddown procedure 8. Depress the brake pedal. The service brakes
should not apply and the service brake status
indicator should not illuminate.
Hydraulic oil escaping under pressure can have
sufficient force to enter a person's body by
penetrating the skin and cause serious injury, and
possibly death, if proper medical treatment is not
received immediately.
Relieve pressure before disconnecting any
hydraulic lines. Tighten all connections securely
before applying pressure.
Ensure that all pressure is removed from the steering,
brake and auxiliary hydraulic circuits before opening
any hydraulic connection or performing any service
work.
FIGURE 30-1. BRAKE MANIFOLD
1. Park the truck on solid, level ground.
1. Brake Accumulator Bleed Valves
2. Place the hoist lever into the FLOAT position and 2. Brake Manifold
verify that the dump body is resting on the frame.
9. Install 35 000 kPa (5,000 psi) pressure gauges in
test ports "BR" (1, Figure 30-2) and "BF" (2) on
the junction manifold to the right of the brake
The steering accumulator bleeddown solenoid is manifold. With the brake pedal depressed, the
energized by the interface module (IM) after the pressure at each test port should be at 103 kPa
truck is stopped, the key switch is OFF, and the (15 psi) or less after the brake system has been
engine is not running. The solenoid will remain bled down.
energized until the IM is shut down.
Do not engage the battery disconnect switch or
remove battery power from the truck in any 2 1
manner during the steering accumulator
bleeddown process. Steering pressure may remain
in the system, creating a personal injury risk when
hydraulic lines are opened.
3. Stop the engine by turning the key switch to the
OFF position. Wait for two minutes for the
steering accumulators to bleed down completely.
86260
4. Chock the rear tires. FIGURE 30-2. JUNCTION MANIFOLD
5. Ensure that all personnel and equipment are 1. Test Port "BR"
clear of the tires. 2. Test Port "BF"
6. Turn the steering wheel back and forth until it can
no longer be turned by hand. 10. Open bleed valve (2, Figure 30-3) on auxiliary
hydraulic manifold (3) to bleed down auxiliary
7. Turn both brake accumulator bleed valves (1,
accumulator (1).
Figure 30-1) clockwise to bleed down the brake
accumulators.
3
CEN30071-05 30 Testing and adjusting
11. To verify that the auxiliary accumulator is bled
down, press override switch (3, Figure 30-4) on
automatic lubrication pump (1). The automatic
lubrication pump will not operate if the auxiliary
accumulator is bled down.
1 2
3
2
86259 86183
FIGURE 30-3. AUXILIARY HYDRAULIC MANIFOLD FIGURE 30-4. AUTOMATIC LUBRICATION
1. Auxiliary Accumulator SYSTEM
2. Accumulator Bleed Valve 1. Automatic Lubrication 3. Override Switch
3. Auxiliary Hydraulic Manifold Pump 4. Hydraulic Motor
2. Manifold
12. Install a 35 000 kPa (5,000 psi) pressure gauge in
test port "GA" on the auxiliary hydraulic manifold
(3, Figure 30-3). The pressure should be at 103
kPa (15 psi) or less after the auxiliary hydraulic
system has been bled down.
13. Install a 35 000 kPa (5,000 psi) pressure gauge in
test port "TP3" on the steering bleeddown
manifold. The pressure should be at 103 kPa (15
psi) or less after the steering system has been
bled down.
14. After the service work is completed, tighten all
hydraulic connections and close all bleed valves.
4
30 Testing and adjusting CEN30071-05
Hydraulic system vacuum procedure General information on system checkout
1. Remove breather filters (1, Figure 30-6) and The hydraulic system checkout procedures are
adapters (2) from the hydraulic tank. intended to help the technician diagnose problems in
the steering and hoist circuits. The technician should
read the checkout procedures to become familiar with
1 the procedures and all the warnings and cautions
before performing any steps. The checkout
procedures begin by checking the basic system before
2 checking individual components.
A data sheet is included in this section to record the
test information obtained during the hydraulic system
checkout procedure. The data sheet is designed to be
printed or copied, then used during the checkout
procedure.
88352
FIGURE 30-5. BREATHER FILTER REMOVAL
1. Breather filter 2. Adapter
The hydraulic system checkout procedures must
be performed before a truck is put back into
2. Install the vacuum kit as shown in Figure 30-6. operation after any hydraulic system service has
been performed.
3. Connect shop air to vacuum pump (2). Wait two
minutes before performing repairs.
NOTE: Shop air must be connected for the duration of NOTE: The interface module (IM) checkout procedure
the repair. must be successfully completed and engine startup
must be possible before beginning the checkout
4. After repairs are completed, disconnect shop air,
procedures.
remove the vacuum kit, and install breather
filters.
2 4
88353
FIGURE 30-6. VACUUM KIT INSTALLATION
1. Muffler 3. Reducer
2. Vacuum Pump 4. Plug
5
CEN30071-05 30 Testing and adjusting
NOTE: Excessive internal leakage within the brake Hydraulic system checkout procedures
circuit may contribute to problems within the steering
circuit. Ensure that brake circuit leakage is not Required equipment
excessive before troubleshooting the steering circuit. • Steering, hoist and brake cooling hydraulic circuit
The steering circuit hydraulic pressure is supplied from schematic
the steering/brake pump and steering accumulators. • Service computer with Interface Module Realtime
Some steering system problems, such as spongy or Data Monitor software
slow steering or abnormal operation of the low steering
• Five 35 000 kPa (5,000 psi) calibrated pressure
pressure warning, can sometimes be traced to internal gauges
leakage of steering components. If internal leakage is
suspected, perform the steering component leakage • Three 24 000 kPa (3,500 psi) calibrated pressure
tests outlined in this section. gauges
The steering circuit can be isolated from the brake • Two 690 kPa (100 psi) calibrated pressure gauges
circuit by first releasing all steering system pressure, • A graduated container marked to measure liquid
then releasing all pressure from the brake volume in cubic inches or milliliters
accumulators and removing the brake system supply
hose from the bottom of the bleeddown manifold. Plug Preliminary steps
the hose and cap the fitting at the bleeddown manifold 1. The steering accumulators, brake accumulators
to prevent high pressure leakage. and auxiliary system accumulator must have the
correct precharge and must be at normal
operating temperature. Refer to Testing and
adjusting section Accumulators and
suspensions for the accumulator charging
procedures.
If the steering pump has just been installed, it is
* Record on Data Sheet
essential that the pump case is full of oil before
starting the engine. NOTE: For best performance, charge the
accumulators in the ambient conditions in which the
machine will be operating.
6
30 Testing and adjusting CEN30071-05
2. Install 35 000 kPa (5,000 psi) calibrated pressure 6. An optional hose/needle assembly for manually
gauges at the following locations: bleeding down the steering accumulators can be
a. steering pump test port "GPA" used. This hose/needle valve assembly is only
for convenience and is not required. It provides a
b. bleeddown manifold test port "TP3" way to manually bleed down both steering
c. bleeddown manifold test port "TP2" accumulators any time during the checkout
procedure.
d. both steering cylinder manifold test ports
The assembly will consist of two 1/4” diameter
3. Install 24 000 kPa (3,500 psi) calibrated pressure
hoses connected to a needle valve. The hose
gauges at the following locations:
material can be 1/4” diameter SAE 100R2, which
a. both hoist filter test ports has 35 000 kPa (5000 psi) rating. The needle
b. overcenter manifold test port "TPD" valve will allow simple opening/closing and must
be rated for 27 500 kPa (4,000 psi) or above. The
length of the hoses is not critical and can be
Also, install 690 kPa (100 psi) calibrated pressure selected to provide the best accessibility to the
gauges at the following locations: needle valve. Connect the opposite ends of the
hose/needle valve assembly as follows.
a. front brake cooling test port on the hoist valve
a. Ensure that both steering accumulators and
outlet
both brake accumulators are bled down.
b. rear brake cooling test port on the brake
cooling/hoist return manifold b. Remove the plug from #10 SAE boss port (1,
Figure 30-7) located near bleeddown manifold
port "TP3" (2). This port has the same
pressure as the steering supply port and
Hydraulic system flushing procedure ACC2 port and will allow both steering
4. Install a jumper hose between the "QD Supply" accumulators to bleed down when the needle
and "QD Return" ports on the bleeddown valve is opened.
manifold. The hose must be rated for at least
24 000 kPa (3,500 psi) in case the steering
system becomes fully pressurized. However, the
pressure during the flushing procedure should be
less than 3 500 kPa (500 psi). 1
5. Use two flushing blocks (PC3074) to join the
piston end and rod end hoist cylinder hoses if not
already assembled.
84722
FIGURE 30-7. BLEEDDOWN MANIFOLD
1. #10 SAE Boss Port
2. Port "TP3"
7
CEN30071-05 30 Testing and adjusting
c. Connect one end of the hose/needle valve 7. If brakes are not installed, connect brake cooling
assembly to the #10 SAE boss port. supply and return hoses together for this entire
d. Remove the plug in brake manifold port "T3" checkout procedure. Service brake and parking
(2, Figure 30-8). This port will return oil that is brake hoses must be fitted with steel plugs rated
bled from the steering accumulators to the for 27 500 kPa (4000 psi) or higher during this
hydraulic tank. checkout procedure.
8. Disconnect or disable all auxiliary hydraulic
systems (auto lube, retractable ladder, radiator
shutters, etc) that may be present on the truck.
9. Fill the steering pump case through case drain
port with clean hydraulic oil.
An alternate method to filling the pump case with
oil is by leaving case drain hose connected and
removing small SEA #6 plug marked "PRG" near
the case drain port on top of the pump. This will
vent air from the pump case if the hydraulic tank
is filled with oil. Install and tighten the plug when
oil appears.
1
NOTE: Filling the pump case with oil does not
eliminate the need for bleeding air from the pump
84723 suction line as described in step 11. Both must be
done.
FIGURE 30-8. BRAKE MANIFOLD
10. Fully open all pump suction line shutoff valves, if
1. Port T3 equipped. Valves are fully open when the handle
is in line with the hose.
e. Connect hose/needle valve assembly to port
"T3".
f. Retain the plugs that were removed from the
manifolds for replacement when the hose/ Serious pump damage will occur if any shutoff
needle valve assembly is removed. valve is not fully open when the engine is started.
NOTE: Use of optional bleeddown hose/needle valve
assembly does not substitute for the use of jumper 11. Fill hydraulic tank with hydraulic oil to upper sight
hose installed in step 4. glass.
12. Bleed the air from all pump suction lines by
loosening each suction hose at the pump inlet.
Ensure that the O-ring does not fall out of the
groove. When oil appears, retighten the
capscrews.
This hose/valve assembly cannot be connected or
disconnected if the steering accumulators are NOTE: Bleeding the piston pump suction line does not
pressurized. eliminate the need for filling the piston pump case with
oil as described in step 9. Both must be done.
13. Check that the oil level in the hydraulic tank is still
The hose/needle valve assembly must be removed visible in the upper sight glass. Add oil if
when the checkout procedure is completed. The necessary.
original plugs must be installed in the manifold ports
and tightened to the proper torque. 14. Place the hoist lever in the FLOAT position.
8
30 Testing and adjusting CEN30071-05
15. It may be necessary at any time during this Start the engine and operate at low idle for no
checkout procedure to stop the engine and allow more than 30 seconds. At low idle with 21°C (70°
the steering accumulators to bleed down. F) oil, pressure at the hoist filters should be
Steering pressure at bleeddown manifold test approximately 552 kPa (80 psi). Pressure at
port "TP3" will be 103 kPa (15 psi) or less after a steering pump test port "GPA" should be approxi-
successful bleed down. The pressure gauge mately 689 kPa (100 psi). Pressure at the front
installed in bleeddown manifold port "TP3" will and rear brake cooling test ports should be
show the steering accumulator pressure. approximately 172 kPa (25 psi) or less.
Refer to step 6 if an optional manual method of
bleeding down the steering accumulators is
desired when performing this checkout proce-
dure.
Do not operate at low idle for more than 30
seconds. Steering pump pressure at test port
"GPA" needs to be at or above 1 724 kPa (250 psi)
during the flushing process to provide adequate
pump internal lubrication. Steering pump damage
If the warning indicator is illuminated, the buzzer is will result if pressure is below 1 724 kPa (250 psi).
sounding and the steering pressure status This also applies to steps 17-20.
indicator is flashing, do not attempt to remove any
hydraulic hose, fitting, plug, switch, etc. Hydraulic
NOTE: Do not turn the steering wheel until step 21. Do
pressure may be trapped.
not apply the brakes at any time during this checkout
procedure.
If fault code A236 is shown on the message
display, the steering accumulators did not 17. With engine at a speed that is fast enough to
properly bleed down. provide at least 1 724 kPa (250 psi) at steering
pump test port "GPA", move the hoist lever to the
Locate and correct any steering accumulator POWER UP or POWER DOWN position. The
bleeddown problem before proceeding. front and rear brake cooling oil supply pressures
should be 0 kPa (0 psi) when the hoist lever is in
POWER UP or POWER DOWN, This confirms
16. Turn the key switch to ON but do not start the
that the hoist valve is functioning properly.
engine. Verify that the low steering accumulator
precharge warning (fault A115) is not displayed. If If the pressures do not drop to 0 kPa (0 psi), the
the warning is displayed, correct the problem hoist valve may be plumbed incorrectly. Stop the
before starting engine. checkout procedure and check all plumbing,
* Record on Data Sheet including all pilot lines. If there is a plumbing
error, repeat this step again. If no plumbing error
NOTE: The brake accumulators and the auxiliary was found or if the pressures still do not drop to 0
system accumulator do not have pressure switches to kPa (0 psi), replace the hoist valve and repeat
warn for low precharge, but they must be precharged this step again.
to 9 653 kPa (1,400 psi) before starting the engine. Do
not start the engine without ensuring that all
accumulators are precharged to 9 653 kPa (1,400 psi).
9
CEN30071-05 30 Testing and adjusting
18. If all pump pressures and brake cooling oil supply If the pressure reaches 24 300 kPa (3,525 psi):
pressures are as stated in steps 16 and 17,
a. The first time through this step:
increase engine to 1500 rpm and flush the
system for 20 minutes. During this time, move the • Stop engine by leaving the key switch ON
hoist lever to POWER UP for 30 seconds. Then and pulling up the engine shutdown switch
move the hoist lever to POWER DOWN for 30 on the center console. Confirm that steering
seconds. Continue to monitor the brake cooling accumulator bleed down does not occur and
that no bleeddown faults are generated.
oil supply pressures. The oil supply pressure
should be 345 kPa (50 psi) or less when the hoist * Record on Data Sheet
lever is in HOLD or FLOAT and drop to 0 kPa (0 • Turn the key switch OFF and confirm that
psi) when the hoist lever is in POWER UP or steering accumulator bleed down begins.
POWER DOWN. Confirm that bleed down is completed
normally within 90 seconds and that fault
Cycle the hoist lever as stated above five times.
A236 “Steering Bleed Fault” is not active.
Steering pressure at bleeddown manifold
test port "TP3" will be 103 kPa (15 psi) or
19. After flushing is complete, stop the engine and less after a successful bleed down.
allow steering accumulators to completely
* Record on Data Sheet
discharge. Remove the special flushing
plumbing. If the optional steering accumulator Continue to step 20c.
hose/needle valve assembly was installed in step
b. For the second and all other times through
6, leave it installed. Reconnect all original
step 20, turn the key switch OFF and allow the
plumbing. Check that oil is visible in upper sight
steering accumulators to bleed down. The
glass on hydraulic tank. Add oil if necessary.
steering pressure at bleeddown manifold test
NOTE: If the brakes are not installed, leave the brake port "TP3" will be 103 kPa (15 psi) or less after
cooling supply and return hoses connected together a successful bleed down.
during this entire checkout procedure. * Record on Data Sheet
c. Open the brake accumulator bleed valves on
NOTE: Step 20 cannot be combined with the flushing the brake manifold and allow the brake
procedure in steps 16-18. This flushing procedure accumulators to fully bleed down. Open the
must be performed after step 19 is completed. bleed valve on the auxiliary hydraulic manifold
to bleed down the auxiliary accumulator. Close
NOTE: Do not steer or apply the brakes at any time the bleed valves.
during step 20.
d. Perform step 20 five times.
20. Flush the accumulators by starting the engine
and operating until the accumulator pressure is
approximately 24 300 kPa (3,525 psi) when the 21. After flushing all of the accumulators, the steering
unloader valve shifts and unloads the steering system must be flushed. Start the engine. Allow
pump. If the pressure will not reach 24 300 kPa the accumulators to fully charge and the steering
(3,525 psi), refer to the pump adjustment pump to unload. Turn the steering wheel fully to
procedure in step 26. the left and right at least 10 times. Stop the
engine and allow the steering accumulators to
bleed down completely. Add oil to the hydraulic
tank if necessary.
10
30 Testing and adjusting CEN30071-05
Flow amplifier adjustment Steering pump unloader valve adjustment
22. In preparation for the steering shock valve 26. The steering pump unloader valve should unload
checkout, adjust the unloader valve on the the pump at a nominal pressure of 24 300 kPa
steering pump by turning the unloader valve (3,525 psi) and reload the accumulators when the
adjustment screw clockwise until a minimum pressure at bleeddown manifold port "TP2" falls
reload pressure of 25 325 ± 172 kPa (3675 ± 25 to 22 240 ± 172 kPa (3225 ± 25 psi). The reload
psi) is measured at bleeddown manifold port pressure is the critical pressure to obtain.
"TP2". The unload pressure will be approximately
If the pump operates as described, proceed to
27 400 kPa (3975 psi).
the end of this step to record pressures. If not,
Turn the steering wheel to verify that at least adjust the unloader valve as follows:
25 150 kPa (3650 psi) is maintained. This is
a. Install a calibrated multiple range pressure
acceptable pump performance for this part of the
gauge capable of 35 000 kPa (5,000 psi) at
checkout procedure.
steering pump test port "GPA".
NOTE: The pump adjustment in this step is to be used b. Install a calibrated pressure gauge capable of
only for checking the steering shock valves. It is not 35 000 kPa (5,000 psi) in bleeddown manifold
intended for normal truck operation. Refer to step 26 test port "TP2".
when adjusting the pump for normal truck operation.
c. Fully open all pump suction shutoff valves.
23. Before checking the steering shock valves, raise
the steering relief valve pressure setting. d. Remove the unloader valve adjuster cap and
Remove the external access plug on the flow completely back out the adjustment screw.
amplifier, then turn the internal adjustment screw e. Start the engine and allow the steering pump
clockwise to gently bottom out the relief valve. to unload. When unloaded, the pressure at
24. To check the steering shock valve pressure steering pump test port "GPA" will be 1 380 -
settings, turn the steering wheel away from the 2 760 kPa (200 - 400 psi).
cylinder stops, then turn the steering wheel fully f. Adjust the unloader valve to reload the
into a stop and continue to turn the steering accumulators when the pressure at
wheel. One gauge on the steering cylinder bleeddown manifold test port "TP2" falls to
manifold should read 24 000 ± 1000 kPa (3480 ± 19 133 ± 172 kPa (2,775 ± 25 psi). The unload
145 psi). pressure will be approximately 21 200 kPa
Turn the steering wheel into opposite stop. The (3,075 psi), but the reload pressure is the
other gauge on the steering cylinder manifold critical pressure to obtain.
should read 24 000 ± 1000 kPa (3480 ± 145 psi). NOTE: If adjusting after step 20, do not turn the
* Record on Data Sheet steering wheel to make the accumulator pressure fall.
The bleed valves on the brake manifold can be
25. After checking the steering shock valve pressure
opened partially to slowly bleed down the steering
settings, lower the steering relief valve pressure
accumulator pressure to allow the pump to cycle every
setting to 20 685 -207/+827 kPa (3000 -30/+120
20-30 seconds while adjusting the unloader valve.
psi). Turn the steering wheel fully to the left or
right into a stop, then adjust the steering pressure g. Tighten the adjustment cap and verify that the
at the flow amplifier while slowly turning the pressures remain as adjusted. If the reload
steering wheel into the stop. When the pressure is 22 065 - 22 400 kPa (3,200 - 3,250
appropriate gauge at the steering cylinder psi) as the pump is cycling, the pump is
manifold reads the correct pressure, replace the properly adjusted. Close the bleed valves.
external access plug on the flow amplifier. * Record on Data Sheet
Tighten the plug to the proper torque.
h. If the pump is being adjusted from step 20,
* Record on Data Sheet return to step 20 now and flush the
accumulators without turning the steering
wheel.
11
CEN30071-05 30 Testing and adjusting
Auxiliary accumulator pressure verification f. With the auxiliary accumulator bleed valve
27. The auxiliary accumulator supply valve closes open, verify that the pressures at test ports
when the steering system supply pressure falls "TP2" and "TP3" remain above 16 550 kPa
below the minimum required for proper system (2400 psi) for at least five minutes after the
operation. Oil that is consumed by any auxiliary auxiliary accumulator is bled down to 103 kPa
systems is not replaced below this pressure. The (15 psi) or less. If either of the steering
supply valve closing pressure is the critical accumulator pressures at test port "TP2" or
pressure to verify. Maximum auxiliary pressure is "TP3" falls or the pressure at auxiliary
equal to the steering pump unload pressure and hydraulic manifold test port “GA” rises, correct
is not independently adjustable. the problem and return to step 27b.
* Record on Data Sheet
The auxiliary accumulator supply valve is located
on the auxiliary hydraulic manifold. It is controlled g. Close the bleed valve on the auxiliary
by a non-adjustable pressure switch in the steer- hydraulic manifold.
ing bleeddown manifold. Verify the auxiliary accu-
mulator supply valve closing pressure as follows: System diagnostics
a. Install calibrated 35 000 kPa (5,000 psi) 28. Start the engine to charge the steering
pressure gauges in auxiliary hydraulic accumulators to at least 22 065 kPa (3200 psi).
manifold test ports “GA” and "GP1". To prevent the accumulators from bleeding down,
leave the key switch ON and pull up the engine
NOTE: Test port “GP1" is connected directly to shutdown switch on the center console to stop
steering bleeddown manifold test port "TP2". For the the engine.
sake of convenience, "GP1" pressure readings may be
used instead of "TP2" pressure readings. 29. Set the wheel speed on the DID panel to 1.0 kPa.
Slowly open the brake accumulator bleed valve
b. Start the engine and allow the steering pump on the brake manifold. Observe the pressure at
to unload. Continue to operate the engine at steering bleeddown manifold test port "TP2"
low idle for at least three minutes to allow the when the buzzer sounds and low steering
accumulator temperatures to stabilize. The pressure fault code A247 appears on the dash
pressures at steering bleeddown manifold test panel message display. The fault should occur at
ports "TP2" and "TP3" and auxiliary hydraulic a falling pressure of 15 860 ± 420 kPa (2300 ± 61
manifold test port “GA” should be at least psi). If outside this range, correct the problem.
22 065 kPa (3,200 psi).
* Record on Data Sheet
c. To prevent the accumulators from bleeding
down, leave the key switch ON and pull up the NOTE: Step 30 may be skipped if no excessive
engine shutdown switch on the center console leakage in the steering system is suspected.
to stop the engine. 30. To check for leakage in the steering system:
d. Slowly open the bleed valve on the auxiliary a. Disconnect the flow amplifier return hose at
hydraulic manifold. the steering bleeddown manifold and plug the
e. Observe the pressure at steering bleeddown fitting on the manifold. Disconnect the steering
manifold test port "TP2" at which the supply control unit return hose at the flow amplifier
valve closes and the pressure at auxiliary and plug the port.
hydraulic manifold test port “GA” falls below b. Start the engine. Allow the steering
the pressure at "TP2". The supply valve accumulators to fully charge and the steering
should close at a falling pressure of 17 580 pump to unload. Do not turn the steering
+690/-345 kPa (2550 +100/-50 psi). If outside wheel while the return hoses are
this range, correct the problem and return to disconnected.
step 27b.
* Record on Data Sheet
12
30 Testing and adjusting CEN30071-05
c. Measure the leakage from the flow amplifier
and the steering control unit.
• Leakage from the flow amplifier should not
exceed 820 mL (50 in.3) per minute. If
leakage is excessive, replace the flow In the next step, DO NOT use the key switch to
amplifier. shut off the engine. If the key switch is turned OFF,
• Leakage from the steering control unit should all accumulator oil will be discharged through the
not exceed 164 mL (10 in.3) per minute. If open port on the bleeddown manifold. If the hose/
leakage is excessive, replace the steering needle valve assembly was installed in step 6, use
control unit. this method to bleed down the steering
accumulators after leakage is measured. If not, the
* Record on Data Sheet
same hose/needle valve assembly can be made
NOTE: Step 31 may be skipped if no excessive and connected between bleeddown manifold test
leakage in the steering bleeddown manifold is port "TP3" and the hydraulic tank fill tube. Both
suspected. steering accumulators will be bled down when test
31. To check for leakage in the steering bleeddown port "TP3" is opened to the tank.
manifold: c. Start the engine and allow the steering pump
a. Disconnect the flow amplifier return hose at to unload. Measure the leakage from the tank
the steering bleeddown manifold and plug the return port in the steering bleeddown manifold.
fitting on the manifold. Disconnect the steering Leakage from the tank return port should not
control unit return hose at the flow amplifier exceed 541 mL (33 in.3) per minute.
and plug the port. Disconnect the tank return * Record on Data Sheet
hose at the steering bleeddown manifold.
32. Reconnect all hoses to the steering bleeddown
manifold.
NOTE: Step 33 may be skipped if no excessive
leakage in the brake system or auxiliary hydraulic
The hydraulic tank oil level is above the level of the system is suspected.
tank return line. It is necessary to draw a vacuum 33. To check for leakage in the brake system and
on the hydraulic tank to prevent a large amount of auxiliary hydraulic system:
oil from draining from the tank with the return line
disconnected from the bleeddown manifold. a. Install pressure gauges at brake manifold
ports "AF3" and "AR3" and at auxiliary
b. Disconnect the hoist pilot valve return hose at hydraulic manifold test port “GA”.
the steering bleeddown manifold and plug the
port. Connect the tank return hose to the hoist b. Start the engine and allow the steering pump
pilot valve return hose, or plug the tank return to unload. Continue to operate the engine at
hose and vent the hoist pilot valve return hose low idle for at least three minutes to allow the
to the tank. Do not plug the hoist pilot valve accumulator temperatures to stabilize. Do not
return hose. operate the service brakes during this
step.
c. With the steering accumulators charged to at
least 22 065 kPa (3,200 psi), turn the key
switch OFF and wait two minutes for the
steering accumulators to bleed down.
d. The pressure gauges at brake manifold ports
"AF3" and "AR3" and at auxiliary hydraulic
manifold test port “GA” should remain above
20 685 kPa (3,000 psi).
* Record on Data Sheet
13
CEN30071-05 30 Testing and adjusting
e. Wait 20 minutes, then record each Hoist counterbalance valve adjustment
accumulator pressure again. Note any
NOTE: Skip step 38 if the dump body is not installed.
changes.
* Record on Data Sheet
• Each pressure gauge at brake manifold ports
"AF3" and "AR3" must be less than 2 275 38. To adjust the hoist counterbalance valve on the
kPa (330 psi). This is a loss of 6 900 kPa overcenter manifold, the dump body must be
(1,000 psi) per hour. empty and the hoist cylinder hoses must be
• The pressure gauge at auxiliary hydraulic connected to the hoist valve.
manifold test port “GA” must be less than a. Move the hoist lever to the FLOAT position
207 kPa (30 psi). This is a loss of 690 kPa and lower the body to the frame, or secure the
(100 psi) per hour. raised body with the proper body retention
* Record on Data Sheet cable or sling. Stop the engine.
f. Remove the pressure gauges from ports b. Loosen the locknut on the needle valve
"AF3", "AR3" and "GA". adjustment stem, then turn the adjustment
34. Disconnect and cap the four hoses from the hoist stem inward. This will block the hoist cylinder
cylinders. head pressure from the counterbalance valve
pilot.
35. Start the engine and raise the engine speed to
high idle. Move the hoist lever to POWER UP. c. Remove the plug from the "PILOT VENT" port
The pressure gauges at the hoist filters should on the overcenter manifold. This will vent the
read 18 960 ± 690 kPa (2 750 ± 100 psi) at high counterbalance valve pilot to atmosphere.
idle. NOTE: Do not allow dirt or debris to enter the open
* Record on Data Sheet pilot vent port. A clean SAE # 4, 1/4" hydraulic hose
can be installed in the port and pointed downward to
36. Move the hoist lever to POWER DOWN. The help prevent entry of contaminants.
pressure gauge at overcenter manifold test port
"TPD" should read 10 340 ± 515 kPa (1 500 ± 75 d. Install a calibrated pressure gauge at
psi) at high idle. overcenter manifold test port "TR". The gauge
will measure hoist cylinder rod end pressure,
* Record on Data Sheet
which is the pressure controlled by the
37. Move the hoist lever to FLOAT to reduce the counterbalance valve.
pressure in the hoist cylinder hoses. Turn the key
NOTE: If adjustment of the counterbalance valve is
switch OFF to stop the engine. Vent the residual
anticipated, skip verification step 38e and proceed to
hoist cylinder hose pressure and remove the
step 38f.
caps from the hoses. Reconnect the four hoses
to the hoist cylinder. NOTE: If the dump body is secured in the raised
position, remove the body retention cable or sling.
e. Start the engine and operate at low idle. Move
the hoist lever to POWER UP until the hoist
cylinders are in the third stage and observe
the pressure gauge at overcenter manifold
test port "TR".
• If the pressure is 20 685 kPa (3,000 psi) or
higher, stop raising the dump body
immediately. The pressure setting is too high
and must be lowered. Repeat step 38a, then
go to step 38f.
14
30 Testing and adjusting CEN30071-05
• If the pressure is below 20 685 kPa (3,000 Final steps
psi), increase the engine speed by
approximately 300 rpm and repeat step 38e. 39. Reconnect or enable any auxiliary hydraulic
Continue testing the pressure setting at systems on the truck (auto lube, hydraulic ladder,
increasing 300 rpm intervals until high idle is radiator shutters, etc).
reached. 40. Perform the individual checkout procedures for
The counterbalance valve pressure must be any auxiliary hydraulic systems.
20 685 kPa (3,000 psi) when the hoist lever is in 41. If the optional hose/needle valve assembly was
POWER UP, the engine is at high idle and the installed in steps 6 or 31, bleed down all of the
hoist cylinder is in the third stage. accumulators, then remove the hose/needle
• If the pressure is correct, repeat step 38a, valve assembly and any associated fittings.
then go to step 38i. Install the port plugs and tighten them to the
proper torques.
• If the pressure does not reach 20 685 kPa
(3,000 psi), step 38a, then go to step 38f. 42. Remove all pressure gauges that were installed
during the checkout procedure.
f. Loosen the locknut on the counterbalance
valve adjustment stem. Turn the adjustment
step fully clockwise to lower the pressure as
much as possible.
NOTE: If the dump body is secured in the raised
position, remove the body retention cable or sling.
g. Start the engine and operate at high idle.
Move the hoist lever to POWER UP until the
hoist cylinders are in the third stage. Adjust
the counterbalance valve adjustment stem as
needed to obtain a reading of 20 685 kPa
(3,000 psi) at overcenter manifold test port
"TR".
NOTE: Turning the adjustment stem clockwise
decreases the pressure. Turning the adjustment stem
counterclockwise increases the pressure. The entire
range of the adjustment stem is three turns.
* Record on Data Sheet
h. Repeat step 38a.
i. Install the plug in the "PILOT VENT" port on
the overcenter manifold and tighten it to the
proper torque.
j. Turn the needle valve adjustment stem fully
outward, then tighten the locknut. This needle
valve must be fully open for normal hoist
operation.
k. Remove the pressure gauge from overcenter
manifold test port "TR".
15
CEN30071-05 30 Testing and adjusting
Oil cleanliness check
43. Before the truck can be put into service, the
cleanliness of the hydraulic oil must be checked.
Use the quick disconnect coupling at either hoist
filter test port to attach a hose and obtain an oil
sample. Do not use the steering filter test port.
Do not use a hose that has been previously
used for system flushing.
a. The hydraulic system checkout procedure
must be completed before taking an oil
sample.
b. Start the engine and operate at high idle for at
least ten minutes. Do not operate the steering,
hoist, brakes or any other hydraulic function
during the oil sampling procedure.
c. Take particle count readings for at least 20
minutes without changing the engine speed.
d. When the particle count level is at or below
ISO 21/18/15 standard and is showing a trend
of improving cleanliness or at least
maintaining the ISO 21/18/15 standard, the
hydraulic oil meets the acceptable criteria for
cleanliness.
e. If the particle count level of the ISO 21/18/15
standard is not achieved within 20 minutes,
continue operating the engine at high idle until
the conditions in step 43d are achieved.
* Record on Data Sheet
44. Replace all hydraulic filter elements before the
truck is put into service. Note the service hour
meter reading.
* Record on Data Sheet
16
30 Testing and adjusting CEN30071-05
Hydraulic system checkout data sheet
** Acceptable values of each measurement are shown in (parenthesis).
Machine Model___________ Unit Number ___________ Serial Number_____________
1e. Steering and brake accumulator precharge pressures:
Front steering accumulator, ACC1 (1400 ± 10 psi at 70º F) ___________ at _______
Rear steering accumulator, ACC2 (1400 ± 10 psi at 70º F) ___________ at _______
Front brake accumulator, AF1 (1400 ± 10 psi at 70º F) ___________ at _______
Rear brake accumulator, AR1 (1400 ± 10 psi at 70º F) ___________ at _______
16. Was low steering accumulator precharge warning A115 displayed before start-up? (circle one)
(No) YES NO
20. Pressure at bleeddown manifold test port TP3:
a.) Does bleed down occur when stopping with engine shutdown switch? (circle one)
(No) YES NO
Pressure at port “TP3” (approximately 3075 psi) ___________
Faults (none) ___________
Pressure at port TP3 and faults after each bleeddown cycle:
1st Bleeddown cycle
Pressure after bleeddown (15 psi or less) ___________
Faults (none) ___________
2nd Bleeddown cycle
Pressure after bleeddown (15 psi or less) ___________
Faults (none) ___________
3rd Bleeddown cycle
Pressure after bleeddown (15 psi or less) ___________
Faults (none) ___________
4th Bleeddown cycle
Pressure after bleeddown (15 psi or less) ___________
Faults (none) ___________
5th Bleeddown cycle
Pressure after bleeddown (15 psi or less) ___________
Faults (none) ___________
24. Flow amplifier shock valve pressures:
Left shock valve pressure (3480 ± 145 psi) ___________
Right shock valve pressure (3480 ± 145 psi) ___________
17
CEN30071-05 30 Testing and adjusting
25. Flow amplifier relief valve pressure: (3000 -30/+120 psi) ___________
26g. Steering pump reload pressure: (3225 ± 25 psi) ___________
Steering pump unload pressure: (3525 psi nominal) ___________
27e. Auxiliary accumulator supply valve closing pressure: (2550 +110/-50 psi) ___________
27f. 5 minutes after auxiliary accumulator bleeddown:
Front steering accumulator pressure, TP2 (> 2400 psi) ___________
Rear steering accumulator pressure, TP3 (> 2400 psi) ___________
Auxiliary accumulator pressure, GA (15 psi or less) ___________
29. Pressure when low steering pressure fault A247 occurs: (3000 ± 61 psi) ___________
30. Was steering system leakage checked? (circle one) (Yes) YES NO
Flow amplifier leakage (< 50 in.3/ min.)___________
Steering control unit leakage (< 10 in.3/ min.)___________
31. Was steering bleeddown manifold leakage checked? (circle one) (Yes) YES NO
Steering bleeddown manifold leakage (< 33 in.3/ min.)___________
33d. After steering accumulator bleeddown:
Front brake accumulator pressure, AF3 (> 3000 psi) ___________
Rear brake accumulator pressure, AR3 (> 3000 psi) ___________
Auxiliary accumulator pressure, GA (> 3000 psi) ___________
33e. 20 minutes after steering accumulator bleeddown:
Front brake accumulator pressure, AF3 (< 330 psi below 33d) ___________
Rear brake accumulator pressure, AR3 (< 330 psi below 33d) ___________
Auxiliary accumulator pressure, GA (< 10 psi below 33d) ___________
35. POWER UP pressure at hoist filter: (2750 ± 100 psi) ___________
36. POWER DOWN pressure at overcenter manifold, TPD: (1500 ± 75 psi) ___________
18
30 Testing and adjusting CEN30071-05
38. Was dump body installed? (circle one) (Yes) YES NO
If dump body is installed, what is the final pressure of the counterbalance valve at
overcenter manifold port TR with hoist cylinders at third stage
(3000 ± 100 psi) ___________
43. Hydraulic fluid cleanliness level after 10 minutes at high idle:
(ISO 21/18/15 or lower)___________
Particle counter printout attached to these sheets? (circle one) (Yes) YES NO
44. Service meter reading (SMR) when filter elements were replaced:
Brake filter (hours) ___________
Front hoist filter (hours) ___________
Rear hoist filter (hours) ___________
Steering filter (hours) ___________
Name of Technician or Inspector Performing Checkout: _________________________
Badge number: ________________________
Date & shift completed:__________________
19
CEN30071-05 30 Testing and adjusting
High altitude steering pump adjustment 2. Loosen the locknut (1, Figure 30-9) securing the
maximum volume adjustment screw (2).
At altitudes above 3050 m (10,000 ft), perform the
following adjustment to optimize steering pump 3. Turn the adjustment screw counterclockwise until
performance and prevent damage to the pump. the screw reaches the stop.
NOTE: Changing the settings for the pressure 4. Turn the screw clockwise 6 1/2 revolutions.
compensator and the unloader valve is not necessary 5. Hold the adjustment screw in place and tighten
for the high altitude adjustment. the locknut.
1. Depressurize the hydraulic system. Refer to the 6. Drive the truck and verify that the steering and
Testing and adjusting section Hydraulic system brake systems are functioning properly.
bleedown procedure.
2 1 88278
FIGURE 30-9. STEERING PUMP
1.Locknut
2.Maximum Volume Adjustment Screw
20
30 Testing and adjusting CEN30071-05
Toe-in adjustment
NOTE: Before returning the truck to operation, the
1 3 2 5 3 4
steering system must first be centered in the straight
ahead position.
1. Check the toe-in by measuring the distance
between the centers of the front tires. Measure
on the horizontal centerline at the front and rear
of the tires. Refer to Figure 30-10.
Radial tires should have equal measurements
(zero toe-in).
84515
FIGURE 30-11. TIE ROD ASSEMBLY
1. Threaded Rod End 4. Locknut
2. Capscrew 5. Clamps
3. Hardened Flat Washer
2. Loosen locknuts (4, Figure 30-11). Rotate the tie
rod as necessary to obtain the correct toe-in
setting. The tie rod length when installed is 3 683
± 10mm (145.0 ± 0.4 in.).
3. When this adjustment is complete, hold the head
of each capscrew (2) with a wrench and use a
torque wrench to tighten each locknut to 1 017 ±
102 N·m (750 ± 75 ft lb).
4. Reapply torque to each locknut (4) until the
specified torque is maintained.
FIGURE 30-10. MEASURING TOE-IN
21
CEN30071-05 30 Testing and adjusting
Measuring steering pin joint wear
Use extreme caution when performing
maintenance on any vehicle with an active
steering system. Serious injury or death can result
from contact with moving parts. Always keep a
safe distance from crush points.
1. Position the front wheels straight ahead.
2. Perform a visual inspection for excessive wear or
damage to bearings and other components in the
pin joints prior to dial indicator test. Remove and
replace components with excessive wear or FIGURE 30-12. TIE ROD PIN JOINT
damage.
1. Steering Arm 3. Indicator Base
3. Attach the base of a dial indicator to the tie rod or 2. Indicator Plunger 4. Tie Rod
steering cylinder to be measured. See Figure 30-
12 for indicator setup on a tie rod and Figure 30-
13 for indicator setup on a steering cylinder.
Use a digital indicator with remote-read capabili-
ties so that someone is not required to be under
the truck while performing step 5. See Figure 30-
14.
4. Place the indicator plunger against the steering
arm (or frame for inboard cylinder joints). Set the
plunger at mid-stroke and then zero the indicator.
NOTE: As an alternate setup, the base of the dial
indicator may be attached to the steering arm or the
frame while placing the indicator plunger against the
steering cylinder eye or tie rod eye.
FIGURE 30-13. STEERING CYLINDER PIN JOINT
1. Steering Arm 3. Indicator Base
2. Indicator Plunger 4. Steering Cylinder
22
30 Testing and adjusting CEN30071-05
5. Turn the front wheels in both directions just
enough to remove the pin play. Record the total
indicator movement. The front tires should move
approximately 5 to 10 degrees (or approximately
1/3 to 2/3 of a steering wheel revolution) away
from the straight ahead position in each direction.
6. Record the maximum positive and maximum
negative dial indicator readings measured while
turning the front wheels in both directions for
each pin joint. Add the absolute value of each
reading together to calculate the total indicator
movement for each joint. Compare the total
indicator movement to the maximum allowable
wear (clearance limit) in Table 1.
7. If total joint clearance exceeds the limit specified
FIGURE 30-14. DATA SETUP in Table 1, replace the worn components. Use
items 2, 3, 4, 5 and 6 in Table 1 as a guide to
1. Laptop Computer 2. Indicator Data Cable
determine which components to replace. See
Figure 30-15 for locations. The press fit between
the spherical bearings and the cylinder and tie
rod housings must be maintained.
Table 1: Steering linkage wear specifications
Criteria
No. Location Tolerance Standard Clearance
Standard Size
Shaft Hole Clearance Limit
Total Joint 1.90 mm
1 — — — —
Clearance 0.075 in.
-0.041 mm 0.000 mm 0.021 mm
Bearing to Pin 88.900 mm -0.0016 in. 0.0000 in. 0.0008 in. 0.06 mm
2
Clearance 3.5000 in. -0.061 mm -0.020 mm 0.061 mm 0.002 in.
-0.0024 in. -0.0008 in. 0.0024 in.
Inner to Outer 146.050 mm — — — 1.46mm
3
Bushing Clearance 5.7500 in. — — — 0.058 in.
-0.092 mm 0.025 mm -0.067 mm
Pin to Arm/Frame 88.951 mm -0.0036 in. 0.0010 in. -0.0026 in. 0.14 mm
4
Clearance 3.5020 in. -0.112 mm -0.025 mm 0.137 mm 0.005 in.
-0.0044 in. -0.0010in. 0.0054 in.
0.090 mm 0.025 mm -0.065 mm
Pin to Arm/Frame 104.950 mm 0.0036 in. 0.0010 in. -0.0026 in. 0.14 mm
5
Clearance 4.1319 in. -0.110 mm -0.025 mm 0.135 mm 0.005 in.
-0.0043 in. -0.0010 in. 0.0053 in.
0.000 mm -0.049 mm -0.089 mm
Rod Eye to Bearing 158.750 mm 0.0000 in. -0.0019 in. -0.035 in.
6 N/A
Clearance 6.2500 in. -0.025 mm -0.089 mm 0.024 mm
-0.0010 in. -0.0035 in. 0.0009 in.
23
CEN30071-05 30 Testing and adjusting
83520
FIGURE 30-15. SPHERICAL BEARING WEAR LIMITS
1. Bearing to Pin Clearance 4. Pin to Arm/Frame Clearance
2. Inner to Outer Bushing Clearance 5. Rod Eye to Bearing Clearance
3. Pin to Arm/Frame Clearance
8. If premature wear of the bearings is evident,
check the automatic lubrication system to ensure
the proper amount of lubrication is being received
at the joint(s) in question.
24
30 Testing and adjusting CEN30071-05
Hoist cylinder leakage test Steering cylinder leakage test
After the hoist cylinder is assembled, perform the After the steering cylinder is assembled, perform the
following tests to verify that performance is within following tests to verify that performance is within
acceptable limits. acceptable limits.
1. With the rod fully extended, piston leakage must 1. Piston leakage must not exceed 2.5 cm3/min.
not exceed 164 cm3/min. (10 in3/min.) at 17 237 (0.15 in3/min.) at 20 700 kPa (3,000 psi) port to
kPa (2,500 psi), port to port. port.
2. With the rod fully retracted, piston leakage must 2. Rod seal leakage must not exceed one drop of oil
not exceed 328 cm3/min. (20 in3/min.) at 17 237 in eight cycles of operation.
kPa (2,500 psi), port to port.
3. Piston break-away force must not exceed 690
3. Rod seal leakage must not exceed one drop of oil
kPa (100 psi).
in eight cycles of operation.
25
CEN30071-05 30 Testing and adjusting
980E Dump truck
Form No. CEN30071-05
26
CEN30072-04
DUMP TRUCK 1SHOP MANUAL
980E
Machine model Serial number
980E-4 A40003 and up
980E-5 A50005 and up
30 Testing and adjusting
Brake system
General information on system checkout.............................................................................................................. 3
Brake system checkout procedures...................................................................................................................... 3
Brake system checkout data sheet ..................................................................................................................... 15
Brake piston leakage test.................................................................................................................................... 23
Brake seal pressure test ..................................................................................................................................... 23
Oil separator seal pressure test .......................................................................................................................... 23
Wet disc brake bleeding procedure .................................................................................................................... 24
Parking brake bleeding procedure ...................................................................................................................... 25
Service brake disc wear inspection..................................................................................................................... 26
Parking brake disc wear inspection .................................................................................................................... 27
Brake valve bench test and adjustment .............................................................................................................. 28
Dual relay valve bench test and adjustment ....................................................................................................... 31
1
CEN30072-04 30 Testing and adjusting
NOTES
2
30 Testing and adjusting CEN30072-04
General information on system checkout Brake system checkout procedures
The brake system checkout procedures are intended
to help the technician diagnose problems in the brake
circuits. The technician should read the entire
checkout procedure to become familiar with the
procedures and all the warnings and cautions before
The steering system supplies the brake system
performing any steps. The checkout procedures begin
with operating pressure. Therefor, the steering
by checking the basic system before checking
system must be checked for proper operation
individual components.
before checking the brake systems. Successfully
A data sheet is included in this section to record the complete the hydraulic system checkout
test information obtained during the brake system procedure before performing the brake system
checkout procedure. The data sheet is designed to be checkout procedures.
copied and used during the checkout procedure.
This section outlines a procedure to test the
functionality of the entire brake system. Pressure
specifications and other criteria that must be
duplicated for the braking system to be considered
ready for daily operations are provided.
Hydraulic oil escaping under pressure can have The steering circuit can be isolated from the brake
sufficient force to enter a person's body by circuit by first releasing all steering system pressure,
penetrating the skin and cause serious injury, and then releasing all pressure from the brake
possibly death, if proper medical treatment by a accumulators and removing the brake system supply
physician familiar with this type of injury is not hose from the bottom of the bleeddown manifold. Plug
received immediately. the hose and cap the fitting at the bleeddown manifold
Relieve pressure before disconnecting any to prevent high pressure leakage.
hydraulic lines. Tighten all connections securely
Required equipment
before applying pressure.
• Brake hydraulic circuit schematic
• Service computer with Interface Module Realtime
NOTE: The interface module (IM) checkout procedure Data Monitor software
must be successfully completed and engine startup
must be possible before beginning the checkout • Accumulator charging kit (EB1759 or equivalent)
procedures. with gauges and dry nitrogen
• Four 24 100 kPa (3,500 psi) pressure gauges
• Clear plastic hose and bucket for brake bleeding
NOTE: If the brakes are not assembled on the truck,
brake simulators will be required.
3
CEN30072-04 30 Testing and adjusting
3 8
9
7 4
DETAIL A DETAIL B
6 5
A
B
86261
FIGURE 30-1. HYDRAULIC BRAKE CABINET - TEST PORTS AND VALVES (EARLIER MODELS)
1. Low Accumulator Pressure Test Port "LAP1" 6. Parking Brake Solenoid Valve "SV2"
2. Parking Brake Release Pressure Test Port "PK3" 7. Auto Apply Sequence Valve "PS1"
3. Brake Lock Apply Pressure Test Port "PP3" 8. Front Brake Pressure Test Port "BF"
4. Pressure Reducing Valve "PR" 9. Rear Brake Pressure Test Port "BR"
5. Brake Lock Solenoid Valve "SV1"
4
30 Testing and adjusting CEN30072-04
4 5
2 1
DETAIL A
88334
FIGURE 10-2. HYDRAULIC BRAKE CABINET - BRAKE CIRCUIT COMPONENTS
(LATER MODELS)
1. Brake Manifold 4. Stop Light Pressure Switch
2. Brake Lock Shuttle Valve 5. Brake Lock Degradation Switch
3. Dual Relay Valve (Front Brakes)
5
CEN30072-04 30 Testing and adjusting
Initial system setup 6. Slowly depress the brake pedal. Rear brake
pressure "BR" should begin to rise before front
NOTE: Configure the DID panel to metric units. The
brake pressure "BF". Verify that the rear brake
truck must remain in PARK and at zero ground speed
pressure is 310 - 1415 kPa (45 - 205 psi) when
unless otherwise noted.
the front brake pressure begins to rise.
NOTE: Securely block the tires to prevent the truck * Record on Data Sheet
from rolling away.
7. Slowly depress the brake pedal. Force feedback
1. Install the calibrated pressure gauges at the of the pedal on your foot should be smooth with
following locations: no abnormal noise or mechanical roughness.
a. junction manifold test port "BR" Verify that the stop lights illuminate when rear
brake pressure "BR" is 517 ± 34 kPa (75 ± 5 psi).
b. junction manifold test port "BF"
* Record on Data Sheet
c. brake manifold test port "LAP1"
8. Quickly and completely depress the brake pedal.
2. The steering accumulators, brake accumulators
Verify that rear brake pressure "BR" and front
and auxiliary system accumulator must have the
brake pressure "BF" are both 17 235 ± 517 kPa
correct precharge and must be at normal
(2,500 ± 75 psi) within one second after the brake
operating temperature. Refer to Testing and
is applied:
adjusting section Accumulators and
suspensions for the accumulator charging Both pressures must remain above their
procedures. minimum values for a minimum of 20 seconds
* Record on Data Sheet while the pedal is fully applied.
* Record on Data Sheet
NOTE: For best performance, charge the
accumulators in the ambient conditions in which the Brake lock / secondary braking checkout
machine will be operating.
9. Disconnect the lead wire from the brake lock
3. Close the brake accumulator bleed valves and solenoid valve (5, Figure 30-1) on the brake
the auxiliary accumulator bleed valve. manifold in the hydraulic brake cabinet.
4. Start the engine. Observe the rising brake 10. Move the directional control lever to NEUTRAL.
pressures at test ports "BR" and "BF" as the
system charges. The brake pressures should 11. Press the brake lock switch. The brake lock will
begin to fall when the auto apply valve releases. not apply if the engine is not operating. Fault
The auto apply valves should release the front code A118 will become active.
and rear brakes when the pressure at test port Depress the brake pedal until fault code A118 is
"LAP1" is 11 375 -515/+2 585 kPa (1,650 -75/ cleared, then very slowly release the pedal until
+375 psi). fault code A118 is active again. Verify that the
* Record on Data Sheet rear brake pressure "BR" drops to 6 895 ± 172
kPa (1,000 ± 25 psi) when the fault reoccurs.
5. Partially depress the brake pedal to bleed air
from each brake. Move the directional control * Record on Data Sheet
lever to NEUTRAL to bleed air from the parking NOTE: There is a three second delay between the
brakes. Then move the directional control lever to time that the brake lock degradation switch senses the
PARK. pressure and fault code A118 occurs. Fault code A265
will also become active during this step.
6
30 Testing and adjusting CEN30072-04
12. Connect the lead wire to brake lock solenoid Parking brake checkout
valve (6).
14. Move the pressure gauge from test port "PP3" to
13. Cycle the brake lock switch several times to parking brake release pressure "PK3" test port
ensure crisp application and release of oil (2, Figure 30-1). Start the engine.
pressure and proper function of the status light.
a. Move the directional control lever to PARK,
Check the pressure readings at pressure test then back to NEUTRAL. The parking brake
ports (BR) and (PP3). Verify that the rear brake status light should illuminate, then go out.
pressure "BR" and the pressure at "PP3" are both Verify that parking brake release pressure at
13 790 ± 690 kPa (2,000 ± 100 psi) when the test port "PK3" is 22 753 ± 1378 kPa (3,300 ±
brake lock is applied. Fault code A118 should 200 psi).
also not be displayed. * Record on Data Sheet
* Record on Data Sheet b. Move the directional control lever to PARK.
If the brake lock does not function correctly, Verify that the parking brake apply pressure at
ensure that all brake lock circuit plumbing is test port "PK3" is 0 kPa (0 psi).
correct. * Record on Data Sheet
If the plumbing is correct, allow the steering If the parking brake does not function correctly,
accumulators to fully charge, then disconnect ensure that all parking brake circuit plumbing is
wire 52B to the brake lock solenoid at TB32-J. correct.
Apply 24V to the disconnected wire 52B. Verify
that the pressure reading at pressure test port If the plumbing is correct, allow the steering
"PP3" is 13 790 ± 690 kPa (2,000 ± 100 psi). accumulators to fully charge, then disconnect
Ignore any resulting brake lock faults. wire 52CS to the parking brake solenoid at TB32-
K. Ground the disconnected wire 52CS. Verify
a. If the pressure is out of range, adjust pressure that the pressure reading at pressure test port
reducing valve (4, Figure 30-1) as required. "PK3" is 22 753 ± 1 378 kPa (3,300 ± 200 psi).
b. If the pressure reducing valve cannot be Ignore any resulting parking brake faults.
adjusted to achieve the correct pressure, a. If the pressure is out of range and the steering
replace the pressure reducing valve. pump has a pressure compensator, verify that
c. If the brake lock solenoid cannot be the pressure compensator adjustment screw
energized, verify that the wiring to the solenoid is properly adjusted.
is correct. If it is correct, then replace the b. If parking brake solenoid cannot be energized,
solenoid. verify that the wiring to the solenoid is correct.
d. If the brake lock valve will not operate, replace If it is correct, then replace the solenoid.
the valve. c. If parking brake solenoid valve (6, Figure 30-1)
e. Connect wire 52B to TB32-J and repeat step will not operate, replace the valve.
13. d. Connect wire 52CS to TB32-K and repeat step
14.
15. Cycle the parking brake several times by moving
the directional control lever between NEUTRAL
and PARK to ensure crisp application and
release of oil pressure and proper function of the
status light.
7
CEN30072-04 30 Testing and adjusting
Service brake checkout
16. Move the directional control lever to PARK and
turn off the brake lock.
17. Move both brake pressure gauges to left rear
brake pressure "LBP" test port (2, Figure 30-3)
and right rear brake pressure "RBP" test port (1)
on the manifold on the left side of the rear axle
housing.
Quickly and completely depress the brake pedal.
Verify that left rear brake pressure "LBP" and
right rear brake pressure "RBP" are both 16 545
± 517 kPa (2,400 ± 75 psi). within one second
after the brake is applied:
Both pressures must remain above their
minimum values for a minimum of 20 seconds.
* Record on Data Sheet FIGURE 30-3. REAR BRAKE PRESSURE
TEST PORTS
18. Release the brake pedal. Verify that both rear
brake pressures "LBP" and "RBP" return to 0 kPa 1. Right Rear Brake Pressure "RBP" Test Port
(0 psi) within two seconds. There should be no 2. Left Rear Brake Pressure "LBP" Test Port
residual pressure trapped in the brakes.
* Record on Data Sheet
19. Move both rear brake pressure gauges to front
brake pressure test ports "LFBP" and "RFBP" (1,
Figure 30-4) on the front brake backplates.
NOTE: These test ports are not stamped on the
spindle.
Quickly and completely depress the brake pedal.
Verify left front brake pressures "LFBP" and
"RFBP" are both 16 545 ± 517 kPa (2,400 ± 75
psi) within one second after the brake is applied:
Both pressures must remain above their
minimum values for a minimum of 20 seconds.
FIGURE 30-4. FRONT BRAKES
* Record on Data Sheet
20. Release the brake pedal. Verify that both front 1. Test Port - "LFBP" and "RFBP"
brake pressures "LFBP" and "RFBP" return to 0 2. Bleed Port
kPa (0 psi) within two seconds. There should be
no residual pressure trapped in the brakes.
* Record on Data Sheet
8
30 Testing and adjusting CEN30072-04
Low brake accumulator pressure and auto apply NOTE: The brake warning system will activate when
checkout the lower pressure in either brake accumulator falls
21. Move both front brake pressure gauges back to below 12 755 ± 360 kPa (1,850 ± 52 psi). The auto
pressure test ports "BF" and "BR" in the hydraulic apply sequence valve will apply the service brakes if
brake cabinet. Start the engine and allow the low the pressure of either brake accumulator drops below
brake accumulator pressure "LAP1" to increase 11 375 ± 517 kPa (1,650 ± 75 psi).
to 22 065 kPa (3,200 psi). 27. While the front brake accumulator bleed valve is
22. Move the directional control lever to NEUTRAL. still open, allow low accumulator pressure "LAP1"
Turn the key switch OFF and allow 90 seconds to continue to drop. Front brake pressures "BF"
for the steering accumulators to bleed down and "BR" will begin to rise when the auto apply
completely. sequence valve (7, Figure 30-1) is activated at
11 375 ± 517 kPa (1,650 ± 75 psi).
23. Turn the key switch ON, but do not start the
engine. Wait for two minutes, then check the low Front brake pressures "BF" and "BR" should be
accumulator pressure reading at low accumulator at 0 kPa (0 psi) when the auto apply sequence
pressure "LAP1" test port (1, Figure 30-1). If the valve is activated.
pressure is below 14 480 kPa (2,100 psi), there is * Record on Data Sheet
excessive leakage in the system. The source of
28. Observe the final pressures at "LAP1", "BF" and
the leakage must be identified and repaired.
"BR" while auto apply is active.
* Record on Data Sheet
• "LAP1" should be 11 375 ± 517 kPa (1,650 ±
24. Start the engine and allow the low brake 75 psi).
accumulator pressure "LAP1" to increase to
• "BF" should be 9 825 kPa (1,425 psi) or
22 065 kPa (3,200 psi) or above. Then, turn the
higher.
key switch OFF and allow 90 seconds for the
steering accumulators to bleed down completely. • "BR" should be 16 545 ± 517 kPa (2,400 ±
75 psi).
25. Turn the key switch ON, but do not start the
engine. Move the directional control lever to * Record on Data Sheet
NEUTRAL. Provide a speed signal of 3 kph from NOTE: The auto apply sequence valve will need an
the DID panel on the rear wall of the operator adjustment if it does not activate at 11 375 ± 517 kPa
cab. Fault code A260 will occur after the speed (1,650 ± 75 psi). After adjusting the valve, repeat steps
signal is generated. 21-28.
26. Slowly open front brake accumulator bleed valve 29. Close the front brake accumulator bleed valve.
(9) a small amount while observing the Provide a speed signal of 0 kph from the DID
decreasing pressure at the low accumulator panel on the rear wall of the operator cab. Fault
pressure "LAP1" test port. Low brake pressure code A260 will be cleared.
fault A261 should occur when the pressure drops
Move the directional control lever to PARK. Start
to 12 755 ± 360 kPa (1,850 ± 52 psi) and the
the engine and allow low brake accumulator
brake pressure switch in port "LAP2" is activated.
pressure "LAP1" to increase to 22 065 kPa
Front brake pressures "BF" and "BR" should be (3,200 psi) or above.
at 0 kPa (0 psi) when fault code A261 appears.
30. Turn the key switch OFF and allow 90 seconds
Fault code A260 should also occur.
for the steering accumulators to bleed down
* Record on Data Sheet completely.
Turn the key switch ON, but do not start the
engine. Move the directional control lever to
NEUTRAL. Provide a speed signal of 3 kph from
the DID panel on the rear wall of the operator
cab. Fault code A260 will occur after the speed
signal is generated.
9
CEN30072-04 30 Testing and adjusting
31. Slowly open rear brake accumulator bleed valve Brake reapplications
(7) a small amount while observing the
35. Start the engine and allow low brake accumulator
decreasing pressure at low accumulator pressure
pressure "LAP1" to increase to 22 065 kPa
"LAP1" test port (15). Low brake pressure fault
(3,200 psi) or above.
A261 should occur when the pressure drops to
within 690 kPa (100 psi) of the observed pressure 36. Pull up on the engine shutdown switch on the
in step 26. center console to shut off the engine. Do not
turn the key switch OFF. The accumulators
Front brake pressures "BF" and "BR" should be must not be allowed to bleed down.
at 0 kPa (0 psi) when fault code A261 appears.
Move the directional control lever to NEUTRAL.
* Record on Data Sheet
Provide a speed signal of 3 kph from the DID
32. While the rear brake accumulator bleed valve is panel on the rear wall of the operator cab.
still open, allow low accumulator pressure "LAP1"
37. While observing the pressure gauges, make
to continue to drop. Front brake pressures "BF"
repeated, slow brake applications until fault code
and "BR" will begin to rise when the auto apply
A261 appears. Fault code A261 must not occur
sequence valve is activated within 690 kPa (100
before the sixth pedal application. Auto apply
psi) of the observed pressure in step 27.
must not occur until after fault code A261 occurs.
Front brake pressures "BF" and "BR" should be * Record on Data Sheet
at 0 kPa (0 psi) when the auto apply sequence
valve is activated. Fault code A260 should also 38. Remove the speed signal from the DID panel. Set
occur. the speed signal to 0 kph.
* Record on Data Sheet
33. Observe the final pressures at "LAP1", "BF" and
"BR" while auto apply is active.
• "LAP1" should be 11 375 ± 517 kPa (1,650 ±
75 psi).
• "BF" should be 16 545 ± 517 kPa (2,400 ± 75
psi).
• "BR" should be 9 825 kPa (1,425 psi) or
higher.
* Record on Data Sheet
34. Close the rear brake accumulator bleed valve.
Provide a speed signal of 0 kph from the DID
panel on the rear wall of the operator cab. Fault
code A260 will be cleared.
10
30 Testing and adjusting CEN30072-04
Parking brake control logic checkout b. Start the engine. Ensure that low brake
accumulator pressure "LAP1" is 21 718 kPa
39. Do not activate the brake lock switch. Keep the
(3,100 psi) or higher, then move the directional
speed signal from the DID panel at 0 kph. If any
control lever to NEUTRAL.
of the following steps are not successfully
completed, find and correct the problem.
Pull up on the engine shutdown switch on the
NOTE: The parking brake will not apply if the truck center console to shut off the engine. Do not
speed is above 0.8 kph (0.5 mph). If the parking brake turn the key switch OFF. The accumulators
is selected and the truck speed is less than 0.8 kph must not be allowed to bleed down. Verify
(0.5 mph), the following sequence will occur: proper operation of the parking brake and
• From 0 - 1 second, brake lock is applied, parking status light. No faults should be generated.
brake is released. Record the highest pressure observed at ports
"PK3", "PP3", "BF" and "BR" during the 1.5
• From 1 - 1.5 seconds, brake lock is applied, seconds of the parking brake application
parking brake is applied. sequence.
• After 1.5 seconds, brake lock is released, parking
• The pressure at test port "PK3" should be
brake is applied.
22 753 ± 1 378 kPa (3,300 ± 200 psi), then
This sequence uses the service brakes to completely fall to 0 kPa (0 psi).
stop the truck before allowing the parking brake to • The pressure at test port "PP3" should rise
apply. from 0 kph (0 psi) to 13 790 ± 690 kPa
a. Start the engine. Ensure that the low brake (2,000 ± 100 psi), then fall to 0 kPa (0 psi).
accumulator pressure "LAP1" is 21 718 kPa • Front brake pressure "BF" should remain at 0
(3,100 psi) or higher, then move the directional kPa (0 psi).
control lever to NEUTRAL.
• Rear brake pressure "BR" should rise from 0
kph (0 psi) to 13 790 ± 690 kPa (2,000 ± 100
Move the directional control lever to PARK and psi), then fall to 0 kPa (0 psi).
verify proper operation of the parking brake
* Record on Data Sheet
and status light. No faults should be
generated. Record the highest pressure c. Start the engine. Ensure that low brake
observed at ports "PK3", "PP3", "BF" and "BR" accumulator pressure "LAP1" is 21 718 kPa
during the 1.5 seconds of the parking brake (3,100 psi) or higher and the directional control
application sequence. lever is in PARK., then turn the key switch to
OFF. Verify that the parking brake remains
• The pressure at test port "PK3" should be
applied. Record the highest pressure
22 753 ± 1 378 kPa (3,300 ± 200 psi), then
fall to 0 kPa (0 psi). observed at ports "PK3", "PP3", "BF" and "BR"
when the key switch is turned to OFF. All of
• The pressure at test port "PP3" should rise the pressure readings should be 0 kPa (0 psi).
from 0 kph (0 psi) to 13 790 ± 690 kPa
(2,000 ± 100 psi), then fall to 0 kPa (0 psi). * Record on Data Sheet
• Front brake pressure "BF" should remain at 0
kPa (0 psi).
• Rear brake pressure "BR" should rise from 0
kph (0 psi) to 13 790 ± 690 kPa (2,000 ± 100
psi), then fall to 0 kPa (0 psi).
* Record on Data Sheet
11
CEN30072-04 30 Testing and adjusting
d. Start the engine. Ensure that low brake Brake lock control logic checkout
accumulator pressure (LAP1) is 21 718 kPa
40. Remove the speed signal from the DID panel.
(3,100 psi) or higher, then move the directional
Keep the speed signal at 0 kph. If any of the
control lever to NEUTRAL and turn the key
following steps are not successfully completed,
switch to OFF. Verify that the parking brake
find and correct the problem.
applies. Record the highest pressure
observed at ports "PK3", "PP3", "BF" and "BR" a. With the engine running, low brake
during the 1.5 seconds of the parking brake accumulator pressure "LAP1" at 21 718 kPa
application sequence. (3,100 psi) or higher, and the directional
control lever to NEUTRAL, turn the brake lock
• The pressure at test port "PK3" should be switch ON and OFF. Verify proper operation of
22 753 ± 1 378 kPa (3,300 ± 200 psi), then
the brake lock and status light. No faults
fall to 0 kPa (0 psi).
should be generated. Record the highest
• The pressures at pressure test ports "PP3", pressure observed at ports "PK3", "PP3", "BF"
"BF" and "BR" should read 0 kPa (0 psi). and "BR" when the brake lock is ON.
* Record on Data Sheet
• The pressure at test port "PK3" should be 22
NOTE: With the key switch OFF, brake lock 753 ± 1 378 kPa (3,300 ± 200 psi).
sequencing with the parking brake will not occur. • The pressure at test port "PP3" should rise to
e. Start the engine. Ensure that low brake 13 790 ± 690 kPa (2,000 ± 100 psi), then fall
accumulator pressure (LAP1) is 21 718 kPa to 0 kPa (0 psi).
(3,100 psi) or higher, then move the directional • Front brake pressure "BF" should be 0 kPa
control lever to NEUTRAL. (0 psi).
• Rear brake pressure "BR" should rise to
Place a jumper wire between circuit 36 and 13 790 ± 690 kPa (2,000 ± 100 psi), then fall
ground. Pull up on the engine shutdown switch to 0 kPa (0 psi).
on the center console to shut off the engine.
* Record on Data Sheet
Do not turn the key switch OFF.
b. With the engine running, low brake
Provide a speed signal of 1 kph from the DID accumulator pressure "LAP1" at 21 718 kPa
panel on the rear wall of the operator cab. (3,100 psi) or higher, and the directional
Attempt to move the directional control lever to control lever to PARK, attempt to turn the
PARK. Verify that the parking brake does not brake lock switch ON. Verify that the brake
apply and fault code A230 is activated. Record lock does not apply, the status light does not
the highest pressure observed at ports "PK3", illuminate, and fault codes A272 and A274 are
"PP3", "BF" and "BR". not activated. Record the highest pressure
observed at ports "PK3", "PP3", "BF" and
• The pressure at test port "PK3" should be
"BR". All of the pressures should be 0 kPa (0
22 753 ± 1 378 kPa (3,300 ± 200 psi), then
fall to 0 kPa (0 psi). psi).
* Record on Data Sheet
• The pressures at pressure test ports "PP3",
"BF" and "BR" should read 0 kPa (0 psi).
* Record on Data Sheet
12
30 Testing and adjusting CEN30072-04
c. With the engine running, low brake e. With the engine running, low brake
accumulator pressure "LAP1" at 21 718 kPa accumulator pressure "LAP1" at 21 718 kPa
(3,100 psi) or higher, directional control lever (3,100 psi) or higher, directional control lever
to NEUTRAL, and brake lock switch ON, in PARK, and brake lock switch OFF, turn the
move the directional control lever to PARK. key switch OFF and attempt to turn on the
Verify that the parking brake applies, the brake brake lock switch during the timed engine
lock releases and the status lights operate shutdown sequence. Verify that the brake lock
properly. Record the highest pressure does not apply and the status light does not
observed at ports "PK3", "PP3", "BF" and illuminate. Record the highest pressure
"BR". observed at ports "PK3", "PP3", "BF" and
"BR". All of the pressures should be 0 kPa (0
• The pressure at test port "PK3" should be 22
psi).
753 ± 1 378 kPa (3,300 ± 200 psi), then fall
to 0 kPa (0 psi). * Record on Data Sheet
• The pressure at test port "PP3" should rise to NOTE: The brake lock will remain applied if the brake
13 790 ± 690 kPa (2,000 ± 100 psi), then fall lock switch is turned ON when a truck speed above 0.8
to 0 kPa (0 psi). kph (0.5 mph) is detected. The switch must be turned
• Front brake pressure "BF" should be 0 kPa OFF to release the brake lock.
(0 psi). f. With the engine running and low brake
• Rear brake pressure "BR" should rise to accumulator pressure "LAP1" at 21 718 kPa
13 790 ± 690 kPa (2,000 ± 100 psi), then fall (3,100 psi) or higher, move the directional
to 0 kPa (0 psi). control lever to NEUTRAL.
* Record on Data Sheet
In the wPTU software, set the "FWD True"
d. With the engine running, low brake
output to ON. Pull up on the engine shutdown
accumulator pressure "LAP1" at 21 718 kPa
switch on the center console to shut off the
(3,100 psi) or higher, directional control lever
engine. Do not turn the key switch OFF.
to NEUTRAL, and brake lock switch ON, pull
up on the engine shutdown switch on the
Provide a speed signal of 1 kph from the DID
center console to shut off the engine. Do not
panel on the rear wall of the operator cab.
turn the key switch OFF.
Place a jumper wire between circuit 36 and
ground. Turn the brake lock switch ON. Verify
Verify that the parking brake applies, the brake
proper operation of the brake lock and status
lock releases and the status lights operate
light. No faults should be generated. Record
properly. Record the highest pressure
the highest pressure observed at ports "PK3",
observed at ports "PK3", "PP3", "BF" and
"PP3", "BF" and "BR".
"BR".
• The pressure at test port "PK3" should be 22
• The pressure at test port "PK3" should be 22 753 ± 1 378 kPa (3,300 ± 200 psi).
753 ± 1 378 kPa (3,300 ± 200 psi), then fall
to 0 kPa (0 psi). • The pressure at test port "PP3" should be
13 790 ± 690 kPa (2,000 ± 100 psi).
• The pressure at test port "PP3" should rise to
13 790 ± 690 kPa (2,000 ± 100 psi), then fall • Front brake pressure "BF" should be 0 kPa
to 0 kPa (0 psi). (0 psi).
• Front brake pressure "BF" should be 0 kPa • Rear brake pressure "BR" should be 13 790
(0 psi). ± 690 kPa (2,000 ± 100 psi).
• Rear brake pressure "BR" should rise to * Record on Data Sheet
13 790 ± 690 kPa (2,000 ± 100 psi), then fall Remove the jumper wire between circuit 36
to 0 kPa (0 psi).
and ground. Reset the speed signal to 0 kph
* Record on Data Sheet from the DID panel on the rear wall of the
operator cab. In the wPTU software, set the
"FWD True" output to OFF.
13
CEN30072-04 30 Testing and adjusting
g. Verify that the brake lock remains applied Move the directional control lever to PARK.
while the truck is moving. With the engine Reset the speed signal to 0 kph. Fault codes
running and low brake accumulator pressure A272 and A274 should be activated when the
"LAP1" at 21 718 kPa (3,100 psi) or higher, speed signal is at 0 kph. Confirm that brake
move the directional control lever to lock is still activated. Record the highest
NEUTRAL. pressure observed at ports "PK3", "PP3", "BF"
and "BR"
In the wPTU software, set the "FWD True"
• The pressure at test port "PK3" should be 0
output to ON. Pull up on the engine shutdown
kPa (0 psi).
switch on the center console to shut off the
engine. Do not turn the key switch OFF. • The pressure at test port "PP3" should be
13 790 ± 690 kPa (2,000 ± 100 psi).
Provide a speed signal of 1 kph from the DID • Front brake pressure "BF" should be 0 kPa
panel on the rear wall of the operator cab. (0 psi).
Place a jumper wire between circuit 36 and
• Rear brake pressure "BR" should be 13 790
ground. Turn the brake lock switch ON. ± 690 kPa (2,000 ± 100 psi).
Confirm that brake lock is activated. Record
the highest pressure observed at ports "PK3", * Record on Data Sheet
"PP3", "BF" and "BR". In the wPTU software, set the "FWD True"
• The pressure at test port "PK3" should be 22 output to OFF. Turn the brake lock switch OFF.
753 ± 1 378 kPa (3,300 ± 200 psi). Confirm that brake lock is deactivated. Record
the highest pressure observed at ports "PK3",
• The pressure at test port "PP3" should be "PP3", "BF" and "BR". All of the pressures
13 790 ± 690 kPa (2,000 ± 100 psi). should be 0 kPa (0 psi).
• Front brake pressure "BF" should be 0 kPa * Record on Data Sheet
(0 psi).
41. Remove the jumper wire between circuit 36 and
• Rear brake pressure "BR" should be 13 790 ground. Remove the pressure gauges.
± 690 kPa (2,000 ± 100 psi).
* Record on Data Sheet
14
30 Testing and adjusting CEN30072-04
Brake system checkout data sheet
** Acceptable values of each measurement are shown in (parenthesis).
Machine Model___________ Unit Number ___________ Serial Number_____________
ACCUMULATOR PRECHARGE
Step 2b ____________ (1,400 psi) Front brake accumulator precharge pressure
____________ (1,400 psi) Rear brake accumulator precharge pressure
INITIAL SYSTEM SETUP
Step 4 ____________ (1,650 -75/+375 psi) Brake accumulator pressure "LAP1" when
auto apply releases
Step 6 ____________ (1,650 -75/+375 psi) Rear brake pressure "BR" when front brake
pressure "BF" begins to rise
____________ (0-5 psi) Front brake pressure "BF" when front brake pressure "BR"
begins to rise
Step 7 _____________ (75 ± 5 psi) Rear brake pressure "BR" when brake lights activate
Step 8 _____________ (2500 ± 75 psi) Front brake pressure "BF" 1 second after pedal applied
_____________ (2500 ± 75 psi) Rear brake pressure "BR" 1 second after pedal applied
_____________ (2500 ± 75 psi) Front brake pressure "BF" 20 seconds after pedal applied
_____________ (2500 ± 75 psi) Rear brake pressure "BR" 20 seconds after pedal applied
BRAKE LOCK / SECONDARY BRAKE CHECKOUT
Step 11 ____________ (1,000 ± 25 psi) Rear brake pressure "BR" when brake degradation
fault A118 occurs
Step 13 ____________ (2,000 ± 100 psi) Rear brake pressure "BR" when brake lock is applied
____________ (2,000 ± 100 psi) Brake lock pressure "PP3" when brake lock is applied
15
CEN30072-04 30 Testing and adjusting
PARKING BRAKE CHECKOUT
Step 14a ___________ (3,300 ± 200 psi) Parking brake release pressure "PK3"
Step 14b ___________ (0 psi) Parking brake apply pressure "PK3"
SERVICE BRAKE CHECKOUT
Step 17 ____________ (2400 ± 75 psi) Left rear brake pressure "LBP" 1 second after
pedal applied
____________ (2400 ± 75 psi) Right rear brake pressure "RBP" 1 second after
pedal applied
____________ (2400 ± 75 psi) Left rear brake pressure "LBP" 20 seconds after
pedal applied
____________ (2400 ± 75 psi) Right rear brake pressure "RBP" 20 seconds after
pedal applied
Step 18 ____________ (0 psi) Left rear brake pressure "LBP" when pedal is released
____________ (0 psi) Right rear brake pressure "RBP" when pedal is released
Step 19 ____________ (2400 ± 75 psi) Left front brake pressure "LFBP" 1 second after
pedal applied
____________ (2400 ± 75 psi) Right front brake pressure "RFBP" 1 second after
pedal applied
____________ (2400 ± 75 psi) Left front brake pressure "LFBP" 20 seconds after
pedal applied
____________ (2400 ± 75 psi) Right front brake pressure "RFBP" 20 seconds after
pedal applied
Step 20 ____________ (0 psi) Left front brake pressure "LFBP" when pedal is released
____________ (0 psi) Right front brake pressure "RFBP" when pedal is released
16
30 Testing and adjusting CEN30072-04
LOW BRAKE ACCUMULATOR PRESSURE AND AUTO APPLY CHECKOUT
Step 23 ____________ (above 2100 psi) Low brake accumulator pressure "LAP1" after 2 minutes
Step 26 ____________ (1,850 ± 52 psi) Low brake accumulator pressure "LAP1" when
low brake pressure fault A261 occurs
____________ (0 psi) Front brake pressure "BF" when low brake pressure
fault A261 occurs
____________ (0 psi) Rear brake pressure "BR" when low brake pressure
fault A261 occurs
____________ (yes) Is fault A260 displayed?
Step 27 ____________ (1,650 ± 75 psi) Low brake accumulator pressure "LAP1" when front brake
pressure "BF" begins to rise
____________ (0 psi) Front brake pressure "BF" when front brake pressure "BF"
begins to rise
____________ (0 psi) Rear brake pressure "BR" when front brake pressure "BF"
begins to rise
Step 28 ____________ (1,650 ± 75 psi) Low brake accumulator pressure "LAP1" when
auto brake apply completes
____________ (1425 psi or above) Front brake pressure "BF" when auto brake apply
completes
____________ (2,400 ± 75 psi) Rear brake pressure "BR" when auto brake apply
completes
Step 31 ____________ (1,850 ± 52 psi) Low brake accumulator pressure "LAP1" when
low brake pressure fault A261 occurs
____________ (0 psi) Front brake pressure "BF" when low brake pressure
fault A261 occurs
____________ (0 psi) Rear brake pressure "BR" when low brake pressure
fault A261 occurs
17
CEN30072-04 30 Testing and adjusting
Step 32 ____________ (1,650 ± 75 psi) Low brake accumulator pressure "LAP1" when
rear brake pressure "BR" begins to rise
____________ (0 psi) Front brake pressure "BF" when rear brake pressure "BR"
begins to rise
____________ (0 psi) Rear brake pressure "BR" when rear brake pressure "BR"
begins to rise
____________ (yes) Is fault A260 displayed?
Step 33 ____________ (1,650 ± 75 psi) Low brake accumulator pressure "LAP1" when
auto brake apply completes
____________ (2,400 ± 75 psi) Front brake pressure "BF" when auto brake apply
completes
____________ (1425 psi or above) Rear brake pressure "BR" when auto brake apply
completes
BRAKE REAPPLICATIONS
Step 37 ____________ (6 or more) Number of brake applications before fault A261 occurs
PARKING BRAKE CONTROL LOGIC CHECKOUT
Step 39a - Maximum pressures during 1.5 second parking brake application sequence
__________ (3,300 ± 200 psi) Parking brake pressure "PK3"
__________ (2,000 ± 100 psi) Brake lock pressure "PP3"
__________ (0 psi) Front brake pressure "BF"
__________ (2,000 ± 100 psi) Rear brake pressure "BR"
Step 39a - Pressures at completion of parking brake application sequence
__________ (0 psi) Parking brake pressure "PK3"
__________ (0 psi) Brake lock pressure "PP3"
__________ (0 psi) Front brake pressure "BF"
__________ (0 psi) Rear brake pressure "BR"
18
30 Testing and adjusting CEN30072-04
Step 39b - Maximum pressures during 1.5 second parking brake application sequence
__________ (3,300 ± 200 psi) Parking brake pressure "PK3"
__________ (2,000 ± 100 psi) Brake lock pressure "PP3"
__________ (0 psi) Front brake pressure "BF"
__________ (2,000 ± 100 psi) Rear brake pressure "BR"
Step 39b - Pressures at completion of parking brake application sequence
__________ (0 psi) Parking brake pressure "PK3"
__________ (0 psi) Brake lock pressure "PP3"
__________ (0 psi) Front brake pressure "BF"
__________ (0 psi) Rear brake pressure "BR"
Step 39c - Maximum pressures
__________ (0 psi) Parking brake pressure "PK3"
__________ (0 psi) Brake lock pressure "PP3"
__________ (0 psi) Front brake pressure "BF"
__________ (0 psi) Rear brake pressure "BR"
Step 39d - Maximum pressures during 1.5 second parking brake application sequence
__________ (3,300 ± 200 psi) Parking brake pressure "PK3"
__________ (0 psi) Brake lock pressure "PP3"
__________ (0 psi) Front brake pressure "BF"
__________ (0 psi) Rear brake pressure "BR"
Step 39d - Pressures at completion of parking brake application sequence
__________ (0 psi) Parking brake pressure "PK3"
__________ (0 psi) Brake lock pressure "PP3"
__________ (0 psi) Front brake pressure "BF"
__________ (0 psi) Rear brake pressure "BR"
19
CEN30072-04 30 Testing and adjusting
Step 39e - Pressures at completion of parking brake application sequence
__________ (3,300 ± 200 psi) Parking brake pressure "PK3"
__________ (0 psi) Brake lock pressure "PP3"
__________ (0 psi) Front brake pressure "BF"
__________ (0 psi) Rear brake pressure "BR"
__________ (yes) Is fault A230 displayed?
BRAKE LOCK CONTROL LOGIC CHECKOUT
Step 40a - Maximum pressures with brake lock ON
__________ (3,300 ± 200 psi) Parking brake pressure "PK3"
__________ (2,000 ± 100 psi) Brake lock pressure "PP3"
__________ (0 psi) Front brake pressure "BF"
__________ (2,000 ± 100 psi) Rear brake pressure "BR"
Step 40a - Pressures at completion with brake lock OFF
__________ (3,300 ± 200 psi) Parking brake pressure "PK3"
__________ (0 psi) Brake lock pressure "PP3"
__________ (0 psi) Front brake pressure "BF"
__________ (0 psi) Rear brake pressure "BR"
Step 40b - Maximum pressures
__________ (0 psi) Parking brake pressure "PK3"
__________ (0 psi) Brake lock pressure "PP3"
__________ (0 psi) Front brake pressure "BF"
__________ (0 psi) Rear brake pressure "BR"
__________ (no) Is fault A272 displayed?
__________ (no) Is fault A274 displayed?
20
30 Testing and adjusting CEN30072-04
Step 40c - Maximum pressures with parking brake applied / brake lock released
__________ (3,300 ± 200 psi) Parking brake pressure "PK3"
__________ (2,000 ± 100 psi) Brake lock pressure "PP3"
__________ (0 psi) Front brake pressure "BF"
__________ (2,000 ± 100 psi) Rear brake pressure "BR"
Step 40c - Pressures at completion with parking brake applied / brake lock released
__________ (3,300 ± 200 psi) Parking brake pressure "PK3"
__________ (0 psi) Brake lock pressure "PP3"
__________ (0 psi) Front brake pressure "BF"
__________ (0 psi) Rear brake pressure "BR"
Step 40d - Maximum pressures with engine shutdown switch engaged
__________ (3,300 ± 200 psi) Parking brake pressure "PK3"
__________ (2,000 ± 100 psi) Brake lock pressure "PP3"
__________ (0 psi) Front brake pressure "BF"
__________ (2,000 ± 100 psi) Rear brake pressure "BR"
Step 40d - Pressures at completion with engine shutdown switch engaged
__________ (0 psi) Parking brake pressure "PK3"
__________ (0 psi) Brake lock pressure "PP3"
__________ (0 psi) Front brake pressure "BF"
__________ (0 psi) Rear brake pressure "BR"
Step 40e - Maximum pressures during timed engine shutdown sequence
__________ (0 psi) Parking brake pressure "PK3"
__________ (0 psi) Brake lock pressure "PP3"
__________ (0 psi) Front brake pressure "BF"
__________ (0 psi) Rear brake pressure "BR"
21
CEN30072-04 30 Testing and adjusting
Step 40f - Pressures at completion with 1 kph speed signal
__________ (3,300 ± 200 psi) Parking brake pressure "PK3"
__________ (2,000 ± 100 psi) Brake lock pressure "PP3"
__________ (0 psi) Front brake pressure "BF"
__________ (2,000 ± 100 psi) Rear brake pressure "BR"
Step 40g - Pressures at completion with 1 kph speed signal
__________ (3,300 ± 200 psi) Parking brake pressure "PK3"
__________ (2,000 ± 100 psi) Brake lock pressure "PP3"
__________ (0 psi) Front brake pressure "BF"
__________ (2,000 ± 100 psi) Rear brake pressure "BR"
Step 40g - Pressures at completion with 0 kph speed signal
__________ (0 psi) Parking brake pressure "PK3"
__________ (2,000 ± 100 psi) Brake lock pressure "PP3"
__________ (0 psi) Front brake pressure "BF"
__________ (2,000 ± 100 psi) Rear brake pressure "BR"
__________ (yes) Is fault A272 displayed?
__________ (yes) Is fault A274 displayed?
Step 40g - Pressures at completion with brake lock OFF
__________ (0 psi) Parking brake pressure "PK3"
__________ (0 psi) Brake lock pressure "PP3"
__________ (0 psi) Front brake pressure "BF"
__________ (0 psi) Rear brake pressure "BR"
Name of Technician or Inspector Performing Checkout ________________________________
DATE ____________________________
22
30 Testing and adjusting CEN30072-04
Brake piston leakage test Oil separator seal pressure test
1. Remove the dust cap on test port (1, Figure 30-5) Check the integrity of the floating seal after installing
on the brake backplate. the wheel hub/brake assembly on the spindle. The
2. Remove the capnut on bleed port (2). Attach a wheel hub must be facing upward.
hydraulic pressure test device to the fitting. 1. Remove fill plug (1, Figure 30-6). Fill the wheel
3. Slowly apply pressure to bleed air from the piston hub cavity with approximately 11.5 L (3 gal) of
cavity. TO-50 oil.
4. Cycle the piston to full stroke ten times by
applying 2 070 kPa (300 psi) of hydraulic
pressure at bleed port (2). Observe the piston for
leakage. 1
5. Minor oil seepage (non-measurable) is
permissible. If the leakage is greater,
disassemble the piston assembly and determine
the cause.
86564
FIGURE 30-5. FRONT BRAKES FIGURE 30-6. WHEEL HUB
1. Test Port - "LFBP" and "RFBP" 1. Fill Plug
2. Bleed Port
2. Connect a hose to the fill port in the hub cover
plate. Ensure that all other ports are plugged.
3. Pressurize the hub cavity to a maximum of 103
kPa (15 psi).
Brake seal pressure test
Check the integrity of the floating seal before installing
the brakes on the truck.
1. Cap the cooling oil ports and pressurize the
brake to a maximum of 103 kPa (15 psi). Do not overpressurize the cavity. Excessive
2. Close off the air supply and monitor the interior pressure may cause damage to the seals.
brake pressure for 15 minutes. 4. Close off the air supply and monitor the hub
3. If the air pressure decreases rapidly, a displaced cavity pressure for 15 minutes.
or damaged brake seal is indicated. Disassemble a. If there is no pressure drop, the integrity of the
the brake and reinstall or replace the floating seals is verified.
seal.
b. If the pressure drops at all, a displaced or
damaged seal is indicated. Disassemble the
hub and reinstall or replace the floating seal.
23
CEN30072-04 30 Testing and adjusting
Wet disc brake bleeding procedure Front wheel brakes:
NOTE: Rear wheel brakes must be bled before rear NOTE: The front wheel brakes are equipped with a
tire installation. diagnostic coupler on the brake backplate. A hose with
1. Make sure that the hydraulic brake supply a mating fitting can be attached to direct the oil into a
(steering circuit) is operating properly. container during the bleeding process.
2. If necessary, charge the brake accumulators. 8. Attach a hose to the diagnostic coupler at test
Refer to Refer to Testing and adjusting section port (1, Figure 30-7) on the brake backplate
Accumulators and suspensions for the (brake apply pressure circuit).
accumulator charging procedure. 9. Slowly depress the brake pedal until the service
3. Make sure that the bleed down valves on the brake is partially applied.
brake manifold are closed. 10. After the oil stream is clear of air, remove the
4. Check the hydraulic tank oil level and fill if hose from the coupler. Release the brake pedal.
necessary. 11. Repeat Steps 8 - 10 for the other front wheel
5. With the wheels securely blocked, start the brake.
engine and allow the accumulators to fill. 12. Shut off the engine and allow 90 seconds for the
6. Slowly depress the brake pedal until the service steering accumulators to depressurize
brake is partially applied. completely. Check the hydraulic tank oil level.
Rear wheel brakes:
7. Slowly open the O-ring plug located next to the
cooling oil port and brake apply port on the brake
backplate. Close the plug after the oil runs clear
and free of bubbles. Repeat for the other rear
wheel brake.
NOTE: The other cooling line has a single hex plug
located adjacent. DO NOT use this plug for bleeding
brake.
FIGURE 30-7. FRONT BRAKES
1. Test Port
2. Bleed Port
24
30 Testing and adjusting CEN30072-04
Parking brake bleeding procedure 5. Open the rear axle housing hatch.
1. Securely block the wheels to prevent the truck 6. Start the engine and allow the steering system to
from rolling away. fully charge (pump unloads). Then move the
2. Open bleed down valves (1, Figure 30-8) on directional control lever to NEUTRAL to
brake manifold (2) to depressurize the brake disengage the parking brake.
accumulators. 7. Connect a clear plastic hose to the bleeder valve
3. To verify that the brake accumulators are at the top of the parking brake. Place the other
depressurized, turn the key switch ON, but do not end of hose into a container.
start the engine. Press the brake lock switch and 8. Slowly open the bleeder valve and allow
apply the service brake pedal. The service brake hydraulic oil to run until it is clear and free of
light should not come on. bubbles. Close the bleeder valve securely.
4. Close bleed down valves (1). 9. Repeat Steps 7 and 8 for the other parking brake.
10. Shut off the engine. Remove the bleed equipment
and close the rear axle housing hatch.
FIGURE 30-8. BRAKE MANIFOLD
1. Brake Accumulator Bleed Down Valves
2. Brake Manifold
84513
FIGURE 30-9. PARKING BRAKE
BLEEDING/FLUSHING PROCEDURE
1. Bleeder Valve
25
CEN30072-04 30 Testing and adjusting
Service brake disc wear inspection NOTE: The front brake assemblies have diagnostic
coupler (2) installed for measuring brake apply
Check brake disc wear by using two front brake wear
pressure. The rear brake assemblies do not have a
indicators (EM1275) and two rear brake wear
diagnostic coupler installed on the brake backplate,
indicators (EM3708) that are included in the tool group
but instead have a plug installed. Do not attempt to
that is shipped with the truck. Refer to Figure 30-11.
install the brake wear indicator in these ports.
NOTE: The brake wear indicator is inserted in a port
5. Start the engine. Allow the steering system
which is open to cooling oil. Removal of the inspection
pressure to stabilize and the brake accumulators
port plug to insert the brake wear indicator will cause
to fill.
the loss of some of this oil. Advance planning will help
to minimize oil loss. 6. While fully applying the service brake pedal,
check the wear on each brake disc as follows:
The brake wear indicators may be permanently
installed in the brake ports if desired. If all of the brake a. Remove cover (1, Figure 30-11) from the
assemblies are equipped with brake wear indicators, brake wear indicator.
future checks will not require installation and removal. b. Push pin (8) inward until it stops against the
1. Place the directional control lever in PARK and brake piston.
turn the rest switch ON. Turn the key switch OFF c. Measure the distance from indicator pin end
to turn off the engine and wait 90 seconds to face (2) to housing face (3).
allow the steering accumulators to depressurize
completely. Block the truck wheels. If indicator pin end face (2) is even with
housing face (3) or below, disc pack is worn to
2. Open bleed down valves (1, Figure 30-8) to the maximum safe wear limits. The brakes
depressurize the brake accumulators. Close the should be scheduled for rebuild.
bleed down valves after the pressure is
If indicator pin end face (2) extends beyond
completely released. housing face (3), brake disc wear is still within
3. Thoroughly clean the brake assemblies, allowable limits.
especially the area surrounding cooling oil lines. d. Pull pin (8) outward until it stops against tool
4. Remove the plug from port (1, Figure 30-10). housing (6). Install cover (1).
Quickly insert the brake wear indicator and
tighten it securely. Repeat this step for each
brake assembly.
2 1
FIGURE 30-11. BRAKE WEAR INDICATOR
86565
1. Cover 5. O-Ring
FIGURE 30-10. BRAKE WEAR INDICATOR 2. Indicator Pin End Face 6. Housing
INSTALLATION 3. Housing Face 7. O-Ring
4. O-Ring 8. Indicator Pin
1. Brake Wear Indicator Installation Port
2. Diagnostic Coupler
26
30 Testing and adjusting CEN30072-04
7. Release the brakes. Turn off the engine and wait Parking brake disc wear inspection
90 seconds to allow the steering accumulators to
Measure the amount of disc wear on both parking
depressurize completely.
brake assemblies as follows:
8. Open bleed down valves (1, Figure 30-8) to
1. Insert a depth micrometer through each piston
depressurize the brake accumulators. Close the
position hole (1, Figure 30-12) and record the
bleed down valves after the pressure is
dimensions.
completely released.
2. Add the three measurements and divide the total
9. If not permanently installing the brake wear
by 3 to determine the average.
indicators, remove the brake wear indicators and
reinstall the plug in each port. If the resulting average of the three
measurements is greater than 24 mm (0.969 in.),
NOTE: Checking the brake disc wear in all the brake
the parking brake assembly must be removed
assemblies is recommended. Disc wear in one brake
and rebuilt.
assembly may be different from another due to
dissimilar operation of parts and/or haul profiles which
require repeated braking while steering in one
direction only. 1
10. Service the hydraulic tank as required.
11. If brake repairs are necessary, refer to
Disassembly and assembly section Brake
system.
NOTE: If any leakage is observed around the brake
wear indicator, replace O-rings (4, 5, and 7).
86381
FIGURE 30-12. PARKING BRAKE
1. Piston Position Holes
27
CEN30072-04 30 Testing and adjusting
Brake valve bench test and adjustment
The following parts and test equipment will be required • Hose fittings for valve ports:
to completely bench test and adjust the brake valve. Port PX . . . . . . . . . . . . . . . . . 7/16 in., # 4 SAE
Ports P1, P2, B1 and B2 . . . . . . 3/4 in., #8 SAE
• Three 20 680 kPa (3,000 psi) pressure gauges Port T. . . . . . . . . . . . . . . . . 1 1/16 in., #12 SAE
• Hydraulic pressure supply, regulated to 18 960 kPa • Ohmmeter or continuity tester
(2,750 psi)
• Hydraulic test stand NOTE: It is possible to check the pressures with the
brake valve installed and connected to the vehicle.
Remove the brake pedal assembly and actuator cap
and boot assembly to adjust individual brake circuit
pressures.
FIGURE 30-13. TEST BENCH SETUP
1. Motor 5. Needle Valve 9. Simulated Brake Volume
2. Pump 6. Brake Valve 10. Rear Brake Pressure Gauge
3. System Pressure Gauge 7. Front Brake Pressure Gauge 11. Relief Valve
4. Needle Valve 8. Shutoff Valves
28
30 Testing and adjusting CEN30072-04
Test setup procedure Brake valve output pressure adjustment
1. Position the valve in the fixture to allow plungers 1. Install the pedal pivot shaft in the actuator base
to be activated by hand using a lever. Refer to by itself without installing the pedal assembly.
Figure 30-13. 2. By placing a screwdriver or pry bar under the
2. Attach the pilot input supply pressure to the pilot pivot pin and on top of the threaded plunger
port labeled “PX” on the rear of the valve. assembly, each circuit can be actuated
3. Attach the main supply input pressure to the O- individually. Refer to Figure 30-13.
ring ports on the rear of the valve labeled “P1” 3. Gradually apply pressure on each circuit one at a
and “P2”. time to check for leaks around the plunger. Make
4. Attach the tank return line to the O-ring port sure that the adjustment collar is screwed all the
labeled “T” on the rear of the valve. way down on the threads.
5. Attach the regulated output ports “B1” and “B2” to 4. “B1” Adjustment: Adjust the adjustment collar
the test lines. Pressure monitoring devices in up (counterclockwise), starting with one-turn
these two lines must be capable of 20 680 kPa increments until the output pressure at port “B1”
(3,000 psi). Connect all ports according to the is 17 235 ± 517 kPa (2,500 ± 75 psi) with the
diagram shown in Figure 30-13. All ports must be adjustment collar contacting the actuator base
used and connected. (fully actuated). Fine adjustment will require
turning the collar only in 1/8 turn increments.
5. “B2” Adjustment: Adjust the adjustment collar
up (counterclockwise), starting with one-turn
increments until the output pressure at port “B2”
is 17 235 ± 517 kPa (2,500 ± 75 psi) with the
All ports must be used. Relieve pressure before adjustment collar contacting the actuator base
disconnecting hydraulic and other lines. Tighten (fully actuated). Fine adjustment will require
all connections before applying pressure. turning the collar only in 1/8 turn increments.
Avoid spillage and contamination! Avoid contact 6. Tighten the set screws in the adjustment collars
with hot oil if the machine has been operating. The to 3 - 4 N·m (25 - 30 in lb). The entire plunger
oil will be at very high pressure. may have to be rotated to get to the set screws.
Hydraulic fluid escaping under pressure can have 7. Check the pressures again after tightening the
sufficient force to enter a person's body by set screws. If the pressures have moved out of
penetrating the skin and cause serious injury and specified range, loosen the appropriate set screw
possibly death if proper medical treatment by a and re-adjust.
physician familiar with this injury is not received 8. Cycle each circuit 50 times using pilot apply. This
immediately. is done by closing needle valve (5, Figure 30-13)
and opening needle valve (4). Read the pressure
• Start the hydraulic pump and regulate output on gauges (7) and (10). Close valve (4) and open
pressure to 18 960 kPa (2,750 psi) at pressure valve (5). The pressure gauges should read zero.
gauge (3). Pressure gauges (7) and (10) should 9. Recheck the pressures after cycling. If they have
read zero. changed, re-adjust the pressures.
• Pilot supply circuit pressure must also be 18 960
kPa (2,750 psi).
• Return line pressure during this test is not to
exceed 34 kPa (5 psi).
• Test the valve with ISO 32 grade hydraulic oil at 49
± 3 °C (120 ± 10 °F).
29
CEN30072-04 30 Testing and adjusting
Final test and adjustment 7. Adjust the set screw until it is just touching the
1. The brake pedal actuator must be installed on the cap.
brake valve body before the final test and 8. Continue turning the set screw until the pressure
adjustment. Refer to "Disassembly and assembly begins to rise on one of the brake apply pressure
of brake valve" in Disassembly and assembly gauges.
section Brake system. 9. Back off the set screw by 1/8 turn.
NOTE: The final test and adjustment procedure can 10. Tighten the jam nut and remove the shim that
also be performed with the brake valve installed in the was inserted previously.
truck. Install the gauges at the “B1” and “B2”
11. Fully stroke the brake pedal actuator to verify that
diagnostic test connectors in the brake cabinet.
the output pressures at port “B1” and “B2” are
2. Reinstall the brake valve with the actuator pedal within specifications.
attached on the test stand.
NOTE: If the pedal is adjusted properly, the spring and
3. With the test stand pump adjusted for 18 960 kPa spring pivots will not interfere with pedal travel.
(2,750 psi) or with the engine running and the
brake system supply pressure at or above 18 960 12. If the pressures are not within specifications, re-
kPa (2,750 psi), depress the pedal as quickly as adjust the set screw. If the pressure is within
possible. The pressure on the output circuits specifications, apply a few drops of Loctite to the
must reach at least 17 235 ± 517 kPa (2,500 ± 75 jam nut.
psi) at port “B1” and port “B2” within one second. 13. Check for internal leakage at port “T”. Leakage
Measurement of time begins the moment force is must be less than 100 cc/minute with the valve in
applied to move the pedal. the released position and system pressure
4. With “B1” and “B2” plugged into a strip chart supplied to the “P1” and “P2” inlet ports.
recorder (if available), check the modulation by 14. “T” port leakage must be less than 250 cc/minute
slowly applying pressure until the maximum with valve pilot pressure or manually applied.
pressure is reached. Make sure that the pressure
increase is smooth and no sticking of the spools
is observed. Fully depress the pedal. The
pressures must remain within specification at
“B1” and “B2” for 20 seconds.
5. Adjust the set screw until it is not touching the
actuator cap. Apply Loctite® 242 to the
adjustment screw before setting the deadband.
6. Set the deadband by placing a 0.254 mm (0.010
in.) thick shim at location (9) between the pedal
structure and the return stop boss on the pivot
structure.
30
30 Testing and adjusting CEN30072-04
Dual relay valve bench test and adjustment • Hose fittings for valve ports:
Port PX . . . . . . . . . . . . . . . . . 7/16 in., # 4 SAE
The following parts and test equipment will be required Ports B1 and B2 . . . . . . . . . . . . 3/4 in., #8 SAE
to completely bench test the dual relay valve. Port T. . . . . . . . . . . . . . . . . 1 1/16 in., #12 SAE
• Four 20 680 kPa (3,000 psi) pressure gauges • Ohmmeter or continuity tester
• Hydraulic pressure supply, regulated to 18 960 kPa NOTE: It is possible to check the pressures with the
(2,750 psi) dual relay valve installed on the truck by using the
• Hydraulic test stand brake treadle valve to modulate pilot pressure and
monitoring brake apply pressure in the appropriate
brake apply pressure lines.
FIGURE 30-14. DUAL RELAY VALVE BENCH TEST SETUP
1. Motor 6. Needle Valve 10. RH Brake Apply Pressure
2. Pump (Pressure Bleed to Tank) Gauge
3. Main Pressure Gauge 7. Pilot Pressure Gauge 11. Needle Valve
4. Pressure Regulator 8. Dual Relay Valve 12. Needle Valve
(Pilot Pressure) 9. LH Brake Apply Pressure 13. Shutoff Valves
5. Needle Valve Gauge 14. Simulated Brake Volume
(Pilot Pressure Release) 15. Relief Valve
31
CEN30072-04 30 Testing and adjusting
Test setup procedure Relay valve output pressure adjustment
1. Position the valve on the test stand as shown in 1. With the pump operating and supply pressure
Figure 30-14. and pilot pressure adjusted as described earlier
2. Attach the pilot input supply line to the port inspect the valve for leakage.
labeled “PX” on the side of the valve. 2. With 17 235 kPa (2,500 psi) of pilot pressure
3. Attach the main supply input pressure line to the applied, verify that pressure gauges (9) and (10)
port on the front of the valve labeled “P”. read 17 235 ± 517 kPa (2,500 ± 75 psi).
4. Attach the tank return line to the port labeled “T”. 3. Close pilot supply needle valve (5) and open pilot
5. Attach the regulated output ports “B1” and “B2” to pressure release needle valve (6) to bleed
the test lines. Pressure monitoring devices in pressure back to the reservoir. Pilot pressure
these two lines must be capable of 20 680 kPa gauge (7) and regulated output pressure gauges
(3,000 psi). Connect all ports according to the (9) and (10) should drop to zero.
diagram shown in Figure 30-14. All ports must be 4. Repeat Steps 2 and 3 approximately 50 times to
used and connected. cycle the valve from minimum to maximum apply
pressure.
5. Verify that the output pressure remains within
specifications. If not, the valve must be rebuilt.
6. While observing pilot pressure gauge (7) and
All ports must be used. Relieve pressure before regulated output pressure gauges (9) and (10),
disconnecting hydraulic and other lines. Tighten apply pilot pressure slowly and steadily until
all connections before applying pressure. 17 235 kPa (2,500 psi) maximum pilot pressure
Avoid spillage and contamination! Avoid contact is obtained.
with hot oil if the machine has been operating. The Pilot pressure and regulated output pressure
oil will be at very high pressure. must track within 345 kPa (50 psi) after the pilot
Hydraulic fluid escaping under pressure can have pressure reaches 690 kPa (100 psi).
sufficient force to enter a person's body by 7. Reduce pilot pressure to zero. Apply 17 235 kPa
penetrating the skin and cause serious injury and (2,500 psi) of pilot pressure as quickly as
possibly death if proper medical treatment by a possible. Regulated output pressure must
physician familiar with this injury is not received increase to 17 235 ± 517 kPa (2,500 ± 75 psi)
immediately. within one second after pressure is applied to the
pilot line.
6. Start the hydraulic pump and regulate output 8. Check for internal valve leakage from port “T”
pressure at 18 960 kPa (2,750 psi) at pressure with full supply pressure (port “P”) applied.
gauge (3). Pressure gauges (9) and (10) should
With pilot pressure released, leakage must
read zero.
not exceed 100 cc/minute.
7. Adjust pressure regulator (4) to set pilot supply
With 17 235 kPa (2,500 psi) of pilot pressure
pressure to 17 235 kPa (2,500 psi) on gauge (7).
applied, leakage must not exceed 150 cc/
8. Return line pressure during this test is not to minute.
exceed zero.
9. Test the valve with ISO 32 grade hydraulic oil at
49 ± 3 °C (120 ± 10 °F).
32
30 Testing and adjusting CEN30072-04
NOTES
33
CEN30072-04 30 Testing and adjusting
980E Dump truck
Form No. CEN30072-04
34
CEN30098-11
DUMP TRUCK
730E 930E
830E 960E
860E 980E
Machine model Serial number Machine model Serial number
730E-8 A40004 and up 960E-1 A30003 - A30026
730E-10 A50002 and up 960E-1K A50003 - A50010
830E-5 A50005 and up 960E-2 A30027 and up
830E-5AT A50005 and up 960E-2K A50011 and up
860E-1K A30031 - A30035, 960E-2KT A50028 and up
A30041, A30042, 980E-4 A40003 and up
A30044 - A30046 980E-4AT A40003 and up
860E-1KT A30004 - A30030, 980E-5 A50005 and up
A30036 - A30040, 980E-5AT A50005 and up
A30043, A30047 -
A30100
930E-5 A40004 and up
930E-5AT A40004 and up
30 Testing and adjusting
Accumulators and suspensions
Accumulator charging and storage ....................................................................................................................... 3
Bladder accumulator charging procedure ............................................................................................................. 4
Piston accumulator charging procedure ............................................................................................................... 8
Piston accumulator storage .................................................................................................................................11
Piston accumulator leak testing ...........................................................................................................................11
Checking for improper suspension charge ......................................................................................................... 12
Suspension oiling and charging procedures ....................................................................................................... 13
Suspension pressure test ................................................................................................................................... 22
1
CEN30098-11 30 Testing and adjusting
NOTES
2
30 Testing and adjusting CEN30098-11
Accumulator charging and storage Temperature during precharge
Temperature variation can affect the precharge
pressure of an accumulator. As the temperature
increases, the precharge pressure increases.
Conversely, decreasing temperature will decrease the
precharge pressure. To ensure the accuracy of the
Always consider any accumulator to contain
accumulator precharge pressure, the temperature
pressure until proven otherwise.
variation must be accounted for.
A temperature variation factor is determined by the
Pure dry nitrogen is the only gas approved for use
ambient temperature encountered at the time when
in the accumulator. The accidental charging of
charging the accumulator on a truck that has been
oxygen or any other gas in this compartment may
shut down for one hour. Refer to Table 1 for charging
cause an explosion. Ensure that pure dry nitrogen
pressures in different ambient operating conditions
gas is being used to charge the accumulator.
that the truck is currently exposed to DURING the
charging procedure.
Before charging or discharging nitrogen gas in the
accumulator, ensure that the warning labels are For example, assuming that the ambient temperature
observed and the instructions regarding the is 10 °C (50 °F), charge the accumulator to 9 294 kPa
charging valve are carefully read and understood. (1,348 psi).
NOTE: If one steering or brake accumulator is low on Table 1: Relationship Between Precharge
nitrogen, check and charge both accumulators at the Pressure and Ambient Temperature
same time. Correct precharge pressure is the most Ambient Charging Pressure
important factor in prolonging accumulator life. Temperature ± 70 kPa (10 psi)
-23°C (-10°F) and below 8 232 kPa (1,194 psi)
NOTE: Use only nitrogen that meets or exceeds CGA
-17°C (0°F) 8 412 kPa (1,220 psi)
(Compressed Gas Association) specification G-10.1
for type 1, grade F. The nitrogen should be 99.9% -12°C (10°F) 8 584 kPa (1,245 psi)
pure. Use only nitrogen cylinders with standard CGA
number 580 connections with the appropriate high -7°C (20°F) 8 763 kPa (1,271 psi)
pressure regulator. -1°C (30°F) 8 943 kPa (1,297 psi)
4°C (40°F) 9 122 kPa (1,323 psi)
NOTE: For best performance, charge the 10°C (50°F) 9 294 kPa (1,348 psi)
accumulators in the temperature conditions in which
the truck is expected to operate. During the precharge, 16°C (60°F) 9 473 kPa (1,374 psi)
allow the temperature of the nitrogen gas to come into
21°C (70°F) 9 653 kPa (1,400 psi)
equilibrium with the ambient temperature.
27°C (80°F) 9 832 kPa (1,426 psi)
32°C (90°F) 10 011 kPa (1,452 psi)
38°C (100°F) 10 184 kPa (1,477 psi)
43°C (110°F) 10 363 kPa (1,503 psi)
49°C (120°F) 10 542 kPa (1,529 psi)
NOTE: A precharge pressure below 8 232 kPa (1,194
psi) is not recommended because of low precharge
pressure warnings. The low accumulator precharge
warning switch activates at 7 584 ± 310 kPa (1,100 ±
45 psi).
3
CEN30098-11 30 Testing and adjusting
Bladder accumulator charging procedure 4. Remove protective cap (1, Figure 30-1) from the
charging valve (2).
Only precharge accumulators to 9653 kPa (1400
psi) while installed on the truck. Never handle an
accumulator with lifting equipment if the nitrogen
precharge pressure is over 827 kPa (120 psi).
Always set the precharge to 690 - 827 kPa (100 -
120 psi) before removing or installing the
accumulators.
Ensure that the nitrogen supply is shut off before
attaching the charging manifold to the nitrogen
container.
Hydraulic oil escaping under pressure can have
sufficient force to enter a person's body by FIGURE 30-1. GAS VALVE COMPONENTS -
penetrating the skin and cause serious injury, and BLADDER ACCUMULATOR
possibly death, if proper medical treatment is not 1. Protective Cap 2. Charging Valve
received immediately.
Relieve pressure before disconnecting any
hydraulic lines. Tighten all connections securely 5. Close inlet valve (4, Figure 30-2) on control
before applying pressure. manifold (6).
1. Refer to the "Hydraulic system bleeddown 6. Connect the nitrogen charging kit to nitrogen
procedure" in Testing and adjusting section: container (8). Open the valve on the container.
7. Turn the “T” handle (1) on charging valve adapter
• Steering, hoist and auxiliary hydraulic
system (730E / 830E / 860E) (2) all the way out (counterclockwise).
8. Close the bleed valve at the bottom of the
• Steering, hoist, brake cooling and auxiliary
accumulator.
hydraulic system (930E / 980E)
9. Attach the charging valve adapter (2) to the
2. Close all accumulator bleed valves.
charging valve on the accumulator. Ensure the
3. Remove the bleed plug in the port valve at the hose does not loop or twist. Tighten the swivel
bottom of each accumulator to vent residual nut on the charging valve adapter finger-tight.
pressure.
10. Turn the “T” handle on charging valve adapter (2)
NOTE: If a new or rebuilt accumulator (or any bladder clockwise to open the accumulator gas valve. Do
accumulator with all nitrogen discharged) is being not turn the “T” handle all the way down as it will
precharged while installed on the truck and connected damage the valve core.
to the hydraulic system, the oil side of the accumulator
must be vented to allow proper bladder expansion. 11. Set the regulator (5) for 172 kPa (25 psi), then
Trapped air or oil on the hydraulic side of the bladder slightly open inlet valve (4) on control manifold
will prevent the proper precharge pressure to be (6) to slowly fill the accumulator.
obtained for safe operation.
4
30 Testing and adjusting CEN30098-11
14. Turn the “T” handle (1) on the charging valve
adapters all the way out (counterclockwise) to
close the accumulator gas valve.
15. Hold the gas valve on the accumulator stationary.
If the precharge is not added slowly, the bladder Loosen the swivel nut on the charging valve
may suffer permanent damage. A “starburst” adapter to remove the nitrogen charging kit.
rupture in the lower end of the bladder is a
characteristic failure caused by charging too 16. Use a common leak reactant to check for nitrogen
quickly. leaks.
12. When 172 kPa (25 psi) of precharge pressure is 17. Install protective cap (1, Figure 30-1) on the gas
obtained, close the nitrogen container valve. Set valve.
the regulator (5) for the charging pressure based 18. Operate the truck and check the steering
on the current ambient temperature. Refer to operation.
Table 1. Then, slowly open the nitrogen container
valve again and fill the accumulator. The proper
fill time for the bladder accumulator is
approximately three minutes.
13. After the accumulator is charged to the desired
pressure, shut off the charging kit and wait 15
minutes to allow the gas temperature to stabilize.
If the desired pressure is maintained, proceed to
step 19. If the desired pressure is exceeded:
a. close the nitrogen container valve, inlet valve
(4) and both outlet valves (3).
b. Disconnect the hose that connects the
manifold (6) to regulator valve (5).
NOTE: A small blast of pressure will escape.
c. Open inlet valve (4) then slowly open each
outlet valve (3) independently until the correct
precharge pressure is obtained in each
accumulator. FIGURE 30-2. HYDRAIR® CHARGING KIT
NOTE: The arrangement of parts may vary from
the illustration depending on the kit part number.
1. “T” Handle Valve
Do not reduce pressure by depressing the valve
2. Charging Valve Adapter
core with a foreign object. High pressure may
3. Manifold Outlet Valves (from gauge)
rupture the rubber valve seat.
4. Inlet Valve (from regulator)
5. Regulator Valve (Nitrogen Pressure)
6. Manifold
7. Charging Pressure Gauge
8. Dry Nitrogen Gas Container
5
CEN30098-11 30 Testing and adjusting
Precharge maintenance Bladder accumulator storage procedure
If the low accumulator precharge warning is active
when the engine start switch is turned ON, do not Always store bladder accumulators with 690 - 827
attempt to start the engine. Permanent bladder kPa (100 - 120 psi) nitrogen precharge pressure.
damage may result. Check the steering This amount of pressure fully expands the bladder
accumulator precharge pressure and adjust it if and holds oil against the inner walls for lubrication
necessary. and rust prevention. Do not exceed 827 kPa (120
psi). Storing accumulators with too much pressure
1. When starting the truck, turn the engine start is not safe due to possible leakage.
switch to the ON position and wait to confirm that
the low accumulator precharge warning does not Only precharge accumulators to 9 653 kPa (1,400
stay active after the system check is complete. If psi) while installed on the truck. Never handle an
the warning stays active, do not operate the accumulator with lifting equipment if the
truck. Notify maintenance personnel. precharge pressure is over 827 kPa (120 psi).
2. Check the accumulator precharge pressure Always set the precharge to 690 - 827 kPa (100 -
every 500 hours. If the precharge pressure is too 120 psi) before removing or installing the
low, the bladder will be crushed into the top of the accumulators.
shell by hydraulic system pressure and can
1. If the accumulator was just rebuilt, ensure that
extrude into the gas stem and become
there is approximately 2 liters (64 oz.) of clean C-
punctured. This condition is known as "pick out".
4 hydraulic oil inside the accumulator before
One such cycle is sufficient to destroy a bladder.
adding a precharge pressure of 690 kPa (100
3. Check all sealing areas on the nitrogen side of psi).
the accumulator (charging valve, pressure 2. Store bladder accumulators with a precharge
switch, manifold, etc) during every precharge pressure of 690 - 827 kPa (100 - 120 psi).
maintenance interval to ensure that the seals do
3. Cover the hydraulic port with a plastic plug to
not leak. Replace all faulty or leaking seals,
prevent contamination. Do not use a screw-in
valves, etc. Failure to repair leaking nitrogen
type plug.
seals may result in a failed accumulator bladder
or low performance from the accumulator. 4. Store the accumulator in an upright position.
NOTE: If the precharge pressure continues to decline
frequently between precharge maintenance intervals,
Bladder storage
and if all nitrogen sealing areas are free of leaks, then
the accumulator bladder most likely has a small hole in The shelf life of bladders under normal storage
it and must be replaced. conditions is one year. Normal storage conditions
4. Check all heat shields and exhaust blankets, as consist of the bladder being heat sealed in a black
provided, during every precharge maintenance plastic bag and placed in a cool dry place away from
interval to ensure that they are in place and good the sun, ultraviolet and fluorescent lights, and
condition. electrical equipment. Direct sunlight or fluorescent light
can cause the bladder to weather check and dry rot,
NOTE: If the truck is equipped with cold weather
which will appear on the bladder surface as cracks.
bladder accumulators, the precharge pressure must
be checked every 100 hours because the nitrogen
permeates this bladder material at a much greater rate
than the standard bladder material.
6
30 Testing and adjusting CEN30098-11
Installing a bladder accumulator from storage Bladder accumulator leak testing
Refer to "Bladder accumulator charging procedure" to Leak testing entails checking for internal and external
install the nitrogen charging kit on the accumulator and leaks at high pressure. A source of 24 130 kPa (3,500
to check the precharge pressure. psi) hydraulic pressure and nitrogen precharge
pressure of 9 653 kPa (1,400 psi) will be required. A
• If the precharge pressure is between 172 kPa (25
small water tank is necessary for a portion of the test.
psi) and 690 kPa (100 psi), set the regulator to 690
kPa (100 psi) and slowly charge the accumulator 1. Remove protective cap (1, Figure 30-1) from the
to 690 kPa (100 psi). Disconnect the nitrogen gas valve.
charging kit from the accumulator and install the 2. Close inlet valve (4, Figure 30-2) on control
accumulator on the truck. Charge the accumulator manifold (6).
to the correct operating precharge pressure. Refer
3. Connect the nitrogen charging kit to nitrogen
to Table 1.
container (8). Open the valve on the container.
• If the precharge pressure is less than 172 kPa (25 4. Turn the “T” handle on charging valve adapter (2)
psi), slowly drain off all of the precharge pressure all the way out (counterclockwise).
and use the following procedure:
5. Close the bleed valve at the bottom of the
1. Remove the nitrogen charging kit from the accumulator.
accumulator. 6. Attach the charging valve adapter (2) to the
2. Lay the accumulator on a suitable work bench so charging valve on the accumulator. Ensure the
the valve port at the bottom of the accumulator is hose does not loop or twist. Tighten the swivel
higher than the top end of the accumulator. nut on the charging valve adapter finger-tight.
Remove the protective cap from the valve port. 7. Turn the “T” handle on charging valve adapter (2)
3. Pour approximately 2 liters (64 oz.) of clean C-4 clockwise to open the accumulator gas valve. Do
hydraulic oil into the accumulator through the not turn the “T” handle all the way down as it will
valve port. Allow time for the oil to run down the damage the valve core.
inside of the accumulator to reach the other end. 8. Set the regulator (5) for 690 kPa (100 psi), then
4. Lay the accumulator flat on the work bench (or slightly open inlet valve (4) on control manifold
floor) and slowly roll the accumulator two (6) to slowly fill the accumulator. After 690 kPa
complete revolutions. This will thoroughly coat (100 psi) is obtained, the charging rate can be
the accumulator walls with a film of oil that is increased until the accumulator is fully charged to
necessary for bladder lubrication during the 9 653 kPa (1,400 psi).
charging procedure. 9. Close inlet valve (4) on control manifold (6) then
5. Stand the accumulator upright. Charge the turn the “T” handle on charging valve adapter (2)
accumulator to 690 kPa (100 psi). Refer to fully counterclockwise to close the accumulator
"Bladder accumulator charging procedure" for the gas valve.
proper charging procedure.
10. Submerge the accumulator assembly under
6. Remove the nitrogen charging kit. Install the water and observe it for 20 minutes. No leakage
protective cap on the valve port. (oil or bubbles) is permitted from the gas valve at
7. Install the accumulator on the truck. the top or the valve port at the bottom. If leakage
8. Charge the accumulator to the correct operating is present, proceed to Step 16.
precharge pressure listed in Table 1. Refer to 11. Hold the gas valve on the accumulator stationary.
"Bladder accumulator charging procedure" for the Loosen the swivel nut on the charging valve
proper charging procedure. adapter to remove the nitrogen charging kit.
12. Install protective cap (1, Figure 30-1) on the gas
valve.
7
CEN30098-11 30 Testing and adjusting
13. Ensure that the bleed valve at the bottom of the
accumulator is closed. Connect a hydraulic
power supply to the valve port at the bottom of
the accumulator.
14. Pressurize the accumulator with oil to 24 130 kPa Hydraulic oil escaping under pressure can have
(3,500 psi). This may take 6 to 8 gallons of oil. No sufficient force to enter a person's body by
external oil leakage is permitted. penetrating the skin and cause serious injury, and
possibly death, if proper medical treatment is not
15. Slowly relieve oil pressure and remove the
received immediately.
hydraulic power supply. Install the protective cap
on the valve port to prevent contamination. Relieve pressure before disconnecting any
16. Install the nitrogen charging kit. hydraulic lines. Tighten all connections securely
before applying pressure.
• If any gas or oil leakage was present,
1. Refer to the "Hydraulic system bleeddown
discharge all nitrogen gas from the
procedure" in Testing and adjusting section:
accumulator. Repair the accumulator as
necessary. • Steering, hoist and auxiliary hydraulic
system (730E / 830E / 860E)
• If there were no leaks, adjust the precharge
pressure to 690 - 827 kPa (100 - 120 psi). • Steering, hoist, brake cooling and auxiliary
hydraulic system (930E / 980E)
17. Verify that all warning and caution labels are
2. Close all accumulator bleed valves.
attached and legible. Install new labels as
required. 3. Remove valve cover (1, Figure 30-3) and spacer
(2).
Piston accumulator charging procedure
1
Only precharge accumulators that are installed on 2 4
the truck. Never use lifting equipment to handle an
accumulator that has a nitrogen precharge of more
than 172 kPa (25 psi). Always set the precharge to
172 kPa (25 psi) or less for storage purposes and 3
before removing or installing accumulators.
Ensure that the nitrogen supply is shut off before
attaching the charging manifold to the nitrogen
container.
NOTE: In piston-type accumulators, an increase in
precharge pressure (after allowing for any appreciable
temperature variation) indicates a gradual leakage of
fluid into the gas side. Conversely, a decrease in
precharge pressure is indicative of nitrogen gas 84476
leakage into the fluid side.
FIGURE 30-3. TOP OF PISTON ACCUMULATOR
1. Valve Cover 3. Charging Valve
2. Spacer 4. Switch Cover
8
30 Testing and adjusting CEN30098-11
NOTE: If a loss in nitrogen pressure is the reason for
recharging, inspect the charging valve and
accumulator for damage. Replace or repair items, as
necessary, before continuing the charging procedure.
7. Hold the gas valve stationary at valve body (3,
Nitrogen pressure may be present in the Figure 30-4) with one wrench, then loosen swivel
accumulator. Only turn the swivel nut (small hex nut (2) with a second wrench. This will open the
nut) during the next step. Turning the entire valve gas valve.
body may result in the valve assembly being
forced out of the accumulator by the nitrogen NOTE: Three turns will fully open the valve.
pressure inside. Wear a protective face mask when 8. Disconnect the hose that connects manifold (6,
discharging nitrogen gas. Figure 30-5) to regulator valve (5).
4. Turn “T” handle (1, Figure 30-5) on the charging NOTE: A small blast of pressure may escape.
valve adapter all the way out (counterclockwise).
9. Open the inlet valve (4) then slowly open the
5. Remove valve cap (1, Figure 30-4) on charging outlet valve (3) connected to the accumulator
valve (3, Figure 30-3) then attach the charging until any stored pressure in the accumulator is
valve adapter (2, Figure 30-5) to the charging relieved.
valve (3, Figure 30-3) on the accumulator. Ensure
the hose does not loop or twist. Tighten the 10. Close inlet valve (4) and outlet valves (3) then
swivel nut on the charging valve adapter finger- reconnect the hose that connects manifold (6) to
tight. regulator valve (5).
6. Close inlet valve (4, Figure 30-5) and outlet 11. Connect the nitrogen charging kit to nitrogen
valves (3) on control manifold (6). container (8). Open the valve on the container.
12. Open outlet valve (3) connected to the
accumulator.
1 13. To prevent damage to the piston, first provide a
precharge to the accumulator by setting the
regulator (5) for 172 kPa (25 psi) then slightly
open inlet valve (4) until the precharge pressure
2 is reached.
14. Set the regulator (5) for the charging pressure
based on the current ambient temperature from
Table 1, then slightly open inlet valve (4) to slowly
3 fill the accumulator.
NOTE: If a loss in nitrogen pressure occurred during
operation, oil may still be present in the accumulator
84483
below the piston. This oil can be bled off during the
FIGURE 30-4. PISTON ACCUMULATOR nitrogen charging procedure by turning the steering
CHARGING VALVE wheel back and forth until resistance prevents the
steering wheel from turning.
1. Valve Cap 3. Valve Body
2. Swivel Nut (Large Hex Nut)
(Small Hex Nut)
9
CEN30098-11 30 Testing and adjusting
15. After the accumulator is charged to the desired
pressure, shut off the charging kit and wait 15
minutes to allow the gas temperature to stabilize.
If the desired pressure is maintained, proceed to
step 16. If the desired pressure is exceeded:
a. Close the nitrogen container valve, inlet valve
(4) and both outlet valves (3).
b. Disconnect the hose that connects manifold
(6) to regulator valve (5).
NOTE: A small blast of pressure will escape.
c. Open the inlet valve (4) then slowly open each
outlet valve (3) independently until the correct
precharge pressure is obtained in each
accumulator.
FIGURE 30-5. HYDRAIR® CHARGING KIT
Do not reduce pressure by depressing the valve
core with a foreign object. High pressure may NOTE: The arrangement of parts may vary from
rupture the rubber valve seat. the illustration depending on the kit part number.
16. Tighten swivel nut (2, Figure 30-4) to 6-11 N·m 1. “T” Handle Valve
(5-8 ft lb). 2. Charging Valve Adapter
17. Use a common leak reactant to check for nitrogen 3. Manifold Outlet Valves (from gauge)
leaks. 4. Inlet Valve (from regulator)
5. Regulator Valve (Nitrogen Pressure)
18. Install charging valve cap (1) finger tight. 6. Manifold
19. Install valve cover (1, Figure 30-3) and tighten 7. Charging Pressure Gauge
capscrews to 34 N·m (25 ft lb). 8. Dry Nitrogen Gas Container
20. Operate the truck and check the steering
operation.
10
30 Testing and adjusting CEN30098-11
Piston accumulator storage Piston accumulator leak testing
It will be necessary to check for internal and external
leaks at high pressure. A source of 24 132 kPa (3,500
psi) hydraulic pressure and nitrogen pressure of 9 653
kPa (1,400 psi) will be required. A small water tank
with the necessary safety guards will be necessary for
When storing a piston accumulator, do not exceed a portion of the test.
the recommended storage pressure of 172 kPa (25
psi) or less. Sudden loss of the accumulator
pressure can result in a projectile hazard that can
cause serious injury or death.
Do not stand near the accumulator during test
Only precharge the accumulators to operating procedure. A box enclosure made of heavy steel
pressure while installed on the truck. DO NOT plate is recommended to contain the accumulator
handle an accumulator with a nitrogen precharge during oil pressurization test.
greater than 172 kPa (25 psi).
1. Ensure there is no pressure in either end of the
accumulator.
Apply a small nitrogen precharge of 172 kPa (25 psi) or
less to prevent seal compression and corrosion due to 2. Fill each end of the accumulator with
condensation. approximately 22.7 L (6 gal) of clean type C-4
hydraulic oil. Install an adapter on the oil end to
Store the accumulator in the upright position in a cool connect to a hydraulic power source. Plug the
dry place away from the sun. The ideal temperature for remaining ports.
storage is 21°C (70°F).
a. Apply 24 132 kPa (3,500 psi) of oil pressure.
Cover the oil port at the bottom of the accumulator with
b. Verify that no external leakage exists.
a plastic plug (without threads) to prevent contamina-
tion. DO NOT install a threaded plug in the oil port. c. Verify that no structural damage exists.
3. Release the pressure and remove the oil side fit-
ting.
4. Drain all the hydraulic oil from both ends of the
accumulator. Leave the oil port open.
5. Slowly pressurize the gas end of the accumulator
with approximately 690 kPa (100 psi) of nitrogen
to move the piston to the bottom of the housing.
6. Submerge the oil end of the accumulator in the
water tank.
7. Apply 9 653 kPa (1,400 psi) of nitrogen pressure
to the gas end and observe for 20 minutes. No
leakage (oil or bubbles) is permitted.
8. Release the nitrogen pressure and remove the
accumulator from the water tank.
9. Drain all remaining oil from the accumulator.
10. If the accumulator is to be placed in storage, add
1.5 L (3 pints) of clean type C-4 hydraulic oil in
the gas side of the accumulator and 0.5 L
(1 pint) in the oil side. Plug all open ports.
11. Verify that all warning and caution labels are
attached and legible. Install new labels as
required.
11
CEN30098-11 30 Testing and adjusting
Checking for improper suspension charge Dirt ring heights should be similar across a typical fleet
of the same truck model. A benchmark dirt ring height
During periodic maintenance inspections, check the
should be established for the truck fleet to help
dirt ring on the exposed portion of each suspension
determine suspect suspension cylinders.
piston. See Figure 30-6. The dirt rings of the front
suspensions should be approximately the same height NOTE: Checking and/or adjusting the suspension
as each other, and the dirt rings of the rear charging pressures during periodic maintenance
suspensions should be approximately the same height inspections is not recommended. The oiling and
as each other. Dirt rings that are at significantly charging procedures must be performed on flat ground
different heights may indicate an improperly charged and under specific controlled conditions.
suspension cylinder.
CLEANED BY
WIPER SEAL CLEANED BY
WIPER SEAL
DIRT RING
DIRT RING
FRONT SUSPENSION
REAR SUSPENSION
73536
FIGURE 30-6. DIRT RING ON SUSPENSION PISTON
12
30 Testing and adjusting CEN30098-11
Suspension oiling and charging procedures For best results, suspensions should be charged in
pairs (front suspensions together and rear
suspensions together). If rear suspensions are to be
charged, the front suspensions should be charged
first. If the truck lifts off of support blocks before
charging is complete, stop charging. If both front and
All HYDRAIR® II suspensions are charged with rear suspensions are serviced, DO NOT remove the
compressed nitrogen gas with sufficient pressure front suspension support blocks until after the rear
to cause injury and/or damage if improperly suspensions have been completely serviced.
handled. Follow safety instructions, cautions, and
Anytime the suspensions are charged, the calibration
warnings provided in the following procedures to
of the payload meter (PLM) system is affected. To
prevent accidents during oiling and charging.
ensure accurate payload records, perform a "Clean
These procedures cover the suspension oiling and Truck Tare" before returning the truck to operation.
charging of Hydrair® II suspensions on Komatsu Refer to the payload meter information later in this
electric drive dump trucks. Suspensions that have section.
been properly charged will provide improved handling
and ride characteristics while also extending the life of Required equipment
the truck frame and improving tire wear. • Hydrair® charging kit (see Figure 30-7)
Inflation pressures and exposed piston lengths are • Jacks and/or overhead crane
calculated for a normal truck gross vehicle weight
(GVW). Additions to truck weight, such as body liners, • Support blocks for oiling
tailgates, water tanks, etc, should be considered part • Support blocks for charging
of the payload. Keeping the truck GVW within the
specification shown on the grade/speed chart in the • Hydrair® oil (see Specifications Chart)
operator cab will extend the service life of the truck • Friction modifier (see Specifications Chart)
main frame and allow the suspensions to produce a
comfortable ride. • Dry nitrogen (see Specifications Chart)
13
CEN30098-11 30 Testing and adjusting
Installing the charging kit
1. Assemble the charging kit as shown in Figure 30-
Removing the charging kit
7, and attach it to a container of pure dry nitrogen
(8). 1. Close both outlet valves (3, Figure 30-7).
2. Remove the protective covers and charging valve 2. Turn "T" handle valves (1) counterclockwise to
caps from the suspensions. release the charging valve cores.
3. Turn "T" handle valves (1, Figure 30-7) of 3. Tighten the swivel nut (small hex) (2, Figure 30-
adapters (2) completely counterclockwise. 10) on the charging valve. If a new charging valve
4. Ensure that outlet valves (3) and inlet valve (4) is being used, tighten the swivel nut to 15 N·m
are closed (turned completely clockwise). (11 ft lb), then loosen and retighten the swivel nut
to 15 N·m (11 ft lb). Loosen the swivel nut again
5. Remove valve cap (1, Figure 30-10) from and retighten to 6 N·m (50 in lb).
charging valve the attach charging valve
adapters (2, Figure 30-7) to each suspension 4. Remove charging valve adapters (2) from the
charging valve. charging valves.
6. Turn the swivel nut (small hex) (2, Figure 30-10) 5. Install the charging valve caps and protective
on the charging valve three full turns covers on both suspensions.
counterclockwise to unseat the valve.
7. Turn "T" handle valves (1) clockwise. This will
depress the core of the charging valve and open
the gas chamber of the suspension.
8. Open both outlet valves (3).
NOTE: By selective opening and closing of outlet
valves (3) and inlet valve (4), suspensions may be
charged separately or together.
FIGURE 30-7. HYDRAIR® CHARGING KIT
1. “T” Handle Valve
2. Charging Valve Adapter
3. Manifold Outlet Valves (from gauge)
4. Inlet Valve (from regulator)
5. Regulator Valve (Nitrogen Pressure)
6. Manifold
7. Charging Pressure Gauge (Suspensions)
8. Dry Nitrogen Gas Container
NOTE: The arrangement of parts may vary from
the illustration.
14
30 Testing and adjusting CEN30098-11
Support blocks for oiling and charging dimensions Support block kits for specific truck models are
available to order from Komatsu. Refer to Disassembly
Before starting the oiling and charging procedures,
and assembly section, Service tools for the correct kit
support blocks must be either fabricated or purchased
part number.
from Komatsu. To maintain the correct exposed piston
rod extensions, different support blocks are required Support blocks may also be fabricated in various
for oiling and for charging. See Table 2 (front) and forms. Mild steel materials are recommended. Square
Table 3 (rear) for the suspension dimensions. At the stock or pipe segments at least 25 mm (1 in.) may be
front suspension, measure from the face of the used. The blocks must be capable of supporting the
cylinder gland or wiper retainer plate to the machined weight of the truck during oiling and charging
surface on the spindle. (see Figure 30-8). At the rear procedures while avoiding contact with plated surfaces
suspension, measure from the face of the cylinder and seals on the suspension. Refer to Figure 30-9 for
gland to the piston (see Figure 30-8). front suspension support block placement and Figure
30-11 for rear suspension support block placement.
NOTE: If using fabricated support blocks, the nitrogen
charging support blocks for the rear suspension are
not necessary. However, oiling blocks are necessary to
properly set the oiling height.
CHARGING
HEIGHT CHARGING
HEIGHT
FRONT SUSPENSION REAR SUSPENSION 73538
FIGURE 30-8. MEASURING THE CHARGING HEIGHT
15
CEN30098-11 30 Testing and adjusting
Front suspensions
NOTE: The dump body must be empty and resting on
the truck frame before performing the following
procedures.
1. Park the truck on a hard, level surface. Place the
directional control lever in PARK.
2. Place wheel chocks in front of and behind both
sets of rear tires to prevent roll away.
NOTE: Do not place wheel chocks around the front
tires. The front tires will roll forward and backward a
small amount as the suspension travels up and down
during the suspension charging process. SUPPORT SUPPORT
BLOCK BLOCK
3. Throughly clean the charging valve area on top of
each front suspension. Remove the protective
covers from the charging valves.
73537
When support blocks are in place, they must be FIGURE 30-9. FRONT SUSPENSION
secured with a strap or by other means to avoid
accidental discharge. An unsecured support block
could fly loose as weight is applied, presenting the
possibility of serious injury to nearby personnel
and/or damage to the equipment. Overhead
clearance may be reduced rapidly and suddenly
when nitrogen pressure is released.
4. Position and secure the oiling support blocks 180
degrees apart as shown in Figure 30-9. When
nitrogen pressure is released, the suspensions
will lower and rest on the blocks.
NOTE: Ensure that the blocks do not mar or scratch
the plated surfaces of the pistons or damage wiper
seals in the lower bearing retainer. Support blocks
must seat on the spindle and the cylinder housing, not
on the capscrew heads.
16
30 Testing and adjusting CEN30098-11
6. Remove the vent plug next to the charging valve.
7. Fill the suspension cylinder with a clean
suspension oil mixture (with 6% friction modifier)
until the oil is even with the top of the plug hole.
Wear a face mask or goggles. Ensure that only the NOTE: As an alternative method, the suspension can
swivel nut turns. Turning the entire charging valve be pressure filled from the rod drain port at the bottom
body may result in the valve assembly being of the cylinder. This would eliminate the 15 minute wait
ejected from the suspension by the gas pressure in the following step.
inside. 8. Allow the suspension to settle for at least 15
5. Discharge the nitrogen pressure from the minutes. Add more suspension oil mixture if
suspension as follows: necessary.
a. Remove valve cap (1, Figure 30-10) from the 9. Install the plug.
charging valve on top of the front suspension. 10. Connect the nitrogen charging kit to the charging
b. Connect the nitrogen charging kit to the valve. Refer to "Installing the charging kit".
charging valve. Refer to "Installing the 11. Charge the suspensions with nitrogen gas to a
charging kit". charging height of approximately 280 mm (11 in.)
c. Turn swivel nut (2) counterclockwise three full in order to accommodate the charging support
turns to unseat the valve seal. Do not turn blocks. Close inlet valve (4, Figure 30-7).
the swivel nut more than three turns. Do 12. Remove the oiling support blocks from the
not turn charging valve body (3). suspensions and install the charging support
d. As the nitrogen pressure is released, the sus- blocks. Secure the blocks to prevent accidental
pension should lower slowly and seat solidly dislodging.
on the support blocks. Remove the nitrogen NOTE: Use caution to prevent damage to plated
charging kit. Refer to "Removing the charging cylinder surfaces and oil seals when installing the
kit". support blocks.
13. Remove the center hose from the charging valve
manifold.
1
14. Slowly release nitrogen gas until the pressure
drops below the estimated charging pressure
listed in Table 2, then close the valve.
2 15. Install the center hose to manifold (6, Figure 30-
7).
84483
FIGURE 30-10. CHARGING VALVE
1. Valve Cap 3. Valve Body
2. Swivel Nut (Large Hex Nut)
(Small Hex Nut)
17
CEN30098-11 30 Testing and adjusting
16. Charge the suspensions to the charging height 17. Close inlet valve (4). Leave outlet valves (3) open
listed in Table 2. for five minutes to allow the pressures in the
suspensions to equalize.
The charging pressure is provided only as a start-
ing point for obtaining the correct charging height. 18. Close outlet valves (3). Remove the charging kit
The pressure may be adjusted as necessary to components. Refer to "Removing the charging
maintain the proper charging height listed in kit".
Table 2. Do not use an overcharge of nitrogen to 19. If the charging valve is being reused, tighten
lift the suspensions off the support blocks. swivel nut (2, Figure 30-10) to 6-11 N·m (5-8 ft
NOTE: There is no specific charging pressure that lb). Install the valve cap finger-tight.
must be maintained. The required pressure for If a new charging valve is being used, tighten
maintaining the charging height will depend upon the swivel nut (2) to 15 N·m (11 ft lb), then loosen
weight of the dump body. and tighten the swivel nut to 15 N·m (11 ft lb).
Loosen the swivel nut again and tighten to 6-11
N·m (5-8 ft lb). Install the valve cap finger-tight.
Table 2: Front Suspension Dimensions (Empty)
Oiling Charging 20. Install the protective guard over the charging
Charging Height valve.
Height Pressure
730E-8 / 730E-10 NOTE: If the rear suspensions are to be serviced at
38.1 mm 228.6 mm * 2 772 kPa this time, leave the charging support blocks in place on
(1.5 in.) (9.00 in.) (402 psi) the front suspensions until after the rear suspensions
are completely serviced.
830E-5
25.4 mm 228.6 mm * 2 696 kPa
(1.00 in.) (9.00 in.) (391 psi)
860E-1K / 860E-1KT
25.4 mm 228.6 mm * 3 365 kPa
(1.00 in.) (9.00 in.) (488 psi)
930E-5
25.4 mm 228.6 mm * 2 930 kPa
(1.00 in.) (9.00 in.) (425 psi)
960E-1 / 960E-1K / 960E-2 / 960E-2K / 960E-2KT
25.4 mm 219 mm * 3 282 kPa
(1.00 in.) (8.62 in.) (476 psi)
980E-4 / 980E-5
25.4 mm 228.6 mm
Standard
(1.0 in.) (9.0 in.) * 3 047 kPa
50.8 mm 203.2 mm (442 psi)
Oil Sands
(2.0 in.) (8.0 in.)
* Charging pressures are for reference only and may vary
depending upon the weight of the dump body. The charging
pressure is provided only as a starting point for obtaining the
correct charging height, which is the critical measurement for a
properly charged suspension. The pressure may be adjusted
as necessary to maintain the proper charging height.
18
30 Testing and adjusting CEN30098-11
Rear suspensions
NOTE: The dump body must be empty and resting on
the truck frame before performing the following
procedures.
1. Park the truck on a hard, level surface. Place the
directional control lever in PARK.
2. Place wheel chocks in front of and behind both
sets of rear tires to prevent roll away.
NOTE: Do not place wheel chocks around the front
tires. The front tires will roll forward and backward a
small amount as the suspension travels up and down
during the suspension charging process.
3. Throughly clean the charging valve area on top of
each rear suspension. Remove the protective
covers from the charging valves.
When support blocks are in place, they must be FIGURE 30-11. SUPPORT BLOCK
secured with a strap or by other means to avoid INSTALLATION
accidental discharge. An unsecured support block 1. Main Frame 3. Rear Axle Housing
could fly loose as weight is applied, presenting the 2. Support Block
possibility of serious injury to nearby personnel
and/or damage to the equipment. Overhead
clearance may be reduced rapidly and suddenly
when nitrogen pressure is released.
4. Position and secure oiling support blocks (2,
Figure 30-11) in place so the blocks are seated
between main frame (1) and rear axle housing
(3). A block should be used on both the left and
right sides of the truck.
19
CEN30098-11 30 Testing and adjusting
NOTE: A plastic tube can be used to help bleed off
trapped air inside the piston.
6. Remove vent plug (1, Figure 30-13), pressure
sensor (2) and charging valve (3).
Wear a face mask or goggles. Ensure that only the 7. Use one of the open ports to fill the suspension
swivel nut turns. Turning the entire charging valve cylinder with a clean suspension oil mixture (with
body may result in the valve assembly being 6% friction modifier) until oil weeps from the open
ejected from the suspension by the gas pressure ports. Use drip pans and clean all spillage from
inside. the outside of the suspension.
5. Discharge the nitrogen pressure from the NOTE: As an alternative method, the suspension can
suspension as follows: be pressure filled from the rod drain port at the bottom
of the cylinder. This would eliminate the 15 minute wait
a. Remove valve cap (1, Figure 30-12) from the
in the following step.
charging valve on top of the rear suspension.
8. Allow the suspension to settle for at least 15
b. Connect the nitrogen charging kit to the minutes. Add more suspension oil mixture if
charging valve. Refer to "Installing the necessary.
charging kit".
9. Install vent plug (1) and pressure sensor (2) into
c. Turn swivel nut (2) counterclockwise three full the suspension cylinder.
turns to unseat the valve seal. Do not turn
the swivel nut more than three turns. Do 10. Install a new O-ring onto charging valve (3) and
not turn charging valve body (3). install it into the suspension cylinder.
d. As the nitrogen pressure is released, the sus-
pension should lower slowly and seat solidly
on the support blocks. Remove the nitrogen
charging kit. Refer to "Removing the charging
kit".
1
1
3
2 73539
3 FIGURE 30-13. REAR SUPENSION PORTS
1. Vent Plug 3. Charging Valve
2. Pressure Sensor
84483
FIGURE 30-12. CHARGING VALVE
1. Valve Cap 3. Valve Body
2. Swivel Nut (Large Hex Nut)
(Small Hex Nut)
11. Connect the nitrogen charging kit to the charging
valve. Refer to "Installing the charging kit".
12. Charge the suspensions with nitrogen gas to a
charging height of approximately 305 mm
(12 in.). Close inlet valve (4, Figure 30-7).
20
30 Testing and adjusting CEN30098-11
14. Close inlet valve (4). Leave outlet valves (3) open
for five minutes to allow the pressures in the
suspensions to equalize.
15. Ensure that both of the rear suspension cylinders
Be aware that the truck may lower suddenly when are extended the same distance ± 10 mm (0.39
releasing nitrogen gas from the suspensions. in.). If the difference in the extension from side to
side exceeds this amount, check the front
13. Slowly release nitrogen gas until the charging
suspensions for equal extension. Adjust the front
heights of both rear suspensions match the
suspensions as necessary.
charging height listed in Table 3.
NOTE: A low left front suspension will cause the right
The charging pressure is provided only as a start-
rear suspension to be high. A low right front
ing point for obtaining the correct charging height.
suspension will cause the left rear suspension to be
The pressure may be adjusted as necessary to
high.
maintain the proper charging height listed in
Table 3. 16. Close outlet valves (3). Remove the charging kit
components. Refer to "Removing the charging
NOTE: There is no specific charging pressure that kit".
must be maintained. The required pressure for
maintaining the charging height will depend upon the 17. If the charging valve is being reused, tighten
weight of the dump body. swivel nut (2, Figure 30-12) to 6-11 N·m (5-8 ft
lb). Install the valve cap finger-tight.
If a new charging valve is being used, tighten
Table 3: Rear Suspension Dimensions (Empty)
swivel nut (2) to 15 N·m (11 ft lb), then loosen
Charging and tighten the swivel nut to 15 N·m (11 ft lb).
Oiling Height Charging Height
Pressure Loosen the swivel nut again and tighten to 6-11
730E-8 / 730E-10 N·m (5-8 ft lb). Install the valve cap finger-tight.
78.6 mm 281.8 mm * 1 544 kPa 18. Install the protective guard over the charging
(3.09 in.) (11.09 in.) (224 psi) valve.
830E-5 19. If the front suspensions were serviced, remove
54.2 mm 270.1 mm * 1 186 kPa the charging support blocks from the front
(2.13 in.) (10.63 in.) (172 psi) suspensions. Floor jacks or an overhead crane
may be necessary to raise the truck if the blocks
860E-1K / 860E-1KT
have become jammed in place.
54.2 mm 270.1 mm * 1 469 kPa
20. Remove the oiling support blocks from the rear
(2.13 in.) (10.63 in.) (213 psi)
axle housing.
930E-5
54.2 mm 219.3 mm * 1 296 kPa
(2.13 in.) (8.63 in.) (188 psi)
960E-1 / 960E-1K / 960E-2 / 960E-2K / 960E-2KT
53.0 mm 218 mm 1 351 kPa
(2.1 in.) (8.60 in.) (196 psi)
980E-4 / 980E-5
47.2 mm 212.3 mm *1 455 kPa
(1.86 in.) (8.36 in.) (211 psi)
* Charging pressures are for reference only and may vary
depending upon the weight of the dump body. The charging
pressure is provided only as a starting point for obtaining the
correct charging height, which is the critical measurement for a
properly charged suspension. The pressure may be adjusted
as necessary to maintain the proper charging height.
21
CEN30098-11 30 Testing and adjusting
Suspension pressure test 4. Front suspension: Pressurize the front
suspension with air or nitrogen to 7 585 ± 1 380
The suspension assembly should be tested for
kPa (1,100 ± 200 psi).
leakage after rebuild procedures are completed. If
leakage occurs, the cause of the leakage must be Rear suspension: Pressurize the rear
identified, and repaired before the suspension is suspension with air or nitrogen to 689 ± 138 kPa
installed on the truck. (100 ± 20 psi).
5. Maintain pressure for a minimum of 20 minutes
and check for bubbles at the following locations:
• Housing bearing/housing joint
• Piston/piston seal area
The entire suspension assembly must be placed in
a containment device that will keep the • Charging valve and plugs
suspension piston in the retracted position and 6. After the test is complete, remove the assembly
prevent it from extending during pressurization. from the water tank and release the air or
Ensure the containment device is capable of nitrogen pressure. Do not remove the charging
withstanding the applied force. valve from the suspension.
1. Collapse the suspension until the piston is fully 7. Remove the suspension from the containment
retracted in the housing. device.
2. Ensure the charging valve and all plugs are 8. Coat any exposed, unpainted areas with rust
installed. Attach the pressurization line to the preventive grease.
charging valve. 9. Store the suspension in a collapsed position to
3. Place the suspension assembly in a containment protect the piston chrome surface until it is
device and submerge the entire assembly in the installed on a truck.
water tank.
22
30 Testing and adjusting CEN30098-11
NOTES
23
CEN30098-11 30 Testing and adjusting
730E Dump truck
830E Dump truck
860E Dump truck
960E Dump truck
930E Dump truck
980E Dump truck
Form No. CEN30098-11
24
CEN30102-02
DUMP TRUCK 1SHOP MANUAL
930E
980E
Machine model Serial number
930E-5 A40004 and up
930E-5AT A40004 and up
980E-5 A50052, A50053,
A50137, A50138
30 Testing and adjusting
Electrical systems
General information on system checkout.............................................................................................................. 3
Truck shutdown procedure.................................................................................................................................... 4
AC drive system.................................................................................................................................................... 5
Electrical system checkout procedures................................................................................................................. 6
Electrical checkout sheet .................................................................................................................................... 12
1
CEN30102-02 30 Testing and adjusting
NOTES
2
30 Testing and adjusting CEN30102-02
General information on system checkout
The electrical system checkout procedures are
intended to help the technician diagnose problems in
the 24V control and lighting systems. The technician
should read the checkout procedures to become DANGEROUS VOLTAGE LEVELS ARE PRESENT
familiar with the procedures and all the warnings and WHEN THE TRUCK IS RUNNING AND CONTINUE
cautions before performing any steps. The checkout TO EXIST AFTER SHUTDOWN IF THE REQUIRED
procedures begin by checking the basic system before SHUTDOWN PROCEDURES ARE NOT
checking individual components. FOLLOWED.
A data sheet is included in this section to record the Before attempting repairs or working near drive
test information obtained during the electrical system system components, the following precautions
checkout procedure. The data sheet is designed to be and truck shutdown procedure must be followed:
printed or copied, then used during the checkout
procedure. • DO NOT step on or use any power cable as a
hand hold when the engine is running.
• NEVER open any electrical control cabinet
covers or touch the retarding grid elements.
Additional drive system safety checks must be
performed by a technician trained to service
the system before working on drive system
This checkout procedure must be performed by
components.
qualified, trained personnel that have knowledge
of the operation of the truck and the stored energy • ALL removal, repairs and installation of drive
systems. Personnel must observe all established system electrical components, and cables
precautions where the checkout procedure is must be performed by an electrical
being performed. All potentially stored energy maintenance technician properly trained to
service the drive system.
within the truck must be released before
performing any troubleshooting. • IN THE EVENT OF A DRIVE SYSTEM
MALFUNCTION, a qualified technician must
inspect the truck and verify the drive system
does not have dangerous voltage levels
present before repairs are started.
• THE DC LINK VOLTAGE LIGHTS MUST NOT BE
Before starting the engine, always sound the horn ILLUMINATED WHEN TEST OR REPAIRS ARE
once prior to cranking. Block wheels of the truck INITIATED. It requires approximately five
to prevent possible roll away before performing minutes after the truck is shut down before the
this procedure DC link voltage has dissipated.
Power cables must be cleated in wood or other
non-ferrous materials. Do not repair cable cleats
by encircling the power cables with metal clamps
or hardware. Always inspect power cable
insulation prior to servicing the cables. Replace
cables that have broken insulation.
3
CEN30102-02 30 Testing and adjusting
Truck shutdown procedure 2. If all drive system warning lights are off, move the
directional control lever to PARK and turn the
Energizing the drive system is not dependent on the
engine start switch to OFF to shut down the
position of the directional control lever or actuation of
engine. Chock the tires to prevent possible roll
the accelerator pedal. If generator field contactor (GF)
away.
switch (2, Figure 30-1) is in the NORMAL (ON)
position and the engine is running, the drive system 3. After the engine has been off for at least five
link is "hot" with dangerous voltage. minutes, verify that DC link voltage lights (3) and
(4) on the front of the main control cabinet are off.
Normal operation of the drive system at shutdown
This indicates that the DC link voltage has been
should leave the system safe to operate. In the event
discharged. Only when the link voltage is
of a system failure, performing the following procedure
discharged the retard grids, wheel motors,
will ensure that hazardous voltages are not present in
alternator and power cables connecting these
the drive system.
devices are secure to work on
1. Before shutting down the engine, verify the status
4. To ensure that the DC link will not be re-
of the drive system warning lights in the cab. If
energized, move generator field contactor (GF)
any of the drive system warning lights are
switch (2, Figure 30-1) to the CUTOUT (OFF)
illuminated, do not attempt to open any cabinets,
position.
disconnect any cables, or reach inside the
retarding grid. 5. At the battery isolation station, move both the
starter disconnect switch and the main battery
disconnect switch to the OFF position.
1 2
4
86939
FIGURE 30-1. MAIN CONTROL CABINET
1. Control Power Switch 3. Primary DC Link Voltage Lights
2. Generator Field Contactor (GF) Switch 4. Secondary DC Link Voltage Lights
4
30 Testing and adjusting CEN30102-02
AC drive system Required software and tools
Several tools are required for the electrical system
checkout procedures.
• Electrical system schematic
• Service computer (1 GHz processor, 512 MB RAM
Certain drive system failures can result in a minimum) with Windows® operating system (XP or
condition where one or more capacitors can later)
remain in a charged state even though the DC link
voltage lights are off. • RS232 serial cable (one male DB9 connector, one
female connector)
Because a danger can still exist when the DC link • Ethernet cable
voltage lights are off, it is necessary to manually
• WebPTU software from GE
discharge the capacitors before touching or
servicing drive system components. Only • GE drive system electrical schematic
authorized service personnel are allowed to • GE Vehicle Test Instructions (VTI)
service the drive system.
• Megger - 0- 1500 volt (0-2000 Mega ohms)
Refer to the GE shop manual for safety rules and • Several jumper wires
procedures regarding the servicing of the drive
• Multimeter (1,000V)
system. Adhere to the proper procedures for
disabling, checking and discharging the drive Web Portable Test Unit (WebPTU)
system.
Web Portable Test Unit (WebPTU) is used to test,
download and record system parameters.
A.For complete AC Drive System Description read
through the GE Vehicle Test Instructions. (See GE VTI • To connect to WebPTU, connect a laptop to the
Procedure from the Checkout Group Procedure. DB9 port - "Diag.6" or the Ethernet port (located on
the back wall in the operator cab, labeled "GE").
Drive system control group components • The WebPTU can also be connected via the DB9
Drive System Control Group (Invertex II) contains: port, or the Ethernet port on the front side of the
Invertex II inside the control cabinet, upper section,
• Control Group door closest to the operator cab.
a. a.Integrated Control Panel II- ICP2
b. Drive System Controller DSC
c. Power Rectifier Panel
d. Rectifier Inverter and Chopper Modules
• A/C Power Alternator
• Retard Grid Assembly
• A/C Propulsion Wheel Motors
5
CEN30102-02 30 Testing and adjusting
Electrical system checkout procedures
Circuit Connection
Visual inspection
11 24VDC bus
1. Verify that all electrical connections for the power
cables and wiring harnesses are securely 12V VEC91-S7
connected except the cable connections to the
24V batteries and circuit 21PT to TB28-J1 in the 71CK TB24-N
aux box. 10V TB31-N
2. At the battery isolation station, verify that both the P710-2
starter disconnect switch and the main battery 5VIM
(Right rear brake temp sensor)
disconnect switch are in the OFF position. Also
check that the battery cables are connected 24VIM TB32-H
correctly.
18VIM TB24-W
3. Check that all fluids are at the correct levels.
Resistance checks
Ensure that DC link voltage is drained before
performing these checks.
1. Remove both of the short jumper battery cables
which connect the positive (+) and ground
between the two batteries that make up 24VDC.
2. Inside aux box, remove circuit 21PT from TB28-
J1 to prevent the engine from cranking.
3. Turn the engine start switch to OFF.
4. Ensure that all switches in the operator cab are
OFF.
5. In the auxiliary control cabinet, use a multimeter
to check the resistance from ground buss circuit 0
to the points in the following table. All points
should measure resistance values from a few
ohms to infinity. Stop and troubleshoot any direct
shorts (0 ohms) to ground. Restore all
connections when done.
6
30 Testing and adjusting CEN30102-02
Voltage checks
Circuit Connection Desc.
Engine battery 24V
11E2 TB27-B
unswitched (child1)
Ensure that DC link voltage is drained before 11E3 TB27-C
Engine battery 24V
performing these checks. unswitched (child2)
Engine battery 24V
11E4 TB27-D
unswitched (service)
Engine start switch OFF checks
1. Verify that the engine start switch is in the OFF Engine battery 24V
11E5 VEC92 - 4B
unswitched (NOX)
position.
2. Verify the GF cut off switch is in cut off position, Engine battery 24V
11E6 VEC92 - 4G
unswitched (child3)
and that the GE link is de-energized.
3. Verify that circuit 21PT is disconnected from 11ER TB22-D Customer comm radio
TB28-J1 in the aux box.
Customer fire
4. Ensure that the engine shutdown switch in the 11FS TB22-F
suppression
operator cab is in the RUN position (pushed
down) and the ground level shutdown switch is HI-beam headlight
11HL relay HBHR-88
pulled out. relay
5. To provide 24VDC, reconnect both of the short 11IM2 VEC91 - 4E Interface module
jumper battery cables which connect the positive 11INT VEC91 - 3G Interface module
(+) and ground between the two batteries.
6. Check battery voltage to ground (circuit 11) inside 11L TB22-C
the battery box. A battery charger may need to be 11LAD TB21-F Hyd. ladder power
installed if battery voltage is low.
DEF line heater
7. At the battery isolation station, turn the main 11LH CB1-1
power
battery disconnect switch ON but leave the
starter disconnect switch OFF. LO-beam headlight
11LL relay HLMR-88
low relay
8. Check battery voltage to ground (circuit 11) in the
auxiliary control cabinet on the 24VDC bus. relay HHMR- LO-beam headlight
11LR
88 high relay
9. Inside the Auxiliary Cabinet, check the following
circuits for the appropriate battery voltage to 11ORS TB28-D Engine oil reserve
ground:
11NOX VEC92 - 4D NOX sensors
a. Check circuit 11B1 (TB24-L) to ground (0) for
11RCNT TB28-L Engine oil reserve
12 vdc.
b. Check the circuits in the following table for the Engine service light
11SL TB24-A
24vdc to ground (0). power
11TP TB32-P Third party data port
Circuit Connection Desc. 39G TB34-T Payload meter power
11A TB35-A 47B relay BULR-88 Back up light relay
11DFP VEC92 - 1B DEF dosing units 80LH VEC92 - 3G Line heater power
11DISP TB23-G Electronic dash panel KOMTRAX plus II /
85 TB28-C Satellite modem
11DSL relay ALLR-88 Access ladder lights
power
Engine battery 24V
11E1 TB27-A
unswitched (parent)
7
CEN30102-02 30 Testing and adjusting
Engine start switch ON checks
Circuit Connection Voltage
1. Turn the engine start switch to ON position.
712DS2 TB24-U 24VDC
2. In the auxiliary control cabinet, check the circuits
712G TB23-Y 24VDC
in the following table for the appropriate battery
voltage to ground (0). 712H TB23-W 24VDC
712P TB35-U 24VDC
Circuit Connection Voltage 712PL TB34-V 24VDC
830E-5 and U97: 712S1 TB30-P 24VDC
P711B
5VIM 5VDC
(Hyd. tank temp 712T TB23-R 24VDC
sensor)
712TP TB32-R 24VDC
930E-5 and U98:
P710-2
5VIM 5VDC
(Right rear brake
temp sensor) GE control switch ON checks
11D TB22-A 24VDC 1. In the main control cabinet, move control power
switch (2, Figure 30-1) to the ON position.
11HH relay TSW-88 24VDC
2. Verify that the LED power indicators are
12H TB21-Z 24VDC
illuminated on the face of Invertex II control
12V VEC91-S7 12VDC panel.
18VIM TB24-W 18VDC 3. Check the circuits in the following table for the
appropriate battery voltage to ground (0).
24VIM TB32-H 24VDC
63 TB24-R 24VDC
Circuit Connection Voltage
67P TB24-T 24VDC
71GE TB24-G 24VDC
67R TB24-S 24VDC
10V TB31-N 10 - 12VDC
71BC TB25-V 24VDC
15RFWS TB33-M 15VDC
71CK TB24-N 24VDC
15LFWS TB33-S 15VDC
71CKC VEC92:3A 24VDC
15LRW TB29-A 15VDC
71CKM TB25-H 24VDC
15RRW TB29-H 15VDC
71LS TB23-M 24VDC
71P TB23-H, TB23-J 24VDC
71SS TB23-T 24VDC
71VHM TB28-B 24VDC
87 TB21-J 24VDC
712 TB24-K 24VDC
DLS-2
712A (Aux box dome light 24VDC
switch)
712DS TB24-C 24VDC
8
30 Testing and adjusting CEN30102-02
Truck function checks c. Move the headlight switch to the headlight
position (top position). Both sets of low beam
If any of the following truck functions fail to operate,
headlights should be on. Pull the multi-
shut down the truck and release all stored energy. Use
function switch lever on the steering column to
the electrical wiring diagram to troubleshoot the
the high beam position. The low beam
circuits within the associated truck function that failed
headlights should remain on and the high
to operate.
beam headlights should turn on. The high
1. Turn the engine start switch to the OFF position. beam indicator on the instrument panel should
a. Verify cab dome light functionality by turning be illuminated.
the dome light switch ON and OFF. d. Verify operation of the fog lights by turning the
b. Check the front horn for proper operation. fog light switch ON and OFF.
c. Turn the ladder light switches ON and OFF e. Actuate the window switches to verify
(inside the operator cab and at ground level operation of the operator side and passenger
near the diagonal ladder entrance). The two side windows.
platform lights, diagonal ladder light and deck f. Move the directional control lever to the
light should illuminate. REVERSE position. The backup alarms and
d. Press the hazard light switch to verify that the the backup lights should turn on. Move the
front and rear hazard lights flash. directional control lever to the NEUTRAL or
FORWARD position. The backup alarms and
e. Verify functionality of the dome lights in the backup lights should turn off.
hydraulic brake cabinet.
g. Press the manual backup light switch to verify
f. In the battery isolation station, verify that the the functionality of the rear backup lights and
indicator lights for each of the disconnect deck mounted backup lights.
switches function properly when the
disconnect switches are turned ON and OFF. h. Move the multi-function switch lever on the
steering column up and down. Verify that the
g. On both sides of the truck, turn the engine clearance lights on the decks, dump body, and
service light switches ON and OFF to verify the turn signal indicators on the instrument
functionality of the engine service lights. panel flash to indicate the proper direction.
2. Turn the key switch to the ON position, do not i. Turn the multi-function switch on the steering
start engine. column to verify operation of the windshield
a. Verify that the switch indicators for the mode wipers in the low, high, and intermittent
switches 1 and 2, manual backup switch, grid speeds.
dry (or engine warming) switch, fog light j. Press the windshield washer button on the
switch and heated mirror switch are end of the multi-function switch lever to verify
illuminated. If equipped, the rotating beacon that the washer pump runs and the wipers
switch should also be illuminated. operate momentarily.
b. Turn the headlight switch to the clearance light k. Verify that both the left side and right side
position (middle position). Verify that the front heated mirrors function when the heated
left/right clearance lights, rear tail lights, mirror switch is turned ON.
instrument panel lights, directional control
l. Verify operation of the cab radio. Check the
lever and engine shutdown switch are
functionality of both front and rear speakers.
illuminated. Verify that the instrument panel
light dimmer can adjust the back light on the m.Check the functionality of the operator seat
electronic display panel brightness. and passenger seat switches.
n. Start the engine. Verify operation of the
heating and air conditioning system by turning
the AC and heater selector switch. Check all
blower speed positions.
o. Verify functionality of the dome lights in the
auxiliary control cabinet.
9
CEN30102-02 30 Testing and adjusting
Interface module (IM) checks Payload meter (PLM) checks
1. Turn the engine start switch to the ON position. 1. Turn the engine start switch to the ON position.
2. Connect the service computer to the IM 2. Connect the service computer to the PC LAN
diagnostic port (IM DIAG) in the cab or in the ethernet diagnostic port (PC) in the cab. Verify
auxiliary control cabinet. Use WebPTU to verify that the latest software configuration has been
that the latest software configuration has been loaded into the payload meter controller. Upload
loaded into the interface module. Upload the the latest software if necessary.
latest software if necessary.
3. Complete the PLM checkout procedure. Refer to
3. Review the IM system error code report and Testing and adjusting section Payload meter IV.
resolve all reported faults.
4. Complete the IM checkout procedure. Refer to
Testing and adjusting section Interface Module
(IM).
KOMTRAX Plus II checks
1. Turn the engine start switch to the ON position.
2. Complete the KOMTRAX Plus II setup and
checkout procedures. Refer to Testing and
adjusting section KOMTRAX Plus II.
10
30 Testing and adjusting CEN30102-02
Drive system checks
Function Criteria
1. Use the Vehicle Test Instructions (VTI) in the GE
BODYDWN Body up proximity switch ON/OFF
service manual to verify functionality of the drive
system. AHT option - Auto/Man signal (RPC
AUTON
CAN)
2. Use the WebPTU software to check the following
drive system digital inputs and outputs.
3. Use the WebPTU software to check the following
Function Criteria drive system analog inputs and outputs.
KEYSW Engine start switch ON/OFF
Output for GE control power (71GE) Function Criteria
CPSFB
ON/OFF
Power Supply Operating value verified
Parking brake applied pressure switch
PKBP Operating range verified and
ON/OFF Retard Pedal
calibrated
BRAKON Service brake applied pressure switch
Operating range verified and
Accelerator Pedal
WHEELOCK Brake lock switch ON/OFF calibrated
BRAKTSREQ Pre-shift brake test switch ON/OFF 10V
Potentiometer Operating value verified
Traction motor pressure switch Reference
AXLEP
ON/OFF
Control cabinet blower pressure Engine delayed shutdown Smart Timer check
CNTRLP
switch (RPM 950- 1150) NOTE: This must be performed after the IM, hydraulic,
SPINDIS Slip-Slide feature disabled and brake checkout procedures have been completed.
FORREQ Directional control lever - REVERSE 1. Install a multimeter to monitor the voltage on
circuit 21NSL (TB27-E) to ground.
REVREQ Directional control lever - FORWARD
2. Start the engine and operate at approximately
Body up override / rest reset switch 1700 rpm. After the engine coolant temperature
REST-DO
ON/OFF rises to 82 °C (180 °F), circuit 21NSL voltage will
rise from 0 to 24VDC.
DATST Data store switch ON/OFF
3. Lower the engine speed to low idle for
Control cabinet DC field cut switch
GFNCO approximately one minute, then turn the engine
ON/OFF
start switch to the OFF position. The engine
PROPLO Propel lockout switches ON/OFF should continue to operate at low idle for
approximately three minutes or less and then
Optional hydraulic access ladder shut down.
OEMACCIN
down limit switch
Engine starter request engine start Body hoist limit switch check
ENGSTRREQ
switch START 1. Place a piece of metal in front of the body up
Engine secondary shutdown cab & switch located at the rear of the truck.
ENGKILL
ground ON/OFF 2. Turn the engine start switch ON.
ENGWARN Engine warning signal (J1939 CAN) 3. In the hydraulic brake cabinet, measure the
WARMUP Grid dry/engine warm switch ON/OFF
voltage at the hoist limit solenoid (circuit 53H) to
ground. There should be battery voltage at the
FULPAYLD Full payload signal (RPC CAN) hoist limit solenoid. Remove the piece of metal
from the body up switch. There should be 0V
OVERPAYLD Overload payload signal (RPC CAN)
when the piece of metal is removed.
11
CEN30102-02 30 Testing and adjusting
Electrical checkout sheet
ELECTRICAL CHECKOUT SHEET
Result
Function Description Criteria
(OK/Fail)
Cab Dome Light Cab dome light functions
Forward Horn Vehicle horn functions
Ladder Lights All ladder and deck lights function
Hazard Lights Hazard lights operate
Hydraulic Brake Cabinet Dome Lights Hyd brake cabinet dome light functions
Isolation Station Engine Service Lights All indicator lights operate correctly with
corresponding disconnect switch
Rear Axle Service Light Service light in axle box operates
Operator Switch Indicators All dash switch indicator lights function correctly
Clearance Lights Deck and axle clearance light function
Headlights LO and HI-Beam headlights operate
Fog Lights If equipped - fog lights operate
Cab Side Windows Driver and passenger windows operate up &
down
Backup Horn and Lights Backup lights and horn work in reverse
Manual Backup Lights Backup lights function with manual backup
switch
Turn Signal Lights Dash indicators, front and rear turn signal
operate left and right
Service Brake Lights Brake light operate with service brake
Windshield Wipers Wipers operate in low and high speed
Windshield Washer Pump Washer pump operates
Heated Mirrors Heated mirrors operate
Cab Radio Radio operates
12
30 Testing and adjusting CEN30102-02
ELECTRICAL CHECKOUT SHEET
Result
Function Description Criteria
(OK/Fail)
Cab Seats Driver and Passenger air seats operate
HVAC System HVAC System operates
Auxiliary Control Cabinet Dome Lights Aux Box Dome lights function
Body Hoist Limit Body hoist limit function
Control Power Relay GE I/O -Output for GE Control Power (71GE)
ON/OFF
Park Brake Input GE I/O -Park Brake Applied Pressure Switch
ON/OFF
Service Brakes ON GE I/O -Service Brake Applied Pressure Switch
Wheel Brake Lock SW GE I/O -Brake Lock Switch Dash ON/OFF
(RPC CAN)
PreShift Brake Test GE I/O -Pre-Shift Park Brake Test Switch
ON/OFF
Axle Blower PSI SW GE I/O -Traction Motor Pressure Switch ON/
OFF
Control Cabinet PSI SW GE Control Cabinet Blower Pressure Switch
(RPM 950- 1150)
Slip Slide Dis GE I/O -Slip Slide Feature Disabled
Forward Direction GE I/O -Directional Shift Selector - Forward
Position
Reverse Direction GE I/O -Directional Shift Selector - Reverse
Position
Body up Reset GE I/O -Body up Override / Rest Reset Switch
ON/OFF
Data Store GE I/O -Data Store Switch ON/OFF
Generator Field Coil SW GE I/O -Control Cabinet DC Field Cut Switch
Propel Lockout GE I/O -Iso Box & GE Cabinet Propel Lockout
Switch ON/OFF
13
CEN30102-02 30 Testing and adjusting
ELECTRICAL CHECKOUT SHEET
Result
Function Description Criteria
(OK/Fail)
OEM Accel Inhibit GE I/O -Optional Hyd Access Ladder Down
Limit Switch
Eng Start Request GE I/O -Engine Starter Request Key Switch
Start
Engine Kill SW GE I/O -Engine Secondary Shutdown Cab &
Ground ON/OFF
Engine Warning GE I/O -Engine Warning Signal (J1939 CAN)
Engine Warming SW GE I/O -Grid Dry / Engine Warm Switch ON/
OFF
Full PayLoad GE I/O -Full Payload Signal (RPC CAN)
Over Load GE I/O -Over Load Payload Signal (RPC CAN)
Body Down SW GE I/O -Body-up Proximity Switch ON/OFF
Autonomous Mode GE I/O -AHT Option - Auto / MAN Signal (RPC
CAN)
Retard Pedal GE I/O – Signal From Retarder Pedal
Accel Pedal GE I/O – Signal from Accelerator Pedal
10V Pot Reference GE I/O - Conditioned Potentiometer Voltage for
GE +15v out
Autonomous Mode GE I/O – AHT Option – Auto/ MAN Signal (RPC
CAN)
Speed Control GE I/O – Speed Control Switch Inputs
Truck S/N: _____________________
Completed By: ______________________________________________
Date: _____________________
14
30 Testing and adjusting CEN30102-02
NOTES
15
CEN30102-02 30 Testing and adjusting
930E Dump truck
980E Dump truck
Form No. CEN30102-02
16
CEN30125-00
DUMP TRUCK 1SHOP MANUAL
730E
830E
930E
980E
Machine model Serial number
730E-10 A50002 and up
830E-5 A50005 and up
830E-5AT A50005 and up
930E-5 A40004 and up
930E-5AT A40004 and up
980E-5 A50137, A50138
30 Testing and adjusting
Interface module 2 (IM2)
Required tools....................................................................................................................................................... 3
Programming the IM2 ........................................................................................................................................... 3
Interface module checkout procedures................................................................................................................. 5
IM checkout sheet............................................................................................................................................... 10
1
CEN30125-00 30 Testing and adjusting
NOTES
2
30 Testing and adjusting CEN30125-00
Required tools Programming the IM2
Several tools are required for interface module 2 (IM2) Updating the software
checkout procedures.
Before the interface module can be used, the latest
• Electrical system schematic application code must be downloaded to the service
• Service computer (1 GHz processor, 512 MB RAM computer then installed on the IM.
minimum) with Windows® operating system (XP or NOTE: The interface module must be powered up to
later)
communicate with the service computer.
• M12 to RJ45 CAT5e ethernet cable
1. Turn the engine start switch to the ON position
• WebPTU software from Wabtec but do not start the engine.
• Latest application code 2. Connect an ethernet cable from the service
• 3/8 in. nut driver computer to ETH1 port (4, Figure 30-1) on the
IM2. The service computer will automatically
• Voltmeter receive an IP address assignment from the IM2.
• Jumper wire 77 mm (3 in.) or longer
3. Open a web browser on the service computer.
• Resistor (300 to 332 ohm)
4. Enter the IP address of the IM2 into the address
• Connector back probes bar.
• Small flat head screwdriver (to push the release IM2 IP address: 192.168.3.120
buttons when removing a wire from a terminal
board)
1 4 5
2 3 88956
FIGURE 30-1. INTERFACE MODULE 2 (IM2)
CONNECTIONS
1. IM1 Connector 4. ETH1 Port
2. IM2 Connector 5. ETH2 Port
3. IM3 Connector 6. USB1 Port
3
CEN30125-00 30 Testing and adjusting
5. Select Software Update in the left side Configuring the IM2
navigation pane, then enter the login credentials.
After the latest application code has been installed, the
Username: komatsu IM must be configured for the correct truck model and
options.
Password: kac2300
1. Select Configuration in the left side navigation
6. Browse to the location of the latest application
pane, then enter the login credentials.
code on the service computer (*.im2).
Username: komatsu
7. Click on Upload to begin the programming. The
process should take approximately four minutes. Password: kac2300
8. When the process is complete, click on Reboot 2. In the drop-down menu, select the appropriate
to restart the IM2 and activate the new software. truck model and installed options.
3. Click on Save, then restart the IM2 to finalize the
configuration.
88957
FIGURE 30-2. INTERFACE MODULE 2 (IM2) WEB PAGE
4
30 Testing and adjusting CEN30125-00
Interface module checkout procedures Checking digital inputs to the IM
Checking for IM fault codes Use the Real-Time Data web page to confirm the
functionality of all IM inputs. The engine start switch
NOTE: The interface module must be powered up to must be ON for all checks.
communicate with the service computer.
1. Hydraulic Tank Level (IM1-13) - Disconnect
1. Turn the engine start switch to the ON position connector P712 at hydraulic tank level sensor.
but do not start the engine. Short pin C to ground momentarily and confirm
2. Connect an ethernet cable from the service state change (1 to 0). Reconnect P712.
computer to ETH1 port (4, Figure 30-1) on the 2. Low Steering Precharge (IM2-1) - This step
IM2. The service computer will automatically requires properly precharged steering
receive an IP address assignment from the IM2. accumulators. Disconnect one of the low
3. Open a web browser on the service computer. accumulator precharge switches momentarily
and confirm state change (0 to 1). Reconnect
4. Enter the IP address of the IM2 into the address switch.
bar.
3. Pump Filter Switches (IM3-44) - Disconnect
IM2 IP address: 192.168.3.120 connector SFSW at steering filter pressure switch
By default, the IM2 website will open to the Real- momentarily and confirm state change (0 to 1).
Time Data web page. Reconnect SFSW.
5. Confirm that there are no fault codes associated 4. Park Brake Released (IM1-39) - Short wire 73S
with the interface module. If any faults are found, to ground at TB33-C momentarily and confirm
these circuits must be analyzed to determine the state change (1 to 0).
cause of the fault. Repair the circuits or, if 5. Park Brake Request (IM2-35) - Short engine oil
required, replace the interface module. pressure switch wire circuit 36 on TB28-A to
ground. Move lever from NEUTRAL to PARK and
confirm state change (1 to 0). Remove ground
from TB28-A.
6. GE Batt + (IM2-36) - Confirm that state is 1.
7. Starter Motor 1 Energized (IM2-14) -
Disconnect wire 11SM1 from cranking motor to
TB28-F at TB28-F. Momentarily short TB28-F to
24V and confirm state change (0 to 1).
Reconnect wire.
8. Starter Motor 2 Energized (IM2-25) -
Disconnect wire 11SM2 from cranking motor to
TB28-G at TB28-G. Momentarily short TB28-G to
24V and confirm state change (0 to 1).
Reconnect wire.
9. Crank Sense (IM3-41) - Open starter disconnect
switch so that there is no battery voltage to the
starters. Momentarily short TB28-J to 24V and
confirm state change (0 to 1). After removing 24V
short from TB28-J, close starter disconnect
switch.
5
CEN30125-00 30 Testing and adjusting
10. Selector Switch [Park] (IM3-42) - Move lever to 19. Mode Switch 1 (IM1-3) - Actuate "left arrow"
PARK and confirm state (1), then move lever to LCD screen navigation switch and confirm state
NEUTRAL and confirm state (0). Return lever to change (1 to 0).
PARK.
20. Mode Switch 2 (IM1-14) - Actuate "OK" LCD
11. Selector Switch [FNR] (IM2-17) - Move lever to screen navigation switch and confirm state
PARK and confirm state (0), then move lever to change (1 to 0).
NEUTRAL, FORWARD and REVERSE. Confirm
21. Mode Switch 3 (IM1-4) - Actuate "down arrow”
state (1) for each position. Return lever to PARK.
LCD screen navigation switch and confirm state
12. Steering Bleed Pressure Switch (IM1-15) - change (1 to 0).
Disconnect connector BLDPS at the steering
22. Mode Switch 4 (IM1-16) - Actuate "up arrow”
bleed pressure switch and confirm state change
LCD screen navigation switch and confirm state
(0 to 1). Reconnect BLDPS.
change (1 to 0).
13. Brake Lock Switch Power Supply (IM2-15) -
23. Crank Request (IM2-6) - Open starter
Ensure that lever is in PARK. Use WebPTU
disconnect switch so that there is no battery
software to turn on FWD True output signal.
voltage to the starters. Momentarily turn key
Confirm state change (0 to 1).
switch to the START position and confirm state
14. Brake Lock (IM2-7) - Actuate brake lock switch change (0 to 1).
and confirm state change (0 to 1). Turn off FWD
24. Park Brake Set (IM2-31) - Momentarily
True signal. Confirm input state remains at 1.
disconnect park brake pressure switch (identified
Turn off brake lock switch. Confirm input state
by circuit 33) and confirm state change (0 to 1).
returns to 0.
25. Seat Belt Switch (IM3-43) - Buckle seat belt,
NOTE: The Brake Lock Switch Power Supply test then unbuckle seat belt and confirm state change
(item 13) must be completed before this test can (0 to 1).
be successfully completed.
26. Snapshot In-Progress (IM1-2) - Actuate data
15. Service Brake Set Switch (IM2-44) - Short wire store switch. Confirm state change (1 to 0).
44R at TB35-F to 24 volts momentarily and
confirm state change (0 to 1). 27. Low Steering Pressure Switch 1 (IM2-21) - Use
back probe to short wire 33F to ground at
16. Engine Shutdown Delay (IM2-26) - Disconnect connector J14, pin 6 momentarily and confirm
wire 21NSL-001 from engine ECM at TB27-E1. state change (1 to 0). Remove back probe.
Leave wire 21NSL-003 to the IM connected at
TB27-E2. Momentarily short TB27-E to 24V and 28. Brake Accumulator Pressure Switch (IM1-6) -
confirm state change (0 to 1). Reconnect wire. Short wire 33BP to ground at TB32-E
momentarily and confirm state change (1 to 0).
17. Engine Secondary Shutdown Switch (IM2-45)
- Actuate engine secondary shutdown switch and 29. Brake Lock Degradation Switch (IM1-17) -
confirm state change (1 to 0). Short wire 33T to ground at TB32-F momentarily
and confirm state change (1 to 0).
18. Key Switch (IM1-28) - Confirm that state is 1.
30. Key Switch Direct (IM2-16) - Confirm that state
is 1. Turn key switch OFF for one second, then
back ON. Confirm state changes to 0, then back
to 1.
6
30 Testing and adjusting CEN30125-00
31. Auto Lube Level (IM2-42) - Disconnect NOTE: Item 38 applies only to 830E-5 trucks equipped
connector J511 at auto lube low level switch. with wet disc brakes.
Short pin C to ground momentarily and confirm
38. Hoist Cylinder Base Pressure Switch (IM2-32)
state change (1 to 0). Reconnect connector J511.
- Note the state of IM1-7. If the hoist pressure is
32. Auto Lube Pressure Switch (IM2-33) - Short less than 500 psi, the state should be 1.
wire 68 to ground at TB35-W momentarily and
Start the engine. Raise the dump body by
confirm state change (1 to 0).
pressing the hoist switch (dump body not
33. Body Up Switch (IM2-5) - If dump body is not required). The state of IM1-7 should change to 0.
installed, place a washer on body proximity
sensor, confirm state change, then remove Lower the dump body by pressing the hoist
washer and confirm state change again. switch or reduce hoist pressure below 500 psi.
Confirm that the state changes back to 1. Turn
If dump body is installed, ensure that dump body the engine off.
is lowered all the way to the frame. Disconnect
wire 71F at TB35-S1 and confirm state change (1
to 0). Reconnect wire 71F. NOTE: Items 39 and 40 apply only to trucks equipped
34. Dynamic Retard (IM2-24) - Momentarily short with the autonomous haulage system (AHS).
wire 74ZA to ground at TB21-D and confirm state 39. Auto/Manual Mode Switch (IM2-43, IM1-38) -
change (1 to 0). Turn the auto/manual mode switch to MANUAL.
35. No Propel/Retard (CPU Running) (IM1-11) - Confirm that the MANUAL state is 0 and the
Confirm that state is 0. In control cabinet low AUTO state is 1.
voltage area, turn control power switch OFF and Turn the auto/manual mode switch to AUTO.
confirm that state changes to 1. Turn control Confirm that the AUTO state is 0 and the
power switch back ON and confirm that state MANUAL state is 1.
changes to 0 once VID panel is booted back up
(may take up to 45 seconds). Wait 30 seconds, then switch back to MANUAL
Confirm that the MANUAL state is 0 and the
36. Engine Air Filter (IM2-3) - Disconnect air AUTO state is 1. Make sure that no fault codes
restriction switch 2 (located on top of engine air have been created.
intake pipe) and confirm state change (0 to 1).
Reconnect switch. 40. Manual Mode Auto Apply Pressure switch
(IM2-11) - Turn the auto/manual mode switch to
37. Shifter Fault (IM1-35) - Disconnect wire 72IM MANUAL. Disconnect the wire from TB51-E and
from TB22-G and confirm state change (0 to 1). confirm state change (0 to 1). Fault A335 should
Reconnect wire 72IM. appear. Reconnect the wire and confirm state
change (1 to 0).
7
CEN30125-00 30 Testing and adjusting
Checking analog inputs to the IM NOTE: Items 9 and 10 apply only to 930E-5 trucks and
830E-5 trucks equipped with wet disc brakes.
Use the Real-Time Data web page to confirm that the
analog inputs are in the correct range of values. The 9. Right Front Brake Oil Temp [°C] (IM3-24) -
engine start switch must be ON for all checks. Disconnect right front brake oil temperature
1. Steering Pressure [kPa] (IM3-11) - Disconnect sensor and confirm fault A169, Hydraulic Oil
steering pressure sensor (identified by circuit Temp - Right Front Sensor Low, is active.
33SP) and confirm that fault A204, Steering Reconnect sensor.
Pressure Sensor Low, is active. Reconnect 10. Left Front Brake Oil Temp [°C] (IM3-25) -
sensor. Disconnect left front brake oil temperature sensor
and confirm fault A168, Hydraulic Oil Temp - Left
2. Ambient Air Temp [°C] (IM3-23) - Confirm that
Front Sensor Low, is active. Reconnect sensor.
reported temperature matches ambient
temperature within 3 °C.
3. Fuel Level [%] (IM3-26) - Confirm that reported NOTE: Item 11 applies only to 830E-5 and 930E-5
level matches actual fuel level in tank +/- 5%. trucks.
4. 12V Converter [V] (IM3-31) - Confirm reported 11. Hoist Pressure 2 [kPa] (IM3-21) - Use back
voltage is 13.5V +/- 0.5V. (24V battery voltage probe to short wire 33HP2 to ground at J16, pin 6
must be greater than 18 volts.) momentarily. Confirm fault A203, Hoist Pressure
2 Sensor Low, is active.
5. Brake Pressure [kPa] (IM3-12) - Disconnect
service brake pressure sensor located in brake
cabinet (identified by circuit 33BPS) and confirm 12. Hoist Pressure 1 [kPa] (IM3-22) - Use back
that fault A205, Brake Pressure Sensor Low, is probe to short wire 33HP1 to ground at J16, pin
active. Reconnect sensor. 32 momentarily. Confirm fault A202, Hoist
Pressure 1 Sensor Low, is active.
NOTE: Item 6 applies only to 730E-10 and 830E-5 13. Battery Voltage 24V [V] (IM--49, 50) - Confirm
trucks. that the reported voltage is +/- 1 volt of actual
measured battery voltage.
6. Hydraulic Oil Temp [°C] (IM3-27) - Disconnect
hydraulic tank oil temperature sensor and confirm
fault A103, Hydraulic Oil Temp - Tank Sensor
Low, is active. Reconnect sensor.
Checking serial communication to the IM
NOTE: Items 7 and 8 apply only to 930E-5 trucks. Proper operation of the serial communication
interfaces to the interface module is assured if faults
7. Right Rear Brake Oil Temp [°C] (IM3-27) - A184, A233, A237 and A257 are not active.
Disconnect right rear brake oil temperature
sensor and confirm fault A167, Hydraulic Oil
Temp - Right Rear Sensor Low, is active.
Reconnect sensor.
8. Left Rear Brake Oil Temp [°C] (IM3-28) -
Disconnect left rear brake oil temperature sensor
and confirm fault A166, Hydraulic Oil Temp - Left
Rear Sensor Low, is active. Reconnect sensor.
8
30 Testing and adjusting CEN30125-00
Checking outputs from the IM 5. Steering Bleeddown Solenoid (IM1-18) -
Confirm that the steering bleeddown solenoid is
NOTE: Before performing the next steps, the engine
de-energized. Turn key switch OFF and confirm
start switch must be turned off for at least seven
that the steering bleeddown solenoid is
minutes to allow the IM to completely shutdown. While
energized by verifying that the coil is magnetized.
performing the following IM output checks, ensure that
no output short circuit fault codes are reported by the 6. Auto Lube Solenoid (IM1-5) - Remove wire 68-
Realtime Data web page. 006 from TB35-R2. Use the dash panel to select
1. Park Brake Solenoid (IM1-20), Brake Auto manual lube. Confirm that circuit 68 on TB35 is 0
Apply (IM1-30) - Short engine oil pressure switch volts. Reconnect wire 68-006.
wire circuit 36 to ground on TB28-A. Turn key
switch ON and move lever to NEUTRAL. Confirm
that park brake solenoid is energized by verifying NOTE: Item 7 applies only to 830E-5 trucks equipped
that coil is magnetized. with wet disc brakes. This check will require two
persons.
Use VID panel to set truck speed above 1 kph.
Move lever to PARK. Confirm that park brake 7. Brake Cooling Manifold Solenoid Valve
solenoid remains energized. (IM2-46) - Start the engine. The body must be in
the down position. If the truck does not have a
Reduce truck speed to 0 kph. Confirm that park dump body installed, make sure that pressure in
brake solenoid de-energizes. Remove ground the hoist circuit is less than 500 psi.
from TB28-A.
Apply the service brakes. Have another person
2. Start Enable (IM2-50) - Disconnect wire 21PS- locate the brake cooling manifold solenoid
006 from TB28-H1. Move lever to PARK and (CMSOL) in the brake cabinet. The coil should be
confirm that circuit 21PS on TB28-H is 24 volts magnetized.
while cranking. Move lever to NEUTRAL and
confirm that circuit 21PS on TB28-H is 0 volts Release the service brakes. After several
while cranking. Reconnect wire 21PS-006. seconds, the solenoid should de-energize. Turn
off the engine.
3. IM On Signal (IM2-30) - Turn key switch ON and
confirm voltage on circuit 110NS at TB35-T is
approximately 0 volts.
4. Red Warn (IM1-40), Sonalert (IM2-19) -
Disconnect the IM from the CAN/RPC network by
unplugging its T-connection to the network.
Confirm the following on the dash panel:
a. All status panel indicators flash on/off.
b. The red warning indicator flashes on/off.
c. Two separate audible alarms can be heard
sounding on/off.
d. A loss of communications message is
displayed on the speedometer.
e. The needles in all of the gauges are moving
through their entire range of motion.
Reconnect the IM to the CAN/RPC network.
9
CEN30125-00 30 Testing and adjusting
IM checkout sheet
TABLE 1. INTERFACE MODULE (IM) CHECKOUT SHEET
Expected Result
Function Description Comments
Result (OK/Fail)
DIGITAL INPUT CHECKS
1 - Hydraulic Tank Level 1 to 0
2 - Low Steering Precharge 0 to 1
3 - Pump Filter Switches 1 to 0
4 - Park Brake Released 1 to 0
5 - Park Brake Request 1 to 0
6 - GE Batt + 1
7 - Starter Motor 1 Energized 0 to 1
8 - Starter Motor 2 Energized 0 to 1
9 - Crank Sense 0 to 1
10 - Selector Switch [PARK] 1 to 0
11 - Selector Switch [FNR] PARK=0
F/N/R=1
12 - Steering Bleed Pressure 0 to 1
13 - Brake Lock Switch Power 0 to 1
Supply
14 - Brake Lock 0 to 1
15 - Service Brake Set 0 to 1
16 - Engine Shutdown Delay 0 to 1
17 - Engine Secondary Shutdown 1 to 0
18 - Keyswitch 1
19 - Mode Switch 1 1 to 0
20 - Mode Switch 2 1 to 0
21 - Mode Switch 3 1 to 0
22 - Mode Switch 4 1 to 0
23 - Crank Request 0 to 1
24 - Park Brake Set 0 to 1
25 - Seat Belt Switch 0 to 1
10
30 Testing and adjusting CEN30125-00
TABLE 1. (Continued)INTERFACE MODULE (IM) CHECKOUT SHEET
Expected Result
Function Description Comments
Result (OK/Fail)
26 - Snapshot In-Progress 1 to 0
27 - Low Steering Pressure Switch 1 to 0
28 - Brake Accum Pressure Switch 1 to 0
29 - Brake Lock Degradation Switch 1 to 0
30 - Keyswitch Direct 1 to 0 to 1
31 - Auto Lube Level Switch 1 to 0
32 - Auto Lube Pressure Switch 1 to 0
33 - Body Up Switch without body =
0 to 1 to 0
with body =
1 to 0
34 - Dynamic Retard 1 to 0
35 - No Propel/Retard 0 to 1 to 0
(GE CPU Running)
36 - Engine Air Filter 0 to 1
37 - Shifter Fault 0 to 1
38 - Hoist Cylinder Base Pressure 1 to 0
Switch [if applicable]
ANALOG INPUT CHECKS
1 - Steering Pressure fault A204
2 - Ambient Air Temp ambient temp
+/- 3°C
3 - Fuel Level tank level
+/- 5%
4 - Converter Voltage (12V) 13.5 +/- 0.5V
5 - Brake Pressure fault A205
6 - Hydraulic Tank Oil Temp fault A103
[if applicable]
7 - Right Rear Brake Oil Temp fault A167
[if applicable]
8 - Left Rear Brake Oil Temp fault A166
[if applicable]
11
CEN30125-00 30 Testing and adjusting
TABLE 1. (Continued)INTERFACE MODULE (IM) CHECKOUT SHEET
Expected Result
Function Description Comments
Result (OK/Fail)
9 - Right Front Brake Oil Temp fault A169
[if applicable]
10 - Left Front Brake Oil Temp fault A168
[if applicable]
11 - Hoist Pressure 2 fault A203
[if applicable]
12 - Hoist Pressure 1 fault A202
13 - Battery Voltage 24V measured
battery voltage
+/- 1V
SERIAL COMMUNICATION INTERFACE CHECKS
CAN/J1939 no faults
Drive System CAN/RPC A184, A233,
Display CAN/RPC A237, A257
Payload CAN/RPC
OUTPUT CHECKS
1 - Park Brake Solenoid energized/
de-energized
2 - Start Enable 24 V, 0 V
3 - IM On Signal 0V
4 - Dash Panel/Sonalarm items function
as described
5 - Steering Bleeddown Solenoid de-energized/
energized
6 - Auto Lube Solenoid de-energized/
energized
7 - Brake Cooling Manifold Solenoid de-energized/
Valve [if applicable] energized
IM Software Version: _____________________ Date: _____________________
Completed By: _________________________________________________________
12
30 Testing and adjusting CEN30125-00
NOTES
13
CEN30125-00 30 Testing and adjusting
730E Dump truck
830E Dump truck
930E Dump truck
980E Dump truck
Form No. CEN30125-00
14
CEN30091-01
DUMP TRUCK 1SHOP MANUAL
730E 930E
830E 960E
860E 980E
Machine model Serial number Machine model Serial number
730E-10 A50005 and up 930E-5 A40004 and up
830E-5 A50005 and up 930E-5AT A40004 and up
830E-5AT A50005 and up 960E-1 A30001, A30003 -
860E-1K A30031 - A30035, A30026
A30041, A30042, 960E-1K A30002, A50003 -
A30044 - A30046, A50010
A30101, A30107 - 960E-2 A30027 and up
A30110, A30117, 960E-2K A50011 and up
A30118 960E-2KT A50028 and up
860E-1KT A30004 - A30030, 980E-5 A50005 - A50138
A30036 - A30040, 980E-5AT A50005 - A50138
A30043, A30047 -
A30100, A30102 -
A30106, A30111 -
A30116
30 Testing and adjusting
KOMTRAX Plus II
Required software and tools ................................................................................................................................. 3
Ethernet connection to KOMTRAX Plus II controller ............................................................................................ 3
KOMTRAX Plus II configuration............................................................................................................................ 5
GPS connection test ............................................................................................................................................. 7
Iridium satellite system opening............................................................................................................................ 9
Data download over ethernet connection for KOMTRAX Plus II initialization ..................................................... 12
1
CEN30091-01 30 Testing and adjusting
NOTES
2
30 Testing and adjusting CEN30091-01
Required software and tools Ethernet connection to KOMTRAX Plus II
Several software programs and tools are required for
controller
KOMTRAX Plus II setup procedures. The following procedure must be completed each time
the KOMTRAX Plus PC Tool software is used to setup,
• Service computer (1 GHz processor, 512 MB RAM
administrate, or download a KOMTRAX Plus II
minimum) with Windows® operating system (XP or
controller.
later)
• Ethernet cable 1. Open the Network and Sharing center, disable
windows firewall or have add a permanent
• KOMTRAX Plus PC Tool software exception for all KOMTRAX Plus II PC Tool
• If Windows® XP or Vista is being used, .Net software.
Framework software must also be installed in 2. Disconnect the service computer from all other
order to use KOMTRAX Plus PC Tool software. network connections including Wi-Fi.
3. Turn the engine start switch to ON. Wait
NOTE: Be aware that the software and data files are approximately three minutes for the KOMTRAX
updated periodically. Check with the local Komatsu Plus II controller to boot.
distributor for the latest software versions. 4. Connect one end of the ethernet cable to the
service computer and the other to the PC
Ethernet port located on the back wall of the cab.
If the truck is equipped with the Komatsu Wireless KOMTRAX Plus II uses DHCP so the service
Bridge (KWB) for wireless connectivity rather than the computer is automatically assigned an IP
Iridium satellite system, refer to Testing and adjusting address.
section Komatsu Wireless Bridge (KWB). Prior steps
are a prerequisite to wireless setup.
86947
FIGURE 30-1. NETWORK AND SHARING CENTER
3
CEN30091-01 30 Testing and adjusting
5. Optional: Open a command prompt to ping
192.168.3.20. A successful ping verifies that the
service computer can communicate with the
KOMTRAX Plus II controller. Continue with the
setup or administration. If the ping is
unsuccessful, troubleshoot the ethernet
connection.
86948
FIGURE 30-2. COMMAND PROMPT
4
30 Testing and adjusting CEN30091-01
KOMTRAX Plus II configuration 4. Click KOMTRAX Plus Configuration on the
Destination Configuration menu.
The following procedure must be completed when the
truck is checked out at the mine site. The purpose is to
populate site specific information.
1. Turn the engine start switch to ON. Wait
approximately three minutes for the KOMTRAX
Plus II controller to boot.
2. Open the KOMTRAX Plus Initial Configuration
Tool.
3. Click Destination Configuration on the main
menu.
86950
FIGURE 30-4. DESTINATION CONFIGURATION
MENU
5. After clicking KOMTRAX Plus Configuration, a
dialog box will open as the tool searches for
KOMTRAX Plus II controllers on the local area
network.
86949
FIGURE 30-3. MAIN MENU
86951
FIGURE 30-5. SCANNING KOMTRAX PLUS
CONTROLLERS DIALOG BOX
5
CEN30091-01 30 Testing and adjusting
6. When the scan is complete, the available 8. Select the Unit Number tab and enter the truck’s
controllers will be shown. Double click the target unit number. (This is the customer assigned
controller. The KOMTRAX Plus configuration designation for the truck.)
page will open. If no controller is found, refer to
the topic "Ethernet connection to KOMTRAX Plus
II controller".
86954
FIGURE 30-8. UNIT NUMBER TAB
86952
FIGURE 30-6. DISCOVERED KOMTRAX PLUS
CONTROLLERS WINDOW
9. Click Apply. A status window will be displayed.
Changes will take approximately three minutes.
7. Select the Calendar tab.
10. Click Next to review the changes
a. Set the time zone.
b. Select the Daylight Saving Time check box if
currently being observed.
86955
FIGURE 30-9. KOMTRAX PLUS CONFIGURATION
STATUS WINDOW
86953
FIGURE 30-7. CALENDAR TAB
6
30 Testing and adjusting CEN30091-01
11. Click Back to complete mine site portion of the GPS connection test
initial configuration.
The following procedure must be completed outside
with an unobstructed view of the sky. The purpose is to
verify that the GPS system is functioning properly.
1. Park the truck away from buildings and any
objects that obstruct a clear view of the sky. Turn
the engine start switch to ON. Wait approximately
five minutes for the KOMTRAX Plus II system to
acquire signals from the GPS satellites.
2. Establish an ethernet connection between the
service computer and the KOMTRAX Plus II
controller.
3. Open the KOMTRAX Plus Initial Configuration
Tool.
4. Click Destination Configuration on the main
menu.
86956
FIGURE 30-10. CONFIGURATION WINDOW
86949
FIGURE 30-11. MAIN MENU
7
CEN30091-01 30 Testing and adjusting
5. Click GPS Test on the Destination Configuration 7. Double click the target controller. The GPS test
menu. screen will open. If no controller is found, refer to
the topic "Ethernet connection to KOMTRAX Plus
II controller".
88889
86952
FIGURE 30-12. DESTINATION CONFIGURATION
MENU FIGURE 30-14. DISCOVERED KOMTRAX PLUS
CONTROLLERS WINDOW
8. The window below is an example of successfully
receiving a GPS signal.
6. After clicking GPS Test, a dialog box will open as
the tool searches for KOMTRAX Plus II
controllers on the local area network. When
complete, the available controllers will be shown.
86951
FIGURE 30-13. SCANNING KOMTRAX PLUS
CONTROLLERS DIALOG BOX
86957
FIGURE 30-15. GPS INFORMATION WINDOW -
SUCCESSFUL
8
30 Testing and adjusting CEN30091-01
The window below is an example of a failed Iridium satellite system opening
attempt at receiving a GPS signal.
The following procedure must be completed outside
In the event of a failure, click Back, check the with an unobstructed view of the sky. The purpose is to
connections and the antenna, then retest. If verify that the Iridium system is functioning properly
successful, click Back to complete the test. and to establish communication.
NOTE: Do not perform this procedure if the truck is not
equipped with the Iridium satellite system.
1. Verify that an Iridium modem is installed.
2. Park the truck away from buildings and any
objects that obstruct a clear view of the sky. Turn
the engine start switch to ON. Wait approximately
five minutes for the KOMTRAX Plus II system to
acquire signals from the GPS satellites and the
Iridium satellites.
3. Establish an ethernet connection between the
service computer and the KOMTRAX Plus II
controller.
4. Open the KOMTRAX Plus Initial Configuration
Tool.
5. Click Destination Configuration on the main
menu.
86958
FIGURE 30-16. GPS INFORMATION WINDOW -
FAILED
86949
FIGURE 30-17. MAIN MENU
9
CEN30091-01 30 Testing and adjusting
6. Click KOMTRAX Configuration on the 8. A status window will appear. It may take 5 to 10
Destination Configuration menu. minutes to complete. Any failure must be
investigated and corrected before proceeding to
the next step.
86950
FIGURE 30-18. DESTINATION CONFIGURATION
MENU 86960
FIGURE 30-20. OPENING INSPECTION STATUS
WINDOW
7. Select the Opening tab. Verify that the with
KOMTRAX Modem radio button is selected, then 10. Click OK. Return to the Opening tab. Click Start
click Start for the opening inspection procedure. for the opening procedure.
86959 86961
FIGURE 30-19. OPENING TAB FIGURE 30-21. OPENING TAB
10
30 Testing and adjusting CEN30091-01
11. The Datum and Time Zone menu will appear. 12. A status window will appear. Click OK to
Make changes if needed, then click Start. complete the Iridium satellite system setup.
86962 86963
FIGURE 30-22. DATUM AND TIME ZONE MENU FIGURE 30-23. KOMTRAX OPENING STATUS
WINDOW
11
CEN30091-01 30 Testing and adjusting
Data download over ethernet connection for 3. Click View Files for a link to the location where
KOMTRAX Plus II initialization the downloaded data is stored.
Downloading data from the KOMTRAX Plus II 4. Open the Data Conversion Tool.
controller immediately after setup can help identify
5. Select the folder that contains data from the
configuration problems and is required for initialization.
download tool. The "Plus_Binary" folder contains
1. Establish an ethernet connection between the the files to be converted.
service computer and the KOMTRAX Plus II
controller. 6. Select binary files from the target machine. They
will have the *.K extension.
2. Open the Data Collection Tool.
7. Click Convert. A success dialog box will appear.
The software will automatically download the Click OK.
data if more than 12 hours has passed since the
previous download. Click the Download button
to force a download if necessary.
86964
FIGURE 30-24. SELECT BINARY FILES
12
30 Testing and adjusting CEN30091-01
8. Click View Files. Data is organized by truck 10. Send the binary file (*.K) from step 6 to
model, truck serial number and date. [email protected] to complete the
KOMTRAX Plus II initialization process.
9. After conversion, the files are ready for analysis.
Use the files in the "Rate_Calendar_Alignment"
folder for human readable date and time stamps.
86965
FIGURE 30-25. CONVERTED BINARY FILES
13
CEN30091-01 30 Testing and adjusting
730E Dump truck
830E Dump truck
860E Dump truck
930E Dump truck
960E Dump truck
980E Dump truck
Form No. CEN30091-01
14
CEN30070-03
DUMP TRUCK 1SHOP MANUAL
730E 930E
830E 960E
860E 980E
Machine model Serial number Machine model Serial number
730E-8 A40002 and up 960E-2 A30027 and up
730E-10 A50002 and up 960E-2K A50011 and up
830E-5 A50005 and up 960E-2KT A50028 and up
830E-5AT A50005 and up 980E-4 A40003 and up
860E-1K A30031 and up 980E-4AT A40003 and up
860E-1KT A30004 and up 980E-5 A50005 and up
930E-5 A40004 and up 980E-5AT A50005 and up
930E-5AT A40004 and up
960E-1 A30001, A30003 -
A30026
960E-1K A30002, A50003 -
A50010
30 Testing and adjusting
Payload meter IV
Payload meter IV software and tools .................................................................................................................... 3
Payload meter IV system configuration ................................................................................................................ 3
Payload meter IV software installation .................................................................................................................. 5
Payload meter IV checkout procedure.................................................................................................................. 6
PLM IV system checkout data sheet................................................................................................................... 12
Downloading PLM IV data and possible errors ................................................................................................... 13
1
CEN30070-03 30 Testing and adjusting
NOTES
2
30 Testing and adjusting CEN30070-03
Payload meter IV software and tools Payload meter IV system configuration
Several software programs and tools are required for Connecting to the payload meter IV web server
Payload Meter IV (PLM IV) setup and checkout
procedures. The PLM IV web server allows users to download data
and configure the payload meter system. PLM IV can
• PLM IV application code (latest version) be connected to a service computer via a Cat5e cable
• Service computer with Windows® operating system connection from RJ45 ethernet port (3, Figure 30-1) on
(200 MHz processor, 64 MB RAM minimum) the payload meter communication module, or it can be
connected to a wireless radio on the truck if a wireless
• Cat5e ethernet cable connection is desired.
• USB drive with 1 - 4GB of memory
Once connected, use a web browser such as Internet
• Four 3 kohm, 1W resistors (58B-06-03100) Explorer® or Google Chrome™ to access the web
• Voltmeter server.
NOTE: Be aware that the software and data files are NOTE: The service computer static IP address must
updated periodically. Download the latest versions be configured within the same network range as the
from the Komatsu extranet at: payload meter.
https://www.komatsuamerica.net/northamerica Configuring a static IP address
For a wired or wireless connection, a static IP address
of the service computer is required to allow
connectivity. Refer to Figure 30-2.
1. Right click on the Wired Connection icon in the
bottom right corner of the window.
2. Click on “Open Network and Sharing Center.”
3. In the Network and Sharing Center window, click
on “Change adapter settings” on the left hand
bar.
4. Right click on the computer's "Wired Connection
Device". If using wireless access, right click on
the "Wireless Connection Device".
5. Click on "Properties".
6. Click on "Internet Protocol Version 4 (TCP/IPv4)"
to highlight the option.
7. Click on "Properties."
8. Select "Use the following IP address".
9. Fill in the following IP Settings:
• Set the service computer’s IP address within the
same IP address range of the PLM IV controller.
The default factory programmed static IP address
of the PLM IV controller is 192.168.3.128.
For example, set the IP address of the service
computer to 192.168.3.123. The last three
numbers can be any number between 1 and 254
except for 128 since that number is already
FIGURE 30-1. PLM IV COMMUNICATION MODULE assigned to the PLM IV controller.
1. USB 2.0 Ports 3. RJ45 Ethernet Port • Subnet Mask: 255.255.255.0
2. LED Indicators 10. Click "OK."
11. Click "OK."
3
CEN30070-03 30 Testing and adjusting
NOTE: To return the service computer’s network card
to normal operation, follow steps 1 - 7, but in step 8
select “Obtain an IP address automatically.”
FIGURE 30-2. PLM IV STATIC IP ADDRESS CONFIGURATION
4
30 Testing and adjusting CEN30070-03
Payload meter IV software installation
1. Insert a blank USB drive into the service
computer. Format the USB drive to FAT32 by
right-clicking on the correct drive letter and
selecting "Format".
2. Copy the truck application software to the USB
drive.
3. Remove the USB drive, then insert the USB drive
into either USB 2.0 port (1, Figure 30-1) on the
PLM IV communication module.
4. Turn the truck’s engine start switch to ON.
5. Ensure that the service computer is set up to
communicate with the PLM IV controller. If not,
refer to "Payload meter IV system configuration".
6. On the home page, click on the "Program Flash"
link. See Figure 30-3.
7. On the next web page, enter the password
Kac2300 in the field at the bottom of the page.
Click on "Start Program" to begin installing the
truck application code.
This process may take approximately 10 minutes
to complete. Do not turn off 24V truck power
during this process. The completion FIGURE 30-3. PLM IV HOME PAGE
percentage will be shown and periodically
updated on the web page as the installation
progresses.
8. When the software installation is complete,
payload meter will automatically restart.
5
CEN30070-03 30 Testing and adjusting
Payload meter IV checkout procedure 5. In the auxiliary control cabinet, use a voltmeter to
1. Ensure that the PLM IV software is up-to-date. check the PLM IV sensor supply voltage between
circuit 39F and 0 (ground). This should be 18 ±
2. Install one resistor (58B-06-03100) in place of 1VDC.
each of the suspension pressure sensors. The
resistors will provide a test load between circuit * Record on Data Sheet
39F and each of the sensor circuits 39FA, 39FB, 6. Use a Cat5e ethernet cable to connect the
39FC and 39FD. service PC to RJ45 ethernet port (3, Figure 30-1)
3. In the auxiliary control cabinet, use a voltmeter to on the PLM IV controller.
check the PLM IV controller input voltage 7. Log on to the PLM IV home page. Refer to
between circuit 39G and 0 (ground). This should Figure 30-3.
be 24VDC supplied by the batteries.
NOTE: After turning the engine start switch to ON, wait
* Record on Data Sheet for five minutes before connecting to the PLM IV
4. Turn the engine start switch to ON. dynamic web browser.
8. Click on the "System Configurations" link. There
are ten parameters that can be set from this web
page. There is no need to reboot the payload
meter after updating any of these parameters.
Refer to Figure 30-6.
6
30 Testing and adjusting CEN30070-03
FIGURE 30-4. PLM IV SYSTEM CONFIGURATIONS PAGE
7
CEN30070-03 30 Testing and adjusting
NOTE: Some of the parameters require a password to change. The password for all parameters except the
Payload Gain is Kac2300. This password is case sensitive. The password for the Payload Gain parameter is not
included in this document.
• Truck Model: There are many different truck models available for selection. The correct truck model must be
selected for the payload meter to accurately estimate payloads.
• PLM IV Mounting Orientation: It is important to configure the payload meter according to its mounted
position in the auxiliary control cabinet. Refer to Figure 30-5 to identify which wall the payload meter is
mounted on in the auxiliary control cabinet. See Figure 30-6 for orientation selection on the configurations
page.
FIGURE 30-5. PLM IV CONTROLLER MOUNTING ORIENTATION
1. Position (1) - Right Tire 3. Position (3) - Truck Forward
2. Position (2) - Truck Rear 4. Position (4) - Left Tire
88388
FIGURE 30-6. PLM IV ORIENTATION SELECTION
8
30 Testing and adjusting CEN30070-03
• Display Units: This parameter can be set to display measurements in metric tons, short tons or long tons.
• Pressure Sensor Units (Real Time Data): Select kg/cm2 or psi for the values displayed on the Real Time
Data web page only.
• Drive System: Choose between CAN BUS and Hardwired, see
88389
FIGURE 30-7. PLM IV DRIVE SYSTEM SELECTION
• Date and Time: If the truck is equipped with 10. To test the functionality of the payload meter load
KOMTRAX Plus, this parameter of the will be lights and wiring, turn on the brake lock. Click on
automatically updated when the truck is powered the check box next to the light(s) to be tested.
up. If not, the date and time must be set. This The lights can be set ON/OFF for five minutes
parameter will be lost after approximately 30 from this web page. After five minutes, the lights
days without truck power up. will return to their default states.
• Payload Load Light Test: Proceed to step 10 to * Record on Data Sheet
perform this test.
Test the following combinations and confirm
• Payload Gain Factor: The default parameter is proper light function:
100%, but it is adjustable between 90% and
110%. It is recommended that this parameter not • Green ON, Amber OFF, Red OFF
be changed. A change in this value will affect all
payload calculations, which may cause errors. • Green OFF, Amber ON, Red OFF
• Truck Tare Reset: This function forces the • Green OFF, Amber OFF, Red ON
payload meter to reset the truck tare to its default • Green OFF, Amber OFF, Red OFF
value. Do not use this function unless the
payload meter state machine is locked up or has
calculated an unusually low tare value. Check the
system for a Sensor Low Pressure alarm.
• Truck Tire Monitor: The default is "No Tire
Monitor". This selection must be changed if the
truck is equipped with a tire pressure monitoring
system.
9
CEN30070-03 30 Testing and adjusting
11. Return to the PLM IV home page. Click on the 13. Return to the PLM IV home page. Click on the
"Truck Data Configuration" link to set the "View Real Time Data" link to check the current
following parameters: status of various PLM IV inputs and outputs.
• Frame Serial Number: This is located on a plate a. Confirm that all suspension pressures are
that is mounted to the truck frame. This field will within the acceptable range. The nominal val-
hold up to 20 alpha-numeric characters. ues should be 25.6 ± 6.4 kg/cm2 (364 ± 91
• Customer Unit: This is number assigned by psi).
most mining operations to each truck in its fleet. * Record on Data Sheet
This field will hold up to 20 alpha-numeric
characters. b. Check the inclinometer reading. Calibrate if
necessary.
• Distributor: This is the name and/or number
assigned to the distributor that installed the * Record on Data Sheet
payload meter system. This will be used for c. To confirm that the body up input is functioning
warranty claims. This field will hold up to 20 properly, place a steel washer on the body up
alpha-numeric characters.
switch. The reading in the Real Time Data win-
• Customer: This is the name and/or number dow should be "OFF". When the washer is
assigned to the customer or mine site where the removed, the reading should be "ON".
truck is in service. This will be used for warranty
claims. This field will hold up to 20 alpha-numeric * Record on Data Sheet
characters. d. To confirm that the brake lock input is function-
Enter the password Kac2300 and click on the ing properly, activate the brake lock switch.
"Save Truck Data" button to save these The reading in the Real Time Data window
parameters. This password is case sensitive. should be "ON". When the switch is deacti-
vated, the reading should be "OFF".
12. Check the PLM IV software version on the "Truck
Data Configuration" page. * Record on Data Sheet
* Record on Data Sheet e. Ensure that the brake lock is OFF. Use the
VID panel on the rear wall of the operator cab
to provide a speed signal of 40 kph (25 mph).
Confirm that the speed value is displayed on
the speedometer and on the Real Time Data
window.
* Record on Data Sheet
14. Return to the PLM IV home page.
FIGURE 30-8. TRUCK DATA CONFIGURATION
FIGURE 30-9. TRUCK DATA CONFIGURATION
PAGE
PAGE
10
30 Testing and adjusting CEN30070-03
15. Remove the resistor from the left rear suspension
pressure sensor. Wait for at least one minute.
16. Remove the resistor from the left rear suspension
pressure sensor. Wait for at least one minute.
17. Remove the resistor from the right rear
suspension pressure sensor. Wait for at least one
minute.
18. Remove the resistor from the right front
suspension pressure sensor. Wait for at least one
minute.
19. On the PLM IV home page, click on the "View
alarms" link to view the list of alarms.
All active alarms will be saved within five
seconds. Confirm that the four alarms occurred in
the order in which the resistors were removed:
• Left front suspension low
• Left rear suspension low
• Right rear suspension low
• Right front suspension low
20. Turn the engine start switch to OFF. Close all
windows on the service computer, then
disconnect the service computer from the PLM IV
communication module.
11
CEN30070-03 30 Testing and adjusting
PLM IV system checkout data sheet
Machine Model ___________ Unit Number ____________ Serial Number _____________
Step 3 - PLM IV controller input voltage 24VDC? ____________________
Step 5 - Pressure sensor supply voltage 18 ± 1VDC? ____________________
Step 10 - Green light functions properly? ____________________
Amber light functions properly? ____________________
Red light functions properly? ____________________
Step 12 - PLM IV software version ____________________
Step 13a - Left front suspension pressure ____________________
Right front suspension pressure ____________________
Left rear suspension pressure ____________________
Right rear suspension pressure ____________________
Step 13b - Inclinometer reading ____________________
Step 13c - Body up input functions properly? ____________________
Step 13d - Brake lock input functions properly? ____________________
Step 13e - Speed input functions properly? ____________________
Name of Technician or Inspector Performing Checkout: _________________________
Badge number: ________________________
Date & shift completed: __________________
12
30 Testing and adjusting CEN30070-03
Downloading PLM IV data and possible 2. Open web browser:
errors Once the service computer is connected to the
During the process of data gathering from PLM IV, it is PLM IV truck controller, a web browser can be
critical to follow a specific sequence of events. used to access the web server. Refer to
"Configuring a static IP address."
1. Connect to PLM IV Controller:
3. Download data:
The PLM IV can be connected to a service
computer via Cat 5e cable connection (RJ45 The home page of the PLM IV includes links for
ethernet port on PLM communication board), or configuration, viewing and downloading data.
via wireless LAN modem on KOMTRAX Plus 2 NOTE: Following the download of PLM IV files, it is
machines. The service computer should be critical to not open the original files. If review is
configured with a static IP address before necessary, then make a copy of the file before
opening the web server program through a web opening. The home page of the PLM IV controller
browser. Refer to KOMTRAX Plus section for provides a cautionary statement, see Figure 30-10.
details.
88872
FIGURE 30-10. PLM IV CAUTIONARY STATEMENT
13
CEN30070-03 30 Testing and adjusting
When the home page is loaded it will check for a. If all the fields contain valid entries: Truck Con-
blank entries in the following fields: fig Status will display "OK" and the system is
ready for downloads to occur. See
• Frame Serial Number
Figure 30-10.
• Customer Unit
b. If at least one field is blank: Truck Config Sta-
• KAC Distributor tus will display "CHECK CONFIG BEFORE
• KAC Customer DOWNLOAD." See Figure 30-11. Navigate to
the "Truck Data Configuration Page" and
update the fields before downloading the PLM
IV files.
88871
FIGURE 30-11. PLM IV CONFIG ERROR PRESENT
14
30 Testing and adjusting CEN30070-03
4. Close web browser:
Closing the web browser eliminates potential to
carry specific machine configuration information
to another machine.
5. Disconnect from PLM IV Controller.
NOTE: PLM files scheduled for upload to the payload
management website (https://www.mykomatsu.com)
should only be the original, unopened .dat file.
NOTE: In order to connect to the PLM controller, the
service compatibility settings must be configured to
allow access to the webserver program.
15
CEN30070-03 30 Testing and adjusting
730E Dump truck
830E Dump truck
860E Dump truck
930E Dump truck
960E Dump truck
980E Dump truck
Form No. CEN30070-03
16
CEN30101-00
DUMP TRUCK 1SHOP MANUAL
830E
930E
980E
Machine model Serial number
830E-5 A50005 and up
830E-5AT A50005 and up
930E-5 A40004 and up
930E-5AT A40004 and up
980E-5 A50005 and up
980E-5AT A50005 and up
30 Testing and adjusting
Komatsu wireless bridge (KWB)
General information .............................................................................................................................................. 3
Required software and tools ................................................................................................................................. 3
Configuring the Bullet wireless radio..................................................................................................................... 4
Installing the Bullet wireless radio ......................................................................................................................... 7
Configuring the NanoStation access point ............................................................................................................ 8
Testing the connection .........................................................................................................................................11
Changing a service computer’s IP address ........................................................................................................ 12
1
CEN30101-00 30 Testing and adjusting
NOTES
2
30 Testing and adjusting CEN30101-00
General information Required software and tools
Komatsu wireless bridge (KWB) is a system that uses Several software programs and tools are required for
commercially available wireless technology to allow KWB setup and checkout procedures.
communication that normally requires a wired
• Service computer (1 GHz processor, 512 MB RAM
connection and a technician on board the truck.
minimum) with Windows® operating system (XP or
Communication requires an access point (often later)
located in a service truck or at the fueling area) and • Bullet Titanium wireless radio (purchased locally)
haul trucks equipped with a Bullet wireless radio. A
service computer with the KOMTRAX Plus PC Tools • NanoStation M2 access point (purchased locally)
software that is connected to the access point can • Two ethernet cables
automatically collect KOMTRAX Plus downloads when
the haul truck comes into range. If setup in a fueling • Latest KWB configuration file
area, downloads can be collected automatically each
time a truck stops for fuel.
NOTE: Trucks are not equipped with wireless radios or
The KOMTRAX Plus PC Tools also provide links to access points from the factory. The wireless radios are
devices on the truck’s local area network (LAN), such governed by regulatory agencies. The only way to
as payload meter and the drive system realtime data ensure that proper approvals are granted is to order
screens. Haul cycle records can also be downloaded locally so that the certifications are applied when
from the payload meter website. imported. Each Bullet wireless radio and access point
must be ordered from a local Ubiquiti networks
distributor.
NOTE: NanoStation M2 devices act as access points
for each network. One NanoStation M2 is required for
each network.
The referenced wireless devices are high power
(1W) RF transmitters in the 2.4GHz band. Before
installing these devices, verify the local regulatory
restrictions regarding the uses of such devices.
Do not use these devices if use is restricted at
your location.
The configuration file contains the settings required to
configure the Bullet wireless radio for communication
with the 0002KPLUS wireless network. The file is
generic so it can be used on each radio with no
specific changes per truck. For convenience,
002KPLUS is the same wireless network used by
other Tier 4 Komatsu equipment such as loaders and
mechanical drive trucks.
NOTE: Be aware that the KWB configuration files are
updated periodically. Check with the local Komatsu
distributor for the latest version to download to the
service computer.
3
CEN30101-00 30 Testing and adjusting
Configuring the Bullet wireless radio 4. Change the service computer’s wired LAN
1. Download the KWB configuration files (.zip file) settings to the following:
and the latest WiFi setup instructions from the IP address: 192.168.1.100
Komatsu extranet to the service computer.
Extract the files onto the service computer. Net mask: 255.255.0.0
2. Connect POE adapter (2, Figure 30-1) to Bullet 5. Open an internet browser (Google Chrome™ is
wireless radio (1) by using a CAT 5E network recommended), type 192.168.1.20 into the
cable. Ensure that the cable is in the POE port as address bar, then press the Enter key.
shown. 6. Proceed to the website regardless of any security
3. Connect POE adapter (2) to service computer (3) messages.
by using another CAT 5E network cable. Ensure
that the cable is in the LAN port as shown.
1 2 3
86981
FIGURE 30-1. KWB POE ADAPTER CONNECTIONS
1. Bullet Wireless Radio 3. Service Computer
2. Power over Ethernet (POE) Adapter
4
30 Testing and adjusting CEN30101-00
7. Login using the following default settings: 11. Click Change, then click Apply on the blue
ribbon that appears toward the top of the screen.
• Username: ubnt
Record the password in a safe place.
• Password: ubnt
12. Under the Configuration Management heading,
8. Click the SYSTEM tab. See Figure 30-2. click Choose File. Select the Bullet wireless
9. Set the time zone. radio configuration file that was downloaded from
10. Click the magnifying glass icon next to the the extranet.
administrator user name. Enter the default 13. Click Upload, then click Apply on the blue ribbon
password and choose a new password. that appears toward the top of the screen.
86977
FIGURE 30-2. FIRMWARE UPDATE SCREEN
5
CEN30101-00 30 Testing and adjusting
14. Wait approximately 30 seconds, then the click Network Mode: Bridge
MAIN tab. Verify that the information matches the
Wireless Mode: Station
fields in Figure 30-3. If not, a problem has
occurred. Repeat steps 12 and 13. SSID: 0002KPLUS
NOTE: This check only works when the wireless radio Security: WPA2-AES
is not within range of a powered 0002Kplus access
point. If the access point cannot be powered off, skip
step 14.
86978
FIGURE 30-3. STATUS SCREEN
6
30 Testing and adjusting CEN30101-00
Installing the Bullet wireless radio 3. Install rubber washer (4, Figure 30-5) on cable
gland body (3) if not already installed.
Trucks equipped with the KWB have the required
cables and hardware already installed. Mount the 4. Slide compression nut (1) and cable gland body
Bullet wireless radio to the antenna station on the front (3) over the ethernet cable. Ensure that the parts
handrail on the left side of the truck. are correctly oriented.
1. Install Bullet wireless radio (4, Figure 30-4) on 5. Connect the ethernet cable to the Bullet wireless
antenna station (2). radio.
2. Install the bolted half of Hydra-zorb clamp (3) 6. Thread the cable gland body into the Bullet
around the Bullet wireless radio and tighten the wireless radio. Tighten the gland body by hand.
capscrews to standard torque. NOTE: Be careful not to twist the ethernet cable or
connector when installing the cable gland body.
7. Split compression seal (2) at the precut location
1 and slide it over the ethernet cable. Push the
compression seal into the back side of cable
gland body (3).
2
8. Thread compression nut (1) onto the cable gland
body. Tighten the nut to compress the seal and
waterproof the connection.
NOTE: Failure to complete the previous steps correctly
may leave the Bullet wireless radio unprotected from
water ingress, which could result in failure of the
wireless radio.
9. Install KWB antenna (1, Figure 30-4) on top of
3 the Bullet wireless radio.
4
DETAIL A 5
5
A 4
3
2
1
86979 86980
FIGURE 30-4. BULLET WIRELESS RADIO FIGURE 30-5. BULLET WIRELESS RADIO
INSTALLATION INSTALLATION
1. KWB Antenna 4. Bullet Wireless Radio 1. Compression Nut 4. Rubber Washer
2. Antenna Station 5. Ethernet Cable 2. Compression Seal 5. Bullet Wireless Radio
3. Hydra-Zorb Clamp 3. Cable Gland Body
7
CEN30101-00 30 Testing and adjusting
Configuring the NanoStation access point 3. Change the service computer’s wired LAN
settings to the following:
NOTE: Each mine site will require at least one access
point because the KWB operates in infrastructure IP address: 192.168.1.100
wireless mode.
Net mask: 255.255.0.0
1. Connect POE adapter (2, Figure 30-1) to 4. Open an internet browser (Google Chrome™ is
NanoStation access point (1) by using a CAT 5E recommended), type 192.168.1.20 into the
network cable. Ensure that the cable is in the address bar, then press the Enter key.
POE port as shown.
5. Proceed to the website regardless of any security
2. Connect POE adapter (2) to service computer (3) messages.
by using another CAT 5E network cable. Ensure
that the cable is in the LAN port as shown.
1 2 3
86982
FIGURE 30-6. KWB POE ADAPTER CONNECTIONS
1. NanoStation Access Point 3. Service Computer
2. Power over Ethernet (POE) Adapter
8
30 Testing and adjusting CEN30101-00
6. Login using the following default settings: 10. Click Change, then click Apply on the blue
ribbon that appears toward the top of the screen.
• Username: ubnt
Record the password in a safe place.
• Password: ubnt
11. Under the Configuration Management heading,
7. Click the SYSTEM tab. See Figure 30-2. click Choose File. Select the NanoStation
8. Set the time zone. access point configuration file that was
9. Click the magnifying glass icon next to the downloaded from the extranet.
administrator user name. Enter the default 12. Click Upload, then click Apply on the blue ribbon
password and choose a new password. that appears toward the top of the screen.
86977
FIGURE 30-7. FIRMWARE UPDATE SCREEN
9
CEN30101-00 30 Testing and adjusting
13. Wait approximately 30 seconds, then the click Network Mode: Router
MAIN tab. Verify that the information matches the
Wireless Mode: Access Point
fields in Figure 30-3. If not, a problem has
occurred. Repeat steps 11 and 12. SSID: 0002KPLUS
NOTE: This check only works when the wireless radio Security: WPA2-AES
is not within range of a powered 0002Kplus access
point. If the access point cannot be powered off, skip
step 14.
86983
FIGURE 30-8. STATUS SCREEN
10
30 Testing and adjusting CEN30101-00
Testing the connection 4. Click on a truck to see links to the devices
1. Power up the NanoStation access point. Connect connected to the onboard local area network
the service computer to the 0002KPLUS wireless (LAN).
network.
2. Ensure that a haul truck equipped with KWB and
KOMTRAX Plus II is nearby. Open the Data
Collection PC Tool.
The Data Collection PC Tool will automatically
discover the truck and download data if more
than 12 hours has passed since the previous
download. Clicking on Download will force a
download immediately.
3. Open the Komtrax Plus Discovery Tool. All trucks
within wireless range will be displayed in the
Discovered Komtrax Plus Machines window.
86985
FIGURE 30-10. KOMTRAX PLUS DISCOVERY
TOOL WINDOW
86984
FIGURE 30-9. KOMTRAX PLUS DISCOVERY
TOOL WINDOW
11
CEN30101-00 30 Testing and adjusting
Changing a service computer’s IP address 4. For automatic IP settings, go to the General tab
(see Figure 30-12):
NOTE: The following instructions are for the Microsoft®
Windows 7® operating system. a. Select the Obtain an IP address
automatically radio button.
1. Click Start > Control Panel. Open the Network
and Sharing Center. b. Select the Obtain DNS server address
automatically radio button.
• If settings are displayed by icons, click “Network
and Sharing Center”. c. Click the "OK" button.
• If settings are displayed by category, click “View d. Click the "OK/Close" button.
network status and tasks”.
2. Click “Change Adapter settings” in the left hand
pane. Right click on the adapter that needs to be
configured, then click “Properties”.
• For WIRELESS connections, use "Wireless
Network Connection".
• For WIRED LAN connections, use "Local Area
Connection".
3. Select “Internet Protocol Version 4 (TCP/IPV4)”.
Click “Properties”. See Figure 30-11.
FIGURE 30-12. AUTOMATIC IP ADDRESS
CONFIGURATION SCREEN
86349
FIGURE 30-11. CONNECTION PROPERTIES
SCREEN
12
30 Testing and adjusting CEN30101-00
NOTES
13
CEN30101-00 30 Testing and adjusting
830E Dump truck
930E Dump truck
980E Dump truck
Form No. CEN30101-00
14
CEN30105-02
DUMP TRUCK 1SHOP MANUAL
730E
830E
930E
980E
Machine model Serial number Machine model Serial number
730E-8 A40015 and up 980E-5 A50005 and up
730E-10 A50002 and up 980E-5AT A50005 and up
830E-5 A50005 and up
830E-5AT A50005 and up
930E-5 A40004 and up
930E-5AT A40004 and up
30 Testing and adjusting
KomVision
Requirements........................................................................................................................................................ 3
Initial setup............................................................................................................................................................ 3
Checkout data sheet ........................................................................................................................................... 10
Calibration sheets ............................................................................................................................................... 15
Camera calibration procedures........................................................................................................................... 22
Radar setting procedure ..................................................................................................................................... 32
1
CEN30105-02 30 Testing and adjusting
NOTES
2
30 Testing and adjusting CEN30105-02
Requirements The truck must be empty, operable and located in a
level area with adequate space for Forward and
The testing and adjusting procedures that are required
Reverse movements of up to 16 kph (10 mph).
depends upon the situation. Refer to Table 1 to
determine the necessary testing and adjusting The calibration sheet layout uses approximately 18 x
procedures for each situation. 25 m (59 X 82 ft) of area with the truck in the interior of
the area. If the calibration sheet is required, the
recommended area is approximately 30 x 35 m (98 X
115 ft).
Table 1: TESTING AND ADJUSTING REQUIREMENTS
Main 6 Camera 1 Camera Radar
Situation
Settings Calibration Calibration Setting
System installation (initial setup) • • •
Controllers are exchanged • • •
After pushing and initializing DEFAULT on a • • •
maintenance screen
Vehicle dimensions are changed by •
attachment exchange
Cameras are exchanged • •
Camera mount is fixed or exchanged • •
Radars are exchanged •
Radar mount is fixed or exchanged •
Initial setup
NOTE: A data sheet is included in this section to
record the setup information obtained during the initial
setup procedure. The data sheet is designed to be
copied and used during the checkout procedure.
1. Turn the engine start switch to the RUN position,
but do not start the engine at this time. Verify that
the KomVision screen displays the logo
immediately (see Figure 30-1).
* Record on Data Sheet
2. System boot up should occur quickly. Record the
number of seconds it takes the screen to change
from the logo screen to the system running 87529
screen. The green standby indicator should also FIGURE 30-1. STARUP LOGO SCREEN
be blinking.
NOTE: The illumination of the green standby indicator
is dim and may be difficult to see when bright ambient
conditions exist. Use a hand to shade the indicator if
needed.
* Record on Data Sheet
3
CEN30105-02 30 Testing and adjusting
3. Enable the maintenance mode by pushing the
following three buttons simultaneously for three
seconds (see Figure 30-2):
Monitor Display Mode button
Guide Line Display button
Lower Body Display button
4. The password entry screen will be displayed.
Enter 6 4 9 1 to gain entry to the maintenance
mode (see Figure 30-3).
• Use the up arrow to increase the number.
• Use the down arrow to decrease the number.
• Use the diagonal down right arrow to tab to the 87530
next field.
• Use the alarm cancel button to finalize the FIGURE 30-2. ENTERING MAINTENANCE MODE
selected numbers (to click the OK button on
the screen).
87531
FIGURE 30-3. PASSWORD SCREEN
4
30 Testing and adjusting CEN30105-02
5. The program software part number and the 6. Use the diagonal down right arrow to tab the red
application version number appear at the top of highlight box to the MAIN SETTING button on the
the main menu (see Figure 30-4). screen, then press the alarm cancel button. This
* Record on Data Sheet will enable the main setting input screen.
87532
FIGURE 30-4. MAIN MENU SCREEN
5
CEN30105-02 30 Testing and adjusting
7. Set the truck type to the proper Machine Code Default values for the selected truck type will be
(see Figure 30-5). seeded, and some values can be stored, as
a. Use the diagonal down right arrow to move the appropriate, for a standard truck after the SAVE
cursor to each data entry field. button is selected.
b. Press the alarm cancel button to change the Confirm that the correct machine type is stored
data in the selected field. by selecting the BACK button, which returns to
the Main Menu screen. Select the MAIN
c. Use the up arrow and down arrow to move the SETTING button again and confirm that the
cursor selection within each field’s drop-down machine code matches the desired truck type.
menu.
d. Press the alarm cancel button to finalize the
8. Record the remaining data inputs from the main
data selection.
setting screen.
* Record on Data Sheet
* Record on Data Sheet
87533
FIGURE 30-5. MAIN SETTING SCREEN
6
30 Testing and adjusting CEN30105-02
9. Return to the Main Menu, then select the Confirm that the correct values are stored by
CAMERA SETTING button on the screen. The All selecting the BACK button, which returns to the
Camera Position screen will appear (see Main Menu screen. Select the CAMERA
Figure 30-6). Adjust the values, as needed. SETTING button again and confirm the stored
values.
10. Record the values, the select the SAVE button to
store the data.
* Record on Data Sheet
87534
FIGURE 30-6. CAMERA SETTING SCREEN
11. Return to the Main Menu, then select the RADAR 12. Record the values, then select the SAVE button
SETTING button on the screen. Record the to store the data.
values from each of the three tabs: Area, * Record on Data Sheet
Threshold, All Radar Position (see Figure 30-7
through Figure 30-9). Adjust the values, as Confirm that the correct values are stored by
needed. selecting the BACK button, which returns to the
Main Menu screen. Select the RADAR SETTING
button again and confirm the stored values.
7
CEN30105-02 30 Testing and adjusting
87535
FIGURE 30-7. RADAR SETTING SCREEN - AREA TAB
87536
FIGURE 30-8. RADAR SETTING SCREEN - THRESHOLD TAB
87537
FIGURE 30-9. RADAR SETTING SCREEN - ALL RADAR POSITION TAB
8
30 Testing and adjusting CEN30105-02
13. Perform the camera calibration procedure. This 19. Verify that body rear hide, grid line display, and
requires the calibration sheets to be laid out display mode buttons function properly. Also
accordingly around the machine on level ground. verify that the brightness buttons for the monitor
are functional.
The quickest calibration technique is automatic 6
camera calibration which, if successful, will * Record on Data Sheet
complete automatically in several minutes. 20. Verify that the display changes to the rear camera
However, the automatic calibration is very view when the directional control lever is moved
sensitive to lighting conditions and surroundings. to REVERSE.
This may require that only manual 6 camera
* Record on Data Sheet
calibration is possible.
21. Place a target in the target zone of the truck.
Manual calibration may take an hour or more if
Verify that the alarm sounds when the target is
technicians are not very familiar with the actual
found only when the directional control lever is
key pressing and entry of the calibration screen
moved to FORWARD or REVERSE. The alarm
points that are outlined the manual calibration
should stop when the directional control lever is
procedure.
moved to NEUTRAL or PARK.
Refer to the topics "Calibration sheets" and * Record on Data Sheet
"Camera calibration procedures" for the
necessary information. 22. Operate truck in FORWARD. Verify that standby
mode activates at a speed above the preset
* Record on Data Sheet
forward low-high speed that was recorded in step
14. After calibration is complete, the runtime screen 8. (The default speed is 15 kph, but it may be set
should appear without any faults present. to a different speed.) Also verify that the screen
Troubleshoot and correct any faults that exist returns to active mode when nearly stopped.
before continuing. * Record on Data Sheet
15. Verify that all buttons are lighted green when not 23. Operate truck in REVERSE. Verify that standby
depressed. mode activates at a speed above the preset
* Record on Data Sheet reverse low-high speed that was recorded in step
16. Verify that all buttons are lighted amber when 8. (The default speed is 15 kph, but it may be set
depressed. to a different speed.) Also verify that the screen
returns to active mode when nearly stopped.
* Record on Data Sheet
* Record on Data Sheet
17. Verify that the radar is functioning properly by
having a person walk around the truck on the 24. Verify that no active faults exist (red icons on the
inside edge of the calibration tarps screen or audible alarm sounding). Clear the fault
[approximately 1 m (3 ft) from the truck]. log.
* Record on Data Sheet
While the person walks around the truck, confirm
that the located target circle tracks properly and 25. Perform the KomVision start-up inspection. Refer
is consistent with the location of the person. Also, to the Operation and Maintenance Manual for
verify that a smooth transition occurs in the bird’s your truck.
eye view. * Record on Data Sheet
* Record on Data Sheet
18. Verify camera selection by pressing each arrow
key which should, in turn, display the respective
camera for that sector of the truck.
* Record on Data Sheet
9
CEN30105-02 30 Testing and adjusting
Checkout data sheet
Machine Model ___________ Unit Number ____________ Serial Number _____________
Step 1 - Screen displays logo immediately? yes no
Step 2 - Standby indicator blinking during boot up? yes no
Number of seconds before logo screen changes to system running screen? _______________
Step 5 - Program part number _______________
Application version number _______________
Step 7 - Machine Code setting _______________
Step 8 - Data inputs:
Offset _______________
Body width _______________
Forward option _______________
Rear wheel to end _______________
Diagonal ladder LH RH
Forward (Low-High) speed _______________
Reverse (Low-High) speed _______________
Hysteresis _______________
Image Magnification - Bird’s Eye View _______________
Radarless option yes no
10
30 Testing and adjusting CEN30105-02
Step 10 - Camera Setting values:
Camera 1 Offset X _______________ Camera 4 Offset X _______________
Camera 1 Offset Y _______________ Camera 4 Offset Y _______________
Camera 1 Offset Z _______________ Camera 4 Offset Z _______________
Camera 1 Roll _______________ Camera 4 Roll _______________
Camera 1 Pitch _______________ Camera 4 Pitch _______________
Camera 1 Yaw _______________ Camera 4 Yaw _______________
Camera 2 Offset X _______________ Camera 5 Offset X _______________
Camera 2 Offset Y _______________ Camera 5 Offset Y _______________
Camera 2 Offset Z _______________ Camera 5 Offset Z _______________
Camera 2 Roll _______________ Camera 5 Roll _______________
Camera 2 Pitch _______________ Camera 5 Pitch _______________
Camera 2 Yaw _______________ Camera 5 Yaw _______________
Camera 3 Offset X _______________ Camera 6 Offset X _______________
Camera 3 Offset Y _______________ Camera 6 Offset Y _______________
Camera 3 Offset Z _______________ Camera 6 Offset Z _______________
Camera 3 Roll _______________ Camera 6 Roll _______________
Camera 3 Pitch _______________ Camera 6 Pitch _______________
Camera 3 Yaw _______________ Camera 6 Yaw _______________
11
CEN30105-02 30 Testing and adjusting
Step 12 - Radar Setting values:
Area Tab
Outside Front _______________
Outside Side _______________
Threshold Tab
Radar 1 _______________
Radar 2 _______________
Radar 3 _______________
Radar 4 _______________
Radar 5 _______________
Radar 6 _______________
Radar 7 _______________
Radar 8 _______________
All Radar Position Tab
Radar 1 Offset X _______________ Radar 2 Offset X _______________
Radar 1 Offset Y _______________ Radar 2 Offset Y _______________
Radar 1 Offset Z _______________ Radar 2 Offset Z _______________
Radar 1 Roll _______________ Radar 2 Roll _______________
Radar 1 Pitch _______________ Radar 2 Pitch _______________
Radar 1 Yaw _______________ Radar 2 Yaw _______________
12
30 Testing and adjusting CEN30105-02
Radar 3 Offset X _______________ Radar 6 Offset X _______________
Radar 3 Offset Y _______________ Radar 6 Offset Y _______________
Radar 3 Offset Z _______________ Radar 6 Offset Z _______________
Radar 3 Roll _______________ Radar 6 Roll _______________
Radar 3 Pitch _______________ Radar 6 Pitch _______________
Radar 3 Yaw _______________ Radar 6 Yaw _______________
Radar 4 Offset X _______________ Radar 7 Offset X _______________
Radar 4 Offset Y _______________ Radar 7 Offset Y _______________
Radar 4 Offset Z _______________ Radar 7 Offset Z _______________
Radar 4 Roll _______________ Radar 7 Roll _______________
Radar 4 Pitch _______________ Radar 7 Pitch _______________
Radar 4 Yaw _______________ Radar 7 Yaw _______________
Radar 5 Offset X _______________ Radar 8 Offset X _______________
Radar 5 Offset Y _______________ Radar 8 Offset Y _______________
Radar 5 Offset Z _______________ Radar 8 Offset Z _______________
Radar 5 Roll _______________ Radar 8 Roll _______________
Radar 5 Pitch _______________ Radar 8 Pitch _______________
Radar 5 Yaw _______________ Radar 8 Yaw _______________
Step 13 - Auto calibration successful? yes no
Manual calibration successful? yes no N/A
13
CEN30105-02 30 Testing and adjusting
Step 15 - Green button lighting when not depressed? yes no
Step 16 - Amber button lighting when depressed? yes no
Step 17 - Radar target follows person correctly? yes no
Smooth transition in bird’s eye view? yes no
Step 18 - Camera selection is functional for all 6 cameras? yes no
If "no", which cameras are malfunctioning? 1 2 3 4 5 6
Step 19 - Display buttons are functioning properly?
Monitor Display Mode button yes no
Guide Line Display button yes no
Lower Body Display button yes no
Bright button yes no
Dim button yes no
Step 20 - Rear camera view in REVERSE? yes no
Step 21 - Alarm sounds when target found in FORWARD or REVERSE? yes no
Alarm stops when in NEUTRAL or PARK? yes no
Step 22 - Speed at which screen enters standby mode in FORWARD _______________
Screen returns to active mode when nearly stopped? yes no
Step 23 - Speed at which screen enters standby mode in REVERSE _______________
Screen returns to active mode when nearly stopped? yes no
Step 24 - Active faults? yes no
Fault log cleared? yes no
Step 25 - Pre-shift inspection completed? yes no
14
30 Testing and adjusting CEN30105-02
Calibration sheets Although a default value is set for each camera
parameter, the actual camera installation position and
Layout and assemblage angle will be in error. Therefore, if a bird's eye view is
For the KomVision® camera system to combine a constructed using the default values, it will create an
bird's eye view from each image of the six cameras, image which has a gap on the boundary between each
the installation position and the parameter of an angle camera (see Figure 30-11).
of each camera are needed. To acquire each camera
parameter, it is necessary to perform the 6 camera
calibration, which requires the use of the calibration 1 2
sheets.
85236
FIGURE 30-11. BIRD’S EYE VIEW
1. Before Calibration 2. After Calibration
85235 Ensure that the site where calibration will occur is
FIGURE 30-10. TOP CALIBRATION SHEET level, clear of all obstacles, and has a minimum of 30 x
35 m (98 X 115 ft) of space.
Place the calibration sheet bundles in a centralized
location of the calibration site.
15
CEN30105-02 30 Testing and adjusting
There are four calibration sheets. Each of the
calibration sheets are defined as follows.
1. Front calibration sheet
2. Right calibration sheet
3. Rear calibration sheet Ensure that the calibration sheets are laid out in
the same position as shown in Figure 30-13 so that
4. Left calibration sheet
the red markers are in the correct locations.
VEHICLE FRONT
1
VEHICLE 5 m VEHICLE
LEFT (5.5 yd) RIGHT
18 m
(19.5 yd)
15 m
(16.5 yd)
4 2
VEHICLE 4 m VEHICLE
FRONT (4.5 yd) REAR
18 m
(19.5 yd)
VEHICLE 5 m VEHICLE
(5.5 yd) RIGHT
LEFT
VEHICLE REAR
85237
FIGURE 30-12. CALIBRATION SHEET DIMENSIONS
16
30 Testing and adjusting CEN30105-02
VEHICLE FRONT 1
10 m
(11 yd)
4 2
15 m
(16.5 yd)
3 VEHICLE REAR
1m
(1 yd)
1m
(1 yd)
600 mm 600 mm
(24 in) (24 in)
600 mm 600 mm
(24 in) (24 in) 85238
FIGURE 30-13. CALIBRATION SHEET LAYOUT
17
CEN30105-02 30 Testing and adjusting
Unfolding a calibration sheet
1 2
3 4
5 6
7 8
9 10
11
85239
18
30 Testing and adjusting CEN30105-02
Folding a calibration sheet
1 2
3 4
5 6
7 8
9 10
85240
19
CEN30105-02 30 Testing and adjusting
Placement of calibration sheets The front calibration sheet is constructed so that the
side of the front calibration sheet may pass along “a”
Both ends of the truck’s front lower platform are
and “b”, and the center of the front calibration sheet
defined as base points “a” and “b.” The measured mid-
may be set to “c.”
point of “a” and “b” is “c” (see Figure 30-14).
After the front calibration sheet is in place, use stakes
to secure the four corners to the ground.
a c b
b c a
Base Points
85241
FIGURE 30-14. FRONT CALIBRATION SHEET BASE POINTS
20
30 Testing and adjusting CEN30105-02
The left calibration sheet and the right calibration sheet Temporarily place the rear calibration sheet so that it is
are constructed to be perpendicular to the front adjacent to the back end of left calibration sheet and
calibration sheet. the back end of the right calibration sheet (similar to
the front calibration sheet).
After each calibration sheet is in place, use stakes to
secure the two corners of side which contacts the front The central line of truck is measured from the body
calibration sheet to the ground. frame. The position of the rear calibration sheet must
be adjusted so that the center of rear calibration sheet
is aligned with the central line of truck.
Make adjustments so that the grid lines of the rear
calibration sheet and the grid lines of the left and right
calibration sheets are in alignment. After the
calibration sheets are in place and correctly adjusted,
1
use stakes to secure the remaining corners to the
ground.
2 3
85242
FIGURE 30-15. LEFT AND RIGHT CALIBRATION
SHEET LAYOUT
21
CEN30105-02 30 Testing and adjusting
Camera calibration procedures 4. When the "Initial 6 Camera Calibration" screen is
displayed, select AUTOMATIC. A 6 camera
Automatic 6 camera calibration calibration screen will appear.
An automatic 6 camera calibration is completed by
performing an image recognition of the grid line of
each camera image, then extracting the coordinates of
the marker points automatically.
Ensure that the calibration sheets are free from
objects or debris. An object may generate
inaccurate image recognition. Furthermore, an
object may create harsh contrasts that may
disrupt the grid pattern as seen by the cameras
which will generate inaccurate image recognition.
85246
If a harsh contrast cannot be removed, it may be FIGURE 30-17. INITAIL 6 CAMERA CALIBRATION
necessary to carry out the manual 6 camera
calibration.
The detection work of camera markers is done by
1. Simultaneously push the Monitor Display Mode image recognition. When image recognition is
Switch, Guide Line Display Switch, and Lower normal, a “Result Bird's Eye View Dialog” screen
Body Display Switch for three seconds or more. is displayed (see Figure 30-18).
The password screen will appear.
2. Enter a password to move to the maintenance
screen.
3. Select 6 CAMERA CALIBRATION.
85247
FIGURE 30-18. INITAIL 6 CAMERA CALIBRATION
85245
FIGURE 30-16. 6 CAMERA CALIBRATION
22
30 Testing and adjusting CEN30105-02
5. Check the Result Window at the lower right side 6. When attempting manual marker selection, there
of the 6 camera calibration screen. are four markers that must be selected per
camera. Choose each marker manually
• If the Result Window states “Calculation
according to the following steps.
Completed Successfully”, select NEXT in the
“Result Bird's Eye View Dialog” screen and a. Determine the position (near a marker) to
proceed to step 7. select by using the "Whole" picture window
• If the Result Window states “Calculation (2nd Tab area). See Figure 30-21.
Completed, But Large Error - x.x pixels”, b. After determining the position, move the
select MANUAL in the “Result Bird's Eye View cursor to the “Magnifying-power change Bar”
Dialog” screen and select a marker according
(4th Tab area) and enlarge the “Expansion”
to step 6.
picture window (3rd Tab area).
• If the Result Window states “CAM1
Calculation Failed. Recheck Marker c. Move the cursor to the “Expansion” picture
Positions”, select a marker according to step window (3rd Tab area) and determine the
6. center of the marker.
d. When the center of the marker is determined,
a “Marker Dialog” screen will be displayed.
See Figure 30-20. Use the cursor to select the
marker name, then select OK. After
registration is complete, the marker changes
to green.
85248
FIGURE 30-19. DISPLAYED 6 CAMERA
CALIBRATION
85250
FIGURE 30-20. MARKER DIALOG SCREEN
23
CEN30105-02 30 Testing and adjusting
1st Tab area
4th
Tab area
2nd Tab area 3rd Tab area
5th Tab area
85249
85251
FIGURE 30-21. TAB AREA LOCATIONS
FIGURE 30-22. RESULT BIRD’S EYE VIEW
DIALOG SCREEN
e. Select the CALC button (5th Tab area) after
determining the markers of all the registration 9. Select OK to close the “Result Bird's Eye View
positions. Dialog.” Select the EXIT button (5th Tab area) of
f. When the “Result Bird's Eye View Dialog” the 6 Camera Calibration screen.
screen appears, it will either be successful or 10. The "End Dialog" screen will appear.
require further attention.
• To save the calibration results, select END
• If the Result Window states “Calculation NEW SETTING. The screen returns to the
Completed Successfully”, select NEXT in maintenance screen.
the “Result Bird's Eye View Dialog” screen
and proceed to step 7. • To perform the 6 camera calibration again,
choose END OLD SETTING.
• If the Result Window states “Calculation
Completed, But Large Error - x.x pixels”,
select MANUAL in the “Result Bird's Eye
View Dialog” screen and repeat step 6.
7. Repeat step 5 for the remaining cameras. It is
acceptable once “Calculation Completed
Successfully” is displayed in the Result Window
for all six cameras.
8. Check the alignment of the calibration sheets in
the “Result Bird's Eye View Dialog” picture. The
sheets should be finely connected with no jagged
breaks.
85252
FIGURE 30-23. END DIALOG SCREEN
24
30 Testing and adjusting CEN30105-02
85244
FIGURE 30-24. SOFTWARE OPERATION FLOW CHART
25
CEN30105-02 30 Testing and adjusting
Manual 6 camera calibration 5. In the Configuration screen for the 6 camera
calibration, choose the number of the calibration
Manual 6 camera calibration is used when the
marker for each camera. See Figure 30-27.
automatic calibration does not complete successfully
or when recommended by service personnel. NOTE: Default value 4 is recommended. The
1. Simultaneously push the Monitor Display Mode calibration sheet corresponds only to 4.
Switch, Guide Line Display Switch, and Lower
Body Display Switch for three seconds or more.
The password screen will appear.
2. Enter a password to move to the maintenance
screen.
3. Select 6 CAMERA CALIBRATION.
85254
FIGURE 30-27. CALIBRATION MARKERS
85245
FIGURE 30-25. 6 CAMERA CALIBRATION
4. When the "Initial 6 Camera Calibration" screen is
displayed, select MANUAL. A 6 camera
calibration screen will appear.
85253
FIGURE 30-26. INITAIL 6 CAMERA CALIBRATION
26
30 Testing and adjusting CEN30105-02
852
85255
852
FIGURE 30-28. CALIBRATION SHEETS
27
CEN30105-02 30 Testing and adjusting
6. When attempting manual marker selection, there
are four markers that must be selected per
camera. Choose each marker manually 1st Tab area
according to the following steps.
4th
a. Determine the position (near a marker) to Tab area
select by using the "Whole" picture window
2nd Tab area 3rd Tab area
(2nd Tab area). See Figure 30-30.
b. After deterng the position, move the cursor to
the “Magnifying-power change Bar” (4th Tab
area) and enlarge the “Expansion” picture
5th Tab area
window (3rd Tab area).
c. Move the cursor to the “Expansion” picture 85249
window (3rd Tab area) and determine the FIGURE 30-30. TAB AREA LOCATIONS
center of the marker.
d. When the center of the marker is determined,
a “Marker Dialog” screen will be displayed. 7. Select the LEFT or RIGHT image switching
See Figure 30-29. Use the cursor to select the button (1st Tab area) and change the selected
marker name, then select OK. After camera. Repeat step 6 for the remaining
registration is complete, the marker changes cameras.
to green.
8. Select the CALC button (5th Tab area) after
determining the markers of all the registration
positions.
When the “Result Bird's Eye View Dialog” screen
appears, it will either be successful or require
further attention.
• If the Result Window states “Calculation
Completed Successfully”, select NEXT in
the “Result Bird's Eye View Dialog” screen
and proceed to step 9.
• If the Result Window states “Calculation
Completed, But Large Error - x.x pixels”,
select MANUAL in the “Result Bird's Eye
View Dialog” screen and repeat step 6.
It is acceptable once “Calculation Completed
Successfully” is displayed in the Result Window
for all six cameras.
85250
FIGURE 30-29. MARKER DIALOG SCREEN
28
30 Testing and adjusting CEN30105-02
9. Check the alignment of the calibration sheets in 1 camera calibration
the “Result Bird's Eye View Dialog” picture. The
When exchanging or replacing cameras, perform the 1
sheets should be finely connected with no jagged
camera calibration.
breaks.
NOTE: A single camera can also be calibrated during
the 6 camera calibration process.
NOTE: A marker is an object that can be easily
recognized or detected by each camera. A pylon
(safety cone) may function as a marker.
1. Place four or more markers near the image
boundary of the proofreading camera and neigh-
boring cameras as shown in Figure 30-33. In this
example, the proofreading camera is the front
camera (CAM1).
85251 target
FIGURE 30-31. RESULT BIRD’S EYE VIEW CAM1
DIALOG SCREEN
Marker
10. Select OK to close the “Result Bird's Eye View
Dialog.” Select the EXIT button (5th Tab area) of
the 6 Camera Calibration screen.
11. The "End Dialog" screen will appear.
• To save the calibration results, select END
NEW SETTING. The screen returns to the
maintenance screen.
• To perform the 6 camera calibration again,
choose END OLD SETTING.
85257
FIGURE 30-33. CAMERA 1 MARKERS
85252
FIGURE 30-32. END DIALOG SCREEN
29
CEN30105-02 30 Testing and adjusting
2. Simultaneously push the Monitor Display Mode 6. The TARGET camera image is displayed on the
Switch, Guide Line Display Switch, and Lower 1 camera calibration screen. Set up the markers
Body Display Switch for three seconds or more. for the TARGET camera.
The password screen will appear.
a. Determine the position (near a marker) to
3. Enter a password to move to the maintenance select by using the "Whole" picture window
screen. (2nd Tab area). See Figure 30-37.
4. Select 1 CAMERA CALIBRATION. b. After determining the position, move the
cursor to the “Magnifying-power change Bar”
(4th Tab area) and enlarge the “Expansion”
picture window (3rd Tab area).
c. Move the cursor to the “Expansion” picture
window (3rd Tab area) and determine the
center of the marker.
d. When the center of the marker is determined,
a “Marker Dialog” screen will be displayed.
See Figure 30-36. Use the cursor to select the
marker name, then select OK. After
registration is complete, the marker changes
to green.
85258
FIGURE 30-34. 1 CAMERA CALIBRATION SCREEN
5. In the Configuration screen for 1 camera
calibration, select the proofreading camera and
the number of boundary markers on each side.
NOTE: The recommended value is 2 on the right and 2
on the left (total of four markers that were set out).
85250
FIGURE 30-36. MARKER DIALOG SCREEN
85259
FIGURE 30-35. CALIBRATION MARKERS
30
30 Testing and adjusting CEN30105-02
9. Select the EXIT button (5th Tab area) of the 1
Camera Calibration screen.
1st Tab area
10. The "End Dialog" screen will appear.
4th • To save the calibration results, select END
Tab area NEW SETTING. The screen returns to the
2nd Tab area 3rd Tab area maintenance screen.
• To perform the 1 camera calibration again,
choose END OLD SETTING.
5th Tab area
85256
FIGURE 30-37. TAB AREA LOCATIONS
7. Select the LEFT or RIGHT image switching
button (1st Tab area) and change the camera.
Set up a marker for the LEFT camera and the
RIGHT camera using the same procedure as
step 6.
8. Select the CALC button (5th Tab area) after
determining the markers of all the registration
positions.
85252
When the “Result Bird's Eye View Dialog” screen FIGURE 30-38. END DIALOG SCREEN
appears, it will either be successful or require
further attention.
• If the Result Window states “Calculation
Completed Successfully”, select NEXT in
the “Result Bird's Eye View Dialog” screen
and proceed to step 9.
• If the Result Window states “Calculation
Completed, But Large Error - x.x pixels”,
select MANUAL in the “Result Bird's Eye
View Dialog” screen and repeat step 6.
It is acceptable once “Calculation Completed
Successfully” is displayed in the Result Window
for the TARGET camera.
31
CEN30105-02 30 Testing and adjusting
Radar setting procedure 1. Place a radar reflector in the areas indicated in
Figure 30-39.
2. Simultaneously push the Monitor Display Mode
Switch, Guide Line Display Switch, and Lower
Body Display Switch for three seconds or more.
The password screen will appear.
When setting the radars, do not place any items 3. Enter a password to move to the maintenance
other than the specified items within 10 m (33 ft) of screen.
the truck. The radar adjustment cannot be properly
achieved.
10m Radar Reflector
(approximately 40cm
or 16in)
6.6m
When carring out the radar setting,
do not place any items other than
the thing specified in this area.
10m
10m
2.5m
2.5m
6.6m
Critical Zone
10m
85260
FIGURE 30-39. RADAR ZONE
32
30 Testing and adjusting CEN30105-02
4. Select the RADAR DETAIL button. 6. Take note of the OBJECT NO column, then
select the BACK button. In the maintenance
screen, select RADAR SETTING.
85261
FIGURE 30-40. RADAR DETAIL SCREEN
85263
FIGURE 30-42. RADAR DETAIL SCREEN
5. Select RADAR ON.
• If no OBJECT is displayed, adjustments are a. When the RADAR SETTING screen is
not necessary. Proceed to step 7. displayed, select the Threshold tab.
• If an OBJECT is displayed, adjustment is b. Increase the number of the RADAR POWER
required. Proceed to step 6. SETTING of the radar that corresponds to the
OBJECT NO from the previous screen, then
select SAVE.
Example: OBJECT NO 102 = RADAR2
CHANGE RADAR2 POWER SETTING 26 to 28
85262
FIGURE 30-41. INTEGRATION SCREEN
85264
FIGURE 30-43. THRESHOLD SCREEN
c. To verify whether the OBJECT is still
displayed, repeat steps 4 and 5. Continue
adjusting the RADAR POWER SETTING until
the OBJECT is no longer displayed. Then
proceed to step 7.
33
CEN30105-02 30 Testing and adjusting
7. Select RADAR SETTING in the maintenance
screen. In the Area tab, select the SET button.
If a radar is attached to the truck in a different
position at the user's order, select the
AllRadarPosition tab of the RADAR SETTING
screen and input the values of for that radar’s
MOUNTING POSITION and MOUNTING ANGLE.
85265
FIGURE 30-44. AREA SCREEN
a. Select YES in the "Set Radar setting?" screen.
85268
FIGURE 30-47. ALLRADARPOSITION SCREEN
85265
FIGURE 30-45. RADAR SCREEN
b. When SET is successful, select OK when the
"Success" window appears.
85265
FIGURE 30-46. RADAR SCREEN
8. Radar setting is complete. Select the BACK
button to return to the maintenance screen.
34
30 Testing and adjusting CEN30105-02
NOTES
35
CEN30105-02 30 Testing and adjusting
730E Dump truck
830E Dump truck
930E Dump truck
980E Dump truck
Form No. CEN30105-02
36
CEN30029-01
DUMP TRUCK 1SHOP MANUAL
730E 930E
830E 960E
860E 980E
Machine model Serial number Machine model Serial number
730E-8 A40002 and up 930E-5 A40004 and up
730E-10 A50002 and up 930E-5AT A40004 and up
830E-5 A50005 and up 960E-1K A50009 - A50010
830E-5AT A50005 and up 960E-2 A30027 and up
860E-1K A30031 - A30035, 960E-2K A50011 and up
A30041, A30042, 960E-2KT A50028 and up
A30044 - A30046, 980E-4 A40003 and up
A30101, A30107 - 980E-4AT A40003 and up
A30110, A30117, 980E-5 A50005 and up
A30118 980E-5AT A50005 and up
860E-1KT A30004 - A30030,
A30036 - A30040,
A30043, A30047 -
A30100, A30102 -
A30106, A30111 -
A30116
30 Testing and adjusting
Cab air conditioning
General information .............................................................................................................................................. 3
Service tools and equipment................................................................................................................................. 4
Detecting leaks ..................................................................................................................................................... 7
System performance test ...................................................................................................................................... 8
Checking system oil .............................................................................................................................................. 9
System flushing................................................................................................................................................... 10
Installing the manifold gauge set .........................................................................................................................11
Recovering and recycling refrigerant .................................................................................................................. 12
Evacuating the air conditioning system............................................................................................................... 14
Charging the air conditioning system.................................................................................................................. 15
1
CEN30029-01 30 Testing and adjusting
NOTES
2
30 Testing and adjusting CEN30029-01
General information
Servicing an air conditioning system really means
closely monitoring refrigerant flow. For this reason, the
following procedures deal extensively with the proper
use, handling, care and safety factors involved in the Federal regulations prohibit venting R-12 and R-
R-134a refrigerant quality and quantity in an air 134a refrigerant into the atmosphere. An SAE and
conditioning system. UL approved recovery/recycle station must be
used to recover refrigerant from the A/C system.
Because the refrigerant in an air conditioning system Refrigerant is stored in a container on the unit for
must remain pressurized and sealed within the unit to recycling, reclaiming, or transporting. In addition,
function properly, safety is a major consideration when technicians servicing A/C systems must be
anything causes this pressurized, sealed condition to certified they have been properly trained to service
change. The following warnings are provided here to the system.
alert service personnel to their importance before
learning the correct procedures. Read, remember, and Although accidental release of refrigerant is a
observe each warning before beginning actual system remote possibility when proper procedures are
servicing. followed, the following warnings must be
observed when servicing A/C systems:
NOTE: If the mine operates a fleet with some trucks
using R-12 and others using R-134a refrigerant, it is • Provide appropriate protection for your eyes
(goggles or face shield) when working around
essential that servicing tools that come into contact
refrigerant.
with the refrigerant (gauge sets, charging equipment,
recycle/recovery equipment etc.) be dedicated to one • A drop of the liquid refrigerant on your skin will
type of refrigerant only in order to prevent cross produce frostbite. Wear gloves and use
contamination. extreme caution when handling refrigerant.
• If even the slightest trace of refrigerant enters
your eye, flood the eye immediately with cool
water and seek medical attention as soon as
possible.
• Ensure that there is sufficient ventilation
Trucks operating in cold weather climates must whenever refrigerant is being discharged from
continue to keep the A/C system charged during a system. Keep in mind that refrigerant is
cold weather months. Keeping the system charged heavier than air and will fall to low-lying areas.
helps prevent moisture intrusion into system oil
• When exposed to flames or sparks, the
and desiccants. components of refrigerant change and become
deadly phosgene gas. This poison gas will
damage the respiratory system if inhaled.
NEVER smoke in an area where refrigerant is
used or stored.
Never leave A/C components, hoses, oil, etc, • Never direct a steam cleaning hose or torch in
direct contact with components in the air
exposed to the atmosphere. Always keep sealed or
conditioning system. Localized heat can raise
plugged until the components are to be installed the pressure to a dangerous level.
and the system is ready for evacuation and
charging. PAG oil and receiver-drier desiccants • Do not heat or store refrigerant containers
attract moisture. Leaving system components above 49 °C (120 °F).
open to the atmosphere will allow moisture to • Do not flush or pressure test the A/C system
invade the system, resulting in component and using shop air or another compressed air
system failures. source. Certain mixtures of air and R-134a
refrigerant are combustible when slightly
pressurized. Shop air supplies also contain
To help prevent air, moisture or debris from
moisture and other contaminants that could
entering an open system, cap or plug open lines, damage system components.
fittings, components and lubricant containers.
Keep all connections, caps, and plugs clean.
3
CEN30029-01 30 Testing and adjusting
Service tools and equipment
Recovery/recycle station
Whenever refrigerant must be removed from the
system, a dual purpose station (Figure 30-1) performs Mixing different types of refrigerant will damage
both recovery and recycle procedures which follows equipment. Dedicate one recovery/recycle station
the new guidelines for handling used refrigerant. The to each type of refrigerant processing to avoid
recovered refrigerant is recycled to reduce equipment damage. DISPOSAL of the gas removed
contaminants, and can then be reused in the same requires laboratory or manufacturing facilities.
machine or fleet.
Test equipment is available to confirm whether the
To accomplish this, the recovery/recycle station refrigerant in the system is actually the type intended
separates the oil from the refrigerant and filters the for the system and has not been contaminated by a
refrigerant multiple times to reduce moisture, acidity, mixture of refrigerant types.
and particulate matter found in a used refrigerant.
Recycling equipment must meet certain standards as
NOTE: To be re-sold, the gas must be “reclaimed” published by the Society of Automotive Engineers
which leaves it as pure as new, but requires equipment (SAE) and carry a UL approved label. The basic
normally too expensive for all but the largest principals of operation remain the same for all
refrigeration shops. machines, even if the details of operation differ
Equipment is also available to just remove or extract somewhat.
the refrigerant. Extraction equipment does not clean
the refrigerant; it is used to recover the refrigerant from Leak detector
an A/C system prior to servicing. The electronic leak detector (Figure 30-2) is very
accurate and safe. It is a small hand-held device with a
flexible probe used to seek refrigerant leaks. A buzzer,
alarm or light will announce the presence of even the
smallest leak.
Some leak detectors are only applicable to one type of
refrigerant. Ensure that the leak detector being used
applies to the refrigerant in the system.
FIGURE 30-1. RECOVERY/RECYCLE STATION FIGURE 30-2. TYPICAL ELECTRONIC LEAK
DETECTOR
4
30 Testing and adjusting CEN30029-01
Manifold gauge set
A typical manifold gauge set (Figure 30-3) has two
screw type hand valves to control access to the
system, two gauges and three hoses. The gauges are
used to read system pressure or vacuum. The
manifold and hoses are for access to the inside of an
air conditioner, to remove air and moisture, and to put
in, or remove, refrigerant from the system. Shutoff
valves are required within 305 mm (12 in.) of the hose
end(s) to minimize refrigerant loss.
A gauge set for R-134a will have a blue hose with a
black stripe for the low side, a red hose with a black
stripe for the high side, and a yellow hose with a black
stripe for the utility (center) hose. The hoses use a 1/2
in. ACME female nut on the gauge end. Special quick
disconnect couplings are normally combined with a
shutoff valve on the high and low side hoses. The free
end of the center hose contains a 1/2 in. ACME female
nut and a shutoff device within 305 mm (12 in.) of the
hose end. These special hoses and fittings are FIGURE 30-3. MANIFOLD GAUGE SET
designed to minimize refrigerant loss and to preclude
putting the wrong refrigerant in a system.
NOTE: When hose replacement becomes necessary,
the new hoses must be marked “SAE J2916 R-134a”.
Functions of the manifold gauge set are included in
many of the commercially available recovery or
recovery/recycle stations.
The low pressure gauge registers both vacuum and
pressure. The vacuum side of the scale is calibrated
from 0 to 30 inches of mercury (in. Hg). The pressure
side of the scale is calibrated to 1035 kPa (150 psi).
Never open the hand valve to the high side when
the air conditioning system is operating. High side
pressure, if allowed, may rupture charging
containers and potentially cause personal injury.
The high pressure gauge is used to measure pressure
only on the discharge side of the compressor. The
scale is calibrated to 3450 kPa (500 psi).
5
CEN30029-01 30 Testing and adjusting
Service valves Vacuum pump
Because an air conditioning system is a sealed The vacuum pump (Figure 30-5) is used to completely
system, two service valves are provided on the evacuate all of the refrigerant, air, and moisture from
compressor to enable diagnostic tests, system the system by deliberately lowering the pressure within
charging or evacuation. Connecting the applicable the system to the point where water turns to a vapor
hoses from the manifold gauge set to the compressor (boils) and together with all air and refrigerant is
service valves enables each of these to be readily withdrawn (pumped) from the system.
performed.
New and unique service hose fittings (Figure 30-4)
have been specified for R-134a systems. Their
purpose is to avoid accidental cross-mixing of
refrigerants and lubricants with R-12 based systems.
The service ports on the system are quick disconnect
type with no external threads. They do contain a
Schrader type valve. The low side fitting has a smaller
diameter than the high side attachment.
Protective caps are provided for each service valve.
When not being used these caps should be in place to
prevent contamination or damage to the service
valves.
FIGURE 30-5. VACUUM PUMP
FIGURE 30-4. R-134a SERVICE VALVE
1. System Service Port 3. Service Hose
Fitting Connection
2. Quick Connect
6
30 Testing and adjusting CEN30029-01
Detecting leaks Several methods are available for detecting refrigerant
leaks.
Refrigerant leaks are probably the most common
cause of air conditioning problems, resulting from NOTE: The refrigerant is heavier than air and will
improper or no cooling, to major internal component move downward when it leaks. Apply pickup hose or
damage. Leaks most commonly develop in two or test probe on the under-surface of all components to
three places. The first is around the compressor shaft locate leaks.
seal, often accompanied by an indication of fresh
• An electronic leak detector (see Figure 30-2) can
refrigerant oil. If a system is not operated for a while
be used to detect leaks. As the test probe is moved
(winter months), the shaft seal may dry out and leak into an area where traces of refrigerant are
slightly. The centrifugal force of the clutch pulley present, a visual or audible announcement
spinning can also cause the problem. When the indicates a leak. Audible units usually change tone
system is operated and lubricant wets the seal, the or speed as intensity changes.
leak may stop. Such leaks can often be located
• Tracer dyes are available that can be added to the
visually or by feeling with your fingers around the shaft
system as refrigerant is added. The system is then
for traces of oil. The R-134a itself is invisible, odorless, operated to thoroughly circulate the dye. As
and leaves no trace when it leaks, but has a great refrigerant escapes, it leaves a trace of the dye at
affinity for refrigerant oil. the point of leakage, which is then detected using
A second common place for leaks is the nylon and an ultraviolet light (“black light”), revealing a bright
fluorescent glow.
rubber hoses where they are crimped or clamped to
the fittings, or where routing allows abrasion. Other • Soap and water can be mixed together and applied
threaded joints or areas where gaskets are used to system components. Bubbles will appear to
should be visually and physically examined. Moving pinpoint the specific location of leaks.
your fingers along the bottom of the condenser and
evaporator, particularly near the drain hole for the
condensate will quickly indicate the condition of the After determining the location or source of leak(s),
evaporator. Any trace of fresh oil here is a clear repair or replace leaking component(s).
indication of a leak. NOTE: The length of the hose will affect the refrigerant
Usually, a 50% charged system is enough to find most capacity. When replacing hoses, always use the same
leaks. If the system is empty, connect the manifold hose length, if possible.
gauge set to the system and charge at least 1.6 kg
(3.5 lbs) of refrigerant into the system.
Before system assembly, check the compressor
oil level and fill to specifications.
Use extreme caution when leak testing a system
while the engine is running. In its natural state,
refrigerant is a harmless, colorless gas. But when
combined with an open flame, it will generate toxic
fumes (phosgene gas) which can cause serious
injuries or death.
7
CEN30029-01 30 Testing and adjusting
System performance test
This test is performed to establish the condition of all 8. Feel the hoses and components on the low side.
components in the system. Observe these conditions They should be cool to the touch. Check the
during testing: connections near the expansion valve. The inlet
side should be warm and the outlet side should
1. Place a fan in front of the condenser to simulate
be cold.
normal ram air flow and allow the system to
stabilize. 9. After a minimum of 10 minutes has elapsed and
the system has stabilized, observe the gauge
2. Install a thermometer into the air conditioning
readings. Compare the readings to the
vent closest to the evaporator.
specifications in Table 2.
3. Start the engine and operate at 1000 rpm.
4. Evaluate the readings obtained from the gauges
to see if they match the readings for the ambient NOTE: Pressures may be slightly higher in very humid
temperature. conditions and lower in very dry conditions. Pressures
listed in the table are during compressor clutch
5. Set the air conditioning system at maximum
engagement.
cooling and maximum blower speed operation.
6. Close all windows and doors to the cab.
7. Carefully feel the hoses and components on the 10. Check the cab vents for cool air. Outlet air
high side. All should be warm or hot to the touch. temperature should be approximately 16 - 22 °C
Check the inlet and outlet of receiver-drier for (30 - 40 °F) below ambient air temperature.
even temperatures. If outlet is cooler than inlet, a 11. If pressures and temperatures are not within the
restriction is indicated. specified ranges, the system is not operating
properly. Refer to Troubleshooting section Cab
air conditioning for tips on diagnosing poor
system performance.
Use extreme caution when placing hands on high
side components and hoses. Under most normal
conditions, these items can be extremely hot.
Table 2: NOMINAL R-134a PRESSURE RANGES
Ambient Air Temperature High Side Pressure Low Side Pressure
21 °C (70 °F) 820 - 1 300 kPa (120 - 190 psi) 70 - 138 kPa (10 - 20 psi)
27 °C (80 °F) 950 - 1 450 kPa (140 - 210 psi) 70 - 173 kPa (10 - 25 psi)
32 °C (90 °F) 1 175 - 1 650 kPa (170 - 240 psi) 105 - 210 kPa (15 - 30 psi)
38 °C (100 °F) 1 300 - 1 850 kPa (190 - 270 psi) 105 - 210 kPa (15 - 30 psi)
43 °C (110 °F) 1 450 - 2 075 kPa (210 - 300 psi) 105 - 210 kPa (15 - 30 psi)
NOTE: All pressures in this chart are for reference only. Weight is the only absolute means of determining
proper refrigerant charge.
8
30 Testing and adjusting CEN30029-01
Checking system oil
R-134a air conditioning systems require the use of
Polyalkylene Glycol (PAG) lubricating oil. This is the
only oil recommended for use in this system. The
Komatsu PAG oil (PC2279) is the oil that is furnished The receiver-drier and accumulator must be
in the system on Komatsu trucks equipped with the replaced each time the system is opened.
compressor as shown in Figure 30-6.
1. Remove the compressor from the truck. With the
• Avoid skin contact and inhalation of PAG oil, as compressor positioned horizontally, remove the
these are normal precautions with any chemical. drain plug and capture the oil in a clear graduated
• PAG oil removed from new or old components container. Rock the compressor back and forth
must not be retained for re-use. It must be stored and rotate the shaft to facilitate oil removal.
in a marked container and properly sealed. PAG oil
is an environmental pollutant and must be properly
disposed of after use.
• PAG oil in containers or in an air conditioning Under no circumstances should the A/C
system must not be left exposed to the
compressor be stood upright onto the clutch
atmosphere any longer than necessary. PAG oil
absorbs moisture very rapidly, and therefore, any assembly. Damage to the compressor clutch will
absorbed moisture could cause damage to an air result, leading to premature compressor failures.
conditioning system. 2. Inspect the oil for any foreign particles. If particles
are found, further investigation and service are
necessary to determine the source. After repair,
the system will need to be flushed. Refer to
"Evacuating the air conditioning system". If no
particles are found, proceed to the next step.
It is critical to keep the correct amount of lubricant 3. Add 300 ml (10.1 oz.) of PAG oil to the
in the air conditioning system at all times. Failure compressor sump. Add the oil through the drain
to do so could result in damage to the compressor. port, and install the drain plug. It is important to
only add the specified amount to ensure optimal
Damage to the compressor can be a result from system performance. Too much oil will result in a
not only a lack of oil, but also too much oil. A lack reduction in cooling. Too little oil will result in
of oil will cause excess friction and wear on compressor failure.
moving parts. Excessive oil can result in
“slugging” the compressor. This condition occurs 4. Determine the correct amount of additional oil to
when the compressor attempts to compress liquid add to the system by using the Replacing Oil
oil as opposed to vaporized refrigerant. Since table. Add this extra oil to the inlet side of the
liquid cannot be compressed, damage to internal receiver drier or to the accumulator.
parts results. NOTE: If truck is being assembled for the first time,
add 207 ml (7oz.) of PAG oil to the inlet side of the
receiver-drier or to the accumulator for initial
lubrication of the A/C components.
EXAMPLE - If only the accumulator and receiver drier
were replaced, then add 120 ml (4 oz.) of PAG oil to
the inlet side of the receiver-drier or to the
accumulator. If the evaporator was also replaced at
this time, then add 150 ml (5 oz.) of PAG oil to the inlet
side of the receiver-drier or to the accumulator.
NOTE: The proper quantity of oil may be injected into
FIGURE 30-6. COMPRESSOR the system during charging as an alternate method of
300 ml - (10.1 oz.) PC2279 PAG OIL adding oil.
9
CEN30029-01 30 Testing and adjusting
System flushing
If any contaminants are found in system hoses,
components or oil, the entire system must be flushed.
Major components such as the compressor are
When installing a new compressor, the extremely susceptible to foreign particles and must be
compressor must be completely drained of its oil replaced. If contaminated, the evaporator and
before installation. Add 300 ml (10.1 oz.) of new condenser must also be replaced. The evaporator and
PAG oil to the compressor to ensure proper condenser are multi-pass units, and they can not be
system oil level. Failure to adjust the amount of oil properly cleaned by flushing.
in the compressor will lead to excessive system oil
and poor A/C performance. Also, a new receiver-
drier and accumulator must be installed and the
correct amount of extra oil (per Table 1) must be
added to either one of these components.
Only SAE and/or Mobile Air Conditioning Society
(MACS) approved flushing methods with the
Table 1: Replacing system oil appropriate refrigerants are to be performed when
removing debris from the system. Other methods
Component Oil to add may be harmful to the environment, as well as air
conditioning components.
Condenser 60-90 ml (2-3 ounces)
1. Remove the compressor, receiver-drier,
Evaporator 30 ml (1 ounce) expansion valve, and accumulator.
Receiver-Drier 60 ml (2 ounces) 2. Inspect all other components such as the
condenser, evaporator, hoses and fittings. If any
Accumulator 60 ml (2 ounces) of these items are damaged or highly
contaminated, replace the components.
Compressor 300 ml (10.1 ounces)
3. Flush the remaining hoses with a flushing unit.
Expansion valve Not necessary Use only R134a as a flushing agent.
Drain and measure the 4. After flushing, blow out the system with dry shop
Hoses air for 5 to 10 minutes.
amount removed.
5. If the expansion valve has been removed of all
foreign contamination, it may be reinstalled back
5. Connect all hoses and components in the into the system. If contamination is still present,
system. Lubricate O-rings with clean mineral oil replace the valve.
before assembly. 6. Install a new compressor, receiver-drier, and
accumulator.
NOTE: Do not use PAG oil to lubricate O-rings or
fittings. PAG oil will attract moisture and will corrode 7. Add oil to the system as outlined in Table 1.
fittings when used externally. Use only clean mineral
oil to lubricate fittings and O-rings during assembly.
6. Evacuate the system. Refer to "Evacuating the
air conditioning system".
10
30 Testing and adjusting CEN30029-01
Installing the manifold gauge set
Before attempting to service the air conditioning
system, a visual inspection of both the engine and air 1
conditioning system components is recommended.
Particular attention should be given to the belts, hoses,
tubing and all attaching hardware as well as the
radiator cap, fan clutch, and thermostat. Inspect both HIGH
the condenser and the radiator for any obstructions or SIDE
potential contamination. Minimize all the possibilities
for error or malfunction of components in the air
conditioning system.
Shut off the engine. DO NOT attempt to connect LOW
service equipment when the engine is running. SIDE
1. Make sure that all valves on the manifold are
closed all the way (turn them clockwise).
2. Check the hose connections on the manifold for
tightness. 2
3. Locate the low and high side system service
fittings and remove their protective caps.
4. Connect the two service hoses from the manifold 3
to the correct service valves on the compressor
and accumulator as shown in Figure 30-7 (high 86210
side to compressor discharge valve and low side FIGURE 30-7. SERVICE HOSE HOOK-UP
to accumulator). Do not open the service valves
at this time. Purging air from the service hoses
This gauge hook-up process will be the same, The purpose of this procedure is to remove all the air
regardless of the gauge set being installed. Whether it trapped in the hoses prior to actual system testing.
is a recovery station or individual gauges, the Environmental regulations require that all service
connections are the same. The procedures performed hoses have a shutoff valve within 12 inches of the
next will vary depending what type of equipment is service end. These valves are required to ensure only
being used. If a recovery/recycling station is being a minimal amount of refrigerant is lost to the
used, complete servicing can be accomplished. Using atmosphere. R-134a gauge sets have a combination
only a set of gauges will limit the servicing to only quick disconnect and shutoff valve on the high and low
adding refrigerant or observing pressures. sides. The center hose also requires a valve.
The initial purging is best accomplished when
connected to recovery or recycle equipment. With the
center hose connected to the recovery station, service
hoses connected to the high and low sides of the
system, we can begin the purging. The manifold
valves and service valves should be closed. Activating
the vacuum pump will now pull any air or moisture out
of the center hose. This will require only a few minutes
of time. The hose is the only area that is being placed
in a vacuum and this will not require a lengthy process.
Closing the valve will then insure the hose is purged. It
is now safe to open the other manifold valves.
11
CEN30029-01 30 Testing and adjusting
Recovering and recycling refrigerant
Recycled refrigerant has been extracted from a mobile
air conditioning system using a recovery unit. The
refrigerant is cleaned by the recovery unit as it passes
through filters located on the unit that meet An unclear sight glass on R-134a systems can
specifications stipulated by Society of Automotive indicate that the system may be low on refrigerant.
Engineers, SAE J2099. The refrigerant that has However, the sight glass should not be used as a
passed through the filtering process has only been gauge for charging the system. Charging the
cleaned of contaminants that are associated with system must be done with a scale to ensure the
mobile systems. Therefore, recycled refrigerant from proper amount of refrigerant has been added.
mobile systems is only acceptable for reuse in mobile
systems. Two basic, readily available containers are used to
store R-134a: the 14 kg (30 lb) or 28 kg (60 lb) bulk
Reclaimed refrigerant has been filtered through a canisters (Figure 30-8). Always read the container
more thorough filtering process and has been label to verify the contents are correct for the system
processed to the same standards of purity as virgin being serviced. Note the containers for R-134a are
refrigerant. Because of this, reclaimed refrigerant is painted light blue.
acceptable for use in all systems, not just mobile. The
reclaiming equipment used for this process is
expensive, and therefore, not common among normal
maintenance shops. Equipment such as this is more
commonly found in air conditioning specialty shops.
Always use new, recycled, or reclaimed refrigerant
when charging a system. Failure to adhere to this
recommendation may result in premature wear or
damage to air conditioning system components
and poor cooling performance.
If not enough refrigerant is charged into the system, FIGURE 30-8. R-134a CONTAINERS
cooling ability will be diminished. If too much
refrigerant is charged into the system, the system will 1. 14 kg (30 lb) Canister 2. 28 kg (60 lb) Canister
operate at higher pressures and, in some cases, may
damage system components. Exceeding the specified
refrigerant charge will not provide better cooling.
If an incorrect charge is suspected, recover the
refrigerant from the system, and charge the system
with the correct operating weight of 3.4 kg (7.4 lb). This
is not only the recommended procedure, but it is also
the best way to ensure that the system is operating
with the proper charge and providing optimum cooling.
Using the sight glass to determine the charge is not an
accurate method.
12
30 Testing and adjusting CEN30029-01
Draining oil from previous recovery cycle 7. Continue extraction until a vacuum exists in the
1. Place the power switch and the controller on the A/C system.
recovery unit in the OFF position. 8. If an abnormal amount of time elapses after the
system reaches 0 kPa (0 psi) and does not drop
2. Plug in the recovery station to the correct power
steadily into the vacuum range, close the
source.
manifold valves and check the system pressure.
3. Drain the recovered oil through the valve marked If it rises to 0 psi and stops, there is a major leak.
“oil drain” on the front of the machine. 9. Check the system pressure after the recovery
4. Place the controller knob in the ON position. The equipment stops. After five minutes, system
low pressure gauge will show a rise. pressure should not rise above 0 kPa (0 psi). If
the pressure continues to rise, restart and begin
5. Immediately switch to the OFF position and allow
the recovery sequence again. This cycle should
the pressure to stabilize. If the pressure does not
continue until the system is void of refrigerant.
rise to 34 - 69 kPa (5 - 10 psi), switch the
controller ON and OFF again. 10. Check the sight glass oil level to determine the
amount of oil that needs to be replaced. (The
6. When the pressure reaches 34-69 kPa (5-10
amount of oil that was lost during the recovery
psi), open the “oil drain” valve, collect the oil in an
cycle must be replaced back into the system).
appropriate container, and dispose of container
as indicated by local, state or federal regulation. 11. Mark the cylinder with a “RECOVERED” (red)
The oil is not reusable due to contaminants that magnetic label to reduce the chance of charging
were absorbed during use. a system with contaminated refrigerant. Record
the amount of refrigerant recovered.
Recovery cycle
Recycling procedure
1. Ensure that the equipment being used is
designed for the refrigerant you intend to recover. The recovered refrigerant contained in the cylinder
2. Observe the sight glass oil level. Having been must undergo the recycle procedure before it can be
drained, it should be at zero. reused. The recycle or clean mode is a continuous
loop design and cleans the refrigerant rapidly. Follow
3. Check the cylinder refrigerant level before
the equipment manufacturer's instructions for this
beginning recovery to make sure you have
procedure.
enough capacity.
4. Confirm that all shutoff valves are closed before
connecting to the A/C system.
5. Attach the appropriate hoses to the system being
recovered.
6. Start the recovery process by operating the
equipment according to the manufacturer's
instructions.
13
CEN30029-01 30 Testing and adjusting
Evacuating the air conditioning system 3. Allow the vacuum pump to run for at least 45
minutes.
Evacuating the complete air conditioning system is
required for all new system installations, when repairs 4. Shut off the vacuum pump and observe the
are made on systems requiring a component gauges. The system should hold the vacuum
replacement (system opened), or when a major loss of within 5 cm Hg (2 in. Hg) of the optimal vacuum
refrigerant has occurred. All these conditions will for five minutes. If the vacuum does not hold,
require that a vacuum be pulled using a vacuum pump moisture may still be present in the system.
that completely removes any moisture from the Repeat the previous step. If the vacuum still does
system. Once properly evacuated, the system can be not hold, a leak may be present in the system.
recharged again. Find the source of the leak, repair, and evacuate
the system again.
Using a pump to create a vacuum in the air
conditioning system effectively vaporizes any NOTE: In some cases, 45 minutes of evacuation may
moisture, allowing the water vapor to be easily drawn not be sufficient to vaporize all of the moisture and
out by the pump. The pump does this by reducing the draw it out of the system. If it has been verified that no
point at which water boils (100 °C, 212 °F at sea level system leaks exist and gauge readings increase after
with 14.7 psi). In a vacuum, water will boil at a lower 45 minutes, extend the evacuation time to ensure total
temperature depending upon how much of a vacuum moisture removal.
is created.
As an example, if the ambient air outside the truck is
24 °C (75 °F) at sea level, by creating a vacuum in the 1
system so that the pressure is below that of the
outside air (in this case, at least 749.3 mm (29.5 in.) of
vacuum is needed), the boiling point of water will be
lowered to 22 °C (72 °F). Thus any moisture in the
system will vaporize and be drawn out by the pump if
the pump is run for approximately an hour. The
following steps indicate the proper procedure for
evacuating all moisture from the heavy duty air
conditioning systems.
Do not attempt to use the air conditioning
VACUUM
compressor as a vacuum pump or the compressor
PUMP
will be damaged.
NOTE: Refer to Table 3 for optimal vacuum
specifications at various altitudes. 2
1. With the manifold gauge set still connected (after
discharging the system), connect the center hose
to the inlet fitting of the vacuum pump as shown 3
in Figure 30-9. Then open both hand valves to
maximum. 86211
2. Open the discharge valve on the vacuum pump FIGURE 30-9. VACUUM PUMP HOOKUP
or remove the dust cap from the discharge outlet.
Turn on the pump and watch the low side gauge.
The pump should pull the system into a vacuum.
If not, the system has a leak. Find the source of
the leak, repair, and attempt to evacuate the
system again.
14
30 Testing and adjusting CEN30029-01
Charging the air conditioning system
Table 3: ALTITUDE VACUUM VARIATIONS The first step in properly charging refrigerant into an R-
Altitude Above 134a system is to recover all of the refrigerant from the
Optimal Vacuum system. Then weigh the charging refrigerant on a
Sea Level
scale to ensure that the proper amount is charged into
0 m (0 ft) 76.0 cm Hg. (29.92 in. Hg.)
the system. Most recovery units include a scale within
305 m (1,000 ft) 73.5 cm Hg. (28.92 in. Hg.) the apparatus, making it easy to charge the correct
610 m (2,000 ft) 70.7 cm Hg. (27.82 in. Hg.) amount every time. If equipment such as this is not
available, a common scale can be used to determine
914 m (3,000 ft) 68.1 cm Hg. (26.82 in. Hg.)
the weight of charge. Simply weigh the charging tank,
1 219 m (4,000 ft) 65.6 cm Hg. (25.82 in. Hg.) subtract the weight of the proper charge, and charge
1 524 m (5,000 ft) 63.3 cm Hg. (24.92) in. Hg. the system until the difference is shown on the scale.
On certain types of equipment, it is also possible to
1 829 m (6,000 ft) 60.8 cm Hg. (23.92 in. Hg.)
add any necessary lubricant when charging the
2 134 m (7,000 ft) 58.5 cm Hg. (23.02 in. Hg.) system.
2 438 m (8,000 ft) 56.4 cm Hg. (22.22 in. Hg.) If a scale is not used when charging R-134a into a
2 743 m (9,000 ft) 54.2 cm Hg. (21.32 In. Hg.) system, it is difficult to determine whether the correct
NOTE: The chart indicates the expected gauge charge has been achieved. The sight glass can
readings at altitude to obtain the optimal vacuum. provide some indication, but it is not a reliable tool for
determining the proper charge.
NOTE: Charging is to be performed while the engine
and compressor are operating. Charge the A/C system
through the low side service port. Trucks equipped
with accumulators may charge the refrigerant as a
liquid or as a vapor.
1. Charge the A/C system with 3.4 kg (7.4 lbs) of R-
134a refrigerant.
2. Check the system for leaks. Refer to "Detecting
leaks".
3. If no leaks are found, verify that the system’s
cooling capacity meets requirements. Refer to
"System performance test".
15
CEN30029-01 30 Testing and adjusting
730E Dump truck
830E Dump truck
860E Dump truck
930E Dump truck
960E Dump truck
980E Dump truck
Form No. CEN30029-01
16
CEN30129-00
DUMP TRUCK 1SHOP MANUAL
730E 960E
830E 980E
860E
930E
Machine model Serial number
980E-5 A50052, A50053,
A50137, A50138
30 Testing and adjusting
Automatic lubrication (auto lube) system
Priming the system ............................................................................................................................................... 3
Checkout procedure.............................................................................................................................................. 4
Adjusting the lubrication cycle timing .................................................................................................................... 5
1
CEN30129-00 30 Testing and adjusting
NOTES
2
30 Testing and adjusting CEN30129-00
Priming the system
3 4
Do not connect the electrical harness to the auto
lube pump until the reservoir has been filled and
all air has been purged from the system. Damage
to the auto lube pump may occur if the pump is
operated with insufficient lubrication.
5
The system must be full of grease and free of air to
function properly. If auto lube pump (3, Figure 30-1)
has been replaced, the new pump must be primed.
1. Fill the reservoir with grease, if necessary.
2. Remove the grease discharge hose from the
pump, then connect a short clean temporary
2
hose to route grease back to the reservoir or into
a suitable container.
1
3. Start the engine.
4. Actuate manual override switch (5) to operate the
pump. Watch for grease flow from the temporary
87502
hose.
5. Once full grease flow is achieved, stop the pump. FIGURE 30-1. AUTO LUBE PUMP
Remove the temporary hose and reconnect the 1. Main Supply Line 4. Plug
discharge hose to the system. 2. Vent Valve 5. Manual Override
3. Auto Lube Pump Switch
NOTE: Full grease flow should appear within two
minutes of starting the pump. If it takes longer than two
minutes, check for problems.
If any lubrication lines were opened or replaced, it will
be necessary to prime the system to purge any
entrapped air. Begin with the main supply lines.
1. Fill the reservoir with grease, if necessary.
2. Remove plug (1, Figure 30-2) from the injector
manifold.
NOTE: Always start with the injector manifold that is
closest to the auto lube pump. The last grease line to
be purged should be the main grease line to the rear
axle (longest grease line).
3. Disconnect main supply line (1, Figure 30-1) from
vent valve (2). Connect an external grease
supply to the main supply line.
4. Pump grease into main supply line (1) until
grease appears at the injector manifold plug.
5. Install plug (1, Figure 30-2) in the injector
manifold. Repeat these steps for the remaining
injector groups.
3
CEN30129-00 30 Testing and adjusting
After all main supply lines are purged of air, the injector Checkout procedure
circuits must be primed.
To check that the auto lube system is functioning
1. If necessary, disconnect an injector grease line properly:
from the component to which that particular
1. Ensure that the engine is off and all hydraulic
injector supplies grease.
system pressure is bled down.
2. Remove grease zerk cap (2, Figure 30-2) from
2. Remove the injector covers (5, Figure 30-2) from
each injector and connect an external grease
the injectors to allow visual inspection of indicator
supply to injector grease zerk (3).
pins (4) during system operation.
3. Pump grease into the injector until grease
3. Remove plug (4, Figure 30-1) from the top of the
appears at the far end of the individual grease
pump manifold and install a 3 500 kPa (500 psi)
line or the joint that is being greased.
hydraulic pressure gauge.
4. Reconnect the injector grease line to the
4. Start the engine. Allow the hydraulic system to
component, then remove the external grease
build pressure.
supply.
5. Actuate manual override switch (5) at the pump.
5. Install the injector grease zerk cap. Repeat these
The hydraulic motor and pump should operate.
steps for the remaining secondary supply lines
6. Allow the pump to reach stall condition. The
After all grease lines are primed, use the manual pressure gauge should read 2 415 - 2 585 kPa
override switch to cycle the auto lube pump a few (350 - 375 psi).
times to lubricate the components. Allow enough time
7. Observe the movement of indicator pin (4) at
between cycles for the injectors to reset.
each injector. With the grease under pressure,
the indicator pin should be retracted inside the
injector body.
8. Check for leakage while the system is under
5 pressure.
9. When the system is at 16 200 - 17 250 kPa
(2,350 - 2,500 psi), the pump should shut off and
the pressure in the system should drop to zero,
4 venting back to the grease reservoir.
10. Stop the engine. Allow all hydraulic system
pressure to bleed down.
11. Remove the pressure gauge and install plug (4,
2 3 Figure 30-1) in the top of the pump manifold.
12. Install injector covers (5, Figure 30-2).
13. Repair any leaks that were observed.
1
87503
FIGURE 30-2. AUTO LUBE INJECTORS
1. Plug 4. Indicator Pin
2. Grease Zerk Cover 5. Injector Cover
3. Injector Grease Zerk
4
30 Testing and adjusting CEN30129-00
Adjusting the lubrication cycle timing
The time between lube events is determined by the
setting that is selected on the Interface Module 2 (IM2)
webpage.
1. Turn the engine switch ON.
2. Connect the IM2 Configuration webpage.
3. Set the Autolube interval configuration.
The available settings are 8, 15, 24, or 30 minutes
between lube cycles. The default setting is 15
minutes.
5
CEN30129-00 30 Testing and adjusting
980E Dump truck
Form No. CEN30129-00
6
CEN40199-01
DUMP TRUCK
980E
Machine model Serial number
980E-5 A50005 and up
980E-5AT A50005 and up
40 Troubleshooting
Fuse, diode and relay locations
Vehicle Electrical Center (VEC-89) ....................................................................................................................... 2
Vehicle Electrical Center (VEC-90) ....................................................................................................................... 4
Vehicle Electrical Center (VEC-91) ....................................................................................................................... 6
Vehicle Electrical Center (VEC-92) ....................................................................................................................... 8
Rear Terminal Mini-fuse and Relay (RTMR3) ....................................................................................................... 9
Rear Terminal Mini-fuse and Relay (RTMR4) ..................................................................................................... 10
Circuit breakers................................................................................................................................................... 10
1
CEN40199-01 40 Troubleshooting
Vehicle Electrical Center (VEC-89)
84052
FIGURE 3-1. VEC-89
Table 1: VEC - 89
Location Amps Device(s) Protected
F2 25 Back-Up Lamps
F3 15 Back-Up Horn
F4 15 Left Low Beam Headlights
F5 15 Right Low Beam Headlights
F6 25 High Beam Headlights
F8 15 Marker & Tail Lights
F9 10 Brake Light
F10 20 Ladder Lights
F11 15 Turn Signal Hazard
F12 10 Steering Bleed Down
F13 10 Retard Lamps
F20 10 Auto Lube
F42 5 IM & Fuel Sensor
F43 5 Direction Selector Switch
Display Mode Switch, Camera Switch and
F44 5
Switch LED Lights
F45 15 GE Drive Control & Feedback
2
40 Troubleshooting CEN40199-01
Table 1: VEC - 89
Location Amps Device(s) Protected
F53 20 Heated Mirror
F56 15 Operator Seat
F57 10 Pre-Shift Brake Test
F61 5 Cab Controller Fans
F62 15 Fog Lamp
F63 15 Seat Belt Alarm
F64 5 Headlight Switch
D14 3 Back-Up Diode 1
D15 3 Back-Up Diode 2
R3 Back-Up Horn Relay
R8 Marker & Tail Light Relay
R9 Brake Light Relay
R11 Left Turn Relay
R12 Right Turn Relay
R13 Turn Signal Hazard Flasher Relay
R14 Steering Bleed Down Relay
R15 Retard Lamps Relay
R29 System Busy Relay
R39 Heated Mirror Relay
R40 Fog Lamp Relay
R41 Seat Belt Alarm Relay
3
CEN40199-01 40 Troubleshooting
Vehicle Electrical Center (VEC-90)
84053
FIGURE 3-2. VEC-90
Table 2: VEC - 90
Location Amps Device(s) Protected
F14 5 Payload Lamps
F15 5 Park Brake Status
F17 5 Payload Meter
F18 15 Ground Level Shutdown Switch
F19 10 Park Brake Control
F46 5 Payload Meter Key Switch Power
F47 5 KOMTRAX Plus Key Switch Power
F48 5 Modular Mining Conn Key Switch Power
D1 3 Key Switch Run Diode
D2 3 Shift Selector Reverse Diode
D3 3 Shift Selector Neutral Diode
D4 3 Shift Selector Forward Diode
D5 3 Park Brake Diode
D6 3 Truck Moving Diode
D7 3 Brake Lock Diode
D8 3 Park Brake Latch Diode
D9 3 GE True Forward Signal Diode
4
40 Troubleshooting CEN40199-01
Table 2: VEC - 90
Location Amps Device(s) Protected
D10 3 GE True Reverse Signal Diode
D11 3 GE Propel System At Rest Diode
D12 3 GE Propel System Not Ready Diode
D13 3 Forward, Neutral, Reverse Signal Diode
D14 3 Engine Running Diode
R16 Payload Red Lamp Relay
R17 Payload Amber Lamp Relay
R18 Payload Green Lamp Relay
R19 Engine Interlock Relay
R20 Timed Engine Shutdown Relay
R21 Engine Running Relay
R22 Park Brake Request Relay
R23 Park Brake Release Relay
R24 Park Brake Switch Relay
R25 Truck Moving Relay
R26 Park Brake Latch Relay
R27 GE Interface Relay
R28 Park Brake Status Relay
5
CEN40199-01 40 Troubleshooting
Vehicle Electrical Center (VEC-91)
84054
FIGURE 3-3. VEC-91
Table 3: VEC - 91
Location Amps Device(s) Protected
F21 10 Ether Start
F22 20 Operator Cab Communication Radio 12V
F23 10 Entertainment Radio 12V
F24 10 A/C Compressor
F25 10 Shutter Control
F26 15 Electronic Gauge Display Un-switched
F27 10 IM Un-switched # 1
F28 10 IM Un-switched # 2
F29 10 KOMTRAX Plus & Iridium
F30 20 Modular Mining Un-switched
F31 15 Engine Oil Reserve Pump Motor
F32 15 Engine Oil Reserve Controller
F33 15 Vehicle Horn / Service Lamps
F34 15 Engine Service Lamps / Hydraulic Mod Lamp
F35 15 Ladder & Hazard Lamp Control Switch
F36 20 Engine Un-switched Power Fuse #1
F37 20 Engine Un-switched Power Fuse #2
F38 20 Engine Un-switched Power Fuse #3
6
40 Troubleshooting CEN40199-01
Table 3: VEC - 91
Location Amps Device(s) Protected
F39 20 Engine Un-switched Power Fuse #4
F40 20 Operator Cab Communication Radio 24V
F41 5 Operator Cab Fire Suppression
F50 10 Windshield Wipers
F51 10 Hoist Limit Switch
F52 5 Turn Signal Switch
F54 5 Electronic Gauge Display Key Switch
F55 5 Aux Box Dome Lamps
F56 20 Electric Window - Left
F58 5 Ladder Switch Control
F59 25 HVAC Control Panel
F60 15 Operator Seat
F62 20 Electric Window - Right
F63 20 Auxiliary Power Port 12V
D13 3 Turn Signal Switch Diode
D14 3 Key Switch Power Diode
D15 3 GE Control Power Diode
R30 Starter Enable Relay
R34 GE Payload 70% Signal Relay
R35 GE Payload 100% Signal Relay
R36 Ether Start Relay
R37 Entertainment Radio Relay
R38 A/C Compressor Relay
R39 Shutter Control Relay
7
CEN40199-01 40 Troubleshooting
Vehicle Electrical Center (VEC-92)
87520
FIGURE 3-4. VEC-92
Table 4: VEC - 92
Location Amps Device(s) Protected
F1 20 Engine NOX Power
F2 20 Engine Child 3
F3 15 KomVision Power
F4 10 VID Panel
F5 15 DEF Supply Pumps
F6 15 NOX Sensors
F7 15 Dosing Modules 1 & 2
F8 20 Oil Reserve Heated Line
F9 15 KomVision Control Key
F10 5 Fan Clutch
F11 20 KomVision Radar
R1 IM System Busy Relay
R2 Shutter Control Relay
R3 Spare
R4 Park Brake Protection Relay
8
40 Troubleshooting CEN40199-01
Rear Terminal Mini-fuse and Relay
(RTMR3)
58B-65-00001
FIGURE 3-5. RTMR3 VEC BLOCK
Table 5: RTMR3
Location Amps Device(s) Protected
F1 15 Line Heater DEF Supply/Return LH1/2
F2 15 Line Heater DEF Supply/Return LH3/4
F3 15 Line Heater DEF Supply/Return LH5/6
F3 15 Line Heater DEF Supply/Return LH7/8
F5 15 Line Heater DEF Suction LH9/10/11/12
Line Heater DEF Transfer LH13
F6 15
Line Heater DEF Fast Fill Receiver/Valve
F7 Unused
F8 Unused
F9 Unused
F10 Unused
R1 Dosing Module #1 Heater Relay
R2 Dosing Module #2 Heater Relay
R3 Dosing Module #3 Heater Relay
R4 Dosing Module #4 Heater Relay
9
CEN40199-01 40 Troubleshooting
Rear Terminal Mini-fuse and Relay
(RTMR4)
WB4011
FIGURE 3-6. RTMR4 VEC BLOCK
Table 6: RTMR4
Location Amps Device(s) Protected
F1 15 DEF Line Heaters Pumps 1 & 2
F2 15 DEF Line Heaters Pumps 3 & 4
R1 DEF Line Heaters Relay
R2 DEF Supply Pump 1 Relay
R3 DEF Supply Pump 2 Relay
R4 DEF Supply Pump 3 Relay
R5 DEF Supply Pump 4 Relay
R6 NOX ECU 1 Relay
R7 NOX ECU 2 Relay
Circuit breakers
Table 7: CIRCUIT BREAKERS
Location Amps Device(s) Protected Circuit
CB60 50 24VDC to 12VDC Converter 11BS
CB1 105 DEF Tank Line Heater 11LH
10
40 Troubleshooting CEN40199-01
NOTES
11
CEN40199-01 40 Troubleshooting
980E Dump truck
Form No. CEN40199-01
12
CEN40178-01
DUMP TRUCK
730E
830E
930E
980E
Machine model Serial number
730E-10 A50002 and up
830E-5 A50005 and up
830E-5AT A50005 and up
930E-5 A40004 and up
930E-5AT A40004 and up
980E-5 A50005 and up
980E-5AT A50005 and up
40 Troubleshooting
Troubleshooting by fault code, part 1
Fault Code A001 ................................................................................................................................................... 4
Fault Code A002 ................................................................................................................................................... 5
Fault Code A003 ................................................................................................................................................... 6
Fault Code A004 ................................................................................................................................................... 7
Fault Code A005 ................................................................................................................................................... 8
Fault Code A006 ................................................................................................................................................... 9
Fault Code A007 ................................................................................................................................................. 10
Fault Code A008 ..................................................................................................................................................11
Fault Code A011 ................................................................................................................................................. 12
Fault Code A013 ................................................................................................................................................. 13
Fault Code A014 ................................................................................................................................................. 14
Fault Code A016 ................................................................................................................................................. 15
Fault Code A017 ................................................................................................................................................. 16
Fault Code A018 ................................................................................................................................................. 17
1
CEN40178-01 40 Troubleshooting
Fault Code A019 ................................................................................................................................................. 18
Fault Code A022 ................................................................................................................................................. 19
Fault Code A101 ................................................................................................................................................. 20
Fault Code A103 ................................................................................................................................................. 21
Fault Code A104 ................................................................................................................................................. 22
Fault Code A105 ................................................................................................................................................. 23
Fault Code A109 ................................................................................................................................................. 24
Fault Code A111.................................................................................................................................................. 25
Fault Code A115 ................................................................................................................................................. 27
Fault Code A117 ................................................................................................................................................. 28
Fault Code A118: Brake pressure is low while in brake lock............................................................................... 30
Fault Code A123: GE has generated a reduced retarding caution ..................................................................... 32
Fault Code A124: GE has generated a no propel / no retard or system not running input ................................. 33
Fault Code A125: GE has generated a no propel warning ................................................................................. 36
Fault Code A126: Oil level in the hydraulic tank is low ....................................................................................... 37
Fault Code A127: IM-furnished +5 volt output for sensors is low........................................................................ 38
Fault Code A128: IM-furnished +5 volt output for sensors is high ...................................................................... 39
Fault Code A139: Low fuel warning .................................................................................................................... 40
2
40 Troubleshooting CEN40178-01
NOTES
3
CEN40178-01 40 Troubleshooting
Fault Code A001
Description Left front suspension pressure sensor signal is high.
Fault Conditions Sets if pressure signal is out of range high (sensor current over 22 ma).
Alert to Operator Repair Lamp
Display Operator Action: None
Display Fault Description: PLM LF PRESS SENS HI
Resulting Problem(s) Bad payload computation.
Related Information 1. A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2. This fault is generated by PLM in response to a problem in the sensor circuit. This
sensor circuit may have a related fault that can be used to resolve the problem. Refer
to the Troubleshooting Instructions for the active parameter fault(s).
3. Check sensor and wiring harness.
Circuit Description Sensor Payload Left Front (730E)
PLM4, 1, 40 (Sche-
matic search) Sensor Payload Pressure Left Front (830E, 930E, 980E)
Expected State Sensor Current between 3 and 21ma
4
40 Troubleshooting CEN40178-01
Fault Code A002
Description Left front suspension pressure sensor signal is low.
Fault Conditions Sets if pressure signal is out of range low (sensor current less than 2 ma).
Alert to Operator Repair Lamp
Display Operator Action: None
Display Fault Description: PLM LF PRESS SENS LO
Resulting Problem(s) Bad payload computation.
Related Information 1. A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2. This fault is generated by PLM in response to a problem in the sensor circuit. This
sensor circuit may have a related fault that can be used to resolve the problem. Refer
to the Troubleshooting Instructions for the active parameter fault(s).
3. Check sensor and wiring harness.
Circuit Description Sensor Payload Left Front (730E)
PLM4, 1, 40 (Sche-
matic search) Sensor Payload Pressure Left Front (830E, 930E, 980E)
Expected State Sensor Current between 3 and 21ma
5
CEN40178-01 40 Troubleshooting
Fault Code A003
Description Right front suspension pressure sensor signal is high.
Fault Conditions Sets if pressure signal is out of range high (sensor current over 22 ma).
Alert to Operator Repair Lamp
Display Operator Action: None
Display Fault Description: PLM RF PRESS SENS HI
Resulting Problem(s) Bad payload computation.
Related Information 1. A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2. This fault is generated by PLM in response to a problem in the sensor circuit. This
sensor circuit may have a related fault that can be used to resolve the problem. Refer
to the Troubleshooting Instructions for the active parameter fault(s).
3. Check sensor and wiring harness.
Circuit Description Sensor Payload Right Front (730E)
PLM4, 2, 40 (Sche-
matic search) Sensor Payload Pressure Right Front (830E, 930E, 980E)
Expected State Sensor Current between 3 and 21ma
6
40 Troubleshooting CEN40178-01
Fault Code A004
Description Right front suspension pressure sensor signal is low.
Fault Conditions Sets if pressure signal is out of range low (sensor current less than 2 ma).
Alert to Operator Repair Lamp
Display Operator Action: None
Display Fault Description: PLM RF PRESS SENS LO
Resulting Problem(s) Bad payload computation.
Related Information 1. A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2. This fault is generated by PLM in response to a problem in the sensor circuit. This
sensor circuit may have a related fault that can be used to resolve the problem. Refer
to the Troubleshooting Instructions for the active parameter fault(s).
3. Check sensor and wiring harness.
Circuit Description Sensor Payload Right Front (730E)
PLM4, 2, 40 (Sche-
matic search) Sensor Payload Pressure Right Front (830E, 930E, 980E)
Expected State Sensor Current between 3 and 21ma
7
CEN40178-01 40 Troubleshooting
Fault Code A005
Description Left rear suspension pressure sensor signal is high.
Fault Conditions Sets if pressure signal is out of range high (sensor current over 22 ma).
Alert to Operator Repair Lamp
Display Operator Action: None
Display Fault Description: PLM LR PRESS SENS HI
Resulting Problem(s) Bad payload computation.
Related Information 1. A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2. This fault is generated by PLM in response to a problem in the sensor circuit. This
sensor circuit may have a related fault that can be used to resolve the problem. Refer
to the Troubleshooting Instructions for the active parameter fault(s).
3. Check sensor and wiring harness.
Circuit Description Sensor Payload Left Rear (730E)
PLM4, 3, 40 (Sche-
matic search) Sensor Payload Pressure Left Rear (830E, 930E, 980E)
Expected State Sensor Current between 3 and 21ma
8
40 Troubleshooting CEN40178-01
Fault Code A006
Description Left rear suspension pressure sensor signal is low.
Fault Conditions Sets if pressure signal is out of range low (sensor current less than 2 ma).
Alert to Operator Repair Lamp
Display Operator Action: None
Display Fault Description: PLM LR PRESS SENS LO
Display Fault Code: A006
Resulting Problem(s) Bad payload computation.
Related Information 1. A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2. This fault is generated by PLM in response to a problem in the sensor circuit. This
sensor circuit may have a related fault that can be used to resolve the problem. Refer
to the Troubleshooting Instructions for the active parameter fault(s).
3. Check sensor and wiring harness..
Circuit Description Sensor Payload Left Rear (730E)
PLM4, 3, 40 (Sche-
matic search) Sensor Payload Pressure Left Rear (830E, 930E, 980E)
Expected State Sensor Current between 3 and 21ma
9
CEN40178-01 40 Troubleshooting
Fault Code A007
Description Right rear suspension pressure sensor signal is high.
Fault Conditions Sets if pressure signal is out of range high (sensor current over 22 ma).
Alert to Operator Repair Lamp
Display Operator Action: None
Display Fault Description: PLM RR PRESS SENS HI
Resulting Problem(s) Bad payload computation.
Related Information 1. A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2. This fault is generated by PLM in response to a problem in the sensor circuit. This
sensor circuit may have a related fault that can be used to resolve the problem. Refer
to the Troubleshooting Instructions for the active parameter fault(s).
3. Check sensor and wiring harness.
Circuit Description Sensor Payload Right Rear (730E)
PLM4, 4, 40 (Sche-
matic search) Sensor Payload Pressure Right Rear (830E, 930E, 980E)
Expected State Sensor Current between 3 and 21ma
10
40 Troubleshooting CEN40178-01
Fault Code A008
Description Right rear suspension pressure sensor signal is low.
Fault Conditions Sets if pressure signal is out of range low (sensor current less than 2 ma).
Alert to Operator Repair Lamp
Display Operator Action: None
Display Fault Description: PLM RR PRESS SENS LO
Resulting Problem(s) Bad payload computation.
Related Information 1. A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2.This fault is generated by PLM in response to a problem in the sensor circuit. This
sensor circuit may have a related fault that can be used to resolve the problem. Refer
to the Troubleshooting Instructions for the active parameter fault(s).
3. Check sensor and wiring harness.
Circuit Description Sensor Payload Right Rear (730E)
PLM4, 4, 40 (Sche-
matic search) Sensor Payload Pressure Right Rear (830E, 930E, 980E)
Expected State Sensor Current between 3 and 21ma
11
CEN40178-01 40 Troubleshooting
Fault Code A011
Description Payload meter speed sensor signal has failed.
Fault Conditions Sets when PLM declares a speed sensor fault.
Alert to Operator Lamp or Buzzer: None - Maintenance Item
Display Fault Description: PLM TRK SPD SENSOR
Resulting Problem(s) Payload and haul cycle data is bad.
Related Information 1. A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2. This fault is produced by PLM in response to a problem in the generation of truck
speed by GE or transmission of the truck speed signal via CAN/RPC to PLM. The CAN
circuit may have a related fault that can be used to resolve the problem. Refer to the
Troubleshooting Instructions for the active parameter fault(s).
Circuit Description
PLM4, 5, 11, 14 CAN/RPC connection (730E, 830E, 930E, 980E)
(Schematic search)
Circuit Description CAN/RPC connection (730E, 830E, 930E, 980E)
IM1I, j, k (Schematic
search)
Circuit Description CAN/RPC connection (730E, 830E, 930E, 980E)
GE, (Schematic
search)
Expected State Updates on truck speed
Related Fault(s) A257 Payload CAN/RPC, A233 Drive System Control Link
12
40 Troubleshooting CEN40178-01
Fault Code A013
Description Body up switch has failed.
Fault Conditions The switch no longer responds to payload cycles.
Alert to Operator Lamp or Buzzer: None - Maintenance Item
Display Fault Description: BODY UP SWITCH FAIL
Resulting Problem(s) Payload and haul cycle data is bad.
Related Information 1. A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2. The primary corrective measure for this fault is to change / correct the body up
switch and wiring to PLM. No other faults are available to troubleshoot this problem.
Circuit Description Body Up (730E, 830E, 930E, 980E)
PLM4, 46 (Schematic
search)
Circuit Description Switch Body-Up Proximity (980E)
GE, P301, v (Sche-
matic search)
Circuit Description Switch Body-Up Proximity (730E, 830E, 930E)
GE, P304, 3 (Sche-
matic search)
Expected State 0: Body is up
13
CEN40178-01 40 Troubleshooting
Fault Code A014
Description Payload meter checksum computation has failed.
Fault Conditions PLM reports a checksum failure.
Alert to Operator Lamp or Buzzer: None - Maintenance Item
Display Fault Description: PLM CHECKSUM FAIL
Resulting Problem(s) Payload and haul cycle data is bad.
Related Information 1. A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2. This fault is totally contained within the payload meter.
14
40 Troubleshooting CEN40178-01
Fault Code A016
Description Payload meter reports a failure in write to flash memory.
Fault Conditions PLM reports a checksum failure.
Alert to Operator Lamp or Buzzer: None - Maintenance Item
Display Fault Description: PLM FLASH MEM WRITE
Resulting Problem(s) Payload and haul cycle data is bad.
Related Information 1.A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2. This fault is totally contained within the payload meter.
15
CEN40178-01 40 Troubleshooting
Fault Code A017
Description A payload memory flash memory read has failed.
Fault Conditions Payload meter reports a failure of flash memory read.
Alert to Operator Lamp or Buzzer: None - Maintenance Item
Display Fault Description: PLM FLASH MEM READ
Resulting Problem(s) Payload and haul cycle data is bad.
Related Information 1. A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2. This fault is totally contained within the payload meter.
16
40 Troubleshooting CEN40178-01
Fault Code A018
Description Right rear flat suspension cylinder warning.
Fault Conditions Sets if PLM detects a flat right rear suspension cylinder.
Alert to Operator Repair Lamp
Display Operator Action: None
Display Fault Description: RR FLAT SUSP CYL FLT
Resulting Problem(s) Potential damage to suspension and frame.
Related Information 1. A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2. The logic that produces this fault is intended to identify flat suspension cylinders.
The primary correction is to recharge / repair the cylinder. If the cylinder is not defec-
tive, use the following procedure to correct PLM
Circuit Description Sensor Payload Left Front (730E)
PLM4,1, 40 (Sche-
matic search) Sensor Payload Pressure Left Front (830E, 930E, 980E)
Circuit Description Sensor Payload Right Front (730E)
PLM4, 2, 40 (Sche-
matic search) Sensor Payload Pressure Right Front (830E, 930E, 980E)
Circuit Description Sensor Payload Left Rear (730E)
PLM4, 3, 40 (Sche-
matic search) Sensor Payload Pressure Left Rear (830E, 930E, 980E)
Circuit Description Sensor Payload Right Rear (730E)
PLM4, 4, 40 (Sche-
matic search) Sensor Payload Pressure Right Rear (830E, 930E, 980E)
Expected State Sensor Current between 3 and 21ma
17
CEN40178-01 40 Troubleshooting
Fault Code A019
Description Left rear flat suspension cylinder warning.
Fault Conditions Sets if PLM detects a flat left rear suspension cylinder.
Resets if condition clears.
Alert to Operator Repair Lamp
Display Operator Action: None
Display Fault Description: LR FLAT SUSP CYL FLT
Resulting Problem(s) Potential damage to suspension and frame.
Related Information 1. A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2. The logic that produces this fault is intended to identify flat suspension cylinders.
The primary correction is to recharge / repair the cylinder. If the cylinder is not defec-
tive, use the following procedure to correct PLM
Circuit Description Sensor Payload Left Front (730E)
PLM4,1, 40 (Sche-
matic search) Sensor Payload Pressure Left Front (830E, 930E, 980E)
Circuit Description Sensor Payload Right Front (730E)
PLM4, 2, 40 (Sche-
matic search) Sensor Payload Pressure Right Front (830E, 930E, 980E)
Circuit Description Sensor Payload Left Rear (730E)
PLM4, 3, 40 (Sche-
matic search) Sensor Payload Pressure Left Rear (830E, 930E, 980E)
Circuit Description Sensor Payload Right Rear (730E)
PLM4, 4, 40 (Sche-
matic search) Sensor Payload Pressure Right Rear (830E, 930E, 980E)
Expected State Sensor Current between 3 and 21ma
18
40 Troubleshooting CEN40178-01
Fault Code A022
Description Carryback load excessive.
Fault Conditions Sets if PLM detects excessive load remaining in the bed after dumping is complete.
Alert to Operator Display Operator Action: None
Display Fault Description: None
Resulting Problem(s) Reduced production.
Related Information 1. A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2. The logic that produces this fault is intended to identify excessive carryback load.
This is a KOMTRAX Plus recording only. No display announces the fault. If excessive
carryback does not exist, troubleshoot the payload system.
Circuit Description Sensor Payload Left Front (730E)
PLM4,1, 40 (Sche-
matic search) Sensor Payload Pressure Left Front (830E, 930E, 980E)
Circuit Description Sensor Payload Right Front (730E)
PLM4, 2, 40 (Sche-
matic search) Sensor Payload Pressure Right Front (830E, 930E, 980E)
Circuit Description Sensor Payload Left Rear (730E)
PLM4, 3, 40 (Sche-
matic search) Sensor Payload Pressure Left Rear (830E, 930E, 980E)
Circuit Description Sensor Payload Right Rear (730E)
PLM4, 4, 40 (Sche-
matic search) Sensor Payload Pressure Right Rear (830E, 930E, 980E)
Expected State Sensor Current between 3 and 21ma
19
CEN40178-01 40 Troubleshooting
Fault Code A101
Description High pressure detected across a hydraulic pump filter.
Fault Conditions Sets if switch is on, engine is running, and oil temperature is above 50 ºC (122 ºF) for
10 seconds.
Alert to Operator Sound Buzzer
Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: HYD OIL FILT RESTRICT
Resulting Problem(s) Hydraulic oil filters will bypass oil without filtration. Continuing operation may damage
hydraulic system components.
Related Information 1. A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2. This fault is generated by series input to IM from the hydraulic oil filter switches. Any
of the three switches can open and cause the warning. The normal corrective measure
for this fault is to change one or more hydraulic filters.
Circuit Description
Switch Hydraulic Filter #1
IM2Y (Schematic
Switch Hydraulic Filter #2
search)
Switch Steering Filter (730E, 830E, 930E, 980E)
Expected State 0: No hydraulic filter switches open.
Engine Speed between 0 to 300 RPM
Engine start switch off
Related Fault Codes Pump filter Switches: A273
Engine Speed : A184
Key Switch: A240
Parameter Expected State and/or Related Fault(s)
Hydraulic Oil 0.016 Volt to 4.89 Volt: Good Readings
Temperature - Tank < 0.016 Volt or > 4.89 Volt: Defective Sensor or Circuit
(IM3m) Fault(s): A104, A014, A193
20
40 Troubleshooting CEN40178-01
Fault Code A103
Description Hydraulic Oil Temp - Tank Sensor Low
Fault Conditions Sets if temperature reading drops to -62ºC (-80 ºF).016 Volts for 3 seconds.
Operator Alerting No Lamp
System Response Display Fault Description: TNK OIL TEMP SENS LO
Resulting Problem(s) Loss of monitoring of the Hydraulic Tank Temperatures with potential for damage if
temperatures also go high
Related Information 1. A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2. The primary correction for this fault is to correct any external wiring or replace the
sensor.
Circuit Description
IM3m (Schematic
Sensor Hydraulic Tank Temp (730E, 830E)
search)
Expected State Sensor Voltage between 0.016 V and 4.89 V
21
CEN40178-01 40 Troubleshooting
Fault Code A104
Description Hydraulic Oil Temp - Tank Sensor High
Fault Conditions Sets if temperature reading rises to 133ºC (271 ºF) 4.89 Volts for 3 seconds.
Operator Alerting No Lamp
System Response Display Fault Description: TNK OIL TEMP SENS HI
Resulting Problem(s) Loss of monitoring of the Hydraulic Tank Temperatures with potential for damage if
temperatures also go high
Related Information 1. A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2. The primary correction for this fault is to correct any external wiring or replace the
sensor.
Circuit Description
IM3m (Schematic
Sensor Hydraulic Tank Temp (730E, 830E)
search)
Expected State Sensor Voltage between 0.016 V and 4.89 V
22
40 Troubleshooting CEN40178-01
Fault Code A105
Description Fuel level sensor is shorted to ground, indicating a false high fuel level.
Fault Conditions Sets if fuel level indication is at 110% for 5 seconds with key-switch on, battery voltage
does not drop below 18, and engine speed below 600 rpm.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: FUEL LEVEL SENSOR LO
Resulting Problem(s) False high fuel gauge readings. If ignored, possible shutdown of engine while on the
haul road.
Related Information 1. A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2. The primary correction for this fault is to correct or change the fuel level sensor and
wiring.
Circuit Description
IM3g (Schematic
Fuel Level Sensor (730E, 830E, 930E, 980E)
search)
Expected State Sensor Voltage between 0.57 V and 8.2 V
Circuit Description
IM1A (Schematic
Battery Voltage (730E, 830E, 930E, 980E)
search)
Expected State Battery Voltage greater than 18 V
Parameters Engine start switch on
Engine Speed between 0 to 600 RPM
Related Fault Codes Fuel Level Sensor: A158
Battery Voltage: A153, A154, A155, A250
Key Switch: A240
Engine Speed: A184
23
CEN40178-01 40 Troubleshooting
Fault Code A109
Description GE has generated a propel system reduced level signal.
Fault Conditions Sets if the GE controller generates a propel system reduced level event.
Alert to Operator Sound Buzzer - single burst
Display Operator Action: MAX SPEED LIMITED
Display Fault Description: REDUCED PROPEL
Resulting Problem(s) Propel system may not permit the truck to remain at full performance. Shutdown of
propel system may occur if severity increases.
Related Information 1. A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2. A laptop running WebPTU software may be required to resolve this fault.
3. This fault is generated by GE placing a message on CAN/RPC
4. It may be necessary to use WebPTU software to determine the actual cause of the
propel system distress.
Parameter Proper System Reduced Level (CAN/RPC) IM1l, j,k
1: Fault active
Related Fault(s) A233
24
40 Troubleshooting CEN40178-01
Fault Code A111
Description A111 is a low steering pressure warning for storage by KOMTRAX Plus. It is designed
to filter out some service and operational conditions that would otherwise produce this
warning.
Fault Conditions A111 sets if low steering pressure input to IM remains after 90 seconds of engine
running at 300 rpm or above and is sustained for 30 seconds at speeds of 1200 rpm or
above.
Alert to Operator Display Operator Action: None
Display Fault Description: None
Resulting Problem(s) Truck may not steer properly.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Circuit Description Switch Low Steering Pressure (730E, 830E, 930E, 980E)
(IM2S)
Parameter/Expected 0: steering pressure normal
State 1: low steering pressure
Engine speed: 300-1200 RPM, @1200 RPM engine is running fast enough to main-
tain steering pressure.
Related Fault Codes Low Steering Pressure Switch: A279, A115, A253
25
CEN40178-01 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Low Steering Pressure Refer to 58D-06-01711, Sheet 14, zones N2 through N8 730E
Switch connection to Refer to 58E-06-02311, sheet 15, zones N2 through N8 830E
IM Refer to 58E-06-02321, sheet 31, zone C3
Refer to 58F-06-02311, Sheet 15, zones N2 through N8 930E
Refer to 58F-06-10561, Sheet 31, zone C3
Refer to 58B-06-02390, Sheet 16, zones N2 through N7 980E
Refer to 58B-06-03570, Sheet 33, zone C3
CAN/J1939 connection Refer to 58D-06-01711, Sheet 16, zone E1 and Sheet 5, zones H2 730E
at Engine through H10
Refer to 58E-06-02311, sheet 17, zones E1 and sheet 7, zones H2 830E
through H10
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones E1 and Sheet 7, zones H2 930E
through H10
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zones E1 and Sheet 7, zones H2 980E
through H8
Refer to 58B-06-03570, Sheet 6, zone A5
CAN/J1939 connection Refer to 58D-06-01711, Sheet 14, zones J9 through J12 and Sheet 16, 730E
at IM zone E6
Refer to 58E-06-02311, sheet 17, zones B5 through B6 and sheet 15, 830E
zones I9 through I12
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones B4 through B5 and Sheet 15, 930E
zones J9 through J12
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zones E4 through E5 and Sheet 16, 980E
zones E6
Refer to 58B-06-03570, Sheet 6, zone A5
26
40 Troubleshooting CEN40178-01
Fault Code A115
Description Low steering precharge pressure is detected.
Fault Conditions Sets and latches if low steering precharge switch operates for 2 seconds with
keyswitch on and “Steering Precharge Mask” not on. The “Steering Precharge Mask”
prevents warnings that might occur from the beginning of steering bleed until 5
minutes after bleed is complete or timed out or keyswitch is turned back on.
Resets when steering bleed comes on. Mask prevents new operations for 5 minutes.
Alert to Operator Sound Buzzer
Flash IM Warning indicator
Display Operator Action: STOP: PARK
Display Fault Description: LOW STRG PRECHARGE
Resulting Problem(s) Low steering accumulator precharge will reduce the amount of stored energy in the
steering system.
Related Information 1.A laptop running “IM Realtime Data Monitor” software may be required to resolve
this fault.
2. The primary correction for this fault is to adjust the nitrogen charge in the steering
accumulators.
Parameter Keyswitch (IM3G)
0: keyswitch is off and the truck is not moving and the engine is not running
1: keyswitch is on or the truck is moving (GE power not yet off)
Related Faults Key Switch: A240
Steering Accum Bled Pressure Switch: A258, A280
Circuit Description Switch Accumulator Low Precharge Pressure #1 (730E, 830E, 930E, 980E)
IM2W (Schematic Switch Accumulator Low Precharge Pressure #2 (730E, 830E, 930E, 980E)
Search)
Expected State 0: Normal reading - full precharge pressure
Circuit Description Switch Steering Bleed Pressure (730E, 830E, 930E, 980E)
IM2WZ (Schematic
Search
Expected State 0: Steering bleed is complete.
27
CEN40178-01 40 Troubleshooting
Fault Code A117
Description A117 is a low brake accumulator pressure warning for storage by KOMTRAX Plus. It is
designed to filter out some service and operational conditions that would otherwise
produce this warning.
Fault Conditions A117 sets if low brake accumulator pressure input to IM remains after 90 seconds of
engine running at 300 rpm or above.
A117 resets if pressure returns or engine stops running for 1 second.
Alert to Operator Display Operator Action: None
Display Fault Description: None
Resulting Problem(s) Service brake may not stop or hold the truck.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Circuit Description
IM2U (Schematic
Search)
Table
1. This fault is generated by more than one parameter, but the independent parameters do not have fault codes
for situations that will affect this fault.
Parameter Expected State and/or Related Fault(s)
Brake Accumulator 0: Brake accumulator pressure normal
Pressure Switch 1: Low brake accumulator pressure
(IM2U)
Engine Speed [RPM] 0: Engine is not running
> 300 RPM: Engine is running
28
40 Troubleshooting CEN40178-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/J1939 connection Refer to 58D-06-01711, Sheet 5, zones H2 through H10 730E
at Engine Refer to 58E-06-02311, sheet 17, zones E1 and sheet 7, zones H2 830E
through H10
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones E1 and Sheet 7, zones H2 930E
through H10
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zones E1 and Sheet 7, zones H2 980E
through H8
Refer to 58B-06-03570, Sheet 6, zone A5
CAN/J1939 connection Refer to 58D-06-01711, Sheet 14, zones I9 through I11 and Sheet 16, 730E
at IM zone F6
Refer to 58E-06-02311, sheet 17, zones B5 through B6 and sheet 15, 830E
zones I9 through I12
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones B4 through B5 and Sheet 15, 930E
zones J9 through J12
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zones E4 through E5 and Sheet 16, 980E
zones E6
Refer to 58B-06-03570, Sheet 6, zone A5
Brake Accumulator Refer to 58D-06-01711, Sheet 14, zones F9 through F16 and Sheet 3, 730E
Pressure Switch to IM zone
Refer to 58E-06-02311, sheet 15, zones F9 through F16 830E
Refer to 58E-06-02321, sheet 5, zones E3 through F3
Refer to 58F-06-02311, Sheet 15, zones F9 through F16 930E
Refer to 58F-06-10561, Sheet 5, zones E3 through F3
Refer to 58B-06-02390, Sheet 16, zones F9 through F16 980E
Refer to 58B-06-03570, Sheet 5, zones E3 through F3
29
CEN40178-01 40 Troubleshooting
Fault Code A118: Brake pressure is low while in brake lock
Operator Action Set Parking Brake
Fault Code A118
Description Brake pressure is low while in brake lock.
Fault Conditions Sets in response to brake lock switch when parking brake is not set and brake lock
degrade on for 3 seconds except when operated by steering bleed circuitry.
Parking brake set is defined as closure of the parking brake set pressure switch and
opening of the parking brake release pressure switch.
Resets if brake lock or brake lock degrade switch are off for 1 second.
Operator Alerting Sound Buzzer
System Response Flash IM Warning indicator
Display Operator Action: SET PARK BRAKE
Display Fault Description: SERV BRAKE DEGRADE
Display Fault Code: A118
Resulting Problem(s) Service brake may not stop or hold the truck.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning
Parameter Expected State and/or Related Fault(s)
Brake Lock (IM2i) 0: brake lock not on
1: brake lock is on
Fault(s): A272
Brake Lock Degrade 0: brake lock degrade not on
Sw (IM2V) 1: brake lock degrade is on
Fault(s): A281
Parking Brake Set 0: Parking Brake is Set
input (IM2f) 1: Parking Brake is not Set
Fault(s): A213
Parking Brake Release 0: Parking Brake is Released
input (IM2M) 1: Parking Brake is not Released
Fault(s): A214
30
40 Troubleshooting CEN40178-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Service Brake Refer to 58D-06-01711, Sheet 14, zones G9 through G16 730E
Degrade Pressure Refer to 58E-06-02311, sheet 15, zones G9 through G16 830E
Switch to IM Refer to 58E-06-02321, sheet 5, zones E3 through F3
Refer to 58F-06-02311, Sheet 15, zones G9 through G16 930E
Refer to 58F-06-10561, Sheet 5, zones E3 through F3
Refer to 58B-06-02390, Sheet 16, zones G9 through G16 980E
Refer to 58B-06-03570, Sheet 5, zones E3 through F3
Brake Lock Switch Refer to 58D-06-01711, Sheet 8, zones N10 through N17 730E
connection to IM Refer to 58E-06-02311, sheet 9, zones N10 through N17 830E
Refer to 58E-06-02321, sheet 5, zone D4
Refer to 58F-06-02311, Sheet 9, zones N10 through N17 930E
Refer to 58F-06-10561, Sheet 5, zone D4
Refer to 58B-06-02390, Sheet 10, zones M11 through M17 980E
Refer to 58B-06-03570, Sheet 5, zone D4
31
CEN40178-01 40 Troubleshooting
Fault Code A123: GE has generated a reduced retarding caution
Operator Action Slow Down Hill
Fault Code A123
Description GE has generated a reduced retarding caution.
Fault Conditions Sets if the GE controller generates a reduced retarding event.
Resets if GE removes the reduced retarding event.
Operator Alerting Sound Buzzer - single burst
System Response Display Operator Action: SLOW DOWN HILL
Display Fault Description: REDUCED RETARDING
Display Fault Code: A123
Resulting Problem(s) Retarding will be at somewhat reduced level, but the truck can still be driven.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
A laptop running WebPTU software may be required to resolve this fault.
Table
1. This fault is generated by GE placing a message on CAN/RPC
2. It may be necessary to use WebPTU software to determine the actual cause of the propel system distress
Parameter Expected State and/or Related Fault(s)
Reduced Retarding 0: Fault not present
Input (CAN/RPC) 1: Fault active
(IM1q, r, s) Fault(s): A233
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 14, zones I9 through I12 and Sheet 16, 730E
at IM zone B6
Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 15, zone I12 and Sheet 17, zone B5 930E
Refer to 58F-06-10561, Sheet 6, zone A2
Refer to 58B-06-02390, Sheet 16, zone D6 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/RPC connection Refer to 58D-06-01711, Sheet 16, zone B9 730E
at GE Refer to 58E-06-02311, sheet 17, zone B3 830E
Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, Sheet 17, zone C4 930E
Refer to 58F-06-10561, Sheet 6, zone B2
Refer to 58B-06-02390, Sheet 18, zone C4 980E
Refer to 58B-06-03570, Sheet 6, zone A2
32
40 Troubleshooting CEN40178-01
Fault Code A124: GE has generated a no propel / no retard or system not running input
Operator Action Stop; Park
Fault Code A124
Description GE has generated a no propel / no retard or system not running input.
Fault Conditions Sets if a No Propel / No Retard input is received from GE on CAN bus or a System
Running input is not received from GE on wire input with Keyswitch, OR on and Park-
ing Brake not Set. Parking brake set is defined as closure of the parking brake set
pressure switch and opening of the parking brake release pressure switch.
Resets when CAN signal is removed or 3 seconds after the System Running signal
appears.
Operator Alerting Sound Buzzer
System Response Flash IM Warning indicator
Display Operator Action: STOP; PARK
Display Fault Description: NO PROPEL / RETARD
Display Fault Code: A124
Resulting Problem(s) The drive system is inoperable in either propel or retard.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
A laptop running WebPTU software may be required to resolve this fault.
Table
1. This fault is generated by GE placing a No Propel/Retard message on CAN/RPC or by a missing System
Running Wire Input.
2. It may be necessary to use WebPTU software to determine the actual cause of the propel system distress.
Parameter Expected State and/or Related Fault(s)
No Propel/Retard 0: fault not present
(CAN/RPC) (IM1i,j,k) 1: fault active
Fault(s): A233
GE System Running 0: system is running
input (IM2n) 1: system not running
Keyswitch, OR input 0: Keyswitch, OR is missing
(IM3G) 1: Keyswitch, OR is active
Fault(s): A240
Parking Brake Set 0: Parking Brake is Set
input (IM2f) 1: Parking Brake is not Set
Fault(s): A213
Parking Brake Release 0: Parking Brake is Released
input (IM2M) 1: Parking Brake is not Released
Fault(s): A214
33
CEN40178-01 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 14, zones I9 through I12 and Sheet 16, 730E
at IM zone B6
Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 15, zone I12 and Sheet 17, zone B5 930E
Refer to 58F-06-10561, Sheet 6, zone A2
Refer to 58B-06-02390, Sheet 16, zone D6 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/RPC connection Refer to 58D-06-01711, Sheet 16, zone B9 730E
at GE Refer to 58E-06-02311, sheet 17, zone B3 830E
Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, Sheet 17, zone C4 930E
Refer to 58F-06-10561, Sheet 6, zone B2
Refer to 58B-06-02390, Sheet 18, zone C4 980E
Refer to 58B-06-03570, Sheet 6, zone A2
Keyswitch, OR Refer to 58D-06-01711, Sheet 14, zones D9 through D19 730E
connection to IM Refer to 58E-06-02311, sheet 15, zones D10 through D19 830E
Refer to 58E-06-02321, sheet 31, zones B8 through B10
Refer to 58F-06-02311, Sheet 15, zones D10 through D19 930E
Refer to 58F-06-10561, Sheet 31, zones B8 through B10
Refer to 58B-06-02390, Sheet 16, zones D10 through D19 980E
Refer to 58B-06-03570, Sheet 33, zones B9 through B10
GE System Running Refer to 58D-06-01711, Sheet 5, zones G15 through G18 730E
connection to IM Refer to 58E-06-02311, sheet 7, zones G15 through G18 830E
Refer to 58E-06-02321, sheet 4, zone D4
Refer to 58F-06-02311, Sheet 7, zones G15 through G18 930E
Refer to 58F-06-10561, Sheet 4, zone D4
Refer to 58B-06-02390, Sheet 10, zones O2 through O5 980E
Refer to 58B-06-03570, Sheet 4, zone D4
34
40 Troubleshooting CEN40178-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Parking Brake Set Refer to 58D-06-01711, Sheet 14, zones F9 through F16 730E
Pressure Switch Refer to 58E-06-02311, sheet 15, zones F10 through F16 830E
connection to IM Refer to 58E-06-02321, sheet 5, zone C8
Refer to 58F-06-02311, Sheet 15, zone F10 to F16 930E
Refer to 58F-06-10561, Sheet 5, zone C8
Refer to 58B-06-02390, Sheet 16, zone F10 to F16 980E
Refer to 58B-06-03570, Sheet 5, zone C8
Parking Brake Release Refer to 58D-06-01711, Sheet 3, zones G3 through H9 730E
Pressure Switch to IM Refer to 58E-06-02311, sheet 5, zones H3 through H9 830E
Refer to 58E-06-02321, sheet 5, zone C9
Refer to 58F-06-02311, Sheet 5, zones H5 through H14 930E
Refer to 58F-06-10561, Sheet 5, zone C9
Refer to 58B-06-02390, Sheet 5, zones H6 through H20 980E
Refer to 58B-06-03570, Sheet 5, zone C9
35
CEN40178-01 40 Troubleshooting
Fault Code A125: GE has generated a no propel warning
Operator Action Stop; Park
Fault Code A125
Description GE has generated a no propel warning.
Fault Conditions Sets in response to a GE No Propel signal on the CAN/RPC bus. Resets when GE
clears the signal.
Operator Alerting Sound Buzzer
System Response Flash IM Warning indicator
Display Operator Action: STOP; PARK
Display Fault Description: NO PROPEL
Display Fault Code: A125
Resulting Problem(s) The drive system is inoperable in propel.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
A laptop running WebPTU software may be required to resolve this fault.
Table
1. This fault is generated by GE placing a message on CAN/RPC
2. It may be necessary to use WebPTU software to determine the actual cause of the propel system distress
Parameter Expected State and/or Related Fault(s)
No Propel (CAN/RPC) 0: Fault not present
(IM1i,j,k) 1: Fault active
Fault(s): A233
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 14, zones I9 through I12 and Sheet 16, 730E
at IM zone B6
Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 15, zone I12 and Sheet 17, zone B5 930E
Refer to 58F-06-10561, Sheet 6, zone A2
Refer to 58B-06-02390, Sheet 16, zone D6 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/RPC connection Refer to 58D-06-01700, Sheet 16, zone B9 730E
at GE Refer to 58E-06-02311, sheet 17, zone B3 830E
Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, Sheet 17, zone C4 930E
Refer to 58F-06-10561, Sheet 6, zone B2
Refer to 58B-06-02390, Sheet 18, zone C4 980E
Refer to 58B-06-03570, Sheet 6, zone A2
36
40 Troubleshooting CEN40178-01
Fault Code A126: Oil level in the hydraulic tank is low
Operator Action Stop; Park; Power Down; Check
Fault Code A126
Description Oil level in the hydraulic tank is low.
Fault Conditions Sets if sensor reports oil level to be low.
Resets if oil level is restored or if steering bleed comes on.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operation Action: STOP: PRK: PWR: CHK
Display Fault Description: HYD OIL LEVEL FAULT
Display Fault Code: A126
Resulting Problem(s) Low hydraulic oil level can cause damage to equipment and failure to operate
properly.Steering and brakes may deteriorate in performance.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This primary correction for this fault is to add oil to the hydraulic system and check for hydraulic leaks.
2. If oil is sufficient, check the sensor and sensor wiring.
3. No additional fault codes are available for this function.
Parameter Expected State and/or Related Fault(s)
Hydraulic Oil Level 0: Oil level is normal
Sensor (IM1W, IM2k) 1: Oil level is low
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hydraulic Oil Level Refer to 58D-06-01711, Sheet 14, zones J9 through J21 730E
connection to IM Refer to 58E-06-02311, sheet 15, zones J10 through J21 830E
Refer to 58E-06-02321, sheet 31, zone C8
Refer to 58F-06-02311, Sheet 15, zones J10 through J21 930E
Refer to 58F-06-10561, Sheet 31, zone C8
Refer to 58B-06-02390, Sheet 16, zones I9 through I19 980E
Refer to 58B-06-03570, Sheet 33, zone C8
37
CEN40178-01 40 Troubleshooting
Fault Code A127: IM-furnished +5 volt output for sensors is low
Operator Action Go To Shop Now
Fault Code A127
Description IM-furnished +5 volt output for sensors is low.
Fault Conditions Sets when Sensor +5V Input drops below 4.52 volts for 2 seconds.
Resets when Sensor +5V Input recovers to 4.66 volts for 2 seconds.
Operator Alerting Sound Buzzer
System Response Operate IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: TEMP SENSOR +5V LOW
Display Fault Code: A127
Resulting Problem(s) All 5 temperature sensors using the +5 Volt supply will report low readings. Control of
engine speed and warnings of high oil temperature will be compromised. Equipment
damage may result.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. No additional fault codes are available for this function.
2. Check external wiring and sensors to determine if problem is outside of IM.
Parameter Expected State and/or Related Fault(s)
Sensor +5V Analog >4.52 Volts: Normal voltage
Input (IM3j) <4.52 Volts: Low voltage
Sensor +5V Output >4.52 Volts: Normal voltage
(IM3c) <4.52 Volts: Low voltage
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
5 Volt Thermal Sensor Refer to 58D-06-01711, Sheet 14, zones K9 through K12 730E
Supply Circuit Refer to 58E-06-02311, sheet 15, zones K10 through K12 830E
Refer to 58E-06-02321, sheet 18, zone A6 and sheet 31, zone C8
Refer to 58F-06-02311, Sheet 15, zone K10 to K12 930E
Refer to 58F-06-10561, Sheet 18, zone A6 and Sheet 5, zones D7
through E7
Refer to 58B-06-02390, Sheet 16, zone J9 to J10 980E
Refer to 58B-06-03570, Sheet 20, zone A6 and Sheet 5, zones D7
through E7
38
40 Troubleshooting CEN40178-01
Fault Code A128: IM-furnished +5 volt output for sensors is high
Operator Action None
Fault Code A128
Description IM-furnished +5 volt output for sensors is high.
Fault Conditions Sets when Sensor +5V Input rises above 5.51 volts for 2 seconds.
Resets when Sensor +5V Input drops to 5.27 volts for 2 seconds.
Operator Alerting Operate Repair Lamp
System Response Display Fault Description: TEMP SENSOR +5V HI
Display Fault Code: A128
Resulting Problem(s) All 5 temperature sensors using the +5 Volt supply will report high readings. Control of
engine speed and warnings of high oil temperature will occur at lower than normal
temperatures. False warnings will occur.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. No additional fault codes are available for this function.
2. Check external wiring and sensors to determine if problem is outside of IM.
Parameter Expected State and/or Related Fault(s)
Sensor +5V Analog <5.51 Volts: Normal voltage
Input (IM3j) >5.51 Volts: High voltage
Sensor +5V Output <5.51 Volts: Normal voltage
(IM3c) >5.51 Volts: High voltage
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
5 Volt Thermal Sensor Refer to 58D-06-01711, Sheet 14, zones K9 through K12 730E
Supply Circuit Refer to 58E-06-02311, sheet 15, zones K10 through K12 830E
Refer to 58E-06-02321, sheet 18, zone A6 and sheet 31, zone C8
Refer to 58F-06-02311, Sheet 15, zone K10 to K12 930E
Refer to 58F-06-10561, Sheet 18, zones A6 and Sheet 5, zones D7
through E7
Refer to 58B-06-02390, Sheet 16, zone J9 to J10 980E
Refer to 58B-06-03570, Sheet 20, zones A6 and Sheet 5, zones D7
through E7
39
CEN40178-01 40 Troubleshooting
Fault Code A139: Low fuel warning
Operator Action None
Fault Code A139
Description A139 is a low fuel level warning for storage by KOMTRAX Plus and for use by A310.
Fault Conditions Sets after 15 seconds of fuel level readings below 10% of full if the engine start switch
is on, low voltage due to cranking is not sensed, and the fuel level sensor is not high.
Resets after 1 minute if fuel level recovers to 15% of full.
Operator Alerting Display Operator Action: None
System Response Display Fault Description: None
Display Fault Code: None
Resulting Problem(s) Possible running out of fuel on haul road. Possible engine damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to add fuel to the tank.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes, then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved, then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Fuel Level Sensor 0.57 to 8.2 Volts: Good readings at 24 volt battery (varies with battery voltage)
(IM3g) <0.57 or >8.2 Volts: Defective sensor or circuit at 24 volt battery (varies with battery
voltage)
Fault(s): A105, A158
Battery Voltage, >18 Volt: Good reading
24 Volt (IM1A) <18 Volt: Low battery voltage (while cranking) blocks this A105 fault code.
Keyswitch (IM3G) 0: keyswitch is off and the truck is not moving and the engine is not running
1: keyswitch is on or the truck is moving (GE power not yet off)
Fault(s): A240
Engine Speed [RPM] < 600 RPM: combined with low voltage means cranking is in process and fault is
blocked
> 300 RPM for 4 seconds: engine is running
40
40 Troubleshooting CEN40178-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Keyswitch, OR Refer to 58D-06-01711, Sheet 14, zones D9 through D19 730E
connection to IM Refer to 58E-06-02311, sheet 15, zones D10 through D19 830E
Refer to 58E-06-02321, sheet 31, zones B8 through B10
Refer to 58F-06-02311, Sheet 15, zones D10 through D19 930E
Refer to 58F-06-10561, Sheet 31, zones B8 through B10
Refer to 58B-06-02390, Sheet 16, zones D10 through D19 980E
Refer to 58B-06-03570, Sheet 33, zones B9 through B10
Fuel Level Sensor Refer to 58D-06-01711, Sheet 14, zones D9 through D22 730E
circuit Refer to 58E-06-02311, sheet 15, zones D10 through D22 830E
Refer to 58E-06-02321, sheet 31, zones B8 through B10
Refer to 58F-06-02311, Sheet 15, zones D10 through D22 930E
Refer to 58F-06-10561, Sheet 31, zones B8 through B10
Refer to 58B-06-02390, Sheet 16, zones C9 through D22 980E
Refer to 58B-06-03570, Sheet 33, zones B9 through B10
Battery Supply Voltage Refer to 58D-06-01711, Sheet 3, zones L4 through L15 730E
to IM Refer to 58E-06-02311, sheet 5, zones L4 through L15 830E
Refer to 58E-06-02321, sheet 18, zones A9 through B9
Refer to 58F-06-02311, Sheet 5, zones L4 through L15 930E
Refer to 58F-06-10561, Sheet 18, zones A9 through B9
Refer to 58B-06-02390, Sheet 5, zones L6 through L14 980E
Refer to 58B-06-03570, Sheet 20, zones A9 through B9
41
CEN40178-01 40 Troubleshooting
730E Dump truck
830E Dump truck
930E Dump truck
980E Dump truck
Form No. CEN40178-01
42
CEN40179-01
DUMP TRUCK
730E
830E
930E
980E
Machine model Serial number
730E-10 A50002 and up
830E-5 A50005 and up
830E-5AT A50005 and up
930E-5 A40004 and up
930E-5AT A40004 and up
980E-5 A50005 and up
980E-5AT A50005 and up
40 Troubleshooting
Troubleshooting by fault code, part 2
Fault Code A145: Hydraulic oil temp sensors cause engine rpm advance to level 1 ........................................... 4
Fault Code A146: Hydraulic oil temp sensors cause engine rpm advance to level 2 ........................................... 6
Fault Code A152: Starter failure............................................................................................................................ 8
Fault Code A153: Battery voltage is low with the truck in operation ................................................................... 10
Fault Code A154: Battery charging voltage is excessive .................................................................................... 13
Fault Code A155: Battery charging voltage is low .............................................................................................. 14
Fault Code A158: Fuel level sensor open or shorted high; false low fuel level indicated ................................... 16
Fault Code A166: Left rear hydraulic oil temperature sensor is low ................................................................... 18
Fault Code A167: Right rear hydraulic oil temperature sensor is low ................................................................. 20
Fault Code A168: Left front hydraulic oil temperature sensor is low................................................................... 22
Fault Code A169: Right front hydraulic oil temperature sensor is low ................................................................ 24
Fault Code A170: Left rear hydraulic oil temperature sensor is high .................................................................. 26
Fault Code A171: Right rear hydraulic oil temperature sensor is high................................................................ 27
Fault Code A172: Left front hydraulic oil temperature sensor is high ................................................................. 28
1
CEN40179-01 40 Troubleshooting
Fault Code A173: Right front hydraulic oil temperature sensor is high ............................................................... 29
Fault Code A184: The J1939 data link is not connected..................................................................................... 30
Fault Code A190: The auto lube control has detected an incomplete lube cycle ............................................... 32
Fault Code A193: Hydraulic Tank Oil Temperature is high.................................................................................. 34
Fault Code A194: Left front hydraulic oil temperature is high ............................................................................. 35
Fault Code A195: Right front hydraulic oil temperature is high........................................................................... 36
Fault Code A196: Left rear hydraulic oil temperature is high .............................................................................. 37
Fault Code A197: Right rear hydraulic oil temperature is high............................................................................ 38
Fault Code A198: Hoist Pressure 1 Sensor is high............................................................................................. 39
Fault Code A199: Hoist Pressure 2 Sensor is high............................................................................................. 40
Fault Code A200: Steering Pressure Sensor High.............................................................................................. 41
Fault Code A201: Brake Pressure Sensor High.................................................................................................. 42
Fault Code A202: Hoist Pressure 1 Sensor Low................................................................................................. 44
Fault Code A203: Hoist Pressure 2 Sensor Low................................................................................................. 46
Fault Code A204: Steering Pressure Sensor Low............................................................................................... 48
Fault Code A205: Brake Pressure Sensor Low .................................................................................................. 50
Fault Code A206: Ambient Temperature Sensor High ........................................................................................ 52
Fault Code A207: Ambient Temperature Sensor Low......................................................................................... 53
Fault Code A213: Parking brake should have applied; detected as not having applied ..................................... 54
Fault Code A214: Parking brake should have released; detected as not having released................................. 60
Fault Code A215: Brake auto apply valve circuit is defective ............................................................................. 66
Fault Code A216: Open or short to ground detected in parking brake command valve circuit ........................... 70
Fault Code A223: Excessive engine cranking occurred or jump start attempted................................................ 74
Fault Code A230: Parking brake has been requested while truck still moving ................................................... 76
Fault Code A231: The body is up while traveling or intending to travel .............................................................. 80
Fault Code A233: Drive system CAN/RPC Control Link not connected ............................................................. 84
Fault Code A235: Steering accumulator is in the process of being bled down ................................................... 88
Fault Code A236: The steering accumulator has not properly bled after 90 seconds ........................................ 90
Fault Code A237: The CAN/RPC connection to the display is open................................................................... 92
Fault Code A240: The keyswitch input to the Interface Module is open ............................................................. 93
Fault Code A242: The fuel level gauge in the display panel is defective ............................................................ 94
Fault Code A243: The engine coolant temp gauge in the display panel is defective .......................................... 95
Fault Code A244: The drive system temp gauge in the dash display panel is defective .................................... 96
Fault Code A245: The hydraulic oil temp gauge in the display panel is defective .............................................. 97
Fault Code A246: PLM reports truck overload .................................................................................................... 98
2
40 Troubleshooting CEN40179-01
NOTES
3
CEN40179-01 40 Troubleshooting
Fault Code A145: Hydraulic oil temp sensors cause engine rpm advance to level 1
Operator Action None
Fault Code A145
Description Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for
cooling of hydraulic oil.
Fault Conditions Sets (advances engine) after 5 seconds at 105ºC (221ºF) after filtering out data from
sensors failed high.
Resets (returns engine to normal) after 5 seconds at 100ºC (212ºF).
Operator Alerting None. This event is recorded by KOMTRAX Plus only.
System Response
Resulting Problem(s) If this control is non-functional, excessive oil temperatures can cause oil and
equipment damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volt: Good readings
Left Rear (IM3i) <0.016 Volt or >4.89 Volt: Defective sensor or circuit
Fault(s): A166, A170
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volt: Good readings
Right Rear (IM3m) <0.016 Volt or >4.89 Volt: Defective sensor or circuit
Fault(s): A167, A171
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volt: Good readings
Left Front (IM3t) <0.016 Volt or >4.89 Volt: Defective sensor or circuit
Fault(s): A168, A172
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volt: Good readings
Right Front (IM3r) <0.016 Volt or >4.89 Volt: Defective sensor or circuit
Fault(s): A169, A173
4
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hydraulic Oil Refer to 58F-06-02311, Sheet 15, zones J9 through L22 930E
Temperature Refer to 58F-06-10561, Sheet 5, zones D4 through E6
connection to IM Refer to 58B-06-02390, Sheet 16, zones J9 through K20 980E
Refer to 58B-06-03570, Sheet 5, zones D4 through E6
5
CEN40179-01 40 Troubleshooting
Fault Code A146: Hydraulic oil temp sensors cause engine rpm advance to level 2
Operator Action None
Fault Code A146
Description Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for
cooling of hydraulic oil.
Fault Conditions Sets (advances engine) after 5 seconds at 120ºC (248ºF) after filtering out data from
sensors failed high.
Resets (returns engine to normal) after 5 seconds at 108ºC (226ºF).
Operator Alerting None. This event is recorded by KOMTRAX Plus only.
System Response
Resulting Problem(s) If this control is non-functional, excessive oil temperatures can cause oil and
equipment damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volt: Good readings
Left Rear (IM3i) <0.016 Volt or >4.89 Volt: Defective sensor or circuit
Fault(s): A166, A170
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volt: Good readings
Right Rear (IM3m) <0.016 Volt or >4.89 Volt: Defective sensor or circuit
Fault(s): A167, A171
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volt: Good readings
Left Front (IM3t) <0.016 Volt or >4.89 Volt: Defective sensor or circuit
Fault(s): A168, A172
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volt: Good readings
Right Front (IM3r) <0.016 Volt or >4.89 Volt: Defective sensor or circuit
Fault(s): A169, A173
6
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hydraulic Oil Refer to 58F-06-02311, Sheet 15, zones J9 through L22 930E
Temperature Refer to 58F-06-10561, Sheet 5, zones D4 through E6
connection to IM Refer to 58B-06-02390, Sheet 16, zones J9 through K20 980E
Refer to 58B-06-03570, Sheet 5, zones D4 through E6
7
CEN40179-01 40 Troubleshooting
Fault Code A152: Starter failure
Operator Action None
Fault Code A152
Description Starter Failure
Fault Conditions Sets if either starter motor is not energized for 2 seconds when cranking is attempted.
Resets only when steering bleed occurs.
Operator Alerting Display: Repair Item
System Response Display Fault Description: STARTER FAILURE
Display Fault Code: A152
Resulting Problem(s) One good starter may be destroyed or engine may not start at all.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Starter Motor 1 0: starter motor 1 not energized
Energized (IM3R) 1: starter motor 1 energized
Fault(s): A275
Starter Motor 2 0: starter motor 2 not energized
Energized (IM3S) 1: starter motor 2 energized
Fault(s): A275
Crank Sense (IM3U) 0: no cranking in process
1: cranking in process
8
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Starter Motors 1 and 2 Refer to 58D-06-01711, Sheet 2, zones K9 through L13 730E
Refer to 58E-06-02311, sheet 4, zones K10 through K12 830E
Refer to 58E-06-02321, sheet 4, zones C8 through C9
Refer to 58F-06-02311, Sheet 4, zones K10 through K12 930E
Refer to 58F-06-10561, Sheet 4, zones C8 through C9
Refer to 58B-06-02390, Sheet 4, zones K10 through K12 980E
Refer to 58B-06-03570, Sheet 4, zones C8 through C9
Starter Motor Refer to 58D-06-01711, Sheet 3, zones L4 through L7 730E
connections to IM Refer to 58E-06-02311, sheet 5, zones L4 through L7 830E
Refer to 58E-06-02321, sheet 4, zones C8 through C9
Refer to 58F-06-02311, Sheet 5, zones L4 through L7 930E
Refer to 58F-06-10561, Sheet 4, zones C8 through C9
Refer to 58B-06-02390, Sheet 5, zones K6 through K10 980E
Refer to 58B-06-03570, Sheet 4, zones C8 through C9
Crank Sense Refer to 58D-06-01711, Sheet 2, zones M9 through N19 and Sheet 4, 730E
connection to IM zones B2 through D4
Refer to 58E-06-02311, sheet 4, zones M9 through N19 and sheet 6, 830E
zones B2 through D4
Refer to 58E-06-02321, sheet 4, zones A7 through B7
Refer to 58F-06-02311, Sheet 4, zones M9 through N19 and Sheet 6, 930E
zones B2 through D4
Refer to 58F-06-10561, Sheet 4, zones A7 through B7
Refer to 58B-06-02390, Sheet 4, zones M9 through N19 and Sheet 6, 980E
zones H2 through H4
Refer to 58B-06-03570, Sheet 4, zones A7 through B7
9
CEN40179-01 40 Troubleshooting
Fault Code A153: Battery voltage is low with the truck in operation
Operator Action Stop; Park
Fault Code A153
Description Battery voltage is low with the truck in operation.
Fault Conditions Sets if battery voltage with the engine running or truck moving is below 23 volts for 5
seconds. Truck moving sets if truck speed is above 0 or if a bad speed signal fault is
active and the parking brake is not set.
Resets if voltage recovers to 25.5 volts
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: STOP: PARK
Display Fault Description: BATTERY VOLTS LOW
Display Fault Code: A153
Resulting Problem(s) Voltage may continue to drop and cause improper operation of the many electrical
controls on the truck.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to charge the batteries.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Battery Voltage, < 23.0 volts: Too low to continue operation.
24 Volt (IM1A) > 23.0 volts: OK to continue operation.
Fault(s): A154, A155, A250
Engine Speed [RPM] < 300 RPM: engine is not running
(CAN/J1939) (IM1q,r,s) > 300 RPM for 4 seconds: engine is running
Fault(s): A184
Truck Speed [kph] 0: truck is not moving
(CAN/RPC) (IM1i,j,k) > 0.8 kph (0.5 mph): truck is moving
Fault(s): A233
Parking Brake Set 0: parking brake pressure switch indicating low pressure and an applied parking brake
(IM2f) 1: parking brake pressure switch indicating higher pressure and an unapplied parking
brake
Fault(s): A213
Parking Brake 0: parking brake pressure switch indicating high pressure and a released parking
Released (IM2M) brake
1: parking brake pressure switch indicating low pressure and an applied parking brake
Fault(s): A214
10
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 14, zones I9 through I11 and Sheet 16, 730E
at IM zone B6
Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 15, zone I12 and Sheet 17, zone B5 930E
Refer to 58F-06-10561, Sheet 6, zone A2
Refer to 58B-06-02390, Sheet 16, zone D6 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/RPC connection Refer to 58D-06-01711, Sheet 16, zone B9 730E
at GE Refer to 58E-06-02311, sheet 17, zone B3 830E
Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, Sheet 17, zone C4 930E
Refer to 58F-06-10561, Sheet 6, zone B2
Refer to 58B-06-02390, Sheet 18, zone C4 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/J1939 connection Refer to 58D-06-01711, Sheet 16, zone E1 730E
at Engine Refer to 58E-06-02311, sheet 17, zones E1 and sheet 7, zones H2 830E
through H10
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones E1 and Sheet 7, zones H2 930E
through H10
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zones E1 and Sheet 7, zones H2 980E
through H8
Refer to 58B-06-03570, Sheet 6, zone A5
CAN/J1939 connection Refer to 58D-06-01711, Sheet 14, zones I9 through I11 and Sheet 16, 730E
at IM zone F6
Refer to 58E-06-02311, sheet 17, zones B5 through B6 and sheet 15, 830E
zones I9 through I12
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones B4 through B5 and Sheet 15, 930E
zones J9 through J12
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zones E4 through E5 and Sheet 16, 980E
zones E6
Refer to 58B-06-03570, Sheet 6, zone A5
11
CEN40179-01 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Parking Brake Set Refer to 58D-06-01711, Sheet 14, zones F9 through F16 730E
Pressure Switch Refer to 58E-06-02311, sheet 15, zones F10 through F16 830E
connection to IM Refer to 58E-06-02321, sheet 5, zone C8
Refer to 58F-06-02311, Sheet 15, zone F10 to F16 930E
Refer to 58F-06-10561, Sheet 5, zone C8
Refer to 58B-06-02390, Sheet 16, zone F10 to F16 980E
Refer to 58B-06-03570, Sheet 5, zone C8
Parking Brake Release Refer to 58D-06-01711, Sheet 3, zones H3 through H9 730E
Pressure Switch to IM Refer to 58E-06-02311, sheet 5, zones H3 through H9 830E
Refer to 58E-06-02321, sheet 5, zone C9
Refer to 58F-06-02311, Sheet 5, zones H5 through H14 930E
Refer to 58F-06-10561, Sheet 5, zone C9
Refer to 58B-06-02390, Sheet 5, zones H6 through H20 980E
Refer to 58B-06-03570, Sheet 5, zone C9
Battery Supply Voltage Refer to 58D-06-01711, Sheet 3, zones L4 through L15 730E
to IM Refer to 58E-06-02311, sheet 5, zones L4 through L15 830E
Refer to 58E-06-02321, sheet 18, zones A9 through B9
Refer to 58F-06-02311, Sheet 5, zones L4 through L15 930E
Refer to 58F-06-10561, Sheet 18, zones A9 through B9
Refer to 58B-06-02390, Sheet 5, zones L6 through L14 980E
Refer to 58B-06-03570, Sheet 20, zones A9 through B9
12
40 Troubleshooting CEN40179-01
Fault Code A154: Battery charging voltage is excessive
Operator Action Stop; Park; Power Down
Fault Code A154
Description Battery charging voltage is excessive.
Fault Conditions Sets if above 32 volts for 5 seconds.
Resets if below 27.5 volts for 5 seconds.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: HIGH BATTERY VOLTS
Display Fault Code: A154
Resulting Problem(s) Sustained excessive charging voltage may burn out electrical and electronic compo-
nents.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to check / replace the battery charger.
2. This fault's logic contains only one parameter.
Parameter Expected State and/or Related Fault(s)
Battery Voltage, > 32.0 volts: Too high to continue operation.
24 Volt (IM1A) < 32.0 volts: OK to continue operation.
Fault(s): A153, A155, A250
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Battery Supply Voltage Refer to 58D-06-01711, Sheet 3, zones L4 through L15 730E
to IM Refer to 58E-06-02311, sheet 5, zones L4 through L15 830E
Refer to 58E-06-02321, sheet 18, zones A9 through B9
Refer to 58F-06-02311, Sheet 5, zones L4 through L15 930E
Refer to 58F-06-10561, Sheet 18, zones A9 through B9
Refer to 58B-06-02390, Sheet 5, zones L6 through L14 980E
Refer to 58B-06-03570, Sheet 20, zones A9 through B9
13
CEN40179-01 40 Troubleshooting
Fault Code A155: Battery charging voltage is low
Operator Action Go to shop now
Fault Code A155
Description Battery charging voltage is low.
Fault Conditions Sets if below 24.5 volts for 5 seconds with engine above 1400 rpm.
Resets if above 26.0 volts for 5 seconds or at steering bleed.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: BATT CHARGING FLT
Display Fault Code: A155
Resulting Problem(s) If defective battery charging alternators are not replaced, batteries may become
discharged and electrical and electronic equipment will stop working.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to check / replace the battery charger.
2. This fault's logic contains more than one parameter, each of which may have it's own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Battery Voltage, < 24.5 volts: Charger must be changed soon.
24 Volt (IM1A) > 26.0 volts: OK to continue operation.
Fault(s): A153, A154, A250
Engine Speed [RPM] < 1400 RPM: engine is not running fast enough for battery charger test.
(CAN/J1939) (IM1q,r,s) > 1400 RPM: engine is running fast enough for battery charger test.
Fault(s): A184
14
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/J1939 connection Refer to 58D-06-01711, Sheet 16, zone E1 and Sheet 5, zones H2 730E
at Engine through H10
Refer to 58E-06-02311, sheet 17, zone E1 and sheet 7, zones H2 830E
through H10
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zone E1 and Sheet 7, zones H2 930E
through H10
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zone E1 and Sheet 7, zones H2 980E
through H8
Refer to 58B-06-03570, Sheet 6, zone A5
CAN/J1939 connection Refer to 58D-06-01711, Sheet 14, zones J9 through J11 and Sheet 16, 730E
at IM zone F6
Refer to 58E-06-02311, sheet 17, zones B5 through B6 and sheet 15, 830E
zones I9 through I12 and Sheet 16, zone F6
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones B4 through B5 and Sheet 15, 930E
zones J9 through J12
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zones E4 through E5 and Sheet 16, 980E
zones E6
Refer to 58B-06-03570, Sheet 6, zone A5
Battery Supply Voltage Refer to 58D-06-01711, Sheet 3, zones L4 through L15 730E
to IM Refer to 58E-06-02311, sheet 5, zones L4 through L15 830E
Refer to 58E-06-02321, sheet 18, zones A9 through B9
Refer to 58F-06-02311, Sheet 5, zones L4 through L15 930E
Refer to 58F-06-10561, Sheet 18, zones A9 through B9
Refer to 58B-06-02390, Sheet 5, zones L6 through L14 980E
Refer to 58B-06-03570, Sheet 20, zones A9 through B9
15
CEN40179-01 40 Troubleshooting
Fault Code A158: Fuel level sensor open or shorted high; false low fuel level indicated
Operator Action Go To Shop Now
Fault Code A158
Description Fuel level sensor is open or shorted high; false low fuel level indicated.
Fault Conditions Sets if fuel level indication is at -18.5% for 3 seconds, and battery voltage does not
drop below 18, with engine speed below 600 rpm.
Resets if fuel level indication is above -12.5% for 3 seconds.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: FUEL LEVEL SENSOR HI
Display Fault Code: A158
Resulting Problem(s) Fuel readings will show an empty tank, whether there is fuel in the tank or not.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct or replace the fuel level sensor or wiring.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Fuel Level Sensor 0.57 to 8.2 Volts: Good Readings at 24 Volt Battery (varies with battery voltage)
(IM3g) < 0.57 or > 8.2 Volts: Defective Sensor or Circuit at 24 Volt Battery (varies with battery
voltage)
Fault(s): A105
Battery Voltage, > 18 Volt: Good Reading
24 Volt (IM1A) < 18 Volt: Low battery voltage (while cranking) blocks this fault code.
Fault(s): A153, A154, A155, A250
Engine Speed [RPM] < 600 RPM: combined with low voltage means cranking is in process and fault is
(CAN/J1939) (IM1q,r,s) blocked
> 600 RPM: engine is running normally
Fault(s): A184
16
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/J1939 connection Refer to 58D-06-01711, Sheet 16, zone E1 and Sheet 5, zones H2 730E
at Engine through H10
Refer to 58E-06-02311, sheet 17, zone E1 and sheet 7, zones H2 830E
through H10
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zone E1 and Sheet 7, zones H2 930E
through H10
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zone E1 and Sheet 7, zones H2 980E
through H8
Refer to 58B-06-03570, Sheet 6, zone A5
CAN/J1939 connection Refer to 58D-06-01711, Sheet 14, zones J9 through J11 and Sheet 16, 730E
at IM zone F6
Refer to 58E-06-02311, sheet 17, zones B5 through B6 and sheet 15, 830E
zones I9 through I12
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones B4 through B5 and Sheet 15, 930E
zones J9 through J12
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zones E4 through E5 and Sheet 16, 980E
zones E6
Refer to 58B-06-03570, Sheet 6, zone A5
Fuel Level Sensor Refer to 58D-06-01711, Sheet 14, zones D9 through D22 730E
circuit Refer to 58E-06-02311, sheet 15, zones D10 through D22 830E
Refer to 58E-06-02321, sheet 31, zones B8 through B10
Refer to 58F-06-02311, Sheet 15, zones D10 through D22 930E
Refer to 58F-06-10561, Sheet 31, zones B8 through B10
Refer to 58B-06-02390, Sheet 16, zones C9 through D22 980E
Refer to 58B-06-03570, Sheet 33, zones B9 through B10
Battery Supply Voltage Refer to 58D-06-01711, Sheet 3, zones L4 through L15 730E
to IM Refer to 58E-06-02311, sheet 5, zones L4 through L15 830E
Refer to 58E-06-02321, sheet 18, zones A9 through B9
Refer to 58F-06-02311, Sheet 5, zones L4 through L15 930E
Refer to 58F-06-10561, Sheet 18, zones A9 through B9
Refer to 58B-06-02390, Sheet 5, zones L6 through L14 980E
Refer to 58B-06-03570, Sheet 20, zones A9 through B9
17
CEN40179-01 40 Troubleshooting
Fault Code A166: Left rear hydraulic oil temperature sensor is low
Operator Action None
Fault Code A166
Description Left rear hydraulic oil temperature sensor is low.
Fault Conditions Sets if temperature reading drops to -51ºC (-60ºF) [.016 Volt] for 3 seconds or remains
10ºC (18ºF) below ambient temperature for 15 minutes after the engine runs.
Resets if temperature reading rises to -46ºC (-51ºF) [.032 Volt] for 3 seconds and
recovers to within 10ºC (18ºF) of ambient temperature.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: LR OIL TEMP SENS LO
Display Fault Code: A166
Resulting Problem(s) Loss of monitoring of the left rear brake temperature begins a compromise of the
brake system temperature monitoring that can only worsen if other sensors are lost.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the sensor.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volts: Good readings
Left Rear (IM3i) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A170
Ambient Temperature 0.016 Volt to 4.89 Volts: Good readings
(IM3e) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A206, A207
Engine Speed [RPM] < 300 RPM: engine is not running
> 300 RPM for 4 seconds: engine is running
18
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hydraulic Oil Refer to 58F-06-02311, Sheet 15, zones J9 through L22 930E
Temperature Refer to 58F-06-10561, Sheet 5, zones D4 through E6
connection to IM Refer to 58B-06-02390, Sheet 16, zones J9 through K20 980E
Refer to 58B-06-03570, Sheet 5, zones D4 through E6
Ambient Temperature Refer to 58F-06-02311, Sheet 15, zones L9 through L21 930E
Sensor connection to Refer to 58F-06-10561, Sheet 5, zone D10
IM Refer to 58B-06-02390, Sheet 16, zones L9 through L19 980E
Refer to 58B-06-03570, Sheet 5, zone D10
19
CEN40179-01 40 Troubleshooting
Fault Code A167: Right rear hydraulic oil temperature sensor is low
Operator Action None
Fault Code A167
Description Right rear hydraulic oil temperature sensor is low.
Fault Conditions Sets if temperature reading drops to -51ºC (-60ºF) [.016 Volt] for 3 seconds or remains
10ºC (18ºF) below ambient temperature for 15 minutes after the engine runs.
Resets if temperature reading rises to -46ºC (-51ºF) [.032 Volt] for 3 seconds and
recovers to within 10ºC (18ºF) of ambient temperature.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: RR OIL TEMP SENS LO
Display Fault Code: A167
Resulting Problem(s) Loss of monitoring of the right rear brake temperature begins a compromise of the
brake system temperature monitoring that can only worsen if other sensors are lost.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the sensor.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volts: Good readings
Right Rear (IM3m) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A171
Ambient Temperature 0.016 Volt to 4.89 Volts: Good Readings
(IM3e) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A206, A207
Engine Speed [RPM] < 300 RPM: engine is not running
> 300 RPM for 4 seconds: engine is running
20
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hydraulic Oil Refer to 58F-06-02311, Sheet 15, zones J9 through L22 930E
Temperature Refer to 58F-06-10561, Sheet 5, zones D4 through E6
connection to IM Refer to 58B-06-02390, Sheet 16, zones J9 through K20 980E
Refer to 58B-06-03570, Sheet 5, zones D4 through E6
Ambient Temperature Refer to 58F-06-02311, Sheet 15, zones L9 through L21 930E
Sensor connection to Refer to 58F-06-10561, Sheet 5, zone D10
IM Refer to 58B-06-02390, Sheet 16, zones L9 through L19 980E
Refer to 58B-06-03570, Sheet 5, zone D10
21
CEN40179-01 40 Troubleshooting
Fault Code A168: Left front hydraulic oil temperature sensor is low
Operator Action None
Fault Code A168
Description Left front hydraulic oil temperature sensor is low.
Fault Conditions Sets if temperature reading drops to -51ºC (-60ºF) [.016 Volt] for 3 seconds or remains
10ºC (18ºF) below ambient temperature for 15 minutes after the engine runs.
Resets if temperature reading rises to -46ºC (-51ºF) [.032 Volt] for 3 seconds and
recovers to within 10ºC (18ºF) of ambient temperature.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: LF OIL TEMP SENS LO
Display Fault Code: A168
Resulting Problem(s) Loss of monitoring of the left front brake temperature begins a compromise of the
brake system temperature monitoring that can only worsen if other sensors are lost.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the sensor.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volts: Good readings
Left Front (IM3t) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A172
Ambient Temperature 0.016 Volt to 4.89 Volts: Good readings
(IM3e) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A206, A207
Engine Speed [RPM] < 300 RPM: engine is not running
> 300 RPM for 4 seconds: engine is running
22
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hydraulic Oil Refer to 58F-06-02311, Sheet 15, zones J9 through L22 930E
Temperature Refer to 58F-06-10561, Sheet 5, zones D4 through E6
connection to IM Refer to 58B-06-02390, Sheet 16, zones J9 through K20 980E
Refer to 58B-06-03570, Sheet 5, zones D4 through E6
Ambient Temperature Refer to 58F-06-02311, Sheet 15, zones L9 through L21 930E
Sensor connection to Refer to 58F-06-10561, Sheet 5, zone D10
IM Refer to 58B-06-02390, Sheet 16, zones L9 through L19 980E
Refer to 58B-06-03570, Sheet 5, zone D10
23
CEN40179-01 40 Troubleshooting
Fault Code A169: Right front hydraulic oil temperature sensor is low
Operator Action None
Fault Code A169
Description Right front hydraulic oil temperature sensor is low.
Fault Conditions Sets if temperature reading drops to -51ºC (-60ºF) [.016 Volt] for 3 seconds or remains
10ºC (18ºF) below ambient temperature for 15 minutes after the engine runs.
Resets if temperature reading rises to -46ºC (-51ºF) [.032 Volt] for 3 seconds and
recovers to within 10ºC (18ºF) of ambient temperature.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: RF OIL TEMP SENS LO
Display Fault Code: A169
Resulting Problem(s) Loss of monitoring of the right front brake temperature begins a compromise of the
brake system temperature monitoring that can only worsen if other sensors are lost.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the sensor.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volts: Good readings
Right Front (IM3r) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A173
Ambient Temperature 0.016 Volt to 4.89 Volts: Good readings
(IM3e) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A206, A207
Engine Speed [RPM] < 300 RPM: engine is not running
> 300 RPM for 4 seconds: engine is running
24
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hydraulic Oil Refer to 58F-06-02311, Sheet 15, zones J9 through L22 930E
Temperature Refer to 58F-06-10561, Sheet 5, zones D4 through E6
connection to IM Refer to 58B-06-02390, Sheet 16, zones J9 through K20 980E
Refer to 58B-06-03570, Sheet 5, zones D4 through E6
Ambient Temperature Refer to 58F-06-02311, Sheet 15, zones L9 through L21 930E
Sensor connection to Refer to 58F-06-10561, Sheet 5, zone D10
IM Refer to 58B-06-02390, Sheet 16, zones L9 through L19 980E
Refer to 58B-06-03570, Sheet 5, zone D10
25
CEN40179-01 40 Troubleshooting
Fault Code A170: Left rear hydraulic oil temperature sensor is high
Operator Action None
Fault Code A170
Description Left rear hydraulic oil temperature sensor is high.
Fault Conditions Sets if temperature reading rises to 211ºC (412ºF) [4.89 Volts] for 3 seconds.
Resets if temperature reading drops to 188ºC (370ºF) [4.77 Volts] for 3 seconds.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: LR OIL TEMP SENS HI
Display Fault Code: A170
Resulting Problem(s) Loss of monitoring of the Left Rear brake temperature begins a compromise of the
brake system temperature monitoring that can only worsen if other sensors are lost.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the sensor.
2. This fault's logic contains only one parameter.
Parameter Expected State and/or Related Fault(s)
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volts: Good readings
Left Rear (IM3i) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A166
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hydraulic Oil Refer to 58F-06-02311, Sheet 15, zones J9 through L22 930E
Temperature Refer to 58F-06-10561, Sheet 5, zones D4 through E6
connection to IM Refer to 58B-06-02390, Sheet 16, zones J9 through K20 980E
Refer to 58B-06-03570, Sheet 5, zones D4 through E6
Ambient Temperature Refer to 58F-06-02311, Sheet 15, zones L9 through L21 930E
Sensor connection to Refer to 58F-06-10561, Sheet 5, zone D10
IM Refer to 58B-06-02390, Sheet 16, zones L9 through L19 980E
Refer to 58B-06-03570, Sheet 5, zone D10
26
40 Troubleshooting CEN40179-01
Fault Code A171: Right rear hydraulic oil temperature sensor is high
Operator Action None
Fault Code A171
Description Right rear hydraulic oil temperature sensor is high.
Fault Conditions Sets if temperature reading rises to 211ºC (412ºF) [4.89 Volts] for 3 seconds.
Resets if temperature reading drops to 188ºC (370ºF) [4.77 Volts] for 3 seconds.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: RR OIL TEMP SENS HI
Display Fault Code: A171
Resulting Problem(s) Loss of monitoring of the right rear brake temperature begins a compromise of the
brake system temperature monitoring that can only worsen if other sensors are lost.
Related Information A laptop running "IM Realtime Data Monitor" software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the sensor.
2. This fault's logic contains only one parameter.
Parameter Expected State and/or Related Fault(s)
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volts: Good readings
Right Rear (IM3m) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A167
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hydraulic Oil Refer to 58F-06-02311, Sheet 15, zones J9 through L22 930E
Temperature Refer to 58F-06-10561, Sheet 5, zones D4 through E6
connection to IM Refer to 58B-06-02390, Sheet 16, zones J9 through K20 980E
Refer to 58B-06-03570, Sheet 5, zones D4 through E6
Ambient Temperature Refer to 58F-06-02311, Sheet 15, zones L9 through L21 930E
Sensor connection to Refer to 58F-06-10561, Sheet 5, zone D10
IM Refer to 58B-06-02390, Sheet 16, zones L9 through L19 980E
Refer to 58B-06-03570, Sheet 5, zone D10
27
CEN40179-01 40 Troubleshooting
Fault Code A172: Left front hydraulic oil temperature sensor is high
Operator Action None
Fault Code A172
Description Left front hydraulic oil temperature sensor is high.
Fault Conditions Sets if temperature reading rises to 211ºC (412ºF) [4.89 Volts] for 3 seconds.
Resets if temperature reading drops to 188ºC (370ºF) [4.77 Volts] for 3 seconds.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: LF OIL TEMP SENS HI
Display Fault Code: A172
Resulting Problem(s) Loss of monitoring of the left front brake temperature begins a compromise of the
brake system temperature monitoring that can only worsen if other sensors are lost.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the sensor.
2. This fault's logic contains only one parameter.
Parameter Expected State and/or Related Fault(s)
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volts: Good readings
Left Front (IM3t) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A168
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hydraulic Oil Refer to 58F-06-02311, Sheet 15, zones J9 through L22 930E
Temperature Refer to 58F-06-10561, Sheet 5, zones D4 through E6
connection to IM Refer to 58B-06-02390, Sheet 16, zones J9 through K20 980E
Refer to 58B-06-03570, Sheet 5, zones D4 through E6
Ambient Temperature Refer to 58F-06-02311, Sheet 15, zones L9 through L21 930E
Sensor connection to Refer to 58F-06-10561, Sheet 5, zone D10
IM Refer to 58B-06-02390, Sheet 16, zones L9 through L19 980E
Refer to 58B-06-03570, Sheet 5, zone D10
28
40 Troubleshooting CEN40179-01
Fault Code A173: Right front hydraulic oil temperature sensor is high
Operator Action None
Fault Code A173
Description Right front hydraulic oil temperature sensor is high.
Fault Conditions Sets if temperature reading rises to 211ºC (412ºF) [4.89 Volts] for 3 seconds.
Resets if temperature reading drops to 188ºC (370ºF) [4.77 Volts] for 3 seconds.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: RF OIL TEMP SENS HI
Display Fault Code: A173
Resulting Problem(s) Loss of monitoring of the right front brake temperature begins a compromise of the
brake system temperature monitoring that can only worsen if other sensors are lost.
Related Information A laptop running "IM Realtime Data Monitor" software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the sensor.
2. This fault's logic contains only one parameter.
Parameter Expected State and/or Related Fault(s)
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volts: Good readings
Right Front (IM3r) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A169
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hydraulic Oil Refer to 58F-06-02311, Sheet 15, zones J9 through L22 930E
Temperature Refer to 58F-06-10561, Sheet 5, zones D4 through E6
connection to IM Refer to 58B-06-02390, Sheet 16, zones J9 through K20 980E
Refer to 58B-06-03570, Sheet 5, zones D4 through E6
Ambient Temperature Refer to 58F-06-02311, Sheet 15, zones L9 through L21 930E
Sensor connection to Refer to 58F-06-10561, Sheet 5, zone D10
IM Refer to 58B-06-02390, Sheet 16, zones L9 through L19 980E
Refer to 58B-06-03570, Sheet 5, zone D10
29
CEN40179-01 40 Troubleshooting
Fault Code A184: The J1939 data link is not connected
Operator Action Stop; Park Power down
Fault Code A184
Description The J1939 data link is not connected.
Fault Conditions Sets if no data is received from the engine for 10 seconds after an initial 11 second
delay at keyswitch ON.
Resets immediately when communication is established.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: NO ENGINE DATA
Display Fault Code: A184
Resulting Problem(s) Loss of engine data makes it impossible to operate the truck in a normal manner with-
out risking serious damage to the engine.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have it's own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
CAN J1939 Data Link No communication for 10 seconds if keyswitch has been on for 11 seconds: J1939 not
(IM1qrs) connected.
Successful read of PGN 61444: J1939 is connected.
Keyswitch (IM3G) 0: keyswitch is off and the truck is not moving and the engine is not running
1: keyswitch is on or the truck is moving or the engine is running NOTE: for this fault,
the keyswitch function is delayed for 11 seconds internally after initial turn on
Fault(s): A240
30
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/J1939 connection Refer to 58D-06-01711, Sheet 16, zone E1 and Sheet 5, zones H2 730E
at Engine through H10
Refer to 58E-06-02311, sheet 17, zones E1 and sheet 7, zones H2 830E
through H10
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones E1 and Sheet 7, zones H2 930E
through H10
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zones E1 and Sheet 7, zones H2 980E
through H8
Refer to 58B-06-03570, Sheet 6, zone A5
CAN/J1939 connection Refer to 58D-06-01711, Sheet 14, zones J9 through J11 and Sheet 16, 730E
at IM zone F6
Refer to 58E-06-02311, sheet 17, zones B5 through B6 and sheet 15, 830E
zones I9 through I12
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones B4 through B5 and Sheet 15, 930E
zones J9 through J12
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zones E4 through E5 and Sheet 16, 980E
zones E6
Refer to 58B-06-03570, Sheet 6, zone A5
Keyswitch, OR Refer to 58D-06-01711, Sheet 14, D9 through D19 730E
connection to IM Refer to 58E-06-02311, sheet 15, zones D10 through D19 830E
Refer to 58E-06-02321, sheet 31, zones B8 through B10
Refer to 58F-06-02311, Sheet 15, zones D10 through D19 930E
Refer to 58F-06-10561, Sheet 31, zones B8 through B10
Refer to 58B-06-02390, Sheet 16, zones D10 through D19 980E
Refer to 58B-06-03570, Sheet 33, zones B9 through B10
31
CEN40179-01 40 Troubleshooting
Fault Code A190: The auto lube control has detected an incomplete lube cycle
Operator Action None
Fault Code A190
Description The auto lube control has detected an incomplete lube cycle.
Fault Conditions Sets if lube cycle is terminated by timeout rather than pressure. Lubrication occurs
with steering pressure up, truck moving, and drive control power on.
Resets when a lube cycle is properly terminated by pressure rather than timeout.
Operator Alerting Operate Repair Lamp
System Response Display Fault Description: AUTO LUBE FAULT
Display Fault Code: A190
Resulting Problem(s) Insufficient lube may result and if left uncorrected could lead to equipment damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Auto Lube Pressure 0: Pressure switch has transferred at 13790 kPa (2000 psi)
Sw (IM3Y) 1: Pressure switch at low pressure or solenoid circuit not on
Fault(s): A304, A305, A361
Low Steering Pressure 0: steering pressure normal (required for lube cycle to proceed)
Sw (IM2S) 1: low steering pressure
Fault(s): A279
Truck Speed [kph] 0: truck is not moving
(CAN/RPC) (IM1i,j,k) > 0 for 10 seconds: truck is moving
Fault(s): A233
GE Batt+ Off (IM3M) 0: power to GE control is off
1: power to GE control is on
Auto Lube Output Status - Open Load: Unexpected. Troubleshoot
(IM1T) Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected except momentarily at termination of a lube
cycle. If detected any other time, troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: Turns off between lubrication cycles.
1. Turns on during lubrication cycle.
Fault(s): A305, A357
32
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 14, zones I9 through I12 and Sheet 16, 730E
at IM zone B6
Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 15, zone I12 and Sheet 17, zone B5 930E
Refer to 58F-06-10561, Sheet 6, zone A2
Refer to 58B-06-02390, Sheet 16, zone D6 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/RPC connection Refer to 58D-06-01711, Sheet 16, zone B9 730E
at GE Refer to 58E-06-02311, sheet 17, zone B3 830E
Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, Sheet 17, zone C4 930E
Refer to 58F-06-10561, Sheet 6, zone B2
Refer to 58B-06-02390, Sheet 18, zone C4 980E
Refer to 58B-06-03570, Sheet 6, zone A2
Auto Lube Pressure Refer to 58D-06-01711, Sheet 14, zones N9 through N19 730E
Switch connection to Refer to 58E-06-02311, sheet 15, zones N9 through N19 830E
IM Refer to 58E-06-02321, sheet 2, zone C3
Refer to 58F-06-02311, Sheet 15, zones N9 through N19 930E
Refer to 58F-06-10561, Sheet 2, zone C3
Refer to 58B-06-02390, Sheet 16, zones L9 through L19 980E
Refer to 58B-06-03570, Sheet 2, zone C3
GE Batt+ Off Refer to 58D-06-01711, Sheet 4, zones B2 through C4 730E
connection to IM Refer to 58E-06-02311, sheet 6, zones B2 through C4 830E
Refer to 58E-06-02321, sheet 4, zone D4
Refer to 58F-06-02311, Sheet 6, zones B2 through C4 930E
Refer to 58F-06-10561, Sheet 4, zone D4
Refer to 58B-06-02390, Sheet 6, zones G2 through G4 980E
Refer to 58B-06-03570, Sheet 4, zone D4
Auto Lube Solenoid Refer to 58D-06-01711, Sheet 14, zones N9 through N19 730E
Refer to 58E-06-02311, sheet 15, zones N9 through N19 830E
Refer to 58E-06-02321, sheet 2, zone B4
Refer to 58F-06-02311, Sheet 15, zones N9 through N19 930E
Refer to 58F-06-10561, Sheet 2, zone B4
Refer to 58B-06-02390, Sheet 16, zones M9 through M21 980E
Refer to 58B-06-03570, Sheet 2, zone B4
33
CEN40179-01 40 Troubleshooting
Fault Code A193: Hydraulic Tank Oil Temperature is high
Operator Action Stop: Park: Run Eng
Fault Code A193
Description Hydraulic Tank Oil Temperature is high
Fault Conditions Sets at 120ºC (248ºF) 4.5 volts after 5 seconds
Resets at 103ºC (217ºF) 4.4 volts after 5 seconds or at steering bleed.
Operator Alerting Operate LED on Oil Temp Gauge
System Response Sound Buzzer
Flash IM Warning indicator
Display Operator Action: STOP: PARK: RUN ENG
Display Fault Description: HOT HYD OIL TANK
Display Fault Code: A193
Resulting Problem(s) Excessively hot oil can cause equipment damage and may reduce service brake effec-
tiveness.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains just one parameter. This fault may be resolved by resolving the parameter(s) active
fault code(s). Refer to the Troubleshooting Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Hydraulic Oil 0.016 Volt to 4.89 Volt: Good Readings
Temperature - Tank < 0.016 Volt or > 4.89 Volt: Defective Sensor or Circuit
(IM3m) Fault(s): A103, A104
Steering Bleed Valve 0: steering bleed is off
(IM1-P) 1: steering bleed is on
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hydraulic Oil Refer to 58D-06-01711, Sheet 14, zones J9 through K21 730E
Temperature Refer to 58E-06-02311, sheet 15, zones J9 through K21 830E
connection to IM Refer to 58E-06-02321, sheet 5, zones D4 through E6
34
40 Troubleshooting CEN40179-01
Fault Code A194: Left front hydraulic oil temperature is high
Operator Action Stop; Park; Run Engine
Fault Code A194
Description Left front hydraulic oil temperature is high.
Fault Conditions Sets at 120ºC (248ºF) [4.13 Volts] after 5 seconds.
Resets at 103ºC (217ºF) [3.78 Volts] after 5 seconds or at steering bleed.
Operator Alerting Sound Buzzer
System Response Flash IM Warning indicator
Display Operator Action: STOP: PARK: RUN ENG
Display Fault Description: HOT HYD OIL LF
Display Fault Code: A194
Resulting Problem(s) Excessively hot oil can cause equipment damage and may reduce service brake effec-
tiveness.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes, then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved, then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volts: Good readings
Left Front (IM3t) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A168, A172
Steering Bleed Valve 0: steering bleed valve is off.
1: steering bleed valve is on.
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hydraulic Oil Refer to 58F-06-02311, Sheet 15, zones J9 through L22 930E
Temperature Refer to 58F-06-10561, Sheet 5, zones D4 through E6
connection to IM Refer to 58B-06-02390, Sheet 16, zones J9 through K20 980E
Refer to 58B-06-03570, Sheet 5, zones D4 through E6
35
CEN40179-01 40 Troubleshooting
Fault Code A195: Right front hydraulic oil temperature is high
Operator Action Stop; Park; Run Engine
Fault Code A195
Description Right front hydraulic oil temperature is high.
Fault Conditions Sets at 120ºC (248ºF) [4.13 Volts] after 5 seconds.
Resets at 103ºC (217ºF) [3.78 Volts] after 5 seconds or at steering bleed.
Operator Alerting Sound Buzzer
System Response Flash IM Warning indicator
Display Operator Action: STOP: PARK: RUN ENG
Display Fault Description: HOT HYD OIL RF
Display Fault Code: A195
Resulting Problem(s) Excessively hot oil can cause equipment damage and may reduce service brake effec-
tiveness.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volts: Good readings
Right Front (IM3r) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A169, A173
Steering Bleed Valve 0: steering bleed valve is off.
1: steering bleed valve is on.
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hydraulic Oil Refer to 58F-06-02311, Sheet 15, zones J9 through L22 930E
Temperature Refer to 58F-06-10561, Sheet 5, zones D4 through E6
connection to IM Refer to 58B-06-02390, Sheet 16, zones J9 through K20 980E
Refer to 58B-06-03570, Sheet 5, zones D4 through E6
36
40 Troubleshooting CEN40179-01
Fault Code A196: Left rear hydraulic oil temperature is high
Operator Action Stop; Park; Run Engine
Fault Code A196
Description Left rear hydraulic oil temperature is high.
Fault Conditions Sets at 120ºC (248ºF) [4.13 Volts] after 5 seconds.
Resets at 103ºC (217ºF) [3.78 Volts] after 5 seconds or at steering bleed.
Operator Alerting Sound Buzzer
System Response Flash IM Warning indicator
Display Operator Action: STOP: PARK: RUN ENG
Display Fault Description: HOT HYD OIL LR
Display Fault Code: A196
Resulting Problem(s) Excessively hot oil can cause equipment damage and may reduce service brake effec-
tiveness.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volts: Good readings
Left Rear (IM3i) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A166, A170
Steering Bleed Valve 0: steering bleed valve is off.
1: steering bleed valve is on.
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hydraulic Oil Refer to 58F-06-02311, Sheet 15, zones J9 through L22 930E
Temperature Refer to 58F-06-10561, Sheet 5, zones D4 through E6
connection to IM Refer to 58B-06-02390, Sheet 16, zones J9 through K20 980E
Refer to 58B-06-03570, Sheet 5, zones D4 through E6
37
CEN40179-01 40 Troubleshooting
Fault Code A197: Right rear hydraulic oil temperature is high
Operator Action Stop; Park; Run Engine
Fault Code A197
Description Right rear hydraulic oil temperature is high.
Fault Conditions Sets at 120ºC (248ºF) [4.13 Volts] after 5 seconds.
Resets at 103ºC (217ºF) [3.78 Volts] after 5 seconds or at steering bleed.
Operator Alerting Sound Buzzer
System Response Flash IM Warning indicator
Display Operator Action: STOP: PARK: RUN ENG
Display Fault Description: HOT HYD OIL RR
Display Fault Code: A197
Resulting Problem(s) Excessively hot oil can cause equipment damage and may reduce service brake effec-
tiveness.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes, then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved, then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volts: Good readings
Right Rear (IM3m) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A167, A171
Steering Bleed Valve 0: steering bleed valve is off
1: steering bleed valve is on
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hydraulic Oil Refer to 58F-06-02311, Sheet 15, zones J9 through L22 930E
Temperature Refer to 58F-06-10561, Sheet 5, zones D4 through E6
connection to IM Refer to 58B-06-02390, Sheet 16, zones J9 through K20 980E
Refer to 58B-06-03570, Sheet 5, zones D4 through E6
38
40 Troubleshooting CEN40179-01
Fault Code A198: Hoist Pressure 1 Sensor is high
Operator Action None
Fault Code A198
Description Hoist Pressure 1 Sensor is high.
Fault Conditions Sets at 27751 kPa (4025 psi) 20.1mA for 5 seconds.
Resets at 25165 kPa (3650 psi) 18.6 mA for 5 seconds.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: HOIST PRES 1 SENS HI
Display Fault Code: A198
Resulting Problem(s) Monitoring of hoist pressures in KOMTRAX Plus 2 will be compromised.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the sensor.
2. This fault's logic contains only one parameter.
Parameter Expected State and/or Related Fault(s)
Hoist Pressure 1 2.4 mA to 20.1 mA: good readings
Sensor (IM3s) < 2.4 mA or > 20.1 mA: Defective sensor or circuit
Fault(s): A202
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hoist Pressure 1 Refer to 58D-06-01711, Sheet 14, zones H1 through I7 730E
Sensor connection to Refer to 58E-06-02311, sheet 15, zones H1 through H8 830E
IM Refer to 58E-06-02321, sheet 31, zone A9
Refer to 58F-06-02311, Sheet 15, zones H1 through H8 930E
Refer to 58F-06-10561, Sheet 31, zone A9
Refer to 58B-06-02390, Sheet 16, zones H1 through H7 980E
Refer to 58B-06-03570, Sheet 33, zone A9
39
CEN40179-01 40 Troubleshooting
Fault Code A199: Hoist Pressure 2 Sensor is high
Operator Action None
Fault Code A199
Description Hoist Pressure 2 Sensor is high.
Fault Conditions Sets at 27751 kPa (4025 psi) 20.1mA for 5 seconds.
Resets at 25165 kPa (3650 psi) 18.6 mA for 5 seconds.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: HOIST PRES 2 SENS HI
Display Fault Code: A199
Resulting Problem(s) Monitoring of hoist pressures in KOMTRAX Plus 2 will be compromised.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the sensor.
2. This fault's logic contains only one parameter.
Parameter Expected State and/or Related Fault(s)
Hoist Pressure 2 2.4 mA to 20.1 mA: good readings
Sensor (IM3q) < 2.4 mA or > 20.1 mA: Defective sensor or circuit
Fault(s): A203
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hoist Pressure 2 Refer to 58E-06-02311, sheet 15, zones I1 through I8 830E
Sensor connection to Refer to 58E-06-02321, sheet 31, zone A9
IM Refer to 58F-06-02311, Sheet 15, zones I1 through I8 930E
Refer to 58F-06-10561, Sheet 31, zone A9
Refer to 58B-06-02390, Sheet 16, zones I1 through I7 980E
Refer to 58B-06-03570, Sheet 33, zone A9
40
40 Troubleshooting CEN40179-01
Fault Code A200: Steering Pressure Sensor High
Operator Action None
Fault Code A200
Description Steering Pressure Sensor High
Fault Conditions Sets at 27751 kPa (4025 psi) 20.1mA for 5 seconds.
Resets at 25165 kPa (3650 psi) 18.6 mA for 5 seconds.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: STRG PRES SENS HI
Display Fault Code: A200
Resulting Problem(s) Monitoring of steering pressure in KOMTRAX Plus 2 will be compromised.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the sensor.
2. This fault's logic contains only one parameter.
Parameter Expected State and/or Related Fault(s)
Steering Pressure 2.4 mA to 20.1 mA: good readings
Sensor (IM3d) < 2.4 mA or > 20.1 mA: Defective sensor or circuit
Fault(s): A204
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Steering Pressure Refer to 58D-06-01711, Sheet 14, zones G1 through G7 730E
Sensor connection to Refer to 58E-06-02311, sheet 15, zones H1 through H8 830E
IM Refer to 58E-06-02321, sheet 31, zone B5
Refer to 58F-06-02311, Sheet 15, zones H1 through H8 930E
Refer to 58F-06-10561, Sheet 31, zone B5
Refer to 58B-06-02390, Sheet 16, zones H1 through H7 980E
Refer to 58B-06-03570, Sheet 33, zone B5
41
CEN40179-01 40 Troubleshooting
Fault Code A201: Brake Pressure Sensor High
Operator Action None
Fault Code A201
Description Brake Pressure Sensor High
Fault Conditions Sets at 27751 kPa (4025 psi) 20.1mA for 5 seconds.
Resets at 25165 kPa (3650 psi) 18.6 mA for 5 seconds.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: BRAKE PRES SENS HI
Display Fault Code: A201
Resulting Problem(s) Monitoring of the service brake system for driver input as well as KOMTRAX Plus 2
data will be compromised.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the sensor.
2. This fault's logic contains only one parameter.
Parameter Expected State and/or Related Fault(s)
Brake Pressure Sensor 2.4 mA to 20.1 mA: good readings
(IM3p) < 2.4 mA or > 20.1 mA: Defective sensor or circuit
Fault(s): A205
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Brake Pressure Refer to 58D-06-01711, Sheet 14, zones K1 through K7 730E
Sensor connection to Refer to 58E-06-02311, sheet 15, zones K1 through K8 830E
IM Refer to 58E-06-02321, sheet 5, zone E10
Refer to 58F-06-02311, Sheet 15, zones K1 through K8 930E
Refer to 58F-06-10561, Sheet 5, zone E10
Refer to 58B-06-02390, Sheet 16, zones K1 through K12 980E
Refer to 58B-06-03570, Sheet 5, zone E10
42
40 Troubleshooting CEN40179-01
NOTES
43
CEN40179-01 40 Troubleshooting
Fault Code A202: Hoist Pressure 1 Sensor Low
Operator Action None
Fault Code A202
Description Hoist Pressure 1 Sensor Low
Fault Conditions Sets at -2765 kPa (-401 psi) 2.4 mA for 5 seconds with cranking state not sensed (<
600 engine rpm and < 18 battery volts).
Resets at -1420 kPa (-206 psi) 3.2 mA
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: HOIST PRES 1 SENS LO
Display Fault Code: A202
Resulting Problem(s) Monitoring of hoist pressures in KOMTRAX Plus 2 will be compromised.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the sensor.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Hoist Pressure 1 2.4 mA to 20.1 mA: good readings
Sensor (IM3s) < 2.4 mA or > 20.1 mA: Defective sensor or circuit
Fault(s): A198
Battery Voltage, 24 > 18 Volt: Good Reading
Volt (IM1A) < 18 Volt: Low battery voltage (while cranking) blocks this fault.
Fault(s): A153, A154, A155, A250
Engine Speed [RPM] < 600 RPM: combined with low voltage means cranking is in process and fault is
(CAN/J1939) (IM1q,r,s) blocked
> 600 RPM: engine is running normally
Fault(s): A184
44
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hoist Pressure 1 Refer to 58D-06-01711, Sheet 14, zones H1 through H7 730E
Sensor connection to Refer to 58E-06-02311, Sheet 15, zones H1 through H8 830E
IM Refer to 58E-06-02321, Sheet 31, zone A9
Refer to 58F-06-02311, Sheet 15, zones H1 through H8 930E
Refer to 58F-06-10561, Sheet 31, zone A9
Refer to 58B-06-02390, Sheet 16, zones H1 through H7 980E
Refer to 58B-06-03570, Sheet 33, zone A9
45
CEN40179-01 40 Troubleshooting
Fault Code A203: Hoist Pressure 2 Sensor Low
Operator Action None
Fault Code A203
Description Hoist Pressure 2 Sensor Low
Fault Conditions Sets at -2765 kPa (-401 psi) 2.4 mA for 5 seconds with cranking state not sensed (<
600 engine rpm and < 18 battery volts).
Resets at -1420 kPa (-206 psi) 3.2 mA
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: HOIST PRES 2 SENS LO
Display Fault Code: A203
Resulting Problem(s) Monitoring of hoist pressures in KOMTRAX Plus 2 will be compromised.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the sensor.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Hoist Pressure 2 2.4 mA to 20.1 mA: good readings
Sensor (IM3q) < 2.4 mA or > 20.1 mA: Defective sensor or circuit
Fault(s): A199
Battery Voltage, 24 > 18 Volt: Good Reading
Volt (IM1A) < 18 Volt: Low battery voltage (while cranking) blocks this fault.
Fault(s): A153, A154, A155, A250
Engine Speed [RPM] < 600 RPM: combined with low voltage means cranking is in process and fault is
(CAN/J1939) (IM1q,r,s) blocked
> 600 RPM: engine is running normally
Fault(s): A184
46
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hoist Pressure 2 Refer to 58E-06-02311, sheet 15, zones I1 through I8 830E
Sensor connection to Refer to 58E-06-02321, sheet 31, zone A9
IM Refer to 58F-06-02311, Sheet 15, zones I1 through I8 930E
Refer to 58F-06-10561, Sheet 31, zone A9
Refer to 58B-06-02390, Sheet 16, zones I1 through I7 980E
Refer to 58B-06-03570, Sheet 33, zone A9
47
CEN40179-01 40 Troubleshooting
Fault Code A204: Steering Pressure Sensor Low
Operator Action None
Fault Code A204
Description Steering Pressure Sensor Low
Fault Conditions Sets at -2765 kPa (-401 psi) 2.4 mA for 5 seconds with cranking state not sensed (<
600 engine rpm and < 18 battery volts).
Resets at -1420 kPa (-206 psi) 3.2 mA
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: STRG PRES SENS LO
Display Fault Code: A204
Resulting Problem(s) Monitoring of steering pressure in KOMTRAX Plus 2 will be compromised.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the sensor.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Steering Pressure 2.4 mA to 20.1 mA: good readings
Sensor (IM3d) < 2.4 mA or > 20.1 mA: Defective sensor or circuit
Fault(s): A200
Battery Voltage, 24 > 18 Volt: Good Reading
Volt (IM1A) < 18 Volt: Low battery voltage (while cranking) blocks this fault.
Fault(s): A153, A154, A155, A250
Engine Speed [RPM] < 600 RPM: combined with low voltage means cranking is in process and fault is
(CAN/J1939) (IM1q,r,s) blocked
> 600 RPM: engine is running normally
Fault(s): A184
48
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Steering Pressure Refer to 58D-06-01711, Sheet 14, zones G1 through G7 730E
Sensor connection to Refer to 58E-06-02311, sheet 15, zones H1 through H8 830E
IM Refer to 58E-06-02321, sheet 31, zone B5
Refer to 58F-06-02311, Sheet 15, zones H1 through H8 930E
Refer to 58F-06-10561, Sheet 31, zone B5
Refer to 58B-06-02390, Sheet 16, zones H1 through H7 980E
Refer to 58B-06-03570, Sheet 33, zone B5
49
CEN40179-01 40 Troubleshooting
Fault Code A205: Brake Pressure Sensor Low
Operator Action None
Fault Code A205
Description Brake Pressure Sensor Low
Fault Conditions Sets at -2765 kPa (-401 psi) 2.4 mA for 5 seconds with cranking state not sensed (<
600 engine rpm and < 18 battery volts).
Resets at -1420 kPa (-206 psi) 3.2 mA
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: BRAKE PRES SENS LO
Display Fault Code: A205
Resulting Problem(s) Monitoring of brake pressure in KOMTRAX Plus 2 will be compromised.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the sensor.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Brake Pressure Sensor 2.4 mA to 20.1 mA: good readings
(IM3p) < 2.4 mA or > 20.1 mA: Defective sensor or circuit
Fault(s): A201
Battery Voltage, 24 > 18 Volt: Good Reading
Volt (IM1A) < 18 Volt: Low battery voltage (while cranking) blocks this fault.
Fault(s): A153, A154, A155, A250
Engine Speed [RPM] < 600 RPM: combined with low voltage means cranking is in process and fault is
(CAN/J1939) (IM1q,r,s) blocked
> 600 RPM: engine is running normally
A184
50
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Brake Pressure Refer to 58D-06-01711, Sheet 14, zones K1 through K7 730E
Sensor connection to Refer to 58E-06-02311, sheet 15, zones K1 through K8 830E
IM Refer to 58E-06-02321, sheet 5, zone E10
Refer to 58F-06-02311, Sheet 15, zones K1 through K8 930E
Refer to 58F-06-10561, Sheet 5, zone E10
Refer to 58B-06-02390, Sheet 16, zones K1 through K12 980E
Refer to 58B-06-03570, Sheet 5, zone E10
51
CEN40179-01 40 Troubleshooting
Fault Code A206: Ambient Temperature Sensor High
Operator Action None
Fault Code A206
Description Ambient Temperature Sensor High
Fault Conditions Sets at 133º C (271º F) 4.89V for 3 seconds.
Resets at 107º C (225º F) 4.77V for 3 seconds.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: AMBIENT TEMP SENS HI
Display Fault Code: A206
Resulting Problem(s) Monitoring of temperatures will be compromised without ambient temperature
information.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the sensor.
2. This fault's logic contains only one parameter.
Parameter Expected State and/or Related Fault(s)
Ambient Temperature 0.016 Volt to 4.89 Volt: Good Readings
Sensor (IM3e) < 0.016 Volt or > 4.89 Volt: Defective Sensor or Circuit
Fault(s): A207
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Ambient Temperature Refer to 58D-06-01711, Sheet 14, zones L9 through L21 730E
Sensor connection to Refer to 58E-06-02311, sheet 15, zones L9 through L21 830E
IM Refer to 58E-06-02321, sheet 5, zone D10
Refer to 58F-06-02311, Sheet 15, zones L9 through L21 930E
Refer to 58F-06-10561, Sheet 5, zone D10
Refer to 58B-06-02390, Sheet 16, zones L9 through L19 980E
Refer to 58B-06-03570, Sheet 5, zone D10
52
40 Troubleshooting CEN40179-01
Fault Code A207: Ambient Temperature Sensor Low
Operator Action None
Fault Code A207
Description Ambient Temperature Sensor Low
Fault Conditions Sets at -62º C (-80º F) 0.016V for 3 seconds.
Resets at -59º C (-74º F) 0.032V for 3 seconds.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: AMBIENT TMP SENS LO
Display Fault Code: A207
Resulting Problem(s) Monitoring of temperatures will be compromised without ambient temperature informa-
tion.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the sensor.
2. This fault's logic contains only one parameter.
Parameter Expected State and/or Related Fault(s)
Ambient Temperature 0.016 Volt to 4.89 Volt: Good Readings
Sensor (IM3e) < 0.016 Volt or > 4.89 Volt: Defective Sensor or Circuit
Fault(s): A206
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Ambient Temperature Refer to 58D-06-01711, Sheet 14, zones L9 through L21 730E
Sensor connection to Refer to 58E-06-02311, sheet 15, zones L9 through L21 830E
IM Refer to 58E-06-02321, sheet 5, zone D10
Refer to 58F-06-02311, Sheet 15, zones L9 through L21 930E
Refer to 58F-06-10561, Sheet 5, zone D10
Refer to 58B-06-02390, Sheet 16, zones L9 through L19 980E
Refer to 58B-06-03570, Sheet 5, zone D10
53
CEN40179-01 40 Troubleshooting
Fault Code A213: Parking brake should have applied; detected as not having applied
Operator Action Secure Vehicle
Fault Code A213
Description The parking brake should have applied but is detected as not having applied.
Fault Conditions Sets if parking brake does not come on in 2 seconds with no Parking Brake Release
Command and either a Selector Switch (forward, neutral, or reverse) signal or a
Parking Brake Request input or a Selector Switch park input is active.
Also sets if parking brake does not come on in 2 seconds after Steering Bleed Valve
operates.
Also sets if parking brake does not come on in 15 seconds after Engine Speed drops
to 0 and there is no Parking Brake Release Command and J1939 control link is
working.
Parking brake set is defined as closure of the parking brake set pressure switch and
opening of the parking brake release pressure switch.
Resets after 3 seconds if the parking brake applies, or if the parking brake request is
canceled and the shifter is not in the park position and the shifter is in the forward,
neutral, or reverse positions and the engine is running.
Operator Alerting Sound Buzzer
System Response Flash IM Warning indicator
Display Operator Action: SECURE VEHICLE
Display Fault Description: NO PARK BRAKE
Display Fault Code: A213
Resulting Problem(s) The parking brake may be non-functional.
Engine cranking may be prevented.
Smart Timed Engine Shutdown may be prevented.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
54
40 Troubleshooting CEN40179-01
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Selector Switch (FNR) 0: shifter is not in forward, neutral, or reverse
(IM2N) 1: shifter is in forward, neutral, or reverse
Fault(s): A271, A303
Selector Switch (Park) 0: shifter is not park
(IM3T) 1: shifter is in park
Fault(s): A271, A303
Parking Brake Request 0: shifter is not in the forward, neutral, or reverse positions or the engine oil pressure is
(IM3V) below the set point of the engine oil pressure switch
1: shifter is in the forward, neutral, or reverse positions and the engine oil pressure is
above the set point of the engine oil pressure switch
Fault(s): A264
Parking Brake Set 0: parking brake pressure switch indicating low pressure and an applied parking brake
(IM2f) 1: parking brake pressure switch indicating higher pressure and an unapplied parking
brake
Parking Brake 0: parking brake pressure switch indicating high pressure and a released parking
Released (IM2M) brake
1: parking brake pressure switch indicating low pressure and an applied parking brake
Fault(s): A214
Engine Speed [RPM] 0: engine is not running
(CAN/J1939) (IM1q,r,s) > 0: engine is running
Fault(s): A184
Parking Brake Sole- Status - Open Load: Unexpected. Troubleshoot.
noid (IM1E) Status - Normal: Expected. No Problem.
Status - Shorted to Ground: Expected if shifter is in the forward, neutral, or reverse
positions and the engine oil pressure is above the set point of the engine oil pressure
switch. Otherwise unexpected and must troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: shifter is not in the forward, neutral, or reverse positions or the engine oil pressure is
below the set point of the engine oil pressure switch and either the speed of the truck
has been 0.8 kph (0.5 mph) or less for 1 second or the service brakes are applied
1: shifter is in the forward, neutral, or reverse positions and the engine oil pressure is
above the set point of the engine oil pressure switch
Fault(s): A216, A351
55
CEN40179-01 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/J1939 connection Refer to 58D-06-01711, Sheet 16, zone E1 and Sheet 5, zones H2 730E
at Engine through 10
Refer to 58E-06-02311, sheet 17, zones E1 and sheet 7, zones H2 830E
through H10
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones E1 and Sheet 7, zones H2 930E
through H10
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zones E1 and Sheet 7, zones H2 980E
through H8
Refer to 58B-06-03570, Sheet 6, zone A5
CAN/J1939 connection Refer to 58D-06-01711, Sheet 14, zones J9 through J12 and Sheet 16, 730E
at IM zone F6
Refer to 58E-06-02311, sheet 17, zones B5 through B6 and sheet 15, 830E
zones I9 through I12
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones B4 through B5 and Sheet 15, 930E
zones J9 through J12
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zones E4 through E5 and Sheet 16, 980E
zones E6
Refer to 58B-06-03570, Sheet 6, zone A5
Parking Brake Set Refer to 58D-06-01711, Sheet 14, zones F9 through F16 730E
Pressure Switch Refer to 58E-06-02311, sheet 15, zones F10 through F16 830E
connection to IM Refer to 58E-06-02321, sheet 5, zone C8
Refer to 58F-06-02311, Sheet 15, zone F10 to F16 930E
Refer to 58F-06-10561, Sheet 5, zone C8
Refer to 58B-06-02390, Sheet 16, zone F10 to F16 980E
Refer to 58B-06-03570, Sheet 5, zone C8
Parking Brake Release Refer to 58D-06-01711, Sheet 3, zones G3 through H9 730E
Pressure Switch to IM Refer to 58E-06-02311, sheet 5, zones H3 through H9 830E
Refer to 58E-06-02321, sheet 5, zone C9
Refer to 58F-06-02311, Sheet 5, zones H5 through H14 930E
Refer to 58F-06-10561, Sheet 5, zone C9
Refer to 58B-06-02390, Sheet 5, zones H6 through H20 980E
Refer to 58B-06-03570, Sheet 5, zone C9
56
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Selector Switch Refer to 58D-06-01711, Sheet 8, zones H11 through H16 730E
Refer to 58E-06-02311, sheet 9, zones H12 through H16 830E
Refer to 58E-06-02321, sheet 17, zones A1 through B1
Refer to 58F-06-02311, Sheet 9, zones H12 through H16 930E
Refer to 58F-06-10561, Sheet 27, zones A1 through B1
Refer to 58B-06-02390, Sheet 10, zones H13 through H16 980E
Refer to 58B-06-03570, Sheet 29, zones A1 through B1
Selector Switch Refer to 58D-06-01711, Sheet 8, zones J16 through L17 730E
connections at IM Refer to 58E-06-02311, sheet 9, zones J16 through L17 830E
Refer to 58E-06-02321, sheet 17, zone C2
Refer to 58F-06-02311, Sheet 9, zones J16 through L17 930E
Refer to 58F-06-10561, Sheet 27, zone C2
Refer to 58B-06-02390, Sheet 10, zones I16 through K17 980E
Refer to 58B-06-03570, Sheet 29, zone C2
Selector Switch Refer to 58D-06-01711, Sheet 8, zones J4 through K4 730E
connections at VEC Refer to 58E-06-02311, sheet 9, zones J5 through K5 830E
Refer to 58E-06-02321, sheet 17, zone C3
Refer to 58F-06-02311, Sheet 9, zones J5 through K5 930E
Refer to 58F-06-10561, Sheet 27, zone C3
Refer to 58B-06-02390, Sheet 10, zones I7 through J7 980E
Refer to 58B-06-03570, Sheet 29, zone C3
Parking Brake Refer to 58D-06-01711, Sheet 8, zone K17 730E
Solenoid connection to Refer to 58E-06-02311, sheet 9, zone K17 830E
IM Refer to 58E-06-02321, sheet 5, zones A7 through B7
Refer to 58F-06-02311, Sheet 9, zone K17 930E
Refer to 58F-06-10561, Sheet 5, zones A7 through B7
Refer to 58B-06-02390, Sheet 10, zone J17 980E
Refer to 58B-06-03570, Sheet 5, zones A7 through B7
57
CEN40179-01 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Parking Brake Refer to 58D-06-01711, Sheet 8, zone K6 730E
Solenoid connection to Refer to 58E-06-02311, sheet 9, zone K6 830E
VEC Refer to 58E-06-02321, sheet 5, zones A7 through B7
Refer to 58F-06-02311, Sheet 9, zone K6 930E
Refer to 58F-06-10561, Sheet 5, zones A7 through B7
Refer to 58B-06-02390, Sheet 10, zone J7 980E
Refer to 58B-06-03570, Sheet 5, zones A7 through B7
Parking Brake Refer to 58D-06-01711, Sheet 5, zone G11 730E
Solenoid Refer to 58E-06-02311, sheet 7, zone G11 830E
Refer to 58E-06-02321, sheet 5, zones A7 through B7
Refer to 58F-06-02311, Sheet 7, zone G11 930E
Refer to 58F-06-10561, Sheet 5, zones A7 through B7
Refer to 58B-06-02390, Sheet 10, zone G3 980E
Refer to 58B-06-03570, Sheet 5, zone A7
58
40 Troubleshooting CEN40179-01
NOTES
59
CEN40179-01 40 Troubleshooting
Fault Code A214: Parking brake should have released; detected as not having released
Operator Action Stop: Park
Fault Code A214
Description The parking brake should have released but is detected as not having released.
Fault Conditions Sets if Parking Brake does not release after the engine has been running for 90 sec-
onds with the Keyswitch (OR) on and Selector Switch Park off and Parking Brake
Request input off for 3 seconds.
Parking brake release is defined as the closure of the parking brake release pressure
switch and the opening of the parking brake set pressure switch.
Resets if Keyswitch (OR) is turned off, engine stops running or Parking Brake releases
for 3 seconds or Selector Switch (Park) input is on for 3 seconds or Parking Brake
Request input is on for 3 seconds.
Operator Alerting Sound Buzzer - single burst
System Response Parking Brake Status Lamp stays on
Display Operator Action: STOP: PRK: PWR: CHK
Display Fault Description: PARK BRAKE ON
Display Fault Code: A214
Resulting Problem(s) Operation of the truck may be prevented or the parking brake may be damaged.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
60
40 Troubleshooting CEN40179-01
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Selector Switch (Park) 0: shifter is not in park
(IM3T) 1: shifter is in park
Fault(s): A271, A303
Parking Brake Request 0: shifter is not in the forward, neutral, or reverse positions or the engine oil pressure is
(IM3V) below the set point of the engine oil pressure switch
1: shifter is in the forward, neutral, or reverse positions and the engine oil pressure is
above the set point of the engine oil pressure switch
Fault(s): A264
Parking Brake 0: parking brake pressure switch indicating high pressure and a released parking
Released (IM2M) brake
1: parking brake pressure switch indicating lower pressure and an applied parking
brake
Parking Brake Set 0: parking brake pressure switch indicating low pressure and an applied parking brake
(IM2f) 1: parking brake pressure switch indicating higher pressure and a released parking
brake
Fault(s): A213
Engine Speed [RPM] < 300 RPM: engine is not running
(CAN/J1939) (IM1q,r,s) > 300 RPM for 4 seconds: engine is running
Fault(s): A184
Keyswitch (IM3G) 0: keyswitch is off and the truck is not moving and the engine is not running
1: keyswitch is on or the truck is moving (GE power not yet off)
Fault(s): A240
Parking Brake Sole- Status - Open Load: Unexpected. Troubleshoot.
noid (IM1E) Status - Normal: Expected. No Problem.
Status - Shorted to Ground: Expected if shifter is in the forward, neutral, or reverse
positions and the engine oil pressure is above the set point of the engine oil pressure
switch. Otherwise unexpected and must troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: shifter is not in the forward, neutral, or reverse positions or the engine oil pressure is
below the set point of the engine oil pressure switch and either the speed of the truck
has been 0.8 kph (0.5 mph) or less for 1 second or the service brakes are applied
1: shifter is in the forward, neutral, or reverse positions and the engine oil pressure is
above the set point of the engine oil pressure switch
Fault(s): A216, A351
61
CEN40179-01 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/J1939 connection Refer to 58D-06-01711, Sheet 16, zone E1 and Sheet 5, zones H2 730E
at Engine through H10
Refer to 58E-06-02311, sheet 17, zones E1 and sheet 7, zones H2 830E
through H10
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones E1 and Sheet 7, zones H2 930E
through H10
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zones E1 and Sheet 7, zones H2 980E
through H8
Refer to 58B-06-03570, Sheet 6, zone A5
CAN/J1939 connection Refer to 58D-06-01711, Sheet 14, zones J9 through J12 and Sheet 16, 730E
at IM zone F6
Refer to 58E-06-02311, sheet 17, zones B5 through B6 and sheet 15, 830E
zones I9 through I12
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones B4 through B5 and Sheet 15, 930E
zones J9 through J12
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zones E4 through E5 and Sheet 16, 980E
zones E6
Refer to 58B-06-03570, Sheet 6, zone A5
Keyswitch, OR Refer to 58D-06-01711, Sheet 14, zones D10 through D19 730E
connection to IM Refer to 58E-06-02311, sheet 15, zones D10 through D19 830E
Refer to 58E-06-02321, sheet 31, zones B8 through B10
Refer to 58F-06-02311, Sheet 15, zones D10 through D19 930E
Refer to 58F-06-10561, Sheet 31, zones B8 through B10
Refer to 58B-06-02390, Sheet 16, zones D10 through D19 980E
Refer to 58B-06-03570, Sheet 33, zones B9 through B10
Parking Brake Set Refer to 58D-06-01711, Sheet 14, zones F10 through F16 730E
Pressure Switch Refer to 58E-06-02311, sheet 15, zones F10 through F16 830E
connection to IM Refer to 58E-06-02321, sheet 5, zone C8
Refer to 58F-06-02311, Sheet 15, zone F10 to F16 930E
Refer to 58F-06-10561, Sheet 5, zone C8
Refer to 58B-06-02390, Sheet 16, zone F10 to F16 980E
Refer to 58B-06-03570, Sheet 5, zone C8
62
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Parking Brake Release Refer to 58D-06-01711, Sheet 3, zones G3 through H9 730E
Pressure Switch to IM Refer to 58E-06-02311, sheet 5, zones H3 through H9 830E
Refer to 58E-06-02321, sheet 5, zone C9
Refer to 58F-06-02311, Sheet 5, zones H5 through H14 930E
Refer to 58F-06-10561, Sheet 5, zone C9
Refer to 58B-06-02390, Sheet 5, zones H6 through H20 980E
Refer to 58B-06-03570, Sheet 5, zone C9
Selector Switch Refer to 58D-06-01711, Sheet 8, zones H11 through H16 730E
Refer to 58E-06-02311, sheet 9, zones H12 through H16 830E
Refer to 58E-06-02321, sheet 17, zones A1 through B1
Refer to 58F-06-02311, Sheet 9, zones H12 through H16 930E
Refer to 58F-06-10561, Sheet 27, zones A1 through B1
Refer to 58B-06-02390, Sheet 10, zones H13 through H16 980E
Refer to 58B-06-03570, Sheet 29, zones A1 through B1
Selector Switch Refer to 58D-06-01711, Sheet 8, zones J16 through L17 730E
connections at IM Refer to 58E-06-02311, sheet 9, zones J16 through L17 830E
Refer to 58E-06-02321, sheet 17, zone C2
Refer to 58F-06-02311, Sheet 9, zones J16 through L17 930E
Refer to 58F-06-10561, Sheet 27, zone C2
Refer to 58B-06-02390, Sheet 10, zones I16 through K17 980E
Refer to 58B-06-03570, Sheet 29, zone C2
Selector Switch Refer to 58D-06-01711, Sheet 8, zones J4 through K4 730E
connections at VEC Refer to 58E-06-02311, sheet 9, zones J5 through K5 830E
Refer to 58E-06-02321, sheet 17, zone C3
Refer to 58F-06-02311, Sheet 9, zones J5 through K5 930E
Refer to 58F-06-10561, Sheet 27, zone C3
Refer to 58B-06-02390, Sheet 10, zones I7 through J7 980E
Refer to 58B-06-03570, Sheet 29, zone C3
Parking Brake Refer to 58D-06-01711, Sheet 8, zone K17 730E
Solenoid connection to Refer to 58E-06-02311, sheet 9, zone K17 830E
IM Refer to 58E-06-02321, sheet 5, zones A7 through B7
Refer to 58F-06-02311, Sheet 9, zone K17 930E
Refer to 58F-06-10561, Sheet 5, zones A7 through B7
Refer to 58B-06-02390, Sheet 10, zone J17 980E
Refer to 58B-06-03570, Sheet 5, zones A7 through B7
63
CEN40179-01 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Parking Brake Refer to 58D-06-01711, Sheet 8, zone K6 730E
Solenoid connection to Refer to 58E-06-02311, sheet 9, zone K6 830E
VEC Refer to 58E-06-02321, sheet 5, zones A7 through B7
Refer to 58F-06-02311, Sheet 9, zone K6 930E
Refer to 58F-06-10561, Sheet 5, zones A7 through B7
Refer to 58B-06-02390, Sheet 10, zone J7 980E
Refer to 58B-06-03570, Sheet 5, zones A7 through B7
Parking Brake Refer to 58D-06-01711, Sheet 5, zone G11 730E
Solenoid Refer to 58E-06-02311, sheet 7, zone G11 830E
Refer to 58E-06-02321, sheet 5, zones A7 through B7
Refer to 58F-06-02311, Sheet 7, zone G11 930E
Refer to 58F-06-10561, Sheet 5, zones A7 through B7
Refer to 58B-06-02390, Sheet 10, zone G3 980E
Refer to 58B-06-03570, Sheet 5, zone A7
64
40 Troubleshooting CEN40179-01
NOTES
65
CEN40179-01 40 Troubleshooting
Fault Code A215: Brake auto apply valve circuit is defective
Operator Action Go To Shop
Fault Code A215
Description Brake auto apply valve circuit is defective.
Fault Conditions Sets if the output driver circuit detects an open circuit or short to ground when the
keyswitch is on and the parking brake is requested, or sets if the output driver circuit
does not detect an open circuit with the engine start switch on and the parking brake
not requested.
Resets only at power down.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: BRK AUTO APPLY FLT
Display Fault Code: A215
Resulting Problem(s) Parking brake may not be protected in an application while rolling, or service brake
may not release and permit movement.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
66
40 Troubleshooting CEN40179-01
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active, deter-
mine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data Monitor
program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the unex-
pected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the malfunc-
tion is still unresolved then check each of the parameters in the Table for proper functionality. Troubleshoot all
item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Parking Brake Request 0: Shift lever is not in Forward, Neutral, or Reverse or the engine oil pressure is below
(IM3V) the set point of the engine oil pressure switch.
1: Shift lever is in Forward, Neutral, or Reverse and the engine oil pressure is above
the set point of the engine oil pressure switch.
Fault(s): A264, A317
Keyswitch (IM3G) 0: Keyswitch is OFF and the truck is not moving and the engine is not running.
1: Keyswitch is ON or the truck is moving (GE power not yet off).
Fault(s): A240
Auto Brake Apply Status - Open Load: Unexpected if parking brake request and keyswitch are on. But
Relay (IM1R) expected if parking brake request is off or keyswitch is off. Troubleshoot if inconsis-
tent.
Status - Normal: Expected if parking brake request and keyswitch are on. Trouble-
shoot if status is normal with parking brake request off or keyswitch off.
Status - Shorted to ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: Normal operation with parking brake either on or off. This valve operates only tran-
siently when the parking brake is turned on.
1: Brake auto apply relay operates the brake lock valve for 1.5 seconds after the park-
ing brake is turned on if the truck is stopped. If moving, it will not operate until truck
speed has dropped to 0.8 kph (0.5 mph).
Fault(s): A359
67
CEN40179-01 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Parking Brake Release Refer to 58F-06-02311, Sheet 9, zone J16 930E
Request connection at Refer to 58F-06-10561, Sheet 5, zone C5
IM Refer to 58B-06-02390, Sheet 10, zone J16 980E
Refer to 58B-06-03570, Sheet 5, zone C5
Parking Brake Release Refer to 58F-06-02311, Sheet 9, zone J6 930E
Request connection at Refer to 58F-06-10561, Sheet 5, zone B6
R22 Refer to 58B-06-02390, Sheet 10, zone I6 980E
Refer to 58B-06-03570, Sheet 5, zone B6
R22 Coil Circuit Refer to 58F-06-02311, Sheet 9, zone J5 and Sheet 7, zone K10 930E
Refer to 58F-06-10561, Sheet 5, zones A4 through B6
Refer to 58B-06-02390, Sheet 10, zone I5 and Sheet 7, zone L9 980E
Refer to 58B-06-03570, Sheet 5, zones A4 through B6
Parking Brake Refer to 58F-06-02311, Sheet 9, zone L17 930E
Protection Relay Refer to 58F-06-10561, Sheet 5, zone C5
connection at IM Refer to 58B-06-02390, Sheet 10, zone L17 980E
Refer to 58B-06-03570, Sheet 5, zone C5
Parking Brake Refer to 58F-06-02311, Sheet 9, zone N8 930E
Protection Relay coil Refer to 58F-06-10561, Sheet 5, zones B5 through C5
circuit Refer to 58B-06-02390, Sheet 10, zone M8 980E
Refer to 58B-06-03570, Sheet 5, zones B5 through C5
68
40 Troubleshooting CEN40179-01
NOTES
69
CEN40179-01 40 Troubleshooting
Fault Code A216: Open or short to ground detected in parking brake command valve circuit
Operator Action Stop, Park
Fault Code A216
Description An open or short to ground has been detected in the parking brake command valve
circuit.
Fault Conditions Sets if valve circuit is open or short to ground with keyswitch and parking brake
request on, or if valve circuit is open with keyswitch on and without parking brake
request being on.
Resets if any conditions change.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: STOP: PARK
Display Fault Description: PRK BRK COMMAND FLT
Display Fault Code: A216
Resulting Problem(s) Parking Brake may not apply or release properly causing equipment and roll away
concerns.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
70
40 Troubleshooting CEN40179-01
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Parking Brake Sole- Status - Open Load: Unexpected. Troubleshoot.
noid (IM1E) Status - Normal: Expected. No Problem.
Status - Shorted to Ground: Expected if Parking Brake Request is in the 24 volt condi-
tion. Otherwise unexpected and must troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: Parking Brake Request Input is in the low voltage (request) condition
1: Parking Brake Request Input is in the high voltage (not requested) condition
Fault(s): A351
Parking Brake Request 0: shifter is not in the forward, neutral, or reverse positions or the engine oil pressure is
(IM3V) below the set point of the engine oil pressure switch
1: shifter is in the forward, neutral, or reverse positions and the engine oil pressure is
above the set point of the engine oil pressure switch
Fault(s): A264
Keyswitch (IM3G) 0: keyswitch is off and the truck is not moving and the engine is not running
1: keyswitch is on or the truck is moving or the engine is running
Fault(s): A240
71
CEN40179-01 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Keyswitch, OR Refer to 58D-06-01711, Sheet 14, zones D10 through D19 730E
connection to IM Refer to 58E-06-02311, sheet 15, zones D10 through D19 830E
Refer to 58E-06-02321, sheet 31, zones B8 through B10
Refer to 58F-06-02311, Sheet 15, zones D10 through D19 930E
Refer to 58F-06-10561, Sheet 31, zones B8 through B10
Refer to 58B-06-02390, Sheet 16, zones D10 through D19 980E
Refer to 58B-06-03570, Sheet 33, zones B9 through B10
Selector Switch Refer to 58D-06-01711, Sheet 8, zones H11 through H16 730E
Refer to 58E-06-02311, sheet 9, zones H12 through H16 830E
Refer to 58E-06-02321, sheet 17, zones A1 through B1
Refer to 58F-06-02311, Sheet 9, zones H12 through H16 930E
Refer to 58F-06-10561, Sheet 27, zones A1 through B1
Refer to 58B-06-02390, Sheet 10, zones H13 through H16 980E
Refer to 58B-06-03570, Sheet 29, zones A1 through B1
Selector Switch Refer to 58D-06-01711, Sheet 8, zones J16 through L17 730E
connections at IM Refer to 58E-06-02311, sheet 9, zones J16 through L17 830E
Refer to 58E-06-02321, sheet 17, zone C2
Refer to 58F-06-02311, Sheet 9, zones J16 through L17 930E
Refer to 58F-06-10561, Sheet 27, zone C2
Refer to 58B-06-02390, Sheet 10, zones I16 through K17 980E
Refer to 58B-06-03570, Sheet 29, zone C2
Selector Switch Refer to 58D-06-01711, Sheet 8, zones J4 through K4 730E
connections at VEC Refer to 58E-06-02311, sheet 9, zones J5 through K5 830E
Refer to 58E-06-02321, sheet 17, zone C3
Refer to 58F-06-02311, Sheet 9, zones J5 through K5 930E
Refer to 58F-06-10561, Sheet 27, zone C3
Refer to 58B-06-02390, Sheet 10, zones I7 through J7 980E
Refer to 58B-06-03570, Sheet 29, zone C3
72
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Parking Brake Refer to 58D-06-01711, Sheet 8, zone K17 730E
Solenoid connection to Refer to 58E-06-02311, sheet 9, zone K17 830E
IM Refer to 58E-06-02321, sheet 5, zones A7 through B7
Refer to 58F-06-02311, Sheet 9, zone K17 930E
Refer to 58F-06-10561, Sheet 5, zones A7 through B7
Refer to 58B-06-02390, Sheet 10, zone J17 980E
Refer to 58B-06-03570, Sheet 5, zones A7 through B7
Parking Brake Refer to 58D-06-01711, Sheet 8, zone K6 730E
Solenoid connection to Refer to 58E-06-02311, sheet 9, zone K6 830E
VEC Refer to 58E-06-02321, sheet 5, zones A7 through B7
Refer to 58F-06-02311, Sheet 9, zone K6 930E
Refer to 58F-06-10561, Sheet 5, zones A7 through B7
Refer to 58B-06-02390, Sheet 10, zone J7 980E
Refer to 58B-06-03570, Sheet 5, zones A7 through B7
Parking Brake Refer to 58D-06-01711, Sheet 5, zone G11 730E
Solenoid Refer to 58E-06-02311, sheet 7, zone G11 830E
Refer to 58E-06-02321, sheet 5, zones A7 through B7
Refer to 58F-06-02311, Sheet 7, zone G11 930E
Refer to 58F-06-10561, Sheet 5, zones A7 through B7
Refer to 58B-06-02390, Sheet 10, zone G3 980E
Refer to 58B-06-03570, Sheet 5, zone A7
73
CEN40179-01 40 Troubleshooting
Fault Code A223: Excessive engine cranking occurred or jump start attempted
Operator Action Wait 120 sec, Retry
Fault Code A223
Description Excessive engine cranking occurred or jump start attempted.
Fault Conditions Sets after 30 seconds of continuous cranking or if either cranking motor is energized
without the start enable circuit (jump start).
Resets after 120 seconds of no cranking.
Operator Alerting Sound Buzzer - Single Burst
System Response Display Operator Action: WAIT 120 SEC: RETRY
Display Fault Description: EXCESS CRANKING
Display Fault Code: A223
Resulting Problem(s) Starters can be damaged by excessive engine cranking.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is not to excessively crank the engine. Starting problems must be
corrected, or starter failures will result.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Crank Sense (IM3U) 0: Engine not being cranked
1: Engine is being cranked
Cranking Motor 1 0: starter motor 1 not energized
Energized (IM3R) 1: starter motor 1 energized
Fault(s): A152, A275, A316
Cranking Motor 2 0: starter motor 2 not energized
Energized (IM3S) 1: starter motor 2 energized
Fault(s): A152, A275, A316
Start Enable (IM1B) Status - Open Load: Unexpected. Troubleshoot
Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: One of several interlocking situations exist to prevent cranking (excessive cranking
history, selector switch in wrong position, engine red light, J1939 not OK, engine
speed either not 0 to begin cranking or over 400 rpm while cranking).
1. No interlocking situations exist to prevent cranking.
Fault(s): A252
74
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Cranking Motors 1 and Refer to 58D-06-01711, Sheet 2, zones K8 through L13 730E
2 Refer to 58E-06-02311, sheet 4, zones K10 through K12 830E
Refer to 58E-06-02321, sheet 4, zones C8 through C9
Refer to 58F-06-02311, Sheet 4, zones K10 through K12 930E
Refer to 58F-06-10561, Sheet 4, zones C8 through C9
Refer to 58B-06-02390, Sheet 4, zones K10 through K12 980E
Refer to 58B-06-03570, Sheet 4, zones C8 through C9
Cranking Motor Refer to 58D-06-01711, Sheet 3, zones L4 through L7 730E
connections to IM Refer to 58E-06-02311, sheet 5, zones L4 through L7 830E
Refer to 58E-06-02321, sheet 4, zones C8 through C9
Refer to 58F-06-02311, Sheet 5, zones L4 through L7 930E
Refer to 58F-06-10561, Sheet 4, zones C8 through C9
Refer to 58B-06-02390, Sheet 5, zones K6 through K10 980E
Refer to 58B-06-03570, Sheet 4, zones C8 through C9
Crank Sense Refer to 58D-06-01711, Sheet 2, zones M9 through N19 and Sheet 4, 730E
connection to IM zones B2 through D4
Refer to 58E-06-02311, sheet 4, zones M9 through N19 and sheet 6, 830E
zones B2 through D4
Refer to 58E-06-02321, sheet 4, zones A7 through B7
Refer to 58F-06-02311, Sheet 4, zones M9 through N19 and Sheet 6, 930E
zones B2 through D4
Refer to 58F-06-10561, Sheet 4, zones A7 through B7
Refer to 58B-06-02390, Sheet 4, zones M9 through N19 and Sheet 6, 980E
zones H2 through H4
Refer to 58B-06-03570, Sheet 4, zones A7 through B7
Start Enable Circuit Refer to 58D-06-01711, Sheet 3, zones K4 through K15 730E
Refer to 58E-06-02311, sheet 5, zones K4 through K15 830E
Refer to 58E-06-02321, sheet 4, zones A7 through A9
Refer to 58F-06-02311, Sheet 5, zones K4 through K15 930E
Refer to 58F-06-10561, Sheet 4, zones A7 through A9
Refer to 58B-06-02390, Sheet 5, zones K7 through K15 980E
Refer to 58B-06-03570, Sheet 4, zones A7 through A9
75
CEN40179-01 40 Troubleshooting
Fault Code A230: Parking brake has been requested while truck still moving
Operator Action Move Shifter from Park
Fault Code A230
Description Parking brake has been requested while truck still moving.
Fault Conditions Sets if parking brake is requested (selector switch moved from forward, neutral,
reverse) while moving 0.8 kph (0.5 mph) and with parking brake released.
Resets if any condition changes.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: MOVE SHFTR FROM PRK
Display Fault Description: PRK BRK SETTING ERR
Display Fault Code: A230
Resulting Problem(s) Parking Brake could be damaged if protective circuitry did not work.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
76
40 Troubleshooting CEN40179-01
Table
1. The primary correction for this fault is just not to move the selector switch while the truck is in motion.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Selector Switch (FNR) 0: shifter is not in forward, neutral, or reverse
(IM2N) 1: shifter is in forward, neutral, or reverse
Fault(s): A271, A303
Truck Speed [kph] < 0.8 kph (0.5 mph): truck is not moving
(CAN/RPC) (IM1i,j,k) > 0.8 kph: truck is moving
Fault(s): A233
Parking Brake Set 0: parking brake pressure switch indicating low pressure and an applied parking brake
(IM2f) 1: parking brake pressure switch indicating higher pressure and an unapplied parking
brake
Fault(s): A213
Parking Brake 0: parking brake pressure switch indicating high pressure and a released parking
Released (IM2M) brake
1: parking brake pressure switch indicating low pressure and an unreleased parking
brake
Fault(s): A214
77
CEN40179-01 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 14, zones I9 through I11 and Sheet 16, 730E
at IM zone B6
Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 15, zone I12 and Sheet 17, zone B5 930E
Refer to 58F-06-10561, Sheet 6, zone A2
Refer to 58B-06-02390, Sheet 16, zone D6 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/RPC connection Refer to 58D-06-01711, Sheet 16, zone B9 730E
at GE Refer to 58E-06-02311, sheet 17, zone B3 830E
Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, Sheet 17, zone C4 930E
Refer to 58F-06-10561, Sheet 6, zone B2
Refer to 58B-06-02390, Sheet 18, zone C4 980E
Refer to 58B-06-03570, Sheet 6, zone A2
Parking Brake Set Refer to 58D-06-01711, Sheet 14, zones F9 through F16 730E
Pressure Switch Refer to 58E-06-02311, sheet 15, zones F10 through F16 830E
connection to IM Refer to 58E-06-02321, sheet 5, zone C8
Refer to 58F-06-02311, Sheet 15, zone F10 to F16 930E
Refer to 58F-06-10561, Sheet 5, zone C8
Refer to 58B-06-02390, Sheet 16, zone F10 to F16 980E
Refer to 58B-06-03570, Sheet 5, zone C8
Parking Brake Release Refer to 58D-06-01711, Sheet 3, zones G3 through H9 730E
Pressure Switch to IM Refer to 58E-06-02311, sheet 5, zones H3 through H9 830E
Refer to 58E-06-02321, sheet 5, zone C9
Refer to 58F-06-02311, Sheet 5, zones H5 through H14 930E
Refer to 58F-06-10561, Sheet 5, zone C9
Refer to 58B-06-02390, Sheet 5, zones H6 through H20 980E
Refer to 58B-06-03570, Sheet 5, zone C9
78
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
GE Batt+ Off Refer to 58D-06-01711, Sheet 4, zones B2 through C4 730E
connection to IM Refer to 58E-06-02311, sheet 6, zones B2 through C4 830E
Refer to 58E-06-02321, sheet 4, zone D4
Refer to 58F-06-02311, Sheet 6, zones B2 through C4 930E
Refer to 58F-06-10561, Sheet 4, zone D4
Refer to 58B-06-02390, Sheet 6, zones G2 through G4 980E
Refer to 58B-06-03570, Sheet 4, zone D4
Selector Switch Refer to 58D-06-01711, Sheet 8, zones H12 through H16 730E
Refer to 58E-06-02311, sheet 9, zones H12 through H16 830E
Refer to 58E-06-02321, sheet 17, zones A1 through B1
Refer to 58F-06-02311, Sheet 9, zones H12 through H16 930E
Refer to 58F-06-10561, Sheet 27, zones A1 through B1
Refer to 58B-06-02390, Sheet 10, zones H13 through H16 980E
Refer to 58B-06-03570, Sheet 29, zones A1 through B1
Selector Switch Refer to 58D-06-01711, Sheet 8, zones J16 through L17 730E
connections at IM Refer to 58E-06-02311, sheet 9, zones J16 through L17 830E
Refer to 58E-06-02321, sheet 17, zone C2
Refer to 58F-06-02311, Sheet 9, zones J16 through L17 930E
Refer to 58F-06-10561, Sheet 27, zone C2
Refer to 58B-06-02390, Sheet 10, zones I16 through K17 980E
Refer to 58B-06-03570, Sheet 29, zone C2
Selector Switch Refer to 58D-06-01711, Sheet 8, zones J5 through K5 730E
connections at VEC Refer to 58E-06-02311, sheet 9, zones J5 through K5 830E
Refer to 58E-06-02321, sheet 17, zone C3
Refer to 58F-06-02311, Sheet 9, zones J5 through K5 930E
Refer to 58F-06-10561, Sheet 27, zone C3
Refer to 58B-06-02390, Sheet 10, zones I7 through J7 980E
Refer to 58B-06-03570, Sheet 29, zone C3
79
CEN40179-01 40 Troubleshooting
Fault Code A231: The body is up while traveling or intending to travel
Operator Action Lower body
Fault Code A231
Description The body is up while traveling or intending to travel.
Fault Conditions Sets after 30 seconds if body is up with selector in forward or reverse and truck moving
or engine running.
Truck moving is defined as speed greater than 0 or if no communication from drive
system and the parking brake not set.
Parking brake set is defined as closure of the parking brake set pressure switch and
opening of the parking brake release pressure switch.
Resets if body is down, selector not in forward or reverse, and truck not moving and
engine not running.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: LOWER BODY
Display Fault Description: BODY UP
Display Fault Code: A231
Resulting Problem(s) Operation with body up can cause accidents or damage to pivot pins.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
80
40 Troubleshooting CEN40179-01
Table
1. No correction is necessary for normal bleeding with the truck properly parked.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning
Parameter Expected State and/or Related Fault(s)
Body Up (CAN/RPC) 0: Body is raised off the truck frame
(IM1i,j,k) 1: Body is down on the truck frame
Fault(s): A233
Engine Speed [RPM] < 300 RPM: engine is not running
(CAN/J1939) (IM1q,r,s) > 300 RPM for 4 seconds: engine is running
Fault(s): A184
Selector Switch 0: Selector Switch is not in Forward
(Forward) (CAN/RPC) 1: Selector Switch is in Forward
(IM1I,j,k) Fault(s): A233
Selector Switch 0: Selector Switch is not in Reverse
(Reverse) (CAN/RPC) 1: Selector Switch is in Reverse
(IM1I,j,k) Fault(s): A233
Truck Speed [kph] Zero: truck is not moving
(CAN/RPC) (IM1I,j,k) > 0: truck is moving
Fault(s): A233
Parking Brake Set 0: parking brake pressure switch indicating low pressure and an applied parking brake
(IM2f) 1: parking brake pressure switch indicating higher pressure and an unapplied parking
brake
Fault(s): A213
Parking Brake 0: parking brake pressure switch indicating high pressure and a released parking
Released (IM2M) brake
1: parking brake pressure switch indicating low pressure and an applied parking brake
Fault(s): A214
81
CEN40179-01 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 14, zones I9 through I12 and Sheet 16, 730E
at IM Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 15, zone I12 and Sheet 17, zone B5 930E
Refer to 58F-06-10561, Sheet 6, zone A2
Refer to 58B-06-02390, Sheet 16, zone D6 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/RPC connection Refer to 58D-06-01711, Sheet 16, zone B6 730E
at GE Refer to 58E-06-02311, sheet 17, zone B3 830E
Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, Sheet 17, zone C4 930E
Refer to 58F-06-10561, Sheet 6, zone B2
Refer to 58B-06-02390, Sheet 18, zone C4 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/J1939 connection Refer to 58D-06-01711, Sheet 16, zone E1 and Sheet 5, zones H2 730E
at Engine through H10
Refer to 58E-06-02311, sheet 17, zone E1 and sheet 7, zones H2 830E
through H10
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zone E1 and Sheet 7, zones H2 930E
through H10
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zone E1 and Sheet 7, zones H2 980E
through H8
Refer to 58B-06-03570, Sheet 6, zone A5
CAN/J1939 connection Refer to 58D-06-01711, Sheet 14, zones H9 through H12 and Sheet 16, 730E
at IM zone F6
Refer to 58E-06-02311, sheet 17, zones B5 through B6 and sheet 15, 830E
zones I9 through I12
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones B4 through B5 and Sheet 15, 930E
zones J9 through J12
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zones E4 through E5 and Sheet 16, 980E
zones E6
Refer to 58B-06-03570, Sheet 6, zone A5
82
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Parking Brake Set Refer to 58D-06-01711, Sheet 14, zones F10 through F16 730E
Pressure Switch Refer to 58E-06-02311, sheet 15, zones F10 through F16 830E
connection to IM Refer to 58E-06-02321, sheet 5, zone C8
Refer to 58F-06-02311, Sheet 15, zone F10 to F16 930E
Refer to 58F-06-10561, Sheet 5, zone C8
Refer to 58B-06-02390, Sheet 16, zone F10 to F16 980E
Refer to 58B-06-03570, Sheet 5, zone C8
Parking Brake Release Refer to 58D-06-01711, Sheet 3, zones G3 through H9 730E
Pressure Switch to IM Refer to 58E-06-02311, sheet 5, zones H3 through H9 830E
Refer to 58E-06-02321, sheet 5, zone C9
Refer to 58F-06-02311, Sheet 5, zones H5 through H14 930E
Refer to 58F-06-10561, Sheet 5, zone C9
Refer to 58B-06-02390, Sheet 5, zones H6 through H20 980E
Refer to 58B-06-03570, Sheet 5, zone C9
Brake Lock connection Refer to 58D-06-01711, Sheet 8, zones L13 through M17 730E
to IM Refer to 58E-06-02311, sheet 9, zones M11 through M17 830E
Refer to 58E-06-02321, sheet 5, zone C4
Refer to 58F-06-02311, Sheet 9, zones M11 through N17 930E
Refer to 58F-06-10561, Sheet 5, zone C4
Refer to 58B-06-02390, Sheet 10, zones M11 through N17 980E
Refer to 58B-06-03570, Sheet 5, zone C4
83
CEN40179-01 40 Troubleshooting
Fault Code A233: Drive system CAN/RPC Control Link not connected
Operator Action Stop; Park Power down
Fault Code A233
Description Drive system CAN/RPC Control Link not connected
Fault Conditions Sets after 5 seconds if Parking Brake is not set, GE Control Power is on, Crank
Request is not on, and Keyswitch, is on or sets after 60 seconds if Parking Brake is
set, GE Control Power is on, Crank Request is not on, and Keyswitch is on
Parking brake set is defined as closure of the parking brake set pressure switch and
opening of the parking brake release pressure switch.
Resets if truck speed is received from GE.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: STOP: PARK
Display Fault Description: NO DRIVE SYS DATA
Display Fault Code: A233
Resulting Problem(s) Control commands not available to drive system. Warnings not available to driver or
KOMTRAX Plus 2.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
84
40 Troubleshooting CEN40179-01
Table
1. This fault's logic contains more than one parameter, each of which may have it's own related fault code(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Drive System Control Should operate 60 seconds after initial power up
Link (IM1i, j, k) Fault(s): A237, A257
Keyswitch (IM3G) 0: keyswitch is off and the truck is not moving and the engine is not running
1: keyswitch is on or the truck is moving or the engine is running
Fault(s): A240
GE Batt+ Off (IM3M) 0: power to GE control is off
1: power to GE control is on
Crank Request (IM2j) 0: cranking not attempted
1: cranking is attempted
Parking Brake Set 0: parking brake pressure switch indicating low pressure and an applied parking brake
(IM2f) 1: parking brake pressure switch indicating higher pressure and an unapplied parking
brake
Fault(s): A213
Parking Brake 0: parking brake pressure switch indicating high pressure and a released parking
Released (IM2M) brake
1: parking brake pressure switch indicating low pressure and an applied parking brake
Fault(s): A214
85
CEN40179-01 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 14, zones I9 through I12 and Sheet 16, 730E
at IM zone C6
Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 15, zone I12 and Sheet 17, zone B5 930E
Refer to 58F-06-10561, Sheet 6, zone A2
Refer to 58B-06-02390, Sheet 16, zone D6 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/RPC connection Refer to 58D-06-01711, Sheet 16, zone C9 730E
at GE Refer to 58E-06-02311, sheet 17, zone B3 830E
Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, Sheet 17, zone C4 930E
Refer to 58F-06-10561, Sheet 6, zone B2
Refer to 58B-06-02390, Sheet 18, zone C4 980E
Refer to 58B-06-03570, Sheet 6, zone A2
Keyswitch, OR Refer to 58D-06-01711, Sheet 14, zones D10 through D19 730E
connection to IM Refer to 58E-06-02311, sheet 15, zones D10 through D19 830E
Refer to 58E-06-02321, sheet 31, zones B8 through B10
Refer to 58F-06-02311, Sheet 15, zones D10 through D19 930E
Refer to 58F-06-10561, Sheet 31, zones B8 through B10
Refer to 58B-06-02390, Sheet 16, zones D10 through D19 980E
Refer to 58B-06-03570, Sheet 33, zones B9 through B10
Parking Brake Set Refer to 58D-06-01711, Sheet 14, zones F9 through F16 730E
Pressure Switch Refer to 58E-06-02311, sheet 15, zones F10 through F16 830E
connection to IM Refer to 58E-06-02321, sheet 5, zone C8
Refer to 58F-06-02311, Sheet 15, zone F10 to F16 930E
Refer to 58F-06-10561, Sheet 5, zone C8
Refer to 58B-06-02390, Sheet 16, zone F10 to F16 980E
Refer to 58B-06-03570, Sheet 5, zone C8
Parking Brake Release Refer to 58D-06-01711, Sheet 3, zones G3 through H9 730E
Pressure Switch to IM Refer to 58E-06-02311, sheet 5, zones H3 through H9 830E
Refer to 58E-06-02321, sheet 5, zone C9
Refer to 58F-06-02311, Sheet 5, zones H5 through H14 930E
Refer to 58F-06-10561, Sheet 5, zone C9
Refer to 58B-06-02390, Sheet 5, zones H6 through H20 980E
Refer to 58B-06-03570, Sheet 5, zone C9
86
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
GE Batt+ Off Refer to 58D-06-01711, Sheet 4, zones B2 through C4 730E
connection to IM Refer to 58E-06-02311, sheet 6, zones B2 through C4 830E
Refer to 58E-06-02321, sheet 4, zone D4
Refer to 58F-06-02311, Sheet 6, zones B2 through C4 930E
Refer to 58F-06-10561, Sheet 4, zone D4
Refer to 58B-06-02390, Sheet 6, zones G2 through G4 980E
Refer to 58B-06-03570, Sheet 4, zone D4
Crank Request Refer to 58D-06-01711, Sheet 3, zone E7 730E
connection at Key Refer to 58E-06-02311, sheet 5, zone E9 830E
Refer to 58E-06-02321, sheet 4, zone E1
Refer to 58F-06-02311, Sheet 5, zone E9 930E
Refer to 58F-06-10561, Sheet 4, zone E1
Refer to 58B-06-02390, Sheet 5, zone E9 980E
Refer to 58B-06-03570, Sheet 4, zone E1
Crank Request Refer to 58D-06-01711, Sheet 3, zone J5 730E
connection at IM Refer to 58E-06-02311, sheet 5, zone J5 830E
Refer to 58E-06-02321, sheet 4, zone E1
Refer to 58F-06-02311, Sheet 5, zone J5 930E
Refer to 58F-06-10561, Sheet 4, zone E1
Refer to 58B-06-02390, Sheet 5, zone J7 980E
Refer to 58B-06-03570, Sheet 4, zone E1
87
CEN40179-01 40 Troubleshooting
Fault Code A235: Steering accumulator is in the process of being bled down
Operator Action Park, do not steer
Fault Code A235
Description Steering accumulator is in the process of being bled down.
Fault Conditions Sets if steering bleed valve comes on and the steering accumulator bleed pressure
switch has yet to operate and 90 seconds have yet to elapse.
Resets either at 90 second timeout or when steering accumulator bleed pressure
switch indicates bleeddown is complete.
Operator Alerting Sound Buzzer - Single Burst
System Response Display Operator Action: PARK: DO NOT STEER
Display Fault Description: STEERING IS BLEEDING
Display Fault Code: A235
Resulting Problem(s) Bleeding the steering accumulator is normal and not a problem as long as the truck is
properly parked during bleeddown.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. No correction is necessary for normal bleeding with the truck properly parked.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning
Parameter Expected State and/or Related Fault(s)
Steering Bleed Valve Status - Open Load: Expected with engine start switch on. No problem. Otherwise,
(IM1P) unexpected. Must troubleshoot.
Status - Normal: Expected only with key off and steering bleed in process. Trouble
shoot if found with key on.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: steering bleed valve is off. This is expected in normal running operation.
1: steering bleed valve is on This is expected after key off initiates steering bleed
operation.
Fault(s): A236, A253, A262, A263, A358
Steering Accum Bled 0: Accumulator is bled.
Pressure Sw (IM2Z) 1: Accumulator is not completely bled.
Fault(s): A258, A280
88
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Steering Bleed Valve Refer to 58D-06-01711, sheet 14, zone B10 730E
connection at IM Refer to 58E-06-02311, sheet 15, zone B10 830E
Refer to 58E-06-02321, sheet 31, zone B1
Refer to 58F-06-02311, Sheet 15, zone B10 930E
Refer to 58F-06-10561, Sheet 31, zone B1
Refer to 58B-06-02390, Sheet 16, zone C12 980E
Refer to 58B-06-03570, Sheet 33, zone B1
Steering Bleed Valve Refer to 58D-06-01711, Sheet 14, zone C18 730E
connection at Fuse Refer to 58E-06-02311, sheet 15, zone C18 830E
Refer to 58E-06-02321, sheet 31, zone A1
Refer to 58F-06-02311, Sheet 15, zone C18 930E
Refer to 58F-06-10561, Sheet 31, zone A1
Refer to 58B-06-02390, Sheet 16, zone C18 980E
Refer to 58B-06-03570, Sheet 33, zone A1
Steering Bleed Switch Refer to 58D-06-01711, Sheet 14, zone O3 730E
Refer to 58E-06-02311, sheet 15, zone O3 830E
Refer to 58E-06-02321, sheet 31, zone C2
Refer to 58F-06-02311, Sheet 15, zone O3 930E
Refer to 58F-06-10561, Sheet 31, zone C2
Refer to 58B-06-02390, Sheet 16, zone O2 980E
Refer to 58B-06-03570, Sheet 33, zone C2
Steering Bleed Switch Refer to 58D-06-01711, Sheet 14, zone O7 730E
connection at IM Refer to 58E-06-02311, sheet 15, zone O7 830E
Refer to 58E-06-02321, sheet 31, zone B2
Refer to 58F-06-02311, Sheet 15, zone O7 930E
Refer to 58F-06-10561, Sheet 31, zone B2
Refer to 58B-06-02390, Sheet 16, zone O7 980E
Refer to 58B-06-03570, Sheet 33, zone B2
89
CEN40179-01 40 Troubleshooting
Fault Code A236: The steering accumulator has not properly bled after 90 seconds
Operator Action Park, do not steer
Fault Code A236
Description The steering accumulator has not properly bled down after 90 seconds.
Fault Conditions Sets if the steering accumulator bleed pressure switch does not indicate bleeddown
complete within 90 seconds.
Resets either at power down, or if keyswitch is turned back on, thereby turning off the
steering bleed valve.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: PARK: DO NOT STEER
Display Fault Description: STEERING BLEED FLT
Display Fault Code: A236
Resulting Problem(s) Failure to bleed the steering accumulator can create dangerous situations under the
truck.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning
Parameter Expected State and/or Related Fault(s)
Steering Bleed Valve Status - Open Load: Expected with engine start switch on. No problem. Otherwise,
(IM1P) unexpected. Must troubleshoot.
Status - Normal: Expected only with key off and steering bleed in process. Trouble
shoot if found with key on.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: steering bleed valve is off. This is expected in normal running operation.
1: steering bleed valve is on This is expected after key off initiates steering bleed
operation.
Fault(s): A253, A262, A263, A358
Steering Accum Bled 0: Accumulator is bled.
Pressure Sw (IM2Z) 1: Accumulator is not completely bled.
Fault(s): A258, A280
90
40 Troubleshooting CEN40179-01
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Steering Bleed Valve Refer to 58D-06-01711, sheet 14, zone B10 730E
connection at IM Refer to 58E-06-02311, sheet 15, zone B10 830E
Refer to 58E-06-02321, sheet 31, zone B1
Refer to 58F-06-02311, Sheet 15, zone B10 930E
Refer to 58F-06-10561, Sheet 31, zone B1
Refer to 58B-06-02390, Sheet 16, zone C12 980E
Refer to 58B-06-03570, Sheet 33, zone B1
Steering Bleed Valve Refer to 58D-06-01711, Sheet 14, zone C18 730E
connection at Fuse Refer to 58E-06-02311, sheet 15, zone C18 830E
Refer to 58E-06-02321, sheet 31, zone A1
Refer to 58F-06-02311, Sheet 15, zone C18 930E
Refer to 58F-06-10561, Sheet 31, zone A1
Refer to 58B-06-02390, Sheet 16, zone C18 980E
Refer to 58B-06-03570, Sheet 33, zone A1
Steering Bleed Switch Refer to 58D-06-01711, Sheet 14, zone O3 730E
Refer to 58E-06-02311, sheet 15, zone O3 830E
Refer to 58E-06-02321, sheet 31, zone C2
Refer to 58F-06-02311, Sheet 15, zone O3 930E
Refer to 58F-06-10561, Sheet 31, zone C2
Refer to 58B-06-02390, Sheet 16, zone O2 980E
Refer to 58B-06-03570, Sheet 33, zone C2
Steering Bleed Switch Refer to 58D-06-01711, Sheet 14, zone O7 730E
connection at IM Refer to 58E-06-02311, sheet 15, zone O7 830E
Refer to 58E-06-02321, sheet 31, zone B2
Refer to 58F-06-02311, Sheet 15, zone O7 930E
Refer to 58F-06-10561, Sheet 31, zone B2
Refer to 58B-06-02390, Sheet 16, zone O7 980E
Refer to 58B-06-03570, Sheet 33, zone B2
91
CEN40179-01 40 Troubleshooting
Fault Code A237: The CAN/RPC connection to the display is open
Operator Action Stop, Park, Power Down
Fault Code A237
Description The CAN/RPC connection to the Display is open.
Fault Conditions Sets if no communication for 1 second (10 seconds at initial power up).
Resets if communication is established.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: NO DISPLAY DATA
Display Fault Code: A237
Resulting Problem(s) Many operational and equipment warnings will not be available to the operator, making
further operation unwise.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the display or replace the
Interface Module.
2. This fault's logic contains only one parameter.
Parameter Expected State and/or Related Fault(s)
CAN/RPC (IM1jki) Fault(s):A233, A257
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 14, zones I9 through I12 and Sheet 16, 730E
at IM zone B6
Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 15, zone I12 and Sheet 17, zone B5 930E
Refer to 58F-06-10561, Sheet 6, zone A2
Refer to 58B-06-02390, Sheet 16, zone D6 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/RPC connection Refer to 58D-06-01711, Sheet 9, zone H10 and Sheet 16, zone B21 730E
at Display Refer to 58E-06-02311, sheet 10, zone H8 and sheet 17, zone B19 830E
Refer to 58E-06-02321, sheet 6, zone D2
Refer to 58F-06-02311, Sheet 10, zone H8 and Sheet 17, zone B19 930E
Refer to 58F-06-10561, Sheet 6, zone D2
Refer to 58B-06-02390, Sheet 11, zone H8 and Sheet 18, zone B19 980E
Refer to 58B-06-03570, Sheet 6, zone D2
92
40 Troubleshooting CEN40179-01
Fault Code A240: The keyswitch input to the Interface Module is open
Operator Action Stop, Park, Repair
Fault Code A240
Description The keyswitch input to the Interface Module is open.
Fault Conditions Sets if both Keyswitch input and Steering Bleed valve are missing for 20 seconds.
Resets if either one turns on.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: STOP: PARK: REPAIR
Display Fault Description: IM KEYSW POWER LOST
Display Fault Code: A240
Resulting Problem(s) Many warnings will be non functional. Some controls will not function as normal.
Steering will bleed as soon as truck comes to a complete stop and the engine stops
running without the keyswitch being turned off.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct the wiring from the keyswitch to the Interface Module.
2. This fault's logic contains just one parameter.
Parameter Expected State and/or Related Fault(s)
Keyswitch (IM3G) 0: keyswitch is off and the truck is not moving and the engine is not running
1: keyswitch is on or the truck is moving or the engine is running
Fault(s):
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Keyswitch, OR Refer to 58D-06-01711, Sheet 14, zones D9 through D19 730E
connection to IM Refer to 58E-06-02311, sheet 15, zones D10 through D19 830E
Refer to 58E-06-02321, sheet 31, zones B8 through B10
Refer to 58F-06-02311, Sheet 15, zones D10 through D19 930E
Refer to 58F-06-10561, Sheet 31, zones B8 through B10
Refer to 58B-06-02390, Sheet 16, zones D10 through D19 980E
Refer to 58B-06-03570, Sheet 33, zones B9 through B10
93
CEN40179-01 40 Troubleshooting
Fault Code A242: The fuel level gauge in the display panel is defective
Operator Action None
Fault Code A242
Description The fuel level gauge in the display panel is defective.
Fault Conditions Sets if display panel reports a fuel gauge fault.
Resets if display panel clears the fault.
Operator Alerting Display Operator Action: None
System Response Display Fault Description: FUEL GAUGE FAULT
Display Fault Code: A242
Resulting Problem(s) Truck could run out of fuel.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault is entirely contained within the display panel. The panel and communication to it must be working
in order for IM to be aware of the fault. Therefore the only diagnostic effort is to check the gauge and wiring
within the panel and replace if necessary.
Parameter Expected State and/or Related Fault(s)
Steering Bleed Valve 0: steering bleed valve is off
(IM1-P) 1: steering bleed valve is on
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Fuel Gauge Refer to 58D-06-01711, Sheet 9, zone C5 730E
Refer to 58E-06-02311, sheet 10, zone D5 830E
Refer to 58E-06-02321, sheet 7, zone A10
Refer to 58F-06-02311, Sheet 10, zone D5 930E
Refer to 58F-06-10561, Sheet 7, zone A10
Refer to 58B-06-02390, Sheet 11, zone D5 980E
Refer to 58B-06-03570, Sheet 7, zone A10
94
40 Troubleshooting CEN40179-01
Fault Code A243: The engine coolant temp gauge in the display panel is defective
Operator Action Go to Shop
Fault Code A243
Description The engine coolant temp gauge in the display panel is defective.
Fault Conditions Sets if display panel reports an engine coolant temperature gauge fault.
Resets if digital display clears the fault or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: ENG COOL TEMP GAUGE
Display Fault Code: A243
Resulting Problem(s) Engine could overheat without warning.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. Except for being masked by the steering bleed process, this fault is entirely contained within the display
panel. The panel and communication to it must be working in order for IM to be aware of the fault. Therefore the
only diagnostic effort is to check the gauge and wiring within the panel and replace if necessary.
Parameter Expected State and/or Related Fault(s)
Steering Bleed Valve 0: steering bleed valve is off
(IM1-P) 1: steering bleed valve is on
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Coolant Temperature Refer to 58D-06-01711, Sheet 9, zone D4 730E
Gauge Refer to 58E-06-02311, sheet 10, zone D4 830E
Refer to 58E-06-02321, sheet 7, zone A10
Refer to 58F-06-02311, Sheet 10, zone D4 930E
Refer to 58F-06-10561, Sheet 7, zone A10
Refer to 58B-06-02390, Sheet 11, zone D4 980E
Refer to 58B-06-03570, Sheet 7, zone A10
95
CEN40179-01 40 Troubleshooting
Fault Code A244: The drive system temp gauge in the dash display panel is defective
Operator Action Go to Shop
Fault Code A244
Description The drive system temp gauge in the dash display panel is defective.
Fault Conditions Sets if a drive system temperature gauge fault is reported.
Resets if the fault clears or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: DRIVE SYS TEMP GAUGE
Display Fault Code: A244
Resulting Problem(s) Drive system could overheat without warning.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. Except for being masked by the steering bleed process, this fault is entirely contained within the dash display
panel. The panel and communication to it must be working in order for interface module (IM) to be aware of the
fault. Therefore the only diagnostic effort is to check the gauge and wiring within the panel and replace if
necessary.
Parameter Expected State and/or Related Fault(s)
Steering Bleed Valve 0: Steering bleed valve is off.
(IM1-P) 1: Steering bleed valve is on.
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Drive System Refer to 58F-06-02311, Sheet 10, zone E6 930E
Temperature Gauge Refer to 58F-06-10561, Sheet 7, zone A10
Refer to 58B-06-02390, Sheet 11, zone E6 980E
Refer to 58B-06-03570, Sheet 7, zone A10
96
40 Troubleshooting CEN40179-01
Fault Code A245: The hydraulic oil temp gauge in the display panel is defective
Operator Action Go to Shop
Fault Code A245
Description The hydraulic oil temp gauge in the display panel is defective.
Fault Conditions Sets if display panel reports a hydraulic oil temperature gauge fault.
Resets if display panel clears the fault or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: HYD OIL TEMP GAUGE
Display Fault Code: A245
Resulting Problem(s) Hydraulic oil could overheat without warning.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. Except for being masked by the steering bleed process, this fault is entirely contained within the display
panel. The panel and communication to it must be working in order for IM to be aware of the fault. Therefore the
only diagnostic effort is to check the gauge and wiring within the panel and replace if necessary.
Parameter Expected State and/or Related Fault(s)
Steering Bleed Valve 0: steering bleed valve is off
(IM1-P) 1: steering bleed valve is on
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hydraulic Oil Refer to 58D-06-01711, Sheet 9, zone E4 730E
Temperature Gauge Refer to 58E-06-02311, sheet 10, zone E4 830E
Refer to 58E-06-02321, sheet 7, zone A10
Refer to 58F-06-02311, Sheet 10, zone E4 930E
Refer to 58F-06-10561, Sheet 7, zone A10
Refer to 58B-06-02390, Sheet 11, zone E4 980E
Refer to 58B-06-03570, Sheet 7, zone A10
97
CEN40179-01 40 Troubleshooting
Fault Code A246: PLM reports truck overload
Operator Action Speed Limit
Fault Code A246
Description PLM reports truck overload.
Fault Conditions Sets if PLM reports an overloaded truck.
Resets if PLM clears the overloaded truck report.
Operator Alerting Sound Buzzer - single burst
System Response Display Operator Action: MAX SPEED LIMIT
Display Fault Description: LOAD EXCEEDS LIMIT
Display Fault Code: A246
Resulting Problem(s) Truck could be damaged by operating in overload condition.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault is entirely contained within PLM (payload meter). The panel and communication to it must be
working in order for IM to be aware of the fault. Normal corrective measures would be to correct the loading
process.
2. Any faults within the payload meter system that might affect its accuracy are developed and reported by
PLM4.
Related Circuit Diagram
Circuit Description Circuit Reference
None None
98
40 Troubleshooting CEN40179-01
NOTES
99
CEN40179-01 40 Troubleshooting
730E Dump truck
830E Dump truck
930E Dump truck
980E Dump truck
Form No. CEN40179-01
100
CEN40180-02
DUMP TRUCK
730E
830E
930E
980E
Machine model Serial number
730E-10 A50002 and up
830E-5 A50005 and up
830E-5AT A50005 and up
930E-5 A40004 and up
930E-5AT A40004 and up
980E-5 A50005 and up
980E-5AT A50005 and up
40 Troubleshooting
Troubleshooting by fault code, part 3
Fault Code A247: Low steering pressure warning ................................................................................................ 4
Fault Code A248: Status module within the dash display panel is defective ........................................................ 7
Fault Code A249: Red warning lamp in the display panel is shorted.................................................................... 9
Fault Code A250: Battery voltage is low with the truck parked ............................................................................11
Fault Code A251: Sonalert circuit is open or shorted to ground ......................................................................... 15
Fault Code A252: Start enable output circuit is either open or shorted to ground .............................................. 17
Fault Code A253: Steering bleed circuit is not open while running..................................................................... 19
Fault Code A256: Red warning lamp in the display panel is open...................................................................... 21
Fault Code A257: Payload CAN/RPC is not connected...................................................................................... 23
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective ............................................ 24
Fault Code A260: Parking brake failure .............................................................................................................. 25
Fault Code A261: Low brake accumulator pressure warning ............................................................................. 27
Fault Code A262: Steering bleed valve circuit open during shutdown ................................................................ 31
Fault Code A264: Parking brake relay circuit is defective................................................................................... 34
Fault Code A265: Service brake failure .............................................................................................................. 37
1
CEN40180-02 40 Troubleshooting
Fault Code A266: Shift lever was not in park while attempting to crank engine ................................................. 39
Fault Code A267: Parking brake was not set while attempting to crank engine ................................................. 41
Fault Code A268: Secondary engine shutdown while cranking .......................................................................... 43
Fault Code A270: Brake lock switch power supply is not on when required....................................................... 45
Fault Code A272: Brake lock switch power supply is not off when required ....................................................... 48
Fault Code A273: Hoist filter or steering filter pressure switch circuit fault detected .......................................... 51
Fault Code A274: A brake setting fault has been detected................................................................................. 52
Fault Code A275: A starter has been detected as engaged without a cranking attempt .................................... 55
Fault Code A277: Parking brake applied while loading....................................................................................... 57
Fault Code A278: Service brake applied while loading....................................................................................... 59
Fault Code A279: Low Steering Pressure Switch bad ........................................................................................ 61
Fault Code A280: Steering accumulator bleed down switch is defective ............................................................ 63
Fault Code A281: Brake lock degrade switch is defective .................................................................................. 65
Fault Code A282: Excessive cranking counts or jump starts without the engine running ................................... 67
Fault Code A283: Engine shutdown delay aborted; parking brake not set ......................................................... 69
Fault Code A284: Engine shutdown delay aborted; secondary shutdown switch operated................................ 73
Fault Code A285: The parking brake was not set when the keyswitch was turned off ....................................... 77
Fault Code A286: A fault was detected in the shutdown delay relay circuit........................................................ 79
Fault Code A292: Shutdown delay relay stays on after latched key switch circuit is off ..................................... 81
2
40 Troubleshooting CEN40180-02
NOTES
3
CEN40180-02 40 Troubleshooting
Fault Code A247: Low steering pressure warning
Operator Action Stop: Park
Fault Code A247
Description This is a low steering pressure warning for display to operator. It is designed to give
immediate information to the operator regardless of the cause of the problem.
Fault Conditions Sets if low steering pressure input to interface module (IM) is on with engine running at
300 rpm or above or if truck begins to move at 0.8 kph (0.5 mph) or more.
Resets if pressure returns or engine stops running and truck stops moving for 1
second.
Operator Alerting Sound Buzzer
System Response Flash IM Warning indicator
Display Operator Action: STOP: RUN WHEN CLR'D
Display Fault Description: LOW STRG PRESSURE
Display Fault Code: A247
Resulting Problem(s) Truck may not steer properly.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes, then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved, then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Low Steering Pressure 0: Steering pressure is normal.
Switch (IM2S) 1: Steering pressure is low.
Fault(s): A279, A115, A253
Engine Speed [RPM] 0: Engine is not running.
> 300: Engine is running.
> 1200: Engine is running fast enough to maintain steering pressure.
Truck Speed [kph] 0: Truck is not moving.
(IM1g,h) > 0.8kph (0.5 mph): Truck is moving.
4
40 Troubleshooting CEN40180-02
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 14, zones J9 through J12 and Sheet 16, 730E
at IM zone F6
Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 15, zone I12 and Sheet 17, zone B5 930E
Refer to 58F-06-10561, Sheet 6, zone A2
Refer to 58B-06-02390, Sheet 16, zone D6 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/RPC connection Refer to 58D-06-01711, Sheet 16, zone C9 730E
at GE Refer to 58E-06-02311, sheet 17, zone B3 830E
Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, Sheet 17, zone C4 930E
Refer to 58F-06-10561, Sheet 6, zone B2
Refer to 58B-06-02390, Sheet 18, zone C4 980E
Refer to 58B-06-03570, Sheet 6, zone A2
Low Steering Pressure Refer to 58D-06-01711, Sheet 14, zones N2 through N8 730E
Switch connection to Refer to 58E-06-02311, sheet 15, zones N2 through N8 830E
IM Refer to 58E-06-02321, sheet 31, zone C3
Refer to 58F-06-02311, Sheet 15, zones N2 through N8 930E
Refer to 58F-06-10561, Sheet 31, zone C3
Refer to 58B-06-02390, Sheet 16, zones N2 through N7 980E
Refer to 58B-06-03570, Sheet 33, zone C3
5
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/J1939 connection Refer to 58D-06-01711, Sheet 16, zone E1 and Sheet 5, zones H2 730E
at Engine through H10
Refer to 58E-06-02311, sheet 17, zones E1 and sheet 7, zones H2 830E
through H10
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones E1 and Sheet 7, zones H2 930E
through H10
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zones E1 and Sheet 7, zones H2 980E
through H8
Refer to 58B-06-03570, Sheet 6, zone A5
CAN/J1939 connection Refer to 58D-06-01711, Sheet 14, zones I9 through I12 and Sheet 16, 730E
at IM zone B6
Refer to 58E-06-02311, sheet 17, zones B5 through B6 and sheet 15, 830E
zones I9 through I12
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones B4 through B5 and Sheet 15, 930E
zones J9 through J12
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zones E4 through E5 and Sheet 16, 980E
zones E6
Refer to 58B-06-03570, Sheet 6, zone A5
6
40 Troubleshooting CEN40180-02
Fault Code A248: Status module within the dash display panel is defective
Operator Action Go to Shop
Fault Code A248
Description Status module within the dash display panel is defective.
Fault Conditions Sets if a status module fault is reported.
Resets if the fault clears or steering bleed comes on.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: STATUS MODULE FLT
Display Fault Code: A248
Resulting Problem(s) Proper operation will be difficult without status information.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. Except for being masked by the steering bleed process, this fault is entirely contained within the dash display
panel. The panel and communication to it must be working in order for interface module (IM) to be aware of the
fault. Therefore the only diagnostic effort is to check the gauge and wiring within the panel and replace if
necessary.
Parameter Expected State and/or Related Fault(s)
Steering Bleed Valve 0: Steering bleed valve is off.
(IM1-P) 1: Steering bleed valve is on.
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Status Module Refer to 58D-06-01711, Sheet 9, zone D2 730E
Refer to 58E-06-02311, sheet 10, zone D2 830E
Refer to 58E-06-02321, sheet 7, zones A10 through C10
Refer to 58F-06-02311, Sheet 10, zone D2 930E
Refer to 58F-06-10561, Sheet 7, zones A10 through C10
Refer to 58B-06-02390, Sheet 11, zone D2 980E
Refer to 58B-06-03570, Sheet 7, zones A10 through C10
7
CEN40180-02 40 Troubleshooting
NOTES
8
40 Troubleshooting CEN40180-02
Fault Code A249: Red warning lamp in the display panel is shorted
Operator Action Go to Shop
Fault Code A249
Description Red warning lamp in the dash display is shorted.
Fault Conditions Sets if the red warning lamp feedback voltage is high for 400 ms with the red warning
lamp on.
Resets at power down.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: RED WARN LAMP FLT
Display Fault Code: A249
Resulting Problem(s) Warnings will be audible only.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains no additional external parameters. The red warning lamp feedback connection is
made internally.
2. Check wiring and connections between interface module (IM) and the dash display, the wiring within the
display to the red warning lamp, and the lamp itself.
Parameter Expected State and/or Related Fault(s)
Red Warning Lamp 0: Red lamp is not on.
(IM1G) 1: Red lamp is on.
Fault(s): A256
Red Warning Lamp > 3.75 volts for 400 ms with the lamp on: Shorted
Feedback (IM1G) < 3.75 volts for 400 ms with the lamp on: Normal
IM Protected 24V '+24VDC with IM operating
Output (IM1W) 0 V with IM not operating
9
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Warn Lamp connection Refer to 58D-06-01711, Sheet 9, zones F4 through F20 730E
to IM and Display Refer to 58E-06-02311, sheet 10, zones D4 through D17 830E
Refer to 58E-06-02321, sheet 7, zones B4 through B6
Refer to 58F-06-02311, Sheet 10, zones E4 through F17 930E
Refer to 58F-06-10561, Sheet 7, zones B4 through B6
Refer to 58B-06-02390, Sheet 11, zones E4 through F17 980E
Refer to 58B-06-03570, Sheet 7, zones B4 through B6
Warn Lamp Power Refer to 58D-06-01711, Sheet 9, zone F7 730E
connection to IM Refer to 58E-06-02311, sheet 5, zone K12 830E
Refer to 58E-06-02321, sheet 18, zone A6
Refer to 58F-06-02311, Sheet 5, zone K12 930E
Refer to 58F-06-10561, Sheet 18, zone A6
Refer to 58B-06-02390, Sheet 5, zone K12 980E
Refer to 58B-06-03570, Sheet 20, zone A6
10
40 Troubleshooting CEN40180-02
Fault Code A250: Battery voltage is low with the truck parked
Operator Action Charge Batteries
Fault Code A250
Description Battery voltage is low with the truck parked.
Fault Conditions Sets if battery voltage with the engine not running, truck not moving, crank state not
sensed, and not in steering bleed is below 23 volts for 5 seconds.
- Engine not running is defined as engine speed at less than 300 rpm.
- Truck not moving is defined as truck speed equal to 0 or, if truck speed is bad,
parking brake is set.
- Crank state sensed is defined as battery less than 18 volts for 1 second with engine
speed less than 600 rpm.
- Parking brake set is defined as closure of the parking brake set pressure switch and
opening of the parking brake release pressure switch.
Resets if voltage recovers to 25.5 volts.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: CHARGE BATTERIES
Display Fault Description: BATTERY VOLTS LOW
Display Fault Code: A250
Resulting Problem(s) Voltage may continue to drop and cause improper operation of the many electrical
controls on the truck.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
11
CEN40180-02 40 Troubleshooting
Table
1. The primary correction for this fault is to charge the batteries.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Battery Voltage, 24 < 23.0 volts: Too low to continue operation.
Volt (IM1A) > 23.0 volts: OK to continue operation.
< 18 volts: cranking is sensed.
Fault(s): A153, A154, A155
Engine Speed [RPM] < 600 RPM: engine not being cranked
(CAN/J1939) (IM1q,r,s) < 300 RPM: engine is not running
> 300 RPM for 4 seconds: engine is running
Fault(s): A184
Truck Speed [kph] 0: truck is not moving
(CAN/RPC) (IM1i,j,k) > 0 for 1 second: truck is moving
Fault(s): A233
Parking Brake Set 0: parking brake pressure switch indicating low pressure and an applied parking brake
(IM2f) 1: parking brake pressure switch indicating higher pressure and an unapplied parking
brake
Fault(s): A213
Parking Brake 0: parking brake pressure switch indicating high pressure and a released parking
Released (IM2M) brake
1: parking brake pressure switch indicating low pressure and an applied parking brake
Fault(s): A214
Steering Bleed Valve 0: steering bleed valve is off
(IM1P) 1: steering bleed valve is on
12
40 Troubleshooting CEN40180-02
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 14, zones I9 through I12 and Sheet 16, 730E
at IM zone B6
Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 15, zone I12 and Sheet 17, zone B5 930E
Refer to 58F-06-10561, Sheet 6, zone A2
Refer to 58B-06-02390, Sheet 16, zone D6 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/RPC connection Refer to 58D-06-01711, Sheet 16, zone B9 730E
at GE Refer to 58E-06-02311, sheet 17, zone B3 830E
Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, Sheet 17, zone C4 930E
Refer to 58F-06-10561, Sheet 6, zone B2
Refer to 58B-06-02390, Sheet 18, zone C4 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/J1939 connection Refer to 58D-06-01711, Sheet 16, zone E1 and Sheet 5, zones H2 730E
at Engine through H10
Refer to 58E-06-02311, sheet 17, zones E1 and sheet 7, zones H2 830E
through H10
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones E1 and Sheet 7, zones H2 930E
through H10
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zones E1 and Sheet 7, zones H2 980E
through H8
Refer to 58B-06-03570, Sheet 6, zone A5
CAN/J1939 connection Refer to 58D-06-01711, Sheet 14, zones J9 through J12 and Sheet 16, 730E
at IM zone E12
Refer to 58E-06-02311, sheet 17, zones B5 through B6 and sheet 15, 830E
zones I9 through I12
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones B4 through B5 and Sheet 15, 930E
zones J9 through J12
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zones E4 through E5 and Sheet 16, 980E
zones E6
Refer to 58B-06-03570, Sheet 6, zone A5
13
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Parking Brake Set Refer to 58D-06-01711, Sheet 14, zones F9 through F16 730E
Pressure Switch Refer to 58E-06-02311, sheet 15, zones F10 through F16 830E
connection to IM Refer to 58E-06-02321, sheet 5, zone C8
Refer to 58F-06-02311, Sheet 15, zone F10 to F16 930E
Refer to 58F-06-10561, Sheet 5, zone C8
Refer to 58B-06-02390, Sheet 16, zone F10 to F16 980E
Refer to 58B-06-03570, Sheet 5, zone C8
Parking Brake Release Refer to 58D-06-01711, Sheet 3, zones G3 through H9 730E
Pressure Switch to IM Refer to 58E-06-02311, sheet 5, zones H3 through H9 830E
Refer to 58E-06-02321, sheet 5, zone C9
Refer to 58F-06-02311, Sheet 5, zones H5 through H14 930E
Refer to 58F-06-10561, Sheet 5, zone C9
Refer to 58B-06-02390, Sheet 5, zones H6 through H20 980E
Refer to 58B-06-03570, Sheet 5, zone C9
Battery Supply Voltage Refer to 58D-06-01711, Sheet 3, zones L4 through L15 730E
to IM Refer to 58E-06-02311, sheet 5, zones L4 through L15 830E
Refer to 58E-06-02321, sheet 18, zones A9 through B9
Refer to 58F-06-02311, Sheet 5, zones L4 through L15 930E
Refer to 58F-06-10561, Sheet 18, zones A9 through B9
Refer to 58B-06-02390, Sheet 5, zones L6 through L14 980E
Refer to 58B-06-03570, Sheet 20, zones A9 through B9
14
40 Troubleshooting CEN40180-02
Fault Code A251: Sonalert circuit is open or shorted to ground
Operator Action Go to Shop
Fault Code A251
Description Sonalert circuit is open or shorted to ground.
Fault Conditions Sets if the Sonalert circuit is open or short to ground for 400 ms and steering bleed not
on.
Resets if circuit is normal for 400 ms or if steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: SONALERT IM FAULT
Display Fault Code: A251
Resulting Problem(s) Warnings will be visual only.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Sonalert (IM1M) Status - Open Load: Unexpected. Troubleshoot
Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: No faults are active that require buzzer operation.
1. One or more faults are active that require buzzer action.
Fault(s): A356
Steering Bleed Valve 0: steering bleed valve is off
(IM1P) 1: steering bleed valve is on
IM Protected 24V +24VDC with IM operating
Output (IM1W) 0V with IM not operating
15
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Sonalert connection to Refer to 58D-06-01711, Sheet 9, zones E9 through E20 730E
IM Refer to 58E-06-02311, sheet 10, zones E9 through E17 830E
Refer to 58E-06-02321, sheet 7, zones B2 through B5
Refer to 58F-06-02311, Sheet 10, zones E9 through E17 930E
Refer to 58F-06-10561, Sheet 7, zones B2 through B5
Refer to 58B-06-02390, Sheet 11, zones E9 through E17 980E
Refer to 58B-06-03570, Sheet 7, zones B2 through B5
Sonalert connection to Refer to 58E-06-02311, Sheet 9, zone F18 730E
Keyswitch Refer to 58E-06-02311, sheet 10, zone G15 830E
Refer to 58E-06-02321, sheet 7, zone B3
Refer to 58F-06-02311, Sheet 10, zone G15 930E
Refer to 58F-06-10561, Sheet 7, zone B3
Refer to 58B-06-02390, Sheet 11, zone G15 980E
Refer to 58B-06-03570, Sheet 7, zone B3
Sonalert Power Refer to 58D-06-01711, Sheet 3, zone K12 730E
connection to IM Refer to 58E-06-02311, sheet 5, zone K12 830E
Refer to 58E-06-02321, sheet 18, zone A6
Refer to 58F-06-02311, Sheet 5, zone K12 930E
Refer to 58F-06-10561, Sheet 18, zone A6
Refer to 58B-06-02390, Sheet 5, zone K12 980E
Refer to 58B-06-03570, Sheet 20, zone A6
16
40 Troubleshooting CEN40180-02
Fault Code A252: Start enable output circuit is either open or shorted to ground
Operator Action None
Fault Code A252
Description Start enable output circuit is either open or shorted to ground.
Fault Conditions Sets if the start enable relay circuit is open or short to ground for 2 seconds.
Resets only at power down.
Operator Alerting Repair Status Light On
System Response Display Operator Action: None
Display Fault Description: STRT ENABLE CKT FLT
Display Fault Code: A252
Resulting Problem(s) Starting will either not be possible, or will lack the protections that IM provides for the
start enable circuit (excessive cranking, selector switch position, J1939 OK, and
engine speed 0 to start and not above 400rpm at finish).
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Start Enable (IM1B) Status - Open Load: Unexpected. Troubleshoot
Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: One of several interlocking situations exist to prevent cranking (excessive cranking
history, selector switch in wrong position, engine red light, J1939 not OK, engine
speed either not 0 to begin cranking or over 400 rpm while cranking).
1. No interlocking situations exist to prevent cranking.
Fault(s): A350
Steering Bleed Valve 0: steering bleed valve is off
(IM1P) 1: steering bleed valve is on
17
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Start Enable Circuit Refer to 58D-06-01711, Sheet 3, zones K4 through K15 730E
Refer to 58E-06-02311, sheet 5, zones K4 through K15 830E
Refer to 58E-06-02321, sheet 4, zones A7 through A9
Refer to 58F-06-02311, Sheet 5, zones K4 through K15 930E
Refer to 58F-06-10561, Sheet 4, zones A7 through A9
Refer to 58B-06-02390, Sheet 5, zones K7 through K15 980E
Refer to 58B-06-03570, Sheet 4, zones A7 through A9
18
40 Troubleshooting CEN40180-02
Fault Code A253: Steering bleed circuit is not open while running
Operator Action None
Fault Code A253
Description Steering bleed circuit is not open while running,
Fault Conditions Sets if the steering bleed circuit is not open for 2 seconds, beginning 11 seconds after
the keyswitch is turned on.
Resets only at power down.
Operator Alerting Repair Status Light On
System Response Display Operator Action: None
Display Fault Description: STG BLD CKT NOT OPN
Display Fault Code: A253
Resulting Problem(s) Steering bleed will be possible during normal running, if IM or some of its inputs should
also malfunction.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Steering Bleed Valve Status - Open Load: Expected with engine start switch on. No problem. Otherwise,
(IM1P) unexpected. Must troubleshoot.
Status - Normal: Expected only with key off and steering bleed in process. Trouble
shoot if found with key on.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: steering bleed valve is off. This is expected in normal running operation.
1: steering bleed valve is on This is expected after key off initiates steering bleed
operation.
Fault(s): A262, A263, A358
Keyswitch (IM3G) 0: keyswitch is off and the truck is not moving and the engine is not running
1: keyswitch is on or the truck is moving or the engine is running
Fault(s): A240
19
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Steering Bleed Circuit Refer to 58D-06-01711, Sheet 14, zones B9 through C19 730E
Refer to 58E-06-02311, sheet 15, zones B10 through C19 830E
Refer to 58E-06-02321, sheet 31, zones A1 through B2
Refer to 58F-06-02311, Sheet 15, zones B10 through C19 930E
Refer to 58F-06-10561, Sheet 31, zones A1 through B2
Refer to 58B-06-02390, Sheet 16, zones F9 through G14 980E
Refer to 58B-06-03570, Sheet 33, zones A1 through B2
Keyswitch OR Power Refer to 58D-06-01711, Sheet 4, zones A10 through C14 730E
to VEC89 Refer to 58E-06-02311, sheet 6, zones A10 through C14 830E
Refer to 58E-06-02321, sheet 3, zone C6 and sheet 4, zone F6
Refer to 58F-06-02311, Sheet 6, zones B10 through C14 930E
Refer to 58F-06-10561, Sheet 3, zone C6 and Sheet 4, zone F6
Refer to 58B-06-02390, Sheet 6, zones F9 through G14 980E
Refer to 58B-06-03570, Sheet 3, zone C6 and Sheet 4, zone F6
20
40 Troubleshooting CEN40180-02
Fault Code A256: Red warning lamp in the display panel is open
Operator Action Go to Shop
Fault Code A256
Description Red warning lamp in the display panel is open.
Fault Conditions Sets if red lamp stays open for 1 second with steering bleed valve off. (The red lamp is
open if feedback voltage stays low for 400 ms with red lamp off.)
Resets if red lamp returns to normal or steering bleed valve operates for 1 second.
(The red lamp is normal if feedback voltage goes high for 400 ms with red lamp off.)
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: RED WARN LAMP FLT
Display Fault Code: A256
Resulting Problem(s) Warnings will be audible only.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains no additional external parameters. The red warning lamp feedback connection is
made internally.
2. Check wiring and connections between IM and the dash display and wiring within the display to the red
warning lamp as well as the lamp itself.
Parameter Expected State and/or Related Fault(s)
Red Warning Lamp 0: Red lamp is off.
(IM1G) 1: Red lamp is on.
Fault(s): A249
Red Warning Lamp Below 3.75 volts for 400 ms with the lamp off: open
Feedback (IM1G) Above 3.75 volts for 400 ms with the lamp off: normal
21
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Warn Lamp connection Refer to 58D-06-01711, Sheet 9, zones F4 through F20 730E
to IM and Display Refer to 58E-06-02311, sheet 10, zones D4 through D17 830E
Refer to 58E-06-02321, sheet 7, zones B4 through B6
Refer to 58F-06-02311, Sheet 10, zones E4 through F17 930E
Refer to 58F-06-10561, Sheet 7, zones B4 through B6
Refer to 58B-06-02390, Sheet 11, zones E4 through F17 980E
Refer to 58B-06-03570, Sheet 7, zones B4 through B6
Warn Lamp Power Refer to 58D-06-01711, Sheet 9, zone F7 730E
connection to IM Refer to 58E-06-02311, sheet 5, zone K12 830E
Refer to 58E-06-02321, sheet 18, zone A6
Refer to 58F-06-02311, Sheet 5, zone K12 930E
Refer to 58F-06-10561, Sheet 18, zone A6
Refer to 58B-06-02390, Sheet 5, zone K12 980E
Refer to 58B-06-03570, Sheet 20, zone A6
22
40 Troubleshooting CEN40180-02
Fault Code A257: Payload CAN/RPC is not connected
Operator Action None
Fault Code A257
Description Payload CAN/RPC is not connected.
Fault Conditions Sets if payload has not been updated for 10 seconds and keyswitch has been ON at
least 11 seconds since power up.
Resets when payload is updated.
Operator Alerting Repair Status Light on
System Response Display Operator Action: None
Display Fault Description: NO PAYLOAD DATA
Display Fault Code: A257
Resulting Problem(s) Payload and overload data is not properly recorded.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the display or replace the
interface module (IM).
2. This fault's logic contains only one parameter.
Parameter Expected State and/or Related Fault(s)
CAN/RPC (IM1j,k,i) Fault(s): A237, A233
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 14, zones I9 through I12 and Sheet 16, 730E
at IM zone B6
Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 15, zone I12 and Sheet 17, zone B5 930E
Refer to 58F-06-10561, Sheet 6, zone A2
Refer to 58B-06-02390, Sheet 16, zone D6 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/RPC connection Refer to 58D-06-01711, Sheet 16, zone B9 730E
at GE Refer to 58E-06-02311, sheet 17, zone B3 830E
Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, Sheet 17, zone C4 930E
Refer to 58F-06-10561, Sheet 6, zone B2
Refer to 58B-06-02390, Sheet 18, zone C4 980E
Refer to 58B-06-03570, Sheet 6, zone A2
23
CEN40180-02 40 Troubleshooting
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective
Operator Action Go to Shop
Fault Code A258
Description Steering accumulator bleed pressure switch circuit is defective.
Fault Conditions Sets if switch input continues to indicate steering accumulator bled down after 90 sec-
onds of engine running above 300 rpm.
Resets at power down.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: STRG BLEED PRESS SW
Display Fault Code: A258
Resulting Problem(s) Indication of steering bleeddown is unreliable.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Steering Accum Bled 0: Accumulator is bled.
Pressure Sw (IM2Z) 1: Accumulator is not completely bled.
Fault(s): A280
Engine Speed [RPM] 0: engine is not running
(CAN/J1939) (IM1q,r,s) > 300 rpm: engine is running
Fault(s): A184
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Steering Accum Bleed Refer to 58D-06-01711, Sheet 14, O2 through O8 730E
Pressure Switch to IM Refer to 58E-06-02311, sheet 15, zones O2 through O8 830E
Refer to 58E-06-02321, sheet 31, zones B2 through C2
Refer to 58F-06-02311, Sheet 15, zones O2 through O8 930E
Refer to 58F-06-10561, Sheet 31, zones B2 through C2
Refer to 58B-06-02390, Sheet 16, zones O2 through O7 980E
Refer to 58B-06-03570, Sheet 33, zones B2 through C2
24
40 Troubleshooting CEN40180-02
Fault Code A260: Parking brake failure
Operator Action Secure Vehicle
Fault Code A260
Description Parking brake failure (Assumed if truck rolls after application of parking brake or if
parking brake is applied while moving.)
Fault Conditions Two cases are tested: After truck is stopped completely (defined as parking brake set
and truck not moving for 1.5 seconds and reset only by parking brake release), and
truck rolling (defined as not stopped completely).
Truck Rolling After Stop: Sets if truck rolls 2 kph (1.2 mph) for 1.5 seconds after the
truck is stopped completely. This case resets if conditions change.
Parking Brake Application While Moving: Sets if trucks speed is 0.8 kph (0.5 mph) or
over for 1.5 seconds with parking brake not released (parking brake released is
defined as parking brake release switch being on and parking brake set switch being
off). This case resets only at power down.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: SECURE VEHICLE
Display Fault Description: PARK BRAKE FAILURE
Display Fault Code: A260
Resulting Problem(s) Parking brake may not hold truck.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Parking Brake 0: parking brake pressure switch indicating high pressure and released parking brake
Released Pressure 1: parking brake pressure switch indicating lower pressure and applied parking brake
Switch (IM2M) Fault(s): A214
Parking Brake Set 0: parking brake pressure switch indicating low pressure and applied parking brake
Pressure Switch (IM2f) 1: parking brake pressure switch indicating higher pressure and released parking
brake
Fault(s): A213
Truck Speed [kph] < 2.0 kph (1.2 mph): truck is not moving in case: Truck Rolling After Stop
(CAN/RPC) (IM1i,j,k) < 0.8 kph (0.5 mph): truck is not moving in case: Parking Brake Applied While Moving
> 2.0 kph (1.2 mph): truck is moving in case: Truck Rolling After Stop
> 0.8 kph (0.5 mph): truck is moving in case: Parking Brake Applied While Moving
Fault(s): A233
25
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 16, zone B9 730E
at GE Refer to 58E-06-02311, sheet 17, zone B3 830E
Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, Sheet 17, zone C4 930E
Refer to 58F-06-10561, Sheet 6, zone B2
Refer to 58B-06-02390, Sheet 18, zone C4 980E
Refer to 58B-06-03570, Sheet 6, zone A2
Body Up Switch Refer to 58D-06-01711, Sheet 14, zone K9 730E
connection to PLM Refer to 58E-06-02311, sheet 16, zone K9 830E
Refer to 58E-06-02321, sheet 31, zones D1 through E1
Refer to 58F-06-02311, Sheet 16, zone K9 930E
Refer to 58F-06-10561, Sheet 31, zones D1 through E1
Refer to 58B-06-02390, Sheet 17, zone K9 980E
Refer to 58B-06-03570, Sheet 31, zones D1 through E1
Parking Brake Set Refer to 58D-06-01711, Sheet 14, zones F10 through F16 730E
Pressure Switch Refer to 58E-06-02311, sheet 15, zones F10 through F16 830E
connection to IM Refer to 58E-06-02321, sheet 5, zone C8
Refer to 58F-06-02311, Sheet 15, zone F10 to F16 930E
Refer to 58F-06-10561, Sheet 5, zone C8
Refer to 58B-06-02390, Sheet 16, zone F10 to F16 980E
Refer to 58B-06-03570, Sheet 5, zone C8
Parking Brake Release Refer to 58D-06-01711, Sheet 3, zones G3 through H9 730E
Pressure Switch to IM Refer to 58E-06-02311, sheet 5, zones H3 through H9 830E
Refer to 58E-06-02321, sheet 5, zone C9
Refer to 58F-06-02311, Sheet 5, zones H5 through H14 930E
Refer to 58F-06-10561, Sheet 5, zone C9
Refer to 58B-06-02390, Sheet 5, zones H6 through H20 980E
Refer to 58B-06-03570, Sheet 5, zone C9
26
40 Troubleshooting CEN40180-02
Fault Code A261: Low brake accumulator pressure warning
Operator Action Stop: Park
Fault Code A261
Description Low brake accumulator pressure warning for display to operator. It is designed to give
immediate information to the operator, regardless of the cause of the problem.
Fault Conditions Sets if pressure is low while engine is running or truck is moving 0.8 kph (0.5 mph) for
1 second.
Resets if pressure returns or engine stops running and truck stops moving for 1
second.
Operator Alerting Sound Buzzer
System Response Flash IM Warning indicator
Display Operator Action: STOP: RUN WHEN CLR'D
Display Fault Description: LOW BRAKE PRESSURE
Display Fault Code: A261
Resulting Problem(s) Service brake may not stop or hold the truck.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault is generated by more than one parameter, but the independent parameters do not have fault codes
for situations that will affect this fault.
Parameter Expected State and/or Related Fault(s)
Brake Accumulator 0: Brake accumulator pressure is normal.
Pressure Switch 1: Brake accumulator pressure is low.
(IM2U)
Engine Speed [RPM] 0: Engine is not running.
> 300 RPM: engine is running.
Truck Speed [kph] 0: Truck is not moving.
(IM1g,h) > 0.8 kph (0.5 mph): Truck is moving.
27
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 14, zones I9 through I12 and Sheet 16, 730E
at IM zone B6
Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 15, zone I12 and Sheet 17, zone B5 930E
Refer to 58F-06-10561, Sheet 6, zone A2
Refer to 58B-06-02390, Sheet 16, zone D6 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/RPC connection Refer to 58D-06-01711, Sheet 16, zone B9 730E
at GE Refer to 58E-06-02311, sheet 17, zone B3 830E
Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, Sheet 17, zone C4 930E
Refer to 58F-06-10561, Sheet 6, zone B2
Refer to 58B-06-02390, Sheet 18, zone C4 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/J1939 connection Refer to 58D-06-01711, Sheet 16, zone E1 and Sheet 5, zones H2 730E
at Engine through H10
Refer to 58E-06-02311, sheet 17, zones E1 and sheet 7, zones H2 830E
through H10
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones E1 and Sheet 7, zones H2 930E
through H10
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zones E1 and Sheet 7, zones H2 980E
through H8
Refer to 58B-06-03570, Sheet 6, zone A5
28
40 Troubleshooting CEN40180-02
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/J1939 connection Refer to 58D-06-01711, Sheet 14, zones J9 through J12 and Sheet 16, 730E
at IM zone F6
Refer to 58E-06-02311, sheet 17, zones B5 through B6 and sheet 15, 830E
zones I9 through I12
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones B4 through B5 and Sheet 15, 930E
zones J9 through J12
Refer to 58F-06-10561, Sheet 6, zone A5
Refer to 58B-06-02390, Sheet 18, zones E4 through E5 and Sheet 16, 980E
zones E6
Refer to 58B-06-03570, Sheet 6, zone A5
Brake Accumulator Refer to 58D-06-01711, Sheet 14, zones F9 through F16 730E
Pressure Switch to IM Refer to 58E-06-02311, sheet 15, zones F9 through F16 830E
Refer to 58E-06-02321, sheet 5, zones E3 through F3
Refer to 58F-06-02311, Sheet 15, zones F9 through F16 930E
Refer to 58F-06-10561, Sheet 5, zones E3 through F3
Refer to 58B-06-02390, Sheet 16, zones F9 through F16 980E
Refer to 58B-06-03570, Sheet 5, zones E3 through F3
29
CEN40180-02 40 Troubleshooting
NOTES
30
40 Troubleshooting CEN40180-02
Fault Code A262: Steering bleed valve circuit open during shutdown
Operator Action Go to Shop
Fault Code A262
Description Steering bleed valve circuit is open during shutdown.
Fault Conditions Sets if steering bleed valve circuit is open for 1 second when the engine start switch
has been turned off, the engine no longer runs, and the truck is stopped (drive system
control power turned off). Energization of the steering bleed valve is delayed for 2 sec-
onds to provide a valid test.
Resets at power down.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: STG BLEED CKT OPEN
Display Fault Code: A262
Resulting Problem(s) Steering will not bleed down properly if circuit is open.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
31
CEN40180-02 40 Troubleshooting
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Steering Bleed Valve Status - Open Load: Expected with engine start switch on. No problem. Otherwise,
(IM1P) unexpected, must troubleshoot.
Status - Normal: Expected only with key off and steering bleed in process. Trouble
shoot if found with key on.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: steering bleed valve is off. This is expected in normal running operation.
1: steering bleed valve is on This is expected after key off initiates steering bleed
operation.
Fault(s): A253, A358
Keyswitch (IM3G) 0: keyswitch is off and the truck is not moving and the engine is not running
1: keyswitch is on or the truck is moving or the engine is running
Fault(s): A240
Engine Speed [RPM] 0: engine is not running
(CAN/J1939) (IM1q,r,s) > 0: engine is running
Fault(s): A184
Truck Speed [kph] 0: truck is not moving
(CAN/RPC) (IM1i,j,k) > 0: truck is moving
Fault(s): A233
32
40 Troubleshooting CEN40180-02
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Steering Bleed Circuit Refer to 58D-06-01711, Sheet 14, zones B9 through C19 730E
Refer to 58E-06-02311, sheet 15, zones B10 through C19 830E
Refer to 58E-06-02321, sheet 31, zones A1 through B2
Refer to 58F-06-02311, Sheet 15, zones B10 through C19 930E
Refer to 58F-06-10561, Sheet 31, zones A1 through B2
Refer to 58B-06-02390, Sheet 16, zones F9 through G14 980E
Refer to 58B-06-03570, Sheet 33, zones A1 through B2
Battery Power to Refer to 58D-06-01711, Sheet 4, zones A5 through C14 730E
VEC89 Refer to 58E-06-02311, sheet 6, zones A5 through C14 830E
Refer to 58E-06-02321, sheet 3, zones D1 through D6 and sheet 4,
zones F5
Refer to 58F-06-02311, Sheet 6, zones A5 through C14 930E
Refer to 58F-06-10561, Sheet 3, zones D1 through D6 and Sheet 4,
zones F5
Refer to 58B-06-02390, Sheet 6, zones F4 through G13 980E
Refer to 58B-06-03570, Sheet 3, zones D1 through D6 and Sheet 4,
zones F5
33
CEN40180-02 40 Troubleshooting
Fault Code A264: Parking brake relay circuit is defective
Operator Action None
Fault Code A264
Description Parking brake relay circuit is defective.
Fault Conditions Sets if parking brake request is not on when selector switch is not in forward, neutral,
or reverse, or engine has not been running for 15 seconds.
Sets if parking brake request is on when selector switch is in forward, neutral, or
reverse and engine has been running for 15 seconds.
Resets only at power down.
Operator Alerting Display Operator Action: None
System Response Display Fault Description: PARK BRAKE RELY CKT
Display Fault Code: A264
Resulting Problem(s) Parking brake may not set or release when expected.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Parking Brake Request 0: Parking Brake Set is Requested (shifter is not in the forward, neutral, or reverse
(IM3V) positions or the engine oil pressure is below the set point of the engine oil pressure
switch)
1: Parking Brake Release is Requested (shifter is in the forward, neutral, or reverse
positions and the engine oil pressure is above the set point of the engine oil pressure
switch)
Fault(s): A213, A214
Selector Switch (FNR) 0: shifter is not in forward, neutral, or reverse
(IM2N) 1: shifter is in forward, neutral, or reverse
Fault(s): A271, A303
Engine Speed [RPM] 0: engine is not running
(CAN/J1939) (IM1q,r,s) > 400: engine is running
Fault(s): A184
34
40 Troubleshooting CEN40180-02
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Selector Switch Refer to 58D-06-01711, Sheet 8, zones H12 through H16 730E
Refer to 58E-06-02311, sheet 9, zones H12 through H16 830E
Refer to 58E-06-02321, sheet 17, zones A1 through B1
Refer to 58F-06-02311, Sheet 9, zones H12 through H16 930E
Refer to 58F-06-10561, Sheet 27, zones A1 through B1
Refer to 58B-06-02390, Sheet 10, zones H13 through H16 980E
Refer to 58B-06-03570, Sheet 29, zones A1 through B1
Selector Switch Refer to 58D-06-01711, Sheet 8, zones J16 throuh L16 730E
connections at IM Refer to 58E-06-02311, sheet 9, zones J16 through L17 830E
Refer to 58E-06-02321, sheet 17, zone C2
Refer to 58F-06-02311, Sheet 9, zones J16 through L17 930E
Refer to 58F-06-10561, Sheet 27, zone C2
Refer to 58B-06-02390, Sheet 10, zones I16 through K17 980E
Refer to 58B-06-03570, Sheet 29, zone C2
Selector Switch Refer to 58D-06-01711, Sheet 8, zones J5 through K5 730E
connections at VEC Refer to 58E-06-02311, sheet 9, zones J5 through K5 830E
Refer to 58E-06-02321, sheet 17, zone C3
Refer to 58F-06-02311, Sheet 9, zones J5 through K5 930E
Refer to 58F-06-10561, Sheet 27, zone C3
Refer to 58B-06-02390, Sheet 10, zones I7 through J7 980E
Refer to 58B-06-03570, Sheet 29, zone C3
35
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Engine Run Oil Refer to 58D-06-01711, Sheet 5, zone L1 730E
Pressure Switch Refer to 58E-06-02311, sheet 7, zone L1 830E
Refer to 58E-06-02321, sheet 5, zone B4
Refer to 58F-06-02311, Sheet 7, zone L1 930E
Refer to 58F-06-10561, Sheet 5, zone B4
Refer to 58B-06-02390, Sheet 7, zone L1 980E
Refer to 58B-06-03570, Sheet 5, zone B4
Engine Run Oil Refer to 58D-06-01711, Sheet 8, zone I2 730E
Pressure Switch at Refer to 58E-06-02311, sheet 9, zone I2 830E
VEC Refer to 58E-06-02321, sheet 5, zone B4
Refer to 58F-06-02311, Sheet 9, zone I2 930E
Refer to 58F-06-10561, Sheet 5, zone B4
Refer to 58B-06-02390, Sheet 10, zone H3 980E
Refer to 58B-06-03570, Sheet 5, zone B4
Engine Run Oil Refer to 58D-06-01711, Sheet 5, zone K8 730E
Pressure Switch at Refer to 58E-06-02311, sheet 7, zone K8 830E
TB28 Refer to 58E-06-02321, sheet 5, zone B4
Refer to 58F-06-02311, Sheet 7, zone K8 930E
Refer to 58F-06-10561, Sheet 5, zone B4
Refer to 58B-06-02390, Sheet 7, zone K8 980E
Refer to 58B-06-03570, Sheet 5, zone B4
36
40 Troubleshooting CEN40180-02
Fault Code A265: Service brake failure
Operator Action Stop: Park
Fault Code A265
Description A service brake failure exists. Operation of either brake lock or brake pedal does not
produce brake light switch operation.
Fault Conditions Sets if brake lock is on or if front brake pressure is above 1724 kPa (250 psi) for 2
seconds and the service brake pressure switch does not turn on if the engine has been
running for 90 seconds.
Resets if conditions change for 2 seconds.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: STOP: PARK
Display Fault Description: SERV BRAKE FAILURE
Display Fault Code: A265
Resulting Problem(s) Service brake may not respond to brake lock switch or pedal.
Brake light switch and brake lights may not respond to brake application.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Brake Lock Input (IM2i) 0: brake lock valve is off
1: brake lock valve is on
Brake Pressure (kPa) < 1724 kPa (250 psi): front brake not applied
(IM3bp) > 1724 kPa (250 psi): front brake applied
Fault(s): A201, A205
Service Brake 0: Service brake not applied
Pressure Switch 1: Service brake applied
(IM3C)
Engine Speed [RPM] < 400 rpm: engine is not running
(CAN/J1939) (IM1q,r,s) > 400 rpm for 15 seconds: engine is running
Fault(s): A184
37
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Brake Lock Switch Refer to 58D-06-01711, Sheet 8, zones N10 through N17 730E
connection to IM Refer to 58E-06-02311, sheet 9, zones N10 through N17 830E
Refer to 58E-06-02321, sheet 5, zone D4
Refer to 58F-06-02311, Sheet 9, zones N10 through N17 930E
Refer to 58F-06-10561, Sheet 5, zone D4
Refer to 58B-06-02390, Sheet 10, zones M11 through M17 980E
Refer to 58B-06-03570, Sheet 5, zone D4
Brake Pressure Refer to 58D-06-01711, Sheet 14, zones K1 through K8 730E
Sensor connection to Refer to 58E-06-02311, sheet 15, zones K1 through K8 830E
IM Refer to 58E-06-02321, sheet 5, zone E10
Refer to 58F-06-02311, Sheet 15, zones K1 through K8 930E
Refer to 58F-06-10561, Sheet 5, zone E10
Refer to 58B-06-02390, Sheet 16, zones K1 through K12 980E
Refer to 58B-06-03570, Sheet 5, zone E10
Service Brake Refer to 58D-06-01711, Sheet 5, zone F12 730E
Pressure Switch Refer to 58E-06-02311, sheet 7, zone F12 830E
Refer to 58E-06-02321, sheet 5, zones D1 through E1
Refer to 58E-06-02311, sheet 7, zone F12 930E
Refer to 58E-06-02321, sheet 5, zones D1 through E1
Refer to 58B-06-02390, Sheet 10, zone G3 980E
Refer to 58B-06-03570, Sheet 5, zones D1 through E1
Service Brake Refer to 58D-06-01711, Sheet 8, zones I16 through I17 730E
Pressure Switch Refer to 58E-06-02311, sheet 9, zones J16 through L17 830E
connection to IM Refer to 58E-06-02321, sheet 5, zones D1 through E1
Refer to 58F-06-02311, Sheet 9, zones J16 through L17 930E
Refer to 58F-06-10561, Sheet 5, zones D1 through E1
Refer to 58B-06-02390, Sheet 10, zone I16 980E
Refer to 58B-06-03570, Sheet 5, zones D1 through E1
38
40 Troubleshooting CEN40180-02
Fault Code A266: Shift lever was not in park while attempting to crank engine
Operator Action Put Selector in Park
Fault Code A266
Description Shift lever was not in Park while attempting to crank engine.
Fault Conditions Sets if selector switch is not in park or is in forward, neutral, or reverse while
attempting to crank engine.
Resets if selector switch is put in park or cranking attempt is stopped.
Operator Alerting Sound Buzzer - single burst
System Response Display Operator Action: PUT SELECTOR IN PARK
Display Fault Description: CAN'T CRANK
Display Fault Code: A266
Resulting Problem(s) IM will not permit cranking if selector switch is not in park.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Selector Switch (Park) 0: shifter is not park
(IM3T) 1: shifter is in park
Fault(s): A271, A303
Selector Switch (FNR) 0: shifter is not in forward, neutral, or reverse
(IM2N) 1: shifter is in forward, neutral, or reverse
Fault(s): A271, A303
Crank Request (IM2j) 0: cranking not attempted
1: cranking is attempted
39
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Selector Switch Refer to 58D-06-01711, Sheet 8, zones H12 through H16 730E
Refer to 58E-06-02311, sheet 9, zones H12 through H16 830E
Refer to 58E-06-02321, sheet 17, zones A1 through B1
Refer to 58F-06-02311, Sheet 9, zones H12 through H16 930E
Refer to 58F-06-10561, Sheet 27, zones A1 through B1
Refer to 58B-06-02390, Sheet 10, zones H13 through H16 980E
Refer to 58B-06-03570, Sheet 29, zones A1 through B1
Selector Switch Refer to 58D-06-01711, Sheet 8, zones J16 through L17 730E
connections at IM Refer to 58E-06-02311, sheet 9, zones J16 through L17 830E
Refer to 58E-06-02321, sheet 17, zone C2
Refer to 58F-06-02311, Sheet 9, zones J16 through L17 930E
Refer to 58F-06-10561, Sheet 27, zone C2
Refer to 58B-06-02390, Sheet 10, zones I16 through K17 980E
Refer to 58B-06-03570, Sheet 29, zone C2
Selector Switch Refer to 58D-06-01711, Sheet 8, zones J5 through K5 730E
connections at VEC Refer to 58E-06-02311, sheet 9, zones J5 through K5 830E
Refer to 58E-06-02321, sheet 17, zone C3
Refer to 58F-06-02311, Sheet 9, zones J5 through K5 930E
Refer to 58F-06-10561, Sheet 27, zone C3
Refer to 58B-06-02390, Sheet 10, zones I7 through J7 980E
Refer to 58B-06-03570, Sheet 29, zone C3
Crank Request Refer to 58D-06-01711, Sheet 3, zone E7 730E
connection at Key Refer to 58E-06-02311, sheet 5, zone E9 830E
Refer to 58E-06-02321, sheet 4, zone E1
Refer to 58F-06-02311, Sheet 5, zone E9 930E
Refer to 58F-06-10561, Sheet 4, zone E1
Refer to 58B-06-02390, Sheet 5, zone E9 980E
Refer to 58B-06-03570, Sheet 4, zone E1
Crank Request Refer to 58D-06-01711, Sheet 3, zone J4 730E
connection at IM Refer to 58E-06-02311, sheet 5, zone J5 830E
Refer to 58E-06-02321, sheet 4, zone E1
Refer to 58F-06-02311, Sheet 5, zone J5 930E
Refer to 58F-06-10561, Sheet 4, zone E1
Refer to 58B-06-02390, Sheet 5, zone J7 980E
Refer to 58B-06-03570, Sheet 4, zone E1
40
40 Troubleshooting CEN40180-02
Fault Code A267: Parking brake was not set while attempting to crank engine
Operator Action Set Parking Brake
Fault Code A267
Description Parking brake was not set while attempting to crank engine.
Fault Conditions Sets if parking brake is not set while attempting to crank engine. Parking brake set is
defined as closure of the parking brake set pressure switch and opening of the parking
brake release pressure switch.
Resets if parking brake sets or cranking attempt is stopped.
Operator Alerting Sound Buzzer - single burst
System Response Display Operator Action: SET PARK BRAKE
Display Fault Description: CAN'T CRANK
Display Fault Code: A267
Resulting Problem(s) IM will not permit cranking if parking brake is not set.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Crank Request (IM2j) 0: cranking not attempted
1: cranking is attempted
Parking Brake Set 0: parking brake pressure switch indicating low pressure and an applied parking brake
(IM2f) 1: parking brake pressure switch indicating higher pressure and an unapplied parking
brake
Fault(s): A213
Parking Brake 0: parking brake pressure switch indicating high pressure and a released parking
Released (IM2M) brake
1: parking brake pressure switch indicating low pressure and an applied parking brake
Fault(s): A214
41
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Parking Brake Set Refer to 58D-06-01711, Sheet 14, zones F10 through F16 730E
Pressure Switch Refer to 58E-06-02311, sheet 15, zones F10 through F16 830E
connection to IM Refer to 58E-06-02321, sheet 5, zone C8
Refer to 58F-06-02311, Sheet 15, zone F10 to F16 930E
Refer to 58F-06-10561, Sheet 5, zone C8
Refer to 58B-06-02390, Sheet 16, zone F10 to F16 980E
Refer to 58B-06-03570, Sheet 5, zone C8
Parking Brake Release Refer to 58D-06-01711, Sheet 3, zones G3 through H9 730E
Pressure Switch to IM Refer to 58E-06-02311, sheet 5, zones H3 through H9 830E
Refer to 58E-06-02321, sheet 5, zone C9
Refer to 58F-06-02311, Sheet 5, zones H5 through H14 930E
Refer to 58F-06-10561, Sheet 5, zone C9
Refer to 58B-06-02390, Sheet 5, zones H6 through H20 980E
Refer to 58B-06-03570, Sheet 5, zone C9
Crank Request Refer to 58D-06-01711, Sheet 3, zone E7 730E
connection at Key Refer to 58E-06-02311, sheet 5, zone E9 830E
Refer to 58E-06-02321, sheet 4, zone E1
Refer to 58F-06-02311, Sheet 5, zone E9 930E
Refer to 58F-06-10561, Sheet 4, zone E1
Refer to 58B-06-02390, Sheet 5, zone E9 980E
Refer to 58B-06-03570, Sheet 4, zone E1
Crank Request Refer to 58D-06-01711, Sheet 3, zone J4 730E
connection at IM Refer to 58E-06-02311, sheet 5, zone J5 830E
Refer to 58E-06-02321, sheet 4, zone E1
Refer to 58F-06-02311, Sheet 5, zone J5 930E
Refer to 58F-06-10561, Sheet 4, zone E1
Refer to 58B-06-02390, Sheet 5, zone J7 980E
Refer to 58B-06-03570, Sheet 4, zone E1
42
40 Troubleshooting CEN40180-02
Fault Code A268: Secondary engine shutdown while cranking
Operator Action Do Not Shut Down
Fault Code A268
Description Secondary engine shutdown while cranking.
Fault Conditions Sets if secondary engine shutdown switch is activated while attempting to crank
engine.
Resets if secondary engine shutdown switch is deactivated or cranking attempt is
stopped.
Operator Alerting Sound Buzzer - single burst
System Response Display Operator Action: DO NOT SHUT DOWN
Display Fault Description: CAN'T CRANK
Display Fault Code: A268
Resulting Problem(s) IM will not permit cranking if parking brake is not set.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, but no additional fault codes are available for them.
2. Since there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Crank Request (IM2j) 0: cranking not attempted
1: cranking is attempted
Secondary Engine 0: secondary engine shutdown is not on
Shutdown (IM3E) 1: secondary engine shutdown is on
43
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Crank Request Refer to 58D-06-01711, Sheet 3, zone E7 730E
connection at Key Refer to 58E-06-02311, sheet 5, zone E9 830E
Refer to 58E-06-02321, sheet 4, zone E1
Refer to 58F-06-02311, Sheet 5, zone E9 930E
Refer to 58F-06-10561, Sheet 4, zone E1
Refer to 58B-06-02390, Sheet 5, zone E9 980E
Refer to 58B-06-03570, Sheet 4, zone E1
Crank Request Refer to 58D-06-01711, Sheet 3, zone J4 730E
connection at IM Refer to 58E-06-02311, sheet 5, zone J5 830E
Refer to 58E-06-02321, sheet 4, zone E1
Refer to 58F-06-02311, Sheet 5, zone J5 930E
Refer to 58F-06-10561, Sheet 4, zone E1
Refer to 58B-06-02390, Sheet 5, zone J7 980E
Refer to 58B-06-03570, Sheet 4, zone E1
Secondary Engine Refer to 58D-06-01711, Sheet 3, zone C16 730E
Shutdown Switch Refer to 58E-06-02311, sheet 5, zone D16 830E
Refer to 58E-06-02321, sheet 12, zone C1
Refer to 58F-06-02311, Sheet 5, zone D16 930E
Refer to 58F-06-10561, Sheet 12, zone C1
Refer to 58B-06-02390, Sheet 5, zone C16 980E
Refer to 58B-06-03570, Sheet 14, zone C1
Secondary Engine Refer to 58D-06-01711, Sheet 3, zone H4 730E
Shutdown Switch at IM Refer to 58E-06-02311, sheet 5, zone H4 830E
Refer to 58E-06-02321, sheet 12, zone D1
Refer to 58F-06-02311, Sheet 5, zone H4 930E
Refer to 58F-06-10561, Sheet 12, zone D1
Refer to 58B-06-02390, Sheet 5, zone H7 980E
Refer to 58B-06-03570, Sheet 14, zone D1
44
40 Troubleshooting CEN40180-02
Fault Code A270: Brake lock switch power supply is not on when required
Operator Action Go to Shop Now
Fault Code A270
Description Brake lock switch power supply is not on when required.
Fault Conditions Sets if brake lock switch power supply is off when steering is not bleeding down, truck
speed above 1 kph (0.6 mph) and parking brake not set or with parking brake
requested and the engine running 400 rpm for 15 seconds and the delayed shutdown
relay not on.
Parking brake set is defined as closure of the parking brake set pressure switch and
opening of the parking brake release pressure switch.
Resets at beginning of steering bleeddown.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: BRK LOCK CKT FAULT
Display Fault Code: A270
Resulting Problem(s) Missing brake lock power supply makes it impossible to use the brake lock in a normal
manner for loading a dumping operations
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
45
CEN40180-02 40 Troubleshooting
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
2. Since there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Brake Lock Switch 0: now power available for brake lock switch
Power Supply (IM3L) 1: power is available for brake lock switch
Fault(s): A272
Truck Speed [kph] < 1 kph (0.6 mph): truck is not moving
(CAN/RPC) (IM1i,j,k) > 1 kph: truck is moving
Fault(s): A233
Engine Speed [RPM] < 400 rpm: engine is not running
(CAN/J1939) (IM1q,r,s) > 400 rpm for 15 seconds: engine is running
Fault(s): A184
Parking Brake Set 0: parking brake pressure switch indicating low pressure and an applied parking brake
(IM2f) 1: parking brake pressure switch indicating higher pressure and an unapplied parking
brake
Fault(s): A213
Parking Brake 0: parking brake pressure switch indicating high pressure and a released parking
Released (IM2M) brake
1: parking brake pressure switch indicating low pressure and an applied parking brake
Fault(s): A214
Parking Brake Request 0: shifter is not in the forward, neutral, or reverse positions or the engine oil pressure is
(IM3V) below the set point of the engine oil pressure switch
1: shifter is in the forward, neutral, or reverse positions and the engine oil pressure is
above the set point of the engine oil pressure switch
Fault(s): A264
Shutdown Delay Relay 0: Shutdown delay is off
(IM1H) 1: Shutdown delay is on
Steering Bleed Valve 0: steering bleed valve is off
(IM1P) 1: steering bleed valve is on
46
40 Troubleshooting CEN40180-02
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Parking Brake Set Refer to 58D-06-01711, Sheet 14, zones F9 through F16 730E
Pressure Switch Refer to 58E-06-02311, sheet 15, zones F10 through F16 830E
connection to IM Refer to 58E-06-02321, sheet 5, zone C8
Refer to 58F-06-02311, Sheet 15, zone F10 to F16 930E
Refer to 58F-06-10561, Sheet 5, zone C8
Refer to 58B-06-02390, Sheet 16, zone F10 to F16 980E
Refer to 58B-06-03570, Sheet 5, zone C8
Parking Brake Release Refer to 58D-06-01711, Sheet 3, zones G3 through H9 730E
Pressure Switch to IM Refer to 58E-06-02311, sheet 5, zones H3 through H9 830E
Refer to 58E-06-02321, sheet 5, zone C9
Refer to 58F-06-02311, Sheet 5, zones H5 through H14 930E
Refer to 58F-06-10561, Sheet 5, zone C9
Refer to 58B-06-02390, Sheet 5, zones H6 through H20 980E
Refer to 58B-06-03570, Sheet 5, zone C9
Brake Control Circuits Refer to 58D-06-01711, Sheet 8, zones J4 through L17 730E
Refer to 58E-06-02311, sheet 9, zones J4 through L17 830E
Refer to 58E-06-02321, sheet 5, zones A1 through C6
Refer to 58F-06-02311, Sheet 9, zones J4 through L17 930E
Refer to 58F-06-10561, Sheet 5, zones A1 through C6
Refer to 58B-06-02390, Sheet 10, zones I4 through M17 980E
Refer to 58B-06-03570, Sheet 5, zones A1 through C6
Delayed Shutdown Refer to 58D-06-01711, Sheet 3, zone D9 730E
Relay Refer to 58E-06-02311, sheet 5, zone D10 830E
Refer to 58E-06-02321, sheet 4, zone E2
Refer to 58F-06-02311, Sheet 5, zone D10 930E
Refer to 58F-06-10561, Sheet 4, zone E2
Refer to 58B-06-02390, Sheet 5, zone D10 980E
Refer to 58B-06-03570, Sheet 4, zone E2
Delayed Shutdown Refer to 58D-06-01711, Sheet 3, zone I4 730E
Relay connection at IM Refer to 58E-06-02311, sheet 5, zone I4 830E
Refer to 58E-06-02321, sheet 4, zone F2
Refer to 58F-06-02311, Sheet 5, zone I4 930E
Refer to 58F-06-10561, Sheet 4, zone F2
Refer to 58B-06-02390, Sheet 5, zone I6 980E
Refer to 58B-06-03570, Sheet 4, zone F2
47
CEN40180-02 40 Troubleshooting
Fault Code A272: Brake lock switch power supply is not off when required
Operator Action Go to Shop Now
Fault Code A272
Description Brake lock switch power supply not off when required.
Fault Conditions Sets if brake lock switch power supply is not off when brake lock is off, and truck speed
is less than 0.5 kph (0.3 mph) and parking brake request is on or engine speed has
been 0 for 15 seconds and J1939 data link is OK, or the shutdown relay is on or the
keyswitch is off, for 3 seconds. Resets at power down.
Alternatively sets if brake lock switch power supply is not off when brake lock is on and
truck speed is less than 0.5 kph (0.3 mph) and parking brake request is on or engine
speed has been 0 for 15 seconds and J1939 data link is OK, or the shutdown relay is
on or the keyswitch is off, for 1 second.
Resets in 1 second if conditions change.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: BRK LOCK CKT FAULT
Display Fault Code: A272
Resulting Problem(s) Defective brake lock power supply circuitry makes it impossible to use the brake lock
in a normal manner for loading a dumping operations.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
48
40 Troubleshooting CEN40180-02
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
2. Since there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Brake Lock Switch 0: now power available for brake lock switch
Power Supply (IM3L) 1: power is available for brake lock switch
Fault(s): A270
Brake Lock (IM2i) 0: brake lock not on
1: brake lock is on
Truck Speed [kph] < 1 kph (0.6 mph): truck is not moving
(CAN/RPC) (IM1i,j,k) > 1 kph: truck is moving
Fault(s): A233
Engine Speed [RPM] 0 rpm for 15 seconds with J1939 working: engine is not running
(CAN/J1939) (IM1q,r,s) > 0 rpm or J1939 not working: engine is running
Fault(s): A184
Parking Brake Request 0: shifter is not in the forward, neutral, or reverse positions or the engine oil pressure is
(IM3V) below the set point of the engine oil pressure switch
1: shifter is in the forward, neutral, or reverse positions and the engine oil pressure is
above the set point of the engine oil pressure switch
Fault(s): A264
Keyswitch (IM3G) 0: keyswitch is off and the truck is not moving and the engine is not running
1: keyswitch is on or the truck is moving or the engine is running
Fault(s): A240
Shutdown Delay Relay 0. Turns off when conditions clear or engine speed drops to zero.
(IM1H) 1: Turns on when Keyswitch, Direct is off, Engine Shutdown Delay is on, Parking
brake is set, Selector Switch is in park, but not J1939 Not Connected, not High Batt
Charge Voltage, not Starter Stuck On, not Active Engine Red Light, and engine speed
above 300 rpm.
Fault(s): A286, A292
49
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Keyswitch, OR Refer to 58D-06-01711, Sheet 14, zones D9 through D19 730E
connection to IM Refer to 58E-06-02311, sheet 15, zones D10 through D19 830E
Refer to 58E-06-02321, sheet 31, zones B8 through B10
Refer to 58F-06-02311, Sheet 15, zones D10 through D19 930E
Refer to 58F-06-10561, Sheet 31, zones B8 through B10
Refer to 58B-06-02390, Sheet 16, zones D10 through D19 980E
Refer to 58B-06-03570, Sheet 33, zones B9 through B10
Brake Control Circuits Refer to 58D-06-01711, Sheet 8, zones J4 through L17 730E
Refer to 58E-06-02311, sheet 9, zones J4 through L17 830E
Refer to 58E-06-02321, sheet 5, zones A1 through C6
Refer to 58F-06-02311, Sheet 9, zones J4 through L17 930E
Refer to 58F-06-10561, Sheet 5, zones A1 through C6
Refer to 58B-06-02390, Sheet 10, zones I4 through M17 980E
Refer to 58B-06-03570, Sheet 5, zones A1 through C6
Delayed Shutdown Refer to 58D-06-01711, Sheet 3, zone D9 730E
Relay Refer to 58E-06-02311, sheet 5, zone D10 830E
Refer to 58E-06-02321, sheet 4, zone E2
Refer to 58F-06-02311, Sheet 5, zone D10 930E
Refer to 58F-06-10561, Sheet 4, zone E2
Refer to 58B-06-02390, Sheet 5, zone D10 980E
Refer to 58B-06-03570, Sheet 4, zone E2
Delayed Shutdown Refer to 58D-06-01711, Sheet 3, zone I4 730E
Relay connection at IM Refer to 58E-06-02311, sheet 5, zone I4 830E
Refer to 58E-06-02321, sheet 4, zone F2
Refer to 58F-06-02311, Sheet 5, zone I4 930E
Refer to 58F-06-10561, Sheet 4, zone F2
Refer to 58B-06-02390, Sheet 5, zone I6 980E
Refer to 58B-06-03570, Sheet 4, zone F2
50
40 Troubleshooting CEN40180-02
Fault Code A273: Hoist filter or steering filter pressure switch circuit fault detected
Operator Action None
Fault Code A273
Description Hoist filter or steering filter pressure switch circuit fault detected.
Fault Conditions Sets if the pump filter pressure switch circuit indicates high pressure across the filters
for 2 seconds with the engine not running at least 300 rpm.
Resets if pump filter pressure switch circuit indicates normal pressure across the filters
or the engine begins to run.
Operator Alerting Repair Lamp
System Response Display Fault Description: HYD OIL FLT CIRCUIT
Display Fault Code: A273
Resulting Problem(s) Hydraulic oil filters might plug up and stop filtering without warning.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, but no additional fault codes are available for them.
2. Since there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Pump Filter Switches 0: No hydraulic filter switches open
(IM2Y) 1: One or more hydraulic filter switches open
Fault(s): A101
Engine Speed [RPM] < 300 RPM: engine is not running
(CAN/J1939) (IM1q,r,s) > 300 RPM for 4 seconds: engine is running
Fault(s): A184
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Pump Filter Switch Refer to 58D-06-01711, Sheet 14, zones D9 through D22 730E
connection at IM Refer to 58E-06-02311, sheet 15, zones D9 through D22 830E
Refer to 58E-06-02321, sheet 31, zones B6 through C8
Refer to 58F-06-02311, Sheet 15, zones D9 through D22 930E
Refer to 58F-06-10561, Sheet 31, zones B6 through C8
Refer to 58B-06-02390, Sheet 16, zones E9 through E22 980E
Refer to 58B-06-03570, Sheet 33, zones B6 through C8
51
CEN40180-02 40 Troubleshooting
Fault Code A274: A brake setting fault has been detected
Operator Action Secure Vehicle
Fault Code A274
Description A brake setting fault has been detected.
Fault Conditions Sets after 5 seconds if parking brake and brake lock are on simultaneously and brake
lock not applied by drive system or brake auto apply and not auto mode operation
requested.
Resets after 5 seconds if conditions cease to exist.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: SECURE VEHICLE
Display Fault Description: BRAKE MALFUNCTION
Display Fault Code: A274
Resulting Problem(s) Improperly controlled brakes are dangerous to equipment as well as operator.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
2. Since there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data Mon-
itor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the malfunc-
tion is still unresolved then check each of the parameters in the Table for proper functionality. Troubleshoot all
item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Parking Brake Set 0: parking brake pressure switch indicating low pressure and an applied parking brake
(IM2f) 1: parking brake pressure switch indicating higher pressure and an unapplied parking
brake
Fault(s): A213
Parking Brake 0: parking brake pressure switch indicating high pressure and a released parking
Released (IM2M) brake
1: parking brake pressure switch indicating low pressure and an applied parking brake
Fault(s): A214
Brake Lock (IM2i) 0: brake lock not on
1: brake lock is on
52
40 Troubleshooting CEN40180-02
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Parking Brake Set Refer to 58D-06-01711, Sheet 14, zones F9 through F16 730E
Pressure Switch Refer to 58E-06-02311, sheet 15, zones F10 through F16 830E
connection to IM Refer to 58E-06-02321, sheet 5, zone C8
Refer to 58F-06-02311, Sheet 15, zone F10 to F16 930E
Refer to 58F-06-10561, Sheet 5, zone C8
Refer to 58B-06-02390, Sheet 16, zone F10 to F16 980E
Refer to 58B-06-03570, Sheet 5, zone C8
Parking Brake Release Refer to 58D-06-01711, Sheet 3, zones G3 through H9 730E
Pressure Switch to IM Refer to 58E-06-02311, sheet 5, zones H3 through H9 830E
Refer to 58E-06-02321, sheet 5, zone C9
Refer to 58F-06-02311, Sheet 5, zones H5 through H14 930E
Refer to 58F-06-10561, Sheet 5, zone C9
Refer to 58B-06-02390, Sheet 5, zones H6 through H20 980E
Refer to 58B-06-03570, Sheet 5, zone C9
Brake Pressure Refer to 58D-06-01711, Sheet 14, zones K1 through K8 730E
Sensor connection to Refer to 58E-06-02311, sheet 15, zones K1 through K8 830E
IM Refer to 58E-06-02321, sheet 5, zone E10
Refer to 58F-06-02311, Sheet 15, zones K1 through K8 930E
Refer to 58F-06-10561, Sheet 5, zone E10
Refer to 58B-06-02390, Sheet 16, zones K1 through K12 980E
Refer to 58B-06-03570, Sheet 5, zone E10
53
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Brake Lock connection Refer to 58D-06-01711, Sheet 8, zones L11 through M17 730E
to IM Refer to 58E-06-02311, sheet 9, zones M11 through M17 830E
Refer to 58E-06-02321, sheet 5, zone C4
Refer to 58F-06-02311, Sheet 9, zones M11 through N17 930E
Refer to 58F-06-10561, Sheet 5, zone C4
Refer to 58B-06-02390, Sheet 10, zones M11 through N17 980E
Refer to 58B-06-03570, Sheet 5, zone C4
Service Brake Refer to 58D-06-01711, Sheet 5, zone F12 730E
Pressure Switch Refer to 58E-06-02311, Sheet 7, zone F12 830E
Refer to 58E-06-02321, sheet 5, zones D1 through E1
Refer to 58F-06-02311, Sheet 7, zone F12 930E
Refer to 58F-06-10561, Sheet 5, zones D1 through E1
Refer to 58B-06-02390, Sheet 10, zone G3 980E
Refer to 58B-06-03570, Sheet 5, zones D1 through E1
Service Brake Refer to 58D-06-01711, Sheet 8, zones J16 through L17 730E
Pressure Switch Refer to 58E-06-02311, Sheet 9, zones J16 through L17 830E
connection to IM Refer to 58E-06-02321, sheet 5, zones D1 through E1
Refer to 58F-06-02311, Sheet 9, zones J16 through L17 930E
Refer to 58F-06-10561, Sheet 5, zones D1 through E1
Refer to 58B-06-02390, Sheet 10, zone I16 980E
Refer to 58B-06-03570, Sheet 5, zones D1 through E1
54
40 Troubleshooting CEN40180-02
Fault Code A275: A starter has been detected as engaged without a cranking attempt
Operator Action Stop, park, power down, check
Fault Code A275
Description A starter has been detected as engaged without a cranking attempt.
Fault Conditions Sets if either starter is engaged for 2 seconds without crank sense being on and while
steering is not bleeding down.
Resets after 2 seconds if conditions change.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: STOP: PRK: PWR : CHK
Display Fault Description: STARTER STUCK ON
Display Fault Code: A275
Resulting Problem(s) Starters may be destroyed by continued operation when stuck on.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The normal corrective measure for this fault is to check the starter motors and engagement to the flywheel.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
3. Since there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Starter Motor 1 0: Starter motor 1 is not energized.
Energized (IM3R) 1: Starter motor 1 is energized.
Fault(s): A152, A316
Starter Motor 2 0: Starter motor 2 is not energized.
Energized (IM3S) 1: Starter motor 2 is energized.
Fault(s): A152, A316
Crank Sense (IM3U) 0: No cranking is in process.
1: Cranking is in process.
Steering Bleed Valve 0: Steering bleed valve is off.
(IM1-P) 1: Steering bleed valve is on.
55
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Starter Motors 1 and 2 Refer to 58D-06-01711, Sheet 2, zones K8 through L12 730E
Refer to 58E-06-02311, sheet 4, zones K10 through K12 830E
Refer to 58E-06-02321, sheet 4, zones C8 through C9
Refer to 58F-06-02311, Sheet 4, zones K10 through K12 930E
Refer to 58F-06-10561, Sheet 4, zones C8 through C9
Refer to 58B-06-02390, Sheet 4, zones K10 through K12 980E
Refer to 58B-06-03570, Sheet 4, zones C8 through C9
Starter Motor Refer to 58D-06-01711, Sheet 3, zones L4 through L7 730E
connections to IM Refer to 58E-06-02311, sheet 5, zones L4 through L7 830E
Refer to 58E-06-02321, sheet 4, zones C8 through C9
Refer to 58F-06-02311, Sheet 5, zones L4 through L7 930E
Refer to 58F-06-10561, Sheet 4, zones C8 through C9
Refer to 58B-06-02390, Sheet 5, zones K6 through K10 980E
Refer to 58B-06-03570, Sheet 4, zones C8 through C9
Crank Sense Refer to 58D-06-01711, Sheet 2, zones M9 through N19 and Sheet 4, 730E
connection to IM zones B2 through D4
Refer to 58E-06-02311, sheet 4, zones M9 through N19 and sheet 6, 830E
zones B2 through D4
Refer to 58E-06-02321, sheet 4, zones A7 through B7
Refer to 58F-06-02311, Sheet 4, zones M9 through N19 and Sheet 6, 930E
zones B2 through D4
Refer to 58F-06-10561, Sheet 4, zones A7 through B7
Refer to 58B-06-02390, Sheet 4, zones M9 through N19 and Sheet 6, 980E
zones H2 through H4
Refer to 58B-06-03570, Sheet 4, zones A7 through B7
56
40 Troubleshooting CEN40180-02
Fault Code A277: Parking brake applied while loading
Operator Action Turn Off Parking Brake
Fault Code A277
Description Parking brake is applied while loading the dump body.
Fault Conditions Sets if parking brake is set and PLM reports a loading state. Parking brake set is
defined as closure of the parking brake set pressure switch and opening of the parking
brake release pressure switch.
Resets if loading state is cleared or parking brake is released.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: MOVE SHFTR FROM PARK
Display Fault Description: IMPROPER BRK USAGE
Display Fault Code: A277
Resulting Problem(s) Parking brake may be damaged; load weights may contain error.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The normal corrective measure for this fault is to release the parking brake. If this does not work, verify that
the input parameters are correct.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
5. If a false loading state signal is suspected, it will be necessary to thoroughly troubleshoot the PLM system.
Parameter Expected State and/or Related Fault(s)
Parking Brake Set 0: parking brake pressure switch indicating low pressure and an applied parking brake
(IM2f) 1: parking brake pressure switch indicating higher pressure and an unapplied parking
brake
Fault(s): A213
Parking Brake 0: parking brake pressure switch indicating high pressure and a released parking
Released (IM2M) brake
1: parking brake pressure switch indicating low pressure and an applied parking brake
Fault(s): A214
Loading State (PLM The loading state input is developed by PLM and communicated to IM via CAN/RPC.
CAN/RPC)
57
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Parking Brake Set Refer to 58D-06-01711, Sheet 14, zones F9 through F16 730E
Pressure Switch Refer to 58E-06-02311, sheet 15, zones F10 through F16 830E
connection to IM Refer to 58E-06-02321, sheet 5, zone C8
Refer to 58F-06-02311, Sheet 15, zone F10 to F16 930E
Refer to 58F-06-10561, Sheet 5, zone C8
Refer to 58B-06-02390, Sheet 16, zone F10 to F16 980E
Refer to 58B-06-03570, Sheet 5, zone C8
Parking Brake Release Refer to 58D-06-01711, Sheet 3, zones G3 through H9 730E
Pressure Switch to IM Refer to 58E-06-02311, sheet 5, zones H3 through H9 830E
Refer to 58E-06-02321, sheet 5, zone C9
Refer to 58F-06-02311, Sheet 5, zones H5 through H14 930E
Refer to 58F-06-10561, Sheet 5, zone C9
Refer to 58B-06-02390, Sheet 5, zones H6 through H20 980E
Refer to 58B-06-03570, Sheet 5, zone C9
58
40 Troubleshooting CEN40180-02
Fault Code A278: Service brake applied while loading
Operator Action Release Service Brake
Fault Code A278
Description Service brake is applied while loading the dump body.
Fault Conditions Sets if PLM declares a loading state while the front brake pressure is at 1207 kPa (175
psi) or more for 10 seconds.
Resets if loading state is cleared or front brake pressure drops below 1034 kPa (150
psi) for 1 second.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: RELEASE SERVICE BRAKE
Display Fault Description: IMPROPER BRK USAGE
Display Fault Code: A278
Resulting Problem(s) Load weights may contain errors.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The normal corrective measure for this fault is to release the service brake. If this does not work, verify that
the input parameters are correct.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
5. If a false loading state signal is suspected, it will be necessary to thoroughly troubleshoot the PLM system.
Parameter Expected State and/or Related Fault(s)
Loading State The loading state input is developed by PLM and communicated to IM via CAN/RPC.
(PLM CAN/RPC)
Brake Pressure (IM3p) > 1207 kPa (175 psi) for 10 seconds: front brakes applied
< 1034 kPa (150 psi) for 1 second; front brakes not applied
Fault(s): 201, 205
59
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Brake Pressure Refer to 58D-06-01711, Sheet 14, zones K1 through K8 730E
Sensor connection to Refer to 58E-06-02311, sheet 15, zones K1 through K8 830E
IM Refer to 58E-06-02321, sheet 5, zone E10
Refer to 58F-06-02311, Sheet 15, zones K1 through K8 930E
Refer to 58F-06-10561, Sheet 5, zone E10
Refer to 58B-06-02390, Sheet 16, zones K1 through K12 980E
Refer to 58B-06-03570, Sheet 5, zone E10
60
40 Troubleshooting CEN40180-02
Fault Code A279: Low Steering Pressure Switch bad
Operator Action Stop: Park: Power Down: Check
Fault Code A279
Description Low Steering Pressure Switch bad
Fault Conditions Sets if low steering pressure switch fails to turn on by the time the steering
accumulator bleed pressure switch indicates that bleeding is complete.
Resets if low steering pressure switch actuates (reports low pressure).
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: STOP: PRK: PWR: CHK
Display Fault Description: BAD STRG PRESS SW
Display Fault Code: A279
Resulting Problem(s) Loss of steering may not be reported.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Low Steering Pressure 0: steering pressure normal
Sw (IM2S) 1: low steering pressure
Steering Accum Bled 0: Accumulator is bled.
Pressure Sw (IM2Z) 1: Accumulator is not completely bled.
Fault(s): A280
Steering Bleed Valve 0: steering bleed valve is off
(IM1P) 1: steering bleed valve is on
61
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Low Steering Pressure Refer to 58D-06-01711, Sheet 14, zones N2 through N8 730E
Switch connection to Refer to 58E-06-02311, sheet 15, zones N2 through N8 830E
IM Refer to 58E-06-02321, sheet 31, zone C3
Refer to 58F-06-02311, Sheet 15, zones N2 through N8 930E
Refer to 58F-06-10561, Sheet 31, zone C3
Refer to 58B-06-02390, Sheet 16, zones N2 through N7 980E
Refer to 58B-06-03570, Sheet 33, zone C3
Steering Bleed Switch Refer to 58D-06-01711, Sheet 14, zone O3 730E
Refer to 58E-06-02311, sheet 15, zone O3 830E
Refer to 58E-06-02321, sheet 31, zone C2
Refer to 58F-06-02311, Sheet 15, zone O3 930E
Refer to 58F-06-10561, Sheet 31, zone C2
Refer to 58B-06-02390, Sheet 16, zone O2 980E
Refer to 58B-06-03570, Sheet 33, zone C2
Steering Bleed Switch Refer to 58D-06-01711, Sheet 14, zone O7 730E
connection at IM Refer to 58E-06-02311, sheet 15, zone O7 830E
Refer to 58E-06-02321, sheet 31, zone B2
Refer to 58F-06-02311, Sheet 15, zone O7 930E
Refer to 58F-06-10561, Sheet 31, zone B2
Refer to 58B-06-02390, Sheet 16, zone O7 980E
Refer to 58B-06-03570, Sheet 33, zone B2
62
40 Troubleshooting CEN40180-02
Fault Code A280: Steering accumulator bleed down switch is defective
Operator Action Go to Shop Now
Fault Code A280
Description Steering accumulator bleed down switch is defective.
Fault Conditions Sets if steering accumulator bleed pressure switch comes on with engine running and
steering pressure normal.
Resets if steering accumulator bleed pressure switch deactuates.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: BAD STRG BLED SW
Display Fault Code: A280
Resulting Problem(s) Improper bleed may not be reported.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Low Steering Pressure 0: steering pressure normal
Sw (IM2S) 1: low steering pressure
Fault(s): A279
Steering Accum Bled 0: Accumulator is bled.
Pressure Sw (IM2Z) 1: Accumulator is not completely bled.
Engine Speed [RPM] < 300 RPM: engine is not running
(CAN/J1939) (IM1q,r,s) > 300 RPM for 4 seconds: engine is running
Fault(s): A184
63
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Low Steering Pressure Refer to 58D-06-01711, Sheet 14, zones N2 through N8 730E
Switch connection to Refer to 58E-06-02311, sheet 15, zones N2 through N8 830E
IM Refer to 58E-06-02321, sheet 31, zone C3
Refer to 58F-06-02311, Sheet 15, zones N2 through N8 930E
Refer to 58F-06-10561, Sheet 31, zone C3
Refer to 58B-06-02390, Sheet 16, zones N2 through N7 980E
Refer to 58B-06-03570, Sheet 33, zone C3
Steering Bleed Switch Refer to 58D-06-01711, Sheet 14, zone O3 730E
Refer to 58E-06-02311, Sheet 15, zone O3 830E
Refer to 58E-06-02321, Sheet 31, zone C2
Refer to 58F-06-02311, Sheet 15, zone O3 930E
Refer to 58F-06-10561, Sheet 31, zone C2
Refer to 58B-06-02390, Sheet 16, zone O2 980E
Refer to 58B-06-03570, Sheet 33, zone C2
Steering Bleed Switch Refer to 58D-06-01711, Sheet 14, zone O7 730E
connection at IM Refer to 58E-06-02311, Sheet 15, zone O7 830E
Refer to 58E-06-02321, Sheet 31, zone B2
Refer to 58F-06-02311, Sheet 15, zone O7 930E
Refer to 58F-06-10561, Sheet 31, zone B2
Refer to 58B-06-02390, Sheet 16, zone O7 980E
Refer to 58B-06-03570, Sheet 33, zone B2
64
40 Troubleshooting CEN40180-02
Fault Code A281: Brake lock degrade switch is defective
Operator Action Go to Shop Now
Fault Code A281
Description Brake lock degrade switch is defective.
Fault Conditions Sets if brake lock degrade switch is not on when neither service brake nor brake lock
are on for 5 seconds. Service brake is off when the service brake pressure switch is off
and front brake pressure is below 1034 kPa (150 psi).
Resets if brake lock degrade switch actuates.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: BAD BRK DEGRADE SW
Display Fault Code: A281
Resulting Problem(s) Operator may not be warned of degradation of brake lock pressure.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Brake Lock Degrade 0: brake lock degrade not on
Sw (IM2V) 1: brake lock degrade is on
Brake Lock (IM2i) 0: brake lock not on
1: brake lock is on
Service Brake 0: Service brake not applied
Pressure Switch 1: Service brake applied
(IM3C)
Brake Pressure (kPa) < 1034 kPa (150 psi): front brake not applied
(IM3p) > 1034 kPa (150 psi): front brake applied
Fault(s): A201, A205
65
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Service Brake Refer to 58D-06-01711, Sheet 14, zones G9 through G16 730E
Degrade Pressure Refer to 58E-06-02311, sheet 15, zones G9 through G16 830E
Switch to IM Refer to 58E-06-02321, sheet 5, zones E3 through F3
Refer to 58F-06-02311, Sheet 15, zones G9 through G16 930E
Refer to 58F-06-10561, Sheet 5, zones E3 through F3
Refer to 58B-06-02390, Sheet 16, zones G9 through G16 980E
Refer to 58B-06-03570, Sheet 5, zones E3 through F3
Brake Pressure Refer to 58D-06-01711, Sheet 14, zones K1 through K8 730E
Sensor connection to Refer to 58E-06-02311, sheet 15, zones K1 through K8 830E
IM Refer to 58E-06-02321, sheet 5, zone E10
Refer to 58F-06-02311, Sheet 15, zones K1 through K8 930E
Refer to 58F-06-10561, Sheet 5, zone E10
Refer to 58B-06-02390, Sheet 16, zones K1 through K12 980E
Refer to 58B-06-03570, Sheet 5, zone E10
Brake Lock connection Refer to 58D-06-01711, Sheet 8, zones L12 through M17 730E
to IM Refer to 58E-06-02311, sheet 9, zones M11 through M17 830E
Refer to 58E-06-02321, sheet 5, zone C4
Refer to 58F-06-02311, Sheet 9, zones M11 through N17 930E
Refer to 58F-06-10561, Sheet 5, zone C4
Refer to 58B-06-02390, Sheet 10, zones M11 through N17 980E
Refer to 58B-06-03570, Sheet 5, zone C4
Service Brake REfer to 58D-06-01711, Sheet 8, zones J16 through L17 730E
Pressure Switch Refer to 58E-06-02311, sheet 9, zones J16 through L17 830E
connection to IM Refer to 58E-06-02321, sheet 5, zones D1 through E1
Refer to 58F-06-02311, Sheet 9, zones J16 through L17 930E
Refer to 58F-06-10561, Sheet 5, zones D1 through E1
Refer to 58B-06-02390, Sheet 10, zone I16 980E
Refer to 58B-06-03570, Sheet 5, zones D1 through E1
66
40 Troubleshooting CEN40180-02
Fault Code A282: Excessive cranking counts or jump starts without the engine running
Operator Action Stop; Park; Power Down; Check
Fault Code A282
Description Excessive cranking counts or jump starts without the engine running.
Fault Conditions Count is increased every time cranking reaches 30 seconds continuous and every
time a jump start is attempted (engagement of either starter without start enable). A
count of 7 disables further start attempts until the power is shut off.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: STOP: PRK: PWR : CHK
Display Fault Description: EXCESS CRANKING
Display Fault Code: A282
Resulting Problem(s) Excessive cranking destroys starters.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The normal corrective measure for this fault is to check and correct engine and/or starting system
deficiencies.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
3. Since there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Crank Sense (IM3U) 0: No cranking is in process.
1: Cranking is in process.
Engine Speed [RPM] < 300 RPM: engine is not running
(CAN/J1939) (IM1q,r,s) > 300 RPM for 4 seconds: engine is running
Fault(s): A184
Start Enable (IM1B) 0: One of several interlocking situations exist to prevent cranking (excessive cranking
history, selector switch in wrong position, engine red light, J1939 not OK, engine
speed either not 0 to begin cranking or over 400 rpm while cranking).
1. No interlocking situations exist to prevent cranking.
Fault(s): A252, A350
Starter Motor 1 0: starter motor 1 not energized
Energized (IM3R) 1: starter motor 1 energized
Fault(s): A152, A223, A275, A316
Starter Motor 2 0: starter motor 1 not energized
Energized (IM3S) 1: starter motor 1 energized
Fault(s): A152, A223, A275, A316
67
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Starter Motors 1 and 2 Refer to 58D-06-01711, Sheet 2, zones K8 through L12 730E
Refer to 58E-06-02311, sheet 4, zones K10 through K12 830E
Refer to 58E-06-02321, sheet 4, zones C8 through C9
Refer to 58F-06-02311, Sheet 4, zones K10 through K12 930E
Refer to 58F-06-10561, Sheet 4, zones C8 through C9
Refer to 58B-06-02390, Sheet 4, zones K10 through K12 980E
Refer to 58B-06-03570, Sheet 4, zones C8 through C9
Starter Motor Refer to 58D-06-01711, Sheet 3, zones L4 through L7 730E
connections to IM Refer to 58E-06-02311, sheet 5, zones L4 through L7 830E
Refer to 58E-06-02321, sheet 4, zones C8 through C9
Refer to 58F-06-02311, Sheet 5, zones L4 through L7 930E
Refer to 58F-06-10561, Sheet 4, zones C8 through C9
Refer to 58B-06-02390, Sheet 5, zones K6 through K10 980E
Refer to 58B-06-03570, Sheet 4, zones C8 through C9
Crank Sense Refer to 58D-06-01711, Sheet 2, zones M through N19 and Sheet 4, 730E
connection to IM zones B2 through D4
Refer to 58E-06-02311, sheet 4, zones M9 through N19 and sheet 6, 830E
zones B2 through D4
Refer to 58E-06-02321, sheet 4, zones A7 through B7
Refer to 58F-06-02311, Sheet 4, zones M9 through N19 and Sheet 6, 930E
zones B2 through D4
Refer to 58F-06-10561, Sheet 4, zones A7 through B7
Refer to 58B-06-02390, Sheet 4, zones M9 through N19 and Sheet 6, 980E
zones H2 through H4
Refer to 58B-06-03570, Sheet 4, zones A7 through B7
Start Enable Circuit Refer to 58D-06-01711, Sheet 3, zones K4 through K15 730E
Refer to 58E-06-02311, sheet 5, zones K4 through K15 830E
Refer to 58E-06-02321, sheet 4, zones A7 through A9
Refer to 58F-06-02311, Sheet 5, zones K4 through K15 930E
Refer to 58F-06-10561, Sheet 4, zones A7 through A9
Refer to 58B-06-02390, Sheet 5, zones K7 through K15 980E
Refer to 58B-06-03570, Sheet 4, zones A7 through A9
68
40 Troubleshooting CEN40180-02
Fault Code A283: Engine shutdown delay aborted; parking brake not set
Operator Action None
Fault Code A283
Description An engine shutdown delay was aborted because the parking brake was not set.
Fault Conditions Sets if keyswitch is turned OFF and engine shutdown delay is on and engine is
running but parking brake set is not on. (Parking brake set is defined as closure of the
parking brake set pressure switch and opening of the parking brake release pressure
switch.)
Resets if keyswitch is turned ON, engine shutdown delay is off, and engine is running.
Operator Alerting Repair Lamp
System Response Display Fault Description: NO SHT DWN DEL / PB
Display Fault Code: A283
Resulting Problem(s) The engine can suffer damage when shut down immediately rather than in a controlled
delay.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
69
CEN40180-02 40 Troubleshooting
Table
1. The normal corrective measure for this fault is to set the parking brake before turning off the engine start
switch.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
3. Since there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Keyswitch, Direct 0: Keyswitch is OFF.
(IM2P) 1: keyswitch is ON.
Fault(s): A240
Engine Shutdown 0: Engine shutdown delay signal is off.
Delay (IM3F) 1: Engine shutdown delay signal is on.
Fault(s): A284
Parking Brake Set 0: Parking brake pressure switch indicates low pressure and an applied parking brake.
(IM2f) 1: Parking brake pressure switch indicates high pressure and a released parking
brake.
Fault(s): A213
Parking Brake 0: Parking brake pressure switch indicates high pressure and a released parking.
Released (IM2M) brake
1: Parking brake pressure switch indicates low pressure and an applied parking brake.
Fault(s): A214
Engine Speed [RPM] < 300 RPM: engine is not running
(CAN/J1939) (IM1q,r,s) > 300 RPM for 4 seconds: engine is running
Fault(s): A184
70
40 Troubleshooting CEN40180-02
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Parking Brake Set Refer to 58D-06-01711, Sheet 14, zones F9 through F16 730E
Pressure Switch Refer to 58E-06-02311, sheet 15, zones F10 through F16 830E
connection to IM Refer to 58E-06-02321, sheet 5, zone C8
Refer to 58F-06-02311, Sheet 15, zone F10 to F16 930E
Refer to 58F-06-10561, Sheet 5, zone C8
Refer to 58B-06-02390, Sheet 16, zone F10 to F16 980E
Refer to 58B-06-03570, Sheet 5, zone C8
Parking Brake Release Refer to 58D-06-01711, Sheet 3, zones G3 through H9 730E
Pressure Switch to IM Refer to 58E-06-02311, sheet 5, zones H3 through H9 830E
Refer to 58E-06-02321, sheet 5, zone C9
Refer to 58F-06-02311, Sheet 5, zones H5 through H14 930E
Refer to 58F-06-10561, Sheet 5, zone C9
Refer to 58B-06-02390, Sheet 5, zones H6 through H20 980E
Refer to 58B-06-03570, Sheet 5, zone C9
Keyswitch Direct Refer to 58D-06-01711, Sheet 3, zone E7 730E
connection at Refer to 58E-06-02311, sheet 5, zone E9 830E
Keyswitch Refer to 58E-06-02321, sheet 4, zone E1
Refer to 58F-06-02311, Sheet 5, zone E9 930E
Refer to 58F-06-10561, Sheet 4, zone E1
Refer to 58B-06-02390, Sheet 5, zone E9 980E
Refer to 58B-06-03570, Sheet 4, zone E1
71
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Keyswitch Direct Refer to 58D-06-01711, Sheet 3, zone J4 730E
connection at IM Refer to 58E-06-02311, sheet 5, zone J4 830E
Refer to 58E-06-02321, sheet 4, zone E1
Refer to 58F-06-02311, Sheet 5, zone J4 930E
Refer to 58F-06-10561, Sheet 4, zone E1
Refer to 58B-06-02390, Sheet 5, zone J7 980E
Refer to 58B-06-03570, Sheet 4, zone E1
Engine Shutdown Refer to 58D-06-01711, Sheet 5, zone D2 730E
Delay at Engine Refer to 58E-06-02311, sheet 7, zone D2 830E
Refer to 58E-06-02321, sheet 12, zone F1
Refer to 58F-06-02311, Sheet 7, zone D2 930E
Refer to 58F-06-10561, Sheet 12, zone F1
Refer to 58B-06-02390, Sheet 7, zone D2 980E
Refer to 58B-06-03570, Sheet 12, zone F1
Engine Shutdown Refer to 58D-06-01711, Sheet 3, zone I4 730E
Delay at IM Refer to 58E-06-02311, sheet 5, zone I4 830E
Refer to 58E-06-02321, sheet 12, zone D1
Refer to 58F-06-02311, Sheet 5, zone I4 930E
Refer to 58F-06-10561, Sheet 12, zone D1
Refer to 58B-06-02390, Sheet 5, zone I7 980E
Refer to 58B-06-03570, Sheet 14, zone D1
72
40 Troubleshooting CEN40180-02
Fault Code A284: Engine shutdown delay aborted; secondary shutdown switch operated
Operator Action None
Fault Code A284
Description An engine shutdown delay was aborted because the secondary shutdown switch was
operated.
Fault Conditions Sets if keyswitch is turned OFF and engine shutdown delay is on and engine is
running but secondary engine shutdown switch is operated.
Resets if keyswitch is turned back on, engine shutdown delay is off, and engine is
running.
Operator Alerting Repair Lamp
System Response Display Fault Description: NO SHT DWN DEL / SEC
Display Fault Code: A284
Resulting Problem(s) The engine can be damaged when shut down immediately, rather than in a controlled
delay.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The normal corrective measure for this fault is to shut down the engine with the keyswitch.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
3. Since there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Secondary Engine 0: Engine is being shut down by secondary switch.
Shutdown Switch 1: Engine is not being shut down by secondary switch.
(IM3E)
Keyswitch, Direct 0: Keyswitch is OFF.
(IM2P) 1: keyswitch is ON.
Fault(s): A240
Engine Shutdown 0: Engine shutdown delay signal is off.
Delay (IM3F) 1: Engine shutdown delay signal is on.
Fault(s): A283
Engine Speed [RPM] < 300 RPM: engine is not running
(CAN/J1939) (IM1q,r,s) > 300 RPM for 4 seconds: engine is running
Fault(s): A184
73
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Secondary Engine Refer to 58D-06-01711, Sheet 3, zone C16 730E
Shutdown Switch Refer to 58E-06-02311, sheet 5, zone D16 830E
Refer to 58E-06-02321, sheet 12, zone C1
Refer to 58F-06-02311, Sheet 5, zone D16 930E
Refer to 58F-06-10561, Sheet 12, zone C1
Refer to 58B-06-02390, Sheet 5, zone C16 980E
Refer to 58B-06-03570, Sheet 14, zone C1
Secondary Engine Refer to 58D-06-01711, Sheet 3, zone H4 730E
Shutdown Switch at IM Refer to 58E-06-02311, sheet 5, zone H4 830E
Refer to 58E-06-02321, sheet 12, zone D1
Refer to 58F-06-02311, Sheet 5, zone H4 930E
Refer to 58F-06-10561, Sheet 12, zone D1
Refer to 58B-06-02390, Sheet 5, zone H7 980E
Refer to 58B-06-03570, Sheet 14, zone D1
Keyswitch Direct Refer to 58D-06-01711, Sheet 3, zone E7 730E
connection at Refer to 58E-06-02311, sheet 5, zone E9 830E
Keyswitch Refer to 58E-06-02321, sheet 4, zone E1
Refer to 58F-06-02311, Sheet 5, zone E9 930E
Refer to 58F-06-10561, Sheet 4, zone E1
Refer to 58B-06-02390, Sheet 5, zone E9 980E
Refer to 58B-06-03570, Sheet 4, zone E1
74
40 Troubleshooting CEN40180-02
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Keyswitch Direct Refer to 58D-06-01711, Sheet 3, zone J4 730E
connection at IM Refer to 58E-06-02311, sheet 5, zone J4 830E
Refer to 58E-06-02321, sheet 4, zone E1
Refer to 58F-06-02311, Sheet 5, zone J4 930E
Refer to 58F-06-10561, Sheet 4, zone E1
Refer to 58B-06-02390, Sheet 5, zone J7 980E
Refer to 58B-06-03570, Sheet 4, zone E1
Engine Shutdown Refer to 58D-06-01711, Sheet 5, zone D2 730E
Delay at engine Refer to 58E-06-02311, sheet 7, zone D2 830E
Refer to 58E-06-02321, sheet 12, zone F1
Refer to 58F-06-02311, Sheet 7, zone D2 930E
Refer to 58F-06-10561, Sheet 12, zone F1
Refer to 58B-06-02390, Sheet 7, zone D2 980E
Refer to 58B-06-03570, Sheet 12, zone F1
Engine Shutdown Refer to 58D-06-01711, Sheet 3, zone I4 730E
Delay at IM Refer to 58E-06-02311, sheet 5, zone I4 830E
Refer to 58E-06-02321, sheet 12, zone D1
Refer to 58F-06-02311, Sheet 5, zone I4 930E
Refer to 58F-06-10561, Sheet 12, zone D1
Refer to 58B-06-02390, Sheet 5, zone I7 980E
Refer to 58B-06-03570, Sheet 14, zone D1
75
CEN40180-02 40 Troubleshooting
NOTES
76
40 Troubleshooting CEN40180-02
Fault Code A285: The parking brake was not set when the keyswitch was turned off
Operator Action Set parking brake
Fault Code A285
Description The parking brake was not set when the keyswitch was turned off.
Fault Conditions Sets if parking brake is not already set when keyswitch is turned OFF. (Parking brake
set is defined as closure of the parking brake set pressure switch and opening of the
parking brake release pressure switch.)
Resets if parking brake is set or if keyswitch is turned back ON.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: SET PARK BRAKE
Display Fault Description: PRK BRK SETTINGS ERR
Display Fault Code: A285
Resulting Problem(s) Truck could roll away if parking brake is not set at shutdown.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The normal corrective measure for this fault is to set the parking brake before turning off the engine start
switch.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
3. Since there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Keyswitch, Direct 0: Keyswitch is OFF.
(IM2P) 1: keyswitch is ON.
Fault(s): A240
Parking Brake Set 0: Parking brake pressure switch indicates low pressure and an applied parking brake.
(IM2f) 1: Parking brake pressure switch indicates high pressure and a released parking
brake.
Fault(s): A213
Parking Brake 0: Parking brake pressure switch indicates high pressure and a released parking.
Released (IM2M) brake
1: Parking brake pressure switch indicates low pressure and an applied parking brake.
Fault(s): A214
77
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Parking Brake Set Refer to 58D-06-01711, Sheet 14, zones F9 through F16 730E
Pressure Switch Refer to 58E-06-02311, sheet 15, zones F10 through F16 830E
connection to IM Refer to 58E-06-02321, sheet 5, zone C8
Refer to 58F-06-02311, Sheet 15, zone F10 to F16 930E
Refer to 58F-06-10561, Sheet 5, zone C8
Refer to 58B-06-02390, Sheet 16, zone F10 to F16 980E
Refer to 58B-06-03570, Sheet 5, zone C8
Parking Brake Release Refer to 58D-06-01711, Sheet 3, zones G3 through H9 730E
Pressure Switch to IM Refer to 58E-06-02311, sheet 5, zones H3 through H9 830E
Refer to 58E-06-02321, sheet 5, zone C9
Refer to 58F-06-02311, Sheet 5, zones H5 through H14 930E
Refer to 58F-06-10561, Sheet 5, zone C9
Refer to 58B-06-02390, Sheet 5, zones H6 through H20 980E
Refer to 58B-06-03570, Sheet 5, zone C9
Keyswitch Direct Refer to 58D-06-01711, Sheet 3, zone E7 730E
connection at Refer to 58E-06-02311, sheet 5, zone E9 830E
Keyswitch Refer to 58E-06-02321, sheet 4, zone E1
Refer to 58F-06-02311, Sheet 5, zone E9 930E
Refer to 58F-06-10561, Sheet 4, zone E1
Refer to 58B-06-02390, Sheet 5, zone E9 980E
Refer to 58B-06-03570, Sheet 4, zone E1
Keyswitch Direct Refer to 58D-06-01711, Sheet 3, zone J4 730E
connection at IM Refer to 58E-06-02311, sheet 5, zone J4 830E
Refer to 58E-06-02321, sheet 4, zone E1
Refer to 58F-06-02311, Sheet 5, zone J4 930E
Refer to 58F-06-10561, Sheet 4, zone E1
Refer to 58B-06-02390, Sheet 5, zone J7 980E
Refer to 58B-06-03570, Sheet 4, zone E1
78
40 Troubleshooting CEN40180-02
Fault Code A286: A fault was detected in the shutdown delay relay circuit
Operator Action None
Fault Code A286
Description A fault was detected in the shutdown delay relay circuit.
Fault Conditions Sets if an open circuit or short to ground is detected in the relay driver circuit.
Resets only at power down.
Operator Alerting Repair Lamp
System Response Display Fault Description: SHT DWN DEL REL CKT
Display Fault Code: A286
Resulting Problem(s) A malfunctioning shutdown delay circuit could cause damage to the engine.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Shutdown Delay Relay Status - Open Load: Unexpected. Troubleshoot
(IM1H) Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0. Turns off when conditions clear or engine speed drops to zero.
1: Turns on when Keyswitch, Direct is off, Engine Shutdown Delay is on, Parking
brake is set, Selector Switch is in park, but not J1939 Not Connected, not High Batt
Charge Voltage, not Starter Stuck On, not Active Engine Red Light, and engine speed
above 300 rpm.
Fault(s): A292
Keyswitch, Direct 0: Keyswitch is OFF.
(IM2P) 1: keyswitch is ON.
Fault(s): A240
79
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Delayed Shutdown Refer to 58D-06-01711, Sheet 3, zone D9 730E
Relay Refer to 58E-06-02311, sheet 5, zone D10 830E
Refer to 58E-06-02321, sheet 4, zone E2
Refer to 58F-06-02311, Sheet 5, zone D10 930E
Refer to 58F-06-10561, Sheet 4, zone E2
Refer to 58B-06-02390, Sheet 5, zone D10 980E
Refer to 58B-06-03570, Sheet 4, zone E2
Delayed Shutdown Refer to 58D-06-01711, Sheet 3, zone I4 730E
Relay connection at IM Refer to 58E-06-02311, sheet 5, zone I4 830E
Refer to 58E-06-02321, sheet 4, zone F2
Refer to 58F-06-02311, Sheet 5, zone I4 930E
Refer to 58F-06-10561, Sheet 4, zone F2
Refer to 58B-06-02390, Sheet 5, zone I6 980E
Refer to 58B-06-03570, Sheet 4, zone F2
Keyswitch Direct Refer to 58D-06-01711, Sheet 3, zone E7 730E
connection at Refer to 58E-06-02311, sheet 5, zone E9 830E
Keyswitch Refer to 58E-06-02321, sheet 4, zone E1
Refer to 58F-06-02311, Sheet 5, zone E9 930E
Refer to 58F-06-10561, Sheet 4, zone E1
Refer to 58B-06-02390, Sheet 5, zone E9 980E
Refer to 58B-06-03570, Sheet 4, zone E1
Keyswitch Direct Refer to 58D-06-01711, Sheet 3, zone J4 730E
connection at IM Refer to 58E-06-02311, sheet 5, zone J4 830E
Refer to 58E-06-02321, sheet 4, zone E1
Refer to 58F-06-02311, Sheet 5, zone J4 930E
Refer to 58F-06-10561, Sheet 4, zone E1
Refer to 58B-06-02390, Sheet 5, zone J7 980E
Refer to 58B-06-03570, Sheet 4, zone E1
80
40 Troubleshooting CEN40180-02
Fault Code A292: Shutdown delay relay stays on after latched key switch circuit is off
Operator Action None
Fault Code A292
Description The shutdown delay relay has remained on after the latched engine start switch circuit
is off.
Fault Conditions Sets if the shutdown relay is still on after the latched engine start switch circuit is off
(GE latches the circuit until the truck and engine have stopped completely).
Resets if engine start switch is turned back on or shutdown delay relay turns off.
Operator Alerting Repair Lamp
System Response Display Fault Description: SHT DWN DEL REL FLT
Display Fault Code: A292
Resulting Problem(s) A malfunctioning shutdown delay circuit could cause damage to the engine.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes, then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved, then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Engine Shutdown 0: Engine shutdown delay signal is off.
Delay (IM3F) 1: Engine shutdown delay signal is on.
Fault(s): A283
Shutdown Delay Relay Status - Open Load: Unexpected. Troubleshoot
(IM1H) Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: Turns off when conditions clear or engine speed drops to 0.
1: Turns on when Keyswitch, Direct is off, engine shutdown delay is on, parking brake
is set, shift lever is in Park, but not J1939 not connected, not high battery charge
voltage, not starter stuck on, not active engine red light, and engine speed above 300
rpm.
Fault(s): A286
Keyswitch (IM3G) 0: Keyswitch is OFF and the truck is not moving and the engine is not running.
1: Keyswitch is ON or the truck is moving (GE power not yet off).
Fault(s): A240
81
CEN40180-02 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Keyswitch, OR Refer to 58D-06-01711, Sheet 14, zones D9 through D19 730E
connection to IM Refer to 58E-06-02311, sheet 15, zones D10 through D19 830E
Refer to 58E-06-02321, sheet 31, zones B8 through B10
Refer to 58F-06-02311, Sheet 15, zones D10 through D19 930E
Refer to 58F-06-10561, Sheet 31, zones B8 through B10
Refer to 58B-06-02390, Sheet 16, zones D10 through D19 980E
Refer to 58B-06-03570, Sheet 33, zones B9 through B10
Delayed Shutdown Refer to 58D-06-01711, Sheet 3, zone D9 730E
Relay Refer to 58E-06-02311, sheet 5, zone D10 830E
Refer to 58E-06-02321, sheet 4, zone E2
Refer to 58F-06-02311, Sheet 5, zone D10 930E
Refer to 58F-06-10561, Sheet 4, zone E2
Refer to 58B-06-02390, Sheet 5, zone D10 980E
Refer to 58B-06-03570, Sheet 4, zone E2
Delayed Shutdown Refer to 58D-06-01711, Sheet 3, zone I4 730E
Relay connection at IM Refer to 58E-06-02311, sheet 5, zone I4 830E
Refer to 58E-06-02321, sheet 4, zone F2
Refer to 58F-06-02311, Sheet 5, zone I4 930E
Refer to 58F-06-10561, Sheet 4, zone F2
Refer to 58B-06-02390, Sheet 5, zone I6 980E
Refer to 58B-06-03570, Sheet 4, zone F2
Engine Shutdown Refer to 58D-06-01711, Sheet 5, zone D2 730E
Delay at engine Refer to 58E-06-02311, sheet 7, zone D2 830E
Refer to 58E-06-02321, sheet 12, zone F1
Refer to 58F-06-02311, Sheet 7, zone D2 930E
Refer to 58F-06-10561, Sheet 12, zone F1
Refer to 58B-06-02390, Sheet 7, zone D2 980E
Refer to 58B-06-03570, Sheet 12, zone F1
Engine Shutdown Refer to 58D-06-01711, Sheet 3, zone I4 730E
Delay at IM Refer to 58E-06-02311, sheet 5, zone I4 830E
Refer to 58E-06-02321, sheet 12, zone D1
Refer to 58F-06-02311, Sheet 5, zone I4 930E
Refer to 58F-06-10561, Sheet 12, zone D1
Refer to 58B-06-02390, Sheet 5, zone I7 980E
Refer to 58B-06-03570, Sheet 14, zone D1
82
40 Troubleshooting CEN40180-02
NOTES
83
CEN40180-02 40 Troubleshooting
730E Dump truck
830E Dump truck
930E Dump truck
980E Dump truck
Form No. CEN40180-02
84
CEN40181-03
DUMP TRUCK
730E
830E
930E
980E
Machine model Serial number
730E-10 A50002 and up
830E-5 A50005 and up
830E-5AT A50005 and up
930E-5 A40004 and up
930E-5AT A40004 and up
980E-5 A50005 and up
980E-5AT A50005 and up
40 Troubleshooting
Troubleshooting by fault code, part 4
Fault Code A303: Shift lever is defective .............................................................................................................. 4
Fault Code A304: Auto lube grease level fault...................................................................................................... 6
Fault Code A305: Auto lube circuit is defective ................................................................................................... 7
Fault Code A307: Both GE inverters are disabled ................................................................................................ 8
Fault Code A309: No brakes applied when expected ......................................................................................... 10
Fault Code A310: Low fuel warning .................................................................................................................... 12
Fault Code A311: Brake lock switch is on when it should not be ........................................................................ 14
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings ...................................... 16
Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings ...................................... 17
Fault Code A315: DCDC converter 12 volt circuit is low..................................................................................... 18
Fault Code A316: Starter engagement has been attempted with engine running .............................................. 20
Fault Code A317: Operation of brake auto apply circuit without a detected response ....................................... 22
Fault Code A318: Unexpected power loss to interface module .......................................................................... 24
Fault Code A328: Drive system not powered up ................................................................................................ 25
Fault Code A332: Seat belt not buckled ............................................................................................................. 26
1
CEN40181-03 40 Troubleshooting
Fault Code A333: The hydraulic ladder controller has declared a ladder fault ................................................... 28
Fault Code A334: Shift lever not in park when propel was either not ready or at rest ........................................ 30
Fault Code A335: Manual/Auto Apply Pressure Fault......................................................................................... 32
Fault Code A337: Engine Air Filter Circuit Fault ................................................................................................. 33
Fault Code A338: Engine Air Filter Fault............................................................................................................. 34
Fault Code A339: The DEF level gauge in the display panel is defective........................................................... 35
Fault Code A340: The shifter controller has declared a fault .............................................................................. 36
Fault Code A341: The shifter control circuit is defective ..................................................................................... 37
Fault Code A342: The Accessory Pump Filter Switch has actuated................................................................... 39
Fault Code A343: Truck speed is limited by GE.................................................................................................. 40
Fault Code A344: GE has posted a No Retarding fault ...................................................................................... 41
Fault Code A345: Engine speed limited by GE................................................................................................... 42
Fault Code A346: Delayed Shut Down by GE .................................................................................................... 43
Fault Code A347: Operator Override of GE is active .......................................................................................... 44
Fault Code A348: GE has disabled load box operation ...................................................................................... 45
Fault Code A349: GE has limited load box operation ......................................................................................... 46
Fault Code A350: Overload on output 1B ........................................................................................................... 47
Fault Code A351: Overload on output 1E ........................................................................................................... 49
Fault Code A352: Overload on output 1H ........................................................................................................... 51
Fault Code A353: Overload on output 1J............................................................................................................ 53
Fault Code A354: Overload on output 1K ........................................................................................................... 55
Fault Code A355: Overload on output 1L............................................................................................................ 56
Fault Code A356: Overload on output 1M........................................................................................................... 57
Fault Code A357: Overload on output 1N ........................................................................................................... 59
Fault Code A358: Overload on output 1P ........................................................................................................... 61
Fault Code A359: Overload on output 1R ........................................................................................................... 63
Fault Code A360: Overload on output 1S ........................................................................................................... 65
Fault Code A361: Overload on output 1T ........................................................................................................... 66
Fault Code A362: Overload on output 1U ........................................................................................................... 67
Fault Code A363: Overload on output 1X ........................................................................................................... 68
Fault Code A364: Overload on output 1Y ........................................................................................................... 69
Fault Code A365: Overload on output 1Z ........................................................................................................... 70
Fault Code A366: Axle box cooling fault ............................................................................................................. 71
2
40 Troubleshooting CEN40181-03
NOTES
3
CEN40181-03 40 Troubleshooting
Fault Code A303: Shift lever is defective
Operator Action Stop; Park; Power Down
Fault Code A303
Description Shift lever is defective.
Fault Conditions Sets if selector switch (FNR) and selector switch (Park) operate simultaneously for 1
second.
Resets if conditions change for 1 second.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: SHIFTER DEFECTIVE
Display Fault Code: A303
Resulting Problem(s) Control of truck and parking brake will be defective.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Selector Switch (Park) 0: Shift lever is not in Park.
(IM3T) 1: Shift lever is in Park.
Fault(s): A271
Selector Switch (FNR) 0: Shift lever is not in Forward, Neutral, or Reverse.
(IM2N) 1: Shift lever is in Forward, Neutral, or Reverse.
Fault(s): A271
4
40 Troubleshooting CEN40181-03
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Selector Switch Refer to 58D-06-01711, Sheet 8, zones H12 through H16 730E
Refer to 58E-06-02311, Sheet 9, zones H12 through H16 830E
Refer to 58E-06-02321, Sheet 17, zones A1 through B1
Refer to 58F-06-02311, Sheet 9, zones H12 through H16 930E
Refer to 58F-06-10561, Sheet 27, zones A1 through B1
Refer to 58B-06-02390, Sheet 10, zones H13 through H16 980E
Refer to 58B-06-03570, Sheet 29, zones A1 through B1
Selector Switch Refer to 58D-06-01711, Sheet 8, zones J16 through L17 730E
connections at IM Refer to 58E-06-02311, Sheet 9, zones J16 through L17 830E
Refer to 58E-06-02321, Sheet 17, zone C2
Refer to 58F-06-02311, Sheet 9, zones J16 through L17 930E
Refer to 58F-06-10561, Sheet 27, zone C2
Refer to 58B-06-02390, Sheet 10, zones I16 through K17 980E
Refer to 58B-06-03570, Sheet 29, zone C2
5
CEN40181-03 40 Troubleshooting
Fault Code A304: Auto lube grease level fault
Operator Action None
Fault Code A304
Description Low auto lube grease level is detected.
Fault Conditions Sets when input switch indicates low grease level for 3 seconds.
Resets when input switch indicates normal grease level for 3 seconds.
Operator Alerting Repair Lamp
System Response Display Fault Description: AUTO LUBE GREASE LO
Display Fault Code: A304
Resulting Problem(s) Auto lubrication will not be completed without grease.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to replenish the grease.
2. If plenty of grease exists, then check sensor and wiring.
Parameter Expected State and/or Related Fault(s)
Auto Lube Grease 0: Auto lube grease level is low.
Level Low Input 1: Auto lube grease level is not low.
(IM3W)
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Grease Level Switch Refer to 58D-06-01711, Sheet 14, zones O9 through P20 730E
connection to IM Refer to 58E-06-02311, sheet 15, zones O10 through P18 830E
Refer to 58E-06-02321, sheet 2, zone C3
Refer to 58F-06-02311, Sheet 15, zones O10 through P18 930E
Refer to 58F-06-10561, Sheet 2, zone C3
Refer to 58B-06-02390, Sheet 16, zones N10 through O18 980E
Refer to 58B-06-03570, Sheet 2, zone C3
6
40 Troubleshooting CEN40181-03
Fault Code A305: Auto lube circuit is defective
Operator Action None
Fault Code A305
Description Auto lube circuit is defective.
Fault Conditions Sets if solenoid sense occurs with lube output off, or does not occur with lube output
on, or pressure switch stays on, or circuit is open or short to ground, any of those for 5
seconds with GE control power on.
Resets at power down.
Operator Alerting Repair Lamp
System Response Display Fault Description: AUTO LUBE CIRCUIT
Display Fault Code: A305
Resulting Problem(s) Automatic lubrication may not work.
Related Information A laptop running "IM Realtime Data Monitor" software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes, then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved, then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Auto Lube Output Status - Open Load: Unexpected. Troubleshoot
(IM1T) Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected except momentarily at termination of a lube
cycle. If detected any other time, troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: Turns off between lubrication cycles.
1: Turns on during lubrication cycle.
Fault(s): A361
Auto Lube Pressure 0: Pressure switch has transferred at 2000 psi
Sw (IM3Y) 1: Pressure switch at low pressure or solenoid circuit not on
Fault(s): A361
Auto Lube Solenoid 0: Auto lube solenoid is energized
Sense (IM3X) 1: Auto lube solenoid is not energized
GE Control Power 0: GE control power is off and the truck is not moving
(IM3M) 1: GE control power is on or the truck is moving
Related Circuit Diagram
Circuit Description Circuit Reference
None None
7
CEN40181-03 40 Troubleshooting
Fault Code A307: Both GE inverters are disabled
Operator Action Stop; Park
Fault Code A307
Description Both GE inverters are disabled.
Fault Conditions Sets if both inverters are reported to be disabled by GE via CAN/RPC while CAN/RPC
is working.
Resets if condition changes for 2 seconds.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: STOP: PARK
Display Fault Description: GE INV1 & INV2 DISABL
Display Fault Code: A307
Resulting Problem(s) Truck will not operate in propel or retard.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to troubleshoot the GE drive system to determine why the inverters
have been shut off.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
GE INV1 Disabled - 0: INV1 not disabled
CAN/RPC Input 1: INV1 disabled
(IM1I,j,k) Fault(s): A233
GE INV2 Disabled - 0: INV2 not disabled
CAN/RPC Input 1: INV2 disabled
(IM1I,J,K) Fault(s): A233
Truck Speed - CAN/ 0: No speed message received
RPC ok 1: Speed message received
Fault(s): A233
Related Circuit Diagram
Circuit Description Circuit Reference
None None
8
40 Troubleshooting CEN40181-03
NOTES
9
CEN40181-03 40 Troubleshooting
Fault Code A309: No brakes applied when expected
Operator Action Apply brake or travel
Fault Code A309
Description No brakes applied when expected.
Fault Conditions Sets if truck speed is 0, parking brake is not set, service brake is not set, and engine is
running for 2 seconds.
Parking brake set is defined as closure of the parking brake set pressure switch and
opening of the parking brake release pressure switch.
Resets if conditions change for 2 seconds.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: APPLY BRK OR TRAVEL
Display Fault Description: NO BRAKES SET
Display Fault Code: A309
Resulting Problem(s) No brakes set may let truck roll away.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Parking Brake Set 0: parking brake pressure switch indicating low pressure and an applied parking brake
(IM2f) 1: parking brake pressure switch indicating higher pressure and an unapplied parking
brake
Fault(s): A213
Parking Brake 0: Parking brake pressure switch indicates high pressure and a released parking
Released (IM2M) brake.
1: Parking brake pressure switch indicates low pressure and an applied parking brake.
Fault(s): A214
Service Brake 0: Service brake not applied
Pressure Switch 1: Service brake applied
(IM3C) Fault(s): A265, A274, A309
Truck Speed [kph] 0: truck is not moving
(CAN/RPC) (IM1i,j,k) > 0: truck is moving
Fault(s): A233
Engine Speed [RPM] < 300 RPM: engine is not running
(CAN/J1939) (IM1q,r,s) > 300 RPM for 4 seconds: engine is running
Fault(s): A184
10
40 Troubleshooting CEN40181-03
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Parking Brake Set Refer to 58D-06-01711, Sheet 14, zones F10 through F16 730E
Pressure Switch Refer to 58E-06-02311, sheet 15, zones F10 through F16 830E
connection to IM Refer to 58E-06-02321, sheet 5, zone C8
Refer to 58F-06-02311, Sheet 15, zone F10 to F16 930E
Refer to 58F-06-10561, Sheet 5, zone C8
Refer to 58B-06-02390, Sheet 16, zone F10 to F16 980E
Refer to 58B-06-03570, Sheet 5, zone C8
Parking Brake Release Refer to 58D-06-01711, Sheet 3, zones G3 through H9 730E
Pressure Switch to IM Refer to 58E-06-02311, sheet 5, zones H3 through H9 830E
Refer to 58E-06-02321, sheet 5, zone C9
Refer to 58F-06-02311, Sheet 5, zones H5 through H14 930E
Refer to 58F-06-10561, Sheet 5, zone C9
Refer to 58B-06-02390, Sheet 5, zones H6 through H20 980E
Refer to 58B-06-03570, Sheet 5, zone C9
Service Brake Refer to 58D-06-01711, Sheet 8, zones I16 730E
Pressure Switch Refer to 58E-06-02311, sheet 9, zones J16 through L17 830E
connection to IM Refer to 58E-06-02321, sheet 5, zones D1 through E1
Refer to 58F-06-02311, Sheet 9, zones J16 through L17 930E
Refer to 58F-06-10561, Sheet 5, zones D1 through E1
Refer to 58B-06-02390, Sheet 10, zone I16 980E
Refer to 58B-06-03570, Sheet 5, zones D1 through E1
11
CEN40181-03 40 Troubleshooting
Fault Code A310: Low fuel warning
Operator Action Refuel Soon
Fault Code A310
Description This is a low fuel warning driver that activates display elements in response to A139.
Fault Conditions A310 sets if A139 is on. It stays on for 3.3 seconds to flash the lamp and buzzer, then
waits 15 minutes before trying again.
Operator Alerting Sound Buzzer
System Response Operate IM Warning Indicator
Display Operator Action: REFUEL SOON
Display Fault Description: LOW FUEL LEVEL
Display Fault Code: A310
Resulting Problem(s) Possible running out of fuel on haul road. Possible engine damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to add fuel to the tank.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes, then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved, then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Fuel Level Sensor 0.57 to 8.2 Volts: Good readings at 24 volt battery (varies with battery voltage)
(IM3g) <0.57 or >8.2 Volts: Defective sensor or circuit at 24 volt battery (varies with battery
voltage)
Fault(s): A105, A158
Battery Voltage, >18 Volt: Good reading
24 Volt (IM1A) <18 Volt: Low battery voltage (while cranking) blocks this fault code.
Keyswitch (IM3G) 0: Keyswitch is OFF and the truck is not moving and the engine is not running.
1: Keyswitch is ON or the truck is moving (GE power not yet off).
Fault(s): A240
Engine Speed [RPM] < 600 RPM: Combined with low voltage means cranking is in process and fault is
blocked.
> 300 RPM for 4 seconds: Engine is running.
12
40 Troubleshooting CEN40181-03
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Keyswitch, OR Refer to 58D-06-01711, Sheet 14, zones D9 through D19 730E
connection to IM Refer to 58E-06-02311, sheet 15, zones D10 through D19 830E
Refer to 58E-06-02321, sheet 31, zones B8 through B10
Refer to 58F-06-02311, Sheet 15, zones D10 through D19 930E
Refer to 58F-06-10561, Sheet 31, zones B8 through B10
Refer to 58B-06-02390, Sheet 16, zones D10 through D19 980E
Refer to 58B-06-03570, Sheet 33, zones B9 through B10
Fuel Level Sensor Refer to 58D-06-01711, Sheet 14, zones D9 through D22 730E
circuit Refer to 58E-06-02311, sheet 15, zones D10 through D22 830E
Refer to 58E-06-02321, sheet 31, zones B8 through B10
Refer to 58F-06-02311, Sheet 15, zones D10 through D22 930E
Refer to 58F-06-10561, Sheet 31, zones B8 through B10
Refer to 58B-06-02390, Sheet 16, zones C9 through D22 980E
Refer to 58B-06-03570, Sheet 33, zones B9 through B10
Battery Supply Voltage Refer to 58D-06-01711, Sheet 3, zones L4 through L15 730E
to IM Refer to 58E-06-02311, sheet 5, zones L4 through L15 830E
Refer to 58E-06-02321, sheet 18, zones A9 through B9
Refer to 58F-06-02311, Sheet 5, zones L4 through L15 930E
Refer to 58F-06-10561, Sheet 18, zones A9 through B9
Refer to 58B-06-02390, Sheet 5, zones L6 through L14 980E
Refer to 58B-06-03570, Sheet 20, zones A9 through B9
13
CEN40181-03 40 Troubleshooting
Fault Code A311: Brake lock switch is on when it should not be
Operator Action Turn Off Brake Lock Switch
Fault Code A311
Description Brake lock switch is on when it should not be.
Fault Conditions Sets if parking brake is set and brake lock is on.
Parking brake set is defined as closure of the parking brake set pressure switch and
opening of the parking brake release pressure switch.
Resets when conditions clear for 2 seconds.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: TURN OFF BRK LOC SW
Display Fault Description: BRK LOC & PRK BRK ON
Display Fault Code: A311
Resulting Problem(s) The roll away protection of the braking systems could be defeated by improper
operation.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Parking Brake Set 0: Parking brake pressure switch indicates low pressure and an applied parking brake.
(IM2f) 1: Parking brake pressure switch indicates high pressure and a released parking
brake.
Fault(s): A213
Parking Brake 0: Parking brake pressure switch indicates high pressure and a released parking
Released (IM2M) brake.
1: Parking brake pressure switch indicates low pressure and an applied parking brake.
Fault(s): A214
Brake Lock (IM2i) 0: Brake lock not on.
1: Brake lock is on.
Fault(s): A272
14
40 Troubleshooting CEN40181-03
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Parking Brake Set Refer to 58D-06-01711, Sheet 14, zones F9 through F16 730E
Pressure Switch Refer to 58E-06-02311, sheet 15, zones F10 through F16 830E
connection to IM Refer to 58E-06-02321, sheet 5, zone C8
Refer to 58F-06-02311, Sheet 15, zone F10 to F16 930E
Refer to 58F-06-10561, Sheet 5, zone C8
Refer to 58B-06-02390, Sheet 16, zone F10 to F16 980E
Refer to 58B-06-03570, Sheet 5, zone C8
Parking Brake Release Refer to 58D-06-01711, Sheet 3, zones G3 through H9 730E
Pressure Switch to IM Refer to 58E-06-02311, sheet 5, zones H3 through H9 830E
Refer to 58E-06-02321, sheet 5, zone C9
Refer to 58F-06-02311, Sheet 5, zones H5 through H14 930E
Refer to 58F-06-10561, Sheet 5, zone C9
Refer to 58B-06-02390, Sheet 5, zones H6 through H20 980E
Refer to 58B-06-03570, Sheet 5, zone C9
Brake Lock connection Refer to 58D-06-01711, Sheet 8, zones L11 through M17 730E
to IM Refer to 58E-06-02311, sheet 9, zones M11 through M17 830E
Refer to 58E-06-02321, sheet 5, zone C4
Refer to 58F-06-02311, Sheet 9, zones M11 through N17 930E
Refer to 58F-06-10561, Sheet 5, zone C4
Refer to 58B-06-02390, Sheet 10, zones M11 through N17 980E
Refer to 58B-06-03570, Sheet 5, zone C4
15
CEN40181-03 40 Troubleshooting
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings
Operator Action None
Fault Code A312
Description The 24VDC to 12VDC converter 12 volt circuit sensing is producing low readings.
Fault Conditions Sets if voltage at 12 volt input drops to 0.2 volts for 3 seconds.
Resets if voltage at 12 volt input rises to 0.8 volts for 3 seconds.
Operator Alerting Repair Lamp
System Response Display Fault Description: DCDC 12V SENSE LOW
Display Fault Code: A312
Resulting Problem(s) Monitoring is lost for the 12 volt output of the DCDC Converter.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring to the 12 volt input.
Parameter Expected State and/or Related Fault(s)
DCDC Converter, 0.2 volts to 16.1 volts: Normal measurement range.
12 Volt (IM3h) < 0.2 or > 16.1: Bad sensing circuit or external connection.
Fault(s): A315
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
DCDC Converter Refer to 58D-06-01711, Sheet 4, zone D5 730E
connections Refer to 58E-06-02311, sheet 6, zone D5 830E
Refer to 58E-06-02321, sheet 4, zone D6
Refer to 58F-06-02311, Sheet 6, zone D5 930E
Refer to 58F-06-10561, Sheet 4, zone D6
Refer to 58B-06-02390, Sheet 6, zone I4 980E
Refer to 58B-06-03570, Sheet 4, zone D6
12 Volt connection at Refer to 58D-06-01711, Sheet 4, zone B3 730E
IM Refer to 58E-06-02311, sheet 6, zone B3 830E
Refer to 58E-06-02321, sheet 4, zone E6
Refer to 58F-06-02311, Sheet 6, zone B3 930E
Refer to 58F-06-10561, Sheet 4, zone E6
Refer to 58B-06-02390, Sheet 6, zone H2 980E
Refer to 58B-06-03570, Sheet 4, zone E6
16
40 Troubleshooting CEN40181-03
Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings
Operator Action None
Fault Code A313
Description The 24VDC to 12VDC converter 12 volt circuit sensing is producing high readings.
Fault Conditions Sets if voltage at 12 volt input rises to 16.1 volts for 3 seconds.
Resets if voltage at 12 volt input drops to 15.5 volts for 3 seconds.
Operator Alerting Repair Lamp
System Response Display Fault Description: DCDC 12V SENSE HIGH
Display Fault Code: A313
Resulting Problem(s) Monitoring is lost for the 12 volt output.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to correct any external wiring to the 12 volt input.
Parameter Expected State and/or Related Fault(s)
DCDC Converter, 0.2 volt to 16.1 volts: Normal measurement range
12 Volt (IM3h) <0.2 volt or >16.1 volts: Bad sensing circuit or external connection
Fault(s): A314
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
DCDC Converter Refer to 58D-06-01711, Sheet 4, zone D5 730E
connections Refer to 58E-06-02311, sheet 6, zone D5 830E
Refer to 58E-06-02321, sheet 4, zone D6
Refer to 58F-06-02311, Sheet 6, zone D5 930E
Refer to 58F-06-10561, Sheet 4, zone D6
Refer to 58B-06-02390, Sheet 6, zone I4 980E
Refer to 58B-06-03570, Sheet 4, zone D6
12 Volt connection at Refer to 58D-06-01711, Sheet 4, zone B3 730E
IM Refer to 58E-06-02311, sheet 6, zone B3 830E
Refer to 58E-06-02321, sheet 4, zone E6
Refer to 58F-06-02311, Sheet 6, zone B3 930E
Refer to 58F-06-10561, Sheet 4, zone E6
Refer to 58B-06-02390, Sheet 6, zone H2 980E
Refer to 58B-06-03570, Sheet 4, zone E6
17
CEN40181-03 40 Troubleshooting
Fault Code A315: DCDC converter 12 volt circuit is low
Operator Action None
Fault Code A315
Description The DCDC Converter 12 volt circuit is low.
Fault Conditions When engine is running and battery voltage is above 22, sets if voltage is below 12.5
volts or if battery voltage is below 22, sets if more than 1.5 volts below battery voltage
divided by 2.
Resets at power down only.
Operator Alerting Repair Lamp
System Response Display Fault Description: DCDC 12V LOW
Display Fault Code: A315
Resulting Problem(s) The 12 Volt DCDC Converter is putting out low voltage. Correction is required to
continue good performance in the 12 volt loads.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary correction for this fault is to eliminate any overload or replace the converter.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
DCDC Converter, <12.5 volts when battery voltage is >22 volts: Voltage is low.
12 Volt (IM3h) < (Batt Voltage / 2) - 1.5 volts: Voltage is low.
Otherwise: Voltage is normal.
Fault(s): A312
Battery Voltage, > 22 volts: 12 volt circuit should have normal readings
24 Volt (IM1A) < 22 volts: 12 volt circuit might have abnormal readings
Fault(s): A153, A154, A155, A250
Engine Speed [RPM] < 300 RPM: engine is not running
(CAN/J1939) (IM1q,r,s) > 300 RPM for 4 seconds: engine is running
Fault(s): A184
18
40 Troubleshooting CEN40181-03
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Battery Supply Voltage Refer to 58D-06-01711, Sheet 3, zones L4 through L15 730E
to IM Refer to 58E-06-02311, sheet 5, zones L4 through L15 830E
Refer to 58E-06-02321, sheet 18, zones A9 through B9
Refer to 58F-06-02311, Sheet 5, zones L4 through L15 930E
Refer to 58F-06-10561, Sheet 18, zones A9 through B9
Refer to 58B-06-02390, Sheet 5, zones L6 through L14 980E
Refer to 58B-06-03570, Sheet 20, zones A9 through B9
DCDC Converter Refer to 58D-06-01711, Sheet 4, zone D5 730E
connections Refer to 58E-06-02311, sheet 6, zone D5 830E
Refer to 58E-06-02321, sheet 4, zone D6
Refer to 58F-06-02311, Sheet 6, zone D5 930E
Refer to 58F-06-10561, Sheet 4, zone D6
Refer to 58B-06-02390, Sheet 6, zone I4 980E
Refer to 58B-06-03570, Sheet 4, zone D6
12 Volt connection at Refer to 58D-06-01711, Sheet 4, zone B3 730E
IM Refer to 58E-06-02311, sheet 6, zone B3 830E
Refer to 58E-06-02321, sheet 4, zone E6
Refer to 58F-06-02311, Sheet 6, zone B3 930E
Refer to 58F-06-10561, Sheet 4, zone E6
Refer to 58B-06-02390, Sheet 6, zone H2 980E
Refer to 58B-06-03570, Sheet 4, zone E6
19
CEN40181-03 40 Troubleshooting
Fault Code A316: Starter engagement has been attempted with engine running
Operator Action Do Not Crank
Fault Code A316
Description Starter engagement has been attempted with engine running.
Fault Conditions If not steering bleed, sets after 2 seconds if either starter engages with engine speed
above 500 rpm with crank sense on.
Resets after 2 seconds if conditions change.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: DO NOT CRANK
Display Fault Description: STARTER ENGAGE FLT
Display Fault Code: A316
Resulting Problem(s) Damage to starter and engine flywheel may occur.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The normal corrective measure for this fault is to not engage the starter with the engine already running.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Starter Motor 1 0: Starter motor 1 is not energized.
Energized (IM3R) 1: Starter motor 1 is energized.
Fault(s): A152, A275
Starter Motor 2 0: Starter motor 2 is not energized.
Energized (IM3S) 1: Starter motor 2 is energized.
Fault(s): A152, A275
Engine Speed [RPM] < 500 rpm: engine is not running
(CAN/J1939) (IM1q,r,s) > 500 rpm: engine is running
Fault(s): A184
Crank Sense (IM3U) 0: Cranking is not in process.
1: Cranking is in process.
Steering Bleed Valve 0: Steering bleed valve is off.
(IM1P) 1: Steering bleed valve is on.
Start Enable (IM1B) 0: One of several interlocking situations exist to prevent cranking (excessive cranking
history, selector switch in wrong position, engine red light, J1939 not OK, engine
speed either not 0 to begin cranking or over 400 rpm while cranking).
1. No interlocking situations exist to prevent cranking.
Fault(s): A252, A350
20
40 Troubleshooting CEN40181-03
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Starter Motors 1 and 2 Refer to 58D-06-01711, Sheet 2, zones K8 through L12 730E
Refer to 58E-06-02311, sheet 4, zones K10 through K12 830E
Refer to 58E-06-02321, sheet 4, zones C8 through C9
Refer to 58F-06-02311, Sheet 4, zones K10 through K12 930E
Refer to 58F-06-10561, Sheet 4, zones C8 through C9
Refer to 58B-06-02390, Sheet 4, zones K10 through K12 980E
Refer to 58B-06-03570, Sheet 4, zones C8 through C9
Starter Motor Refer to 58D-06-01711, Sheet 3, zones L4 through L7 730E
connections to IM Refer to 58E-06-02311, sheet 5, zones L4 through L7 830E
Refer to 58E-06-02321, sheet 4, zones C8 through C9
Refer to 58F-06-02311, Sheet 5, zones L4 through L7 930E
Refer to 58F-06-10561, Sheet 4, zones C8 through C9
Refer to 58B-06-02390, Sheet 5, zones K6 through K10 980E
Refer to 58B-06-03570, Sheet 4, zones C8 through C9
Crank Sense Refer to 58D-06-01711, Sheet 2, zones M9 through N19 and Sheet 4, 730E
connection to IM zones B2 through D4
Refer to 58E-06-02311, sheet 4, zones M9 through N19 and sheet 6, 830E
zones B2 through D4
Refer to 58E-06-02321, sheet 4, zones A7 through B7
Refer to 58F-06-02311, Sheet 4, zones M9 through N19 and Sheet 6, 930E
zones B2 through D4
Refer to 58F-06-10561, Sheet 4, zones A7 through B7
Refer to 58B-06-02390, Sheet 4, zones M9 through N19 and Sheet 6, 980E
zones H2 through H4
Refer to 58B-06-03570, Sheet 4, zones A7 through B7
Start Enable Circuit Refer to 58D-06-01711, Sheet 3, zones K4 through K15 730E
Refer to 58E-06-02311, sheet 5, zones K4 through K15 830E
Refer to 58E-06-02321, sheet 4, zones A7 through A9
Refer to 58F-06-02311, Sheet 5, zones K4 through K15 930E
Refer to 58F-06-10561, Sheet 4, zones A7 through A9
Refer to 58B-06-02390, Sheet 5, zones K7 through K15 980E
Refer to 58B-06-03570, Sheet 4, zones A7 through A9
21
CEN40181-03 40 Troubleshooting
Fault Code A317: Operation of brake auto apply circuit without a detected response
Operator Action Go to shop now
Fault Code A317
Description Operation of brake auto apply circuit without a detected response.
Fault Conditions Sets if operation of brake auto apply relay for 1 second does not cause the service
brake pressure switch to operate or the front brake pressure to increase.
Parking brake release is defined as the closure of the parking brake release pressure
switch and the opening of the parking brake set pressure switch.
Resets when parking brake is released for 5 seconds.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: BRK AUTO APPLY FLT
Display Fault Code: A317
Resulting Problem(s) Failure of brake auto apply circuit could cause damage to parking brake.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Auto Brake Apply Status - Open Load: Unexpected if parking brake request and keyswitch are on. But
Relay (IM1R) expected if parking brake request is off or keyswitch is off. Troubleshoot if
inconsistent.
Status - Normal: Expected if parking brake request and keyswitch are on.
Troubleshoot if status is normal with parking brake request off or keyswitch off.
Status - Shorted to ground: Unexpected. Troubleshoot
Status - Overload: Unexpected. Troubleshoot.
0: normal operation with parking brake either on or off. This valve operates only
transiently when the parking brake is turned on.
1: brake auto apply valve operates for 1.5 seconds after the parking brake is turned on
if the truck is stopped. If moving, it will not operate until truck speed has dropped to 0.8
kph(0.5 mph).
Fault(s): A215
Service Brake 0: Service brake not applied
Pressure Switch 1: Service brake applied
(IM3C)
22
40 Troubleshooting CEN40181-03
Parking Brake 0: parking brake pressure switch indicating high pressure and a released parking
Released (IM2M) brake
1: parking brake pressure switch indicating lower pressure and an applied parking
brake
Fault(s): A214
Parking Brake Set 0: parking brake pressure switch indicating low pressure and an applied parking brake
(IM2f) 1: parking brake pressure switch indicating higher pressure and a released parking
brake
Fault(s): A213
Brake Pressure Sensor 2.4 mA to 20.1 mA: good readings
(IM3p) < 2.4 mA or > 20.1 mA: Defective sensor or circuit
Fault(s): A205
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Parking Brake Set Refer to 58F-06-02311, Sheet 15, zone F10 to F16 930E
Pressure Switch Refer to 58F-06-10561, Sheet 5, zone C8
connection to IM Refer to 58B-06-02390, Sheet 16, zone F10 to F16 980E
Refer to 58B-06-03570, Sheet 5, zone C8
Parking Brake Release Refer to 58F-06-02311, Sheet 5, zones H5 through H14 930E
Pressure Switch to IM Refer to 58F-06-10561, Sheet 5, zone C9
Refer to 58B-06-02390, Sheet 5, zones H6 through H20 980E
Refer to 58B-06-03570, Sheet 5, zone C9
Brake Pressure Refer to 58F-06-02311, Sheet 15, zones K1 through K8 930E
Sensor connection to Refer to 58F-06-10561, Sheet 5, zone E10
IM Refer to 58B-06-02390, Sheet 16, zones K1 through K12 980E
Refer to 58B-06-03570, Sheet 5, zone E10
Service Brake Refer to 58F-06-02311, Sheet 7, zone F12 930E
Pressure Switch Refer to 58F-06-10561, Sheet 5, zones D1 through E1
Refer to 58B-06-02390, Sheet 10, zone G3 980E
Refer to 58B-06-03570, Sheet 5, zones D1 through E1
Auto Brake Apply Refer to 58F-06-02311, Sheet 9, zones L5 through O17 930E
Relay & Circuit Refer to 58F-06-10561, Sheet 5, zones B4 through C5
Refer to 58B-06-02390, Sheet 10, zones L5 through O17 980E
Refer to 58B-06-03570, Sheet 5, zones B4 through C5
23
CEN40181-03 40 Troubleshooting
Fault Code A318: Unexpected power loss to interface module
Operator Action None
Fault Code A318
Description Unexpected power loss to interface module (IM).
Fault Conditions Sets if open file markers are discovered at power up.
Resets if no open file markers are discovered at power up.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: PWR LOSS NOT EXPECT
Display Fault Code: A318
Resulting Problem(s) Data may be compromised by irregular shutdowns.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary corrective action for this fault is to keep the interface module (IM) working and shutting itself
down in a regular manner.
Parameter Expected State and/or Related Fault(s)
Open file markers Stored in IM FLASH
Battery Voltage, > 22 volts: 12 volt circuit should have normal readings
24 Volt (IM1A) < 22 volts: 12 volt circuit might have abnormal readings
Fault(s): A153, A154, A155, A250
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Battery Supply Voltage Refer to 58D-06-01711, Sheet 3, zones L4 through L15 730E
to IM Refer to 58E-06-02311, sheet 5, zones L4 through L15 830E
Refer to 58E-06-02321, sheet 18, zones A9 through B9
Refer to 58F-06-02311, Sheet 5, zones L4 through L15 930E
Refer to 58F-06-10561, Sheet 18, zones A9 through B9
Refer to 58B-06-02390, Sheet 5, zones L6 through L14 980E
Refer to 58B-06-03570, Sheet 20, zones A9 through B9
24
40 Troubleshooting CEN40181-03
Fault Code A328: Drive system not powered up
Operator Action Stop; Park
Fault Code A328
Description Drive system not powered up.
Fault Conditions Sets if drive system does not power up within 30 seconds after engine is running.
Resets if conditions change for 2 seconds.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operation Action: STOP: PRK
Display Fault Description: NO DRIVE SYS POWER
Display Fault Code: A328
Resulting Problem(s) Drive system can neither retard nor propel without control power.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. Check wiring from GE control power to the interface module
2. Check control power wiring, relay, and drive circuitry from GE
3. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
4. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
5. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning
Parameter Expected State and/or Related Fault(s)
Engine Speed [RPM] < 300 RPM: engine is not running
(CAN/J1939) (IM1q,r,s) > 300 RPM for 4 seconds: engine is running
A184
Drive System Control 0: Control power is off
Power (IM3M) 1: Control power is on
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
GE Control Power Refer to 58D-06-01711, Sheet 4, zone C3 730E
connection to IM Refer to 58E-06-02311, sheet 6, zone C3 830E
Refer to 58E-06-02321, sheet 4, zone E6
Refer to 58F-06-02311, Sheet 6, zone C3 930E
Refer to 58F-06-10561, Sheet 4, zone D4
Refer to 58B-06-02390, Sheet 6, zone H2 980E
Refer to 58B-06-03570, Sheet 4, zone D4
25
CEN40181-03 40 Troubleshooting
Fault Code A332: Seat belt not buckled
Operator Action Buckle Seat Belt
Fault Code A332
Description Seat belt not buckled.
Fault Conditions Sets if seat belt is not buckled, engine is running, and parking brake is not set for 10
seconds. (Parking brake set is defined as closure of the parking brake set pressure
switch and opening of the parking brake release pressure switch.)
Resets if conditions change for 2 seconds.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: BUCKLE SEAT BELT
Display Fault Description: BELT NOT BUCKLED
Display Fault Code: A332
Resulting Problem(s) Unbuckled seat belt cannot prevent injury to operator.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Seat Belt Switch Input 0: Seat belt is buckled.
(IM2g) 1: Seat belt is not buckled.
Engine Speed [RPM] < 300 RPM: Engine is not running
(CAN/J1939) (IM1q,r,s) > 300 RPM for 4 seconds: Engine is running
Fault(s): A184
Parking Brake Set 0: parking brake pressure switch indicating low pressure and an applied parking brake
(IM2f) 1: parking brake pressure switch indicating higher pressure and an unapplied parking
brake
Fault(s): A213
Parking Brake 0: parking brake pressure switch indicating high pressure and a unapplied parking
Released (IM2M) brake
1: parking brake pressure switch indicating low pressure and an applied parking brake
Fault(s): A214
26
40 Troubleshooting CEN40181-03
Seat Belt Alarm Output Status - Open Load: Unexpected. Troubleshoot
(IM1J) Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0. Turns off when belt is buckled or truck is parked or engine is not running.
1: Turns on when belt is not buckled and engine is running and parking brake is not
applied.
Fault(s): A353
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Parking Brake Set Refer to 58D-06-01711, Sheet 14, zones F10 through F16 730E
Pressure Switch Refer to 58E-06-02311, sheet 15, zones F10 through F16 830E
connection to IM Refer to 58E-06-02321, sheet 5, zone C8
Refer to 58F-06-02311, Sheet 15, zone F10 to F16 930E
Refer to 58F-06-10561, Sheet 5, zone C8
Refer to 58B-06-02390, Sheet 16, zone F10 to F16 980E
Refer to 58B-06-03570, Sheet 5, zone C8
Parking Brake Release Refer to 58D-06-01711, Sheet 3, zones G3 through H9 730E
Pressure Switch to IM Refer to 58E-06-02311, sheet 5, zones H3 through H9 830E
Refer to 58E-06-02321, sheet 5, zone C9
Refer to 58F-06-02311, Sheet 5, zones H5 through H14 930E
Refer to 58F-06-10561, Sheet 5, zone C9
Refer to 58B-06-02390, Sheet 5, zones H6 through H20 980E
Refer to 58B-06-03570, Sheet 5, zone C9
Seat Belt Switch Refer to 58D-06-01711, Sheet 14, zone A10 730E
connection to IM Refer to 58E-06-02311, sheet 15, zone A10 830E
Refer to 58E-06-02321, sheet 16, zone B4
Refer to 58F-06-02311, Sheet 15, zone A10 930E
Refer to 58F-06-10561, Sheet 16, zone B4
Refer to 58B-06-02390, Sheet 16, zone A10 980E
Refer to 58B-06-03570, Sheet 18, zone B4
Seat Belt Alarm Option Refer to 58D-06-01711, Sheet 14, zone B18 730E
Refer to 58E-06-02311, sheet 15, zone B18 830E
Refer to 58E-06-02321, sheet 16, zone B4
Refer to 58F-06-02311, Sheet 15, zone B18 930E
Refer to 58F-06-10561, Sheet 16, zone B4
Refer to 58B-06-02390, Sheet 16, zone B18 980E
Refer to 58B-06-03570, Sheet 18, zone B4
27
CEN40181-03 40 Troubleshooting
Fault Code A333: The hydraulic ladder controller has declared a ladder fault
Operator Action Stop; Park; Repair
Fault Code A333
Description The hydraulic ladder controller has declared a ladder fault.
Fault Conditions Sets if the hydraulic ladder controller declares a fault.
Resets when the hydraulic ladder controller clears the fault.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operation Action: STOP: PARK: REPAIR
Display Fault Description: HYD LADDER FAULT
Display Fault Code: A333
Resulting Problem(s) Ladder may not stow properly for traveling or may not operate for ascent or descent.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault is generated by the hydraulic ladder controller in response to problems within the controller or
external switches and limit switches that control the hydraulic ladder.
Parameter Expected State and/or Related Fault(s)
Hydraulic Ladder 1: An alarm exists.
Alarm (IM2a) 0: No alarm exists.
Related Circuit Diagram
Circuit Description Circuit Reference
None None
28
40 Troubleshooting CEN40181-03
NOTES
29
CEN40181-03 40 Troubleshooting
Fault Code A334: Shift lever not in park when propel was either not ready or at rest
Operator Action Stop; Park
Fault Code A334
Description Shift lever not in park when propel was either not ready or at rest.
Fault Conditions Sets when Selector Switch is moved from Park position with either “Propel not Ready”
on or “Propel at Rest” on.
Resets when conditions change.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operation Action: STOP: PARK
Display Fault Description: PROPEL NOT READY
Display Fault Code: A334
Resulting Problem(s) Truck could roll away if parking brake is released with Propel Not Ready or Propel at
Rest signal.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. Primary corrective measure is to leave selector switch in park until drive system is ready to go.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning
Parameter Expected State and/or Related Fault(s)
Selector Switch (FNR) 0: Shifter is not in forward, neutral, or reverse
(IM2N) 1: Shifter is in forward, neutral, or reverse
Fault(s): A271, A303
GE Propel at Rest or 1: Ge has generated a propel not ready or propel at rest signal
Not Ready (CAN/RPC) 0: No propel at rest or propel not ready signal exists
(IM1i,j,k)
30
40 Troubleshooting CEN40181-03
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Selector Switch Refer to 58D-06-01711, Sheet 8, zones H12 through H16 730E
Refer to 58E-06-02311, sheet 9, zones H12 through H16 830E
Refer to 58E-06-02321, sheet 17, zones A1 through B1
Refer to 58F-06-02311, Sheet 9, zones H12 through H16 930E
Refer to 58F-06-10561, Sheet 27, zones A1 through B1
Refer to 58B-06-02390, Sheet 10, zones H13 through H16 980E
Refer to 58B-06-03570, Sheet 29, zones A1 through B1
Selector Switch Refer to 58D-06-01711, Sheet 8, zones J16 through L17 730E
connections at IM Refer to 58E-06-02311, sheet 9, zones J16 through L17 830E
Refer to 58E-06-02321, sheet 17, zone C2
Refer to 58F-06-02311, Sheet 9, zones J16 through L17 930E
Refer to 58F-06-10561, Sheet 27, zone C2
Refer to 58B-06-02390, Sheet 10, zones I16 through K17 980E
Refer to 58B-06-03570, Sheet 29, zone C2
31
CEN40181-03 40 Troubleshooting
Fault Code A335: Manual/Auto Apply Pressure Fault
Fault Code A335
Description Autonomous auto apply pressure is not released in manual mode.
Message Manual/Auto Apply Pressure Fault
Possible Cause Sets if autonomous auto apply pressure is not released in manual mode after 5 sec-
onds
Remedy Reset if autonomous auto apply pressure is released in manual mode (or autonomous
mode is entered again) after 5 seconds.
32
40 Troubleshooting CEN40181-03
Fault Code A337: Engine Air Filter Circuit Fault
Operator Action None
Fault Code A337
Description Engine Air Filter Circuit Fault
Fault Conditions Sets if Engine Air Filter Restriction Switch indicates full filter with engine speed at zero
for 2 seconds.
Resets if Engine Air Filter Restriction Switch indicates filter OK or engine begins to
run.
Operator Alerting Display: Repair Item
System Response Display Fault Description: ENG AIR FILT CIRCUIT
Display Fault Code: A337
Resulting Problem(s) Failure to monitor engine air filter restriction could result in engine problems.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The normal corrective measure for this fault is to change the engine air filter restriction switch or correct the
wiring.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Engine Air Filter 0: Engine Air Filter Restriction Switch not operating
Restriction Switch 1: Engine Air Filter Restriction Switch indicating filter restriction
(IM2X) Fault(s): A338
Engine Speed [RPM] 0 for 2 seconds: Engine is not running
(CAN/J1939) (IM1q,r,s) > 0: Engine is running
Fault(s): A184
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Engine Air Filter Refer to 58D-06-01711, Sheet 14, zone B2 730E
Restriction Switch Refer to 58E-06-02311, sheet 15, zone B2 830E
Refer to 58E-06-02321, sheet 12, zone F3
Refer to 58F-06-02311, Sheet 15, zone B2 930E
Refer to 58F-06-10561, Sheet 12, zone F3
Refer to 58B-06-02390, Sheet 16, zone A2 980E
Refer to 58B-06-03570, Sheet 14, zone F3
33
CEN40181-03 40 Troubleshooting
Fault Code A338: Engine Air Filter Fault
Operator Action Go To Shop Now
Fault Code A338
Description Engine Air Filter Fault
Fault Conditions Sets if Engine Air Filter Switch indicates filter is full for 2 seconds with the engine
running.
Resets if Engine Air Filter Switch turns off or engine stops running.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: ENG AIR FILT RSTRICT
Display Fault Code: A338
Resulting Problem(s) Plugged filter could damage engine.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The normal corrective measure for this fault is to change the engine air filter.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Engine Air Filter 0: Engine Air Filter Restriction Switch not operating
Restriction Switch 1: Engine Air Filter Restriction Switch indicating filter restriction
(IM2X) Fault(s): A337
Engine Speed [RPM] <300 RPM: Engine is not running
(CAN/J1939) (IM1q,r,s) >300 RPM: Engine is running
Fault(s): A184
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Engine Air Filter Refer to 58D-06-01711, Sheet 14, zone B2 730E
Restriction Switch Refer to 58E-06-02311, sheet 15, zone B2 830E
Refer to 58E-06-02321, sheet 12, zone F3
Refer to 58F-06-02311, Sheet 15, zone B2 930E
Refer to 58F-06-10561, Sheet 12, zone F3
Refer to 58B-06-02390, Sheet 16, zone A2 980E
Refer to 58B-06-03570, Sheet 14, zone F3
34
40 Troubleshooting CEN40181-03
Fault Code A339: The DEF level gauge in the display panel is defective
Operator Action Go To Shop Now
Fault Code A339
Description The DEF level gauge in the display panel is defective.
Fault Conditions Sets if display panel reports a diesel exhaust fluid level gauge fault.
Reset if display panel clears the fault or at steering bleed.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: DEF FLUID LEVEL GAGE
Display Fault Code: A339
Resulting Problem(s) Running low on Diesel Exhaust Fluid will cause operator inducements (limitation of
truck performance).
Related Information
Table
1. Except for being masked by the steering bleed process, this fault is entirely contained within the display
panel. The panel and communication to it must be working in order for IM to be aware of the fault. Therefore the
only diagnostic effort is to check the gauge and wiring within the panel and replace if necessary.
Parameter Expected State and/or Related Fault(s)
Steering Bleed Valve 0: steering bleed valve is off
1: steering bleed valve is on
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Diesel Exhaust Fluid Refer to 58D-06-01711, Sheet 9, zone E6 730E
Level Gauge Refer to 58E-06-02311, sheet 10, zone E6 830E
Refer to 58E-06-02321, sheet 7, zone A9
Refer to 58F-06-02311, Sheet 10, zone E6 930E
Refer to 58F-06-10561, Sheet 7, zone A9
Refer to 58B-06-02390, Sheet 11, zone E6 980E
Refer to 58B-06-03570, Sheet 7, zone A9
35
CEN40181-03 40 Troubleshooting
Fault Code A340: The shifter controller has declared a fault
Operator Action Stop, Park, Power Down
Fault Code A340
Description The shifter controller has declared a fault.
Fault Conditions Sets if the Shifter Controller detects a fault with the Keyswitch, on for 3 seconds.
Resets if the fault goes away for 3 seconds or the steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: SHIFT CONTROL FAULT
Display Fault Code: A340
Resulting Problem(s) Truck may not be operational.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. Except for being masked by the steering bleed process, this fault is contained within the Shifter Controller,
the Shifter itself, or associated wiring.
2. This fault's logic contains just one parameter, which may have additional fault codes.
3. Based on the truck's setup while this fault is active, determine which of the parameters in the Table is not
shown in its expected state on the IM Realtime Data Monitor program. Refer to the schematic to identify which
item(s) may be causing the parameter(s) to be in the unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Shifter Controller Fault 0: operation normal
Input (IM2m) 1: fault exists
Fault(s): A341
Steering Bleed Valve 0: steering bleed valve is off
1: steering bleed valve is on
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Shifter Controller Fault Refer to 58D-06-01711, Sheet 8, zone J16 730E
Input to IM Refer to 58E-06-02311, sheet 9, zone J16 830E
Refer to 58E-06-02321, sheet 27, zone C2
Refer to 58F-06-02311, Sheet 9, zone J16 930E
Refer to 58F-06-10561, Sheet 27, zone C2
Refer to 58B-06-02390, Sheet 10, zone I16 980E
Refer to 58B-06-03570, Sheet 29, zone C2
36
40 Troubleshooting CEN40181-03
Fault Code A341: The shifter control circuit is defective
Operator Action Stop, Park, Power Down
Fault Code A341
Description The shifter control circuit is defective.
Fault Conditions Sets if shifter is not in either Park or FNR (forward, neutral, reverse) position for 2 sec-
onds with keyswitch on.
Resets if conditions change for 2 seconds.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: SHIFT CONT CIRC FLT
Display Fault Code: A341
Resulting Problem(s) Truck may not be operational.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. Except for being masked by the keyswitch, OR signal to IM, this fault is contained within the wiring of the
shifter to IM.
2. This fault's logic contains more than one parameter, which may have additional fault codes.
3. Based on the truck's setup while this fault is active, determine which of the parameters in the Table is not
shown in its expected state on the IM Realtime Data Monitor program. Refer to the schematic to identify which
item(s) may be causing the parameter(s) to be in the unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Selector Switch (Park) 0: Switch not in Park
(IM3T) 1: Switch in Park position
Fault(s): A340
Selector Switch (FNR) 0: Keyswitch, OR off
(IM2N) 1: Keyswitch, OR on
Fault(s): A240
Keyswitch, Or (IM3G) 0: Keyswitch, OR off
1: Keyswitch, OR on
Fault(s): A240
37
CEN40181-03 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Keyswitch, OR Refer to 58D-06-01711, Sheet 14, zones D10 through D19 730E
connection to IM Refer to 58E-06-02311, sheet 15, zones D10 through D19 830E
Refer to 58E-06-02321, sheet 31, zones B8 through B10
Refer to 58F-06-02311, Sheet 15, zones D10 through D19 930E
Refer to 58F-06-10561, Sheet 31, zones B8 through B10
Refer to 58B-06-02390, Sheet 16, zones D10 through D19 980E
Refer to 58B-06-03570, Sheet 33, zones B9 through B10
Selector Switch Refer to 58D-06-01711, Sheet 8, zones J16 through L17 730E
connections at IM Refer to 58E-06-02311, sheet 9, zones J16 through L17 830E
Refer to 58E-06-02321, sheet 17, zone C2
Refer to 58F-06-02311, Sheet 9, zones J16 through L17 930E
Refer to 58F-06-10561, Sheet 27, zone C2
Refer to 58B-06-02390, Sheet 10, zones I16 through K17 980E
Refer to 58B-06-03570, Sheet 29, zone C2
38
40 Troubleshooting CEN40181-03
Fault Code A342: The Accessory Pump Filter Switch has actuated
Operator Action Go To Shop Now
Fault Code A342
Description The Accessory Pump Filter Switch has actuated.
Fault Conditions Sets if switch is on, engine is running, and oil temperature is above 50º C (122º F) for
10 seconds.
Resets if conditions clear for 10 seconds.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: ACC HYD OIL FILT RST
Display Fault Code: A342
Resulting Problem(s) High oil temperatures may cause equipment damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. The primary cause for this fault is a plugged filter.
2. This fault's logic contains more than one parameter, which may have additional fault codes.
3. Based on the truck's setup while this fault is active, determine which of the parameters in the Table is not
shown in its expected state on the IM Realtime Data Monitor program. Refer to the schematic to identify which
item(s) may be causing the parameter(s) to be in the unexpected state. Troubleshoot these items.
4. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Accessory Pump Filter 0: Switch off, normal operation
Switch (IM3X) 1: Switch on, pressure is high
Hydraulic Oil Temp - < 50º C (122º F): Normal operating range
Tank (IM3m) >50º C (122º F): High temperature range
Fault(s): A103, A104, A193
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Hydraulic Oil Refer to 58E-06-02311, sheet 15, zones J9 through K21 830E
Temperature Refer to 58E-06-02321, sheet 5, zones D4 through E6
connection to IM
Accessory Pump Filter Refer to 58E-06-02311, sheet 15, zone E10 830E
Switch input to IM Refer to 58E-06-02321, sheet 30, zone C6
39
CEN40181-03 40 Troubleshooting
Fault Code A343: Truck speed is limited by GE
Operator Action Max Speed Limited
Fault Code A343
Description Truck speed is limited by GE.
Fault Conditions Sets when GE transmits a Speed Limit signal on CAN/RPC.
Resets when GE clears the Speed Limit signal on CAN/RPC.
Operator Alerting Single Burst of Sound on Buzzer
System Response No Warning Indicator
Display Operator Action: MAX SPEED LIMITED
Display Fault Description: GE SPEED LIMT
Display Fault Code: A343
Resulting Problem(s) Truck will not perform well.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault is developed within the GE drive system and transmitted to IM via CAN/RPC.
2. Troubleshoot the GE drive and check for malfunction in CAN/RPC.
Parameter Expected State and/or Related Fault(s)
CAN/RPC (IM i, j, k) Fault: A233
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 14, zones I9 through I12 and Sheet 16, 730E
at IM zone B6
Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 15, zone I12 and Sheet 17, zone B5 930E
Refer to 58F-06-10561, Sheet 6, zone A2
Refer to 58B-06-02390, Sheet 16, zone D6 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/RPC connection Refer to 58D-06-01711, Sheet 16, zone B9 730E
at GE Refer to 58E-06-02311, sheet 17, zone B3 830E
Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, Sheet 17, zone C4 930E
Refer to 58F-06-10561, Sheet 6, zone B2
Refer to 58B-06-02390, Sheet 18, zone C4 980E
Refer to 58B-06-03570, Sheet 6, zone A2
40
40 Troubleshooting CEN40181-03
Fault Code A344: GE has posted a No Retarding fault
Operator Action Stop, Park, Repair
Fault Code A344
Description GE has posted a No Retarding fault.
Fault Conditions Sets when GE transmits a No Retarding message on CAN/RPC.
Resets when GE clears the No Retarding message on CAN/RPC.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: STOP: PARK: REPAIR
Display Fault Description: NO RETARD
Display Fault Code: A344
Resulting Problem(s) Truck can not continue to operate without retarding.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault is developed within the GE drive system and transmitted to IM via CAN/RPC.
2. Troubleshoot the GE drive and check for malfunction in CAN/RPC.
Parameter Expected State and/or Related Fault(s)
CAN/RPC (IM i, j, k) Fault: A233
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 14, zones I9 through I12 and Sheet 16, 730E
at IM zone B6
Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 15, zone I12 and Sheet 17, zone B5 930E
Refer to 58F-06-10561, Sheet 6, zone A2
Refer to 58B-06-02390, Sheet 16, zone D6 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/RPC connection Refer to 58D-06-01711, Sheet 16, zone B9 730E
at GE Refer to 58E-06-02311, sheet 17, zone B3 830E
Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, Sheet 17, zone C4 930E
Refer to 58F-06-10561, Sheet 6, zone B2
Refer to 58B-06-02390, Sheet 18, zone C4 980E
Refer to 58B-06-03570, Sheet 6, zone A2
41
CEN40181-03 40 Troubleshooting
Fault Code A345: Engine speed limited by GE
Operator Action Max Speed Limited
Fault Code A345
Description Engine speed limited by GE
Fault Conditions Sets when GE transmits an Engine Speed Limited message on CAN/RPC.
Resets when GE clears the Engine Speed Limited message on CAN/RPC.
Operator Alerting Single Burst of Sound on Buzzer
System Response No Warning Indicator
Display Operator Action: MAX SPEED LIMITED
Display Fault Description: ENG SPD LIMIT BY GE
Display Fault Code: A345
Resulting Problem(s) Performance will be limited.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault is developed within the GE drive system and transmitted to IM via CAN/RPC.
2. Troubleshoot the GE drive and check for malfunction in CAN/RPC.
Parameter Expected State and/or Related Fault(s)
CAN/RPC (IM i, j, k) Fault: A233
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 14, zones I9 through I12 and Sheet 16, 730E
at IM zone B6
Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 15, zone I12 and Sheet 17, zone B5 930E
Refer to 58F-06-10561, Sheet 6, zone A2
Refer to 58B-06-02390, Sheet 16, zone D6 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/RPC connection Refer to 58D-06-01711, Sheet 16, zone B9 730E
at GE Refer to 58E-06-02311, sheet 17, zone B3 830E
Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, Sheet 17, zone C4 930E
Refer to 58F-06-10561, Sheet 6, zone B2
Refer to 58B-06-02390, Sheet 18, zone C4 980E
Refer to 58B-06-03570, Sheet 6, zone A2
42
40 Troubleshooting CEN40181-03
Fault Code A346: Delayed Shut Down by GE
Operator Action Stop, Park, Repair
Fault Code A346
Description Delayed Shut Down by GE
Fault Conditions Sets when GE transmits a Delayed Shut Down warning on CAN/RPC.
Resets when GE clears the Delayed Shut Down warning on CAN/RPC.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: STOP: PARK: REPAIR
Display Fault Description: LIMITED RETARD
Display Fault Code: A346
Resulting Problem(s) Truck will soon be non-operational.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault is developed within the GE drive system and transmitted to IM via CAN/RPC.
2. Troubleshoot the GE drive and check for malfunction in CAN/RPC.
Parameter Expected State and/or Related Fault(s)
CAN/RPC (IM i, j, k) Fault: A233
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 14, zones I9 through I12 and Sheet 16, 730E
at IM zone B6
Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 15, zone I12 and Sheet 17, zone B5 930E
Refer to 58F-06-10561, Sheet 6, zone A2
Refer to 58B-06-02390, Sheet 16, zone D6 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/RPC connection Refer to 58D-06-01711, Sheet 16, zone B9 730E
at GE Refer to 58E-06-02311, sheet 17, zone B3 830E
Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, Sheet 17, zone C4 930E
Refer to 58F-06-10561, Sheet 6, zone B2
Refer to 58B-06-02390, Sheet 18, zone C4 980E
Refer to 58B-06-03570, Sheet 6, zone A2
43
CEN40181-03 40 Troubleshooting
Fault Code A347: Operator Override of GE is active
Operator Action Max Speed Limited
Fault Code A347
Description Operator Override of GE is active.
Fault Conditions Sets when Ge transmits an Operator Override of GE Active message on CAN/RPC.
Resets when GE clears the Operator Override of GE Active message on CAN/RPC.
Operator Alerting Single Burst of Sound on Buzzer
System Response No Warning Indicator
Display Operator Action: MAX SPEED LIMITED
Display Fault Description: OVERRIDE ACTIVE
Display Fault Code: A347
Resulting Problem(s) Truck performance will be limited.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault is developed within the GE drive system and transmitted to IM via CAN/RPC.
2. Troubleshoot the GE drive and check for malfunction in CAN/RPC.
3. Troubleshoot the Override Switch and override input to GE.
Parameter Expected State and/or Related Fault(s)
CAN/RPC (IM i, j, k) Fault: A233
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 14, zones I9 through I12 and Sheet 16, 730E
at IM zone B6
Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 15, zone I12 and Sheet 17, zone B5 930E
Refer to 58F-06-10561, Sheet 6, zone A2
Refer to 58B-06-02390, Sheet 16, zone D6 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/RPC connection Refer to 58D-06-01711, Sheet 16, zone B9 730E
at GE Refer to 58E-06-02311, sheet 17, zone B3 830E
Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, Sheet 17, zone C4 930E
Refer to 58F-06-10561, Sheet 6, zone B2
Refer to 58B-06-02390, Sheet 18, zone C4 980E
Refer to 58B-06-03570, Sheet 6, zone A2
44
40 Troubleshooting CEN40181-03
Fault Code A348: GE has disabled load box operation
Operator Action Stop, Park, Repair
Fault Code A348
Description GE has disabled load box operation.
Fault Conditions Sets when GE transmits a Load Box Disabled signal on CAN/RPC.
Resets when GE clears the Load Box Disabled signal on CAN/RPC.
Operator Alerting Single Burst of Sound on Buzzer
System Response No Warning Indicator
Display Operator Action: STOP: PARK: REPAIR
Display Fault Description: LOAD BOX DISABLED
Display Fault Code: A348
Resulting Problem(s) Load box operation can not continue.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault is developed within the GE drive system and transmitted to IM via CAN/RPC.
2. Troubleshoot the GE drive and check for malfunction in CAN/RPC.
Parameter Expected State and/or Related Fault(s)
CAN/RPC (IM i, j, k) Fault: A233
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 14, zones I9 through I12 and Sheet 16, 730E
at IM zone B6
Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 15, zone I12 and Sheet 17, zone B5 930E
Refer to 58F-06-10561, Sheet 6, zone A2
Refer to 58B-06-02390, Sheet 16, zone D6 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/RPC connection Refer to 58D-06-01711, Sheet 16, zone B9 730E
at GE Refer to 58E-06-02311, sheet 17, zone B3 830E
Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, Sheet 17, zone C4 930E
Refer to 58F-06-10561, Sheet 6, zone B2
Refer to 58B-06-02390, Sheet 18, zone C4 980E
Refer to 58B-06-03570, Sheet 6, zone A2
45
CEN40181-03 40 Troubleshooting
Fault Code A349: GE has limited load box operation
Operator Action Stop, Park, Repair
Fault Code A349
Description GE has limited load box operation.
Fault Conditions Sets when GE transmits a Limited Load Box message on CAN/RPC.
Resets when GE clears the Limited Load Box message on CAN/RPC.
Operator Alerting Single Burst of Sound on Buzzer
System Response No Warning Indicator
Display Operator Action: STOP: PARK: REPAIR
Display Fault Description: LOAD BOX LIMITED
Display Fault Code: A349
Resulting Problem(s) Load box operation only at reduced level.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault is developed within the GE drive system and transmitted to IM via CAN/RPC.
2. Troubleshoot the GE drive and check for malfunction in CAN/RPC.
Parameter Expected State and/or Related Fault(s)
CAN/RPC (IM i, j, k) Fault: A233
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 14, zones I9 through I12 and Sheet 16, 730E
at IM zone B6
Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 15, zone I12 and Sheet 17, zone B5 930E
Refer to 58F-06-10561, Sheet 6, zone A2
Refer to 58B-06-02390, Sheet 16, zone D6 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/RPC connection Refer to 58D-06-01711, Sheet 16, zone B9 730E
at GE Refer to 58E-06-02311, sheet 17, zone B3 830E
Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, Sheet 17, zone C4 930E
Refer to 58F-06-10561, Sheet 6, zone B2
Refer to 58B-06-02390, Sheet 18, zone C4 980E
Refer to 58B-06-03570, Sheet 6, zone A2
46
40 Troubleshooting CEN40181-03
Fault Code A350: Overload on output 1B
Operator Action None
Fault Code A350
Description Overload on output 1B.
Fault Conditions Sets if driver chip detects over current or over temp on output 1B. Output is turned off
when overload is detected.
Resets at power down.
Operator Alerting Repair Lamp
System Response Display Fault Description: STRT ENABLE CKT FLT
Display Fault Code: A350
Resulting Problem(s) Starting circuit is disabled.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains just one parameter, which may have additional fault code(s). This fault may be
resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting Instructions for the
active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Start Enable (IM1B) Status - Open Load: Unexpected. Troubleshoot
Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: One of several interlocking situations exist to prevent cranking (excessive cranking
history, selector switch in wrong position, engine red light, J1939 not OK, engine
speed either not 0 to begin cranking or over 400 rpm while cranking).
1. No interlocking situations exist to prevent cranking.
Fault(s): A252g situations exist to prevent cranking.
Fault(s): A252
47
CEN40181-03 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Start Enable Relay coil Refer to 58D-06-01711, Sheet 3, zone K14 730E
circuit Refer to 58E-06-02311, sheet 5, zone K14 830E
Refer to 58E-06-02321, sheet 4, zone A8
Refer to 58F-06-02311, Sheet 5, zone K14 930E
Refer to 58F-06-10561, Sheet 4, zone A8
Refer to 58B-06-02390, Sheet 5, zone K14 980E
Refer to 58B-06-03570, Sheet 4, zone A8
48
40 Troubleshooting CEN40181-03
Fault Code A351: Overload on output 1E
Operator Action Go To Shop Now
Fault Code A351
Description Overload on output 1E.
Fault Conditions Sets if driver chip detects over current or over temp on output 1E. Output is turned off
when overload is detected.
Resets at power down.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: PRK BRK COMMAND FLT
Display Fault Code: A351
Resulting Problem(s) Parking brake solenoid valve circuit is disabled (parking brake will not release).
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains just one parameter, which may have additional fault code(s). This fault may be
resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting Instructions for the
active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Parking Brake Sole- Status - Open Load: Unexpected. Troubleshoot.
noid (IM1E) Status - Normal: Expected. No Problem.
Status - Shorted to Ground: Expected if parking rake request is in the 24 volt condition.
Otherwise, unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: Parking brake request input is in the low voltage (request) condition.
1: Parking brake request input is in the high voltage (not requested) condition.
Fault(s): A214, A216
49
CEN40181-03 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Parking Brake Refer to 58D-06-01711, Sheet 8, zone K17 730E
Solenoid connection to Refer to 58E-06-02311, sheet 9, zone K17 830E
IM Refer to 58E-06-02321, sheet 5, zones A7 through B7
Refer to 58F-06-02311, Sheet 9, zone K17 930E
Refer to 58F-06-10561, Sheet 5, zones A7 through B7
Refer to 58B-06-02390, Sheet 10, zone J17 980E
Refer to 58D-06-03570, Sheet 5, zones A7 through B7
Parking Brake Refer to 58D-06-01711, Sheet 8, zone K5 730E
Solenoid connection to Refer to 58E-06-02311, sheet 9, zone K6 830E
VEC Refer to 58E-06-02321, sheet 5, zones A7 through B7
Refer to 58F-06-02311, Sheet 9, zone K6 930E
Refer to 58F-06-10561, Sheet 5, zones A7 through B7
Refer to 58B-06-02390, Sheet 10, zone J7 980E
Refer to 58B-06-03570, Sheet 5, zones A7 through B7
Parking Brake Refer to 58D-06-01711, Sheet 5, zone G11 730E
Solenoid Refer to 58E-06-02311, sheet 7, zone G11 830E
Refer to 58E-06-02321, sheet 5, zones A7 through B7
Refer to 58F-06-02311, Sheet 7, zone G11 930E
Refer to 58F-06-10561, Sheet 5, zones A7 through B7
Refer to 58B-06-02390, Sheet 10, zone G3 980E
Refer to 58B-06-03570, Sheet 5, zone A7
50
40 Troubleshooting CEN40181-03
Fault Code A352: Overload on output 1H
Operator Action None
Fault Code A352
Description Overload on output 1H.
Fault Conditions Sets if driver chip detects over current or over temp on output 1H. Output is turned off
when overload is detected.
Resets at power down.
Operator Alerting Repair Lamp
System Response Display Fault Description: SHUTDOWN DELAY CKT
Display Fault Code: A352
Resulting Problem(s) Shutdown delay circuit is disabled.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains just one parameter, which may have additional fault code(s). This fault may be
resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting Instructions for the
active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Shutdown Delay Relay Status - Open Load: Unexpected. Troubleshoot
(IM1H) Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0. Turns off when conditions clear or engine speed drops to zero.
1: Turns on when Keyswitch, Direct is off, Engine Shutdown Delay is on, Parking
brake is set, Selector Switch is in park, but not J1939 Not Connected, not High Batt
Charge Voltage, not Starter Stuck On, not Active Engine Red Light, and engine speed
above 300 rpm.
Fault(s): A286, A292
51
CEN40181-03 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Shutdown Delay Relay Refer to 58D-06-01711, Sheet 3, zone D10 730E
coil circuit Refer to 58E-06-02311, sheet 5, zone D10 830E
Refer to 58E-06-02321, sheet 4, zone E2
Refer to 58F-06-02311, sheet 5, zone D10 930E
Refer to 58F-06-10561, sheet 4, zone E2
Refer to 58B-06-02390, sheet 5, zone D10 980E
Refer to 58B-06-03570, sheet 4, zone E2
52
40 Troubleshooting CEN40181-03
Fault Code A353: Overload on output 1J
Operator Action None
Fault Code A353
Description Overload on output 1J.
Fault Conditions Sets if driver chip detects over current or over temp on output 1J. Output is turned off
when overload is detected.
Resets at power down.
Operator Alerting Repair Lamp
System Response Display Fault Description: SEAT BELT ALARM FLT
Display Fault Code: A353
Resulting Problem(s) Seat belt alarm relay is disabled.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains just one parameter. There are no additional fault codes to investigate.
Parameter Expected State and/or Related Fault(s)
Seat Belt Alarm Output Status - Open Load: Unexpected. Troubleshoot
(IM1J) Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0. No seat belt alarm
1: Seat belt alarm exists
53
CEN40181-03 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Seat Belt Alarm Option Refer to 58D-06-01711, Sheet 14, zone B18 730E
relay coil circuit Refer to 58E-06-02311, sheet 15, zone B18 830E
Refer to 58E-06-02321, sheet 16, zone B4
Refer to 58F-06-02311, sheet 15, zone B18 930E
Refer to 58F-06-10561, sheet 16, zone B4
Refer to 58B-06-02390, sheet 16, zone B18 980E
Refer to 58B-06-03570, sheet 18, zone B4
Seat Belt Alarm Option Refer to 58D-06-01711, Sheet 3, zone K12 730E
relay coil circuit Refer to 58E-06-02311, sheet 5, zone K12 830E
voltage Refer to 58E-06-02321, sheet 18, zone A6
Refer to 58F-06-02311, sheet 5, zone K12 930E
Refer to 58F-06-10561, sheet 18, zone A6
Refer to 58B-06-02390, sheet 5, zone J11 980E
Refer to 58B-06-03570, sheet 20, zone A6
54
40 Troubleshooting CEN40181-03
Fault Code A354: Overload on output 1K
Operator Action None
Fault Code A354
Description Overload on output 1K.
Fault Conditions Sets if driver chip detects over current or over temp on output 1K. Output is turned off
when overload is detected.
Resets at power down.
Operator Alerting Repair Lamp
System Response Display Fault Description: IM ON SIGNAL FAULT
Display Fault Code: A354
Resulting Problem(s) Loss of interface module (IM) ON signal causes the display to stop functioning.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains just one parameter. There are no additional fault codes to investigate.
Parameter Expected State and/or Related Fault(s)
IM On Signal (IM1K) Status - Open Load: Unexpected. Troubleshoot.
Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: Off. Display is permitted to go to sleep.
1: On. Display is awakened.
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
IM On Signal load Refer to 58D-06-01711, Sheet 9, zones G5 through G20 730E
circuit Refer to 58E-06-02311, sheet 10, zones G5 through G17 830E
Refer to 58E-06-02321, sheet 7, zone C9
Refer to 58F-06-02311, sheet 10, zones G5 through G17 930E
Refer to 58F-06-10561, sheet 7, zone C9
Refer to 58B-06-02390, sheet 11, zones G5 through G17 980E
Refer to 58B-06-03570, sheet 7, zone C8
55
CEN40181-03 40 Troubleshooting
Fault Code A355: Overload on output 1L
Operator Action None
Fault Code A355
Description Overload on output 1L.
Fault Conditions Sets if driver chip detects over current or over temp on output 1L. Output is turned off
when overload is detected.
Resets at power down.
Operator Alerting Repair Lamp
System Response Display Fault Description: IM OUTPUT 1L FAULT
Display Fault Code: A355
Resulting Problem(s) Unused outputs with short circuits on them might damage the driver chip if not
corrected.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains just one parameter. There are no additional fault codes to investigate.
2. Any spare wires connected to this output should be removed to prevent ultimate failure of the driver chip.
Parameter Expected State and/or Related Fault(s)
Spare IM Output Status - Open Load: Expected. No problem.
(IM1L) Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0. Off
1: On
Related Circuit Diagram
Circuit Description Circuit Reference
None None
56
40 Troubleshooting CEN40181-03
Fault Code A356: Overload on output 1M
Operator Action Go To Shop Now
Fault Code A356
Description Overload on output 1M.
Fault Conditions Sets if driver chip detects over current or over temp on output 1M. Output is turned off
when overload is detected.
Resets at power down.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: SONALERT IM FAULT
Display Fault Code: A356
Resulting Problem(s) The sonalert with the display cannot be driven.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains just one parameter, which may have additional fault code(s). This fault may be
resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting Instructions for the
active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Sonalert (IM1M) Status - Open Load: Unexpected. Troubleshoot
Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: No faults are active that require buzzer operation.
1. One or more faults are active that require buzzer action.
Fault(s): A251
57
CEN40181-03 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Sonalert connection to Refer to 58S-06-01711, Sheet 9, zones E9 through E19 730E
IM Refer to 58E-06-02311, sheet 10, zones E9 through E17 830E
Refer to 58E-06-02321, sheet 7, zones B2 through B5
Refer to 58F-06-02311, sheet 10, zones E9 through E17 930E
Refer to 58F-06-10561, sheet 7, zone B2 through B5
Refer to 58B-06-02390, sheet 11, zones E9 through E17 980E
Refer to 58B-06-03570, sheet 7, zones B2 through B5
Sonalert connection to Refer to 58D-06-01711, Sheet 9, zone F15 730E
Keyswitch Refer to 58E-06-02311, sheet 10, zone G15 830E
Refer to 58E-06-02321, sheet 7, zone B3
Refer to 58F-06-02311, sheet 10, zone G15 930E
Refer to 58F-06-10561, sheet 7, zone B3
Refer to 58B-06-02390, sheet 11, zone G15 980E
Refer to 58B-06-03570, sheet 7, zone B3
Sonalert Power Refer to 58D-06-01711, Sheet 3, zone K12 730E
connection to IM Refer to 58E-06-02311, sheet 5, zone K12 830E
Refer to 58E-06-02321, sheet 18, zone A6
Refer to 58F-06-02311, sheet 5, zone K12 930E
Refer to 58F-06-10561, sheet 18, zone A6
Refer to 58B-06-02390, sheet 5, zone K12 980E
Refer to 58B-06-03570, sheet 20, zone A6
58
40 Troubleshooting CEN40181-03
Fault Code A357: Overload on output 1N
Operator Action None
Fault Code A357
Description Overload on output 1N.
Fault Conditions Sets if driver chip detects over current or over temp on output 1N. Output is turned off
when overload is detected.
Resets at power down.
Operator Alerting Repair Lamp
System Response Display Fault Description: IM OUTPUT 1N FAULT
Display Fault Code: A357
Resulting Problem(s) Unused outputs with short circuits on them might damage the driver chip if not
corrected.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains just one parameter. There are no additional fault codes to investigate.
2. Any spare wires connected to this output should be removed to prevent ultimate failure of the driver chip.
Parameter Expected State and/or Related Fault(s)
Spare IM Output Status - Open Load: Unexpected. Troubleshoot.
(IM1N) Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: Off.
1: On.
Related Circuit Diagram
Circuit Description Circuit Reference
None None
59
CEN40181-03 40 Troubleshooting
NOTES
60
40 Troubleshooting CEN40181-03
Fault Code A358: Overload on output 1P
Operator Action Go To Shop Now
Fault Code A358
Description Overload on output 1P.
Fault Conditions Sets if driver chip detects over current or over temp on output 1P. Output is turned off
when overload is detected.
Resets at power down.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: STG BLEED CKT FAULT
Display Fault Code: A358
Resulting Problem(s) The steering bleed circuit might not work properly, therefore causing a threat to
operators and mechanics.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains just one parameter, which may have additional fault code(s). This fault may be
resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting Instructions for the
active parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Steering Bleed Valve Status - Open Load: Expected with engine start switch on. No problem. Otherwise,
(IM1P) unexpected. Troubleshoot.
Status - Normal: Expected only with keyswitch OFF and steering bleed in process.
Troubleshoot if found with key ON.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: Steering bleed valve is off. This is expected in normal running operation.
1: Steering bleed valve is on. This is expected after keyswitch OFF initiates steering
bleed operation.
Fault(s): A235, A236, A253, A262
61
CEN40181-03 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Steering Bleed Valve Refer to 58D-06-01711, Sheet 14, zone B9 730E
connection at IM Refer to 58E-06-02311, sheet 15, zone B10 830E
Refer to 58E-06-02321, sheet 31, zone B1
Refer to 58F-06-02311, sheet 15, zone B10 930E
Refer to 58F-06-10561, sheet 31, zone B1
Refer to 58B-06-02390, sheet 16, zone C12 980E
Refer to 58B-06-03570, sheet 33, zone B1
Steering Bleed Valve Refer to 58D-06-01711, Sheet 14, zone C18 730E
connection at Fuse Refer to 58E-06-02311, sheet 15, zone C18 830E
Refer to 58E-06-02321, sheet 31, zone A1
Refer to 58F-06-02311, sheet 15, zone C18 930E
Refer to 58F-06-10561, sheet 31, zone A1
Refer to 58B-06-02390, sheet 16, zone C18 980E
Refer to 58B-06-03570, sheet 33, zone A1
62
40 Troubleshooting CEN40181-03
Fault Code A359: Overload on output 1R
Operator Action Go To Shop Now
Fault Code A359
Description Overload on output 1R.
Fault Conditions Sets if driver chip detects over current or over temp on output 1R. Output is turned off
when overload is detected.
Resets at power down.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: BRK AUTO APPLY FLT
Display Fault Code: A359
Resulting Problem(s) A non-functional brake auto apply valve might cause damage to the parking brake.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains just one parameter, which may have additional fault code(s). This fault may be
resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting Instructions for the
active parameter fault(s).
2. If there are no active parameter fault codes, then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved, then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Auto Brake Apply Status - Open Load: Unexpected if parking brake request and keyswitch are on.
Solenoid (IM1R) Expected if parking brake request is off or keyswitch is off. Troubleshoot if
inconsistent.
Status - Normal: Expected if parking brake request and keyswitch are on.
Troubleshoot if status is normal with parking brake request off or keyswitch off.
Status - Shorted to ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: Normal operation with parking brake either applied or released. This valve operates
only transiently when the parking brake is set.
1: Brake auto apply relay operates the brake lock valve for 1.5 seconds after the
parking brake is applied if the truck is stopped. If moving, it will not operate until truck
speed has dropped to 0.8 kph (0.5 mph).
Fault(s): A215, A317
63
CEN40181-03 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Auto Brake Apply Refer to 58F-06-02311, sheet 9, zones L5 through O17 930E
Relay & Circuit Refer to 58F-06-10561, sheet 5, zones B4 through C5
Refer to 58B-06-02390, sheet 10, zones L5 through O17 980E
Refer to 58B-06-03570, sheet 5, zones B4 through C5
64
40 Troubleshooting CEN40181-03
Fault Code A360: Overload on output 1S
Operator Action None
Fault Code A360
Description Overload on output 1S.
Fault Conditions Sets if driver chip detects over current or over temp on output 1S. Output is turned off
when overload is detected.
Resets at power down.
Operator Alerting Repair Lamp
System Response Display Fault Description: IM OUTPUT 1S FAULT
Display Fault Code: A360
Resulting Problem(s) Unused outputs with short circuits on them might damage the driver chip if not
corrected.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains just one parameter. There are no additional fault codes to investigate.
2. Any spare wires connected to this output should be removed to prevent ultimate failure of the driver chip.
Parameter Expected State and/or Related Fault(s)
Spare IM Output Status - Open Load: Unexpected. Troubleshoot.
(IM1S) Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: Off
1: On
Related Circuit Diagram
Circuit Description Circuit Reference
None None
65
CEN40181-03 40 Troubleshooting
Fault Code A361: Overload on output 1T
Operator Action None
Fault Code A361
Description Overload on output 1T.
Fault Conditions Sets if driver chip detects over current or over temp on output 1T. Output is turned off
when overload is detected.
Resets at power down.
Operator Alerting Repair Lamp
System Response Display Fault Description: AUTO LUBE CIRCUIT
Display Fault Code: A361
Resulting Problem(s) Auto lube circuit is disabled.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, which may have additional fault code(s). This fault may
be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting Instructions for the
active parameter fault(s).
2. If there are no active parameter fault codes, then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved, then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Auto Lube Output Status - Open Load: Unexpected. Troubleshoot.
(IM1T) Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected except momentarily at termination of a lube
cycle. If detected any other time, troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: Turns off between lubrication cycles.
1: Turns on during lubrication cycle.
Fault(s): A190
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
Auto Lube Solenoid Refer to 58D-06-01711, Sheet 14, zones N9 through N19 730E
Refer to 58E-06-02311, sheet 15, zones N9 through N19 830E
Refer to 58E-06-02321, sheet 2, zone B4
Refer to 58F-06-02311, sheet 15, zones N9 through N19 930E
Refer to 58F-06-10561, sheet 2, zone B4
Refer to 58B-06-02390, sheet 16, zones M9 through M21 980E
Refer to 58B-06-03570, sheet 2, zone B4
66
40 Troubleshooting CEN40181-03
Fault Code A362: Overload on output 1U
Operator Action None
Fault Code A362
Description Overload on output 1U.
Fault Conditions Sets if driver chip detects over current or over temp on output 1U. Output is turned off
when overload is detected.
Resets at power down.
Operator Alerting Repair Lamp
System Response Display Fault Description: IM OUTPUT 1U FAULT
Display Fault Code: A362
Resulting Problem(s) Unused outputs with short circuits on them might damage the driver chip if not
corrected.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains just one parameter. There are no additional fault codes to investigate.
2. Any spare wires connected to this output should be removed to prevent ultimate failure of the driver chip.
Parameter Expected State and/or Related Fault(s)
Spare IM Output Status - Open Load: Unexpected. Troubleshoot.
(IM1U) Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: Off
1: On
Related Circuit Diagram
Circuit Description Circuit Reference
None None
67
CEN40181-03 40 Troubleshooting
Fault Code A363: Overload on output 1X
Operator Action None
Fault Code A363
Description Overload on output 1X.
Fault Conditions Sets if driver chip detects over current or over temp on output 1X. Output is turned off
when overload is detected.
Resets at power down.
Operator Alerting Repair Lamp
System Response Display Fault Description: IM OUTPUT 1X FAULT
Display Fault Code: A363
Resulting Problem(s) Unused outputs with short circuits on them might damage the driver chip if not
corrected.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains just one parameter. There are no additional fault codes to investigate.
2. Any spare wires connected to this output should be removed to prevent ultimate failure of the driver chip.
Parameter Expected State and/or Related Fault(s)
Brake Cooling RPM Status - Open Load: Unexpected. Troubleshoot.
Advance 2: (IM1X) Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: Off
1: On
Fault(s): A146
Related Circuit Diagram
Circuit Description Circuit Reference
None None
68
40 Troubleshooting CEN40181-03
Fault Code A364: Overload on output 1Y
Operator Action None
Fault Code A364
Description Overload on output 1Y.
Fault Conditions Sets if driver chip detects over current or over temp on output 1Y. Output is turned off
when overload is detected.
Operator Alerting Repair Lamp
System Response Display Fault Description: IM OUTPUT 1Y FAULT
Display Fault Code: A364
Resulting Problem(s) Unused outputs with short circuits on them might damage the driver chip if not
corrected.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains just one parameter. There are no additional fault codes to investigate.
2. Any spare wires connected to this output should be removed to prevent ultimate failure of the driver chip.
Parameter Expected State and/or Related Fault(s)
Spare IM Output Status - Open Load: Unexpected. Troubleshoot.
(IM1Y) Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: Off
1: On
Related Circuit Diagram
Circuit Description Circuit Reference
None None
69
CEN40181-03 40 Troubleshooting
Fault Code A365: Overload on output 1Z
Operator Action None
Fault Code A365
Description Overload on output 1Z.
Fault Conditions Sets if driver chip detects over current or over temp on output 1Z. Output is turned off
when overload is detected.
Operator Alerting Repair Monitor
System Response Display Fault Description: IM OUTPUT 1Z FAULT
Display Fault Code: A365
Resulting Problem(s) Unused outputs with short circuits on them might damage the driver chip if not
corrected.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains just one parameter. There are no additional fault codes to investigate.
2. Any spare wires connected to this output should be removed to prevent ultimate failure of the driver chip.
Parameter Expected State and/or Related Fault(s)
Spare IM Output Status - Open Load: Unexpected. Troubleshoot.
(IM1Z) Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: Off
1: On
Related Circuit Diagram
Circuit Description Circuit Reference
None None
70
40 Troubleshooting CEN40181-03
Fault Code A366: Axle box cooling fault
Operator Action Go To Shop Now
Fault Code A366
Description Axle box cooling fault.
Fault Conditions Sets if Blower Speed Full Request remains on for 10 seconds while the Axle Box
Blower Speed remains below 100%.
Resets if Axle Box Blower Speed returns to 100% for 10 seconds.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: AXLE BOX COOL FLT
Display Fault Code: A366
Resulting Problem(s) Poor cooling can cause equipment damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault's logic contains more than one parameter, which may have additional fault codes.
2. Based on the truck's setup while this fault is active, determine which of the parameters in the Table is not
shown in its expected state on the IM Realtime Data Monitor program. Refer to the schematic to identify which
item(s) may be causing the parameter(s) to be in the unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Brake Pressure 2.4 mA to 20.1 mA: good readings
IM(3b,3p) < 2.4 mA or more than 20.1 mA: Defective sensor or circuit
Fault(s): A201, A205
Truck Speed [kph] Fault(s): A233
(CAN/RPC) (IM1i,j,k)
Wheel Blower Speed
(%) (CAN/RPC)
(IM1i,J,K)
71
CEN40181-03 40 Troubleshooting
Related Circuit Diagram
Circuit Description Circuit Reference Machine
Reference
CAN/RPC connection Refer to 58D-06-01711, Sheet 14, zones I9 through I12 and Sheet 16, 730E
at IM zone B6
Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, sheet 15, zones K1 through K8 930E
Refer to 58F-06-10561, sheet 5, zone E10
Refer to 58B-06-02390, sheet 16, zones K1 through K12 980E
Refer to 58B-06-03570, sheet 5, zone E10
CAN/RPC connection Refer to 58D-06-01711, Sheet 16, zone B9 730E
at GE Refer to 58E-06-02311, sheet 17, zone B3 830E
Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, sheet 15, zone I12 and sheet 17, zone B5 930E
Refer to 58F-06-10561, sheet 6, zone A2
Refer to 58B-06-02390, sheet 16, zone D6 and sheet 18, zone B8 980E
Refer to 58B-06-03570, sheet 6, zone A2
Brake Pressure Refer to 58D-06-01711, Sheet 14, zones K1 through K7 730E
Sensor connection to Refer to 58E-06-02311, sheet 15, zones K1 through K8 830E
IM Refer to 58E-06-02321, sheet 5, zone E10
Refer to 58F-06-02311, sheet 17, zone C4 930E
Refer to 58F-06-10561, sheet 6, zone B2
Refer to 58B-06-02390, sheet 18, zone C4 980E
Refer to 58B-06-03570, sheet 6, zone A2
72
40 Troubleshooting CEN40181-03
NOTES
73
CEN40181-03 40 Troubleshooting
730E Dump truck
830E Dump truck
930E Dump truck
980E Dump truck
Form No. CEN40181-03
74
CEN40182-00
DUMP TRUCK
730E
830E
930E
980E
Machine model Serial number
730E-10 A50002 and up
830E-5 A50005 and up
830E-5AT A50005 and up
930E-5 A40004 and up
930E-5AT A40004 and up
980E-5 A50005 and up
980E-5AT A50005 and up
40 Troubleshooting
Troubleshooting by fault code, part 5
Fault Code A400: Tire 1 (Front Left) High Pressure RED..................................................................................... 4
Fault Code A401: Tire 1 (Front Left) High Pressure AMBER................................................................................ 5
Fault Code A402: Tire 1 (Front Left) Low Pressure RED...................................................................................... 6
Fault Code A403: Tire 1 (Front Left) Low Pressure AMBER ................................................................................ 7
Fault Code A404: Tire 1 (Front Left) No Data / Sensor Failure / Not Connected.................................................. 8
Fault Code A405: Tire 1 (Front Left) High Temperature RED ............................................................................... 9
Fault Code A406: Tire 1 (Front Left) High Temperature AMBER........................................................................ 10
Fault Code A407: Tire 1 (Front Left) Bad Value Sensor Error / Not Connected ..................................................11
Fault Code A408: Tire 2 (Front Right) High Pressure RED ................................................................................ 12
Fault Code A409: Tire 2 (Front Right) High Pressure AMBER ........................................................................... 13
Fault Code A410: Tire 2 (Front Right) Low Pressure RED ................................................................................. 14
Fault Code A411: Tire 2 (Front Right) Low Pressure AMBER ............................................................................ 15
Fault Code A412: Tire 2 (Front Right) No Data / Sensor Failure / Not Connected ............................................. 16
Fault Code A413: Tire 2 (Front Right) High Temperature RED........................................................................... 17
Fault Code A414: Tire 2 (Front Right) High Temperature AMBER ..................................................................... 18
1
CEN40182-00 40 Troubleshooting
Fault Code A415: Tire 2 (Front Right) Bad Value Sensor Error / Not Connected ............................................... 19
Fault Code A416: Tire 3 (Rear Left Outboard) High Pressure RED.................................................................... 20
Fault Code A417: Tire 3 (Rear Left Outboard) High Pressure AMBER .............................................................. 21
Fault Code A418: Tire 3 (Rear Left Outboard) Low Pressure RED .................................................................... 22
Fault Code A419: Tire 3 (Rear Left Outboard) Low Pressure AMBER ............................................................... 23
Fault Code A420: Tire 3 (Rear Left Outboard) No Data / Sensor Failure / Not Connected ................................ 24
Fault Code A421: Tire 3 (Rear Left Outboard) High Temperature RED.............................................................. 25
Fault Code A422: Tire 3 (Rear Left Outboard) High Temperature AMBER......................................................... 26
Fault Code A423: Tire 3 (Rear Left Outboard) Bad Value Sensor Error / Not Connected .................................. 27
Fault Code A424: Tire 4 (Rear Left Inboard) High Pressure RED ...................................................................... 28
Fault Code A425: Tire 4 (Rear Left Inboard) High Pressure AMBER ................................................................. 29
Fault Code A426: Tire 4 (Rear Left Inboard) Low Pressure RED ....................................................................... 30
Fault Code A427: Tire 4 (Rear Left Inboard) Low Pressure AMBER .................................................................. 31
Fault Code A428: Tire 4 (Rear Left Inboard) No Data / Sensor Failure / Not Connected ................................... 32
Fault Code A429: Tire 4 (Rear Left Inboard) High Temperature RED................................................................. 33
Fault Code A430: Tire 4 (Rear Left Inboard) High Temperature AMBER ........................................................... 34
Fault Code A431: Tire 4 (Rear Left Inboard) Bad Value Sensor Error / Not Connected ..................................... 35
Fault Code A432: Tire 5 (Rear Right Inboard) High Pressure RED .................................................................... 36
Fault Code A433: Tire 5 (Rear Right Inboard) High Pressure AMBER............................................................... 37
Fault Code A434: Tire 5 (Rear Right Inboard) Low Pressure RED..................................................................... 38
Fault Code A435: Tire 5 (Rear Right Inboard) Low Pressure AMBER................................................................ 39
Fault Code A436: Tire 5 (Rear Right Inboard) No Data / Sensor Failure / Not Connected................................. 40
Fault Code A437: Tire 5 (Rear Right Inboard) High Temperature RED .............................................................. 41
Fault Code A438: Tire 5 (Rear Right Inboard) High Temperature AMBER ......................................................... 42
Fault Code A439: Tire 5 (Rear Right Inboard) Bad Value Sensor Error / Not Connected................................... 43
Fault Code A440: Tire 6 (Rear Right Outboard) High Pressure RED ................................................................. 44
Fault Code A441: Tire 6 (Rear Right Outboard) High Pressure AMBER ............................................................ 45
Fault Code A442: Tire 6 (Rear Right Outboard) Low Pressure RED .................................................................. 46
Fault Code A443: Tire 6 (Rear Right Outboard) Low Pressure AMBER............................................................. 47
Fault Code A444: Tire 6 (Rear Right Outboard) No Data / Sensor Failure / Not Connected .............................. 48
Fault Code A445: Tire 6 (Rear Right Outboard) High Temperature RED ........................................................... 49
Fault Code A446: Tire 6 (Rear Right Outboard) High Temperature AMBER ...................................................... 50
Fault Code A447: Tire 6 (Rear Right Outboard) Bad Value Sensor Error / Not Connected................................ 51
2
40 Troubleshooting CEN40182-00
NOTES
3
CEN40182-00 40 Troubleshooting
Fault Code A400: Tire 1 (Front Left) High Pressure RED
Operator Action Stop; Park; Power Down
Fault Code A400
Description Tire 1 (Front Left) High Pressure RED Fault
Fault Conditions Sets if Pressure hardware max or Pressure limit RED max or Pressure band RED high
are on and Bad Value Sensor Error / Not Connected Fault is not on.
Resets when conditions change or steering bleed comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: #1 TIRE PRESSURE HI
Display Fault Code: A400
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 1 Data (CAN/RPC) Faults: A401, A402, A403, A404, A405, A406, A407
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
4
40 Troubleshooting CEN40182-00
Fault Code A401: Tire 1 (Front Left) High Pressure AMBER
Operator Action Go to Shop Now
Fault Code A401
Description Tire 1 (Front Left) High Pressure AMBER Fault
Fault Conditions Sets if pressure band AMBER high is on and Bad Value Sensor Error / Not Connected
Fault is not on.
Resets when conditions change or steering bleed comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: #1 TIRE PRESSURE HI
Display Fault Code: A401
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 1 Data (CAN/RPC) Faults: A400, A402, A403, A404, A405, A406, A407
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
5
CEN40182-00 40 Troubleshooting
Fault Code A402: Tire 1 (Front Left) Low Pressure RED
Operator Action Stop, Park, Power Down
Fault Code A402
Description Tire 1 (Front Left) Low Pressure RED Fault.
Fault Conditions Sets if Pressure hardware min or Pressure limit RED low or Pressure band RED low
are on and Bad Value Sensor Error / Not Connected Fault is not on.
Resets when conditions change or steering bleed comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: #1 TIRE PRESSURE LO
Display Fault Code: A402
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 1 Data (CAN/RPC) Faults: A400, A401, A403, A404, A405, A406, A407
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
6
40 Troubleshooting CEN40182-00
Fault Code A403: Tire 1 (Front Left) Low Pressure AMBER
Operator Action Go to Shop Now
Fault Code A403
Description Tire 1 (Front Left) Low Pressure AMBER Fault.
Fault Conditions Sets if pressure band AMBER low is on and Bad Value Sensor Error / Not Connected
Fault is not on.
Resets when conditions change or steering bleed comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: #1 TIRE PRESSURE LO
Display Fault Code: A403
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 1 Data (CAN/RPC) Faults: A400, A401, A402, A404, A405, A406, A407
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
7
CEN40182-00 40 Troubleshooting
Fault Code A404: Tire 1 (Front Left) No Data / Sensor Failure / Not Connected
Operator Action None
Fault Code A404
Description Tire 1 (Front Left) No Data / Sensor Failure / Not Connected Fault
Fault Conditions Sets if Tag time out is on and Bad Value sensor Error / Not Connected Fault is not on.
Resets if conditions change.
Operator Alerting Repair Status Light On
System Response Display Operator Action: None
Display Fault Description: TIRE #1 NO DATA
Display Fault Code: A404
Resulting Problem(s) Loss of tire monitoring could permit tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 1 Data (CAN/RPC) Faults: A400, A401, A402, A403, A405, A406, A407
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
8
40 Troubleshooting CEN40182-00
Fault Code A405: Tire 1 (Front Left) High Temperature RED
Operator Action Stop, Park, Power Down
Fault Code A405
Description Tire 1 (Front Left) High Temperature RED Fault.
Fault Conditions Sets if Temp limit RED is on and Bad Value sensor Error / Not Connected Fault is not
on.
Resets if conditions change or if steering bleed begins.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: #1 TIRE TEMP HI
Display Fault Code: A405
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 1 Data (CAN/RPC) Faults: A400, A401, A402, A403, A404, A406, A407
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
9
CEN40182-00 40 Troubleshooting
Fault Code A406: Tire 1 (Front Left) High Temperature AMBER
Operator Action Go to Shop Now
Fault Code A406
Description Tire 1 (Front Left) High Temperature AMBER Fault.
Fault Conditions Sets if Temp limit AMBER is on and Bad Value Sensor Error / Not Connected Fault is
not on.
Resets if conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: #1 TIRE TEMP HI
Display Fault Code: A406
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 1 Data (CAN/RPC) Faults: A400, A401, A402, A403, A404, A405, A407
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
10
40 Troubleshooting CEN40182-00
Fault Code A407: Tire 1 (Front Left) Bad Value Sensor Error / Not Connected
Operator Action None
Fault Code A407
Description Tire 1 (Front Left) Bad Value Sensor Error / Not Connected Fault.
Fault Conditions Sets if Last Tag Status Input is equal to 2. Resets if not equal to 2.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: TIRE #1 BAD VALUE
Display Fault Code: A407
Resulting Problem(s) Tire data is bad.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 1 Data (CAN/RPC) Faults: A400, A401, A402, A403, A404, A405, A406
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
11
CEN40182-00 40 Troubleshooting
Fault Code A408: Tire 2 (Front Right) High Pressure RED
Operator Action Stop, Park, Power Down
Fault Code A408
Description Tire 2 (Front Right) High Pressure RED Fault
Fault Conditions Sets if Pressure hardware max or Pressure limit RED max or Pressure band RED high
are on and Bad Value Sensor Error / Not Connected Fault is not on.
Resets when conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: #2 TIRE PRESSURE HI
Display Fault Code: A408
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 2 Data (CAN/RPC) Faults: A409, A410, A411, A412, A413, A414, A415
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
12
40 Troubleshooting CEN40182-00
Fault Code A409: Tire 2 (Front Right) High Pressure AMBER
Operator Action Go to Shop Now
Fault Code A409
Description Tire 2 (Front Right) High Pressure AMBER Fault
Fault Conditions Sets if pressure band AMBER high is on and Bad Value Sensor Error / Not Connected
Fault is not on.
Resets when conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: #2 TIRE PRESSURE HI
Display Fault Code: A409
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 2 Data (CAN/RPC) Faults: A408, A410, A411, A412, A413, A414, A415
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
13
CEN40182-00 40 Troubleshooting
Fault Code A410: Tire 2 (Front Right) Low Pressure RED
Operator Action Stop, Park, Power Down
Fault Code A410
Description Tire 2 (Front Right) Low Pressure RED Fault.
Fault Conditions Sets if Pressure hardware min or Pressure limit RED low or Pressure band RED low
are on and Bad Value Sensor Error / Not Connected Fault is not on.
Resets when conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: #2 TIRE PRESSURE LO
Display Fault Code: A410
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 2 Data (CAN/RPC) Faults: A408, A409, A411, A412, A413, A414, A415
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
14
40 Troubleshooting CEN40182-00
Fault Code A411: Tire 2 (Front Right) Low Pressure AMBER
Operator Action Go to Shop Now
Fault Code A411
Description Tire 2 (Front Right) Low Pressure AMBER Fault.
Fault Conditions Sets if pressure band AMBER low is on and Bad Value Sensor Error / Not Connected
Fault is not on.
Resets when conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: #2 TIRE PRESSURE LO
Display Fault Code: A411
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 2 Data (CAN/RPC) Faults: A408, A409, A410, A412, A413, A414, A415
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
15
CEN40182-00 40 Troubleshooting
Fault Code A412: Tire 2 (Front Right) No Data / Sensor Failure / Not Connected
Operator Action None
Fault Code A412
Description Tire 2 (Front Right) No Data / Sensor Failure / Not Connected Fault
Fault Conditions Sets if Tag time out is on and Bad Value sensor Error / Not Connected Fault is not on.
Resets if conditions change.
Operator Alerting Repair Status Light On
System Response Display Operator Action: None
Display Fault Description: TIRE #2 NO DATA
Display Fault Code: A412
Resulting Problem(s) Loss of tire monitoring could permit tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 2 Data (CAN/RPC) Faults: A408, A409, A410, A411, A413, A414, A415
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
16
40 Troubleshooting CEN40182-00
Fault Code A413: Tire 2 (Front Right) High Temperature RED
Operator Action Stop, Park, Power Down
Fault Code A413
Description Tire 2 (Front Right) High Temperature RED Fault.
Fault Conditions Sets if Temp limit RED is on and Bad Value sensor Error / Not Connected Fault is not
on.
Resets if conditions change or if steering bleed begins.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: #2 TIRE TEMP HI
Display Fault Code: A413
Resulting Problem(s) Potential Tire Damage
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 2 Data (CAN/RPC) Faults: A408, A409, A410, A411, A412, A414, A415
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
17
CEN40182-00 40 Troubleshooting
Fault Code A414: Tire 2 (Front Right) High Temperature AMBER
Operator Action Go to Shop Now
Fault Code A414
Description Tire 2 (Front Right) High Temperature AMBER Fault.
Fault Conditions Sets if Temp limit AMBER is on and Bad Value Sensor Error / Not Connected Fault is
not on.
Resets if conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: #2 TIRE TEMP HI
Display Fault Code: A414
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 2 Data (CAN/RPC) Faults: A408, A409, A410, A411, A412, A413, A415
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
18
40 Troubleshooting CEN40182-00
Fault Code A415: Tire 2 (Front Right) Bad Value Sensor Error / Not Connected
Operator Action None
Fault Code A415
Description Tire 2 (Front Right) Bad Value Sensor Error / Not Connected Fault.
Fault Conditions Sets if Last Tag Status Input is equal to 2. Resets if not equal to 2.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: TIRE #2 BAD VALUE
Display Fault Code: A415
Resulting Problem(s) Tire data is bad.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 2 Data (CAN/RPC) Faults: A408, A409, A410, A411, A412, A413, A414
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
19
CEN40182-00 40 Troubleshooting
Fault Code A416: Tire 3 (Rear Left Outboard) High Pressure RED
Operator Action Stop, Park, Power Down
Fault Code A416
Description Tire 3 (Rear Left Outboard) High Pressure RED Fault
Fault Conditions Sets if Pressure hardware max or Pressure limit RED max or Pressure band RED high
are on and Bad Value Sensor Error / Not Connected Fault is not on.
Resets when conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: #3 TIRE PRESSURE HI
Display Fault Code: A416
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 3 Data (CAN/RPC) Faults: A417, A418, A419, A420, A421, A422, A423
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
20
40 Troubleshooting CEN40182-00
Fault Code A417: Tire 3 (Rear Left Outboard) High Pressure AMBER
Operator Action Go To Shop Now
Fault Code A417
Description Tire 3 (Rear Left Outboard) High Pressure AMBER Fault
Fault Conditions Sets if pressure band AMBER high is on and Bad Value Sensor Error / Not Connected
Fault is not on.
Resets when conditions change or steering bleed comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: #3 TIRE PRESSURE HI
Display Fault Code: A417
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 3 Data (CAN/RPC) Faults: A416, A418, A419, A420, A421, A422, A423
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
21
CEN40182-00 40 Troubleshooting
Fault Code A418: Tire 3 (Rear Left Outboard) Low Pressure RED
Operator Action Stop, Park, Power Down
Fault Code A418
Description Tire 3 (Rear Left Outboard) Low Pressure RED Fault.
Fault Conditions Sets if Pressure hardware min or Pressure limit RED low or Pressure band RED low
are on and Bad Value Sensor Error / Not Connected Fault is not on.
Resets when conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: #3 TIRE PRESSURE LO
Display Fault Code: A418
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 3 Data (CAN/RPC) Faults: A416, A417, A419, A420, A421, A422, A423
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
22
40 Troubleshooting CEN40182-00
Fault Code A419: Tire 3 (Rear Left Outboard) Low Pressure AMBER
Operator Action Go to Shop Now
Fault Code A419
Description Tire 3 (Rear Left Outboard) Low Pressure AMBER Fault.
Fault Conditions Sets if pressure band AMBER low is on and Bad Value Sensor Error / Not Connected
Fault is not on.
Resets when conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: #3 TIRE PRESSURE LO
Display Fault Code: A419
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 3 Data (CAN/RPC) Faults: A416, A417, A418, A420, A421, A422, A423
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
23
CEN40182-00 40 Troubleshooting
Fault Code A420: Tire 3 (Rear Left Outboard) No Data / Sensor Failure / Not Connected
Operator Action None
Fault Code A420
Description Tire 3 (Rear Left Outboard) No Data / Sensor Failure / Not Connected Fault
Fault Conditions Sets if Tag time out is on and Bad Value sensor Error / Not Connected Fault is not on.
Resets if conditions change.
Operator Alerting Repair Status Light On
System Response Display Operator Action: None
Display Fault Description: TIRE #3 NO DATA
Display Fault Code: A420
Resulting Problem(s) Loss of tire monitoring could permit tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 3 Data (CAN/RPC) Faults: A416, A417, A418, A419, A421, A422, A423
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
24
40 Troubleshooting CEN40182-00
Fault Code A421: Tire 3 (Rear Left Outboard) High Temperature RED
Operator Action Stop, Park, Power Down
Fault Code A421
Description Tire 3 (Rear Left Outboard) High Temperature RED Fault.
Fault Conditions Sets if Temp limit RED is on and Bad Value sensor Error / Not Connected Fault is not
on.
Resets if conditions change or if steering bleed begins.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: #3 TIRE TEMP HI
Display Fault Code: A421
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 3 Data (CAN/RPC) Faults: A416, A417, A418, A419, A420, A422, A423
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
25
CEN40182-00 40 Troubleshooting
Fault Code A422: Tire 3 (Rear Left Outboard) High Temperature AMBER
Operator Action Go to Shop Now
Fault Code A422
Description Tire 3 (Rear Left Outboard) High Temperature AMBER Fault.
Fault Conditions Sets if Temp limit AMBER is on and Bad Value Sensor Error / Not Connected Fault is
not on.
Resets if conditions change or steering bleed comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: #3 TIRE TEMP HI
Display Fault Code: A422
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 3 Data (CAN/RPC) Faults: A416, A417, A418, A419, A420, A421, A423
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
26
40 Troubleshooting CEN40182-00
Fault Code A423: Tire 3 (Rear Left Outboard) Bad Value Sensor Error / Not Connected
Operator Action None
Fault Code A423
Description Tire 3 (Rear Left Outboard) Bad Value Sensor Error / Not Connected Fault.
Fault Conditions Sets if Last Tag Status Input is equal to 2. Resets if not equal to 2.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: TIRE #3 BAD VALUE
Display Fault Code: A423
Resulting Problem(s) Tire data is bad.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 3 Data (CAN/RPC) Faults: A416, A417, A418, A419, A420, A421, A422
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
27
CEN40182-00 40 Troubleshooting
Fault Code A424: Tire 4 (Rear Left Inboard) High Pressure RED
Operator Action Stop, Park, Power Down
Fault Code A424
Description Tire 4 (Rear Left Inboard) High Pressure RED Fault
Fault Conditions Sets if Pressure hardware max or Pressure limit RED max or Pressure band RED high
are on and Bad Value Sensor Error / Not Connected Fault is not on.
Resets when conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: #4 TIRE PRESSURE HI
Display Fault Code: A424
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 4 Data (CAN/RPC) Faults: A425, A426, A427, A428, A429, A430, A431
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
28
40 Troubleshooting CEN40182-00
Fault Code A425: Tire 4 (Rear Left Inboard) High Pressure AMBER
Operator Action Go to Shop Now
Fault Code A425
Description Tire 4 (Rear Left Inboard) High Pressure AMBER Fault
Fault Conditions Sets if pressure band AMBER high is on and Bad Value Sensor Error / Not Connected
Fault is not on.
Resets when conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: #4 TIRE PRESSURE HI
Display Fault Code: A425
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 4 Data (CAN/RPC) Faults: A424, A426, A427, A428, A429, A430, A431
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
29
CEN40182-00 40 Troubleshooting
Fault Code A426: Tire 4 (Rear Left Inboard) Low Pressure RED
Operator Action Stop, Park, Power Down
Fault Code A426
Description Tire 4 (Rear Left Inboard) Low Pressure RED Fault.
Fault Conditions Sets if Pressure hardware min or Pressure limit RED low or Pressure band RED low
are on and Bad Value Sensor Error / Not Connected Fault is not on.
Resets when conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: #4 TIRE PRESSURE LO
Display Fault Code: A426
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 4 Data (CAN/RPC) Faults: A424, A425, A427, A428, A429, A430, A431
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
30
40 Troubleshooting CEN40182-00
Fault Code A427: Tire 4 (Rear Left Inboard) Low Pressure AMBER
Operator Action Go to Shop Now
Fault Code A427
Description Tire 4 (Rear Left Inboard) Low Pressure AMBER Fault.
Fault Conditions Sets if pressure band AMBER low is on and Bad Value Sensor Error / Not Connected
Fault is not on.
Resets when conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: #4 TIRE PRESSURE LO
Display Fault Code: A427
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 4 Data (CAN/RPC) Faults: A424, A425, A426, A428, A429, A430, A431
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
31
CEN40182-00 40 Troubleshooting
Fault Code A428: Tire 4 (Rear Left Inboard) No Data / Sensor Failure / Not Connected
Operator Action None
Fault Code A428
Description Tire 4 (Rear Left Inboard) No Data / Sensor Failure / Not Connected Fault
Fault Conditions Sets if Tag time out is on and Bad Value sensor Error / Not Connected Fault is not on.
Resets if conditions change.
Operator Alerting Repair Status Light On
System Response Display Operator Action: None
Display Fault Description: TIRE #4 NO DATA
Display Fault Code: A428
Resulting Problem(s) Loss of tire monitoring could permit tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 4 Data (CAN/RPC) Faults: A424, A425, A426, A427, A429, A430, A431
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
32
40 Troubleshooting CEN40182-00
Fault Code A429: Tire 4 (Rear Left Inboard) High Temperature RED
Operator Action Stop, Park, Power Down
Fault Code A429
Description Tire 4 (Rear Left Inboard) High Temperature RED Fault.
Fault Conditions Sets if Temp limit RED is on and Bad Value sensor Error / Not Connected Fault is not
on.
Resets if conditions change or if steering bleed valve begins.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: #4 TIRE TEMP HI
Display Fault Code: A429
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 4 Data (CAN/RPC) Faults: A424, A425, A426, A427, A428, A430, A431
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
33
CEN40182-00 40 Troubleshooting
Fault Code A430: Tire 4 (Rear Left Inboard) High Temperature AMBER
Operator Action Go to Shop Now
Fault Code A430
Description Tire 4 (Rear Left Inboard) High Temperature AMBER Fault.
Fault Conditions Sets if Temp limit AMBER is on and Bad Value Sensor Error / Not Connected Fault is
not on.
Resets if conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: #4 TIRE TEMP HI
Display Fault Code: A430
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 4 Data (CAN/RPC) Faults: A424, A425, A426, A427, A428, A429, A431
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
34
40 Troubleshooting CEN40182-00
Fault Code A431: Tire 4 (Rear Left Inboard) Bad Value Sensor Error / Not Connected
Operator Action None
Fault Code A431
Description Tire 4 (Rear Left Inboard) Bad Value Sensor Error / Not Connected Fault.
Fault Conditions Sets if Last Tag Status Input is equal to 2. Resets if not equal to 2.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: TIRE #4 BAD VALUE
Display Fault Code: A431
Resulting Problem(s) Tire data is bad.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 4 Data (CAN/RPC) Faults: A424, A425, A426, A427, A428, A429, A430
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
35
CEN40182-00 40 Troubleshooting
Fault Code A432: Tire 5 (Rear Right Inboard) High Pressure RED
Operator Action Stop, Park, Power Down
Fault Code A432
Description Tire 5 (Rear Right Inboard) High Pressure RED Fault
Fault Conditions Sets if Pressure hardware max or Pressure limit RED max or Pressure band RED high
are on and Bad Value Sensor Error / Not Connected Fault is not on.
Resets when conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: #5 TIRE PRESSURE HI
Display Fault Code: A432
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 5 Data (CAN/RPC) Faults: A433, A434, A435, A436, A437, A438, A439
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
36
40 Troubleshooting CEN40182-00
Fault Code A433: Tire 5 (Rear Right Inboard) High Pressure AMBER
Operator Action Go to Shop Now
Fault Code A433
Description Tire 5 (Rear Right Inboard) High Pressure AMBER Fault
Fault Conditions Sets if pressure band AMBER high is on and Bad Value Sensor Error / Not Connected
Fault is not on.
Resets when conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: #5 TIRE PRESSURE HI
Display Fault Code: A433
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 5 Data (CAN/RPC) Faults: A432, A434, A435, A436, A437, A438, A439
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
37
CEN40182-00 40 Troubleshooting
Fault Code A434: Tire 5 (Rear Right Inboard) Low Pressure RED
Operator Action Stop, Park, Power Down
Fault Code A434
Description Tire 5 (Rear Right Inboard) Low Pressure RED Fault.
Fault Conditions Sets if Pressure hardware min or Pressure limit RED low or Pressure band RED low
are on and Bad Value Sensor Error / Not Connected Fault is not on.
Resets when conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: #5 TIRE PRESSURE LO
Display Fault Code: A434
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 5 Data (CAN/RPC) Faults: A432, A433, A435, A436, A437, A438, A439
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
38
40 Troubleshooting CEN40182-00
Fault Code A435: Tire 5 (Rear Right Inboard) Low Pressure AMBER
Operator Action Go to Shop Now
Fault Code A435
Description Tire 5 (Rear Right Inboard) Low Pressure AMBER Fault.
Fault Conditions Sets if pressure band AMBER low is on and Bad Value Sensor Error / Not Connected
Fault is not on.
Resets when conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: #5 TIRE PRESSURE LO
Display Fault Code: A435
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 5 Data (CAN/RPC) Faults: A432, A433, A434, A436, A437, A438, A439
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
39
CEN40182-00 40 Troubleshooting
Fault Code A436: Tire 5 (Rear Right Inboard) No Data / Sensor Failure / Not Connected
Operator Action None
Fault Code A436
Description Tire 5 (Rear Right Inboard) No Data / Sensor Failure / Not Connected Fault
Fault Conditions Sets if Tag time out is on and Bad Value sensor Error / Not Connected Fault is not on.
Resets if conditions change.
Operator Alerting Repair Status Light On
System Response Display Operator Action: None
Display Fault Description: TIRE #5 NO DATA
Display Fault Code: A436
Resulting Problem(s) Loss of tire monitoring could permit tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 5 Data (CAN/RPC) Faults: A432, A433, A434, A435, A437, A438, A439
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
40
40 Troubleshooting CEN40182-00
Fault Code A437: Tire 5 (Rear Right Inboard) High Temperature RED
Operator Action Stop, Park, Power Down
Fault Code A437
Description Tire 5 (Rear Right Inboard) High Temperature RED Fault.
Fault Conditions Sets if Temp limit RED is on and Bad Value sensor Error / Not Connected Fault is not
on.
Resets if conditions change or if steering bleed valve begins.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: #5 TIRE TEMP HI
Display Fault Code: A437
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 5 Data (CAN/RPC) Faults: A432, A433, A434, A435, A436, A438, A439
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
41
CEN40182-00 40 Troubleshooting
Fault Code A438: Tire 5 (Rear Right Inboard) High Temperature AMBER
Operator Action Go to Shop Now
Fault Code A438
Description Tire 5 (Rear Right Inboard) High Temperature AMBER Fault.
Fault Conditions Sets if Temp limit AMBER is on and Bad Value Sensor Error / Not Connected Fault is
not on.
Resets if conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: #5 TIRE TEMP HI
Display Fault Code: A438
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 5 Data (CAN/RPC) Faults: A432, A433, A434, A435, A436, A437, A439
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
42
40 Troubleshooting CEN40182-00
Fault Code A439: Tire 5 (Rear Right Inboard) Bad Value Sensor Error / Not Connected
Operator Action None
Fault Code A439
Description Tire 5 (Rear Right Inboard) Bad Value Sensor Error / Not Connected Fault.
Fault Conditions Sets if Last Tag Status Input is equal to 2. Resets if not equal to 2.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: TIRE #5 BAD VALUE
Display Fault Code: A439
Resulting Problem(s) Tire data is bad.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 5 Data (CAN/RPC) Faults: A432, A433, A434, A435, A436, A437, A438
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
43
CEN40182-00 40 Troubleshooting
Fault Code A440: Tire 6 (Rear Right Outboard) High Pressure RED
Operator Action Stop, Park, Power Down
Fault Code A440
Description Tire 6 (Rear Right Outboard) High Pressure RED Fault
Fault Conditions Sets if Pressure hardware max or Pressure limit RED max or Pressure band RED high
are on and Bad Value Sensor Error / Not Connected Fault is not on.
Resets when conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: #6 TIRE PRESSURE HI
Display Fault Code: A440
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 6 Data (CAN/RPC) Faults: A441, A442, A443, A444, A445, A446, A447
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
44
40 Troubleshooting CEN40182-00
Fault Code A441: Tire 6 (Rear Right Outboard) High Pressure AMBER
Operator Action Go to Shop Now
Fault Code A441
Description Tire 6 (Rear Right Outboard) High Pressure AMBER Fault
Fault Conditions Sets if pressure band AMBER high is on and Bad Value Sensor Error / Not Connected
Fault is not on.
Resets when conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: #6 TIRE PRESSURE HI
Display Fault Code: A441
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 6 Data (CAN/RPC) Faults: A440, A442, A443, A444, A445, A446, A447
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
45
CEN40182-00 40 Troubleshooting
Fault Code A442: Tire 6 (Rear Right Outboard) Low Pressure RED
Operator Action Stop, Park, Power Down
Fault Code A442
Description Tire 6 (Rear Right Outboard) Low Pressure RED Fault.
Fault Conditions Sets if Pressure hardware min or Pressure limit RED low or Pressure band RED low
are on and Bad Value Sensor Error / Not Connected Fault is not on.
Resets when conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: #6 TIRE PRESSURE LO
Display Fault Code: A442
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 6 Data (CAN/RPC) Faults: A440, A441, A443, A444, A445, A446, A447
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
46
40 Troubleshooting CEN40182-00
Fault Code A443: Tire 6 (Rear Right Outboard) Low Pressure AMBER
Operator Action Go to Shop Now
Fault Code A443
Description Tire 6 (Rear Right Outboard) Low Pressure AMBER Fault.
Fault Conditions Sets if pressure band AMBER low is on and Bad Value Sensor Error / Not Connected
Fault is not on.
Resets when conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: #6 TIRE PRESSURE LO
Display Fault Code: A443
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 6 Data (CAN/RPC) Faults: A440, A441, A442, A444, A445, A446, A447
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
47
CEN40182-00 40 Troubleshooting
Fault Code A444: Tire 6 (Rear Right Outboard) No Data / Sensor Failure / Not Connected
Operator Action None
Fault Code A444
Description Tire 6 (Rear Right Outboard) No Data / Sensor Failure / Not Connected Fault
Fault Conditions Sets if Tag time out is on and Bad Value sensor Error / Not Connected Fault is not on.
Resets if conditions change.
Operator Alerting Repair Status Light On
System Response Display Operator Action: None
Display Fault Description: TIRE #6 NO DATA
Display Fault Code: A444
Resulting Problem(s) Loss of tire monitoring could permit tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 6 Data (CAN/RPC) Faults: A440, A441, A442, A443, A445, A446, A447
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
48
40 Troubleshooting CEN40182-00
Fault Code A445: Tire 6 (Rear Right Outboard) High Temperature RED
Operator Action Stop, Park, Power Down
Fault Code A445
Description Tire 6 (Rear Right Outboard) High Temperature RED Fault.
Fault Conditions Sets if Temp limit RED is on and Bad Value sensor Error / Not Connected Fault is not
on.
Resets if conditions change or if steering bleed begins.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: STOP: PARK: PWR
Display Fault Description: #6 TIRE TEMP HI
Display Fault Code: A445
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 6 Data (CAN/RPC) Faults: A440, A441, A442, A443, A444, A446, A447
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
49
CEN40182-00 40 Troubleshooting
Fault Code A446: Tire 6 (Rear Right Outboard) High Temperature AMBER
Operator Action Go to Shop Now
Fault Code A446
Description Tire 6 (Rear Right Outboard) High Temperature AMBER Fault.
Fault Conditions Sets if Temp limit AMBER is on and Bad Value Sensor Error / Not Connected Fault is
not on.
Resets if conditions change or steering bleed valve comes on.
Operator Alerting Sound Buzzer
System Response Flash Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: #6 TIRE TEMP HI
Display Fault Code: A446
Resulting Problem(s) Potential tire damage.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 6 Data (CAN/RPC) Faults: A440, A441, A442, A443, A444, A445, A447
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
50
40 Troubleshooting CEN40182-00
Fault Code A447: Tire 6 (Rear Right Outboard) Bad Value Sensor Error / Not Connected
Operator Action None
Fault Code A447
Description Tire 6 (Rear Right Outboard) Bad Value Sensor Error / Not Connected Fault.
Fault Conditions Sets if Last Tag Status Input is equal to 2. Resets if not equal to 2.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: TIRE #6 BAD VALUE
Display Fault Code: A447
Resulting Problem(s) Tire data is bad.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Parameter Expected State and/or Related Fault(s)
Tire 6 Data (CAN/RPC) Faults: A440, A441, A442, A443, A444, A445, A446
(IMI,j,k)
Related Circuit Diagram
Circuit Description Circuit Reference
None None
51
CEN40182-00 40 Troubleshooting
730E Dump truck
830E Dump truck
930E Dump truck
980E Dump truck
Form No. CEN40182-00
52
CEN40104-05
DUMP TRUCK
860E
960E
980E
Machine model Serial number Machine model Serial number
860E-1K A30031 - A30035, 960E-1K A50003 - A50010
A30041, A30042, 960E-2 A30027 and up
A30044 - A30046, 960E-2K A50011 and up
A30101, A30107 - 960E-2KT A50028 and up
A30110, A30117, 980E-4 A40003 and up
A30118 980E-4AT A40003 and up
860E-1KT A30004 - A30030, 980E-5 A50005 and up
A30036 - A30040, 980E-5AT A50005 and up
A30043, A30047 -
A30100, A30102 -
A30106, A30111 -
A30116
40 Troubleshooting
Steering system
Steering circuit troubleshooting chart.................................................................................................................... 3
Steering circuit troubleshooting guidelines............................................................................................................ 5
Basic hydraulic system checks ............................................................................................................................. 6
System leakage check .......................................................................................................................................... 7
Steering pump troubleshooting guide ................................................................................................................... 9
Pump pressure control checks............................................................................................................................ 12
1
CEN40104-05 40 Troubleshooting
NOTES
2
40 Troubleshooting CEN40104-05
Steering circuit troubleshooting chart
SUGGESTED CORRECTIVE
TROUBLE POSSIBLE CAUSE
ACTION
1. Overloaded steering axle 1. Reduce axle loading.
2. Malfunctioning relief valve preventing 2. Check system pressure.
Slow steering, hard adequate system pressure build-up Adjust or replace relief valve.
steering or loss of power
assist 3. Worn or malfunctioning pump 3. Replace pump.
4. Restricted high pressure filter or suction 4. Replace filter element or clean
strainer strainer.
1. A small rate of extension may
1. Rod end of cylinder slowly extends be normal on a closed center
Drift - truck veers slowly in without turning the steering wheel system.
one direction. 2. Inspect and replace linkage if
2. Worn or damaged steering linkage necessary. Check alignment
or toe-in of the front wheels.
1. Correct oil supply problem or
1. Air in system due to low oil level, pump bleed air.
cavitation, leaking fitting, pinched hoses 2. Repair or replace steering
2. Loose cylinder piston cylinder.
3. Broken centering springs (spool valve, 3. Repair or replace steering
Wander - truck will not stay steering valve) control unit.
in straight line
4. Worn mechanical linkage 4. Repair or replace.
5. Bent linkage or cylinder rod 5. Repair or replace defective
6. Severe wear in steering control unit components.
6. Repair or replace steering
control unit.
Slip - a slow movement of 1. Leakage of steering cylinder piston 1. Repair or replace steering
steering wheel fails to steer seals cylinder.
front wheels 2. Worn steering control unit meter 2. Replace steering control unit.
1. Low oil level 1. Service hydraulic tank and
Spongy or soft steering 2. Air in hydraulic system. Probably air check for leakage.
trapped in cylinders or lines. 2. Bleed air from system.
1. Air in system due to low oil level, 1. Correct condition and add oil
cavitating pump, leaky fittings, pinched as necessary.
Erratic steering hose, etc. 2. Repair or replace steering
2. Loose steering cylinder piston cylinder.
1. Splines of steering column/steering 1. Repair or replace steering
control unit coupling may be column or coupling.
Free wheeling - steering disengaged or damaged 2. Repair as required:
wheel turns freely with no 2. No flow to steering control unit: a. Add oil and check for
back pressure - front a. Low oil level leakage.
wheels do not steer b. Ruptured hose b. Replace hose.
c. Broken steering control unit gerotor c. Repair or replace steering
drive pin control unit.
3
CEN40104-05 40 Troubleshooting
SUGGESTED CORRECTIVE
TROUBLE POSSIBLE CAUSE
ACTION
1. Check for loose fitting
bearings at anchor points in
1. Broken or worn linkage between
Excessive free play at steering linkage between
steering cylinder and steered wheels
steered wheels cylinder and steered wheels.
2. Leaky steering cylinder seals
2. Repair or replace steering
cylinder.
1. Align column to steering
1. Binding or misalignment in steering control unit.
column or splined coupling and steering 2. Remove restriction in the lines
control unit or circuit. Check for
2. High back pressure in tank can cause obstruction or pinched lines.
Binding or poor centering of
slow return to center - should not 3. Clean steering control unit and
steered wheels
exceed 2 068 kPa (300 psi) filter the oil. If another
3. Large particles can cause binding component has malfunctioned
between the spool and sleeve in the (generating contaminating
steering control unit materials), flush the entire
hydraulic system.
1. Clean the steering control unit.
1. Large particles in meter section 2. Check hydraulic system
Steering control unit locks
2. Insufficient hydraulic power pressure.
up
3. Severe wear and/or broken pin 3. Repair or replace steering
control unit.
1. Check line routing and
Steering wheel oscillates or 1. Lines connected to wrong ports
connections.
turns by itself 2. Parts assembled wrong; steering
2. Reassemble correctly and re-
control unit improperly timed
time control valve.
Steered wheels turn in
opposite direction when 1. Inspect and correct line
1. Lines connected to wrong cylinder ports
operator turns steering connections.
wheel
4
40 Troubleshooting CEN40104-05
Steering circuit troubleshooting
guidelines
These troubleshooting guidelines are intended to
assist in diagnosing steering pump problems. How-
ever, before troubleshooting the pump, basic checks Verify all pressure gauges being used are in good
should be performed on the steering and braking sys- working condition and properly calibrated.
tems. These checks are listed in the topic Basic
Hydraulic System Checks. These checks are
sequenced to determine whether the issue is due to
the pump or elsewhere in the system. Failure to per-
form these checks may result in unnecessary compo- To prevent hydraulic system contamination, clean
nent replacement or unnecessary repairs. system components before installing gauges or
removing hoses, fittings, etc. Use caps and plugs
on open hoses and fittings to keep dirt from
entering the system during testing and
maintenance.
Various hydraulic pressure settings are referenced
in this bulletin. Use only those values for the truck
model being serviced. Damage or injury may result
if incorrect values are used.
DO NOT loosen or disconnect hydraulic lines or
components until the engine is stopped and the
engine start switch has been OFF for at least 90
seconds.
Pressurized hydraulic fluid can have sufficient
force to enter a person's body by penetrating the
skin. This can cause serious injury and possibly
death. If fluid has penetrated the skin, immediately
seek the proper medical treatment by a physician
familiar with this injury.
Depressurize system accumulators before
opening hydraulic circuits or installing test
gauges.
For the steering circuit, turn the engine start
switch to OFF and allow 90 seconds for the
accumulators to depressurize. After 90 seconds,
turn the steering wheel to verify that pressure has
been purged from the circuit. If the wheels do not
move, the steering circuit is safe to service.
For the brake circuit, chock the wheels. Then open
the shut-off valves on the brake manifold. Opening
the valves allows accumulator pressure to be
released.
5
CEN40104-05 40 Troubleshooting
Basic hydraulic system checks
Table 1: Basic Hydraulic System Checks
Truck Condition Verification Check Corrective Action
Truck parked on level Confirm reported problem:
ground with wheels - Talk to operator
Refer to the service
chocked, engine at low - Operator repair report
manual to determine the
idle, steering and braking - Truck warning lights
cause.
system pressurized (if - Truck audible alarms
possible) - Truck fault code record (if equipped)
Verify oil level in hydraulic tank. Refill as needed.
Verify hydraulic tank breather(s) are not plugged. Repair.
Visually inspect for external leakage. Repair.
Verify pump suction shut-off valve (if equipped) is fully open. Fully open valve.
Visually inspect hoses for kinks or damage. Look for abrasions,
cracks, blisters, separations, delaminations and bulges.
Disconnect and inspect interior if suspect. Inspect each hose:
- Suction / inlet Repair.
Truck parked on level
- Pressure / outlet
ground with wheels
- Accumulator feedback
chocked, key off, engine
- Case drain
off, hydraulic steering and
braking system Inspect for unusual odors such as burnt oil and elastomers
depressurized Locate and repair.
(seals) near pump, valves and cylinders.
Visually inspect pump drive shaft connection. Repair.
Verify pump stroke adjuster setting.
Reset. Refer to Testing
Altitude < 3 050 m (10,000 ft)
and Adjusting, Steering,
- Full out
brake cooling and hoist
Altitude > 3 050 m (10,000 ft)
hydraulic system.
- 6.5 turns in
Verify bleeddown manifold solenoid actuates while cycling the
Repair.
key off and on.
Visually inspect for external leakage Repair.
Visually inspect hoses for kinks, distortion, collapses and bulges.
Turn off engine, depressurize, disconnect and inspect hose
interior if suspect. Inspect each hose:
- Suction / inlet
Repair.
Truck parked on level - Pressure / outlet
ground with wheels - Accumulator feedback
chocked, engine at low - Pump Case drain
idle, steering and braking Note: Maximum pump case pressure = 172 kPa (25 psi)
system pressurized (if
Listen for unusual sounds such as bypassing oil, mechanical
possible) Locate and repair.
grinding, aeration and cavitation (rapid popping sound in pump).
Inspect components for abnormal local heat generation using
Locate and repair.
hand contact or infrared temperature gun.
Check for system leakage. Refer to "System leakage
check".
6
40 Troubleshooting CEN40104-05
System leakage check 4. Connect a 0 - 35 000 kPa (0-5000 psi) pressure
1. Park the truck on level ground and turn the gauge to GPA test port (7, Figure 40-1) on the
engine off. Wait 90 seconds for the steering steering pump. Connect a second 0 - 35 000 kPa
accumulators to depressurize. Turn the steering (0-5000 psi) pressure gauge to the steering
wheel to verify that the steering system is no bleeddown manifold at test port TP2 (2,
longer pressurized. Figure 40-2).
2. Chock the wheels. 5. Start the engine and allow the steering and brake
accumulators to pressurize. Do not turn the
3. Open both brake accumulator bleeddown valves
steering wheel or apply the brakes until the test is
to completely depressurize the brake
complete. The steering pump should unload if
accumulators.
operating properly.
FIGURE 40-1. STEERING PUMP PORTS AND COMPONENTS
1. GP4 Test Port 5. Case Drain Fitting
2. Outlet To Filter 6. Suction
3. Unload Valve 7. GPA Test Port
4. Stroke Adjuster 8. GP2 Test Port
7
CEN40104-05 40 Troubleshooting
6. Allow the system pressure to stabilize for a 7. Turn the engine off by pulling up on the engine
minimum of three minutes after the manifold shutdown switch on the center console, but leave
gauge has reached its maximum pressure. The the engine start switch in the ON position. This
pressure gauge at GPA test port (7, Figure 40-1) will stop the engine without bleeding down the
should also rise to within 172 kPa (25 psi) of the steering accumulators.
pressure gauge at test port TP2 (2, Figure 40-2).
NOTE: The engine start switch must remain ON. The
For the purposes of this test, the manifold
steering accumulator bleeddown cycle will initiate if the
pressure is permitted to be less than the
engine start switch is turned to the OFF position.
specified reload/unload pressure range. If it is
greater, adjust the pressure controls as outlined 8. Observe the gauges as the engine stops. The
in the topic "Setting pump pressure controls". pump pressure gauge will drop to zero.
NOTE: Incorrect pressure readings could occur if the a. Slow pressure drop - If the manifold pressure
system is not allowed to stabilize for at least three gauge remains near the original (engine on)
minutes. pressure or drops slowly [less than 1 034 kPa
(150 psi) per minute], minimal leakage is pres-
a. If both gauges are at or near 0 kPa (0 psi), a ent. Pump functions may be confirmed refer-
pump problem is indicated. Refer to "Pump ring to "Steering pump troubleshooting guide".
case drain check".
b. Gradual pressure drop - If the manifold
b. If the pump gauge indicates pressure and the pressure gauge exhibits a gradual drop in
manifold gauge is at or near 0 kPa (0 psi), pressure (between 1 042 kPa (151 psi) and
confirm the manifold gauge is connected to 4 137 kPa (600 psi) per minute), leakage is
the correct port. If the gauge is on the correct present, but does not require repair prior to
port, inspect the system for blockage. confirming the pump functions by referring to
Blockage may be caused by a defective hose, "Steering pump troubleshooting guide".
a stuck inlet check valve or other obstruction, Hydraulic pump controls settings may require
or a hose installed on the wrong port. minor re-adjustment after the leaks are
repaired.
c. Excessive pressure drop - If both pressure
gauges drop rapidly to zero (greater than
4 137 kPa (600 psi) per minute), excessive
leakage is present. The system downstream
of the pump is leaking excessively. Locate and
repair the leakage before proceeding to
"Steering pump troubleshooting guide".
FIGURE 40-2. BLEEDDOWN MANIFOLD
1. Bleeddown Manifold 2. Test Port TP2
8
40 Troubleshooting CEN40104-05
Steering pump troubleshooting guide
The pump troubleshooting guide assumes the steering
and braking systems have successfully passed the
recommended checks listed in Table 1. Failure to
perform these checks prior to troubleshooting may
result in misdiagnosis, unnecessary component Follow the safety guidelines outlined in the shop
replacement or delayed repairs. manual when working with the hydraulic system.
Serious injury or death may occur if proper safety
guidelines are not followed.
Table 2: Steering pump troubleshooting guide
SYMPTOM POSSIBLE CAUSE DIAGNOSTIC VERIFICATION CORRECTIVE ACTION
Pump input shaft not Verify internal part movement by
Repair.
turning placing hand on pump case.
Bleed trapped air. Refer to
Perform audible check with the
Air trapped inside pump Steering and Brake Pump -
engine on.
No output flow Installation in Section 50.
Pump pressure control
Perform pump pressure control Refer to "Pump pressure control
malfunctioning or set
checks. checks"
incorrectly
Pump internal parts Refer to "Pump case drain
Perform pump case drain check.
worn check".
Pump pressure control Perform pump pressure control Refer to "Pump pressure control
settings incorrect checks. checks"
Low flow -
Initial charge time Pump internal parts Refer to "Pump case drain
Perform pump case drain check.
exceeds 2 minutes worn check".
with truck stationary
and engine idling Check for clogged suction strainer.
Clean hydraulic tank and
Limited oil at pump inlet Note: Maximum suction vacuum =
strainer.
35 mm (1.4 in.) Hg.
Check warning light in cab.
Note: Precharge switch factory Refill with nitrogen as needed.
Accumulator precharge setting = 7 584 kPa (1100 psi). Refer to steering accumulator
low Verify precharge pressure of 9 653 charging procedure in Section
kPa (1400 psi) at 21° C (70° F) with 30.
gauge.
Pump short cycling -
Demand exceeds pump
Cycle period less Excessive steering or braking usage. Train operator.
capacity
than specification.
Inspect movement audibly or with
Accumulator piston
sensors. Inspect for excess oil above Repair.
travel restricted
piston.
Inspect for hot oil flow in
Refer to "Pump control valve
Unload valve leakage accumulator feedback hose using
inspection and trouble shooting".
hand contact or infrared heat gun.
9
CEN40104-05 40 Troubleshooting
Table 2: Steering pump troubleshooting guide
SYMPTOM POSSIBLE CAUSE DIAGNOSTIC VERIFICATION CORRECTIVE ACTION
Pump pressure control Perform pump pressure control Refer to "Pump pressure control
settings incorrect checks. checks".
Pump internal parts Refer to "Pump case drain
Perform pump case drain check.
Low pressure worn check".
Check for clogged suction strainer.
Clean hydraulic tank and
Limited oil at pump inlet Note: Maximum suction vacuum =
strainer.
35 mm (1.4 in.) Hg.
Pump pressure controls Perform pump pressure control Refer to "Pump pressure control
malfunctioning checks. checks".
Pump internal parts Refer to "Pump case drain
Perform pump case drain check.
Sluggish response worn check".
Check for clogged suction strainer.
Clean hydraulic tank and
Limited oil at pump inlet Note: Maximum suction vacuum =
strainer.
35 mm (1.4 in.) Hg.
Visually inspect suction hoses and
Air entering pump Tighten loose fittings, repair
connections. Coat suspect areas
suction seals as needed.
with heavy oil or grease
Check indicator light in cab.
Clogged hydraulic
Note: Filter switch factory setting = Replace element.
steering filter
241 kPa (35 psi) drop.
Unsteady or surging
Pump pressure controls Refer to "Pump pressure control
pressure Check pump pressure controls.
malfunctioning checks".
Pump internal parts Refer to "Pump case drain
Perform pump case drain check.
worn check".
Check for clogged suction strainer.
Clogged hydraulic tank Clean hydraulic tank and
Note: Maximum suction vacuum =
suction strainers strainer.
35 mm (1.4 in.) Hg.
Pump pressure controls
Perform pump pressure control Refer to "Setting pump pressure
Excessive pressure malfunctioning or set
checks. controls".
incorrectly
10
40 Troubleshooting CEN40104-05
Table 2: Steering pump troubleshooting guide
SYMPTOM POSSIBLE CAUSE DIAGNOSTIC VERIFICATION CORRECTIVE ACTION
Reset. Refer to Testing and
Pump stroke adjuster set too high. Adjusting section, Steering,
(High altitude trucks only.) brake cooling and hoist
hydraulic system.
Verify hydraulic oil viscosity is
Restricted oil at inlet Correct or warm oil before
correct for current ambient
starting.
temperature.
Check for clogged suction strainer.
Clean hydraulic tank and
Note: Maximum suction vacuum =
strainer.
35 mm (1.4 in.) Hg.
Pump case has Disconnect hose at pump fitting.
Fill case.
insufficient oil Verify case is full.
Visually inspect suction hoses and
Air entering pump Tighten loose fittings, repair
Noisy connections. Coat suspect areas
suction seals as needed.
with heavy oil or grease.
Verify driveshaft fasteners are
Install and tighten as needed.
present and secure.
Pump input shaft Verify pump mounting fasteners and
misaligned brackets are present and secure.
Note: Maximum pump input shaft Install and tighten as needed.
misalignment = 0.13 mm (0.005 in.)
TIR.
Replace pump and flush system.
Examine hydraulic steering filter
Install new steering and hoist
element for debris.
Internal pump damage filter elements.
Refer to "Pump case drain
Perform pump case drain check.
check".
Visually inspect suction hoses and
Air entering pump Tighten loose fittings, repair
connections. Coat suspect areas
suction seals as needed.
with heavy oil or grease.
Measure suction and case drain oil
temperatures near the pump.
Repair or replace.
Excessive heat Maximum temperature rise through
Pump internal parts case drain = 15° C (59° F).
worn Measure suction and outlet oil
temperatures near the pump.
Repair or replace.
Maximum temperature rise through
main line = 7° C (45° F).
11
CEN40104-05 40 Troubleshooting
Pump pressure control checks To verify pump reloading:
To verify pump unload pressure: 1. With the steering accumulators charged and the
engine at low idle, observe the pressures on the
NOTE: The critical pressure setting is the reload
gauges. A drop in pressure indicates a loss of oil
pressure. The unload pressure cannot be set
from the steering accumulator system. Some loss
independently, but should be approximately 1 380 -
of oil is acceptable. Record the pressure at which
3 795 kPa (200 - 550 psi) above the reload pressure.
the pump reloads (starts pumping) to recharge
The purpose of this check is to determine if the unload
the accumulator system.
valve is functioning properly by unloading in the
correct pressure range above reload pressure. NOTE: If desired, the rate of pressure drop may be
increased by slightly opening a brake accumulator
1. Connect a 0 - 35 000 kPa (0 - 5000 psi) pressure
manual bleeddown valve, or by turning the steering
gauge to GPA test port (7, Figure 40-1) on the
wheel. Refer to the shop manual for the location of the
steering pump.
brake manifold bleeddown valves.
2. Start the engine. With the engine idling, the
accumulators should charge in less than two
minutes. Refer to the Pump Control Set Points
table for new truck charge time estimates. The
pressure indicated by the gauge will increase as
the accumulators charge. Note the pressure at
which the steering pump unloads (switches to Ensure that there is adequate clearance and no
stand-by). Pump unloading is indicated by an personnel in the area before turning the steering
abrupt reduction in the pump sound level. wheel.
a. If the unload pressure approximates the value a. If the reload pressure is 1 380 - 3 792 kPa
listed in Table 4, continue to verify pump (200 - 550 psi) below the observed unload
reloading. pressure, the unload valve is functioning prop-
b. If the pressure exceeds the specified value by erly. Specified unload pressure values are
more than 1 724 kPa (250 psi), or if the pump approximate. Observed pressures may differ.
does not unload, refer to "Pump fails to b. Next, verify the reload pressure is within the
unload". specifications listed in Table 4. Refer to
c. If the pressure is significantly less than the "Setting pump pressure controls" if adjustment
specified value, refer to "Pump fails to develop is required.
pressure". c. If the reload pressure is more than 3 792 kPa
d. If the charging time exceeds two minutes, (550 psi) below the unload pressure that was
refer to "Pump slow in developing pressure". observed in Step 1, the unload valve is not
functioning properly. Repair or replace the
control valve assembly. Refer to "Pump
control valve inspection and trouble shooting"
for details.
2. Close the brake accumulator bleeddown valves
that were opened during the test. Remove all
gauges. Cap or close all test ports.
12
40 Troubleshooting CEN40104-05
Pump fails to unload Pump fails to develop pressure
1. Install a 0 - 35 000 kPa (0 - 5000 psi) pressure 1. Install a 0 - 35 000 kPa (0 - 5000 psi) pressure
gauge in GPA test port (7, Figure 40-1). gauge in GPA test port (7, Figure 40-1).
2. Start the engine and allow the system to 2. Start the engine and allow the system to
pressurize. Do not turn the steering wheel or pressurize. Do not turn the steering wheel or
apply the brakes until the check is complete. apply the brakes until the check is complete.
3. Check the pressure on the gauge. a. If the pressure is 2 413 ± 1 034 kPa (350 ±
a. If the pressure is above 17 237 kPa (2500 psi) 150 psi) and constant, turn adjustment screw
and constant, turn the adjustment screw on on unload valve (1, Figure 40-1) inward (clock-
unload valve (1, Figure 40-1) outward (coun- wise).
terclockwise). •If the pump unloads at a higher pressure, the
•If the pump unloads at a lower pressure, reset valve has been set incorrectly. Reset the
the valve as outlined in "Setting pump valve as outlined in "Setting pump pressure
pressure controls". controls".
•If no change in pressure occurs, the control •If the pressure remains low, but above 1 379
valve assembly is malfunctioning. Inspect the kPa (200 psi), inspect the pump control valve
control valve assembly as outlined in "Pump assembly. Refer to "Pump control valve
control valve inspection and trouble inspection and trouble shooting".
shooting". b. If the pressure is 1 034 kPa (150 psi) or less,
b. If the pressure is below 17 237 kPa (2500 psi), the pump has internal damage. Repair or
turn the adjustment screw on unload valve (1, replace the pump.
Figure 40-1) outward (counterclockwise). The
pressure should drop. Turn the adjustment
screw inward (clockwise) by 2 1/2 turns.
•If the pressure increases, continue until
17 237 kPa (2500 psi) is achieved. Repeat
Step 3a.
•If no change in pressure occurs, or if 17 237
kPa (2500 psi) is not achieved, the control
valve assembly is malfunctioning. Inspect the
control valve assembly as outlined in "Pump
control valve inspection and trouble
shooting".
Table 3: Steering pump control pressures vs. stroke position
Pump State GPA GP2 GP4 Stroke Adjuster
(Output Pressure) (Control Pres- (Bias Pressure) Stud
sure) (Pump Stroke)1
Pumping System pressure near 0 kPa (0 psi) GPA + 0 / -3 447 kPa Stud tight
- (re)loading no pressure (+0 / -500 psi) - maximum stroke
Standby 1 379 - 2 758 kPa 0 - 2 758 kPa near 0 kPa (0 psi) Stud loose
- unloaded (200 - 400 psi) (0 - 400 psi) no pressure - minimum stroke
(1) Loosen the stud jam nut before testing. Retighten after testing is complete.
13
CEN40104-05 40 Troubleshooting
Pump slow in developing pressure Pump control valve inspection and trouble
1. Install 0 - 35 000 kPa (0 - 5000 psi) pressure shooting
gauges in GPA test port (7, Figure 40-1) and GP4 To inspect the 4-way valve:
test port (1). Start the engine and observe the
1. Use a 7/8" wrench to remove cap (7, Figure 40-3)
gauges. As the pump cycles, the pressures at
and the spring opposite the control block
both gauges should rise and fall at nearly the
pressure adjustment.
same rate.
2. Use a 7/8" wrench to remove cap (4). Remove 4-
a. If the pressures at the GPA test port and the way valve spool (6).
GP4 test port rise and fall simultaneously, pro-
ceed to Step 2. NOTE: Valve sleeve (10) is permanently fixed in the
control valve body and should not be removed.
b. If the pressure change at the GP4 test port is
noticeably slower than the GPA test port, 3. Verify the valve is free of contaminants and all
perform the following checks: orifices and passages are open. The spool is
hollow and contains small orifices. Flush with
•Inspect the orifice in the four-way valve. Refer clean hydraulic fluid or filtered, dry low pressure
to "Pump control valve inspection and trouble air. Do not use probes made of hard materials.
shooting".
4. Inspect the spool outer diameter for scratches
•Verify that the pump control piston seal ring is and indications of binding. Verify that the spool
not broken. Replace the ring or replace the slides freely within the control valve assembly.
pump as necessary. Replace the spool if defective.
•If no cause is found, the pump is leaking 5. Install the spool, spring and end caps. Tighten
internally. Repair or replace the pump. each cap to 68 N•m (50 ft lb).
2. Loosen the jam nut on stroke adjuster (4,
To inspect the unload valve:
Figure 40-1) and note the effort required to turn
the stud while the pump cycles. Refer to Table 3. 1. Use a 1-1/4" wrench to remove the unload valve
When the pump is unloaded, the stud will turn bonnet (3), spring and poppet.
easily. When the pump is loaded, the stud will be 2. Use a 7/16" socket to remove unload valve seat
difficult to turn. Do not use excessive force. (11) and the push pin.
a. If the stud is always loose or always tight, the 3. Verify that the seat seals are in good condition. If
pump has internal damage. Repair or replace the seal on the seat nose is missing or severely
the pump. eroded, replace the seals and seat.
b. If the stud turns easily when unloaded, and is 4. Verify that the sealing edges of the poppet and
difficult to turn when loaded, the pump control seat are well defined, free of chips, impressions
valves are functioning properly. Tighten the and embedded material. Replace as needed.
jam nut on the stroke adjuster. Continue to the 5. Inspect the outer diameter of the push pin for
next troubleshooting item. scratches and indications of binding. Verify that
the pin slides freely within the valve seat.
Replace the pin if defective.
6. Use a 7/8" wrench to remove cap (8).
7. Use a 3/16" hex wrench to remove the stop plug.
8. Verify that the valve is free of contaminants and
that all orifices and passages are open.
14
40 Troubleshooting CEN40104-05
NOTE: The stop plug is hollow and contains an orifice. 11. Insert the push pin into unload valve seat (11) and
9. Install the stop plug. Tighten the stop plug to 163 install the seat into the control block. Tighten the
N•m (120 in. lb). seat to 20 N•m (15 ft lb).
10. Install cap (8). Tighten the cap to 61 N•m (45 ft 12. Install the poppet, spring and unload valve
lb). bonnet (3). Tighten the bonnet body to 115 N•m
(85 ft lb).
13. Verify the final valve setting. Refer to "Setting
pump pressure controls" for details.
FIGURE 40-3. CONTROL VALVE ASSEMBLY
1. Adjustment Screw 6. 4-Way Valve Spool 9. Accumulator Feedback
2. Locking Cap (with Orifices) Port (ACC)
3. Unload Valve Bonnet 7. Cap (Spring Access) 10. Valve Sleeve
4. Cap (Spool) 8. Cap 11. Unload Valve Seat
5. Pressure (From Pump)
15
CEN40104-05 40 Troubleshooting
Pump case drain check Setting pump pressure controls
1. With the engine off, disconnect the case drain
hose from fitting (5, Figure 40-1). Plug the hose Table 4: Pump Control Set Points
to prevent contamination.
Pump Control Set Points
2. Connect a hose to case drain fitting (5) and place
the other end in an empty container [19 liters (5 Reload 19 133 ± 172 kPa
gal) or larger] to collect the hydraulic oil. (2,775 ± 25 psi)
860E
3. Although the pump is not turning, hydraulic oil Unload (1) 21 200 kPa
may flow from the hose. If flow occurs, measure (approximate) (3,075 psi)
and record the volume of oil that is discharged
Reload 22 236 ± 172 kPa
during a 60 second time period.
960E (3,225 ± 25 psi)
4. Start the engine and operate at idle.
980E Unload (1) 24 300 kPa
5. Measure and record the volume of oil that is
(approximate) (3,525 psi)
discharged in 60 seconds.
6. Visually inspect the oil for metallic contaminants. Charge time limits See Note 2
If found, replace the pump, flush the system and (reference)
clean the hydraulic filters and the tank. • Initial startup 60 seconds
7. Compare the recorded volumes.
• Recharge 6 seconds
a. If the volume obtained in Step 5 is less than
that obtained in Step 3, repeat the test. • Cycle period (min.) 20 seconds
b. If the two volumes are equal, the pump input (1) Reload and unload set points are not independently
shaft is not turning or the suction line is adjustable. One adjustment screw controls both. Set the
adjustment screw for the specified reload value. Actual
blocked. Inspect and repair as needed.
unload values may vary from that shown.
c. If the volume obtained in Step 5 is less than
(2) With the engine at low idle, truck stationary, oil above
13.3 liters (3.5 gal) above the volume obtained 20° C (68° F)
in Step 3, excessive internal pump wear is not
indicated. Return to troubleshooting.
d. If the volume obtained in Step 5 is greater than Reload set point - The pressure where the pump
13.3 liters (3.5 gal) above the volume obtained switches from its standby state to its pumping state as
in Step 3, excessive internal pump wear is the pressure within the steering and braking system
indicated. Repair or replace the pump. declines.
Unload set point - The pressure where the pump
switches from its pumping state to its standby state as
the pressure within the steering and braking system
increases.
Initial startup time - The time it takes to initially
charge the steering and braking system from a depres-
surized shut-down state to the pump unload pressure.
Recharge time - The time it takes to charge the steer-
ing and braking system from the pump reload pressure
to the unload pressure with the system at operating
temperature.
Cycle period - The time between consecutive pump
reloads (or unloads) with the system at operating tem-
perature. This is the total time it takes to cycle through
a pump reload, then unload, and return to reload.
NOTE: Cycle periods greater than the values listed are
desirable.
16
40 Troubleshooting CEN40104-05
This adjustment procedure assumes the following: 11. Turn the engine start switch to the OFF position to
stop the engine. Close the bleeddown valve that
• Truck parked on level ground with parking brake
set was opened in Step 7.
• Engine start switch in OFF position with engine off, 12. Start the engine and operate at low idle. Observe
and hydraulic system depressurized the reload and unload settings on the pressure
gauge while slowly steering the truck. Turn the
• Hydraulic tank filled to proper level engine start switch to the OFF position to stop the
• Steering pump functioning properly engine.
a. If the reload setting is within specifications,
proceed to Step 13.
1. Connect a 0 - 35 000 kPa (0 - 5000 psi) pressure
gauge to test port TP2 (2, Figure 40-2) on the b. If the reload setting is not within specifications,
steering accumulator bleeddown manifold. return to Step 5.
2. Start the engine and operate at low idle. Observe 13. Turn the engine start switch to the OFF position
the reload and unload settings on the pressure to stop the engine. Allow 90 seconds for the
gauge while slowly steering the truck. Turn the steering accumulators to completely
engine start switch to the OFF position to stop the depressurize. Turn the steering wheel to verify
engine. that no pressure remains.
3. If the reload setting is within specifications, 14. Remove the pressure gauge and cap test port
proceed to Step 11. TP2.
4. If the reload setting is not within specifications, 15. If the pump control valve cannot be adjusted to
proceed to the next step. specifications, return to the "Steering pump
5. Remove cap (2, Figure 40-3) located on unload troubleshooting guide".
valve (3).
6. Start the engine and operate at low idle.
7. Gradually open either brake accumulator
bleeddown valve on the brake manifold so that
the pump unloads every 20 to 30 seconds.
8. Slowly turn adjustment screw (1) outward
(counterclockwise) until the pump unloads. While
observing the pressure gauge, continue to back
out the screw (1/4 turn or less per cycle) until the
pump reloads at a pressure approximately 3 447
kPa (500 psi) less than the reload pressure listed
in Table 4.
9. Slowly turn the adjustment screw inward
(clockwise) until the specified reload pressure is
obtained for a minimum of three consecutive
cycles.
10. Repeat Steps 6 and 7 as necessary. Install and
tighten cap (2).
17
CEN40104-05 40 Troubleshooting
860E Dump truck
960E Dump truck
980E Dump truck
Form No. CEN40104-05
18
CEN40200-01
DUMP TRUCK
730E
830E
930E
980E
Machine model Serial number Machine model Serial number
730E-8 A40015 and up 980E-5 A50005 and up
730E-10 A50002 and up 980E-5AT A50005 and up
830E-5 A50005 and up
830E-5AT A50005 and up
930E-5 A40004 and up
930E-5AT A40004 and up
40 Troubleshooting
KomVision
KomVision fault codes .......................................................................................................................................... 3
1
CEN40200-01 40 Troubleshooting
NOTES
2
40 Troubleshooting CEN40200-01
KomVision fault codes
KOMVISION TROUBLESHOOTING
KAC SUB FAULT PHENOMENON KLTD
ACTION
CODE CODE PART NAME CODE
Camera
controller Please check camera harness.
Output power supply low voltage fault
CM0001 - output power Please exchange controllers, when DBP5KP
(under 6V)
supply1 (for there is no problem in harness.
camera 8V)
Please turn off the power for a while.
Camera
Please exchange controllers, when
CM0002 - controller over over temperature DBP0NR
the same error takes place, even if it
temperature
switches on a power supply again.
Camera
CM0003 - controller Communication fault Check the CAN5 harness DBPVKR
CAN5
Camera
CM0004 - controller Communication fault Check the CAN4 harness DBPUKR
CAN4
Camera
CM0005 - controller Communication fault Check the CAN3 harness DBPTKR
CAN3
Camera
CM0006 - controller Communication fault Check the CAN2 harness DBPQKR
CAN2
Camera
CM0007 - controller Communication fault Check the CAN1 harness DBPRKR
CAN1
CM0008 - LED Wire break Check the harness DUMBKA
Objection
CM0009 - detection Wire break Check the harness DV00KA
alarm
CM0010 - Fault alarm Wire break Check the harness DV01KA
Monitor display
CM0011 - Wire break Check the harness DPQ4KA
ON/OFF
CM0012 - Relay output Wire break Check the harness D1J0KA
CM0013 - LED Short-circuit Check the harness DUMBKB
Objection
CM0014 - detection Short-circuit Check the harness DV00KB
alarm
CM0015 - Fault alarm Short-circuit Check the harness DV01KB
Monitor display
CM0016 - Short-circuit Check the harness DPQ4KB
ON/OFF
CM0017 - Relay output Short-circuit Check the harness D1J0KB
I/F switch
CM0018 LP01 FRONT Switch Check the monitor panel harness DPQ1LD
panel
I/F switch
CM0018 LP02 RH FRONT Switch Check the monitor panel harness DPQ1LD
panel
3
CEN40200-01 40 Troubleshooting
KOMVISION TROUBLESHOOTING
KAC SUB FAULT PHENOMENON KLTD
ACTION
CODE CODE PART NAME CODE
I/F switch
CM0018 LP03 RH REAR Switch Check the monitor panel harness DPQ1LD
panel
I/F switch
CM0018 LP04 REAR Switch Check the monitor panel harness DPQ1LD
panel
I/F switch
CM0018 LP05 LH REAR Switch Check the monitor panel harness DPQ1LD
panel
I/F switch
CM0018 LP06 LH FRONT Switch Check the monitor panel harness DPQ1LD
panel
I/F switch
CM0018 LP07 Monitor Display Mode Switch Check the monitor panel harness DPQ1LD
panel
I/F switch
CM0018 LP08 Guide Line Display Switch Check the monitor panel harness DPQ1LD
panel
I/F switch
CM0018 LP09 Lower Body Display Switch Check the monitor panel harness DPQ1LD
panel
I/F switch
CM0018 LP10 Object Clear Switch Check the monitor panel harness DPQ1LD
panel
Camera
CM0019 CA01 The abnormalities of a main board Exchange the Camera controller DBP0KT
controller inner
Camera The abnormalities of an image-
CM0019 CA02 Exchange the Camera controller DBP0KT
controller inner processing board
Camera
CM0019 CA03 Device open error Exchange the Camera controller DBP0KT
controller inner
Camera
CM0019 CA04 Memory error Exchange the Camera controller DBP0KT
controller inner
Camera
CM0019 CA05 LUT generation error Exchange the Camera controller DBP0KT
controller inner
Camera
CM0019 CA06 C drive file IO error Exchange the Camera controller DBP0KT
controller inner
Please carry out Check disc.
Camera
CM0019 CA07 D drive file IO error Please exchange controllers, when DBP0KT
controller inner
not improved.
Camera
CM0019 CA08 The abnormalities in a thread Exchange the Camera controller DBP0KT
controller inner
Camera The abnormalities in an application
CM0019 CA09 Exchange the Camera controller DBP0KT
controller inner manager
Camera
CM0019 CA10 The file IO error for communication Exchange the Camera controller DBP0KT
controller inner
Camera
CM0019 CA11 Other errors Exchange the Camera controller DBP0KT
controller inner
Camera
Please carry out the 6 camera
CM0020 SA01 controller The calibration is not carried out. DBP0KM
calibration.
setting
Camera
CM0020 SA02 controller The Main setting is not carried out. Please carry out the main setting. DBP0KM
setting
4
40 Troubleshooting CEN40200-01
KOMVISION TROUBLESHOOTING
KAC SUB FAULT PHENOMENON KLTD
ACTION
CODE CODE PART NAME CODE
Camera
CM0020 SA03 controller The radar setup is not carried out. Please carry out a radar setup. DBP0KM
setting
Check the camera harness. If the
CM0050 - NTSC 1 input NTSC 1 input - Wire break harness has no problem, please DR10KA
exchange the camera1.
Check the camera harness. If the
CM0051 - NTSC 2 input NTSC 2 input - Wire break harness has no problem, please DR20KA
exchange the camera2.
Check the camera harness. If the
CM0052 - NTSC 3 input NTSC 3 input - Wire break harness has no problem, please DR30KA
exchange the camera3.
Check the camera harness. If the
CM0053 - NTSC 4 input NTSC 4 input - Wire break harness has no problem, please DR40KA
exchange the camera4.
Check the camera harness. If the
CM0054 - NTSC 5 input NTSC 5 input - Wire break harness has no problem, please DR50KA
exchange the camera5.
Check the camera harness. If the
CM0055 - NTSC 6 input NTSC 6 input - Wire break harness has no problem, please DR60KA
exchange the camera6.
CM0056 - Mirror output Mirror output - Short-circuit Check the camera harness DR11KB
ERR_SENS_TEMP_HIGH
CM0100 - UWB Radar 1 Exchange the Radar1 DQ11NR
(107 degrees or more)
CM0101 RC04 UWB Radar 1 ERR_SENS_VOLTAGE_INPUT Exchange the Radar1 DQ11MA
ERR_SENS_SENSITIVITY_LOW_
CM0101 RC01 UWB Radar 1 Exchange the Radar1 DQ11MA
EXTERNAL
Please check whether the radar is
interrupted by something. If there is
CM0101 RC02 UWB Radar 1 ERR_SENS_BLOCKAGE DQ11MA
nothing that is interrupted, Exchange
the Radar1
ERR_SENS_SENSITIVITY_LOW_
CM0101 RC03 UWB Radar 1 Exchange the Radar1 DQ11MA
EXTERNAL_NO_VEL
CM0102 - UWB Radar 1 HARNESS_FAULT Exchange the Radar1 DQ11KQ
ERR_SENS_SENSITIVITY_LOW_
CM0103 RA01 UWB Radar 1 Exchange the Radar1 DQ11KT
INTERNAL
ERR_SENS_HARDWARE_FAILURE_
CM0103 RA02 UWB Radar 1 Exchange the Radar1 DQ11KT
INIT
ERR_SENS_CALIBRATION_FAILUR
CM0103 RA03 UWB Radar 1 Exchange the Radar1 DQ11KT
E
ERR_SENS_HARDWARE_FAILURE_
CM0103 RA04 UWB Radar 1 Exchange the Radar1 DQ11KT
ONLINE
Please check whether there are any
abnormalities in a controller. If there
CM0104 RB01 UWB Radar 1 COMMUNICATION_ERROR DQ11KR
are no abnormalities in a controller,
Exchange the Radar1
5
CEN40200-01 40 Troubleshooting
KOMVISION TROUBLESHOOTING
KAC SUB FAULT PHENOMENON KLTD
ACTION
CODE CODE PART NAME CODE
ERR_SENS_CAN_MESSAGE_
CM0104 RB02 UWB Radar 1 Exchange the Radar1 DQ11KR
MISSING_OR_CONTENT_INVALID
ERR_SENS_CAN_SYNC_TIMING_
CM0104 RB03 UWB Radar 1 Exchange the Radar1 DQ11KR
INVALID
Exchange the Radar1. It may be
caused by disconnection when the
disconnection error has occurred
CM0105 - UWB Radar 1 VERSION FAULT DQ11KM
simultaneously.
Please cancel a disconnection error
first.
ERR_SENS_TEMP_HIGH
CM0200 - UWB Radar 2 Exchange the Radar2 DQ12NR
(107 degrees or more)
CM0201 RC04 UWB Radar 2 ERR_SENS_VOLTAGE_INPUT Exchange the Radar2 DQ12MA
ERR_SENS_SENSITIVITY_LOW_
CM0201 RC01 UWB Radar 2 Exchange the Radar2 DQ12MA
EXTERNAL
Please check whether the radar is
interrupted by something. If there is
CM0201 RC02 UWB Radar 2 ERR_SENS_BLOCKAGE DQ12MA
nothing that is interrupted, Exchange
the Radar2
ERR_SENS_SENSITIVITY_LOW_
CM0201 RC03 UWB Radar 2 Exchange the Radar2 DQ12MA
EXTERNAL_NO_VEL
CM0202 - UWB Radar 2 HARNESS_FAULT Exchange the Radar2 DQ12KQ
ERR_SENS_SENSITIVITY_LOW_
CM0203 RA01 UWB Radar 2 Exchange the Radar2 DQ12KT
INTERNAL
ERR_SENS_HARDWARE_FAILURE_
CM0203 RA02 UWB Radar 2 Exchange the Radar2 DQ12KT
INIT
ERR_SENS_CALIBRATION_FAILUR
CM0203 RA03 UWB Radar 2 Exchange the Radar2 DQ12KT
E
ERR_SENS_HARDWARE_FAILURE_
CM0203 RA04 UWB Radar 2 Exchange the Radar2 DQ12KT
ONLINE
Please check whether there are any
abnormalities in a controller. If there
CM0204 RB01 UWB Radar 2 COMMUNICATION_ERROR DQ12KR
are no abnormalities in a controller,
Exchange the Radar2
ERR_SENS_CAN_MESSAGE_
CM0204 RB02 UWB Radar 2 Exchange the Radar2 DQ12KR
MISSING_OR_CONTENT_INVALID
ERR_SENS_CAN_SYNC_TIMING_
CM0204 RB03 UWB Radar 2 Exchange the Radar2 DQ12KR
INVALID
Exchange the Radar2. It may be
caused by disconnection when the
CM0205 - UWB Radar 2 VERSION FAULT disconnection error has occurred DQ12KM
simultaneously. Please cancel a
disconnection error first.
ERR_SENS_TEMP_HIGH
CM0300 - UWB Radar 3 Exchange the Radar3 DQ13NR
(107 degrees or more)
CM0301 RC04 UWB Radar 3 ERR_SENS_VOLTAGE_INPUT Exchange the Radar3 DQ13MA
6
40 Troubleshooting CEN40200-01
KOMVISION TROUBLESHOOTING
KAC SUB FAULT PHENOMENON KLTD
ACTION
CODE CODE PART NAME CODE
ERR_SENS_SENSITIVITY_LOW_
CM0301 RC01 UWB Radar 3 Exchange the Radar3 DQ13MA
EXTERNAL
Please check whether the radar is
interrupted by something. If there is
CM0301 RC02 UWB Radar 3 ERR_SENS_BLOCKAGE DQ13MA
nothing that is interrupted, Exchange
the Radar3
ERR_SENS_SENSITIVITY_LOW_
CM0301 RC03 UWB Radar 3 Exchange the Radar3 DQ13MA
EXTERNAL_NO_VEL
CM0302 - UWB Radar 3 HARNESS_FAULT Exchange the Radar3 DQ13KQ
ERR_SENS_SENSITIVITY_LOW_
CM0303 RA01 UWB Radar 3 Exchange the Radar3 DQ13KT
INTERNAL
ERR_SENS_HARDWARE_FAILURE_
CM0303 RA02 UWB Radar 3 Exchange the Radar3 DQ13KT
INIT
ERR_SENS_CALIBRATION_FAILUR
CM0303 RA03 UWB Radar 3 Exchange the Radar3 DQ13KT
E
ERR_SENS_HARDWARE_FAILURE_
CM0303 RA04 UWB Radar 3 Exchange the Radar3 DQ13KT
ONLINE
Please check whether there are any
abnormalities in a controller. If there
CM0304 RB01 UWB Radar 3 COMMUNICATION_ERROR DQ13KR
are no abnormalities in a controller,
Exchange the Radar3
ERR_SENS_CAN_MESSAGE_
CM0304 RB02 UWB Radar 3 Exchange the Radar3 DQ13KR
MISSING_OR_CONTENT_INVALID
ERR_SENS_CAN_SYNC_TIMING_
CM0304 RB03 UWB Radar 3 Exchange the Radar3 DQ13KR
INVALID
Exchange the Radar3. It may be
caused by disconnection when the
disconnection error has occurred
CM0305 - UWB Radar 3 VERSION FAULT DQ13KM
simultaneously.
Please cancel a disconnection error
first.
ERR_SENS_TEMP_HIGH
CM0400 - UWB Radar 4 Exchange the Radar4 DQ14NR
(107 degrees or more)
CM0401 RC04 UWB Radar 4 ERR_SENS_VOLTAGE_INPUT Exchange the Radar4 DQ14MA
ERR_SENS_SENSITIVITY_LOW_
CM0401 RC01 UWB Radar 4 Exchange the Radar4 DQ14MA
EXTERNAL
Please check whether the radar is
interrupted by something. If there is
CM0401 RC02 UWB Radar 4 ERR_SENS_BLOCKAGE DQ14MA
nothing that is interrupted, Exchange
the Radar4
ERR_SENS_SENSITIVITY_LOW_
CM0401 RC03 UWB Radar 4 Exchange the Radar4 DQ14MA
EXTERNAL_NO_VEL
CM0402 - UWB Radar 4 HARNESS_FAULT Exchange the Radar4 DQ14KQ
ERR_SENS_SENSITIVITY_LOW_
CM0403 RA01 UWB Radar 4 Exchange the Radar4 DQ14KT
INTERNAL
ERR_SENS_HARDWARE_FAILURE_
CM0403 RA02 UWB Radar 4 Exchange the Radar4 DQ14KT
INIT
7
CEN40200-01 40 Troubleshooting
KOMVISION TROUBLESHOOTING
KAC SUB FAULT PHENOMENON KLTD
ACTION
CODE CODE PART NAME CODE
ERR_SENS_CALIBRATION_FAILUR
CM0403 RA03 UWB Radar 4 Exchange the Radar4 DQ14KT
E
ERR_SENS_HARDWARE_FAILURE_
CM0403 RA04 UWB Radar 4 Exchange the Radar4 DQ14KT
ONLINE
Please check whether there are any
abnormalities in a controller. If there
CM0404 RB01 UWB Radar 4 COMMUNICATION_ERROR DQ14KR
are no abnormalities in a controller,
Exchange the Radar4
ERR_SENS_CAN_MESSAGE_
CM0404 RB02 UWB Radar 4 Exchange the Radar4 DQ14KR
MISSING_OR_CONTENT_INVALID
ERR_SENS_CAN_SYNC_TIMING_
CM0404 RB03 UWB Radar 4 Exchange the Radar4 DQ14KR
INVALID
Exchange the Radar4. It may be
caused by disconnection when the
disconnection error has occurred
CM0405 - UWB Radar 4 VERSION FAULT DQ14KM
simultaneously.
Please cancel a disconnection error
first.
ERR_SENS_TEMP_HIGH
CM0500 - UWB Radar 5 Exchange the Radar5 DQ15NR
?107 degrees or more?
CM0501 RC04 UWB Radar 5 ERR_SENS_VOLTAGE_INPUT Exchange the Radar5 DQ15MA
ERR_SENS_SENSITIVITY_LOW_
CM0501 RC01 UWB Radar 5 Exchange the Radar5 DQ15MA
EXTERNAL
Please check whether the radar is
interrupted by something. If there is
CM0501 RC02 UWB Radar 5 ERR_SENS_BLOCKAGE DQ15MA
nothing that is interrupted, Exchange
the Radar5
ERR_SENS_SENSITIVITY_LOW_
CM0501 RC03 UWB Radar 5 Exchange the Radar5 DQ15MA
EXTERNAL_NO_VEL
CM0502 - UWB Radar 5 HARNESS_FAULT Exchange the Radar5 DQ15KQ
ERR_SENS_SENSITIVITY_LOW_
CM0503 RA01 UWB Radar 5 Exchange the Radar5 DQ15KT
INTERNAL
ERR_SENS_HARDWARE_FAILURE_
CM0503 RA02 UWB Radar 5 Exchange the Radar5 DQ15KT
INIT
ERR_SENS_CALIBRATION_FAILUR
CM0503 RA03 UWB Radar 5 Exchange the Radar5 DQ15KT
E
ERR_SENS_HARDWARE_FAILURE_
CM0503 RA04 UWB Radar 5 Exchange the Radar5 DQ15KT
ONLINE
Please check whether there are any
abnormalities in a controller. If there
CM0504 RB01 UWB Radar 5 COMMUNICATION_ERROR DQ15KR
are no abnormalities in a controller,
Exchange the Radar5
ERR_SENS_CAN_MESSAGE_
CM0504 RB02 UWB Radar 5 Exchange the Radar5 DQ15KR
MISSING_OR_CONTENT_INVALID
ERR_SENS_CAN_SYNC_TIMING_
CM0504 RB03 UWB Radar 5 Exchange the Radar5 DQ15KR
INVALID
8
40 Troubleshooting CEN40200-01
KOMVISION TROUBLESHOOTING
KAC SUB FAULT PHENOMENON KLTD
ACTION
CODE CODE PART NAME CODE
Exchange the Radar5. It may be
caused by disconnection when the
disconnection error has occurred
CM0505 - UWB Radar 5 VERSION FAULT DQ15KM
simultaneously.
Please cancel a disconnection error
first.
ERR_SENS_TEMP_HIGH
CM0600 - UWB Radar 6 Exchange the Radar6 DQ16NR
(107 degrees or more)
CM0601 RC04 UWB Radar 6 ERR_SENS_VOLTAGE_INPUT Exchange the Radar6 DQ16MA
ERR_SENS_SENSITIVITY_LOW_
CM0601 RC01 UWB Radar 6 Exchange the Radar6 DQ16MA
EXTERNAL
Please check whether the radar is
interrupted by something. If there is
CM0601 RC02 UWB Radar 6 ERR_SENS_BLOCKAGE DQ16MA
nothing that is interrupted, Exchange
the Radar6
ERR_SENS_SENSITIVITY_LOW_
CM0601 RC03 UWB Radar 6 Exchange the Radar6 DQ16MA
EXTERNAL_NO_VEL
CM0602 - UWB Radar 6 HARNESS_FAULT Exchange the Radar6 DQ16KQ
ERR_SENS_SENSITIVITY_LOW_
CM0603 RA01 UWB Radar 6 Exchange the Radar6 DQ16KT
INTERNAL
ERR_SENS_HARDWARE_FAILURE_
CM0603 RA02 UWB Radar 6 Exchange the Radar6 DQ16KT
INIT
ERR_SENS_CALIBRATION_FAILUR
CM0603 RA03 UWB Radar 6 Exchange the Radar6 DQ16KT
E
ERR_SENS_HARDWARE_FAILURE_
CM0603 RA04 UWB Radar 6 Exchange the Radar6 DQ16KT
ONLINE
Please check whether there are any
abnormalities in a controller. If there
CM0604 RB01 UWB Radar 6 COMMUNICATION_ERROR DQ16KR
are no abnormalities in a controller,
Exchange the Radar6
ERR_SENS_CAN_MESSAGE_
CM0604 RB02 UWB Radar 6 Exchange the Radar6 DQ16KR
MISSING_OR_CONTENT_INVALID
ERR_SENS_CAN_SYNC_TIMING_
CM0604 RB03 UWB Radar 6 Exchange the Radar6 DQ16KR
INVALID
Exchange the Radar6
It may be caused by disconnection
when the disconnection error has
CM0605 - UWB Radar 6 VERSION FAULT DQ16KM
occurred simultaneously.
Please cancel a disconnection error
first.
ERR_SENS_TEMP_HIGH
CM0700 - UWB Radar 7 Exchange the Radar7 DQ17NR
?107 degrees or more?
CM0701 RC04 UWB Radar 7 ERR_SENS_VOLTAGE_INPUT Exchange the Radar7 DQ17MA
ERR_SENS_SENSITIVITY_LOW_
CM0701 RC01 UWB Radar 7 Exchange the Radar7 DQ17MA
EXTERNAL
9
CEN40200-01 40 Troubleshooting
KOMVISION TROUBLESHOOTING
KAC SUB FAULT PHENOMENON KLTD
ACTION
CODE CODE PART NAME CODE
Please check whether the radar is
interrupted by something. If there is
CM0701 RC02 UWB Radar 7 ERR_SENS_BLOCKAGE DQ17MA
nothing that is interrupted, Exchange
the Radar7
ERR_SENS_SENSITIVITY_LOW_
CM0701 RC03 UWB Radar 7 Exchange the Radar7 DQ17MA
EXTERNAL_NO_VEL
CM0702 - UWB Radar 7 HARNESS_FAULT Exchange the Radar7 DQ17KQ
ERR_SENS_SENSITIVITY_LOW_
CM0703 RA01 UWB Radar 7 Exchange the Radar7 DQ17KT
INTERNAL
ERR_SENS_HARDWARE_FAILURE_
CM0703 RA02 UWB Radar 7 Exchange the Radar7 DQ17KT
INIT
ERR_SENS_CALIBRATION_FAILUR
CM0703 RA03 UWB Radar 7 Exchange the Radar7 DQ17KT
E
ERR_SENS_HARDWARE_FAILURE_
CM0703 RA04 UWB Radar 7 Exchange the Radar7 DQ17KT
ONLINE
Please check whether there are any
abnormalities in a controller. If there
CM0704 RB01 UWB Radar 7 COMMUNICATION_ERROR DQ17KR
are no abnormalities in a controller,
Exchange the Radar7
ERR_SENS_CAN_MESSAGE_
CM0704 RB02 UWB Radar 7 Exchange the Radar7 DQ17KR
MISSING_OR_CONTENT_INVALID
ERR_SENS_CAN_SYNC_TIMING_
CM0704 RB03 UWB Radar 7 Exchange the Radar7 DQ17KR
INVALID
Exchange the Radar7
It may be caused by disconnection
when the disconnection error has
CM0705 - UWB Radar 7 VERSION FAULT DQ17KM
occurred simultaneously.
Please cancel a disconnection error
first.
ERR_SENS_TEMP_HIGH
CM0800 - UWB Radar 8 Exchange the Radar8 DQ18NR
(107 degrees or more)
CM0801 RC04 UWB Radar 8 ERR_SENS_VOLTAGE_INPUT Exchange the Radar8 DQ18MA
ERR_SENS_SENSITIVITY_LOW_
CM0801 RC01 UWB Radar 8 Exchange the Radar8 DQ18MA
EXTERNAL
Please check whether the radar is
interrupted by something. If there is
CM0801 RC02 UWB Radar 8 ERR_SENS_BLOCKAGE DQ18MA
nothing that is interrupted, Exchange
the Radar8
ERR_SENS_SENSITIVITY_LOW_
CM0801 RC03 UWB Radar 8 Exchange the Radar8 DQ18MA
EXTERNAL_NO_VEL
CM0802 - UWB Radar 8 HARNESS_FAULT Exchange the Radar8 DQ18KQ
ERR_SENS_SENSITIVITY_LOW_
CM0803 RA01 UWB Radar 8 Exchange the Radar8 DQ18KT
INTERNAL
ERR_SENS_HARDWARE_FAILURE_
CM0803 RA02 UWB Radar 8 Exchange the Radar8 DQ18KT
INIT
ERR_SENS_CALIBRATION_FAILUR
CM0803 RA03 UWB Radar 8 Exchange the Radar8 DQ18KT
E
10
40 Troubleshooting CEN40200-01
KOMVISION TROUBLESHOOTING
KAC SUB FAULT PHENOMENON KLTD
ACTION
CODE CODE PART NAME CODE
ERR_SENS_HARDWARE_FAILURE_
CM0803 RA04 UWB Radar 8 Exchange the Radar8 DQ18KT
ONLINE
Please check whether there are any
abnormalities in a controller. If there
CM0804 RB01 UWB Radar 8 COMMUNICATION_ERROR DQ18KR
are no abnormalities in a controller,
Exchange the Radar8
ERR_SENS_CAN_MESSAGE_
CM0804 RB02 UWB Radar 8 Exchange the Radar8 DQ18KR
MISSING_OR_CONTENT_INVALID
ERR_SENS_CAN_SYNC_TIMING_
CM0804 RB03 UWB Radar 8 Exchange the Radar8 DQ18KR
INVALID
Exchange the Radar8
It may be caused by disconnection
when the disconnection error has
CM0805 - UWB Radar 8 VERSION FAULT DQ18KM
occurred simultaneously.
Please cancel a disconnection error
first.
11
CEN40200-01 40 Troubleshooting
730E Dump truck
830E Dump truck
930E Dump truck
980E Dump truck
Form No. CEN40200-01
12
CEN40202-00
DUMP TRUCK
730E 960E
830E 980E
860E
930E
Machine model Serial number Machine model Serial number
730E-8 A40002 and up 930E-5 A40004 and up
730E-10 A50002 and up 930E-5AT A40004 and up
830E-5 A50005 and up 960E-2 A30027 and up
830E-5AT A50005 and up 960E-2KT A50074 and up
860E-1K A30031 - A30035, 980E-4 A40003 and up
A30041, A30042, 980E-4AT A40083 and up
A30044 - A30046, 980E-5 A50005 and up
A30101, A30107 - 980E-5AT A50005 and up
A30110, A30117,
A30118
860E-1KT A30004 - A30030,
A30036 - A30040,
A30043, A30047 -
A30100, A30102 -
A30106, A30111 -
A30116
40 Troubleshooting
Automatic lubrication (auto lube) system
Autolube troubleshooting chart ............................................................................................................................. 3
1
CEN40202-00 40 Troubleshooting
NOTES
2
40 Troubleshooting CEN40202-00
Autolube troubleshooting chart
AUTOMATIC LUBRICATION SYSTEM FAULT CODE TROUBLESHOOTING
Fault Code Description Possible Condition Possible Cause Corrective Action
Repair electrical fault and
No power to check fuse.
solenoid valve
Refer to electrical schematic.
Check hydraulic supply for
proper pressure and flow and
repair as necessary.
Hydraulic supply pressure
Auto lube control has
may be checked at steering
detected an incomplete No or insufficient manifold as grease pump is
lube cycle. hydraulic fluid flow fed from hydraulic steering
or pressure circuit. If accompanied by low
Occurs when lube
Grease pump does pressure steering fault,
A190 cycle is terminated by
not run. troubleshoot steering system.
timeout rather than
pressure. Resets when Check return line for
a lube cycle is properly obstructions and clear if
terminated by pressure necessary.
rather than timeout. Faulty solenoid
Replace solenoid valve.
valve
Grease pump is
stalled due to
Check vent valve.
grease back
pressure.
Dismantle pump and repair
Grease pump is
defective or seized
seized or damaged.
component or replace pump.
3
CEN40202-00 40 Troubleshooting
AUTOMATIC LUBRICATION SYSTEM FAULT CODE TROUBLESHOOTING
Fault Code Description Possible Condition Possible Cause Corrective Action
Follow Auto Lube Checkout
Low or empty
procedure to fill reservoir and
grease reservoir
purge system of air.
Check hydraulic supply for
proper pressure and flow and
repair as necessary.
Hydraulic supply pressure
may be checked at steering
Insufficient hydraulic manifold as grease pump is
fluid flow or fed from hydraulic steering
pressure circuit. If accompanied by low
pressure steering fault,
troubleshoot steering system.
Check return line for
obstructions and clear if
necessary.
Follow Auto Lube Checkout
Grease pump runs Air trapped in
procedure to purge system of
but does not build grease system
Auto lube control has air.
pressure to 18 615-
detected an incomplete Leak at grease
24 132 kPa (2700- Identify leaky components and
lube cycle. pump, supply lines,
3500 psi). repair or replace.
or injectors
Occurs when lube
A190 cycle is terminated by Grease vent valve is
timeout rather than not staying closed Clean or replace orifice fitting
pressure. Resets when due to insufficient at pump manifold.
a lube cycle is properly pressure.
terminated by pressure Grease vent valve
Repair vent valve or remove
rather than timeout. damage or
contamination.
contamination
Grease pump tube
malfunction
Service grease pump
Grease pump assembly.
pistons or checks
are worn.
Faulty inlet or
discharge check
Replace faulty components.
valve in grease
pump
Replace grease pressure
switch.
Pump runs and Grease pressure Repair electrical fault and
builds grease line switch circuit faulty check fuse.
pressure to 18 615-
24 132 kPa (2700-
Refer to electrical schematic.
3500 psi).
Grease line Check grease lines and clear
obstruction any obstruction.
4
40 Troubleshooting CEN40202-00
AUTOMATIC LUBRICATION SYSTEM FAULT CODE TROUBLESHOOTING
Fault Code Description Possible Condition Possible Cause Corrective Action
Low auto lube grease
level is detected.
Occurs when input
switch indicates low
grease level for 3
seconds. Resets when If this fault code is present, an aftermarket low grease level sensing
A304 input switch indicates system has been installed. Refer to the aftermarket system supplier for
normal grease level for troubleshooting information.
3 seconds.
NOTE: A low auto lube
grease level switch is
not available from
Komatsu.
Auto lube circuit is Replace grease pressure
defective. switch.
Grease pump runs Grease pressure Repair electrical fault and
Occurs for any of the during an IM switch circuit faulty check fuse.
following conditions: initiated lube event
and shuts down
• Solenoid sense Refer to electrical schematic.
occurs with lube when it is terminated
by IM. Grease pump does
output off.
not unload grease Check vent valve.
• Solenoid sense
circuit pressure.
does not occur with
lube output on. Faulty solenoid Check valve function and
Grease pump valve replace if necessary.
• Pressure switch
stays on. continues to run
A305 Hydraulic inlet Install hydraulic inlet orifice
after lube event is
• Circuit is open or orifice disc not disc. (Refer to PSN AA17114
short to ground. terminated by IM.
installed for further instruction.)
NOTE: The conditions Repair electrical fault and
listed above must Grease pump runs
Faulty solenoid check fuse.
occur for 5 seconds when not initiated by
circuit
with control power on. IM.
Refer to electrical schematic.
• Grease line
Replace solenoid valve.
pressure persists
for 30 seconds after Grease pump does Faulty solenoid Repair electrical fault and
output is off. not run. circuit check fuse.
Resets at power down. Refer to electrical schematic.
Overload on output 1T Remove valves and flush
pump manifold. If fault
Stuck solenoid valve
Occurs when IM persists, replace solenoid
detects over current or valve.
Grease pump does
A361 over temp on output 1T.
not run. Auto lube circuit Repair electrical fault and
Output is turned off
when overload is short to ground, check fuse.
detected. Resets at overload, or open
power down. load Refer to electrical schematic.
5
CEN40202-00 40 Troubleshooting
730E Dump truck
830E Dump truck
860E Dump truck
930E Dump truck
960E Dump truck
980E Dump truck
Form No. CEN40202-00
6
CEN40256-00
DUMP TRUCK
830E
930E
980E
Machine model Serial number
830E-5 A50005 and up
830E-5AT A50005 and up
930E-5 A40004 and up
930E-5AT A40004 and up
980E-5 A50005 and up
980E-5AT A50005 and up
40 Troubleshooting
Electronic fan clutch
Electronic fan clutch troubleshooting .................................................................................................................... 3
1
CEN40256-00 40 Troubleshooting
NOTES
2
40 Troubleshooting CEN40256-00
Electronic fan clutch troubleshooting
For trucks that are equipped with the electronic fan LED indicator on the cover. The color pattern and
clutch, the fan clutch controller is installed in the blinking frequency of the LED indicator provide status
auxiliary control cabinet. The controller has a single information about the fan clutch.
2 1
74019
FIGURE 40-1. ELECTRONIC FAN CLUTCH CONTROLLER
1. Controller 2. LED Indicator
3
CEN40256-00 40 Troubleshooting
Table 1: CONTROLLER LED STATUS
Color Pattern /
Description Action
Blinking Frequency
1. Check that GT280 (C1) connector on controller is
unplugged or wires are damaged.
No power 2. Check that input voltage is > 9VDC referenced to
GND.
OFF 3. Check 5A fuse.
This is a calculation timing fault affected by CAN
message broadcast rates.
Firmware 230022/4172712 and earlier:
Cycle power to the controller to clear the fault.
Real time operating system
(RTOS) fault
Firmware 230023/4172713 and later:
5 Hz - Red/OFF Fault clears automatically.
If the error persists, contact your Komatsu
representative.
The controller is not programmed correctly. Return
Application/APT fault
the controller for further investigation.
1 Hz - Red/OFF
The CAN bus is in either a driver error (hardware,
CAN/Cable fault wrong CAN baud rate) or it has experienced a BUS
OFF condition.
Solid ON - Red
Check that GT150 (C2) connector on controller to
Output/Clutch fault
clutch is unplugged or wires are damaged.
1 Hz - Red/Amber
If the fan appears to be fully running, one of the
critical inputs is missing for controls.
Input fault
1. Check system voltage to verify it is within the limits.
1 Hz - Green/Amber 2. Check the wiring if this is a new wiring harness.
Manual mode active,
None
No faults
1 Hz - Amber
Override active None
1 Hz - Green
Auto mode, Normal,
None
No faults
Solid ON - Green
4
40 Troubleshooting CEN40256-00
NOTES
5
CEN40256-00 40 Troubleshooting
830E Dump truck
930E Dump truck
830E Dump truck
Form No. CEN40256-00
6
CEN50046-05
DUMP TRUCK
980E
Machine model Serial number
980E-4 A40003 and up
980E-5 A50005 and up
50 Disassembly and assembly
Service tools
Special tool group ................................................................................................................................................. 3
Additional service tools ......................................................................................................................................... 4
KomVision calibration tools ................................................................................................................................... 4
Locally made tools ................................................................................................................................................ 4
1
CEN50046-05 50 Disassembly and assembly
NOTES
2
50 Disassembly and assembly CEN50046-05
Special tool group
The following tools are included in special tool group that is shipped with the truck.
Part number Description Qty. Use
58B-00-40200 Suspension block kit 1 Suspension charging/discharging
58B-00-50090 Puller tool kit 1 Spindle removal
58B-06-00800 Custom meter kit (0-2000VDC) 1 Control cabinet capacitor discharge
58B-98-01180 Sleeve alignment tool 1 Steering linkage installation
58B-98-40050 Floating seal tool H-75 1 Floating seal installation
58C-98-00310 12-point socket - 1 1/4", 1" square drive 1 Steering arm installation
58F-98-40910 Floating seal tool HEL-1 1 Floating seal installation
58F-98-50010 Oil sampling probe 1 Oil sampling
ED3348 Installation tool 1 Duo cone seal installation
Power module removal and
EH8687 Roller assembly 2
installation
EK6089 Front brake tool group 1
Brake assembly and installation
EK6090 Rear brake tool group 1
EM1275 Front brake wear indicator 1
Brake wear measurement
EM3708 Rear brake wear indicator 1
PB9067 Bulkhead connector 1 Auxiliary battery power source
Operator cab removal and
PC1980 Offset box end wrench - 1 11/16" 1
installation
PC2228 HD wrench handle - 3/4" square drive 1 Various
XB0887 Hydraulic tank vacuum kit 1 Hydraulic system service
XB5777 Steering bypass hose 1
Hydraulic system flushing
XB7075 Fitting assembly 1
3
CEN50046-05 50 Disassembly and assembly
Additional service tools
The following tools may be required for servicing the truck.
Part number Description Qty. Use
EB1759 Nitrogen charging kit 1 Accumulator charging
EC6027 Suspension oil charging kit 1 Suspension charging
58B-98-90020 Seal installation ring 1
Hoist cylinder seal installation
58B-98-90030 Seal installation ring 1
XC2293 Spacer block 2
Body pad installation
C1624 Capscrew - 1/2" - 13NC X 4" 4
PC2660 Body retention sling 1
Body up retention
PC0367 Shackle assembly 2
XA6348 Piston push rod 1
Piston accumulator assembly
XA6349 Sleeve 1
PC3034 Flushing blocks 2 Hydraulic system flushing
XA5340 Steel spacer 1 Wheel motor installation
58E-98-00330 Smart rim expander tool 1 Smart rim installation
KomVision calibration tools
The following tools are required for calibrating the KomVision system.
Part number Description Qty. Use
58E-98-01401 Tripod stand 1
58B-98-00910 Calibration sheet - front 1
58B-98-00920 Calibration sheet - side 2 KomVision calibration
58B-98-00930 Calibration sheet - rear 1
XB0841 Radar reflector 1
Locally made tools
The following tools must be made locally. Contact your Komatsu service representative for the required drawings.
Part number Description Qty. Use
SS1143 Hoist cylinder quill installation tool 1
Hoist cylinder quill installation
SS1158 Check ball plug installation tool 1
4
50 Disassembly and assembly CEN50046-05
NOTES
5
CEN50046-05 50 Disassembly and assembly
980E Dump truck
Form No. CEN50046-05
6
CEN50107-01
DUMP TRUCK
980E
Machine model Serial number
980E-5 A50137, A50138
50 Disassembly and assembly
Wheels, spindles and rear axle
General precautions for tires and rims.................................................................................................................. 3
Rim components ................................................................................................................................................... 4
Wheel stud maintenance ...................................................................................................................................... 5
Removal and installation of front wheel ................................................................................................................ 6
Removal and installation of rear wheel ................................................................................................................. 8
Rim and tire service .............................................................................................................................................11
Removal and installation of front wheel hub and spindle .................................................................................... 25
Disassembly and assembly of front wheel hub and spindle ............................................................................... 32
Hub floating ring seal assembly and installation ................................................................................................. 49
Removal and installation of rear axle .................................................................................................................. 56
Removal and installation of anti-sway bar .......................................................................................................... 59
Removal and installation of pivot pin .................................................................................................................. 62
Pivot eye and bearing service............................................................................................................................. 64
Removal and installation of wheel motor ............................................................................................................ 66
Removal and installation of rear brake assembly ............................................................................................... 73
1
CEN50107-01 50 Disassembly and assembly
NOTES
2
50 Disassembly and assembly CEN50107-01
General precautions for tires and rims • DO NOT use lock rings with open ends (ends that
do not touch). There is a danger that the lock ring
Improper servicing of tires and rims entails a serious
will not set correctly.
risk of an explosive separation of the rim, which can
lead to serious, even fatal, accidents for the worker as • DO NOT remove or install components or
well as to others in the vicinity. Workers and persons otherwise modify a rim in such a way that the
responsible for supervising the work must comply product specifications are changed.
strictly with the following precautions. • DO NOT make modifications involving welding,
heating, soldering, etc. Such modifications could
lead to the deformation as well as the deterioration
of the strength and structural integrity of the rim
components.
• When the tire is being mounted, it is strictly
• When servicing tires and rims, always start by forbidden to perform tasks that may generate heat,
completely deflating the tire. flames, or sparks such as welding, soldering or
• Before removing the tire and rim from a truck, grinding. Resulting gases inside the tire may ignite,
completely deflate the tire before removing the causing an explosion.
clamp components and other parts installed in the • Prior to inflation, it may be necessary to tap the rim
rim base. components into position to set them. DO NOT use
• Before servicing a tire, remove the valve core to a steel mallet. Use a soft metal or hard plastic
ensure that all of the air can escape. mallet. Using a steel mallet could cause
deformation or cracking of components.
• Identify the appropriate combination of rim
components by using the matching charts and • While inflating the tire, when the air pressure
product markings. reaches 35 kPa (5 psi), check whether the rim
components are set correctly. If they are not set
• If air pressure has fallen 80% below the pressure correctly, immediately stop the work in progress,
at the time of inflation, or the tire has been deflate the tire completely and disassemble the
punctured, dismantle the rim and determine the components. Inspect the component's mating
cause. After the cause has been determined, surfaces and discard any components or materials
replace any deformed or damaged rim that interfere with complete assembly. When the
components that may have caused air leaks. problem is resolved, resume assembly.
• Until the above-mentioned checks have been • Comply with the air pressure recommended by the
performed, DO NOT inflate the tire. tire manufacturer. DO NOT exceed the standard
air pressure without checking first with your
• DO NOT combine rim components from different authorized tire dealer.
manufacturers. There may be differences in terms
of shape and other features between components
from other companies and components
manufactured by an authorized supplier (lock
rings, rim bases, bead seat bands, side rings).
Ensure that components are not mixed by
checking the manufacturer’s markings prior to
assembly.
3
CEN50107-01 50 Disassembly and assembly
Rim components
1
2
4 5 6
3
11
7
9 10 3 8
87968
FIGURE 50-1. RIM COMPONENTS
1. Side ring 4. Rim base 7. Gutter 10. Disc
2. Bead seat area 5. Bead seat band 8. Bolt hole 11. Back Flange
3. Rim circum-weld 6. Lock ring 9. Valve hole (tube type)
Smart rim component layout
1 2 3 4 3 2
1 4 3 2
84829
FIGURE 50-3. SMART RIM (7-PIECE)
1. Rim Base 3. Bead Seat band
2. Lock Ring 4. Side Ring
84828
FIGURE 50-2. STANDARD RIM (5-PIECE)
1. Rim Base 3. Bead Seat band
2. Lock Ring 4. Side Ring
4
50 Disassembly and assembly CEN50107-01
Wheel stud maintenance
The wheel mounting hardware used on some trucks
may no longer be able to maintain the specified clamp-
ing force (tightening torque). Inadequate clamping
force may lead to broken studs, stripped threads, and/ While replacing missing or damaged studs, the
or failure of the stud knurl which would allow the stud condition of all other stud threads must be
to rotate when the nut is loosened or tightened. Stud inspected. If minor corrosion or dirt is found in the
replacement is necessary based on the following threads, wire brush thoroughly. If damaged
guidelines: (nicked or highly corroded) threads are found, the
stud(s) must be replaced.
• The maximum allowable number of missing or
damaged studs in any one bolt circle is four.
• The position of missing or damaged studs must not
be in consecutive locations. In addition, there must
be a minimum of four properly functioning studs
between each missing stud. Refer to Figure 50-4.
FIGURE 50-4. MISSING/DAMAGED WHEEL STUD ALLOWANCE
5
CEN50107-01 50 Disassembly and assembly
Removal and installation of front wheel 5. Inspect the brake hydraulic lines for damage and
leaking fittings. Repair as needed.
Removal
6. Grip the tire and wheel assembly with a tire
1. Park the truck on level ground and chock the rear handler. Remove flanged nuts (1, Figure 50-5)
wheels to prevent truck movement. that secure the wheel assembly.
2. Place the directional control lever in PARK and 7. Pull the wheel assembly straight away from the
turn the rest switch ON. Turn the key switch OFF wheel hub and move it to a clean work area. Be
to shut down the engine and allow 90 seconds for careful not to damage tire inflation hose (2)
the steering system accumulators to bleed down. during tire removal.
3. Place a jack under the spindle or frame at the
front cross tube. Refer to the topic "Jack point
locations" in the Foreword, safety and general
information section.
4. Raise the front end of the truck until the tire Do not attempt to disassemble a wheel assembly
clears the ground. Block up the truck securely until all air pressure is bled off. Always keep
under the frame. personnel away from a wheel assembly when it is
being removed or installed.
1 2
TIRE INFLATION
VALVE 86452
FIGURE 50-5. FRONT WHEEL HUB AND RIM ASSEMBLY
1. Flanged Nut
2. Tire Inflation Hose
6
50 Disassembly and assembly CEN50107-01
Installation
NOTE: Clean all mating surfaces and check stud
threads before installing wheel assemblies. Refer to
the topic "Wheel stud maintenance".
a
1. Remove all dirt and rust from mating parts before
installing the wheel assembly. d d
2. Grip the wheel assembly with the tire handler and
align tire inflation hose (2, Figure 50-5) and the
wheel hub. Position the rim onto the wheel hub b c
studs. e
c b
d d
Grease containing molybdenum disulphide must a
never be used on wheel mounting hardware. Use
of this type of grease on wheel mounting hardware
86453
may result in wheel mounting studs stretching
beyond their elastic limit, making them susceptible FIGURE 50-6. NUT TIGHTENING
to breakage. SEQUENCE
3. Lubricate all stud threads and nut seating flanges
with a lithium based grease that does not contain
molybdenum disulphide. Install and tighten
flanged nuts (1) in the following sequence (see 4. Remove the blocking and lower the jack.
Figure 50-6): 5. Operate the truck for one load, then retighten the
a. Install six nuts at the 12 o'clock and six nuts at wheel nuts a clockwise direction to 2 500 ± 136
the 6 o'clock positions. Tighten each nut to N·m (1,843 ± 100 ft lb).
2 655 ± 136 N·m (1,958 ± 100 ft lb).
b. Install three nuts directly below the 3 o'clock
and three nuts directly above the 9 o'clock
positions. Tighten the nuts to 2 655 ± 136 N·m
(1,958 ± 100 ft lb).
c. Install three nuts directly above the 3 o'clock
and three nuts directly below the 9 o'clock
positions. Tighten these nuts to 2 655 ± 136
N·m (1,958 ± 100 ft lb).
d. Install the remaining nuts and torque in a
clockwise direction to 2 655 ± 136 N·m (1,958
± 100 ft lb).
e. Retighten all nuts in a clockwise direction to
2 655 ± 136 N·m (1,958 ± 100 ft lb).
7
CEN50107-01 50 Disassembly and assembly
Removal and installation of rear wheel 7. Pull the wheel assembly straight away from the
wheel hub and move it to a clean work area. Be
Removal careful not to damage the tire inflation hose
1. Park the truck on level ground and chock the during tire removal.
front wheels to prevent truck movement. NOTE: Adapter ring (2) will remain attached to the
2. Place the directional control lever in PARK and outer rim. The adapter ring may be removed from the
turn the rest switch ON. Turn the key switch OFF outer rim, if necessary, by removing outer flanged nuts
to shut down the engine and allow 90 seconds for (4).
the steering system accumulators to bleed down.
8. If removal of the inner wheel is necessary,
3. Place a jack under the rear suspension mounting remove inner tire inflation extension (5).
plates. Refer to the topic "Jack point locations" in
9. Position the tire handler to grip the inner wheel.
the Foreword, safety and general information
Remove flanged nuts (6).
section.
10. Pull the wheel assembly straight away from the
4. Raise the rear axle housing until the tires are off
wheel hub and move it to a clean work area. Be
the ground. Securely block up the rear axle
careful not to damage the tire inflation hose
housing near the wheel motor mounting flange.
during tire removal.
5. Remove tire inflation hose outer extension (1,
Figure 50-7) at the clamp on the outer wheel,
then disconnect the outer extension from tire
inflation hose inner extension (5).
6. Grip outer wheel and tire with the tire handler. If the wheel motor is to be removed from the truck
Remove inner flanged nuts (3) from adapter ring for service, install approximately eight flanged
(2) that secures the outer rim to the wheel motor nuts with appropriate spacers in place of the outer
hub. wheel adapter ring and nuts. This will provide
additional support for the wheel motor
transmission during removal and transportation.
5
1
4
6 2
INNER RIM 3 OUTER RIM 86454
FIGURE 50-7. DUAL REAR WHEEL ASSEMBLY
1. Tire Inflation Hose Outer Extension 4. Outer Flanged Nut
2. Adapter Ring 5. Tire Inflation Hose Inner Extension
3. Inner Flanged Nut 6. Flanged Nut
8
50 Disassembly and assembly CEN50107-01
Installation e. Retighten all nuts in a clockwise direction to
2325 ± 136 N·m (1715 ± 100 ft lb).
NOTE: Clean all mating surfaces and check stud
threads before installing wheel assemblies. Refer to
the topic "Wheel stud maintenance".
1. If either wheel motor has been removed, bleed
the brakes before installing the rear tires. Refer to
"Wet disc brake bleeding procedure" in Testing a
and adjusting section Brake system. d d
2. If removed, grip the inner wheel assembly with
the tire handler and install it onto the wheel hub.
Ensure that the tire inflation hose on the inner rim b c
is aligned with the clamps for inner extension (5,
Figure 50-7). e
c b
d d
a
86453
FIGURE 50-8. NUT TIGHTENING
SEQUENCE
Grease containing molybdenum disulphide must
never be used on wheel mounting hardware. Use
of this type of grease on wheel mounting hardware
may result in wheel mounting studs stretching
beyond their elastic limit, making them susceptible
to breakage.
3. Lubricate all stud threads and nut seating flanges
with a lithium based grease that does not contain
molybdenum disulphide. Install and tighten
flanged nuts (6) in the following sequence (see
Figure 50-8):
a. Install six nuts at the 12 o'clock and six nuts at
the 6 o'clock positions. Tighten each nut to
2325 ± 136 N·m (1715 ± 100 ft lb).
b. Install three nuts directly below the 3 o'clock
and three nuts directly above the 9 o'clock
positions. Tighten the nuts to 2325 ± 136 N·m
(1715 ± 100 ft lb)..
c. Install three nuts directly above the 3 o'clock
and three nuts directly below the 9 o'clock
positions. Tighten these nuts to 2325 ± 136
N·m (1715 ± 100 ft lb).
d. Install the remaining nuts and torque in a
clockwise direction to 2325 ± 136 N·m (1715 ±
100 ft lb).
9
CEN50107-01 50 Disassembly and assembly
4. Install inner tire inflation extension (5, Figure 50- 6. Grip the outer wheel assembly with the tire
7) to the inner rim tire inflation hose. handler and install it onto the wheel hub. Ensure
that the tire inflation hose bracket is aligned with
NOTE: The nut torque for installing the adapter ring inner tire inflation extension (5, Figure 50-7).
onto the outer rim is greater than the nut torque for
installing the rims onto the truck. 7. Lubricate all stud threads and nut seating flanges
with a lithium based grease that does not contain
5. If removed, install adapter ring (2) onto the outer
molybdenum disulphide. Install and tighten inner
rim. Lubricate all stud threads and nut seating
flanged nuts (3) in the following sequence (see
flanges with a lithium based grease that does not
Figure 50-8):
contain molybdenum disulphide. Install and
tighten outer flanged nuts (4) in the following a. Install six nuts at the 12 o'clock and six nuts at
sequence (see Figure 50-8): the 6 o'clock positions. Tighten each nut to
2 655 ± 136 N·m (1,958 ± 100 ft lb).
a. Install six nuts at the 12 o'clock and six nuts at
the 6 o'clock positions. Tighten each nut to b. Install three nuts directly below the 3 o'clock
2 655 ± 136 N·m (1,958 ± 100 ft lb). and three nuts directly above the 9 o'clock
positions. Tighten the nuts to 2 655 ± 136 N·m
b. Install three nuts directly below the 3 o'clock
(1,958 ± 100 ft lb).
and three nuts directly above the 9 o'clock
positions. Tighten the nuts to 2 655 ± 136 N·m c. Install three nuts directly above the 3 o'clock
(1,958 ± 100 ft lb). and three nuts directly below the 9 o'clock
positions. Tighten these nuts to 2 655 ± 136
c. Install three nuts directly above the 3 o'clock
N·m (1,958 ± 100 ft lb).
and three nuts directly below the 9 o'clock
positions. Tighten these nuts to 2 655 ± 136 d. Install the remaining nuts and tighten in a
N·m (1,958 ± 100 ft lb). clockwise direction to 2 655 ± 136 N·m (1,958
± 100 ft lb).
d. Install the remaining nuts and tighten in a
clockwise direction to 2 655 ± 136 N·m (1,958 e. Retighten all nuts in a clockwise direction to
± 100 ft lb). 2 655 ± 136 N·m (1,958 ± 100 ft lb).
e. Retighten all nuts in a clockwise direction to 8. Install tire inflation hose outer extension (1,
2 655 ± 136 N·m (1,958 ± 100 ft lb). Figure 50-7). Secure the tire inflation hoses to the
clamps on the outer rim.
9. Remove the blocks from under the truck and
lower the truck to the ground.
10. Operate the truck for one load and retighten the
flanged nuts.
• Retighten flanged nuts (4) and (6) to 2 655 ±
136 N·m (1,958 ± 100 ft lb).
• Retighten flanged nuts (3) to 2 655 ± 136 N·m
(1,958 ± 100 ft lb).
10
50 Disassembly and assembly CEN50107-01
Rim and tire service Lock ring retainer installation
Lubricants 1. Inspect the retainers, capscrews and lock ring
threads before use. Look for damage or cracks
The proper amount and type of lubricant is key to on the retainers. The screws and threads must be
successful mounting of radial off-road tires. in good condition and threads must be cleaned
• Use only water-based or vegetable-based before installing the retainers.
lubricants. Lubricants should be of a type that 2. Insert the capscrews through the retainers and
vaporize over time and not leave any residue on into the lock ring. Tighten the capscrews slightly.
the rim or tire surfaces.
• Paste lubricants should be diluted with water
according to the specific lubricant manufacturer’s
recommendations.
• Only lubricate the parts on the rim that are in
contact with the bead sole area of the tire. Be 84834
careful not to apply lubricant in the O-ring gutter.
FIGURE 50-10.
• When lubricating the tire bead, lubricant should be
sparingly applied to the tire bead surface only. The
lubricant should be painted or sprayed on
uniformly without any lumps in the paste or soap. 3. Insert retainer bolt (2, Figure 50-11) through the
retainer with no thread and into the retainer that
is threaded. Tighten the bolt slightly.
Tire inflation
1. Wherever possible, place the tire and rim inside a
tire inflation safety cage, then inflate tire. During
inflation, keep away from the tire.
1 2
84839
FIGURE 50-11.
1. Capscrews 2. Retainer Bolt
84825
4. Keep the retainers parallel to each other while
FIGURE 50-9. tightening both capscrews (1) hand-tight. Then
tighten retainer bolt (2) hand-tight.
5. Tighten retainer bolt (2) to a final torque of 40
N·m (30 ft lb) and both capscrews (1) to a final
2. When tire has been inflated to a pressure of torque of 110 N·m (81 ft lb).
approximately 35 kPa (5 psi), check assembly of
tire and rim components.
3. If assembled correctly, continue inflating up to the
rated value.
11
CEN50107-01 50 Disassembly and assembly
Removing the lock ring 5. Expand the lock ring expander tool to an accept-
able gap that will achieve a minimal sliding diam-
eter for the lock ring.
NOTE: DO NOT expand the lock ring unnecessarily.
Keep fingers clear of the area between the lock
ring and the lock ring groove and rim base.
1. Adjust the expander tool jaws into the lock ring
holes.
2. Insert the capscrews through the holes of the
lock ring expander tool jaws and into the lock ring
holes.
84838
FIGURE 50-15.
6. Lift and slide the expanded lock ring along the
outer rim base and install the lock ring into the
outside lock ring groove of the outer dual.
84835 7. Place the lock ring expander tool at an easily
FIGURE 50-12. accessed position.
8. Place the pneumatic power tool on the end of the
lock ring expander tool lead screw, then unscrew
3. Check that the capscrews are completely the lead screw until the lock ring is seated in the
installed in the lock ring holes and the lock ring lock ring groove.
expander tool is seated into position.
Be careful not to over-drive the lock ring expander
tool.
9. Remove the capscrews from the lock ring and
place the lock ring expander tool in a safe stor-
84836 age location.
FIGURE 50-13. 10. Remove the lock ring from the outside of the
outer dual.
4. Place the pneumatic power tool on the end of the
lock ring expander tool lead screw.
84837
FIGURE 50-14.
12
50 Disassembly and assembly CEN50107-01
Installing the lock ring 6. Expand the lock ring expander tool to an accept-
able gap that will achieve a minimal sliding diam-
eter for the lock ring.
Keep fingers clear of the area between the lock
ring and the lock ring groove and rim base.
1. Install the lock ring onto lock ring groove at the
outside position of the outer dual.
2. Adjust the expander tool jaws by hand until the 84838
holes line up with the lock ring holes. FIGURE 50-19.
3. Insert the capscrews through the holes of the
lock ring expander tool jaws and into the lock ring
holes.
7. Outside position of inner dual: Lift and slide
the expanded lock ring along the rim base of the
outer dual and guide it into the lock ring groove
on the outside of inner dual.
Inside position of outer dual: Lift and remove
the expanded lock ring from the outside position
of outer dual and rotate it so that the interface
area with bead seat band is facing outward.
84835 8. Place the lock ring expander tool at an easily
accessed position.
FIGURE 50-16.
9. Place the pneumatic power tool on the end of the
lock ring expander tool lead screw. Unscrew the
4. Check that the capscrews are completely
lead screw until the lock ring is seated in the lock
installed in the lock ring holes and the lock ring
ring groove.
expander tool is seated into position.
Be careful not to over-drive the lock ring expander
tool.
10. Remove the capscrews from the lock ring and
FIGURE 50-17. 84836 place the lock ring expander tool in a safe stor-
age location.
5. Place the pneumatic power tool on the end of the
lock ring expander tool lead screw.
84837
FIGURE 50-18.
13
CEN50107-01 50 Disassembly and assembly
Removing the tire from the front rim 1. Before demounting the tire from the rim, release
(5-piece rim) the air by using valve tool (3) to remove valve
core housing (2, Figure 50-20).
If the proper procedure for performing mainte-
nance or replacement of the wheel or tire is not
used, the wheel or tire may burst, causing damage,
serious injury, or even death. When performing
such maintenance, consult your authorized
regional Komatsu distributor or the tire manufac-
turer.
DO NOT stand in front of a rim and locking ring
when inflating a tire mounted on the machine.
Observers must not be permitted in the area.
DO NOT weld or heat the rim assembly with the tire 1 2 3
mounted on the rim. Resulting gases inside the
tire may ignite, causing explosion of the tire and 84830
rim. FIGURE 50-20. VALVE REMOVAL
If dual assemblies (tires and rims) require service, 1. Valve 3. Valve Tool
both dual tires must be deflated prior to 2. Valve Core Housing
commencing work regardless if rims or wheels are
involved.
Be aware of the trajectory of the valve core as it
may shoot out during its removal. 2. After fully releasing the air, place the tire and rim
on the ground with the gutter side facing up.
84831
FIGURE 50-21.
14
50 Disassembly and assembly CEN50107-01
3. Mount bead breaker on the bead seat band. 7. Use the tire lever to push down on the bead seat
Operate the bead breaker, push down the side band so that the O-ring is freed. Remove the O-
ring, and unseat the tire bead from the bead seat ring.
band.
84855
84859
FIGURE 50-24.
FIGURE 50-22.
8. Use lifting equipment to remove the bead seat
band.
4. Remove capscrews (1, Figure 50-32) and the
retainers that secure the lock ring to the rim.
1 2
84839
FIGURE 50-23.
1. Capscrews 2. Retainer Bolt
84861
FIGURE 50-25.
5. Move the bead seat band to gain access to the
lock ring groove and O-ring groove.
6. Remove the expanded lock ring. Refer to
"Removing the lock ring"
15
CEN50107-01 50 Disassembly and assembly
9. Use lifting equipment to remove the side ring. 11. Mount bead breaker on the rim base. Operate the
bead breaker, push down the side ring, and
unseat the tire bead from the bead seat band.
84862
FIGURE 50-26.
84864
10. Use lifting equipment to turn over the tire and rim, FIGURE 50-28.
and place them on the ground.
12. Use lifting equipment to remove the rim base.
84863
84865
FIGURE 50-27.
FIGURE 50-29.
13. Use lifting equipment to remove the side ring.
84871
FIGURE 50-30.
16
50 Disassembly and assembly CEN50107-01
Removing the tire from the rear outer dual rim 1. Before demounting the tire from the rim, release
(7-piece Smart rim) the air by using valve tool (3) to remove valve
core housing (2, Figure 50-31).
If the proper procedure for performing mainte-
nance or replacement of the wheel or tire is not
used, the wheel or tire may burst, causing damage,
serious injury, or even death. When performing
such maintenance, consult your authorized
regional Komatsu distributor, or the tire manufac-
turer.
DO NOT stand in front of a rim and locking ring
when inflating a tire mounted on the machine.
Observers must not be permitted in the area.
DO NOT weld or heat the rim assembly with the tire 1 2 3
mounted on the rim. Resulting gases inside the
tire may ignite, causing explosion of the tire and
84830
rim.
FIGURE 50-31. VALVE REMOVAL
If dual assemblies (tires and rims) require service, 1. Valve 3. Valve Tool
both dual tires must be deflated prior to
2. Valve Core Housing
commencing work regardless if rims or wheels are
involved.
Be aware of the trajectory of the valve core as it
may shoot out during its removal. 2. Remove capscrews (1, Figure 50-32) and the
retainers that secure the lock ring to the rim.
1 2
84839
FIGURE 50-32.
1. Capscrews 2. Retainer Bolt
17
CEN50107-01 50 Disassembly and assembly
3. Move the bead seat band to gain access to the 7. Move the rock ejector out of the way.
lock ring groove and O-ring groove.
4. Remove the lock ring from the outside of the
outer dual.
Rock ejector bar must be secured. If the rock
ejector falls it may result in injury to people or
damage to equipment.
8. Remove the O-ring from the inner side of the
outer dual.
9. Remove the capscrews and retainer of the inside
lock ring of the outer dual.
Outer dual Inner dual
10. Remove the expanded lock ring from the inside
85031 lock ring groove of outer dual. Refer to "Remov-
FIGURE 50-33.
ing the lock ring".
5. Remove the O-ring from the rim.
6. Remove the tire and rim components as one unit.
Store the tire in a safe and clean area.
Outer dual Inner dual
85032
FIGURE 50-35.
Outer dual Inner dual
84833
FIGURE 50-34.
18
50 Disassembly and assembly CEN50107-01
Removing the tire from the rear inner dual rim 1. Before demounting the tire from the rim, release
(5-piece rim) the air by using valve tool (3) to remove valve
core housing (2, Figure 50-36).
If the proper procedure for performing mainte-
nance or replacement of the wheel or tire is not
used, the wheel or tire may burst, causing damage,
serious injury, or even death. When performing
such maintenance, consult your authorized
regional Komatsu distributor, or the tire manufac-
turer.
DO NOT stand in front of a rim and locking ring
when inflating a tire mounted on the machine.
Observers must not be permitted in the area.
DO NOT weld or heat the rim assembly with the tire
1 2 3
mounted on the rim. Resulting gases inside the
tire may ignite, causing explosion of the tire and
rim. 84830
FIGURE 50-36. VALVE REMOVAL
If dual assemblies (tires and rims) require service,
both dual tires must be deflated prior to 1. Valve 3. Valve Tool
commencing work regardless if rims or wheels are 2. Valve Core Housing
involved.
Be aware of the trajectory of the valve core as it
may shoot out during its removal. 2. Remove capscrews (1, Figure 50-37) and the
retainers that secure the lock ring to the rim.
1 2
84839
FIGURE 50-37.
1. Capscrews 2. Retainer Bolt
19
CEN50107-01 50 Disassembly and assembly
3. Move the bead seat band to gain access to the Preparation before assembly
lock ring groove and O-ring groove.
1. Confirm tire and rim component combination.
4. Remove the expanded lock ring from the outside
a. Check the tire size and markings on the rim
the inner dual. Refer to "Removing the lock ring".
base, and ensure that the combination is
correct.
b. Check the markings on rim components and
matching charts, and ensure that the combina-
tion is correct.
2. Clean rim components with a wire brush so that
examination, maintenance, and mounting can be
done correctly.
Outer dual Inner dual
85033
FIGURE 50-38.
5. Remove the O-ring from the rim.
6. Apply a bead breaker to the back flange area.
Remove the tire bead from the bead seat of the
rim back flange.
84840
FIGURE 50-41.
3. Check that there is no deformation, cracking,
wear, corrosion, or damage on the rim compo-
nents.
Outer dual Inner dual 4. Re-coat any areas where the anti-corrosive oil or
paint is peeling.
85034 5. Confirm there are no tire defects.
FIGURE 50-39.
6. Apply lubricant to both tire bead seats. Refer to
“Lubricants” for details.
7. Remove the tire and rim components as a unit.
Store the tire in a safe and clean area.
DO NOT apply tire lubricant to areas other than
where the rim components come in contact with
the tire. Doing so could cause circumferential
slippage between rim components when the
vehicle is being driven. Consult your tire dealer
when selecting tire lubricant.
Outer Inner
85035
FIGURE 50-40.
20
50 Disassembly and assembly CEN50107-01
Installing the tire on the front rim 5. Place the tire on the rim base and assemble the
(5-piece rim) rim.
1. Place the rim base on a rim base stand with the 6. Install the side ring on the tire rim.
gutter side up.
2. Install the side ring.
84862
FIGURE 50-44.
7. Insert the bead seat band into the side ring and
rim base.
84872
FIGURE 50-42.
3. Install the valve.
4. Apply lubricant to both tire bead seats. Refer to
“Lubricants” for details.
Lubricate Lubricate
85029
FIGURE 50-45.
FIGURE 50-43.
21
CEN50107-01 50 Disassembly and assembly
8. Use the tire lever to push in the bead seat band 10. Install the lock ring. Refer to "Installing the lock
so that its edge fits with the tire bead. ring".
11. Starting opposite the lock ring gap, lightly tap the
lock ring with a soft metal or hard plastic hammer
in both directions back to the lock ring gap to
ensure that the lock ring is clamped into the lock
Keep fingers away during installation. ring groove.
12. Ensure that the combinations, facings, and posi-
tions of rim components are correct.
85030
FIGURE 50-46.
9. Install O-ring in the O-ring groove of the rim.
84869
FIGURE 50-47.
22
50 Disassembly and assembly CEN50107-01
Installing the tire on the rear inner dual rim 5. Install the tire on the inner dual.
(5-piece rim)
Inspection of the rim component and seating must
be performed to prevent serious injury and death
to people and damage to equipment. It is vital to
follow these instructions to manage the Outer dual Inner dual
component seating process safely.
Inspection must be performed prior to assembly,
before inflation, after initial inflation, during
inflation and after inflation is completed.
Appropriate lifting equipment must be used while
handling heavy items.
Be cautious while moving tire and rims to avoid Outer dual Inner dual
accidental drops or falls that could injure
personnel. 84849
FIGURE 50-49.
Rock ejector bar must be secured. If the rock Excessive force may push the vehicle off its
ejector falls it may result in injury to people or stands.
damage to equipment.
6. Move the bead seat band to gain access to the
1. Move the rock ejector out of the way. lock ring groove and O-ring groove.
2. Perform a rim component inspection before 7. Install O-ring over the rim and into the O-ring
assembly. Refer "Preparation before assembly". groove.
3. Lift and install the side ring into position on the 8. Install the lock ring to the outside of the inner
rim to interface with the back flange. dual. Refer "Installing the lock ring".
4. Apply lubricant to the tire bead/rim interface.
Refer to "Lubricants".
Outer dual Inner dual
Outer dual Inner dual
84848
FIGURE 50-48.
84850
FIGURE 50-50.
9. Install the retainer and capscrews to the lock ring.
Refer "Lock ring retainer installation".
23
CEN50107-01 50 Disassembly and assembly
Installing the tire on the rear outer dual rim 4. Install the tire and rim components to the rim.
(7-piece Smart rim)
Inspection of the rim component and seating must
be performed to prevent serious injury and death
to people and damage to equipment. It is vital to Outer dual Inner dual
follow these instructions to manage the
component seating process safely.
Inspection must be performed prior to assembly,
before inflation, after initial inflation, during
inflation and after inflation is completed.
Appropriate lifting equipment must be used while
handling heavy items.
Outer dual Inner dual
Be cautious while moving tire and rims to avoid
accidental drops or falls that could injure person-
84851
nel.
FIGURE 50-51.
1. Install the expanded lock ring to the inside of the
outer dual. Refer "Installing the lock ring".
2. Install the retainer and capscrews to the lock ring.
Refer "Lock ring retainer installation".
Excessive force may push the vehicle off its
3. Install the O-ring over the rim and into the O-ring
stands.
groove.
5. Move the bead seat band to gain access to the
lock ring groove and O-ring groove.
6. Install the O-ring over the rim and into the O-ring
groove.
7. Install the lock ring to outside of the outer dual.
Outer dual Inner dual
84852
FIGURE 50-52.
8. Install the retainer and capscrews to the lock ring.
Refer to "Lock ring retainer installation".
24
50 Disassembly and assembly CEN50107-01
Removal and installation of front wheel 5. Install vacuum pump kit (XB0887) on the
hub and spindle hydraulic tank to prevent the loss of oil when
disconnecting hydraulic lines.
Removal
6. Disconnect front wheel speed sensor harness (1,
Figure 50-54) from the top of the brake assembly.
Tie back the cable to prevent damage during hub
and spindle removal.
Hydraulic oil escaping under pressure can have
sufficient force to enter a person's body by
penetrating the skin and cause serious injury, and
possibly death, if proper medical treatment is not
received immediately.
Relieve pressure before disconnecting any
hydraulic lines. Tighten all connections securely
before applying pressure.
1
86456
1. Refer to the "Hydraulic system bleeddown
procedure" in Testing and adjusting section FIGURE 50-54. FRONT WHEEL SPEED SENSOR
Steering, hoist, brake cooling and auxiliary
1. Front Wheel Speed Sensor Harness
hydraulic system.
2. Activate the battery disconnect switches.
3. Remove the front tire and rim assembly. Refer to 7. Disconnect brake cooling lines (1, Figure 50-55)
"Removal and installation of front wheel". and brake apply line (2) at the inlet and outlet
ports on the brake housing. Plug the lines and
4. Install three shipping brackets (1, Figure 50-53)
ports to help prevent contamination.
120 degrees apart to prevent movement of the
hub on the spindle. 8. After the hydraulic lines have been plugged, turn
off the vacuum pump.
1
1
86537
FIGURE 50-53. WHEEL HUB & SPINDLE
SHIPPING BRACKET INSTALLATION
1. Shipping Bracket
2
86532
FIGURE 50-55. FRONT BRAKE LINES
1. Brake Cooling Line 2. Brake Apply Line
25
CEN50107-01 50 Disassembly and assembly
9. Remove drain plugs (1, Figure 50-56) and (2) 11. Disconnect the steering cylinder and the tie rod
and allow the oil to drain from the brake housing from the spindle that is being removed. Refer to
and catchment tank into a suitable container. "Removal and installation of steering cylinders
and tie rod" in Disassembly and assembly
section Steering system.
Use lifting equipment with adequate capacity to
remove and install the components.
NOTE: The front wheel hub, spindle and brake
1 assembly weighs approximately 6 681 kg (14,728 lb).
12. Position a fork lift under the wheel hub and
2 spindle assembly as shown in Figure 50-58. Use
blocking as necessary to keep the spindle, hub
86533
and brake assembly level.
FIGURE 50-56. FRONT BRAKE DRAIN PLUGS
1. Brake Housing 2. Catchment Tank
Drain Plug Drain Plug
10. Remove magnetic drain plug (1, Figure 50-57)
and allow the oil to drain from the front hub
bearing into a suitable container.
FIGURE 50-58. TYPICAL LIFTING DEVICE
(FORKLIFT)
1
86534
FIGURE 50-57. FRONT HUB BEARING
MAGNETIC DRAIN PLUG
1. Front Hub Bearing Magnetic Drain Plug
26
50 Disassembly and assembly CEN50107-01
13. Remove 12-point capscrews (1, Figure 50-59) 14. Remove 16 of 27 12-point capscrews (4) and
and hardened flat washers (2) that secure hardened flat washers (2) as follows:
retainer plate (3) to the front suspension cylinder.
a. Refer to Figure 50-60. Remove only the
To prevent thread damage, loosen the capscrews
capscrews that are designated by an “X”.
in a circular pattern in torque increments of 678
N·m (500 ft lb). Remove retainer plate (3). b. Loosen the capscrews using a circular pattern
in torque increments of 678 N·m (500 ft lb).
There is a total of 15 capscrews.
Do not attempt to remove each capscrew in
one sequence.
15. Run a tap (1 1/4” - 12 UNF) in the threads after
the capscrews are removed.
4 2
2
3
1 86535
FIGURE 50-59. FRONT SPINDLE REMOVAL AND
INSTALLATION
1. 12-Pt. Capscrews 3. Retainer Plate
(for retainer plate) 4. 12-Pt. Capscrews
2. Hardened Flat Washers (for steering arm)
FIGURE 50-60. SPINDLE REMOVAL TOOL
27
CEN50107-01 50 Disassembly and assembly
NOTE: Older spindle removal tools (5, Figure 50-61)
may have been made with a round tube (shown as a
dotted line) welded on one side. The tool can be
installed upside down and used with a hydraulic ram
as shown.
Do not apply pressure to the hydraulic ram until all
The spindle removal tool may be fabricated locally to 16 capscrews are installed.
aid in spindle removal. Refer to Disassembly and
assembly section General information for fabrication The maximum force that can be applied during the
information. Use of this tool is described in the spindle removal process is not to exceed 701 000
following steps. kgf (1,545,600 lb).
The hydraulic ram must be a low profile hydraulic ram
(pancake jack) to fit in this area. Most hydraulic rams 20. Install the remaining 13 capscrews and tighten
that will fit in this area are rated at 150 tons. them to 68 N·m (50 ft lb). This is to ensure that
all capscrews will pull evenly when pressure is
applied by the hydraulic ram.
16. Locate 16 capscrews (1, Figure 50-61) and
hardened flat washers (2) as specified below:
Capscrew (KC7095) . . . . . . .1 1/4" - 12NF x 8"
Hardened flat washer (WA0366) . . . . . . . 1 1/4"
NOTE: Hardened flat washers must be used under the
removal tool capscrews to prevent galling.
17. Lubricate the capscrew threads and flat washers
with chassis grease.
18. Install spindle removal tool (5) as shown in Figure
50-61 using only three capscrews (1), three
washers (2) and three spacers (6). The three
capscrews must be evenly spaced. Tighten the
three capscrews to 68 N·m (50 ft lb).
NOTE: Verify that the minimum thread engagement of
41.1 mm (1.62 in.) is achieved for the removal tool
capscrews when inserted.
19. Ensure that hydraulic ram (4) is completely
FIGURE 50-61. SPINDLE REMOVAL TOOL
retracted. Install the hydraulic ram with reaction
INSTALLATION WITH RAM
plate (3) on top of the hydraulic ram.
NOTE: If there is a large gap between reaction plate 1. Capscrew (KC7095) 6. Spacer
(3) and suspension piston (9), it may be necessary to 2. Hardened Flat Washer 7. Steering Arm
add steel spacers below the hydraulic ram to close the (WA0366) 8. Spindle
gap. 3. Reaction Plate 9. Suspension Piston
4. Hydraulic Ram 10. Area to heat
5. Spindle Removal Tool
28
50 Disassembly and assembly CEN50107-01
Spindle removal (off the truck)
If the hydraulic ram method (with heat) did not sepa-
rate the spindle from the suspension piston, the spin-
dle, hub and brake and the front suspension must be
Heavy components and high forces are involved in removed from the truck as an assembly. With the sus-
this procedure. Use caution at all times when pension on the ground, the spindle removal tool can
applying force to these parts. Sudden release of be used to separate the spindle from the suspension
the spindle could cause components to move piston. Refer to Disassembly and assembly section
forcefully and unexpectedly. Suspensions for the front suspension removal proce-
dure.
21. Start applying pressure to the hydraulic ram to
separate spindle (8) from suspension piston (9). The spindle removal tool may be fabricated locally to
aid in spindle removal. Refer to Disassembly and
22. If the specified maximum force of the hydraulic assembly section General information for fabrication
ram is reached and the spindle has not been information. Spacers and/or multiple hardened flat
separated from the suspension piston, slowly and washers may be required under the capscrews to be
uniformly apply heat to spindle area (10, Figure effective.
50-61).
Heat must be applied in two locations 180
degrees apart. Allow the heat to penetrate into
the spindle. Reapply heat as required. Do not
exceed 454 °C (850 °F) anywhere on the spin- Use lifting equipment and lifting devices with
dle. adequate capacity to support the components.
1. Position the front suspension and spindle, hub
and brake assembly on the work floor as shown
in Figure 50-62.
The wheel hub must be supported with an over-
Heating the spindle in excess of 454° C (850° F) head hoist.
may cause serious damage to the spindle.
2. Locate 16 capscrews and hardened flat washers
23. Use heat as specified in the previous step and a (1, Figure 50-62) as specified below:
large hammer to carefully tap the top surface of
spindle (8) until the spindle breaks free. Capscrew (KC7095). . . . . . . 1 1/4" - 12NF x 8"
If the spindle does not separate from the suspen- Hardened flat washer (WA0366) . . . . . . .1 1/4"
sion piston, the spindle, hub and brake and the NOTE: Hardened flat washers must be used under the
front suspension must be removed from the truck removal tool capscrews to prevent galling.
as an assembly. Refer to "Spindle removal (off
the truck)" to separate the spindle from the sus- 3. Lubricate the capscrew threads and flat washers
pension. with chassis grease.
24. After separation, lower the spindle, hub and 4. Install spindle removal tool (2) as shown in Figure
brake assembly from the suspension piston. Be 50-62 using capscrews and washers (1).
careful during removal to prevent damage to the
NOTE: Verify that the minimum thread engagement of
suspension piston rod taper and the tapered
41.1 mm (1.62 in.) is achieved for the removal tool
spindle bore.
capscrews when inserted.
25. Move the spindle, hub and brake assembly to a
clean work area for repair.
29
CEN50107-01 50 Disassembly and assembly
Heavy structures and high forces are involved in Heating the spindle in excess of 454° C (850° F)
this procedure. Use caution at all times when may cause serious damage to the spindle.
applying force to these parts. Sudden release of 7. Tighten the capscrews again to the maximum
the spindle could cause components to move specified torque as described in step 5.
forcefully and unexpectedly.
8. Use a large hammer and heat at the specified
5. After the spindle removal tool has been installed, locations to carefully tap on the top surface of the
progressively increase the torque on the cap- spindle until the piston breaks free.
screws in a circular pattern until the tapered pis-
ton breaks loose, or until the maximum specified NOTE: In extreme cases, it may be necessary to
torque on the capscrews of 2 142 N·m (1,580 ft remove additional steering arm retaining capscrews
lb) is reached. and use additional capscrews to apply more force.
6. If the specified torque is reached and the parts 10. After separation, use the lifting device to move
have not separated, slightly loosen the cap- the spindle, hub and brake assembly to a clean
screws, then slowly and uniformly apply heat to work area for repair.
spindle area (3 Figure 50-62).
Heat must be applied in two locations 180
degrees apart. Allow the heat to penetrate into
the spindle. Reapply heat as required. Do not
exceed 454 °C (850 °F) anywhere on the spin-
dle.
FIGURE 50-62. SPINDLE REMOVAL TOOL INSTALLATION
OFF THE TRUCK
1. Capscrew & Hardened Flat Washer 3. Area to heat
2. Spindle Removal Tool
30
50 Disassembly and assembly CEN50107-01
Installation 6. Connect the steering cylinder and the tie rod to
NOTE: If the spindle and front suspension had to be the spindle. Refer to "Removal and installation of
removed from the truck as an assembly, first install the steering cylinders and tie rod" in Disassembly
suspension on the truck. Refer to Disassembly and and assembly section Steering system.
assembly section Suspensions for the front 7. Install vacuum pump kit (XB0887) on the
suspension installation procedure. hydraulic tank to prevent the loss of oil when
1. Clean the spindle bore and suspension piston reconnecting hydraulic lines.
taper so that they are free of rust, dirt and oil. 8. Install brake cooling lines (1, Figure 50-55) and
2. Lubricate the spindle bore and suspension piston brake apply line (2) at the inlet and outlet ports on
taper with lithium based multi-purpose EP NLGI 2 the brake housing. Use new O-rings.
grease containing no molybdenum-disulphide. 9. Ensure that drain plug (1, Figure 50-57) for the
front hub bearing is installed.
10. Ensure that drain plugs (1, Figure 50-56) and (2)
for the brake housing and catchment tank are
installed.
Use of anti-seize compounds that contain copper
11. After all hydraulic lines have been reconnected,
are prohibited from use on spindle bores and
turn off the vacuum pump and remove the
piston tapers. These lubricants can cause severe
vacuum pump from the hydraulic tank.
damage. Only use lithium based multi-purpose EP
NLGI 2 grease containing no molybdenum- 12. Connect front wheel speed sensor harness (1,
disulphide. Figure 50-54) to the wheel speed sensor at the
top of the brake assembly.
3. Position the spindle, hub and brake assembly on
a fork lift or similar lifting device as shown in 13. Remove shipping brackets (1, Figure 50-53) from
Figure 50-58. Raise the spindle, hub and brake the hub.
assembly into position on the suspension piston
14. Perform the hydraulic system checkout
taper.
procedure and the brake system checkout
4. Lubricate the threads and seats of 12-point procedure. Refer to the appropriate Testing and
capscrews (1, Figure 50-59) and hardened flat adjusting sections in the shop manual.
washers (2) with lithium based multi-purpose EP
15. Install the wheel and tire. Refer to "Removal and
NLGI 2 grease containing no molybdenum-
installation of front wheel".
disulphide.
There is a total of 15 capscrews.
5. Secure the spindle to the suspension piston by
installing retainer plate (3), hardened flat washers
(2) and 12-point capscrews (1). Tighten the
capscrews as follows:
a. Tighten the capscrews uniformly to 678 N·m
(500 ft lb).
b. Continue to tighten the capscrews uniformly in
increments of 339 N·m (250 ft lb) until a final
torque of 2 705 ± 135 N·m (1,995 ± 100 ft lb)
is obtained.
31
CEN50107-01 50 Disassembly and assembly
Disassembly and assembly of front wheel
hub and spindle
Cross Section View
2 1 23
22
3
DETAIL B
4 21
20
B
5
6
12 13
7
9 14
A
DETAIL A
10
15
11
19 18 17 16
86570
FIGURE 50-63. SPINDLE, HUB & BRAKE ASSEMBLY
1. Brake Assembly 9. Outer Bearing Cone 17. Oil Seal
2. Shipping Bracket 10. Outer Bearing Cup 18. Seal Carrier/Speed Sensor Gear
3. Wheel Hub 11. Magnetic Drain Plug 19. Shims
4. Fill Plug 12. Shims 20. Spacer
5. Hub Cover 13. Inner Bearing Cone 21. Seal Assembly (Oil Separator)
6. Check Valve 14. Inner Bearing Cup 22. Seal Carrier (Spindle)
7. Sight Gauge 15. Spindle 23. Seal Carrier (Wheel Hub)
8. Bearing Retainer 16. Seal Assembly (Brake)
32
50 Disassembly and assembly CEN50107-01
Disassembly 4. Disconnect the wheel speed sensor from cable
bracket (1, Figure 50-65). Loosen capscrews (3)
and flat washers (4), then remove wheel speed
sensor (2) from sensor bracket (5).
Use a lifting device with adequate capacity to 1
remove and install the components.
1. Remove the wheel hub and spindle. Refer to
"Removal and installation of front wheel hub and 2
spindle".
2. Remove any dirt and mud from the assembly.
3. Remove remaining 12-point capscrews (1, Figure
50-64) and hardened flat washers (2) that secure
steering arm (3) to spindle (4). 4 3 5 86538
Loosen the capscrews using a circular pattern in FIGURE 50-65. WHEEL SPEED SENSOR
torque increments of 678 N·m (500 ft lb). Do not REMOVAL & INSTALLATION
attempt to remove each capscrew in one
sequence. Run a tap (1 1/4” - 12 UNF) in the 1. Cable Bracket 4. Flat Washer
threads after the capscrews are removed. 2. Wheel Speed Sensor 5. Sensor Bracket
3. Capscrew
5. Remove capscrews (1, Figure 50-66),
4 lockwashers (2) and hub cover (3) from the wheel
hub. Discard the O-ring.
3 1 2
3 1 2 86536
FIGURE 50-64. STEERING ARM INSTALLATION
1. 12-Pt. Capscrews 3. Steering Arm
2. Hardened Flat Washers 4. Spindle
NOTE: To aid in the complete disassembly of the
wheel hub and spindle assembly, use a fabricated 86539
spindle stand to support the assembly in a vertical FIGURE 50-66. WHEEL HUB COVER
position (hub cover up). REMOVAL & INSTALLATION
1. Capscrew 3. Hub Cover
2. Lockwasher
33
CEN50107-01 50 Disassembly and assembly
6. Remove ten capscrews (1, Figure 50-67) and 8. Remove 12-point capscrews (1, Figure 50-68)
hardened flat washers (2). and hardened flat washers (2).
7. Remove bearing retainer (3), O-ring (4), and There is a total of 54 capscrews.
shims (5). Discard the O-ring.
2 3
4
2
5
1
86541
FIGURE 50-68. WHEEL HUB/BRAKE ASSEMBLY
REMOVAL & INSTALLATION
1. 12-Pt. Capscrew 2. Hardened Flat
Washer
86540
FIGURE 50-67. WHEEL HUB BEARING
RETAINER REMOVAL
1. Capscrew 4. O-ring
2. Hardened Flat Washer 5. Shims
3. Bearing Retainer
34
50 Disassembly and assembly CEN50107-01
9. Attach a lifting device to wheel hub/brake 11. Rotate the hub/brake assembly 180 degrees and
assembly (1, Figure 50-69) and carefully lift it place it on blocking to prevent damage to the
straight up and off spindle (2). wheel studs and machined surfaces.
10. Remove outer bearing cone (3) and retainer pin 12. Remove O-ring (1, Figure 50-70) from the brake
(4) from the wheel hub. piston housing.
13. Remove eight Allen head capscrews (2), seal
carrier (4) with one half of seal assembly (3) and
4 O-ring (5) from the hub.
3
1
86542
FIGURE 50-69. WHEEL HUB/BRAKE ASSEMBLY
REMOVAL & INSTALLATION
1. Wheel Hub/Brake 3. Outer Bearing Cone
Assembly 4. Retainer Pin 86543
2. Spindle FIGURE 50-70. SEAL CARRIER
REMOVAL & INSTALLATION
1. O-ring 4. Seal Carrier
2. Allen Head Capscrew 5. O-ring
3. Seal Assembly
35
CEN50107-01 50 Disassembly and assembly
14. Remove 12-point capscrews (1, Figure 50-71) 16. Ring gear retainer bars (1, Figure 50-72) must be
and hardened flat washers (2) that secure the installed to retain the inner gear inside the brake
brake assembly inner gear to the wheel hub. assembly.
There is a total of 32 capscrews.
15. Remove shipping brackets (3) that secure the 1
brake assembly to the wheel hub.
1
86415
FIGURE 50-72. RING GEAR RETAINER BARS
ON BRAKE ASSEMBLY
1. Ring Gear Retainer Bars
86544
FIGURE 50-71. BRAKE ASSEMBLY REMOVAL
1. 12-Pt. Capscrew 3. Shipping Bracket
2. Hardened Flat Washer
36
50 Disassembly and assembly CEN50107-01
17. Attach lifting eyes and an overhead hoist to brake 18. Turn over the brake assembly so that the
assembly (1, Figure 50-73). Carefully lift the catchment tank is facing upward. Remove seal
brake assembly from wheel hub (2). ring (1, Figure 50-74) and O-ring (2) from the
brake back plate.
NOTE: The front brake assembly weighs
approximately 1 687 kg (3,719 lb). These components are one half of the complete
seal assembly.
NOTE: For brake assembly rebuild instructions, refer
to Disassembly and assembly section Brake system.
2
1
86546
FIGURE 50-74. SEAL ASSEMBLY REMOVAL
1. Seal Ring 2. O-ring
86545
FIGURE 50-73. BRAKE ASSEMBLY
REMOVAL & INSTALLATION
1. Brake Assembly 2. Wheel Hub
37
CEN50107-01 50 Disassembly and assembly
19. Remove two capscrews and hardened flat 23. If the bearings require replacement, press
washers (1, Figure 50-75) at six locations around bearing cups (1, Figure 50-76) and (2) from the
the wheel hub. Remove seal carrier/speed wheel hub.
sensor gear (3) and shims (2).
20. Remove seal carrier O-ring (7) from the wheel
hub. 1
21. Remove oil seal (4) from the seal carrier.
22. Remove seal ring (6) and O-ring (5) from the seal
carrier.
These components are one half of the complete
seal assembly.
4 2
3
7
86549
FIGURE 50-76. BEARING REPLACEMENT
1. Inner Bearing Cup 2. Outer Bearing Cup
86548
FIGURE 50-75. SEAL CARRIER REMOVAL
1. Capscrews & 4. Oil Seal
Hardened Flat Washers 5. O-ring
2. Shims 6. Seal Ring
3. Seal Carrier/ 7. Seal Carrier O-ring
Speed Sensor Gear
38
50 Disassembly and assembly CEN50107-01
24. Remove inner bearing cone (1, Figure 50-77), Cleaning and inspection
retainer pin (8) and spacer (2) from spindle (7).
1. Clean all metal parts in fresh cleaning solvent.
25. Remove eight Allen head capscrews (3), seal
2. Remove and clean magnetic drain plug (1, Figure
carrier (5) with one half of seal assembly (4) and
50-78).
O-ring (6) from the spindle.
3. Remove and inspect sight gauge (3) and check
valve (4).
1 4. Inspect wheel studs (2). Replace any studs that
are damaged or broken.
2 NOTE: If new studs are being installed, coat the hole
3 in the hub and the serrated portion of the stud with an
anti-seize compound before installation. Do not coat
4 the threads.
5. Inspect all threaded holes in the spindle and
5 wheel hub. Re-tap the holes as necessary.
6. Inspect the bearing seating surfaces in the wheel
6 hub and on the spindle. Inspect the bearing
spacer. Use a stone to carefully dress high spots
that may interfere with reassembly.
7. Inspect all other machined surfaces for damage.
7
4
2 1
86551
FIGURE 50-78. WHEEL HUB CLEANING &
86550
INSPECTION
FIGURE 50-77. SEAL CARRIER 1. Magnetic Drain Plug 3. Sight Gauge
REMOVAL & INSTALLATION 2. Wheel Stud 4. Check Valve
1. Inner Bearing Cone 5. Seal Carrier
2. Spacer 6. Seal Carrier O-ring
3. Allen Head Capscrew 7. Spindle
4. Seal Assembly 8. Retainer Pin
39
CEN50107-01 50 Disassembly and assembly
Assembly 2. Position the spindle vertically (hub end up).
3. Check both bearing cones for a slip fit on the
spindle.
4. Install spacer (1, Figure 50-77). If necessary, tap
lightly to seat the spacer against spindle (2). The
Use a lifting device with adequate capacity to spacer must fit tightly against the spindle
remove and install the components. shoulder.
5. Lightly lubricate the bearings with clean TO50
hydraulic oil before installation.
6. Install retainer pin (4) in the pin groove, then
install inner bearing cone (5) against the spacer.
All mating surfaces of the wheel and brake The bearing cone is a loose fit on the spindle.
components must be clean and dry during
assembly. No thread lubricant is permitted on NOTE: To facilitate wheel bearing adjustment, do not
these surfaces. install the brake assembly at this time.
7. Install wheel hub (3) onto spindle (2).
NOTE: Always use new O-ring seals during assembly.
8. Install outer bearing cone (6) and retainer pin (7)
1. If removed, install bearing cups (1, Figure 50-76)
in the wheel hub.
and (2) in the wheel hub as follows:
a. Preshrink the bearing cups by packing them in
dry ice or by placing them in a deep-freeze
unit.
Do not cool below -65°C (-54°F). Cooling below
this temperature can cause microstructure
changes in the steel which may result in premature
bearing failure. Liquid nitrogen MUST NOT be
used for cooling.
b. Install the bearing cups in the wheel hub
bores.
c. After the bearing cups have warmed to
ambient temperature, press the bearing cups
tight against the hub shoulder as follows:
Inner cup - Apply 22 680 kg (25 tons) of force.
Outer cup - Apply 20 860 kg (23 tons) of force.
40
50 Disassembly and assembly CEN50107-01
Wheel bearing adjustment
9. Install bearing retainer (3, Figure 50-80) without
7
the O-ring or shims.
6
NOTE: The thickness of the bearing retainer is etched
on the surface of the retainer. This side must be facing
outward when installed.
10. Use five of ten capscrews (2) and hardened flat
washers (3) to secure the bearing retainer. The
capscrews must be equally spaced so that two of
the capscrews are adjacent to small access holes
(4).
3 2 1 3
5
2 4
86553
1
4 FIGURE 50-80. BEARING RETAINER
INSTALLATION
1. Capscrew 3. Bearing Retainer
2. Hardened Flat Washer 4. Access Hole
11. Seat the wheel bearings by using the following
procedure:
a. Tighten the five capscrews to 95 N·m (70 ft
lb). Rotate the wheel hub at least three full
revolutions.
86552 b. Tighten the five capscrews to 190 N·m (140 ft
FIGURE 50-79. WHEEL BEARING ADJUSTMENT lb). Rotate the wheel hub at least three full
PREPARATION revolutions.
1. Spacer 5. Inner Bearing Cone c. Repeat Step 11b until the torque is
2. Spindle 6. Outer Bearing Cone maintained.
3. Wheel Hub 7. Retainer Pin d. Loosen the five capscrews and rotate the hub
4. Retainer Pin at least three revolutions.
e. Tighten the five capscrews to 54 N·m (40 ft
lb). Rotate the wheel hub at least three full
revolutions.
f. Repeat Step 11e until the torque is
maintained.
41
CEN50107-01 50 Disassembly and assembly
12. Place a depth micrometer through each small Seal assembly gap adjustment
access hole (4) to measure and record the 17. Before the assembly of the wheel hub and brake
distance between the face of the bearing retainer is completed, the gap between the seal seat of
and spindle. the wheel hub and the brake assembly back plate
13. Add the two dimensions measured in the Step 12. must be measured and adjusted if necessary.
Divide the sum by 2 to obtain the average depth.
a. Measure dimension “A” (Figure 50-82) from
14. Subtract the bearing retainer thickness that is the flange of spindle (2) to the seal seat of
etched on the surface of bearing retainer (3), wheel hub (1). Record the results.
from the result calculated in Step 13. Then
subtract an additional 0.23 mm (0.009 in.).
1 2
15. Assemble a shim pack that equals the dimension
calculated in Step 14 ± 0.03 mm (0.001 in.).
NOTE: The above procedure results in a shim pack
which will provide a nominal 0.56 mm (0.022 in.)
preload for the bearings after assembly. The shim pack
must be compressed while measuring to obtain an
accurate measurement.
Example:
Step 13 average depth 1.416 in.
Step 14 subtract etched dim. -1.375 in.
Step 14 subtract additional -0.009 in.
Step 15 Required shim pack = 0.032 in. A 86555
FIGURE 50-82. SEAL ASSEMBLY GAP CHECK
16. Install hub cover (3, Figure 50-81), capscrews (1) 1. Wheel Hub 2. Spindle
and lockwashers (2). Install sight gauge (4) and
check valve (5) in the hub cover.
b. Measure dimension “B” (Figure 50-83) of the
4 5 brake assembly from the face of piston
3 1 2 housing (2) to the face of the seal cavity of
back plate (1). Record the results.
86554
FIGURE 50-81. HUB COVER INSTALLATION
2 86556
1. Capscrew 4. Sight Gauge
2. Lockwasher 5. Check Valve FIGURE 50-83. SEAL ASSEMBLY GAP CHECK
3. Hub Cover 1. Back Plate 2. Piston Housing
42
50 Disassembly and assembly CEN50107-01
c. Measure dimension “C” (Figure 50-83), which Seal installation
is the total thickness of the seal carrier/speed
18. Remove the hub cover, bearing retainer, outer
sensor gear. Record the results.
bearing cone, retainer pin and wheel hub from
the spindle in preparation for brake assembly
1 installation.
C
19. Lubricate and install new O-ring (4, Figure 50-85)
on the wheel hub.
86557 20. Place the necessary number of shims (2) that
was determined in Step 17 at each of the six
FIGURE 50-84. SEAL ASSEMBLY GAP CHECK locations around the wheel hub. Install seal
carrier/speed sensor gear (3) onto the wheel hub.
1. Seal Carrier/Speed Sensor Gear
Secure the components to the wheel hub with
capscrews (1).
21. Apply a bead of silicone sealant in the area
d. Subtract dimension “B” and "C" from between the wheel hub and the seal carrier/
dimension “A”. The target result is 3.90 ± 0.13 speed sensor gear to seal the area between the
mm (0.154 ± 0.005 in.). hub and seal carrier.
• If the result is 3.90 ± 0.13 mm (0.154 ± 0.005
in.), no shims are necessary.
3
• If the gap is more than 4.03 mm (0.159 in.),
subtract 3.90 mm (0.154 in.) from the result,. 4
Then, add shims (2, Figure 50-75) at each
location until the gap is within the target range.
NOTE: Two different shim thicknesses can be used to 2
adjust the gap: 0.51 mm (0.020 in.) and 0.25 mm
(0.010 in.). Make sure that the shim pack at each 1
location is identical.
Example:
Step 17a Dimension "A" 420.52 mm
Step 17b Dimension "B" -362.05 mm
86558
Step 17c Dimension "C" - 53.20 mm
Step 17d Resulting gap = 5.27 mm FIGURE 50-85. SEAL CARRIER INSTALLATION
Resulting gap > 4.03 in. - 3.90 mm
Required shim pack = 1.37 mm 1. Capscrews & 3. Seal Carrier/
Hardened Flat Washers Speed Sensor Gear
Add two 0.51 mm shims and one 0.25 mm shim at 2. Shims 4. O-ring
each location to bring the gap to 4.00 mm.
After a shim pack has been determined, the shim
pack, spindle, wheel hub, spacer, and bearings are
now an interdependent group. If any of the parts
are replaced, the shim pack is no longer valid and
a new pack must be calculated.
43
CEN50107-01 50 Disassembly and assembly
22. Use installation tool (58F-98-00110) to install NOTE: Visually inspect both halves of the duo cone
each half of seal assembly (3, Figure 50-86) into seal assembly before installation. Check for nicks,
the back plate of brake assembly (1) and seal dents and damage to the metal rings and toric rings. If
carrier/speed sensor gear (2). there is any damage, the entire duo cone seal
assembly must be replaced.
NOTE: Refer to the topic "Brake floating ring seal
assembly and installation" in Disassembly and 24. Lubricate and install O-ring (3, Figure 50-87) in
assembly section Brake System for the proper seal carrier (2).
installation instructions for seal assembly (3).
25. Install the seal carrier on the wheel hub. Install
23. Install oil seal (4) into the back plate of brake and tighten eight Allen head capscrews (4) to 142
assembly (1). Pack the area between the oil seal ± 13 N·m (105 ± 10 ft lb).
lips with grease.
26. Install one half of seal assembly (1) in seal carrier
(2). The metal ring must be facing outward.
3 NOTE: Refer to the topic ""Hub floating ring seal
assembly and installation" for the proper installation
instructions for both halves of seal assembly (1).
2
4
4
2
3
1 3
86559
FIGURE 50-86. SEAL INSTALLATION
1. Brake Assembly 3. Seal Assembly
86561
2. Seal Carrier/ 4. Oil Seal
Speed Sensor Gear FIGURE 50-87. SEAL INSTALLATION
1. Seal Assembly 3. O-ring
2. Seal Carrier 4. Allen Head Capscrew
44
50 Disassembly and assembly CEN50107-01
27. Lubricate and install O-ring (3, Figure 50-88) in Brake installation
seal carrier (2).
NOTE: Do not remove the shipping bars from the
28. Install the seal carrier on the spindle. Install and brake assembly piston housing until the inner gear is
tighten eight Allen head capscrews (4) to 142 ± secured to the wheel hub in Step 31.
13 N·m (105 ± 10 ft lb).
30. Install lifting eyes on brake assembly (1, Figure
29. Install the other half of seal assembly (1) in seal 50-89) and attach it to an overhead hoist. Lower
carrier (2). The metal ring must be facing the brake assembly onto wheel hub (2).
outward.
1
4
86562
FIGURE 50-89. BRAKE ASSEMBLY
INSTALLATION
1. Brake Assembly 2. Wheel Hub
86560
FIGURE 50-88. SEAL INSTALLATION
1. Seal Assembly 3. O-ring
2. Seal Carrier 4. Allen Head Capscrew
45
CEN50107-01 50 Disassembly and assembly
31. Install 12-point capscrews (1, Figure 50-90) and 34. Lubricate and install O-ring (4, Figure 50-91) onto
hardened flat washers (2) that secure the brake spindle (3). Ensure that the O-ring is not twisted.
assembly inner gear to the wheel hub. Tighten
35. Install wheel hub/brake assembly (5) onto the
the capscrews to 2 705 ± 135 N·m (1,995 ± 100 ft
spindle. Align the brake assembly with the
lb).
spindle by installing three 12-point capscrews (1)
There is a total of 32 capscrews. and hardened flat washers (2) hand-tight only.
32. Remove the shipping bars from the brake 36. Install bearing cone (6) and retainer pin (7).
assembly.
33. Install shipping brackets (3) with flat washers and
7
nuts at three equally-spaced locations around the
wheel hub.
6
3
5
3
86544
FIGURE 50-90. BRAKE ASSEMBLY
INSTALLATION 2
1. 12-Pt. Capscrew 3. Shipping Bracket
2. Hardened Flat Washer 1
86563
FIGURE 50-91. WHEEL HUB/BRAKE
INSTALLATION
1. 12-Pt. Capscrew 5. Wheel Hub/Brake
2. Hardened Flat Washer Assembly
3. Spindle 6. Bearing Cone
4. O-ring 7. Retainer Pin
46
50 Disassembly and assembly CEN50107-01
37. Install remaining capscrews (1) and hardened 41. Lubricate and install a new O-ring on cover (3,
washers (2). Tighten all 54 capscrews to 1 166 ± Figure 50-93). Install the cover, capscrews (1)
116 N·m (860 ± 86 ft lb). and lockwashers (2). Tighten the capscrews to
the standard torque.
38. Lubricate and install O-ring (4, Figure 50-92) onto
bearing retainer (3). Ensure that the O-ring is not
twisted.
3 1 2
39. Install shim pack (5) that was determined in Step
15.
40. Install bearing retainer (3), capscrews (1), and
hardened flat washers (2). While rotating the hub,
tighten the capscrews alternately in several
successive increments to a final torque of 1 017 ±
102 N·m (750 ± 75 ft lb).
2 3
4
86539
5
FIGURE 50-93. WHEEL HUB COVER
REMOVAL & INSTALLATION
1. Capscrew 3. Hub Cover
2. Lockwasher
42. Perform a hydraulic pressure test on the wheel
hub to ensure the integrity of the seals. Refer to
"Wheel Hub Pressure Test" in Testing and
adjusting section Brake system.
86540
FIGURE 50-92. WHEEL HUB BEARING
RETAINER REMOVAL
1. Capscrew 4. O-ring
2. Hardened Flat Washer 5. Shims
3. Bearing Retainer
47
CEN50107-01 50 Disassembly and assembly
Speed sensor installation and adjustment 45. Rotate the hub so that fill plug (1, Figure 50-96) is
43. Install wheel speed sensor (2, Figure 50-94) in at the 12 o'clock position above sight gauge (2)
sensor bracket (5). Tighten two capscrews (3) as shown. Remove the fill plug.
and flat washers (4) to the standard torque. 46. Add TO50 hydraulic oil through the plug port until
Connect the sensor cable to cable bracket (1). the floating ball is at the highest position. The
capacity of the bearing oil cavity is approximately
68 L (18 gal).
1
1
2
4 3 5 86538
FIGURE 50-94. WHEEL SPEED SENSOR
REMOVAL & INSTALLATION
1. Cable Bracket 4. Flat Washer
2. Wheel Speed Sensor 5. Sensor Bracket
3. Capscrew
2 87606
44. Adjust the sensor as follows:
FIGURE 50-96. ADDING OIL TO WHEEL HUB
a. Rotate the hub to position the center line of a
gear tooth directly under the sensor tip. 1. Fill Plug 2. Sight Gauge
b. Turn in the sensor until the tip contacts the
gear tooth. Then, back off 1/2 turn.
c. Continue turning out the sensor until the flats
of the sensor housing are perpendicular to the
gear tooth motion (See Figure 50-95).
d. Lock the sensor in place. Rotate the hub 180
degrees to verify that there is enough sensor
clearance. There should be 2.0 ± 0.1 mm
(0.079 ± 0.004 in.) of clearance.
FIGURE 50-95. SPEED SENSOR ADJUSTMENT
48
50 Disassembly and assembly CEN50107-01
47. Remove the spindle, hub and brake assembly Hub floating ring seal assembly and
from the spindle stand. installation
48. Install steering arm (3, Figure 50-97) onto spindle Failures of floating seals are usually caused by a
(4). Install all 12-point capscrews (1) and combination of factors rather than one single cause,
hardened flat washers (2), then tighten the but many failures have one common denominator -
capscrews in an alternating pattern to 2 705 ± assembly and installation issues.
135 N·m (1,995 ± 100 ft lb).
There are five common failure modes:
• Oil leakage
• Galling
4 • Pumping mud past the toric
• Toric failure
• Seal ring breakage
The following procedure using necessary installation
tools must be accomplished to be assured of
satisfactory floating seal performance.
3 1 2 86536
FIGURE 50-97. STEERING ARM INSTALLATION
1. 12-Pt. Capscrews 3. Steering Arm
2. Hardened Flat Washers 4. Spindle
FIGURE 50-98. SEAL TERMINOLOGY
1. Seal Ring 5. Seal Ring Housing
2. Rubber Toric 6. Seal Ring Face
3. Housing Retainer Lip 7. Seal Ring Ramp
4. Housing Ramp 8. Seal Ring Retainer Lip
49
CEN50107-01 50 Disassembly and assembly
3. Carefully inspect the polished sealing surfaces
on the seal rings for scratches or any other
damage. Inspect the entire seal contact area on
all the parts for scratches or nicks that may
damage the O-rings during installation or cause a
Floating ring seals must always be installed in path of leakage after installation. If scratches are
matched pairs. The seal rings must be new. DO present, hone and then clean the damaged area.
NOT mate a new ring with a used ring. DO NOT
install two used rings. Always install new O-rings 4. Use clean, lint-free cloths and isopropyl alcohol
(toric rings). to remove all traces of oil, dust, protective coating
or other foreign matter from the metal seal rings,
1. Prepare a completely clean work area to handle the O-rings, the back plate and the seal contact
the large seal rings, O-rings and seal carriers. areas on all of the parts. Allow the surfaces to dry
Absolute cleanliness is essential during the completely.
assembly process to prevent premature seal
failure and possible oil leaks. NOTE: Oil from adjacent bearing installations or seal
ring face lubrication must not get on the ramp or toric
NOTE: Use isopropyl alcohol in a spray bottle to clean until after both seal rings are together in their final
the parts prior to assembly. Use clean, lint-free assembled position.
material such as Micro-Wipes # 05310 for cleaning
5. Place the O-rings on a clean flat surface. Ensure
and wiping. Do not use Stanosol or any other liquid
that the O-rings are not twisted. Use a white paint
that leaves an oily film or does not evaporate quickly.
pen to mark a continuous line or dots every 38
2. Thoroughly clean the rubber O-rings with mm (1.5 in.) on the O-rings (as shown in Figure
isopropyl alcohol to remove the white powder like 50-99) all the way around the circumference of
coating and any other contaminants. Use the O-ring.
isopropyl alcohol to clean the seal contact
surfaces on housing ramp (4, Figure 50-98)
where the O-rings will be seated on the brake
housings and on the seal carriers. Also clean the
polished sealing surface on the seal rings.
72609
FIGURE 50-99. LOCATION OF WHITE LINE
1. White Marker 3. O-Ring
2. 45° Angle
50
50 Disassembly and assembly CEN50107-01
6. Install O-rings (2, Figure 50-100) to seal rings (1).
After installation, check the O-rings for any
twisting with reference to the white line or dots, or
the flash line in the middle of the ring. Ensure that
the O-ring is straight and uniform all the way
around the seal ring, and that the O-ring is seated
against the retaining lip. Adjust the O-ring as
necessary.
1 2
72610
FIGURE 50-100. O-RING INSTALLATION
1. Seal Ring 2. O-Ring
51
CEN50107-01 50 Disassembly and assembly
7. Place installation tool onto the seal ring with the 8. With all surfaces of the toric ring wet, use the
toric ring. Lower the rings into a container of installation tool to position seal ring and toric ring
isopropyl alcohol until all surfaces of the toric ring squarely against the seal housing.Push on the
are wet. tool (NOT the seal ring) evenly during installation
until the O-ring is installed. The O-ring should
squeeze (or pop) into place below the retaining
lip before the installation tool touches the
housing.
NOTE: Each floating seal comes with its own unique
installation tool designed for leakage and damage free
installation of the seal. Use appropriate installation
tool.
ALTERNATE PROCEDURE: 9. After installing the floating seal assemblies,
check the O-ring for twisting. The white line or
After positioning the seal squarely over the retaining dots. should be visible around the entire
lip, thoroughly lubricate the ring by spraying it with tri- circumference of the O-ring as indicated by the
chloroethane #111. white dot in Figure 50-101. Adjust the O-ring if
DO NOT USE Stanosol or any other liquid that leaves necessary, but DO NOT push directly on the seal
an oily film or does not evaporate quickly. ring.
NOTE: Handle the seal ring carefully. Nicks and
scratches on the seal ring face can cause leaks.
72613
1
FIGURE 50-101. SEAL INSPECTION
1. White Dots
52
50 Disassembly and assembly CEN50107-01
10. Use a gauge (Figure 50-102) to check the seal
height variation (marked by arrows, Figure 50-
104) between seal ring (2) and back plate (1).
Check the assembled height in four places that
are 90° apart. The height variation around the
assembled ring must be less than 1.0 mm (0.04
in).
If small adjustments are necessary, do not push
directly on the seal ring. Use the installation
tool to make any required adjustments. The seal
rings must be level as shown in Figure 50-106.
FIGURE 50-102. CHECKING SEAL RING
The O-rings can twist during adjustments,
especially if there is a dry spot on the O-ring or if
there are burrs or fins on the housing retaining lip. FIGURE 50-104. CHECKING SEAL HEIGHT
Verify that the O-rings are not twisted as shown in
1. Back Plate 2. Seal Ring
Figure 50-103. A bulging O-ring or crooked seal
ring will lead to eventual failure.
NOTE: Toric ring must not slip on ramps of either seal
ring or housing. To prevent slippage, wait at least two
minutes. Let all solvent evaporate before further
assembly. Once correctly in place, the toric ring must
roll on the ramps only. If correct installation is not
obvious, repeat steps 1 through 10.
FIGURE 50-103. TWISTED O-RING
53
CEN50107-01 50 Disassembly and assembly
11. After both seal ring heights have been checked
and adjusted, wipe the polished seal ring
surfaces with a lint-free material and isopropyl
alcohol to remove all foreign material and
fingerprints.
FIGURE 50-105. CORRECT ASSEMBLY
No foreign particles of any kind are allowed on the
polished seal ring faces. Something as small as a
paper towel fiber will hold the seal faces apart and
could cause damage or leakage.
12. Apply a thin film of clean hydraulic oil (C-4 type
SAE 10W) on the polished seal faces on both
seal rings. Use a lint-free applicator or a clean
finger to distribute the oil evenly. Ensure that no
oil comes in contact with the rubber toric rings or
their mating surfaces.
13. During assembly, ensure that both housings are
square, concentric and in correct alignment as
FIGURE 50-106. CORRECT ALIGNMENT
shown in Figure 50-106. Move the parts slowly
and carefully toward each other. Do not slam,
bump or drop the seal rings together. High impact
can damage the seal ring face and cause
leakage.
54
50 Disassembly and assembly CEN50107-01
55
CEN50107-01 50 Disassembly and assembly
Removal and installation of rear axle 6. Disconnect and unclamp all electrical harnesses
that are attached to the rear axle housing.
Removal
7. Disconnect and unclamp all automatic lubrication
system hoses that are attached to the rear axle
housing. Secure the hoses to the frame to
prevent interference during removal of the rear
axle housing.
Hydraulic oil escaping under pressure can have
8. Remove the power cable grips at power cable
sufficient force to enter a person's body by
mount (1, Figure 50-107) on the right side of the
penetrating the skin and cause serious injury, and
rear axle housing. Pull the power cables from the
possibly death, if proper medical treatment is not
rear axle housing.
received immediately.
Relieve pressure before disconnecting any
hydraulic lines. Tighten all connections securely
before applying pressure.
1. Refer to the "Hydraulic system bleeddown
procedure" in Testing and adjusting section
Steering, hoist, brake cooling and auxiliary
hydraulic system.
2. Remove the dump body. Refer to Disassembly
and assembly section Body and structures.
3. Remove the rear suspensions. Refer to
Disassembly and assembly section
Suspensions. 1 87907
4. Remove the anti-sway bar. Refer to "Removal
FIGURE 50-107. POWER CABLES
and installation of anti-sway bar".
1. Power Cable Mount
5. Remove the wheel motors. Refer to "Removal
and installation of wheel motor".
56
50 Disassembly and assembly CEN50107-01
10. Install vacuum pump kit (XB0887) on the
hydraulic tank to prevent the loss of oil when
disconnecting hydraulic lines.
11. Disconnect and unclamp the hoses at hydraulic
hose manifold (1, Figure 50-108) and dual relay Use a lifting device with adequate capacity to
valve (2) on the left side of the rear axle housing. remove and install the components.
Cap the fittings and plug the hoses to prevent
contamination. Do not allow the lifting chains/slings to contact the
truck frame while hoisting the rear axle housing.
Pulling on the truck frame could cause the truck
1 2 frame to fall.
13. Attach one overhead hoist or crane to nose cone
lifting eye (1, Figure 50-109). Attach a second
overhead hoist or crane through rear suspension
mount lifting eyes (2) Lower the nose cone and
carefully move the rear axle housing toward the
rear of the truck.
86568
FIGURE 50-108. REAR BRAKE HOSES
1. Hydraulic Hose Manifold
2. Dual Relay Valve
12. Remove the pivot pin. Refer to "Removal and
installation of pivot pin".
2
2
86569
FIGURE 50-109. REAR AXLE HOUSING
LIFTING EYES
1. Nose Cone Lifting Eye
2. Rear Suspension Mount Lifting Eye
14. Lower the nose cone to the ground, then remove
the overhead hoist or crane. Use a fork truck to
move the rear axle housing away from the truck.
57
CEN50107-01 50 Disassembly and assembly
Cleaning and inspection Installation
1. Thoroughly clean the capscrew holes and wheel 1. Use a fork truck to position the rear axle housing
motor mounting faces. Re-tap the holes if the under the truck frame.
threads are damaged.
2. Check the wheel motor mounting faces for nicks,
scratches and other damage. Inspect all welds
and repair them as necessary.
Use a lifting device with adequate capacity to
3. Inspect the pivot pin bearing. If it is worn or remove and install the components.
damaged, refer to "Pivot eye and bearing
service". Do not allow the lifting chains/slings to contact the
4. Inspect the hoses inside the rear axle housing. truck frame while hoisting the rear axle housing.
Inspect the hose connections at the hydraulic Pulling on the truck frame could cause the truck
hose manifold and dual relay valve. Repair leaks frame to fall.
or damaged hoses as required. 2. Attach one overhead hoist or crane to nose cone
5. Inspect the wheel motor power cables, terminals, lifting eye (1, Figure 50-109). Attach a second
cable grips and clamps. Replace any cables or overhead hoist or crane through rear suspension
hardware that is worn or damaged. mount lifting eyes (2) Raise the nose cone and
carefully move the rear axle housing toward the
rear of the truck.
3. Align the pivot pin bores and install the pivot pin.
Refer to Refer to "Removal and installation of
All propulsion system power cables must be pivot pin".
properly secured in their wood or other non- 4. Install the anti-sway bar. Refer to "Removal and
ferrous cable cleats. If any clamps are cracked or installation of anti-sway bar".
broken, replace them with new parts. Inspect the
cable insulation and replace the entire cable if the 5. Install the rear suspensions. Refer to
insulation is damaged. Disassembly and assembly section
Suspensions.
6. Connect and clamp all automatic lubrication
system hoses and electrical harnesses to the
rear axle housing.
7. Route the power cables through power cable
mount (1, Figure 50-107) on the right side of the
rear axle housing. Clamp them in place. Install
the cable grips at the power cable mount.
8. Connect and clamp the hoses at hydraulic hose
manifold (1, Figure 50-108) and dual relay valve
(2) on the left side of the rear axle housing.
9. Install the wheel motors. Refer to "Removal and
installation of wheel motor".
58
50 Disassembly and assembly CEN50107-01
Removal and installation of anti-sway bar 5. Disconnect lubrication lines (1) from both ends of
the anti-sway bar.
Removal
1. Park truck on a hard, level surface and block all
the wheels.
2. Place the directional control lever in PARK and
turn the rest switch ON. Turn the key switch OFF 1
to shut down the engine and allow 90 seconds for
the steering system accumulators to bleed down.
3. Position the frame and the rear axle housing to
allow use of a puller arrangement to remove the
pins.
4. Securely install support blocks (2, Figure 50-110)
between main frame (1) and rear axle housing
(3).
86461
FIGURE 50-111. ANTI-SWAY BAR BEARINGS
LUBRICATION LINES
1. Lubrication Lines
FIGURE 50-110. SUPPORT BLOCK
1. Main Frame 3. Rear Axle Housing
2. Support Block
59
CEN50107-01 50 Disassembly and assembly
8. Attach a puller and remove pin (2) from each end
of the anti-sway bar.
NOTE: The anti-sway bar mounting arrangement is
identical at each end.
Use a lifting device with adequate capacity to
remove and install the components. 9. Remove the anti-sway bar from the mounting
brackets.
6. Position a fork lift or attach an appropriate lifting
device to anti-sway bar (1, Figure 50-112). 10. Remove bearing spacers (6) and inspect for
damage and wear. Replace if necessary.
7. Remove locknut (5), flat washer (4) and shoulder
bolt (3) at each mount.
1 3
5
2
86462
FIGURE 50-112. ANTI-SWAY BAR REMOVAL & INSTALLATION
1. Anti-Sway Bar 4. Locknut
2. Shoulder Bolt 5. Pin
3. Flat Washer 6. Bearing Spacer
60
50 Disassembly and assembly CEN50107-01
11. If necessary, remove retainer rings (1, Figure 50- Installation
113) from the bores at both ends of the anti-sway
1. If removed, press new bearings (2, Figure 50-
bar and press out spherical bearings (2).
113) into the anti-sway bar and install retainer
12. If the bearings are removed, inspect the bearing rings (1). Ensure that the retainer rings are
bores of the anti-sway bar. If the bores are properly seated in the grooves.
damaged, repair or replace the anti-sway bar.
2. Install one bearing spacer (6, Figure 50-112).
3. Place pin (2) into position at the front of the frame
mount. Push the pin through the spacer.
1
Use a lifting device with adequate capacity to
remove and install the components.
4. Raise anti-sway bar (1) into position. Push pin (2)
through the spherical bearing. Insert the second
bearing spacer on the other side of the pin bore,
then continue pushing the pin into the other
mounting bore.
NOTE: The pin may need to be rotated to align the
hole for the shoulder bolt with the hole in the mounting
bracket.
1 5. Install shoulder bolt (3), flat washer (4) and
locknut (5). Tighten the locknut to 68 N·m (50 ft
86463
lb).
FIGURE 50-113. SPHERICAL BEARING 6. Repeat the steps 2 - 5 to install the remaining pin
REMOVAL & INSTALLATION and spacers at the opposite end of the bar. Start
the pin into the bore from the rear of the frame
1. Retainer Ring 2. Spherical Bearing mount.
7. Attach lubrication lines (1, Figure 50-111). Pump
grease into the bearing to verify that the line and
the automatic lubrication system are operational.
8. Remove support blocks (2, Figure 50-110)
between main frame (1) and rear axle housing
(3).
9. If necessary, charge the suspensions. Refer to
Testing and adjusting section Accumulators and
suspensions for the proper charging procedure.
61
CEN50107-01 50 Disassembly and assembly
Removal and installation of pivot pin 8. Place a jack under the pivot eye or attach a crane
to the lifting eye to control the downward
Removal movement of the front of the axle housing.
1. Park truck on a hard, level surface and block all 9. Disconnect pivot eye bearing lubrication line (1,
the wheels. Figure 50-114). Remove ground wire (2) between
2. Place the directional control lever in PARK and the pivot eye and the main frame.
turn the rest switch ON. Turn the key switch OFF
to shut down the engine and allow 90 seconds for
the steering system accumulators to bleed down.
1
3. Ensure that the body is resting on the frame.
4. Charge the rear suspensions with nitrogen until
the pistons are fully extended. Refer to Testing
and adjusting section Accumulators and
suspensions for the proper charging procedure. 2
5. Place blocks or jack stands under each frame
member beneath the hoist cylinders.
6. Release the nitrogen from the front suspensions,
then release the nitrogen from the rear
suspensions.
7. Remove rear axle blower hose (1, Figure 50-1) 86473
and the support bracket to allow access to pivot FIGURE 50-114. TOP OF PIVOT EYE
eye (2).
1. Lubrication Line 2. Ground Wire
2 10. Remove three capscrews (1, Figure 50-115) and
lockwashers (2).
11. Remove seven 12-point capscrews (3) and pin
retainer (4).
1
87924
FIGURE 50-1. REAR AXLE BLOWER HOSE
1. Rear Axle Blower Hose 2. Pivot Eye
2 1 86475
FIGURE 50-115. PIN RETAINER
1. Capscrew 3. 12-Point Capscrew
2. Lockwasher 4. Pin Retainer
62
50 Disassembly and assembly CEN50107-01
12. Install a puller in tapped holes in the head of pivot Installation
pin (1). Pull out the pivot pin.
NOTE: It may be necessary to place a pry bar or jack
between the mounting structure and the pivot eye to
push the pivot eye downward and away from the
mounting structure. Both spacers (2) will fall free. Use a lifting device with adequate capacity to
remove and install the components.
1. Raise the pivot eye into position between the
frame bores. Ensure that the inner race of the
pivot eye bearing is aligned with the pin bore.
2. Install one bearing spacer (2, Figure 50-116).
2 3. Place pin (1) into position on the right side of the
frame mount. Push the pin through the spacer.
4. Push pin (1) through the pivot eye bearing. Insert
the second bearing spacer on the other side of
the pin bore, then continue pushing the pin into
the other mounting bore.
1 5. Install pin retainer (4, Figure 50-115) and 12-point
capscrews (3) on the end of the pivot pin.
6. Install capscrews (1) and lockwashers (2) to
secure the pivot pin.
86476
7. Tighten capscrews (1) to 237 N·m (175 ft lb).
FIGURE 50-116. PIVOT PIN REMOVAL & Tighten 12-point capscrews (3) to 2 325 N·m
INSTALLATION (1,715 ft lb).
1. Pivot Pin 2. Spacer 8. Install ground wire (2, Figure 50-114) between
the pivot eye and the main frame.
9. Connect pivot eye bearing lubrication line (1).
Pump grease into the bearing to verify that the
line and the automatic lubrication system are
operational.
10. Charge the front suspension. Refer to Testing
and adjusting section Accumulators and
suspensions for the proper charging procedure.
11. Charge the rear suspensions with nitrogen until
the pistons are fully extended. Refer to Testing
and adjusting section Accumulators and
suspensions for the proper charging procedure.
12. Release the nitrogen from the rear suspension,
then charge them again.
63
CEN50107-01 50 Disassembly and assembly
Pivot eye and bearing service
Bearing replacement
1 3
1. Remove the pivot pin. Refer to the topic
"Removal and installation of pivot pin".
2. Remove 12-point capscrews (1, Figure 50-117)
5
and locknuts (2). There is a total of 16.
3. Remove bearing retainers (3).
4. Setup an appropriate tool to press spherical
bearing (4) from pivot eye (5).
5. Inspect all parts for excessive wear and damage. 4
Replace parts as required.
Spherical bearing O.D.:
281.66 - 281.70 mm (11.089 - 11.090 in.)
Spherical bearing I.D.:
177.77 - 177.80 mm (6.999 - 7.000 in.)
3
6. Set up an appropriate tool to press spherical 2
bearing (4) into pivot eye (5). Ensure that the
bearing is centered and properly installed in the 86478
pivot eye to allow proper lubrication. FIGURE 50-117. PIVOT EYE BEARING REMOVAL
7. Install bearing retainers (3), 12-point capscrews & INSTALLATION
(1) and locknuts (2). Tighten the capscrews to the 1. 12-Point Capscrew 4. Spherical Bearing
standard torque. 2. Locknut 5. Pivot Eye
3. Bearing Retainer
64
50 Disassembly and assembly CEN50107-01
Pivot eye repair 5. Inspect the pivot eye bore for excessive wear and
damage. Replace the pivot eye if necessary.
Pivot eye bore (new):
307.023 ± 0.013 mm (12.0875 ± 0.0005 in.)
Use a lifting device with adequate capacity to
remove and install the components. 6. Setup an appropriate tool to press bearing carrier
(4) into the pivot eye bore.
1. Attach an appropriate lifting device to the lifting
eye on pivot eye (1, Figure 50-118). NOTE: With parts of the correct size, the fit of the
bearing carrier into the pivot eye bore may be 0.025 -
2. Remove capscrews (2) and flat washers (3). 0.080 mm (0.001 - 0.003 in.) interference fit. Freezing
Remove pivot eye (1) from the rear axle housing. the bearing carrier will ease installation.
3. If installed, setup an appropriate tool to press the
spherical bearing from the pivot eye.
4. Setup an appropriate tool to press bearing carrier
(4) out of the pivot eye bore.
Bearing carrier I.D. (new): The lubrication groove in the outer diameter of the
281.660 ± 0.013 mm (11.0889 ± 0.0005 in.) bearing carrier must be aligned with the
lubrication fitting hole in the pivot eye.
Bearing carrier O.D. (new):
307.160 ± 0.013 mm (12.0929 ± 0.0005 in.) 7. Press bearing carrier (4) into the pivot eye bore.
Ensure that the bearing carrier is pressed fully
into the pivot eye bore and flush with the sides to
allow proper lubrication.
8. Press the spherical bearing into the pivot eye.
2 3 9. Ensure that the mating surfaces of the rear axle
housing and pivot eye (1) are clean and not
damaged.
4 10. Attach an appropriate lifting device to the lifting
eye on pivot eye (1). Lift the pivot eye into
position on the front of the rear axle housing.
Insert several capscrews (2) and flat washers (3)
to align the parts, then remove the lifting device.
11. Install the remaining capscrews and flat washers.
Tighten the capscrews alternately until the pivot
eye is properly seated, then tighten the
capscrews to 3 078 ± 307 N·m (2,270 ± 227 ft
lb).
86458
FIGURE 50-118. PIVOT EYE REPAIR
1. Pivot Eye 3. Flat Washer
2. Capscrew 4. Bearing Carrier
65
CEN50107-01 50 Disassembly and assembly
Removal and installation of wheel motor Removal
Preparation NOTE: If suitable equipment is available to lift the
wheel motor assembly from the axle housing, it is not
Read and observe the following instructions before necessary to remove the dump body. The equipment
attempting any repairs on propulsion system used must be capable of lifting and supporting the
components. weight of the complete wheel motor assembly. It must
also be mobile and capable of aligning the wheel
motor with the axle housing mounting flange during
installation. If the wheel motor must be removed by
use of a crane or overhead hoist, refer to Disassembly
and assembly section Body and structures, for dump
• Do not step on or use any power cable as a body removal instructions.
hand hold when the engine is running.
1. Block up the truck and remove the rear wheels.
• All removal, repairs and installation of Refer to "Removal and installation of rear wheel".
propulsion system electrical components,
cables, etc, must be performed by an electrical NOTE: Ensure that additional capscrews have been
maintenance technician properly trained to installed to provide support for the wheel motor
service the system. transmission housing while the rear tires are removed.
• In the event of a propulsion system 2. Install vacuum pump kit (XB0887) on the
malfunction, a qualified technician should hydraulic tank to prevent the loss of oil when
inspect the truck and verify that the propulsion disconnecting hydraulic lines.
system does not have dangerous voltage
levels present before repairs are started. 3. Remove drain plug (2, Figure 50-119) at the
bottom of both rear brakes (1). Drain the oil from
the brakes into a suitable container.
Hydraulic oil escaping under pressure can have
sufficient force to enter a person's body by
penetrating the skin and cause serious injury, and
possibly death, if proper medical treatment is not
received immediately.
Relieve pressure before disconnecting any
hydraulic lines. Tighten all connections securely
before applying pressure.
1. Refer to the "Hydraulic system bleeddown
procedure" in Testing and adjusting section
Steering, hoist, brake cooling and auxiliary
1 2
86459
hydraulic system.
FIGURE 50-119. REAR BRAKE DRAIN PLUG
2. After the truck is parked for the repairs, the truck
must be shut down properly to ensure the safety 1. Rear Brake 2. Drain Plug
of those working in the area of the wheel motors,
control cabinet and retarding grids. Ensure that
the electrical system is properly discharged
before repairs are started.
66
50 Disassembly and assembly CEN50107-01
4. Disconnect brake cooling hoses (1, Figure 50- 7. After all disconnected hydraulic lines have been
120) and brake apply hoses (2) from both of the plugged, turn off the vacuum pump.
rear brakes. Plug the hoses and ports.
8. Disconnect six wheel motor power cables (1,
5. Remove the clamps that secure the brake hoses Figure 50-122) and wheel speed sensor
to the brake ports. harnesses (2) from each wheel motor.
9. Tie up any cables and hoses as necessary to
prevent damage during wheel motor removal.
1
1 1
86460
FIGURE 50-120. REAR BRAKE HOSES
1. Brake Cooling Hose 2. Brake Apply Hose
6. Open the rear axle access hatch. Disconnect and
plug parking brake hoses (2, Figure 50-121) from
parking brake (1) on each wheel motor.
86525
FIGURE 50-122. WHEEL MOTOR POWER
1 CABLES
1. Wheel Motor Power Cables
2. Wheel Speed Sensor Harness
2 86524
FIGURE 50-121. PARKING BRAKE HOSES
1. Parking Brake 2. Parking Brake Hose
67
CEN50107-01 50 Disassembly and assembly
11. Remove 12-point capscrews (1, Figure 50-124)
and hardened flat washers (2) that secure the
wheel motor to the rear axle housing. There is a
total of 66 capscrews and flat washers per wheel
Use lifting devices with adequate capacity to motor assembly.
remove and install the components. 12. Move the wheel motor assembly out of the rear
axle housing. Be careful not to damage the brake
hoses and power cables.
When lifting the wheel motor assembly, do not
place lifting straps/cables on, or lift from, the inner
wheel rim adapter ring. Lifting straps/cables
should be placed so the weight of the wheel motor
assembly is supported by wheel motor mounting
flange (1, Figure 50-123) and machined hub
surface (2).
10. Attach a lifting device to the wheel motor
assembly. See Figure 50-123 for a typical
example.
1 2 86530
FIGURE 50-124. WHEEL MOTOR REMOVAL
1. 12-Point Capscrews
2. Hardened Flat Washers
1 2 86528
FIGURE 50-123. LIFTING THE WHEEL MOTOR
1. Wheel Motor 2. Machined Hub
Mounting Flange Surface
68
50 Disassembly and assembly CEN50107-01
Cleaning and inspection Installation
1. Thoroughly clean the threaded holes and the NOTE: Refer to the drive system manual for wheel
mounting faces of the rear axle housing and motor to transmission mating procedures.
wheel motor.
1. Apply a lithium based grease containing 3%
2. Inspect the capscrew holes in the rear axle molybdenum-disulphide to the threaded
housing for damage. Re-tap any holes that have capscrew holes in the rear axle housing.
damaged threads. Thoroughly clean any
capscrew holes that have been re-tapped. 2. Install two guide pins 180° apart (3 o’clock and 9
o’clock positions) in the rear axle housing.
3. Check the mounting faces of the rear axle
housing and the wheel motor for surface defects
(nicks, scratches, etc). Repair any defects before
installing the wheel motor.
4. Check the flatness of both mounting faces of the
rear axle housing. Check the flatness at four Use lifting devices with adequate capacity to
equally spaced intervals (for example, 0°, 45°, remove and install the components.
90° and 135°).
The maximum allowable variation in flatness is
2.29 mm (0.09 in.). Do not use a rear axle hous-
ing that does not meet this specification.
When lifting the wheel motor assembly, do not
5. Inspect the brake system relay valve and hoses place lifting straps/cables on, or lift from, the inner
inside the rear axle housing for leaks. Repair wheel rim adapter ring. Lifting straps/cables
leaks or damaged hoses as required. should be placed so the weight of the wheel motor
6. Inspect the wheel motor power cables, terminals assembly is supported by wheel motor mounting
and clamps. Replace any cables or hardware that flange (1, Figure 50-123) and machined hub
is worn or damaged. surface (2).
3. Attach a lifting device to the wheel motor
assembly. See Figure 50-123 for a typical
example.
Lift the wheel motor into position on the rear axle
All propulsion system power cables must be housing. Ensure that all cables and hoses are
properly secured in their wood clamps or other clear before installation.
non-ferrous cable cleats. If clamps are cracked or
If the brake system hoses are installed, guide
broken, replace them with new parts. If the cable
them through the holes in the wheel motor
insulation is damaged, replace the entire cable.
mounting flange during installation.
69
CEN50107-01 50 Disassembly and assembly
The wheel motors must be properly aligned before High tightening force is required to install the
installing them onto the rear axle housing. Two capscrews that secure the wheel motors to the
sets of dimples are located on each wheel motor rear axle housing. Repeated tightening will result
mounting flange at the 3 o’clock and 9 o’clock in capscrew fatigue and damage.
positions. The hole closest to the identification
plate on the motor side of the mounting flange is Do not reuse any wheel motor mounting hardware
the 12 o’clock position of the wheel motor. (capscrews and hardened washers). Replace the
hardware after one use.
The rear axle housing also has two sets of dimples
next to the wheel motor mounting surface at the 3 Do not retighten any wheel motor mounting
o’clock and 9 o’clock positions. Refer to Figure 50- capscrew that has loosened after the truck has
125. been placed into operation. If any wheel motor
mounting capscrew has loosened during truck
When installing the wheel motors, ensure that the operation, all of the capscrews and hardened
dimples on both components are aligned, then washers must be replaced with new hardware.
rotate each wheel motor slightly clockwise (while
viewed from the outer end) to align the capscrew The capscrews that are used to secure the wheel
holes properly. motors to the rear axle housing are specially
hardened to meet or exceed grade 8
specifications. Replace these capscrews with only
new capscrews of the correct hardness. Refer to
the appropriate parts book for the correct part
number.
The use of dry threads in this application is not
recommended. Due to the high tightening force
that is required to install the wheel motor
mounting capscrews, dry threads may cause
damage to tools, capscrews or the rear axle
housing.
Komatsu does not recommend the use of special
friction-reducing lubricants, such as Copper Coat,
Never-Seez® or other similar products, on the
threads of standard fasteners where standard
1 2 torque values are applied. The use of special
86531 friction-reducing lubricants will significantly alter
FIGURE 50-125. ALIGNING THE WHEEL MOTOR the clamping force during the tightening process.
If a special friction-reducing lubricant is used,
1. Wheel Motor 2. Axle Housing
excessive stress and possible breakage of the
Alignment Dimples Alignment Dimples
fasteners may result.
70
50 Disassembly and assembly CEN50107-01
4. Select the hardware to be installed in Group 1 of
the tightening sequence. Refer to Figure 50-127.
Inspect each capscrew for rust, corrosion and
surface defects on any seat or thread. Do not use
any capscrew if a defect is suspected.
5. Lubricate the capscrew threads, capscrew head
seats and washer faces with a lithium based
grease containing 5% molybdenum disulphide.
NOTE: The special hardened washers that are used in
this application may have a punch lip on one side due
to the manufacturing process. When placing this
washer under the capscrew head, the washers must
be installed with the punch lip facing away from the
capscrew head to prevent damage to the fillet between
the capscrew head and the shank. Refer to Figure 50- FIGURE 50-126. INSTALLING HARDENED
126.
1. Washer 2. Capscrew
GROUP 2
8 CAPSCREWS
GROUP 6 GROUP 7
8 CAPSCREWS 8 CAPSCREWS
GROUP 4 GROUP 3
8 CAPSCREWS 8 CAPSCREWS
GROUP 8 GROUP 5
9 CAPSCREWS 9 CAPSCREWS
GROUP 1
8 CAPSCREWS
86302
FIGURE 50-127. WHEEL MOTOR MOUNTING HARDWARE INSTALLATION SEQUENCE
71
CEN50107-01 50 Disassembly and assembly
6. Install the hardware for Group 1. Tighten each
capscrew to 542 N·m (400 ft lb).
All propulsion system power cables must be
properly secured in their wood clamps or other
non-ferrous cable cleats. If clamps are cracked or
Install and tighten all of the hardware in a group
broken, replace them with new parts. If the cable
before proceeding to the next group in the
insulation is damaged, replace the entire cable.
tightening sequence. Remove the guide pins that
were installed in step 2 when installing the 14. Connect six power cables (1, Figure 50-122) and
hardware for Groups 3 and 4. wheel speed sensor harnesses (2) to their
appropriate locations.
7. Repeat steps 4 - 6 for each remaining group in
the tightening sequence. Refer to Figure 50-127. 15. After all hydraulic lines have been reconnected,
turn off the vacuum pump and remove the
8. After all of the hardware in all of the groups has
vacuum pump from the hydraulic tank. Check for
been installed and tightened to 542 N·m (400 ft
leaks from the hoses in the rear axle housing.
lb), move back to Group 1. Increase the torque
on each capscrew in Group 1 to 4 040 N·m 16. Close the rear axle housing hatch.
(2,980 ft lb). Repeat this step for each remaining
17. Check the oil level in each wheel motor. Rotate
group in the tightening sequence. Refer to Figure
one of the eight plugs to the 6 o’clock position
50-127.
and remove the plug. The oil level should be
9. Install vacuum pump kit (XB0887) on the even with the bottom of the plug opening. Refer
hydraulic tank to prevent the loss of oil when to Figure 50-128. Fill the wheel motor with the
reconnecting hydraulic lines. recommended oil as necessary.
10. Connect brake apply hose (2, Figure 50-120) and
brake cooling hoses (1) to the each rear brake
assembly. Use new O-rings.
11. To prevent cooling air loss, use Uniseal® 310S
sealant or an equivalent sealant to seal the gap
around the brake cooling hoses where the hoses
pass through the mounting flange holes.
12. After both wheel motors are installed, open the
rear axle access hatch. Connect parking brake
hoses (2, Figure 50-121) to parking brake (1) on
each wheel motor.
13. Install the remaining hose clamps. If removed,
connect the nylon tube to the blower pressure
switch.
FIGURE 50-128. WHEEL MOTOR OIL LEVEL
72
50 Disassembly and assembly CEN50107-01
18. Check the hydraulic tank oil level before and after Removal and installation of rear brake
engine start-up. Service the hydraulic tank oil as assembly
necessary. Refer to the appropriate GE service manual for the
19. Bleed the air from the brake apply lines. Refer to removal and installation procedures.
"Wet disc brake bleeding procedure" in Testing
NOTE: The rear wheel brake assembly weighs
and adjusting section Brake system.
approximately 2 031 kg (4,479 lb).
20. Check the hydraulic tank oil level after the brake
bleeding procedure. Service the hydraulic tank oil
as necessary.
21. Install the tires and rims. Refer to "Removal and
installation of rear wheel".
High tightening force is required to install the
capscrews that secure the wheel motors to the
rear axle housing. Repeated tightening will result
in capscrew fatigue and damage.
Do not retighten any wheel motor mounting
capscrew that has loosened after the truck has FIGURE 50-129. WHEEL MOTOR ASSEMBLY
been placed into operation. If any wheel motor
mounting capscrew has loosened during truck 1. Wheel Motor 3. Wheel Hub
operation, all of the capscrews and hardened 2. Brake Assembly 4. Transmission
washers must be replaced with new hardware.
73
CEN50107-01 50 Disassembly and assembly
980E Dump truck
Form No. CEN50107-01
74
CEN50023-02
DUMP TRUCK
980E
Machine model Serial number
980E-5 A50005 and up
50 Disassembly and assembly
Brake system
Removal and installation of brake valve ............................................................................................................... 3
Disassembly and assembly of brake valve/pedal assembly ................................................................................. 5
Removal and installation of dual relay valve ......................................................................................................... 8
Removal and installation of brake manifold .........................................................................................................11
Disassembly and assembly of brake manifold.................................................................................................... 12
Removal and installation of piston brake accumulator........................................................................................ 13
Disassembly and assembly of piston brake accumulator ................................................................................... 15
Disassembly and assembly of front wheel brake................................................................................................ 19
Disassembly and assembly of rear wheel brake................................................................................................. 25
Brake floating ring seal assembly and installation .............................................................................................. 33
Removal and installation of parking brake .......................................................................................................... 40
Disassembly and assembly of parking brake...................................................................................................... 42
1
CEN50023-02 50 Disassembly and assembly
NOTES
2
50 Disassembly and assembly CEN50023-02
Removal and installation of brake valve 3. Clean brake valve (2, Figure 50-2) and the
surrounding area to help avoid contaminating the
Removal hydraulic oil when the hoses are disconnected.
NOTE: If the brake valve is to be removed from the NOTE: Before disconnecting hydraulic hoses, tag the
truck, additional equipment will be required as outlined hoses for proper identification during installation. See
in the disassembly and assembly procedures. Minor Figure 50-4.
repairs and service adjustment may not require the
removal of the brake valve. 4. Disconnect and plug six hydraulic hoses (1) from
the brake valve.
Hydraulic oil escaping under pressure can have 2
sufficient force to enter a person's body by
penetrating the skin and cause serious injury, and
possibly death, if proper medical treatment is not
received immediately.
Relieve pressure before disconnecting any 1
hydraulic lines. Tighten all connections securely
before applying pressure.
1. Refer to the "Hydraulic system bleeddown
procedure" in Testing and adjusting section
87546
Steering, hoist, brake cooling and auxiliary
hydraulic system. FIGURE 50-2. BRAKE VALVE REMOVAL &
2. Remove front access cover (1, Figure 50-1) from INSTALLATION
the operator cab. 1. Hydraulic Hoses 2. Brake Valve
1 86676
FIGURE 50-1. ACCESSING THE BRAKE VALVE
1. Front Access Cover
3
CEN50023-02 50 Disassembly and assembly
5. Disconnect the retarder pedal harness from the Installation
truck harness.
1. Slide brake valve/pedal assembly (3, Figure 50-
6. Remove capscrews (1, Figure 50-3) and 3) into position in the cab and secure it with
lockwashers (2) that secure brake valve/pedal capscrews (1) and lockwashers (2). Tighten the
assembly (3) to the cab. capscrews to the standard torque.
7. Slide the brake valve/pedal assembly through the 2. Unplug and connect six hydraulic hoses (1,
hole and remove it from the cab. Move the brake Figure 50-2) to their proper ports on brake valve
valve/pedal assembly to a clean work area for (2). Refer to Figure 50-4.
disassembly, if required.
P2 P1
3
B2 B1
2 1
T
PX
86388
87547
FIGURE 50-3. BRAKE VALVE REMOVAL & FIGURE 50-4. BRAKE VALVE PORT
INSTALLATION IDENTIFICATION
1. Capscrews 3. Brake Valve/
2. Lockwashers Pedal Assembly “P1” - Pressure Inlet “B2” - Regulated Output
“P2” - Pressure Inlet “T” - Return to Tank
“B1” - Regulated Output “PX” - Pilot Inlet
4
50 Disassembly and assembly CEN50023-02
3. Connect the retarder pedal harness to the truck Disassembly and assembly of brake
harness. valve/pedal assembly
4. With the engine off and the key switch OFF, open
Disassembly
both brake accumulator bleed down valves (1,
Figure 50-5) on brake manifold (2). Precharge 1. Remove electronic retarder pedal (1, Figure 50-
both brake accumulators. Refer to Testing and 6) from the brake pedal by removing two retaining
adjusting section Accumulators and clips and pivot shaft (2).
suspensions for the accumulator charging 2. Remove hose fittings (7) from the brake valve
procedure. ports. Rotate the brake valve over a suitable
5. Close both accumulator bleed down valves after container and allow the oil to drain.
the accumulators have been properly charged.
8
2
9
FIGURE 50-5. BRAKE MANIFOLD
1. Brake Accumulator Bleed Valves 4 8
2. Brake Manifold
5
6. Before checking the brake valve operation, the
steering accumulators must have the proper
nitrogen precharge. Refer to Testing and
adjusting section Accumulators and
suspensions for the accumulator charging 6
procedure.
7. Bleed the air from the brakes and brake lines. 7
Refer to "Wet disc brake bleeding procedure" in
Testing and adjusting section Brake system.
8. Check for oil leaks at the brake valve.
86389
9. Install front access cover (1, Figure 50-1) on the
operator cab. FIGURE 50-6. BRAKE VALVE/PEDAL
ASSEMBLY
NOTE: When installing the front access cover, ensure
that the bottom false hinge of the cover is engaging 1. Retarder Pedal 6. Brake Valve
into the bottom edge of the sheet metal panel of the 2. Pivot Shaft 7. Hose Fittings
cab front enclosure. 3. Brake Pedal Actuator 8. Spring Pivot
4. Retainer Clip 9. Spring
5. Pivot Shaft
5
CEN50023-02 50 Disassembly and assembly
NOTE: During disassembly, precision machined parts Assembly
should be ink marked or tagged to ensure proper
1. Inspect threaded inserts (7, Figure 50-7) in
reassembly and minimize adjustment time. All items
actuator base (6). If any of the threads are
must be placed back into the bores from which they
damaged, the inserts must be replaced.
were removed.
2. If any threaded inserts (7) were removed from
3. Match mark each section of the brake valve
actuator base (6), position the actuator base
Place the brake valve in an upright position and
upside down on the work bench and support it
secure it in a vice.
directly under each of the four mounting holes.
4. Remove spring pivots (8) and spring (9).
3. Install the threaded inserts into the actuator base
5. To remove brake pedal actuator (3), remove two by tapping lightly with a small hammer until the
retainer clips (4), then use a punch and hammer insert flanges become flush with the actuator
to drive out pivot shaft (5). base. To avoid breaking the base, make sure that
6. Remove four button head screws (3, Figure 50-7) the base is supported.
that secure retainer plate (4). 4. Thoroughly clean the actuator base and set it
7. Remove retainer plate (4), boot (2) and actuator aside.
cap (1) as an assembly by grasping the boot and 5. Examine boot (2) for any cracks, tears, or other
gently lifting it from the valve body. damage. If damage is evident, the boot must be
replaced.
6. If damaged, remove the boot from actuator cap
(1) and discard the old boot. Thoroughly clean
the sides of the cap by using a knife or suitable
scraper to scrape the lip where the cap contacts
the boot. Clean the cap thoroughly to remove all
adhesive or particles of the old boot.
7. Apply a thin bead of Loctite® Prism 410 onto the
upper sides of the cap. Apply the bead to the two
long sides only. Do not apply it to the rounded
ends. The rounded ends must not be sealed to
allow the boot to “breathe”.
8. Carefully position the cap into the new boot
groove. Wipe off any excess glue.
9. Position the boot so that it conforms to the
contour of the cap, then set it aside. The
adhesive requires about 30 minutes to cure.
10. Once the adhesive has cured, install actuator
base (6, Figure 50-7) on top of the valve body.
Position the actuator base properly for correct
port direction. Install and tighten two socket head
capscrews (5) to 20 - 21 N·m (180 - 190 in lb).
11. Ensure that jam nut (2, Figure 50-9) and
FIGURE 50-7. ACTUATOR CAP & BOOT
adjustment screw (1) are installed in the brake
1. Actuator Cap 5. Capscrew pedal actuator.
2. Boot 6. Actuator Base
3. Allen Screw 7. Threaded Insert
4. Retainer Plate
6
50 Disassembly and assembly CEN50023-02
12. Install one retainer clip (7, Figure 50-8) to one
end of pivot shaft (4). Ensure that nylon bushings
(5) are installed in both shaft bores of the brake
pedal actuator.
13. Align the shaft bores of the brake pedal actuator
and the brake valve actuator base, then partially
insert pivot shaft (4). Move the brake pedal
actuator to the “B2” side of the brake valve and
insert shims (6) between the mounting ears to fill
the gap. Fully insert the pivot shaft, then install
remaining retainer clip (7).
2 1 2
3 3 3
6
4
5 5 5
6 6 3
1 2
7 7
86390
FIGURE 50-8. BRAKE VALVE/PEDAL
ASSEMBLY PIVOT SHAFTS
1. Pivot Shaft 5. Nylon Bushing 86390
2. Retaining Clip 6. Shims FIGURE 50-9. BRAKE VALVE/PEDAL
3. Nylon Bushing 7. Retainer Clip ASSEMBLY
4. Pivot Shaft
1. Adjustment Screw 4. Spring
2. Jam Nut 5. Jam Nut
3. Spring Pivot 6. Adjustment Screw
7
CEN50023-02 50 Disassembly and assembly
14. Inspect spring pivots (3, Figure 50-9) for wear. If Removal and installation of dual relay
any wear is evident, replace the spring pivots. valve
15. Assemble spring (4) and both spring pivots (3) Removal
onto the brake pedal.
Hydraulic oil escaping under pressure can have
Install the spring assembly so that the larger ball sufficient force to enter a person's body by
socket end is toward the brake pedal and the penetrating the skin and cause serious injury, and
smaller end is toward the brake valve. possibly death, if proper medical treatment is not
received immediately.
NOTE: When the pedal is adjusted properly, the spring
assembly will not interfere with pedal travel. Relieve pressure before disconnecting any
hydraulic lines. Tighten all connections securely
16. Install nylon bearings (3, Figure 50-8) in the shaft
before applying pressure.
bores of the retarder pedal.
17. Align the shaft bores of the brake pedal actuator
and the retarder pedal, then insert pivot shaft (1). Refer to the "Hydraulic system bleeddown procedure"
Install two retainer clips (2). in Testing and adjusting section Steering, hoist,
18. Loosen jam nut (5, Figure 50-9) and turn brake cooling and auxiliary hydraulic system.
adjustment screw (6) until the roller on the
retarder pedal just contacts the brake pedal
actuator. Tighten jam nut (5).
19. Bench test the brake valve. Refer to Testing and
adjusting section Brake system for the test
procedure.
8
50 Disassembly and assembly CEN50023-02
Front brake circuit 1
1. Tag and remove all hydraulic lines from dual relay
valve (1, Figure 50-10) or (Figure 50-11). Plug all
lines and ports to prevent possible contamination.
2. Remove two capscrews and washers that secure
the valve to the rear wall of the hydraulic brake
cabinet. Remove the valve and move it to a clean
work area for disassembly.
1
1
88335
FIGURE 50-11. DUAL RELAY VALVE - FRONT
BRAKE CIRCUIT (LATER MODELS)
1. Dual Relay Valve
87548
FIGURE 50-10. DUAL RELAY VALVE - FRONT
BRAKE CIRCUIT (EARLIER MODELS)
1. Dual Relay Valve
9
CEN50023-02 50 Disassembly and assembly
Rear brake circuit 1 Installation
1. Remove protective cover (1, Figure 50-12) from
Front brake circuit 1
the left side of the rear axle housing.
1. Install dual relay valve (1, Figure 50-10) or
2. Tag and remove all hydraulic lines from dual relay (Figure 50-11) in the hydraulic brake cabinet.
valve (2). Plug all lines and ports to prevent Install the two mounting capscrews and
possible contamination. lockwashers to secure the relay valve. Tighten
3. Remove two capscrews and washers that secure the capscrews to the standard torque.
the relay valve to the mounting bracket. Remove 2. Unplug all hoses and fittings and attach the
the relay valve and move it to a clean work area hoses to the proper valve ports. See Figure 50-
for disassembly. 13.
3. Start the engine and check for leaks and proper
brake operation. Shut off the engine.
Rear brake circuit 1
1. Install dual relay valve (2, Figure 50-12) on the
mounting bracket on the rear axle housing. Install
2 the two mounting capscrews and lockwashers to
secure the relay valve. Tighten the capscrews to
the standard torque.
2. Unplug all hoses and fittings and attach the
hoses to the proper valve ports. See Figure 50-
13.
3. Start the engine and check for leaks and proper
brake operation. Shut off the engine.
4. Install protective cover (1) and the mounting
hardware. Tighten the four capscrews to the
standard torque.
1 86392
FIGURE 50-12. REAR DUAL RELAY VALVE
1. Protective Cover 2. Dual Relay Valve
2
86446
FIGURE 50-13. DUAL RELAY VALVE PORTS
1. Return to Tank 3. B1 Pressure
2. P1 Pressure Inlet 4. B2 Pressure
10
50 Disassembly and assembly CEN50023-02
Removal and installation of brake
manifold
Removal
NOTE: If the brake manifold is leaking oil, an O-ring or
cartridge can be replaced without removing the
manifold from the truck. Refer to "Disassembly and
assembly of brake manifold".
Hydraulic oil escaping under pressure can have
sufficient force to enter a person's body by
penetrating the skin and cause serious injury, and
possibly death, if proper medical treatment is not
1
86393
received immediately.
FIGURE 50-14. BRAKE MANIFOLD REMOVAL
Relieve pressure before disconnecting any & INSTALLATION
hydraulic lines. Tighten all connections securely
before applying pressure. 1. Brake Manifold Mounting Hardware
1. Refer to the "Hydraulic system bleeddown
procedure" in Testing and adjusting section
Steering, hoist, brake cooling and auxiliary Installation
hydraulic system. 1. Place the brake manifold into position in the
2. Close all accumulator bleed valves by rotating hydraulic brake cabinet. Install and tighten
them clockwise. mounting hardware (1, Figure 50-14) to the
3. Disconnect and tag all hydraulic lines from the standard torque.
brake manifold. Plug all hydraulic lines and ports 2. Remove all plugs and connect all lines and
to prevent possible contamination. electrical wiring to the proper locations.
4. Disconnect and tag all electrical wiring from the 3. Start the engine. Check for leaks and for proper
brake manifold components. operation.
5. Remove mounting hardware (1, Figure 50-14) 4. Shut off the engine and ensure that the hydraulic
from the bottom of the hydraulic brake cabinet tank is filled to the proper level.
and move the brake manifold to a clean work
area for disassembly.
11
CEN50023-02 50 Disassembly and assembly
Disassembly and assembly of brake Assembly
manifold 1. Install new O-rings on all components that were
Disassembly removed from the manifold.
2. Coat all bores, cartridges and O-rings with clean
1. Mark all plugs, valves and cartridges before
hydraulic oil.
removal to ensure proper assembly.
2. Remove the plugs, valves and cartridges as NOTE: Do not overtighten any cartridges or solenoids.
needed. Damage to the cartridge may occur.
NOTE: Check valve (4, Figure 50-15) and reducing 3. When installing parking brake solenoid valve (2,
valve (5) both have an orifice disc located below them. Figure 50-15) and brake lock solenoid valve (3)
The two orifices are different sizes. Therefore, it is very into the brake manifold, tighten the cartridges to
important to properly match each orifice with the 34 - 36 N·m (24 - 26 ft lb). Tighten the solenoid
correct installation location. nut to 7 - 9 N·m (5 - 7 ft lb).
3. Clean all parts with an approved cleaning 4. Before installing check valve (4) or reducing
solution. valve (5), refer to Figure 50-16 for proper orifice
disc installation. The orifice discs must be
4. Blow all parts dry with pressure air and protect
installed in the direction shown for proper
them from dust and any foreign matter until
operation.
installation.
5. Replace all O-rings and any other items that are • Check valve orifice - 1.58 mm (0.062 in.)
deemed unsuitable for further usage. • Reducing valve orifice - 2.54 mm (0.100 in.)
5. Install all remaining components in the correct
bores (see Figure 50-15). Tighten each cartridge
7 11 10 9 8 to 34 - 36 N·m (24 - 26 ft lb).
7 6
5
1 2 3 4 86394
FIGURE 50-15. BRAKE MANIFOLD
COMPONENTS
1. Automatic Apply Sequence Valve
2. Parking Brake Solenoid Valve
3. Brake Lock Solenoid Valve
4. Check Valve (with Orifice Disc)
5. Pressure Reducing Valve (with Orifice Disc)
6. Parking Brake Release Pressure Switch
7. Check Valve
8. Parking Brake Apply Pressure Switch FIGURE 50-16. ORIFICE INSTALLATION
9. Low Brake Pressure Switch 1. Cartridge 3. Cavity
10. Hot Oil Cartridge 2. Brake Manifold 4. Orifice Disc
11. Load Shuttle Cartridge
12
50 Disassembly and assembly CEN50023-02
Removal and installation of piston brake
accumulator
1
Removal
2
Hydraulic oil escaping under pressure can have
sufficient force to enter a person's body by
penetrating the skin and cause serious injury, and
possibly death, if proper medical treatment is not 3
received immediately.
Relieve pressure before disconnecting any
hydraulic lines. Tighten all connections securely
before applying pressure.
1. Refer to the "Hydraulic system bleeddown
procedure" in Testing and adjusting section
Steering, hoist, brake cooling and auxiliary
hydraulic system.
2. Remove valve cover (1, Figure 50-17) and
spacer (2). 86395
FIGURE 50-17. TOP OF PISTON
ACCUMULATOR
1. Valve Cover 3. Charging Valve
2. Spacer
Wear a face mask or goggles. Make sure that only
the swivel nut turns. Turning the entire charging
valve assembly may result in the valve assembly
being ejected from the accumulator by the gas 1
pressure inside.
3. Discharge the nitrogen pressure from the piston
accumulator as follows:
a. Remove valve cap (1, Figure 50-18) from the 2
charging valve.
b. Hold valve body (3) with one wrench, then turn
swivel nut (2) counterclockwise three turns
with a second wrench. Do not turn the swivel 3
nut more than three turns. Do not turn the
charging valve body.
84483
c. Connect the nitrogen charging kit to the
charging valve. Refer to Testing and adjusting FIGURE 50-18. PISTON ACCUMULATOR
section Accumulators and suspensions for CHARGING VALVE
the charging kit installation information.
1. Valve Cap 3. Valve Body
2. Swivel Nut (Large Hex Nut)
(Small Hex Nut)
13
CEN50023-02 50 Disassembly and assembly
4. Disconnect hydraulic hose (1, Figure 50-19) from
the flange at the bottom of accumulator (3). Plug
the hose and the accumulator port.
3
Use a lifting device with adequate capacity to
remove and install the components.
5. Attach a lifting device to the top of the
accumulator and take up slack.
6. Remove clamps (2) that secure the accumulator
to the frame mounting bracket. 2
7. Lift accumulator (3) from the lower mounting
bracket. Move the accumulator to a clean work
area.
86396
FIGURE 50-19. PISTON ACCUMULATOR
REMOVAL & INSTALLATION
1. Hydraulic Hose 3. Accumulator
2. Clamp
14
50 Disassembly and assembly CEN50023-02
Installation Disassembly and assembly of piston
1. New or rebuilt piston accumulators should have brake accumulator
1.4 L (48 oz) of oil in the gas end to prevent Disassembly
rusting of the accumulator walls and to provide
for piston seal lubrication.
If the accumulator does not have oil in the gas
end, remove charging valve (3, Figure 50-17)
and add 1.4 L (48 oz) of clean C-4 hydraulic oil to
the gas end of the accumulator. This provides Wear a face mask or goggles. Make sure that only
enough oil above the top of the piston for seal the swivel nut turns. Turning the entire charging
lubrication. valve assembly may result in the valve assembly
being ejected from the accumulator by the gas
pressure inside.
1. Before disassembly, ensure that all pressure has
been discharged from the piston accumulator as
Use a lifting device with adequate capacity to follows:
remove and install the components. a. Remove valve cap (1, Figure 50-20) from the
2. Keep the accumulator upright and attach a lifting charging valve.
device to the top of the accumulator. Ensure that b. Hold valve body (3) with one wrench, then turn
the base ring is installed in the lower mounting swivel nut (2) counterclockwise three turns
bracket, then lift accumulator (3, Figure 50-19) with a second wrench. Do not turn the swivel
into position in the lower mounting bracket. nut more than three turns. Do not turn the
3. Install clamps (2) and the hardware that secure charging valve body.
the accumulator to the frame mounting bracket. c. Connect the nitrogen charging kit to the
Tighten the capscrews to the standard torque. charging valve. Refer to Testing and adjusting
4. Remove the plugs from the hose and accumula- section Accumulators and suspensions for
tor port. Install a new O-ring in the flange, then the charging kit installation information.
connect hydraulic hose (1) at the bottom of the 2. Loosen valve body (3) to remove the charging
accumulator. valve from the top of the accumulator.
5. Precharge the piston accumulator. Refer to
"Piston accumulator charging procedure" in
Testing and adjusting section Accumulators and 1
suspensions.
84483
FIGURE 50-20. PISTON ACCUMULATOR
CHARGING VALVE
1. Valve Cap 3. Valve Body
2. Swivel Nut (Large Hex Nut)
(Small Hex Nut)
15
CEN50023-02 50 Disassembly and assembly
3. Remove the hose fitting, flange (1, Figure 5-21) 4. Secure the accumulator horizontally in a chain
and plugs (2) from the bottom of the piston accu- vise.
mulator. 5. Install two lifting eyes or long capscrews in two of
the three 5/8" - 11UNC lifting holes in the end
cap.
2 6. Use a bar to turn the end cap counterclockwise.
Remove the end cap.
7. Repeat steps 5 and 6 for the other end cap.
1
3
2
2 84480
FIGURE 50-21. BOTTOM OF PISTON
ACCUMULATOR
1. Flange 2. Plug
84479
FIGURE 50-22. REMOVING THE END CAP
1. Capscrew 3. End Cap
2. Bar
16
50 Disassembly and assembly CEN50023-02
8. Use a long dowel (wood, plastic or padded) or Cleaning and inspection
push rod (XA6348) to carefully tap piston (1, Fig-
1. Check the seals on the piston and end caps for
ure 5-23) out of the accumulator housing. Be
cuts, score marks and other damage. If there are
careful not to damage the piston or seals on the
excessive cuts on the seals, perform a thorough
end cap threads.
examination of the metal surfaces for damage.
NOTE: Never use pressurized air to remove the 2. Clean the piston and housing bore. Use a
piston. cleaning solvent and dry them with a soft, clean
towel or rag.
3. Inspect the piston and housing bore for foreign
material, scratches and other damage. Replace
1 the piston if damaged. Scratches on the housing
bore must be removed to ensure optimal service
life of the seals.
Repair of the housing by welding, machining or
plating to salvage a worn area is NOT APPROVED.
These procedures may weaken the housing and
result in serious injury to personnel when
pressurized.
84481
FIGURE 50-23. PISTON REMOVAL (TYPICAL)
1. Piston 2. End Cap
17
CEN50023-02 50 Disassembly and assembly
Piston seal replacement Assembly
NOTE: Replace all seals when the accumulator is NOTE: Assemble the accumulator in a dust and lint
completely disassembled. free area. Maintain complete cleanliness during
1. Apply clean hydraulic oil to the seals, piston assembly to prevent possible contamination.
lands and grooves. 1. Secure the accumulator horizontally in a vise,
2. Assemble the seals into the appropriate piston preferably a chain vise.
grooves. Start with seal (5, Figure 50-24), then 2. Carefully insert piston assembly (2, Figure 50-25)
move outward to seals (2) to reduce the risk of into the accumulator housing bore. Avoid cocking
seal damage. Ensure that seals (2) and (5) are to prevent damaging the piston and/or seals on
not folded or twisted. the end cap threads. If necessary, tap the piston
3. Insert backup rings (3) and (4) carefully so as not lightly with a soft hammer. Be careful not to pinch
to stretch any more than necessary. Ensure that the backup rings.
the backup ring gaps are offset from one another NOTE: Assembly sleeve (1) may be used to help
as they are installed and not aligned on one side install and prevent damage to the piston assembly.
of the piston.
1 2
1
4
84482
5 FIGURE 50-25. PISTON ASSEMBLY
1. Assembly Sleeve 2. Piston Assembly
4 (XA6349)
1
85209
FIGURE 50-24. PISTON REPLACEMENT SEALS
1. Piston Bearing 4. Backup Ring (thin)
2. Piston Seal - “U” 5. Piston Seal - “T”
3. Backup Ring (thick)
18
50 Disassembly and assembly CEN50023-02
3. Assemble the backup ring and O-ring into the Disassembly and assembly of front wheel
end cap groove. The backup ring must be toward brake
the threaded side or outside of the end cap.
Apply a light coat of grease to the threads and O- Disassembly
ring of the end cap.
NOTE: Check the face of piston and tube for any
contamination before installing the end caps.
4. Secure the accumulator horizontally in a chain Disassemble and reassemble the brake assembly
vise. on a clean, dry work surface. The work surface
should be wooden. If the work surface is metal or
5. Install two lifting eyes or long capscrews in two of
concrete, use padding to prevent damage to
the three 5/8" - 11UNC lifting holes in the end
machined surfaces. Handle all parts carefully to
cap.
avoid damage to polished sealing surfaces.
6. Use a bar to tighten the end cap clockwise to a
torque of 300 N·m (221 ft lb).
After the end cap is tightened, the end cap
should be flush ± 1.5 mm (± 0.06 in) with the end
of the accumulator housing.
Use a lifting device with adequate capacity to
7. Repeat steps 5 and 6 for the other end cap. remove and install the components.
8. Remove the screws from both end caps. Clean
1. Remove the brake assembly from the truck.
the excess lubricant from the end cap areas at
Refer to the Disassembly and assembly section
both ends of the accumulator.
Wheels, spindles and rear axle.
9. Install plugs (2, Figure 5-21) in the oil end cap.
2. Ring gear retainer bars (1, Figure 50-26) must be
Also install a plug in place of flange (1) and the
installed to retain the inner gear inside the brake
hose fitting.
assembly.
10. Before closing up the ports, add 1.4 L (48 oz) of 3. Position the brake assembly on a work surface
oil to the gas end. so that the ring gear retainer bars are on the
11. Install the charging valve with a new O-ring. bottom as shown in Figure 50-27.
Tighten valve body (3, Figure 5-20) to 22 N·m (16
ft lb).
12. Test the accumulator for leaks. Refer to "Piston 1
accumulator leak testing" in Testing and adjusting
section Accumulators and suspensions.
1
86415
FIGURE 50-26. RING GEAR RETAINER BARS
ON BRAKE ASSEMBLY
1. Ring Gear Retainer Bars
19
CEN50023-02 50 Disassembly and assembly
4. Match mark the brake assembly across the back 6. Remove capscrews (2, Figure 50-28) and
plate, outer ring gear and piston housing to hardened flat washers (3) from back plate (1).
ensure proper orientation during assembly. 7. Insert 3/4” - 10UNC x 2” pusher bolts (4) in each
5. Remove four capscrews (1, Figure 50-27) and of the three tapped holes in the back plate.
flat washers (2). Lift catchment tank (3) from the Tighten the bolts evenly to lift the back plate from
brake assembly and remove adapter (4). outer ring gear (6).
8. Remove and discard O-ring (5).
2 1 3
4 2 3 1 4
86416
FIGURE 50-27. CATCHMENT TANK REMOVAL &
INSTALLATION 5
1. Capscrew 3. Catchment Tank
2. Flat Washer 4. Adapter
6 86404
FIGURE 50-28. BACK PLATE REMOVAL &
INSTALLATION
1. Back Plate 4. Pusher Bolt
2. Capscrew (12 Pt.) 5. O-ring
3. Hardened Flat Washer 6. Outer Ring Gear
20
50 Disassembly and assembly CEN50023-02
NOTE: Note the order of the discs, plates and 10. Turn over the brake assembly to position ring
dampers as they are removed from the brake pack. gear retainer bars (1, Figure 50-30) on top as
9. Remove damper (2, Figure 50-29) from the top of shown.
brake pack (1). Remove friction discs (3), 11. Remove capscrews and flat washers (2) that
separator plates (4), and the remaining damper attach the retainer bars to the piston housing.
at the bottom of brake pack (1).
12. Attach a lifting strap through ring gear retainer
bars (1), then lift inner gear (5) out of outer ring
gear (6).
2 13. Remove capscrews and lockwashers (3) that
attach the retainer bars to inner gear (5). Remove
retainer bars (1) and spacers (4).
3
1 3 4 2
4
1
86405
FIGURE 50-29. BRAKE PACK REMOVAL &
INSTALLATION 6 86417
1. Brake Pack 3. Friction Disc FIGURE 50-30. INNER GEAR REMOVAL &
2. Damper 4. Separator Plate INSTALLATION
1. Ring Gear Retainer Bars 4. Spacer
2. Capscrew & Flat Washer 5. Inner Gear
3. Capscrew & Lockwasher 6. Outer Ring Gear
21
CEN50023-02 50 Disassembly and assembly
14. Remove capscrews (1, Figure 50-31) and 16. Turn over the piston assembly so that the piston
hardened flat washers (2) from piston assembly retract springs are on top as shown.
(4).
17. Apply a small amount of heat to the piston
15. Insert 7/8” - 9NC x 2” pusher bolts (3) in each of housing. Remove capscrews (1, Figure 50-32),
the three tapped holes in the piston housing. spring guides (2), and piston retract springs (3).
Tighten the bolts evenly to lift the piston
NOTE: The capscrew threads are coated with Loctite®
assembly from outer ring gear (6). Remove and
during assembly. A small amount of heat is required
discard O-ring (5).
for removal.
18. Carefully lift piston (4) out of piston housing (7).
Remove seal assemblies (5) and (6) from the
1 2 3 3 3 piston.
4 3
5 5
6
7
6 86418
FIGURE 50-31. PISTON ASSEMBLY
REMOVAL & INSTALLATION
1. Capscrew (12 Pt.) 4. Piston Assembly 86419
2. Hardened Flat Washer 5. O-ring
FIGURE 50-32. PISTON REMOVAL &
3. Pusher Bolt 6. Outer Ring Gear
INSTALLATION
1. Capscrew 5. Seal Assembly
2. Spring Guide 6. Seal Assembly
3. Piston Retract Spring 7. Piston Housing
4. Piston
22
50 Disassembly and assembly CEN50023-02
Cleaning and inspection 6. Inspect separator plates (4, Figure 50-29) for
warping and tooth wear.
Disc thickness (new):
. . . . . . . . . . . . 3.7 ± 0.1 mm (0.146 ± 0.004 in.)
Flatness (new): . . . . . . .0.5 mm (0.020 in.)
If the brake wear indicator test indicates that
internal brake components are worn to the 7. Inspect dampers (2, Figure 50-29) for warping,
maximum allowable limit, all friction discs, tooth wear and excessive facing material wear.
separator plates and dampers must be replaced
with new parts. Always replace seal assemblies Disc thickness including facing material:
and O-rings with new parts. . . . . . . . . . . . . 6.9 ± 0.5 mm (0.272 ± 0.020 in.)
Disc thickness, steel plate only (new):
1. Clean all parts thoroughly before inspection.
. . . . . . . . . . . . 3.7 ± 0.1 mm (0.146 ± 0.004 in.)
2. Inspect piston housing (7, Figure 50-32) for nicks
Flatness, steel plate (new):
and scratches in the piston seal area. If any nicks
. . . . . . . . . . . . . . . . . . . . . . .0.5 mm (0.020 in.)
or scratches cannot be removed by polishing,
replace the piston housing. 8. Inspect outer ring gear (6, Figure 50-31) for
3. Inspect the piston seal assembly grooves for excessive tooth wear and for nicks and scratches
damage. in the O-ring seal grooves.
4. Inspect piston retract springs (3, Figure 50-32). 9. Inspect inner gear (5, Figure 50-30) for excessive
Check the free height and test for height under tooth wear and damage at the capscrew holes.
load. Replace the springs if they are not within
approximately 10% of specification.
Free Height:. . . . . . . . . 88.9 mm (3.50 in.)
Height at 1 290 N (290 lb) working load:
. . . . . . . . . . . . . . . . . . . . 74.60 mm (2.937 in.)
Height at 2 936 N (660 lb) working load:
. . . . . . . . . . . . . . . . . . . . 56.46 mm (2.223 in.)
5. Inspect friction discs (3, Figure 50-29) for
warping, tooth wear, and excessive friction
material wear. Replace the friction discs if wear
exceeds the minimum allowable groove depth.
Disc thickness including friction material:
. . . . . . . . . . . . . 7.7 ± 0.3 mm (0.30 ± 0.01 in.)
Friction material thickness (new):
. . . . . . . . . . . . . . . . . . . . . . . 1.1 mm (0.04 in.)
Nominal friction material groove depth:
. . . . . . . . . . . . . . . . . . . . 0.63 mm (0.025 in.)
Minimum allowable friction material groove
depth: . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Flatness over friction material (new):
. . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.018 in.)
23
CEN50023-02 50 Disassembly and assembly
Assembly 7. Assemble twelve capscrews (1), spring guides
(2) and retract springs (3). Apply Loctite® 271 to
the capscrew threads and install the assembled
parts through the piston and into the tapped holes
in the piston housing. Tighten the capscrews to
Disassemble and reassemble the brake assembly 122 N·m (90 ft lb).
on a clean, dry work surface. The work surface 8. Install any missing plugs in the piston housing,
should be wooden. If the work surface is metal or then test the piston for leakage. For instructions,
concrete, use padding to prevent damage to refer to "Brake piston leakage test" in Testing and
machined surfaces. Handle all parts carefully to adjusting section Brake system.
avoid damage to polished sealing surfaces.
9. After completing the piston leakage test, release
the pressure, remove the hydraulic pressure test
device, and drain the oil from the piston apply
cavity. Plug the ports to prevent contamination.
10. Install O-ring (5, Figure 50-31) in the groove of
Use a lifting device with adequate capacity to outer ring gear (6).
remove and install the components.
11. Attach lifting eyes to the piston assembly and
1. Position piston housing (7, Figure 50-32) on a lower it into position over outer ring gear (6).
clean work surface with the bore facing upward. Ensure that the piston assembly is oriented
2. Lubricate the square O-ring portion of piston seal properly according to the match marks that were
assemblies (5) and (6) with clean hydraulic oil made during disassembly. Install capscrews (1)
and install the seals in the grooves in piston (4). and hardened flat washers (2). Alternately tighten
Ensure that the seal assemblies are not twisted. the capscrews to 1 166 N·m (860 ft lb).
NOTE: It is recommended that the seals be heated to 12. Install retainer bars (1, Figure 50-30), spacers (4),
80-100°C (176-212°F) before installation by using hot capscrews and lockwashers (3) to inner gear (5).
oil, hot air or hot water. This allows for easier seal Attach a lifting strap through the retainer bars,
installation without stretching the seals. then lift the inner gear into the piston assembly.
3. Lubricate the piston groove and outer piston seal 13. Attach the retainer bars to the piston housing by
rings. Install the seal ring portion of piston seal installing capscrews and flat washers (2) at the
assemblies (5) and (6) in the grooves over the O- ends of the retainer bars.
ring portions. Use your fingers or a smooth 14. Attach lifting eyes to the brake assembly. Turn
rounded object to push the seal ring into the over the assembly so that the piston housing is
groove. on the bottom.
4. Install two equally spaced 1/2” - 13NC x 5” guide
studs in piston housing (7) in the tapped
mounting holes for piston retract springs (3).
5. Lubricate the piston housing bore. Install lifting
eyes and attach an overhead hoist to piston (4).
Position the piston over the piston housing with
the piston retract spring mounting holes aligned
with the guide studs. Place spring guide (2) over
each stud to aid in alignment.
6. Carefully lower the piston straight into the piston
housing bore until it is seated against the
housing. If necessary, seat the piston by tapping
it with a soft mallet. Remove the guide studs.
24
50 Disassembly and assembly CEN50023-02
15. Install brake pack (1, Figure 50-29) as follows: Disassembly and assembly of rear wheel
a. Insert one damper into the outer ring gear. The brake
friction material must be facing the piston. Disassembly
b. Insert one friction disc (3).
c. Install one separator plate (4).
d. Continue installing the remaining friction discs
and separator plates, alternating each type as Disassemble and reassemble the brake assembly
installed. on a clean, dry work surface. The work surface
should be wooden. If the work surface is metal or
e. Install remaining damper (2) on top of the last concrete, use padding to prevent damage to
friction disc. The friction material must be machined surfaces. Handle all parts carefully to
facing away from the top friction disc. avoid damage to polished sealing surfaces.
NOTE: The brake pack contains eleven friction discs,
ten separator plates and two dampers.
16. Install a new O-ring (5, Figure 50-28) on back
plate (1). Install back plate (1) over outer ring
gear (6). Ensure that the back plate is oriented Use a lifting device with adequate capacity to
properly according to the match marks that were remove and install the components.
made during disassembly.
1. Remove the brake assembly from the truck.
17. Install 12 pt. capscrews (2) and hardened flat Refer to the Disassembly and assembly section
washers (3). Alternately tighten capscrews (2) to Wheels, spindles and rear axle.
a final torque of 1 166 N·m (860 ft lb).
2. Ring gear retainer bars (1, Figure 50-33) must be
18. Install adapter (4, Figure 50-27) with new O-rings installed to retain the inner gear inside the brake
in the back plate. Install catchment tank (3) with assembly.
four capscrews (1) and flat washers (2).
3. Position the brake assembly on a work surface
NOTE: For installation of the brake assembly, refer to so that the ring gear retainer bars are on the
the Disassembly and assembly section Wheels, bottom as shown in Figure 50-34.
spindles and rear axle.
1
86402
FIGURE 50-33. RING GEAR RETAINER BARS
ON BRAKE ASSEMBLY
1. Ring Gear Retainer Bars
25
CEN50023-02 50 Disassembly and assembly
4. Match mark hub adapter (4, Figure 50-34) and 7. Remove capscrews (2, Figure 50-35) and
the back plate of brake assembly (1) to ensure hardened flat washers (3) from back plate (1).
proper orientation during assembly. 8. Insert 3/4” - 10UNC x 2” pusher bolts (4) in each
5. Remove capscrews (2) and hardened flat of the three tapped holes in the back plate.
washers (3). Lift hub adapter (4) from the brake Tighten the bolts evenly to lift the back plate from
assembly. Note the number of shims that are outer ring gear (6).
used at six locations around the hub adapter. 9. Remove and discard O-ring (5).
6. Remove seal carrier (6) and the seals. Remove
two dowel pins (5) that hold the seal carrier to the
hub adapter.
4 2 3 1 4
3 2
4
4
5
5
6 5
1 6 86404
86403
FIGURE 50-34. HUB ADAPTER/SEAL CARRIER FIGURE 50-35. BACK PLATE REMOVAL &
REMOVAL & INSTALLATION INSTALLATION
1. Brake Assembly 4. Hub Adapter 1. Back Plate 4. Pusher Bolt
2. Capscrew (12 Pt.) 5. Dowel Pin 2. Capscrew (12 Pt.) 5. O-ring
3. Hardened Flat Washer 6. Seal Carrier 3. Hardened Flat Washer 6. Outer Ring Gear
26
50 Disassembly and assembly CEN50023-02
NOTE: Note the order of the discs, plates and 11. Turn over the brake assembly to position ring
dampers as they are removed from the brake pack. gear retainer bars (1, Figure 50-37) on top as
10. Remove damper (2, Figure 50-36) from the top of shown.
brake pack (1). Remove friction discs (3), 12. Remove capscrews and flat washers (2) that
separator plates (4), and the remaining damper attach the retainer bars to the piston housing.
at the bottom of brake pack (1).
13. Attach a lifting strap through ring gear retainer
bars (1), then lift inner gear (5) out of outer ring
gear (6).
2 14. Remove capscrews and lockwashers (3) that
attach the retainer bars to inner gear (5). Remove
retainer bars (1) and spacers (4).
1 3 4 2
4
1
86405
FIGURE 50-36. BRAKE PACK REMOVAL & 6 86406
INSTALLATION
FIGURE 50-37. INNER GEAR REMOVAL &
1. Brake Pack 3. Friction Disc INSTALLATION
2. Damper 4. Separator Plate
1. Ring Gear Retainer Bars 4. Spacer
2. Capscrew & Flat Washer 5. Inner Gear
3. Capscrew & Lockwasher 6. Outer Ring Gear
27
CEN50023-02 50 Disassembly and assembly
15. Remove six remaining capscrews (1, Figure 50- 17. Turn over the piston assembly so that the piston
38) and hardened flat washers (2) from piston retract springs are on top as shown.
assembly (4).
18. Apply a small amount of heat to the piston
16. Insert 7/8” - 9UNC x 2” pusher bolts (3) in each of housing. Remove capscrews (1, Figure 50-39),
the three tapped holes in the piston housing. spring guides (2), and piston retract springs (3).
Tighten the bolts evenly to lift the piston
NOTE: The capscrew threads are coated with Loctite®
assembly from outer ring gear (6). Remove and
during assembly. A small amount of heat is required
discard O-ring (5).
for removal.
19. Carefully lift piston (4) out of piston housing (7).
Remove seal assemblies (5) and (6) from the
3 3 2 1 3 piston.
4 3
5 5
6
7
6 86407
FIGURE 50-38. PISTON ASSEMBLY
REMOVAL & INSTALLATION
1. Capscrew (12 Pt.) 4. Piston Assembly 86408
2. Hardened Flat Washer 5. O-ring
FIGURE 50-39. PISTON REMOVAL &
3. Pusher Bolt 6. Outer Ring Gear
INSTALLATION
1. Capscrew 5. Seal Assembly
2. Spring Guide 6. Seal Assembly
3. Piston Retract Spring 7. Piston Housing
4. Piston
28
50 Disassembly and assembly CEN50023-02
Cleaning and inspection 6. Inspect friction discs (3, Figure 50-36) for
warping, tooth wear, and excessive friction
material wear. Replace the friction discs if wear
exceeds the minimum allowable groove depth.
Disc thickness including friction material:
If the brake wear indicator test indicates that . . . . . . . . . . . . . . 7.7 ± 0.3 mm (0.30 ± 0.01 in.)
internal brake components are worn to the Friction material thickness (new):
maximum allowable limit, all friction discs, . . . . . . . . . . . . . . . . . . . . . . . .1.1 mm (0.04 in.)
separator plates and dampers must be replaced
Nominal friction material groove depth:
with new parts. Always replace seal assemblies
. . . . . . . . . . . . . . . . . . . . .0.63 mm (0.025 in.)
and O-rings with new parts.
Minimum allowable friction material groove
1. Clean all parts thoroughly before inspection. depth:. . . . . . . . . . . . . . . . .0.25 mm (0.010 in.)
2. For the rear brake assembly, remove and discard Flatness over friction material (new):
the seal assemblies in seal carrier (6, Figure 50- . . . . . . . . . . . . . . . . . . . . . .0.45 mm (0.018 in.)
34) and back plate (1, Figure 50-35).
3. Inspect piston housing (7, Figure 50-39) for nicks 7. Inspect separator plates (4, Figure 50-36) for
and scratches in the piston seal area. If any nicks warping and tooth wear.
or scratches cannot be removed by polishing,
Disc thickness (new):
replace the piston housing.
. . . . . . . . . . . . 3.7 ± 0.1 mm (0.146 ± 0.004 in.)
4. Inspect the piston seal assembly grooves for
Flatness (new): . . . . . . .0.5 mm (0.020 in.)
damage.
5. Inspect piston retract springs (3, Figure 50-39). 8. Inspect dampers (2, Figure 50-36) for warping,
Check the free height and test for height under tooth wear and excessive facing material wear.
load. Replace the springs if they are not within
approximately 10% of specification. Disc thickness including facing material:
. . . . . . . . . . . . 6.9 ± 0.5 mm (0.272 ± 0.020 in.)
Free Height:. . . . . . . . . 88.9 mm (3.50 in.)
Disc thickness, steel plate only (new):
Height at 1 290 N (290 lb) working load: . . . . . . . . . . . . 3.7 ± 0.1 mm (0.146 ± 0.004 in.)
. . . . . . . . . . . . . . . . . . . . 74.60 mm (2.937 in.) Flatness, steel plate (new):
Height at 2 669 N (600 lb) working load: . . . . . . . . . . . . . . . . . . . . . . .0.5 mm (0.020 in.)
. . . . . . . . . . . . . . . . . . . . 56.46 mm (2.223 in.)
9. Inspect outer ring gear (6, Figure 50-38) for
excessive tooth wear and for nicks and scratches
in the O-ring seal grooves.
10. Inspect inner gear (5, Figure 50-37) for excessive
tooth wear and damage at the capscrew holes.
29
CEN50023-02 50 Disassembly and assembly
Assembly 7. Assemble twelve capscrews (1), spring guides
(2) and retract springs (3). Apply Loctite® 271 to
the capscrew threads and install the assembled
parts through the piston and into the tapped holes
in the piston housing. Tighten the capscrews to
Disassemble and reassemble the brake assembly 122 N·m (90 ft lb).
on a clean, dry work surface. The work surface 8. Install any missing plugs in the piston housing,
should be wooden. If the work surface is metal or then test the piston for leakage. For instructions,
concrete, use padding to prevent damage to refer to "Brake piston leakage test" in Testing and
machined surfaces. Handle all parts carefully to adjusting section Brake system.
avoid damage to polished sealing surfaces.
9. After completing the piston leakage test, release
the pressure, remove the hydraulic pressure test
device, and drain the oil from the piston apply
cavity. Plug the ports to prevent contamination.
10. Install O-ring (5, Figure 50-38) in the groove of
Use a lifting device with adequate capacity to outer ring gear (6).
remove and install the components.
11. Attach lifting eyes to the piston assembly and
1. Position piston housing (7, Figure 50-39) on a lower it into position over outer ring gear (6).
clean work surface with the bore facing upward. Ensure that the piston assembly is oriented
2. Lubricate the square O-ring portion of piston seal properly according to the match marks that were
assemblies (5) and (6) with clean hydraulic oil made during disassembly. Install capscrews (1)
and install the seals in the grooves in piston (4). and hardened flat washers (2). Alternately tighten
Ensure that the seal assemblies are not twisted. the capscrews to 1 166 N·m (860 ft lb).
NOTE: It is recommended that the seals be heated to 12. Install retainer bars (1, Figure 50-37), spacers (4),
80-100°C (176-212°F) before installation by using hot capscrews and lockwashers (3) to inner gear (5).
oil, hot air or hot water. This allows for easier seal Attach a lifting strap through the retainer bars,
installation without stretching the seals. then lift the inner gear into the piston assembly.
3. Lubricate the piston groove and outer piston seal 13. Attach the retainer bars to the piston housing by
rings. Install the seal ring portion of piston seal installing capscrews and flat washers (2) at the
assemblies (5) and (6) in the grooves over the O- ends of the retainer bars.
ring portions. Use your fingers or a smooth 14. Attach lifting eyes to the brake assembly. Turn
rounded object to push the seal ring into the over the assembly so that the piston housing is
groove. on the bottom.
4. Install two equally spaced 1/2” - 13NC x 5” guide
15. Install brake pack (1, Figure 50-36) as follows:
studs in piston housing (7) in the tapped
mounting holes for piston retract springs (3). a. Insert one damper into the outer ring gear. The
5. Lubricate the piston housing bore. Install lifting friction material must be facing the piston.
eyes and attach an overhead hoist to piston (4). b. Insert one friction disc (3).
Position the piston over the piston housing with
c. Install one separator plate (4).
the piston retract spring mounting holes aligned
with the guide studs. Place spring guide (2) over d. Continue installing the remaining friction discs
each stud to aid in alignment. and separator plates, alternating each type as
6. Carefully lower the piston straight into the piston installed.
housing bore until it is seated against the e. Install remaining damper (2) on top of the last
housing. If necessary, seat the piston by tapping friction disc. The friction material must be
it with a soft mallet. Remove the guide studs. facing away from the top friction disc.
NOTE: The brake pack contains eleven friction discs,
ten separator plates and two dampers.
30
50 Disassembly and assembly CEN50023-02
NOTE: Before installing the hub adapter on the rear
brake, check the integrity of the brake seals. Refer to
the instructions in Testing and adjusting section Brake
system.
16. Insert three shims (1, Figure 50-40) with
capscrews and flat washers (2) at six locations Cleanliness and proper installation are critical
around the flange of hub adapter (3). factors for proper brake seal function. Refer to the
topic "Brake floating ring seal assembly and
installation" for detailed instructions.
18. Install each half of seal assembly (2, Figure 50-
3
41) in brake assembly (4) and hub adapter (1).
2 19. Install oil seal (3) in the back plate of brake
assembly (4) with Loctite® 648. Pack the area
between the seal lips with grease.
NOTE: Apply grease to the oil seal only. Do not apply
grease to any part of seal assembly (2).
86410
FIGURE 50-40. HUB ADAPTER SHIM 2
INSTALLATION
1. Shims 3. Hub Adapter
2. Capscrew & Flat Washer
3
4
17. Ensure that dowel pins (5, Figure 50-34) are
installed in seal carrier (6). Install seal carrier (6)
with new O-rings into hub adapter (4). 86411
FIGURE 50-41. SEAL INSTALLATION
1. Hub Adapter 3. Oil Seal
2. Seal Assembly 4. Back Plate
31
CEN50023-02 50 Disassembly and assembly
20. Install a new O-ring (5, Figure 50-35) on back 23. Gently lower hub adapter (4, Figure 50-43) onto
plate (1). Install back plate (1) over outer ring the inner gear in the brake assembly. Orient the
gear (6). Ensure that the back plate is oriented hub adapter according to the match marks that
properly according to the match marks that were were made during disassembly.
made during disassembly.
NOTE: Be careful not to have any sudden movements
21. Install three support plates (4, Figure 50-42) and or impacts. The seal halves should come together very
1" - 8NC X 4" capscrews (3) at three equally gently so as not to damage either sealing face.
spaced positions around the back plate. Install
24. Install capscrews (3) and hardened flat washers
remaining 12 pt. capscrews (1) and hardened flat
to secure hub adapter (4) to the inner gear.
washers (2). Alternately tighten capscrews (1) to
Alternately tighten the capscrews to a final torque
a final torque of 1 166 N·m (860 ft lb).
of 2 705 N·m (1,995 ft lb).
25. Install new O-ring (5) on hub adapter (4).
26. Install spacers (1) at each support plate using
3
2 1 three socket head capscrews (2) and two flat
washers at each capscrew.
4
4
2 3 4
5
4
86409
86412
FIGURE 50-42. SUPPORT PLATE INSTALLATION
1. Capscrew (12 Pt.) 3. Capscrew FIGURE 50-43. HUB ADAPTER INSTALLATION
2. Hardened Flat Washer 4. Support Plate 1. Socket Head Capscrew 3. Capscrew (12 Pt.)
2. Spacer 4. Hub Adapter
22. Use a lint free cloth and isopropyl alcohol to clean
the face of each metal sealing face of seal NOTE: For installation of the brake assembly, the rear
assembly (2, Figure 50-41). Allow the sealing seal carrier and its seals, refer to the appropriate GE
faces to dry completely, then apply a light coat of service manual.
oil.
32
50 Disassembly and assembly CEN50023-02
Brake floating ring seal assembly and 1. Prepare a completely clean work area to handle
installation the large seal rings, O-rings and seal carriers.
Failures of floating seals are usually caused by a Absolute cleanliness is essential during the
combination of factors rather than one single cause, assembly process to prevent premature seal
but many failures have one common denominator - failure and possible oil leaks.
assembly and installation issues. NOTE: Use isopropyl alcohol in a spray bottle to clean
the parts prior to assembly. Use clean, lint-free
There are five common failure modes: material such as Micro-Wipes # 05310 for cleaning
and wiping. Do not use Stanosol or any other liquid
• Oil leakage
that leaves an oily film or does not evaporate quickly.
• Galling
2. Thoroughly clean the rubber O-rings with
• Pumping mud past the toric isopropyl alcohol to remove the white powder like
• Toric failure coating and any other contaminants. Use
• Seal ring breakage isopropyl alcohol to clean seal contact surfaces
(2, Figure 50-44) where the O-rings will be
seated on the brake housings and on the seal
The following procedure using necessary installation carriers. Also clean the polished sealing surface
tools must be accomplished to be assured of on the seal rings.
satisfactory floating seal performance.
3. Carefully inspect the polished sealing surfaces
on the seal rings for scratches or any other
damage. Inspect the entire seal contact area on
all the parts for scratches or nicks that may
damage the O-rings during installation or cause a
Floating ring seals must always be installed in path of leakage after installation. If scratches are
matched pairs. The seal rings must be new. DO present, hone and then clean the damaged area.
NOT mate a new ring with a used ring. DO NOT
install two used rings. Always install new O-rings
(toric rings).
1 2
A
VIEW A
72607
FIGURE 50-44. O-RING CONTACT AREA
1. Back Plate 2. Seal Contact Surface
33
CEN50023-02 50 Disassembly and assembly
4. Use clean, lint-free cloths and isopropyl alcohol 6. Place the O-rings on a clean flat surface. Visually
to remove all traces of oil, dust, protective coating inspect the toric seal in a free state on the table
or other foreign matter from the metal seal rings, and verify the flash line is parallel to the table. A
the O-rings, the back plate and the seal contact flash line is a tooling line that separates top half
areas on all of the parts. Allow the surfaces to dry and bottom half of the O-ring. Ensure the O-rings
completely. are not twisted. Mark white points on the O-rings
5. Apply clean hydraulic oil (C-4 type SAE 10W) to as shown in (Figure 50-46) at regular intervals
the O-ring ramp surface (2, Figure 50-45) on the every 15° or 102 mm (4.2 in.) all the way around
back plate and the O-ring ramp area on the seal the circumference of the O-ring while it is in a free
carrier. state on the table.
1 2
A
VIEW A
72608
FIGURE 50-45. BACK PLATE
1. Back Plate Housing 2. Lubricant Area On Seal Ramp
72609
FIGURE 50-46. LOCATION OF WHITE LINE
1. White Marker 2. 45° Angle 3. O-Ring
34
50 Disassembly and assembly CEN50023-02
7. Install O-rings (2, Figure 50-47) to seal rings (1). 8. Position the floating seal assembly on the back
Visually inspect the toric seal in a free state on plate and apply clean hydraulic oil (C-4 type SAE
the table and verify the flash line is parallel to the 10W) to the O-ring all the way around as shown
table. After installation, check the O-rings for any in Figure 50-48.
twisting with reference to the white points (Figure
50-46) or the flash line in the middle of the ring.
Ensure that the O-ring is straight and uniform all
the way around the seal ring, and that it is seated
against the retaining lip. The white points should
be in a plane parallel to the seal ring. Adjust the
O-ring as necessary.
1 2
72610
FIGURE 50-47. O-RING INSTALLATION
1. Seal Ring 2. O-Ring
72611
FIGURE 50-48. ADDING LUBRICANT
35
CEN50023-02 50 Disassembly and assembly
9. Set seal installation tool (1, Figure 50-49) in place 11. Repeat Steps 5-10 to install the floating seal
on top of the seal assembly. Push on the tool assembly into the seal carrier.
(NOT the seal ring) evenly during installation until 12. After installing the floating seal assemblies, check
the O-ring is installed. The O-ring should the O-ring for twisting with reference to white dots
squeeze or pop into place below the retaining lip (Figure 50-49). Visually inspect the toric seal in a
before the installation tool touches the housing. free state on the table and verify the flash line is
NOTE: Each floating seal comes with its own unique parallel to the table. Adjust the O-ring if
installation tool designed for leakage and damage free necessary, but DO NOT push directly on the seal
installation of the seal. Use appropriate installation ring.
tool. NOTE: Handle the seal ring carefully. Nicks and
10. Push on the tool (NOT the seal ring) evenly scratches on the seal ring face can cause leaks.
during installation until the O-ring is installed. The
O-ring should squeeze (or pop) into place below
the retaining lip before the installation tool
touches the housing.
72612
FIGURE 50-49. SEAL INSTALLATION
1. Seal Installation Tool 3. Housing
2. O-Ring 4. Seal Ring
36
50 Disassembly and assembly CEN50023-02
13. Use a gauge (Figure 50-50) to check the seal
height variation (marked by arrows, Figure 50-52)
between seal ring (2) and back plate (1). Check
the assembled height in four places that are 90°
apart. The height variation around the assembled
ring must be less than 1.0 mm (0.04 in).
If small adjustments are necessary, do not push
directly on the seal ring. Use the installation
tool to make any required adjustments. The seal
rings must be level as shown in Figure 50-54.
NOTE: A certified depth gage in the form of a depth
micrometer, dial caliper or dial indicator with the
magnetic base would be acceptable. This step is
necessary to ensure that the seal is located parallel to
the mating part, and that it will move down the seal
ramp uniformly.
FIGURE 50-50. CHECKING SEAL RING
FIGURE 50-52. CHECKING SEAL HEIGHT
1. Back Plate 2. Seal Ring
The O-rings can twist during adjustments,
especially if there is a dry spot on the O-ring or if
there are burrs or fins on the housing retaining lip.
Verify that the O-rings are not twisted as shown in
Figure 50-51. A bulging O-ring or crooked seal ring
will lead to eventual failure.
FIGURE 50-51. TWISTED O-RING
37
CEN50023-02 50 Disassembly and assembly
14. Use a gauge to check the seal height variation 15. After both seal ring heights have been checked
(marked by arrows, Figure 50-53) between seal and adjusted, wipe the polished seal ring
ring (3) and seal carrier (2). Check the surfaces with a lint-free material and isopropyl
assembled height in four places that are 90° alcohol to remove all foreign material and
apart. The height variation around the assembled fingerprints.
seal ring must be less than 1.0 mm (0.04 in).
If small adjustments are necessary, do not push
directly on the seal ring. Make any required
adjustments using the installation tool. The seal
rings must be level as shown in Figure 50-54. No foreign particles of any kind are allowed on the
NOTE: A certified depth gage in the form of a depth polished seal ring faces. Something as small as a
micrometer, dial caliper or dial indicator with the paper towel fiber will hold the seal faces apart and
magnetic base would be acceptable. This step is could cause damage or leakage.
necessary to ensure that the seal is located parallel to 16. Apply a thin film of clean hydraulic oil (C-4 type
the mating part, and that it will move down the seal SAE 10W) on the polished seal faces on both
ramp uniformly. seal rings. Use a lint-free applicator or a clean
finger to distribute the oil evenly.
17. During assembly, ensure that both housings are
square, concentric and in correct alignment as
shown in Figure 50-55. Move the parts slowly and
carefully toward each other. Do not slam, bump
or drop the seal rings together. High impact can
damage the seal ring face and cause leakage.
FIGURE 50-54. CORRECT ASSEMBLY
FIGURE 50-53. CHECKING SEAL HEIGHT
1. Housing 3. Seal Ring
2. Seal Carrier
FIGURE 50-55. CORRECT ALIGNMENT
38
50 Disassembly and assembly CEN50023-02
18. To test the floating seal assembly installation,
place the spindle, hub and brake assembly on a
test stand as shown in Figure 13. Pump oil
through the brake cooling chamber at an inlet
pressure of 83 - 103 kPa (12 - 15 psi). Rotate the
hub as follows:
a. Run right at 12 rpm for 10 minutes.
b. Run left at 12 rpm for 10 minutes.
c. Run right at 24 rpm for 10 minutes.
d. Run left at 24 rpm for 10 minutes.
e. Run right at 36 rpm for 10 minutes
f. Run left at 36 rpm for 10 minutes
85363
FIGURE 50-56. SPINDLE, HUB AND BRAKE
No visible leakage should be detected during this ASSEMBLY TEST STAND
test.
39
CEN50023-02 50 Disassembly and assembly
Removal and installation of parking brake
Removal
NOTE: Whenever possible, parking brake repairs
should be performed when the wheel motor is Use a lifting device with adequate capacity to
removed from the truck. If repairs are necessary when remove and install the components.
the wheel motor is installed, a lifting device must be 3. If the wheel motor is installed in the rear axle
set up inside the rear axle housing to support the housing, open the rear axle housing hatch. Set
weight of the parking brake assembly when it is up a lifting device inside the rear axle housing to
removed from the wheel motor. support the weight of the parking brake
assembly.
If the wheel motor is removed from the truck,
attach a suitable lifting device to the parking
brake.
Hydraulic oil escaping under pressure can have 4. Remove eight capscrews and lockwashers (2,
sufficient force to enter a person's body by Figure 50-57). Install guide studs in two of the
penetrating the skin and cause serious injury, and mounting holes to support parking brake (1)
possibly death, if proper medical treatment is not when it is removed from the wheel motor frame.
received immediately.
5. Disconnect supply hose (3) from the parking
Relieve pressure before disconnecting any brake. Plug and cap the hose and port to help
hydraulic lines. Tighten all connections securely prevent contamination.
before applying pressure. 6. Slide the parking brake off the wheel motor
1. Refer to the "Hydraulic system bleeddown frame.
procedure" in Testing and adjusting section 7. If adapter gear (6) is worn, damaged, or
Steering, hoist, brake cooling and auxiliary otherwise requires removal, perform the following
hydraulic system. steps:
2. Close the brake accumulator bleed valves by NOTE: The adapter gear is shrink fit on the splined
rotating them clockwise. motor shaft.
a. Remove capscrew and hardened flat washer
(4) from the shaft. Remove retainer plate (5).
b. Install a gear puller using the tapped holes
provided in adapter gear (6).
c. Apply heat around gear hub area while
tightening the puller until the adapter gear is
removed from the rotor shaft.
40
50 Disassembly and assembly CEN50023-02
5
6 3 86397
FIGURE 50-57. PARKING BRAKE REMOVAL & INSTALLATION
1. Parking Brake 4. Capscrew & Hardened Flat Washer
2. Capscrew & Lockwasher 5. Retainer Plate
3. Supply Hose 6. Adapter Gear
41
CEN50023-02 50 Disassembly and assembly
Installation Disassembly and assembly of parking
1. If adapter gear (6, Figure 50-57) was removed, brake
install the adapter gear before installing the NOTE: Disassemble and reassemble the brake
parking brake on the wheel motor frame: assembly on a clean, dry work surface. The surface
a. Thoroughly clean the adapter gear and the should be wooden or, if it is metal, covered with
rotor shaft. Inspect the splines and remove padding to prevent damage to machined surfaces.
any burrs that may interfere with installation.
Disassembly
b. Heat the adapter gear to 280°C (536°F).
1. Draw match mark line (1, Figure 50-58) across
Immediately install the adapter gear on the
the brake pack housing, piston housing and end
shaft. The adapter gear must be fully seated
cap to properly orient the components during
against the shoulder of the rotor shaft.
assembly.
c. Install retainer plate (5). Secure the retainer
plate with hardened flat washer and capscrew
(4). Tighten the capscrew to 595 - 670 N·m
(440 - 495 ft lb).
2. Install two guide studs in the wheel motor frame
mounting holes to guide the parking brake into The following procedure is necessary to properly
position. Ensure that the mating surfaces are relieve the pressure exerted by the Belleville
clean and free of burrs. springs on the end cap. Failure to follow this
3. Lift parking brake (1) into position for installation. procedure could result in capscrew failure and
Note the proper orientation depending on personal injury during disassembly.
whether the parking brake is to be installed on
the left or right wheel motor. (The bleeder screw 2. Loosen 12 capscrews (2) evenly in 27 N·m (20 ft
at the top of the parking brake will be tilted toward lb) increments. Alternate by selecting a
the front of the truck.) successive capscrew that is located
4. Slide the parking brake over the guide studs and approximately 180 degrees from the previously
adapter gear (6). loosened capscrew.
5. Install eight capscrews and lockwashers (2). Continue loosening capscrews until the spring
Tighten the capscrews evenly to ensure that the pressure is released and the capscrews and flat
parking brake housing is properly seated on the washers can be removed by hand.
wheel motor frame. Tighten the capscrews to a
final torque of 420 N·m (310 ft lb).
6. If the wheel motor is still installed in the rear axle
housing, connect supply hose (3) and remove the 2
lifting equipment.
7. Before operating the truck, bleed the air from the
parking brake and supply line. Refer to "Parking
brake bleeding procedure" in Testing and
adjusting section Brake system.
1 86398
FIGURE 50-58. PARKING BRAKE
DISASSEMBLY & ASSEMBLY
1. Match Mark Line 2. Capscrew (12 Pt.)
42
50 Disassembly and assembly CEN50023-02
3. Remove 12 capscrews (1, Figure 50-59), 5. Remove piston (1, Figure 50-60) from piston
hardened flat washers (2) and end cap (3). Lift housing (4). Remove and discard piston seals (2)
Belleville washers (4) out of the piston. and (3).
4. Lift piston housing (5) and the piston from brake 6. If necessary, remove bleed valve (5).
pack housing (6).
1
2 1
3
3
4
86400
5 FIGURE 50-60. PARKING BRAKE
DISASSEMBLY & ASSEMBLY
1. Piston 4. Piston Housing
2. Piston Seal 5. Bleed Valve
3. Piston Seal
86399
FIGURE 50-59. PARKING BRAKE
DISASSEMBLY & ASSEMBLY
1. Capscrew (12 Pt.) 4. Belleville Washers
2. Hardened Flat Washer 5. Piston Housing
3. End Cap 6. Brake Pack Housing
43
CEN50023-02 50 Disassembly and assembly
7. Remove four separator discs (1, Figure 50-61), Cleaning and inspection
three friction discs (2), and compression springs
1. Clean all parts thoroughly.
(3) from brake pack housing (5).
2. It is recommended that the separator discs and
friction discs be replaced if the friction material on
either side of the friction disc is worn to less than
1 1.5 mm (0.06 in.).
3. Check the piston and piston housing bore for
scratches, nicks, pitting and other defects that
may cause seal leakage. Slight defects may be
3 repaired by polishing.
2 4. Inspect dowel pins (4, Figure 50-61). If the dowel
pins are grooved from excessive wear or
otherwise damaged, press the dowel pins out of
brake pack housing (5).
5. Check the free height of compression springs (3)
3 and test for height under load. Replace the
springs if they are not within approximately 10%
of specification.
Free Height:. . . . . . . . . . . . . . . 11.58 mm (0.456 in.)
Height at 162 N (36.4 lb): . . . . . .8.89 mm (0.350 in.)
3 6. Inspect the compression springs for cracks and
damage. Replace any springs that are damaged
or significantly worn.
7. Measure the unsprung total height (cone height +
material thickness) of the Belleville washers. The
height must be greater than or equal to 21.16 mm
4 (0.833 in.). Discard any Belleville washers that do
not meet this specification.
5
86401
FIGURE 50-61. PARKING BRAKE
DISASSEMBLY & ASSEMBLY
1. Separator Disc 4. Dowel Pin
2. Friction Disc 5. Brake Pack Housing
3. Compression Spring
44
50 Disassembly and assembly CEN50023-02
8. A load deflection test must now be conducted to e. Note the depth indicator as it moves from 10%
determine whether the Belleville washers will be to 100% compression of the cone height.
reused or discarded. The equipment that is Record the force that is required to deflect the
needed for this test are as follows: Belleville washer in 10% increments up to
100% of the unsprung cone height as shown
• Universal Testing Machine (UTM) -
capacity minimum of 18 144 kgf (40,000 lbf) in in Table 1.
compression f. Repeat Steps c through e two more times.
• Machined flat plate g. Average the three recorded force values from
• Height stand and depth indicator with minimum Steps c through e for a respective deflection
range of 25 mm (1 in.) percentage.
a. Place the Belleville washer on a clean, flat and h. Compare the average force values with the
leveled testing machine bed. "Minimum" values in Table 1. If all of the
average force values are above or equal to the
b. Put the machined flat plate on top of the
minimum specified values, the Belleville
Belleville washer. Make sure that the plate will
washer is acceptable for use in the parking
not slip from the Belleville washer when force
brake assembly.
is applied.
i. If any of the average force values are below
c. Adjust the height stand so that the depth
the minimum specified values, the Belleville
indicator is at zero.
washer will not be of sufficient strength to
d. Gradually apply force. Follow all necessary cause the piston to compress and hold the
safety precautions for operating the UTM. The disc pack. Discard the Belleville washer and
Belleville washer will start deflecting due to replace it with a new one during assembly.
compression as shown in the example in
Figure 50-62.
FIGURE 50-62. BELLEVILLE WASHER DEFLECTION
45
CEN50023-02 50 Disassembly and assembly
Table 1: BELLEVILLE WASHER DEFLECTION SPECIFICATIONS
Load
Percentage Deflection
Average Minimum
10% 0.94 mm (0.037 in.) 2 285 kgf (5,038 lbf) 1 828 kgf (4,030 lbf)
20% 1.88 mm (0.074 in.) 4 340 kgf (9,568 lbf) 3 472 kgf (7,654 lbf)
30% 2.82 mm (0.111 in.) 6 190 kgf (13,647 lbf) 4 952 kgf (10,918 lbf)
40% 3.76 mm (0.148 in.) 7 862 kgf (17,332 lbf) 6 290 kgf (13,866 lbf)
50% 4.70 mm (0.185 in.) 9 380 kgf (20,679 lbf) 7 504 kgf (16,543 lbf)
60% 5.64 mm (0.222 in.) 10 770 kgf (23,744 lbf) 8 616 kgf (18,995 lbf)
70% 6.58 mm (0.259 in.) 12 058 kgf (26,583 lbf) 9 646 kgf (21,266 lbf)
80% 7.52 mm (0.296 in.) 13 269 kgf (29,253 lbf) 10 615 kgf (23,402 lbf)
90% 8.46 mm (0.333 in.) 14 429 kgf (31,811 lbf) 11 543 kgf (25,449 lbf)
100% 9.40 mm (0.370 in.) 15 564 kgf (34,312 lbf) 12 451 kgf (27,450 lbf)
Cleaning and inspecting new discs 3. Thoroughly clean the teeth with an organic-based
cleaning solvent as detailed previously.
A rust preventive coating is applied to separator discs
and friction discs. This coating must be removed
before installing the parking brake.
NOTE: Use a cleaner containing organic-based
solvents, such as acetone, methanol or ethanol, to
clean the coating from the discs. Water-based
cleaners, such as mild soaps and detergents, do not
adequately remove the rust preventive coating.
1. Spray or coat both sides of the disc with the
cleaner.
2. Use a cloth to quickly wipe away the coating
before the cleaner evaporates.
3. Reapply the cleaner and wipe as necessary.
During the manufacture of friction discs, excess
adhesive, which is used to bond the friction material to FIGURE 50-63. FRICTION DISC INNER TEETH
the disc, may get onto the inner teeth of the friction
1. Adhesive
disc and solidify. This adhesive may prevent the
2. Excess Adhesive on Inner Tooth
friction disc from properly engaging the parking brake
adapter gear.
1. Inspect the inner teeth of each friction disc. The
NOTE: If a new wheel motor is installed or adapter
teeth must be free of burrs and excess adhesive.
gear (6, Figure 50-57) is replaced, clean the rust
Refer to Figure 50-63.
preventive coating from the adapter gear teeth with an
2. If adhesive is found on the teeth, use a diamond organic-based cleaning solvent as detailed previously.
needle file (half-round, 150 grit) to slowly and Do not install the parking brake until the adapter gear
carefully remove the excess adhesive from the is completely dry.
inside of each affected tooth.
46
50 Disassembly and assembly CEN50023-02
Assembly 7. Lubricate the piston seals and insert piston (1)
into piston housing (4).
NOTE: New friction discs and separator discs must be
cleaned and inspected to ensure proper parking brake 8. If removed, install bleed valve (5).
operation. If new discs are being installed, refer to the 9. Install piston housing (5, Figure 50-59) over the
topic “Cleaning and inspecting new discs”. dowels in brake pack housing (6). Ensure that the
1. If dowel pins (4, Figure 50-61) have been match mark lines are aligned.
removed, press new dowel pins into the holes in 10. Place Belleville washers (4) into piston (5) so that
brake pack housing (5) until they are fully seated the convex sides are facing each other.
against the shoulder.
11. Place end cap (3) on the top of the assembly.
2. Install one separator disc (1) over the dowel pins. Ensure that the match mark lines are aligned.
Insert one compression spring (3) over each of
the dowel pins. Insert one friction disc (2). 12. Insert 12 capscrews (1) and hardened flat
washers (2). Do not tighten the capscrews.
3. Install second separator disc (1) over the dowel
pins. Install second compression spring (3) over
each of the dowel pins. Insert second friction disc
(2).
4. Install third separator disc (1) over the dowel
pins. Install third compression spring (3) over The following procedure is necessary to properly
each of the dowel pins. Insert third friction disc compress the Belleville washers. Failure to follow
(2). this procedure could result in capscrew failure and
5. Install remaining separator disc (1) over the personal injury during assembly.
dowel pins.
13. Select three capscrews that are 120 degrees
NOTE: The internal teeth of the friction discs must be apart and mark them.
aligned and must be concentric with the pilot diameter a. Tighten the marked capscrews to 41 N·m (30
machined on the rear of the housing to enable the ft lb). Snug the remaining capscrews.
completed assembly to be installed properly. If
available, an adapter gear as installed on the wheel b. Retighten the marked capscrews until the gap
motor rotor shaft should be used to simplify alignment. between the end cap and piston housing is
equalized. Snug the remaining capscrews.
6. Assemble piston seals (2, Figure 50-60) and (3)
on piston (1) as follows: c. Retighten the marked capscrews in 27 N·m
(20 ft lb) increments until they are fully
a. Install the O-ring seal in the bottom of each
tightened to 122 N·m (90 ft lb).
groove. Ensure that the O-rings are not
twisted. d. Tighten the remaining capscrews to 122 N·m
(90 ft lb).
b. If available, use an expander to expand the
outside diameter of each seal enough to allow 14. Install a fitting in one of the oil supply ports and
it to slide onto the piston. attach a hydraulic power source. Install an O-ring
plug in the remaining port.
NOTE: If an expander tool is not available, the seals
may be heated to a maximum of 204°C (400°F). This 15. Slowly apply pressure and open the bleeder
will allow the ring to be manually expanded until it will valve to bleed air from the piston cavity. Close the
fit over the piston. bleeder valve. Apply 2 068 kPa (300 psi) of
hydraulic pressure and hold it for one minute.
c. When each seal is over the groove, resize by
compressing the seal ring. Use a full circle 16. Check for oil leakage. If leakage occurs, the
clamp with any sharp edges or grooves parking brake assembly must be disassembled
covered to prevent damage to the seal and repaired.
surfaces.
d. Install the quad ring in each seal.
47
CEN50023-02 50 Disassembly and assembly
980E Dump truck
Form No. CEN50023-02
48
CEN50045-00
DUMP TRUCK
980E
Machine model Serial number
980E-5 A50005 and up
980E-5AT A50005 and up
50 Disassembly and assembly
Steering system
Removal and installation of steering control unit .................................................................................................. 3
Disassembly and assembly of steering control unit .............................................................................................. 5
Removal and installation of steering column ...................................................................................................... 10
Removal and installation of steering wheel......................................................................................................... 12
Removal and installation of bleeddown manifold ................................................................................................ 13
Removal and installation of flow amplifier ........................................................................................................... 15
Removal and installation of steering cylinders and tie rod .................................................................................. 16
Disassembly and assembly of steering cylinders ............................................................................................... 18
Removal and installation of steering/brake pump ............................................................................................... 21
Removal and installation of piston steering accumulator .................................................................................... 23
Disassembly and assembly of piston steering accumulator ............................................................................... 25
1
CEN50045-00 50 Disassembly and assembly
NOTES
2
50 Disassembly and assembly CEN50045-00
Removal and installation of steering 3. Clean steering control unit (2, Figure 50-2) and
control unit the surrounding area to help avoid contaminating
the hydraulic oil when the hoses are
Removal disconnected.
NOTE: Before disconnecting hydraulic hoses, tag the
hoses for proper identification during installation. See
Figure 50-3.
4. Disconnect and plug five hydraulic hoses (1) from
Hydraulic oil escaping under pressure can have the steering control unit.
sufficient force to enter a person's body by
penetrating the skin and cause serious injury, and 5. Remove mounting hardware (3). Remove
possibly death, if proper medical treatment is not steering control unit (2) and the mounting plate. If
received immediately. necessary, remove mounting plate (4) from the
steering control unit. Move the steering control
Relieve pressure before disconnecting any unit to a clean work area for disassembly, if
hydraulic lines. Tighten all connections securely required.
before applying pressure.
1. Refer to the "Hydraulic system bleeddown
procedure" in Testing and adjusting section
Steering, hoist, brake cooling and auxiliary
hydraulic system.
2 4
2. Remove front access cover (1, Figure 50-1) from
the operator cab.
1 86676
2
FIGURE 50-1. ACCESSING THE STEERING
CONTROL UNIT
87549
1. Front Access Cover
FIGURE 50-2. STEERING CONTROL UNIT
REMOVAL & INSTALLATION
1. Hydraulic Hoses 3. Mounting Hardware
2. Steering Control Unit 4. Mounting Plate
3
CEN50045-00 50 Disassembly and assembly
Installation
NOTE: Whenever the steering column or steering
control unit is removed for service, inspect the splines
of the steering column shaft. Refer to "Removal and
installation of steering column". Serious personal injury to the operator or to
1. Lubricate the splines of the steering column shaft anyone positioned near the front wheels may
with a molybdenum disulphide or multi-purpose occur if a truck is operated with the hydraulic
NLGI grease. steering hoses improperly installed. Improperly
installed hoses can result in uncontrolled steering
2. If removed, install mounting plate (4, Figure 50-2) and/or sudden and rapid rotation of the steering
on steering control unit (2) wheel as soon as the steering wheel is moved. It
3. Align the steering control unit with the steering will turn rapidly and cannot be stopped manually.
column shaft splines. Secure the steering control
unit in place with mounting hardware (3). Tighten After servicing the steering control unit, check the
the capscrews finger tight at this time. hydraulic steering hoses for correct hook-up
before starting the engine.
4. Check for proper steering wheel rotation. Ensure
that the steering wheel does not bind and that it
returns to the centered position after being 7. Start the engine. Check for proper steering
rotated by 1/4 turn to the left and right. If function and leaks.
necessary, adjust the steering control unit and/or
steering column to realign the components. 8. Install front access cover (1, Figure 50-1) on the
operator cab.
5. Tighten capscrews (3) to the standard torque.
NOTE: When installing the front access cover, ensure
6. Unplug and connect five hydraulic hoses (1) to
that the bottom false hinge of the cover is engaging
their proper ports on the steering control unit.
into the bottom edge of the sheet metal panel of the
Refer to Figure 50-3.
cab front enclosure.
FIGURE 50-3. STEERING CONTROL UNIT
PORT IDENTIFICATION
1. Steering Control Unit “L” - Left Steering
“T” - Return to Tank “R” - Right Steering
“P” - Supply from Pump “LS” - Load Sensing
4
50 Disassembly and assembly CEN50045-00
Disassembly and assembly of steering 4. Remove end cover (4, Figure 50-5) and O-ring
control unit (2).
Disassembly 5. Remove the outer gear of gear wheel set (1) and
the O-ring between the gear set and the
NOTE: The steering control unit is a precision unit distribution plate.
manufactured to close tolerances. Therefore,
complete cleanliness is essential when handling the
unit. Perform the work in a clean area and use lint free
wiping materials or dry compressed air.
1. Allow the oil to drain from the valve ports.
2. Match mark the gear wheel set and end cover to
ensure proper relocation during reassembly.
Refer to Figure 50-4.
3. Remove the end cover capscrews and washers.
Remove capscrew with rolled pin (3, Figure 50-
4). Mark the hole location of the capscrew with
rolled pin on end cover (4) to aid in reassembly.
FIGURE 50-5. END COVER REMOVAL
1. Gear Wheel Set
2. O-Ring
FIGURE 50-4. MARKING VALVE COMPONENTS
1. Valve Assembly 3. Capscrew With
2. Match Marks Rolled Pin
4. End Cover
5
CEN50045-00 50 Disassembly and assembly
FIGURE 50-6. STEERING CONTROL UNIT
1. Dust Seal 7. Bearing Assembly 13. Tube 19. End Cover
2. Housing & Spools 8. Ring 14. O- ring 20. Washers
3. Ball 9. Cross Pin 15. Distribution Plate 21. Rolled Pin
4. Threaded Bushing 10. Neutral Position Springs 16. Gear Wheel Set 22. Capscrew With Pin
5. O-ring 11. Cardan Shaft 17. O-ring 23. Capscrews
6. Kin Ring 12. Spacer 18. O-ring
6
50 Disassembly and assembly CEN50045-00
6. Lift the inner gear off cardan shaft (11, Figure 50- Assembly
6).
1. Clean all parts carefully with fresh cleaning
7. Remove cardan shaft (11), distribution plate (15) solvent.
and O-ring (14).
2. Inspect all parts carefully and make any
8. Remove threaded bushing (4) and ball (3). replacements necessary.
9. With the valve housing positioned with the spool NOTE: All O-rings, seals and neutral position springs
and sleeve vertical, carefully lift the spool must be replaced. Before reassembly, thoroughly
assembly out of the housing bore. lubricate all parts with clean type C-4 hydraulic oil.
NOTE: When assembling the spool and sleeve, only
one of the two possible matching positions of the
spring slots can be used because, in the other end of
the sleeve and spool (opposite end of the spring slots),
If housing is not vertical when spool and sleeve there are three slots in the spool and three holes in the
are removed, pin (9) may slip out of position and sleeve. These must be opposite each other upon
trap spools inside housing bore. assembly so that the holes are partly visible through
10. Remove O-ring (5), kin ring (6) and bearing the slots in the spool. Refer to Figure 50-8.
assembly (7).
11. Remove ring (8) and pin (9) and carefully push
the inner spool out of the outer sleeve.
12. Press neutral position springs (10) out of their slot
in the inner spool.
13. Use a screwdriver to remove dust seal (2, Figure
50-7). Be careful not to scratch or damage the
dust seal bore.
FIGURE 50-8. SPOOL AND SLEEVE ASSEMBLY
1. Slots 3. Spool
2. Hole 4. Sleeve
FIGURE 50-7. DUST SEAL REMOVAL
1. Screwdriver 3. Housing
2. Dust Seal
7
CEN50045-00 50 Disassembly and assembly
FIGURE 50-9. NEUTRAL POSITION SPRING INSTALLATION
3. To install the neutral position springs, place a
screwdriver in the spool slot as shown in Figure
50-9.
4. Place one flat neutral position spring on each
side of the screwdriver blade. Do not remove the
screwdriver.
5. Push two curved neutral position springs in
between one side of the screwdriver blade and a
flat spring. Repeat for the opposite side. Remove
the screwdriver.
6. Slide the inner spool in the sleeve. Compress the
ends of the neutral position springs and push the
neutral position springs in place in the sleeve.
7. Install cross pin (2, Figure 50-10).
8. With neutral position springs (7) centered in
spool and sleeve, install ring (3), rear bearing
race (4), thrust bearing (5) and front bearing race
(6) in that order. The chamfer on the rear bearing
must be facing away from the bearing.
9. Place dust seal (1, Figure 50-6) in position. Using
a flat iron block over the seal, tap it into the FIGURE 50-10. BEARING INSTALLATION
housing. 1. Sleeve 5. Thrust Bearing
10. Position O-ring (5) and kin ring (6) on the spool. 2. Cross Pin 6. Bearing Race
3. Ring 7. Neutral Position
4. Bearing Race (with Springs
chamfer)
8
50 Disassembly and assembly CEN50045-00
11. Position the steering control unit so that housing 16. Position the inner gear wheel onto the cardan
(1, Figure 50-11) is horizontal. Slowly guide shaft. It may be necessary to rotate the gear
lubricated spool assembly (2) with fitted parts into slightly to find the matching splines on the cardan
the bore using light turning movements. shaft. Splines are machined to ensure proper
alignment of the cardan shaft and inner gear
wheel.
17. Lubricate O-rings (17) and (18) on both sides of
the outer gear wheel with light grease and install
them.
18. Align the outer gear wheel bolt holes with the
tapped holes in the housing and the match
marks.
19. Align cover (19), using the match marks as a
reference. Install capscrews (23) and washers
(20).
20. Install capscrew with pin (22) into the proper hole.
21. Install the end cover. Install and tighten the
capscrews with washers hand-tight in a criss-
cross pattern.
FIGURE 50-11. SPOOL INSTALLATION
1. Housing
2. Spool Assembly
The cross pin must remain horizontal when the
spool and sleeve are pushed into the bore to
prevent the pin from dropping out of the spool.
12. Install check ball (2, Figure 50-12) in hole (1).
Install and lightly tighten the threaded bushing.
13. Lubricate O-ring (3) with light grease and install it
in the groove of housing (4).
14. Install distribution plate (15, Figure 50-6) so that
the plate holes match the corresponding holes in
the housing. FIGURE 50-12. CHECK BALL INSTALLATION
15. Guide cardan shaft (11) down into the bore with 1. Hole 3. O-ring
the slot in the cardan shaft aligned with cross pin 2. Check Ball 4. Housing
(9).
9
CEN50045-00 50 Disassembly and assembly
Removal and installation of steering 4. Disconnect and unclamp speed control switch
column harness (1, Figure 50-14) and multi-function
switch harness (2).
Removal
5. Remove steering column bottom cover (3) and
1. Park truck on a hard, level surface and block all coupling cover (4).
the wheels.
2. Place the shift control lever in PARK and turn the
rest switch ON. Turn the key switch OFF to shut
down the engine and allow 90 seconds for the
steering system accumulators to bleed down.
3. Remove lower dash panel cover (1, Figure 50-
13).
3 1
4 2 87551
FIGURE 50-14. REMOVING THE STEERING
COLUMN
1. Speed Control Switch 3. Steering Column
Harness Bottom Covers
1 87550
2. Multi-Function Switch 4. Coupling Cover
Harness
FIGURE 50-13. ACCESSING THE STEERING
COLUMN
1. Lower Dash Panel Cover
10
50 Disassembly and assembly CEN50045-00
6. Remove four internal hex mounting capscrews Installation
and flat washers (1, Figure 50-15). Remove the
1. Slide the steering column assembly into the
steering column from the instrument panel.
instrument panel.
NOTE: Coupling (2) may be detached from the 2. If coupling (2, Figure 50-15) is installed on the
steering column shaft and remain installed in the end of the steering column, lubricate the male
steering control unit. splines on the end of the coupling and guide the
coupling into the mating female part of the
steering control unit.
If the coupling remained with the steering control
unit, attach the end of the coupling to the
steering column shaft. Tighten the clamping
screw securely.
3. Install four internal hex mounting capscrews and
flat washers (1). Tighten the capscrews to the
standard torque.
4. Check for proper steering wheel rotation. Ensure
that the steering wheel does not bind and that it
returns to the centered position after being
rotated by 1/4 turn to the left and right. If
necessary, adjust the steering column to realign
the components.
1 1
5. Connect and clamp speed control switch harness
(1, Figure 50-14) and multi-function switch
harness (2).
6. Start the engine. Check for proper steering
function.
7. Install steering column bottom cover (3, Figure
2 87552 50-14) and coupling cover (4).
FIGURE 50-15. STEERING COLUMN MOUNTING 8. Install lower dash panel cover (1, Figure 50-13).
HARDWARE
1. Capscrews & Hardened Flat Washers
2. Coupling
11
CEN50045-00 50 Disassembly and assembly
Removal and installation of steering wheel Installation
Removal 1. If removed, install horn contact (5, Figure 50-16)
in the bracket notch. Install cover (4).
1. Park truck on a hard, level surface and block all
2. Place steering wheel (3, Figure 50-16) into
the wheels.
position on the steering column shaft while
2. Place the shift control lever in PARK and turn the guiding the horn wire through the access hole in
rest switch ON. Turn the key switch OFF to shut the steering wheel. Align the marks on the
down the engine and allow 90 seconds for the steering wheel and the shaft that were made
steering system accumulators to bleed down. during disassembly. Align the serrations and
3. Use a small screwdriver to pry horn button (1, push the steering wheel onto the shaft.
Figure 50-16) from steering wheel (3). NOTE: Do NOT lubricate the spline or taper. Use
4. Disconnect the horn wire and set the horn button Loctite® Threadlocker Blue 242 on the retaining nut
aside. threads.
5. Remove retaining nut (2). 3. Install retaining nut (2). Tighten the nut to 81 ± 7
N·m (60 ± 5 ft lb).
6. Use a marker to make alignment marks on the
steering wheel and the shaft. 4. Connect the horn wire to horn button (1).
7. Pull the steering wheel from the column. If the 5. Install the horn button onto the steering wheel.
steering wheel will not slide off the shaft it may be Verify that the horn functions properly.
necessary to install a puller into the tapped holes
(5/16" - 24NF) in the steering wheel.
8. If necessary, remove cover (4) and horn contact
(5).
3
1 2 87553
FIGURE 50-16. STEERING WHEEL
REMOVAL & INSTALLATION
1. Horn Button 4. Cover
2. Retaining Nut 5. Horn Contact
3. Steering Wheel
12
50 Disassembly and assembly CEN50045-00
Removal and installation of bleeddown
manifold
2 1
Removal
NOTE: It may not be necessary to remove the
bleeddown manifold from the truck for component
replacement. If the problem area has been isolated,
remove the inoperative component and replace it.
Hydraulic oil escaping under pressure can have
sufficient force to enter a person's body by
penetrating the skin and cause serious injury, and
possibly death, if proper medical treatment is not
received immediately.
Relieve pressure before disconnecting any
hydraulic lines. Tighten all connections securely
before applying pressure.
1. Refer to the "Hydraulic system bleeddown
procedure" in Testing and adjusting section
Steering, hoist, brake cooling and auxiliary 1
hydraulic system.
2. Remove mounting hardware (1, Figure 50-17)
and protective cover (2). 86358
FIGURE 50-17. BLEEDDOWN MANIFOLD COVER
1. Mounting Hardware 2. Protective Cover
13
CEN50045-00 50 Disassembly and assembly
3. Disconnect all solenoids, switches and sensors Installation
on bleeddown manifold (2, Figure 50-18).
NOTE: Use vacuum pump kit (XB0887) to hold the oil
back in the hydraulic tank.
4. Tag the hoses for proper identification during
Use a lifting device with adequate capacity to
installation. Disconnect and plug all hydraulic
remove and install the components.
hoses from the bleeddown manifold.
1. Position the bleeddown manifold on the mounting
bracket on the left side of the truck frame. Install
and tighten four long capscrews (1, Figure 50-18)
to the standard torque.
Use a lifting device with adequate capacity to
remove and install the components. NOTE: Use vacuum pump kit (XB0887) to hold the oil
back in the hydraulic tank.
5. Remove four long capscrews (1). Lift bleeddown 2. Unplug the hydraulic hoses. Install new O-rings
manifold (2) off the mounting bracket. at the flange fittings and attach the hoses to the
proper ports. Tighten the connections securely.
6. Clean the exterior of the bleeddown manifold
before removing any components from the 3. Connect all solenoids, switches and sensors on
manifold. the bleeddown manifold. If the check valves or
relief valves were removed, install new O-ring
seals before installation.
4. Start the engine. Check the steering system and
1 2 brake system for proper operation and leaks.
5. Install the protective cover (2, Figure 50-17) and
mounting hardware (1).
NOTE: Relief valves are factory preset. Do not attempt
to reset the relief valves or repair defective relief
valves. Replace relief valves as a unit. The check
valves must also be replaced only as units.
6. Perform the hydraulic system checkout
procedures. Refer to Testing and adjusting
section Steering, hoist, brake cooling and
auxiliary hydraulic system.
1
86364
FIGURE 50-18. BLEEDDOWN MANIFOLD
REMOVAL
1. Mounting Hardware 2. Bleeddown Manifold
14
50 Disassembly and assembly CEN50045-00
Removal and installation of flow amplifier NOTE: Use vacuum pump kit (XB0887) to hold the oil
back in the hydraulic tank.
Removal 3. Unplug the hydraulic hoses and tubes. Install
new O-rings on the flange fittings and connect
the hydraulic lines at their proper locations.
Tighten the fittings securely.
4. Perform the hydraulic system checkout
Hydraulic oil escaping under pressure can have procedures. Refer to Testing and adjusting
sufficient force to enter a person's body by section Steering, hoist, brake cooling and
penetrating the skin and cause serious injury, and auxiliary hydraulic system.
possibly death, if proper medical treatment is not
received immediately.
Relieve pressure before disconnecting any
hydraulic lines. Tighten all connections securely
before applying pressure.
1. Refer to the "Hydraulic system bleeddown
procedure" in Testing and adjusting section
Steering, hoist, brake cooling and auxiliary
hydraulic system.
NOTE: Use vacuum pump kit (XB0887) to hold the oil
back in the hydraulic tank. Before disconnecting
hydraulic hoses, tag the hoses for proper identification
during installation.
2. Disconnect and plug all hydraulic hoses and
tubes from the flow amplifier.
2
If necessary, use a lifting device with adequate
capacity to remove and install the components.
NOTE: The weight of the flow amplifier is
approximately 29 kg (64 lb). 1
3. Support the flow amplifier so that it does not fall.
Remove mounting hardware (1, Figure 50-19),
then remove flow amplifier (2).
Installation
1. Move flow amplifier (2, Figure 50-19) into position REAR VIEW 86368
and support the flow amplifier against the
FIGURE 50-19. FLOW AMPLIFIER
mounting bracket.
REMOVAL & INSTALLATION
2. Install and tighten mounting hardware (1) to the
standard torque. 1. Mounting Hardware 2. Flow Amplifier
15
CEN50045-00 50 Disassembly and assembly
Removal and installation of steering Installation
cylinders and tie rod NOTE: Use the sleeve alignment tool included in the
NOTE: The steering cylinders and tie rod mounting tool group to hold bearing spacers (6, Figure 50-20) in
arrangements are similar. The same removal and position when the pins are inserted during assembly.
installation procedures are applicable to both
1. Align the bearing bore of the steering cylinder or
components.
tie rod with the pin bores in the spindle or frame.
Removal Insert bearing spacers (6).
NOTE: The tie rod must be installed with the heads of
the clamping bolts toward the front of the truck. The
steering cylinders must be installed with the hydraulic
hose ports facing upward.
Hydraulic oil escaping under pressure can have
sufficient force to enter a person's body by 2. Install pin (5), retainer (7), capscrews (3),
penetrating the skin and cause serious injury, and hardened flat washers (4) and nuts (8) at each
possibly death, if proper medical treatment is not pin joint. Tighten each nut to 420 ± 41 N·m (310 ±
received immediately. 30 ft lb).
Relieve pressure before disconnecting any NOTE: Ensure that the air has been bled from the
hydraulic lines. Tighten all connections securely steering cylinders and hydraulic hoses.
before applying pressure. 3. Unplug and connect the hydraulic hoses to
1. Refer to the "Hydraulic system bleeddown steering cylinder (1) or the lubrication lines to tie
procedure" in Testing and adjusting section rod (2). Turn the steering wheel and check for
Steering, hoist, brake cooling and auxiliary leaks and proper operation.
hydraulic system. 4. Perform the toe-in adjustment. Refer to Testing
2. Disconnect the two hydraulic hoses from steering and adjusting section Steering, hoist, brake
cylinder (1, Figure 50-20) and/or the lubrication cooling and auxiliary hydraulic system for the
line from tie rod (2). Plug all open fittings and procedure.
cylinder ports to prevent contamination of the
hydraulic system.
If necessary, use lifting equipment and a lifting
device with adequate capacity to remove and
install the components.
3. Support the steering cylinder or tie rod so that it
does not fall. Remove nuts (8), hardened flat
washers (4), capscrews (3) and retainer (7) from
each pin joint.
4. Remove pin (5) from each pin joint. Move the
steering cylinder or tie rod to a clean work area.
Bearing spacers (6) are secured by the pin. Keep
the spacers from falling during removal of the pin.
Damage to the spacers and/or personal injury may
result.
16
50 Disassembly and assembly CEN50045-00
SEE
PIN DETAIL
SEE
PIN DETAIL
2
4
PIN DETAIL 8
86369
FIGURE 50-20. STEERING CYLINDER / TIE ROD REMOVAL & INSTALLATION
1. Steering Cylinder 5. Pin
2. Tie Rod 6. Bearing Spacers
3. Capscrews 7. Retainer
4. Hardened Flat Washers 8. Nut
17
CEN50045-00 50 Disassembly and assembly
Disassembly and assembly of steering 2. Remove four short capscrews (1, Figure 50-22),
cylinders two long capscrews (2) and flat washers (3). Pull
rod (4), piston (6) and gland (5) out of cylinder
NOTE: For proper seal installation and contamination
housing (7) as one unit.
prevention, disassembly and assembly work must be
done in a clean, temperature controlled environment.
Disassembly
1. If spherical bearings (2, Figure 50-21) require
replacement, place the steering cylinder on
stands and secure it with a chain vise. Remove
retainer rings (1) and press the bearing from the 2
bore. 1
NOTE: Do not use metal tools to strike the bearings. 3
3
1 4
5
2
6
1 7
86375
FIGURE 50-21. SPHERICAL BEARING REMOVAL
1. Retainer Ring 2. Spherical Bearing
86370
FIGURE 50-22. STEERING CYLINDER ROD
REMOVAL & INSTALLATION
1. Short Capscrew 5. Gland
2. Long Capscrew 6. Piston
3. Flat Washer 7. Cylinder Housing
4. Rod
18
50 Disassembly and assembly CEN50045-00
3. Remove screw (4, Figure 50-23), then unscrew 4. Remove wiper seal (1, Figure 50-24), main seal
piston (3) from the end of rod (1). Pull the rod free (2), buffer seal (3), and bearing (4) from the bore
of gland (2). of gland (5).
5. Remove O-ring (7) and backup ring (6) from the
outside of gland (5).
2 4
1
3
5
2
6
7
86373
FIGURE 50-24. GLAND DISASSEMBLY &
3 ASSEMBLY
1. Wiper Seal 5. Gland
2. Main Seal 6. Backup Ring
3. Buffer Seal 7. O-ring
4 4. Rod Bearing
86371
FIGURE 50-23. STEERING CYLINDER ROD
DISASSEMBLY & ASSEMBLY
1. Rod 3. Piston
2. Gland 4. Screw
19
CEN50045-00 50 Disassembly and assembly
6. Remove piston bearing (5, Figure 50-25) and Assembly
piston seal assembly (4) from the outside of NOTE: Lubricate the O-rings with clean hydraulic oil
piston (3). before installation.
7. Remove both backup rings (1) and O-ring (2)
1. Install O-ring (2, Figure 50-25) and both backup
from the bore of piston (3).
rings (1) in the bore of piston (3).
2. Install piston seal assembly (4) and piston
bearing (5) on the outside of piston (3).
2 3. Install bearing (4, Figure 50-24), buffer seal (3),
1
main seal (2), wiper seal (1) in the bore of gland
(5).
4. Install O-ring (7) and backup ring (6) on the
outside of gland (5).
3 5. Slowly push rod (1, Figure 50-23) through the top
of gland (2). Be careful not to damage the seals
and bearing.
4 6. Screw piston (3) onto rod (1). Tighten the piston
to 294 ± 29 N·m (217 ± 21 ft lb).
7. Apply Loctite No. 262 to the threads of screw (4).
Install and tighten the screw to 59 - 74 N·m (44 -
5 55 ft lb).
86372 8. Coat the piston and the rod with clean hydraulic
oil, then carefully install the rod, piston and gland
FIGURE 50-25. PISTON DISASSEMBLY & assembly into cylinder housing (7, Figure 50-22).
ASSEMBLY Ensure that the backup ring and O-ring on gland
1. Backup Rings 4. Piston Seal (5) are not damaged during installation.
2. O-ring Assembly 9. Install four short capscrews (1), two long
3. Piston 5. Piston Bearing capscrews (2) and flat washers (3). Tighten the
capscrews evenly to the standard torque.
10. If spherical bearings (2, Figure 50-21) were
Cleaning and inspection removed, place the steering cylinder on stands
and secure it with a chain vise and install the
spherical bearings. Install retainer rings (1) to
secure the bearings.
NOTE: Before installation, spherical bearings must be
When using cleaning agents, follow the solvent shrunk by freezing. The temperature must not be
manufacturer's instructions. below -54°C (-65°F). A press may be necessary for
installation. Do not use metal tools to strike the
1. Clean all parts thoroughly in fresh cleaning
bearings.
solvent. Use a solvent that does not leave a film
after evaporation such as trichloroethane, 11. Test the performance of the steering cylinder.
acetone or lacquer thinner. Refer to "Steering cylinder leakage test" in the
2. Dry all parts completely using only dry, filtered Testing and adjusting section Steering system.
compressed air and lint free wiping materials.
3. Inspect all parts for evidence of wear or damage.
Inspect plated surfaces for scratches, nicks or
other defects. Replace or repair any damaged
parts.
NOTE: Contact your local Komatsu distributor for
repair information and instructions not covered in this
manual.
20
50 Disassembly and assembly CEN50045-00
Removal and installation of
steering/brake pump
Removal
Always maintain complete cleanliness when
opening any hydraulic connection. Ensure that all
system lines and components are capped while
the component is removed from the truck.
Hydraulic oil escaping under pressure can have 3. Disconnect steering filter hose (1, Figure 50-26),
sufficient force to enter a person's body by unloader feedback hose (2), supply hose (3) and
penetrating the skin and cause serious injury, and case drain hose (4) and from the steering/brake
possibly death, if proper medical treatment is not pump. Plug all hoses and ports to prevent oil
received immediately. contamination.
Relieve pressure before disconnecting any
hydraulic lines. Tighten all connections securely
before applying pressure. 4
1. Refer to the "Hydraulic system bleeddown
procedure" in Testing and adjusting section 3
Steering, hoist, brake cooling and auxiliary
hydraulic system.
NOTE: Use vacuum pump kit (XB0887) to hold the oil
back in the hydraulic tank. Before disconnecting
hydraulic hoses, tag the hoses for proper identification
during installation.
2. Clean the steering/brake pump and surrounding
area carefully to help avoid contamination of
1
hydraulic oil when the hoses are disconnected 2 86377
are opened.
FIGURE 50-26. STEERING/BRAKE PUMP HOSES
1. Steering Filter Hose 3. Supply Hose
2. Unloader Feedback Hose 4. Case Drain Hose
21
CEN50045-00 50 Disassembly and assembly
Installation
NOTE: Lubricate the O-ring with clean Type C-4
hydraulic oil before installation.
1. Install new O-ring (2, Figure 50-27) and seating
Use a lifting device with adequate capacity to rings (6) in the hoist pump mounting flange.
remove and install the components.
2. Ensure that the steering/brake pump splined
4. Support steering/brake pump (1, Figure 50-27) coupler is in place inside the hoist pump before
and the rear section of the hoist pump. Remove installation.
two capscrews (3), two nuts (4) and two
lockwashers (5).
5. Move the steering/brake pump rearward to
disengage the drive coupler splines from the
hoist pump. Remove the steering/brake pump.
6. Remove seating rings (6) and O-ring (2) from the Use a lifting device with adequate capacity to
hoist pump mounting flange. remove and install the components.
7. Move the pump to a clean work area for 3. Move steering/brake pump (1, Figure 50-26) into
disassembly. position. Engage the pump shaft with the splined
drive coupler in the hoist pump.
4. Install two nuts (4), two lockwashers (5) and two
capscrews (3). Tighten the hardware to the
4 5 standard torque.
NOTE: Use vacuum pump kit (XB0887) to hold the oil
back in the hydraulic tank.
5. Remove all plugs from the hoses and ports.
Install new O-rings on the flange fittings and
connect steering filter hose (1, Figure 50-26),
unloader feedback hose (2) and supply hose (3)
to the steering/brake pump. Tighten the
capscrews securely.
2 6 NOTE: Do not connect case drain hose (4) at this time.
1 3 6. Before connecting the case drain hose, remove
86378
the hose fitting from the pump housing. Add
FIGURE 50-27. STEERING/BRAKE PUMP clean C-4 hydraulic oil to the pump through the
REMOVAL & INSTALLATION opening until the pump housing is full. This may
require 2 to 3 liters (2 to 3 qt.) of oil.
1. Steering/Brake Pump 4. Nut
7. Install the case drain fitting and tighten it to the
2. O-ring 5. Lockwasher
standard torque. Connect case drain hose (4) to
3. Capscrew (12 Point) 6. Seating Ring
the fitting.
8. Perform the hydraulic system checkout
procedures. Refer to Testing and adjusting
section Steering, hoist, brake cooling and
auxiliary hydraulic system.
22
50 Disassembly and assembly CEN50045-00
Removal and installation of piston
steering accumulator
Removal
1
Hydraulic oil escaping under pressure can have
sufficient force to enter a person's body by 2 4
penetrating the skin and cause serious injury, and
possibly death, if proper medical treatment is not
received immediately.
3
Relieve pressure before disconnecting any
hydraulic lines. Tighten all connections securely
before applying pressure.
1. Refer to the "Hydraulic system bleeddown
procedure" in Testing and adjusting section
Steering, hoist, brake cooling and auxiliary
hydraulic system.
2. Remove valve cover (1, Figure 50-28) and
spacer (2). Remove switch cover (4).
84476
FIGURE 50-28. TOP OF PISTON
ACCUMULATOR
1. Valve Cover 3. Charging Valve
2. Spacer 4. Switch Cover
Wear a face mask or goggles. Make sure that only
the swivel nut turns. Turning the entire charging
valve assembly may result in the valve assembly
being forced out of the suspension by the gas 1
pressure inside.
3. Discharge the nitrogen pressure from the piston
accumulator as follows:
a. Remove valve cap (1, Figure 50-29) from the 2
charging valve.
b. Hold valve body (3) with one wrench, then turn
swivel nut (2) counterclockwise three turns
with a second wrench. Do not turn the swivel 3
nut more than three turns. Do not turn the
charging valve body.
84483
c. Connect the nitrogen charging kit to the
charging valve. Refer to Testing and adjusting FIGURE 50-29. PISTON ACCUMULATOR
section Accumulators and suspensions for CHARGING VALVE
the charging kit installation information.
1. Valve Cap 3. Valve Body
2. Swivel Nut (Large Hex Nut)
(Small Hex Nut)
23
CEN50045-00 50 Disassembly and assembly
4. Disconnect the wiring harness from pressure
switch (4, Figure 50-30).
5. Disconnect hydraulic hose (1) from the flange at 4
the bottom of accumulator (3). Plug the hose and
the accumulator port.
Use a lifting device with adequate capacity to
remove and install the components.
6. Attach a lifting device to the top of the accumula-
tor and take up slack.
3
7. Remove clamps (2) that secure the accumulator
to the frame mounting bracket.
8. Lift accumulator (3) from the lower mounting
bracket. Move the accumulator to a clean work
area.
1 86379
FIGURE 50-30. PISTON ACCUMULATOR
REMOVAL & INSTALLATION
1. Hydraulic Hose 3. Accumulator
2. Clamp 4. Pressure Switch
24
50 Disassembly and assembly CEN50045-00
Installation Disassembly and assembly of piston
1. New or rebuilt piston accumulators should have steering accumulator
1.5 L (3 pt) of oil in the gas end to prevent rusting Disassembly
of the accumulator walls and to provide for piston
seal lubrication.
If the accumulator does not have oil in the gas
end, remove charging valve (3, Figure 50-28)
and add 1.5 L (3 pt) of clean C-4 hydraulic oil to
the gas end of the accumulator. This provides Wear a face mask or goggles. Make sure that only
enough oil above the top of the piston for seal the swivel nut turns. Turning the entire charging
lubrication. valve assembly may result in the valve assembly
2. Install the charging valve with a new O-ring. being ejected from the accumulator by the gas
Tighten valve body (3, Figure 50-29) to 22 N·m pressure inside.
(16 ft lb). 1. Before disassembly, ensure that all pressure has
been discharged from the piston accumulator as
follows:
a. Remove valve cap (1, Figure 50-31) from the
charging valve.
Use a lifting device with adequate capacity to b. Hold valve body (3) with one wrench, then turn
remove and install the components. swivel nut (2) counterclockwise three turns
3. Keep the accumulator upright and attach a lifting with a second wrench. Do not turn the swivel
device to the top of the accumulator. Ensure that nut more than three turns. Do not turn the
the base ring is installed in the lower mounting charging valve body.
bracket, then lift accumulator (3, Figure 50-30) c. Connect the nitrogen charging kit to the
into position in the lower mounting bracket. charging valve. Refer to Testing and adjusting
4. Install clamps (2) and the hardware that secure section Accumulators and suspensions for
the accumulator to the frame mounting bracket. the charging kit installation information.
Tighten the capscrews to the standard torque. 2. Loosen valve body (3) to remove the charging
5. Install pressure switch (4) and connect the switch valve from the top of the accumulator.
to the wiring harness.
6. Remove the plugs from the hose and accumula-
tor port. Install a new O-ring in the flange, then 1
connect hydraulic hose (1) at the bottom of the
accumulator.
7. Precharge the piston accumulator. Refer to 2
"Piston accumulator charging procedure" in
Testing and adjusting section Accumulators and
suspensions.
84483
FIGURE 50-31. PISTON ACCUMULATOR
CHARGING VALVE
1. Valve Cap 3. Valve Body
2. Swivel Nut (Large Hex Nut)
(Small Hex Nut)
25
CEN50045-00 50 Disassembly and assembly
3. Remove pressure switch (1, Figure 5-38) and 5. Secure the accumulator horizontally in a chain
valve assembly (2) vise.
6. Install two lifting eyes or long capscrews (1,
Figure 50-34) in two of the three 5/8" - 11UNC
2 1 lifting holes in end cap (3).
7. Use a bar to turn the end cap counterclockwise.
Remove the end cap.
8. Repeat steps 5 and 6 for the other end cap.
3
3
2
84478
FIGURE 50-32. PISTON ACCUMULATOR END CAP
1. Pressure Switch 3. Charging Valve
2. Valve Assembly
4. Remove the hose fitting, flange (1, Figure 5-39)
and plugs (2) from the bottom of the piston accu-
mulator. 1
84479
FIGURE 50-34. REMOVING THE END CAP
1 1. Capscrew 3. End Cap
2. Bar
2 84480
FIGURE 50-33. PISTON ACCUMULATOR END CAP
1. Flange 2. Plug
26
50 Disassembly and assembly CEN50045-00
9. Use a long dowel (wood, plastic or padded) or Cleaning and inspection
push rod (XA6348) to carefully tap piston (1, Fig-
1. Check the seals on the piston and end caps for
ure 5-35) out of the accumulator housing. Be
cuts, score marks and other damage. If there are
careful not to damage the piston or seals on the
excessive cuts on the seals, perform a thorough
end cap threads.
examination of the metal surfaces for damage.
NOTE: Never use pressurized air to remove the 2. Clean the piston and housing bore. Use a
piston. cleaning solvent and dry them with a soft, clean
towel or rag.
3. Inspect the piston and housing bore for foreign
material, scratches and other damage. Replace
1 the piston if damaged. Scratches on the housing
bore must be removed to ensure optimal service
life of the seals.
Repair of the housing by welding, machining or
plating to salvage a worn area is NOT APPROVED.
These procedures may weaken the housing and
result in serious injury to personnel when
pressurized.
84481
FIGURE 50-35. PISTON REMOVAL (TYPICAL)
1. Piston 2. End Cap
27
CEN50045-00 50 Disassembly and assembly
Piston seal replacement Assembly
NOTE: Replace all seals when the accumulator is NOTE: Assemble the accumulator in a dust and lint
completely disassembled. free area. Maintain complete cleanliness during
1. Apply clean hydraulic oil to the seals, piston assembly to prevent possible contamination.
lands and grooves. 1. Secure the accumulator horizontally in a vise,
2. Assemble the seals into the appropriate piston preferably a chain vise.
grooves. Start with seal (5, Figure 50-36), then 2. Carefully insert piston assembly (2, Figure 50-37)
move outward to seals (2) to reduce the risk of into the accumulator housing bore. Avoid cocking
seal damage. Ensure that seals (2) and (5) are to prevent damaging the piston and/or seals on
not folded or twisted. the end cap threads. If necessary, tap the piston
3. Insert backup rings (3) and (4) carefully so as not lightly with a soft hammer. Be careful not to pinch
to stretch any more than necessary. Ensure that the backup rings.
the backup ring gaps are offset from one another NOTE: Assembly sleeve (1) may be used to help
as they are installed and not aligned on one side install and prevent damage to the piston assembly.
of the piston.
1 2
1
4
84482
5 FIGURE 50-37. PISTON ASSEMBLY
1. Assembly Sleeve 2. Piston Assembly
4 (XA6349)
1
85209
FIGURE 50-36. PISTON REPLACEMENT SEALS
1. Piston Bearing 4. Backup Ring (thin)
2. Piston Seal - “U” 5. Piston Seal - “T”
3. Backup Ring (thick)
28
50 Disassembly and assembly CEN50045-00
3. Assemble the backup ring and O-ring into the 9. Install plugs (2, Figure 5-39) in the oil end cap.
end cap groove. The backup ring must be toward Also install a plug in place of flange (1) and the
the threaded side or outside of the end cap. hose fitting.
Apply a light coat of grease to the threads and O-
10. Before closing up the ports, add 1.4 L (48 oz) of
ring of the end cap.
oil to the gas end.
NOTE: Check the face of piston and tube for any 11. Install the charging valve with a new O-ring.
contamination before installing the end caps. Tighten valve body (3, Figure 5-31) to 22 N·m (16
4. Secure the accumulator horizontally in a chain ft lb).
vise.
12. Test the accumulator for leaks. Refer to "Piston
5. Install two lifting eyes or long capscrews (1, accumulator leak testing" in Testing and adjusting
Figure 50-34) in two of the three 5/8" - 11UNC section Accumulators and suspensions.
lifting holes in end cap (3).
13. If the accumulator is being installed on a truck:
6. Use a bar to tighten the end cap clockwise to a
torque of 300 N·m (221 ft lb). a. Install pressure switch (1, Figure 5-38) into
valve assembly (2).
After the end cap is tightened, the end cap
should be flush ± 1.5 mm (± 0.06 in) with the end b. Install flange (1, Figure 5-39). Install the hose
of the accumulator housing. fitting and tighten to standard torque.
7. Repeat steps 5 and 6 for the other end cap.
8. Remove the screws from both end caps. Clean
the excess lubricant from the accumulator head
area at both ends of the accumulator.
29
CEN50045-00 50 Disassembly and assembly
980E Dump truck
Form No. CEN50045-00
30
CEN50049-01
DUMP TRUCK
980E
Machine model Serial number
980E-4 A40003 and up
980E-4AT A40003 and up
980E-5 A50005 and up
980E-5AT A50005 and up
50 Disassembly and assembly
Suspensions
Removal and installation of front suspension ....................................................................................................... 3
Disassembly and assembly of front suspension ..................................................................................................11
Removal and installation of rear suspension ...................................................................................................... 16
Disassembly and assembly of rear suspension.................................................................................................. 20
1
CEN50049-01 50 Disassembly and assembly
NOTES
2
50 Disassembly and assembly CEN50049-01
Removal and installation of Removal
front suspension 1. Remove the front tire and rim. Refer to
Disassembly and assembly section Wheels,
General information
spindles and rear axle.
Hydrair® II suspensions are hydro-pneumatic 2. Remove the front wheel hub and spindle. Refer
components containing oil and nitrogen gas. The oil to Disassembly and assembly section Wheels,
and gas in the four suspensions carry the gross truck spindles and rear axle.
weight less wheels, spindles and rear axle assembly. 3. Remove the clamp and boot (1, Figure 50-1) from
The front suspension cylinders consist of two basic the front suspension.
components: a suspension housing attached to the 4. Remove protective cover (2) from the charging
truck frame and a suspension rod attached to the front valve block.
spindle.
Check valves and orifice dampening holes control
suspension travel to provide good ride qualities on 2
haul roads under loaded and empty conditions.
The front suspension rods also act as kingpins for
steering the truck.
The suspension cylinder requires only normal care
when handling as a unit. However, after being
disassembled, these parts must be handled carefully
to prevent damage to the machined surfaces.
Surfaces are machined to extremely close tolerances
and are precisely fitted. All parts must be completely
clean during assembly.
86317
FIGURE 50-1. FRONT SUSPENSION
1. Boot 2. Protective Cover
3
CEN50049-01 50 Disassembly and assembly
Wear a face mask or goggles. Make sure that only
the swivel nut turns. Turning the entire charging
valve assembly may result in the valve assembly
A
being ejected from the suspension by the gas
pressure inside.
5. Discharge the nitrogen pressure from the
suspension as follows:
a. Remove the cap from charging valve (2,
Figure 50-2).
b. Turn charging valve swivel nut (3)
2
counterclockwise three full turns to unseat the
valve seal. Do not turn the swivel nut more
than three turns. Do not turn charging
valve body (4).
c. Connect the nitrogen charging kit to the
charging valve. Refer to "Suspension oiling
and charging procedures" in Testing and
adjusting section Accumulators and
4 suspensions for the charging kit installation
information.
6. Remove pressure sensor (1) from the charging
valve block.
7. Place a suitable container under the suspension
cylinder. Remove recessed drain plug (2, Figure
50-3) and allow the cylinder to drain completely.
A properly charged front suspension cylinder
contains approximately 151.4 L (40 gal) of oil.
3
DETAIL A 83222
FIGURE 50-2. SUSPENSION CHARGING VALVE
1. Pressure Sensor 4. Charging Valve Body
2. Charging Valve (Large Hex)
3. Swivel Nut (Small Hex)
1 2 86318
FIGURE 50-3. FRONT SUSPENSION DRAIN PLUG
1. Piston Plug Retaining 2. Drain Plug
Plate Capscrew
4
50 Disassembly and assembly CEN50049-01
Installation
1. Remove all paint, rust, dirt and foreign debris
from the suspension mounting surfaces. See
Figure 50-4.
Use a lifting device with adequate capacity to
remove and install the components.
8. Use a fork truck or suitable lifting device to the
suspension. Secure the suspension to the fork
truck or lifting device.
10. Remove six upper capscrews (1, Figure 50-5).
11. Remove four lower outer capscrews (4).
12. Remove four lower capscrews (4) with spacers
(7).
13. Move the suspension to a clean work area for dis-
assembly.
14. Discard the suspension mounting capscrews,
washers and nuts.
FIGURE 50-4. REMOVING DEBRIS FROM
MOUNTNG SURFACES
2. Clean and dry the mounting surfaces on both the
High tightening torque is required to load the front
suspension and the frame. Use a cleaning agent
suspension mounting capscrews. Repeated
that does not leave a film after evaporation, such
tightening will result in capscrew fatigue and
as isopropyl alcohol, acetone or lacquer thinner.
damage. DO NOT reuse mounting capscrews,
washers and nuts. Replace the hardware after 3. Inspect the mounting surfaces of the suspension
each use. and frame for damage or wear. Check for the
following criteria:
Suspension mounting capscrews are hardened to Flatness of each surface must be within 0.25
meet or exceed grade 8 specifications. Replace mm (0.010 in.).
only with capscrews of correct hardness. Refer to
the appropriate parts book for the correct part Surface finish must not exceed 6.4 µm (250
µ in.) roughness average (Ra).
numbers.
If measurements are not within specifications,
contact your Komatsu customer service manager
for further instructions.
4. Clean and dry all suspension mounting
hardware. Use the same cleaning agent that was
used to clean the mounting surfaces.
5
CEN50049-01 50 Disassembly and assembly
High tightening torque is required to load the front The use of dry threads in this application is not
suspension mounting capscrews. Repeated recommended. Due to the high tightening forces
tightening will result in capscrew fatigue and required to load these capscrews, dry threads or
damage. DO NOT reuse mounting capscrews, threads lubricated with anti-seize compounds may
washers and nuts. Replace the hardware after result in damage. Only use the approved lubricant
each use. specified below.
Suspension mounting capscrews are hardened to
meet or exceed grade 8 specifications. Replace 5. Lubricate the capscrew threads, capscrew head
only with capscrews of correct hardness. Refer to seats, washer faces and nut seats with a lithium
the appropriate parts book for the correct part based multi-purpose EP NLGI 2 grease (3%
numbers. minimum molybdenum-disulphide).
6. Identify and separate the hardware according to
location on the suspension. Refer to Figure 50-5.
FIGURE 50-5. HARDWARE IDENTIFICATION
1. Capscrew - 1 1/2" - 6NC x 6 1/2" (G8)
2. Hardened Flat Washer - 1 1/2"
3. Nut - 1 1/2" - 6NC (G8)
4. Capscrew - 2" - 4.5NC x 15" (G8)
5. Hardened Flat Washer - 2"
6. Nut - 2" - 4.5NC (G8)
7. Spacer
8. Shear Key
9. Part Of Frame
6
50 Disassembly and assembly CEN50049-01
NOTE: Most hardened flat washers used on the front
suspensions are punched during the manufacturing
process. When assembling the capscrews and
washers, position the punched lip away from the
capscrew head to prevent damage. Refer to Figure 50-
Use a lifting device with adequate capacity to
6.
remove and install the components.
7. Lift the front suspension into position on the
frame.
8. Install the mounting hardware and the shear key.
Install the shear key flush with the side face of
the suspension.
Install one washer under each capscrew head
and one washer under each nut (where
applicable).
FIGURE 50-6. FLAT WASHER ORIENTATION
1. Hardened Flat Washer 2. Capscrew
FIGURE 50-7. SUSPENSION INSTALLATION
7
CEN50049-01 50 Disassembly and assembly
9. Tighten all 14 capscrews to 1 356 ± 136 N·m 10. The mounting capscrews now must be loosened
(1,000 ± 100 ft lb) in the sequence shown in one at time and then tightened one at time by
Figure 50-8. This ensures that the suspension turning the hardware by a specified number of
has been seated properly on the frame. Use a degrees. This is known as angle advance.
properly calibrated torque wrench to ensure
Use the map shown in Figure 50-8 for the proper
accuracy.
tightening sequence. Refer to the angle advance
NOTE: Do not exceed 4 rpm tightening speed. Do not methods on the following pages for the proper
hammer or jerk the wrench while tightening. tightening procedures. After tightening is
complete, continue with step 11 below.
Failure to tighten all capscrews to the proper
torque and in the proper sequence could affect the The capscrews at the upper mounting joint require
integrity of the joint. a different tightening procedure than the
capscrews at the lower mounting joint. It is
important to refer to the correct procedure as each
capscrew is tightened in sequence.
11. Install pressure sensor (1) in the charging valve
block.
12. Charge the front suspension with dry nitrogen to
fully extend the suspension piston before
installing the front wheel hub and spindle. Refer
to Testing and adjusting section Accumulators
and suspensions.
13. Install spindle, wheel and tire. Refer to
Disassembly and assembly section Wheels,
spindles and rear axle.
14. Service the front suspensions. Refer to Testing
and adjusting section Accumulators and
suspensions for the oiling and charging
procedure.
15. Install boot (1, Figure 50-1) and the clamp.
FIGURE 50-8. TIGHTENING SEQUENCE MAP
8
50 Disassembly and assembly CEN50049-01
Upper mounting joint - 60° advance 5. Make new reference lines along the capscrew,
1. Loosen the capscrew. All other capscrews must nut and frame at the rear of the joint as shown in
remain tightened. Figure 50-10. These reference lines will be used
to verify the capscrews have maintained their
2. Tighten the capscrew to 95 N·m (70 ft lb). torque.
NOTE: Do not exceed 4 rpm tightening speed. Do not NOTE: If for any reason these fasteners need to be
hammer or jerk the wrench while tightening. checked for tightness after completing this procedure,
3. Mark a corner of the capscrew head with a paint replace all the hardware and repeat the entire process.
marker as shown in Figure 50-9. Draw a
reference line on the suspension surface next to
the marked corner on the capscrew. Draw a
reference line on the suspension 60 degrees in
advance of the marked corner on the capscrew.
4. Advance the capscrew to the 60° advance mark.
Hold the nut at the rear of the joint stationary
while tightening.
FIGURE 50-10. MAKING REFERENCE LINES
FIGURE 50-9. 60 DEGREE ADVANCE
9
CEN50049-01 50 Disassembly and assembly
Lower mounting joint - 90° advance 5. Make new reference lines along the capscrew,
1. Loosen the capscrew. All other capscrews must nut and frame at the rear of the joint as shown in
remain tightened. Figure 50-10. For the four capscrews with
spacers, refer to Figure 50-12. These reference
2. Tighten the capscrew to 475 N·m (350 ft lb). lines will be used to verify the capscrews have
NOTE: Do not exceed 4 rpm tightening speed. Do not maintained their torque.
hammer or jerk the wrench while tightening. NOTE: If for any reason these fasteners need to be
3. Mark a corner of the capscrew head with a paint checked for tightness after completing this procedure,
marker as shown in Figure 50-11. Draw a replace all the hardware and repeat the entire process.
reference line on the suspension surface (or
frame) next to the marked corner on the
capscrew. Draw a reference line on the
suspension surface (or frame) 90 degrees in
advance of the marked corner on the capscrew.
4. Advance the capscrew to the 90° advance mark.
Hold the nut at the rear of the joint (where
applicable) stationary while tightening.
FIGURE 50-12. MAKING REFERENCE LINES
FIGURE 50-11. 90 DEGREE ADVANCE Inspection
Visual inspections of the bolted joints are necessary
after the truck has been released for operation. Inspect
the joints at each front suspension at the following
intervals: 8 hours, 50 hours, 250 hours, and 500 hours.
• If the reference lines on the hardware (Figure 50-
10 and Figure 50-12) have remained in alignment,
the trucks may remain in operation.
• If at least one of the capscrews has shown signs of
movement, the truck must be taken out of service.
The suspension mounting capscrews must be
removed, cleaned, and inspected. If any
capscrews have signs of damage, replace all
capscrews. Install the capscrews again according
to this installation procedure.
10
50 Disassembly and assembly CEN50049-01
Disassembly and assembly of 2. With the suspension housing and piston held in a
front suspension vertical position (end cap up), remove capscrews
(1, Figure 50-14) and hardened washers (2).
NOTE: For proper seal installation and contamination
prevention, disassembly and assembly work must be 3. Attach a hoist to top cap (3) and lift the top cap,
done in a clean, temperature controlled environment. upper bearing retainer and piston out of the
suspension housing as one unit.
Disassembly
1. Loosen charging valve body (4, Figure 50-13)
and remove the charging valve assembly. 2 1 3
4
86320
FIGURE 50-14. TOP CAP REMOVAL
1. Capscrew 3. Top Cap
2. Hardened Washer
3
DETAIL A 83222
FIGURE 50-13. SUSPENSION CHARGING VALVE
1. Pressure Sensor 4. Charging Valve Body
2. Charging Valve (Large Hex)
3. Swivel Nut (Small Hex)
11
CEN50049-01 50 Disassembly and assembly
4. Support the bottom of piston (4, Figure 50-15). 5. Remove spring pins (1, Figure 50-16), wheel nut
Remove capscrews (1) and hardened washers (2), piston stop (3) and key (4). Separate top cap
(2). Separate upper bearing retainer (3) and the (9) from upper bearing retainer (5).
top cap from piston (4). 6. Remove two O-rings (7) and backup rings (8)
NOTE: The check balls may fall free from four bosses from the top cap. Remove upper bearing (6) from
(5) when the upper bearing retainer and top cap are upper bearing retainer (5).
removed.
2 1 3
7 8
4 3
4
1
1 86322
86321
FIGURE 50-16. BEARING RETAINER / END CAP
FIGURE 50-15. BEARING RETAINER / PISTON SEPARATION
SEPARATION
1. Spring Pin 6. Upper Bearing
1. Capscrew 4. Piston 2. Wheel Nut 7. O-rings
2. Hardened Washer 5. Boss 3. Piston Stop 8. Backup Rings
3. Upper Bearing Retainer 4. Key 9. Top Cap
5. Upper Bearing Retainer
12
50 Disassembly and assembly CEN50049-01
7. Rotate the suspension housing 180 degrees. 10. If necessary, remove capscrew (7, Figure 50-18),
8. Remove capscrews (1, Figure 50-17), hardened flat washer (8) and retaining plate (6) from the
washers (2) and wiper retainer plate (3), if bottom of piston (1). Push piston plug (4) upward
equipped. Install eye bolts and remove lower far enough to remove retaining ring (5).
bearing retainer (7).
9. Remove wiper seal (4), main seal (5), buffer seal
(6), O-rings (9) and backup rings (10) from the
suspension housing.
10. Remove lower bearing (8) from lower bearing DO NOT use compressed air to remove the piston
retainer (7). plug. Damage to components may occur.
11. Re-install capscrew (7) and use a slide hammer
to remove the piston plug from the piston.
1 2 Remove backup ring (2) and O-ring (3) from pis-
ton plug (4).
3
4 1
7 2 3
4
8
5
10 9 6
8 7
86323
FIGURE 50-18. PISTON PLUG REMOVAL
1. Piston 5. Retaining Ring
2. O-Ring 6. Retaining Plate
3. Backup Ring 7. Capscrew
86319
4. Piston Plug 8. Flat Washer
FIGURE 50-17. LOWER BEARING REMOVAL
1. Capscrew 6. Buffer Seal
2. Hardened Washer 7. Lower Bearing
3. Wiper Retainer Plate Retainer
(if equipped) 8. Lower Bearing
4. Wiper Seal 9. O-Ring
5. Main Seal 10. Backup Ring
13
CEN50049-01 50 Disassembly and assembly
Cleaning and inspection
When installing backup rings with the main seal
When using cleaning agents, follow the solvent and the buffer seal, ensure that the radius is
manufacturer's instructions. positioned toward the seal and the white dot is
positioned away from the seal.
1. Clean all parts thoroughly in fresh cleaning
solvent. Use a solvent that does not leave a film 4. Install new buffer seal (6, Figure 50-17), new
after evaporation such as trichloroethane, main seal (5) and new wiper seal (4) in the
acetone or lacquer thinner. suspension housing.
2. Dry all parts completely using only dry, filtered 5. Install new O-rings (9) and backup rings (10) in
compressed air and lint free wiping materials. their appropriate grooves on lower bearing
retainer (7).
3. Inspect all parts for evidence of wear or damage.
Inspect plated surfaces for scratches, nicks or NOTE: The backup rings must be positioned toward
other defects. Replace or repair any damaged the bearing retainer bolt flange with the concave side
parts. toward the O-ring as shown in Figure 50-19.
NOTE: Contact your local Komatsu distributor for 6. Install new lower bearing (8, Figure 50-17) into
repair information and instructions not covered in this lubricated lower bearing retainer (7). Install the
manual. lower bearing retainer into the suspension
housing.
7. If equipped, install wiper retainer plate (3),
Assembly hardened washers (2) and capscrews (1).
Tighten the capscrews to 678 N·m (500 ft lb).
Be careful not to damage the machined or plated
surfaces, O-rings or seals when installing the
piston assembly.
NOTE: Lubricate all interior parts and bores with clean
suspension oil.
1. If piston (1, Figure 50-18) was disassembled,
thoroughly lubricate and install new O-ring (2)
and backup ring (3) on piston plug (4).
2. Use a rubber mallet to seat piston plug (4) in the
bottom of piston (1). Install the piston plug just far
enough to expose the retaining ring groove.
FIGURE 50-19. BACKUP RING REPLACEMENT
Install retaining ring (5).
3. Install retaining plate (6), flat washer (8) and 1. O-ring 3. Lower Bearing
capscrew (7). Tighten the capscrew to 122 N·m 2. Backup Ring Retainer
(90 ft lb).
14
50 Disassembly and assembly CEN50049-01
8. Install new O-rings (7, Figure 50-16) and backup NOTE: If the suspension is to be stored, put in one liter
rings (8) in the grooves of top cap (9). Backup (two pints) of a rust preventive oil. This oil must be
rings must be positioned toward the flange of the drained when the suspension is put into service.
end cap. 17. Install a new O-ring onto charging valve (2,
9. Install new upper bearing (6) on upper bearing Figure 50-13). Install the charging valve onto the
retainer (5). cylinder. Tighten charging valve body (4) to 23
10. Slide upper bearing retainer (5) over the top cap N·m (17 ft lb).
rod. If a new charging valve is being used, tighten
11. Install key (4) and piston stop (3) on the top cap swivel nut (3) to 15 N·m (11 ft lb), then loosen
rod. Ensure that the piston stop is fully seated and retighten the swivel nut to 15 N·m (11 ft lb).
against the rod shoulder. Loosen the swivel nut again, then retighten it to 6
N·m (50 in lb). Install the valve cap finger-tight.
12. Install wheel nut (2) until it is snug against the pis-
ton stop. Tighten the wheel nut by an additional 18. Pressure test the suspension. Refer to the
1/2 turn until the hole for the spring pins is in Testing and adjusting section Accumulators and
alignment. Install spring pins (1). suspensions.
13. Attach a lifting device to top of the top cap. Lower 19. After a successful pressure test, add
the end cap/bearing retainer assembly onto pis- approximately 151.4 liters (40 gallons) of
ton (4, Figure 50-15). suspension oil.
NOTE: Ensure that the check balls are installed in all 20. Apply rust preventative grease to any exposed
four bosses (5) before fully seating the upper bearing machined surfaces.
retainer on top of the piston. A small amount of
petroleum jelly should prevent the balls from dropping
out during assembly.
14. Install new capscrews (1) and hardened washers
(2) that secure piston (4) to upper bearing
retainer (3). Tighten the capscrews to 678 N·m
(500 ft lb).
Always use new capscrews during assembly.
Used capscrews will be stressed and fatigued
because of loads imposed on these capscrews
during operation.
15. Apply a light coating of petroleum jelly to all of the
seals and both bearings. With the suspension
housing in a vertical position, carefully lower the
top cap/upper bearing retainer/piston assembly
into the bore of the suspension housing until the
piston taper passes through the wiper seal and
the top cap is in position on top of the suspension
housing.
16. Install capscrews (1, Figure 50-14) and hardened
washers (2). Tighten the capscrews to 1 017 N·m
(750 ft lb).
15
CEN50049-01 50 Disassembly and assembly
Removal and installation of rear Removal
suspension 1. Remove the clamp and boot (1, Figure 50-20)
from the front suspension.
General information
2. If necessary, remove protective cover (2) to
Hydrair® II suspensions are hydro-pneumatic access the charging valve.
components containing oil and nitrogen gas. The oil
and gas in the four suspensions carry the gross truck
weight less wheels, spindles and rear axle assembly.
The rear suspension cylinders consist of two basic
components: a suspension housing attached to the
frame and a suspension rod attached to the rear axle
housing.
The suspension cylinder requires only normal care
when handling as a unit. However, after being 2
disassembled, these parts must be handled carefully
to prevent damage to the machined surfaces.
Surfaces are machined to extremely close tolerances
and are precisely fitted. All parts must be completely
clean during assembly.
86326
FIGURE 50-20. REAR SUSPENSION
1. Boot 2. Protective Cover
16
50 Disassembly and assembly CEN50049-01
4 3
Wear a face mask or goggles. Make sure that only
the swivel nut turns. Turning the entire charging
valve assembly may result in the valve assembly
being ejected from the suspension by the gas
pressure inside.
3. Discharge the nitrogen pressure from the
suspension as follows:
a. Connect the nitrogen charging kit to the
charging valve. Refer to "Suspension oiling
and charging procedures" in Testing and
adjusting section Accumulators and suspen-
sions for the charging kit installation informa-
tion.
b. If necessary, charge the suspension that is
being removed with dry nitrogen until the rod
is exposed approximately 127 mm (5 in.).
c. Place stands or cribbing under the truck frame
at each hoist cylinder mount.
d. Open the valve on the suspension charging kit
to release nitrogen from the suspension.
1 2
Ensure that the suspension is resting on
stands or cribbing. 86327
e. Disconnect the suspension charging kit.
FIGURE 50-21. SUSPENSION CHARGING VALVE
4. Disconnect the lubrication lines and remove
pressure sensor (1).
1. Pressure Sensor 4. Charging Valve Body
2. Charging Valve (Large Hex)
3. Swivel Nut (Small Hex)
17
CEN50049-01 50 Disassembly and assembly
6. Remove locknut (4, Figure 50-22), flat washer (3)
and shoulder bolt (2) at pin (1). Drive the pin from
the bore.
NOTE: Spacers (5) will fall free.
Use lifting equipment/lifting devices with adequate 7. Repeat step 6 for the upper pin.
capacity to remove and install the components.
8. Remove rear suspension (6) from the truck.
5. Secure the rear suspension to a lift truck or crane Move the suspension to a clean work area for
by using a suitable lifting device. disassembly.
NOTE: Remove the lower pin first. The mounting
arrangement for the top and bottom pins is identical.
7 1 2
5 5
86328
FIGURE 50-22. REAR SUSPENSION PIN REMOVAL & INSTALLATION
1. Pin 5. Spacer
2. Shoulder Bolt 6. Rear Suspension
3. Flat Washer 7. Shoulder Bolt Hole
4. Locknut
18
50 Disassembly and assembly CEN50049-01
Installation 9. Adjust the height of the piston rod until the lower
1. Inspect mounting bores and bearing spacers (5, suspension eye aligns with the lower frame
Figure 50-22) for damage and wear. Check the fit mounting ears. Repeat steps 3-8 to install the
of the pins in the bores before installing the bottom pin.
suspension. Replace worn or damaged parts. NOTE: The mounting arrangement for the top and
NOTE: The suspension assembly must be retracted bottom pins is identical.
as far as possible before installation. 10. Connect the lubrication lines and the pressure
sensor (1).
11. Service the rear suspensions. Refer to Testing
and adjusting section Accumulators and
suspensions for the oiling and charging
Use lifting equipment/lifting devices with adequate procedure.
capacity to remove and install the components. 12. Install boot (1, Figure 50-20) and the clamp.
2. Secure the rear suspension to a lift truck or crane
by using a suitable lifting device.
3. Position the top suspension eye between the
upper frame mounting ears. Orient the cylinder
so that the charging valve is facing the opposite
suspension cylinder.
4. Lubricate all pin bores with anti-seize compound.
Lubricating the pin bores aids in removal and
installation, as well as prevention of rust and
corrosion.
5. Align the shoulder bolt hole in pin (1) with
matching shoulder bolt hole (7) in the outer frame
mounting ear. Drive the pin far enough into the
outer frame mounting ear so that the pin is held in
position.
6. Insert one bearing spacer (5) between the top
suspension eye and the outer frame mounting
ear, then continue to drive in the pin through the
spherical bearing in the top suspension eye.
7. Insert remaining spacer (5) on the other side of
the top suspension eye and continue to drive in
the pin until the shoulder bolt hole in pin (1) is
aligned with matching shoulder bolt hole (7) in
the outer frame mounting ear.
8. Install shoulder bolt (2), flat washer (3) and
locknut (4). Tighten the locknut to 68 N·m (50 ft
lb).
19
CEN50049-01 50 Disassembly and assembly
Disassembly and assembly of rear 5. With the suspension in a vertical position (piston
suspension rod down), remove drain plug (1, Figure 50-24)
and allow the suspension oil to drain. A properly
NOTE: For proper seal installation and contamination charged rear suspension cylinder contains
prevention, disassembly and assembly work must be approximately 64.4 L (17 gal) of oil.
done in a clean, temperature controlled environment.
NOTE: There is another drain plug on the opposite
Disassembly side of the rod eye. Only one should be removed.
1. Place the rear suspension in a fixture with the rod
end down. The fixture should allow the
suspension to be rotated 180 degrees vertically.
2. If installed, remove protective cover (1, Figure
50-23).
To avoid possible injury, wear a face mask or
goggles while relieving nitrogen gas pressure.
3. Use a tool such as a screwdriver to depress the
valve stem of charging valve (2) to ensure that all 1
nitrogen gas pressure has been released.
4. After all nitrogen pressure has been relieved,
loosen the charging valve body (large hex) and
remove the charging valve assembly.
86335
1
FIGURE 50-24. REAR SUSPENSION DRAIN PLUG
1. Drain Plug
86330
FIGURE 50-23. SUSPENSION CHARGING VALVE
1. Protective Cover 2. Charging Valve
20
50 Disassembly and assembly CEN50049-01
8. Remove and wiper seal (1, Figure 50-26), main
seal (2), buffer seal (3) and rod bearing (4) from
the inside of bearing retainer (5).
9. Remove O-ring (7) and backup ring (6) from the
Use a lifting device with adequate capacity to outside of bearing retainer (5). Discard the O-ring
remove and install the components. and backup ring.
6. Rotate the cylinder 180 degrees. Remove
capscrews (1, Figure 50-25) and flat washers (2).
Lift piston (3) and bearing retainer (4) from 1
housing (6).
7. Remove bearing retainer (4) and piston bearing
(5) from piston (3). 2
3
2 1 3
5 6
7
86337
FIGURE 50-26. BEARING RETAINER SEALS
6
1. Wiper Seal 5. Bearing Retainer
2. Main Seal 6. Backup Ring
3. Buffer Seal 7. O-ring
4. Rod Bearing
86336
FIGURE 50-25. PISTON ROD REMOVAL
1. Capscrew 4. Bearing Retainer
2. Flat Washer 5. Piston Bearing
3. Piston Rod 6. Housing
21
CEN50049-01 50 Disassembly and assembly
10. If spherical bearings (2, Figure 50-27) require Cleaning and inspection
replacement, remove retaining rings (1) and
press the bearing from the bore.
NOTE: Do not use metal tools to strike the spherical
bearings.
When using cleaning agents, follow the solvent
manufacturer's instructions.
1
1. Clean all parts thoroughly in fresh cleaning
solvent. Use a solvent that does not leave a film
after evaporation such as trichloroethane,
2 acetone or lacquer thinner.
2. Dry all parts completely using only dry, filtered
compressed air and lint free wiping materials.
3. Inspect all parts for evidence of wear or damage.
Inspect plated surfaces for scratches, nicks or
other defects. Replace or repair any damaged
parts.
1 NOTE: Contact your local Komatsu distributor for
repair information and instructions not covered in this
manual.
86338
FIGURE 50-27. SPHERICAL BEARING REMOVAL
1. Retaining Ring 2. Spherical Bearing
22
50 Disassembly and assembly CEN50049-01
Assembly
NOTE: Lubricate all interior parts and bores with clean
suspension oil.
1. If removed, install spherical bearings (2, Figure
Use a lifting device with adequate capacity to
50-27). Install retaining rings (1) to secure the
remove and install the components.
bearings.
NOTE: Before installation, spherical bearings must be
shrunk by freezing. The temperature must not be
below -54°C (-65°F). A press may be necessary for
installation. Do not use metal tools to strike the
spherical bearings. Be careful during piston installation to prevent
2. Install bearing (4, Figure 50-26), buffer seal (3), damage to machined and chrome surfaces.
main seal (2) and wiper seal (1) on the inside of
bearing retainer (5). 4. Slide piston bearing (5, Figure 50-25) onto
3. Install new O-ring (7) and backup ring (6) on the lubricated piston (3).
outside of bearing retainer (5). 5. With housing (6) held in a vertical position, lower
the piston assembly partially into the housing.
NOTE: Refer Figure 50-28 for the proper orientation of Slide bearing retainer (4) over the piston and into
the seals. the housing. Install flat washers (2) and
capscrews (1). Tighten the capscrews to 420 ± 42
N·m (310 ± 31 ft lb).
NOTE: If the suspension is to be stored, fill with one
liter (two pints) of a rust preventive oil. This oil must be
1 drained when the suspension is put back into service.
6. Install a new O-ring onto charging valve (2,
Figure 50-23). Install the charging valve into the
cylinder. Tighten the charging valve body (large
2 hex) to 23 N·m (17 ft lb).
If a new charging valve is being used, tighten the
swivel nut (small hex) to 15 N·m (11 ft lb), then
loosen and retighten the swivel nut to 15 N·m (11
ft lb). Loosen the swivel nut again, then retighten
it to 6 N·m (50 in lb). Install the valve cap finger-
3 tight.
7. Install protective cover (1).
8. Pressure test the rear suspension. Refer to the
Testing and adjusting section Accumulators and
4 suspensions.
5
86339
FIGURE 50-28. SEAL ORIENTATION
1. Wiper Seal 4. Backup Ring
2. Main Seal 5. O-ring
3. Buffer Seal
23
CEN50049-01 50 Disassembly and assembly
980E Dump truck
Form No. CEN50049-01
24
CEN50110-00
DUMP TRUCK 1SHOP MANUAL
980E
Machine model Serial number
980E-5 A50137, A50138
50 Disassembly and assembly
Hoist circuit
Removal and installation of hoist pump ................................................................................................................ 3
Disassembly and assembly of hoist pump............................................................................................................ 8
Removal and installation of hoist valve ............................................................................................................... 17
Disassembly and assembly of hoist valve .......................................................................................................... 19
Overcenter manifold service ............................................................................................................................... 27
Removal and installation of hoist pilot valve ....................................................................................................... 28
Disassembly and assembly of hoist pilot valve................................................................................................... 31
Removal and installation of hoist cylinders ......................................................................................................... 33
Disassembly and assembly of hoist cylinders..................................................................................................... 36
1
CEN50110-00 50 Disassembly and assembly
NOTES
2
50 Disassembly and assembly CEN50110-00
Removal and installation of hoist pump
Removal
2
NOTE: The hoist pump can be removed without
disconnecting the steering/brake pump hydraulic
hoses from the truck if desired.
Hydraulic oil escaping under pressure can have
sufficient force to enter a person's body by
penetrating the skin and cause serious injury, and 1
87927
possibly death, if proper medical treatment is not
received immediately. FIGURE 50-1. REAR AXLE BLOWER HOSE
Relieve pressure before disconnecting any 1. Rear Axle Blower Hose
hydraulic lines. Tighten all connections securely 2. Hoist Pump
before applying pressure.
1. Refer to the "Hydraulic system bleeddown
procedure" in Testing and adjusting section
Steering, hoist, brake cooling and auxiliary
hydraulic system.
2. Remove rear axle blower hose (1, Figure 50-1)
and the support bracket to allow hoist pump (2) to
be lowered from the pump mount bracket.
NOTE: Use vacuum pump kit (XB0887) to hold the oil
back in the hydraulic tank. Before disconnecting
hydraulic hoses, tag the hoses for proper identification
during installation.
3. Clean the hoist pump and surrounding area
carefully to help avoid contamination of hydraulic
oil when the hoses are disconnected are opened.
3
CEN50110-00 50 Disassembly and assembly
4. Loosen the capscrews that secure the outlet hoses
(1, Figure 50-2) and (2) and inlet hoses (3) and
(4) to the hoist pump. Allow the oil to drain from
each hose into a suitable container.
Always maintain complete cleanliness when 5. Remove the outlet hoses and inlet hoses. Cap or
opening any hydraulic connection. Ensure that all cover all hoses and pump ports to prevent
system lines and components are capped while contamination.
the component is removed from the truck.
3 2
86431
FIGURE 50-2. HOIST PUMP HOSE REMOVAL & INSTALLATION
1. Outlet Hose to Filter 3. Inlet Hose from Tank
2. Outlet Hose to Filter 4. Inlet Hose from Tank
4
50 Disassembly and assembly CEN50110-00
7. Open the driveshaft guard. Remove flange
mounting hardware (3) that secures the hoist
pump companion flange to the driveshaft. There
are a total of eight capscrews.
Use a lifting device with adequate capacity to 8. Remove hoist pump mounting hardware (2) that
remove and install the component. secures the hoist pump to the mounting structure.
There are a total of four capscrews.
6. Attach a suitable lifting device to hoist pump (1,
Figure 50-3). Attach a support to the front end of
the steering/brake pump to hold it in place during
removal of the hoist pump.
2 1
3
86432
FIGURE 50-3. HOIST PUMP REMOVAL & INSTALLATION
1. Hoist Pump 3. Flange Mounting Hardware
2. Hoist Pump Mounting Hardware
5
CEN50110-00 50 Disassembly and assembly
9. Ensure that the lifting and support devices are in 11. Remove two capscrews (3). Slide the hoist pump
place on both pumps. Loosen (but do not forward to disengage the splines of the coupling
remove) two capscrews (3, Figure 50-4) that from steering/brake pump shaft (5).
secure steering/brake pump (2) to hoist pump (1).
12. Move the hoist pump to a clean work area for
10. Remove two nuts, lockwashers and flat washers disassembly.
(4), then slide the threaded stud out of the
support bracket. Lower the pumps, allowing hoist
pump (1) to come down farther than steering/
brake pump (2).
2
1
FIGURE 50-4. HOIST PUMP REMOVAL & INSTALLATION
1. Hoist Pump 4. Nut, Lockwasher and Flat Washer
2. Steering/Brake Pump 5. Pump Shaft
3. Capscrew
6
50 Disassembly and assembly CEN50110-00
Installation 4. Slide the threaded studs through the pump
mounting holes and support bracket, then install
NOTE: The following procedure assumes that the
two nuts, lockwashers and flat washers (4).
steering/brake pump hydraulic hoses are already
Tighten the nuts to the standard torque.
connected.
5. Install hoist pump mounting hardware (2, Figure
1. Install new O-ring (2, Figure 50-5) and shaft 50-3) that secures the hoist pump to the
coupling (1) on the hoist pump. mounting structure. Tighten the four capscrews to
the standard torque.
6. Install flange mounting hardware (3) that secures
the hoist pump companion flange to the
2 driveshaft. Tighten the eight capscrews to the
1
standard torque. Close the driveshaft guard.
7. Uncap the inlet hoses (1,2, Figure 50-2), the
outlet hoses (3,4) and the pump ports. Attach the
hoses to the pump with new O-rings. Tighten the
86434
capscrews securely.
FIGURE 50-5. HOIST PUMP SHAFT COUPLING 8. Fill the hydraulic tank with clean hydraulic oil.
1. Shaft Coupling 2. O-ring
If trapped air is not bled from the pump, possible
pump damage and no output may result.
Use a lifting device with adequate capacity to 9. To bleed trapped air from the pump, loosen the
remove and install the component. capscrews on inlet hoses (3, Figure 50-2) and (4)
at the pump, then loosen the capscrews on outlet
2. Attach a suitable lifting device to the hoist pump. hoses (1) and (2) at the pump. Tighten all
Move the pump into position for installation. capscrews securely.
3. Lubricate the splines of steering/brake pump 10. Install rear axle blower hose (1, Figure 50-1) and
shaft (5, Figure 50-4) and align it with the shaft the support bracket.
coupling on hoist pump (1, Figure 50-5). Install
the hoist pump onto steering/brake pump (2,
Figure 50-4) using capscrews (3) with hardened
washers. Tighten the capscrews to the standard
torque. Raise the pumps into position.
7
CEN50110-00 50 Disassembly and assembly
Disassembly and assembly of hoist pump 3. Place hoist pump (1, Figure 50-7) on wood
blocks (2) so that the shaft of input drive gear (3)
Disassembly is facing downward. Draw a match mark across
NOTE: As parts are removed, they should be laid out each section of the hoist pump to aid in
in a group in the same order in which they are reassembly.
removed.
1. Thoroughly clean the exterior of the pump
assembly. If the steering/brake pump is attached,
remove the steering/brake pump from the hoist
pump.
2. Remove coupling (1, Figure 50-6) from transition
plate (2). Remove and discard the internal snap
ring if installed.
1
2
86505
FIGURE 50-6. HOIST PUMP DISASSEMBLY & 3
ASSEMBLY 86506
1. Coupling 2. Transition Plate FIGURE 50-7. HOIST PUMP DISASSEMBLY &
ASSEMBLY
1. Hoist Pump 3. Input Drive Gear
2. Wood Blocks
8
50 Disassembly and assembly CEN50110-00
4. Remove four nuts (1, Figure 50-8) and flat 6. Remove eight nuts (1, Figure 50-9) and flat
washers (2). Remove transition plate (3) and washers (2). Remove connector plate (3) and the
bearing plate (4) as a unit. Remove the O-ring O-ring. If the connector plate is stuck, tap it lightly
from the bearing plate. with a plastic hammer to loosen it.
5. Remove the capscrews that secure bearing plate 7. Remove studs (4), the dowels and shaft bearings
(4) to transition plate (3). Separate the plates and from connector plate (3) if necessary.
remove the O-ring. Remove the dowels if
necessary.
4 3
2 1
3
2 1
2 1
4
86509
86508
FIGURE 50-9. HOIST PUMP DISASSEMBLY &
ASSEMBLY
FIGURE 50-8. HOIST PUMP DISASSEMBLY &
ASSEMBLY 1. Nut 3. Connector Plate
2. Flat Washer 4. Stud
1. Nut 3. Transition Plate
2. Flat Washer 4. Bearing Plate
9
CEN50110-00 50 Disassembly and assembly
8. Remove O-ring (1, Figure 50-10) and backup ring 11. Remove bearing plate (1, Figure 50-11) and the
(2). Remove dowels (5) from gear plate (4) if O-ring. Remove eight stud O-rings (2). Remove
necessary. dowels (4) if necessary.
9. Grasp idler gear (6) and rear drive gear (7) and 12. Remove coupling (6). Remove retainer ring (5) if
pull straight up and out of the bore of gear plate replacement is necessary.
(4). Remove pressure plate (3) from the gears.
NOTE: Disassembly of the rear pump section is now
10. Remove gear plate (4). Remove remaining complete. Do not remove studs (3) at this time as the
pressure plate (3), backup ring (2) and O-ring (1). studs serve as guides for assembly.
3 4
A 6 7 A
2
5 5
1
4
6
1 2 3
3 2
86507
FIGURE 50-11. HOIST PUMP DISASSEMBLY &
ASSEMBLY
1
1. Bearing Plate 4. Dowel
VIEW A - A 2. Stud O-ring 5. Retainer Ring
86510
FIGURE 50-10. HOIST PUMP DISASSEMBLY & 3. Stud 6. Coupling
ASSEMBLY
1. O-ring 5. Dowel
2. Backup Ring 6. Idler Gear
3. Pressure Plate 7. Rear Drive Gear
4. Gear Plate
10
50 Disassembly and assembly CEN50110-00
13. Remove connector plate (1, Figure 50-12) and 17. Remove gear plate (4). Remove remaining
both O-rings. If the connector plate is stuck, tap it pressure plate (3), backup ring (2) and O-ring (1).
lightly with a plastic hammer to loosen it.
14. Remove 16 stud O-rings (2). Remove dowels (3)
if necessary.
A 6 7 A
3
5
2
4
1
1 2 3
3 2
86513
FIGURE 50-12. HOIST PUMP DISASSEMBLY &
ASSEMBLY
1. Connector Plate 3. Dowel
2. Stud O-ring
1
VIEW A - A 86515
FIGURE 50-13. HOIST PUMP DISASSEMBLY &
15. Remove O-ring (1, Figure 50-13) and backup ring ASSEMBLY
(2). Remove dowels (5) from gear plate (4) if
necessary. 1. O-ring 5. Dowel
2. Backup Ring 6. Idler Gear
16. Grasp idler gear (6) and drive gear (7) and pull 3. Pressure Plate 7. Input Drive Gear
straight up and out of the bore of gear plate (4). 4. Gear Plate
Remove pressure plate (3) from the gears.
11
CEN50110-00 50 Disassembly and assembly
18. Unscrew and remove eight studs (1, Figure 50- 21. After the shaft seals and retainer ring have been
14) from flange (2). Remove dowels (3) if removed, clean the bore thoroughly. If necessary,
necessary. the bore may be smoothed with number 400
19. Remove inboard shaft seal (4) and snap ring (5) emery paper only.
from the flange bore.
20. Use a hammer and punch to tap outboard shaft
seal (6) out of the flange bore (see Figure 50-15).
Be careful not to mar, scratch or damage the seal
bore surface or bearings.
5 7
6 86516
FIGURE 50-14. HOIST PUMP DISASSEMBLY &
ASSEMBLY
1. Stud 4. Inboard Shaft Seal
2. Flange 5. Snap Ring
3. Dowel 6. Outboard Shaft Seal
7. Weep hole FIGURE 50-15. SHAFT SEAL REMOVAL
1. Flange 3. Bearings
2. Punch
12
50 Disassembly and assembly CEN50110-00
Inspection 5. Inspect the bearings. If they are worn beyond the
1. Inspect the gear bores in both gear plates (2, gray TeflonTM into the bronze material, the entire
Figure 50-16). During the initial break-in, the flange, connector plate or bearing plate must be
gears cut into the aluminum gear plates. The replaced.
nominal depth of this cut is 0.203 mm (0.008 in.)
and should not exceed 0.381 mm (0.015 in.).
As the gear teeth cut into the gear plates, metal is
rolled against the pressure plates. Use a knife or
sharp pointed scraper to remove the metal that
was rolled against the pressure plates. Remove
all metal chips that were broken loose.
When removing the rolled up metal, do not attempt
to remove gear track-in grooves (1).
2. Inspect the pressure plates. They should not FIGURE 50-16. GEAR BORE INSPECTION
show excessive wear on the bronzed side. If 1. Gear Track-In Groove 2. Gear Plate
deep, curved wear marks are visible, replace the
pressure plates.
3. Inspect the gears. If excessive wear is visible on
NOTE: Installing a new bearing in the flange,
the journals, sides, or face of the gears, or at the
connector plates or bearing plate is not recommended
point where the drive gear rotates in the lip seal,
due to close tolerances and special tooling required for
replace the gears.
crimping the bearing in place to prevent bearing spin.
4. If any of the internal parts show excessive wear,
6. Inspect the flange seal bore for scratches and
replace them. Replace all O-rings and seals.
gouges which may interfere with shaft seal
installation.
13
CEN50110-00 50 Disassembly and assembly
Assembly 3. Lubricate the shaft seals with clean type C-4
hydraulic oil. Position inboard shaft seal (4,
NOTE: A suitable seal press ring or plug and two small
Figure 50-14) so that the metal face is toward the
wood blocks should be available.
outboard end of flange (2).
The following seal installation procedure is outlined for 4. Position the press ring over the inboard shaft
use with a vise, but it can be adapted for use with a seal. Ensure that the seal stays centered and
press if one is available. true with the bore, then start applying pressure
1. Open the vise jaws wide enough to accept the with the vise. Continue pressing the seal until it
combined thickness of the flange, wood blocks just clears the retainer ring groove in the bore.
and press ring. 5. Install snap ring (5) so that the retainer ring
2. Place wood blocks (2, Figure 50-17) flat against opening is over the weep hole (7).
the fixed jaw of the vise. Place flange (1) against 6. Install outboard shaft seal (6) so that the metal
the wood blocks so that bearing projections (3) face is toward the outboard end of flange (2) until
are between the wood blocks and clear of the it just contacts snap ring (5).
vise jaw. 7. Remove flange (2) from the vise (or press). Place
the flange on wood blocks so that, when
installed, the input driveshaft is facing downward.
See Figure 50-7.
8. Lubricate the threads of four short studs (1,
Figure 50-18) and four long studs (2) with clean
type C-4 hydraulic oil. Thread the studs into
flange (2, Figure 50-14) until they bottom out.
Refer to Figure 50-18 for proper stud location.
2
SUCTION
1 1
FIGURE 50-17. SHAFT SEAL INSTALLATION
1. Flange 3. Bearing Projection
2. Wood Blocks DISCHARGE
2
86517
FIGURE 50-18. STUD INSTALLATION
1. Short Studs 2. Long Studs
14
50 Disassembly and assembly CEN50110-00
NOTE: Align the match marks when assembling the 17. Lubricate and install both O-rings and 16 stud O-
pump plates. rings (2, Figure 50-12) in connector plate (1).
9. Lubricate and install the O-ring in flange (2 Figure Lubricate the bearings in the connector plate.
50-14). If removed, install dowels (3). 18. If removed, install dowels (3). Install connector
10. Install gear plate (4, Figure 50-13). Ensure that plate (1).
the recess in the gear plate is facing upward. 19. Install retainer ring (5, Figure 50-11) and coupling
11. Install backup ring (2) and O-ring (1) into the gear (6).
bores. Ensure that the O-ring and backup ring 20. Lubricate and install the O-ring and eight stud O-
are oriented toward the discharge side of the rings (2) in bearing plate (1). If removed, install
gear plate. Refer to Figure 50-18. dowels (4). Install bearing plate (1).
12. Slide pressure plate (3, Figure 50-13) down into 21. If removed, install dowels (5, Figure 50-10).
the gear bores until the backup ring and O-ring Install gear plate (4). Ensure that the recess in
are seated in the groove. Do not force the the gear plate is facing downward.
pressure plate down into the gear bores. If it
gets stuck, work the pressure plate back and 22. Install backup ring (2) and O-ring (1) into the gear
forth until it slides freely into place. bores. Ensure that the O-ring and backup ring
are oriented toward the discharge side of the
13. Lubricate the bearings in the gear plate, idler gear plate. Refer to Figure 50-18.
gear (6) and drive gear (7) with clean type C-4
hydraulic oil. 23. Slide pressure plate (3, Figure 50-10) down into
the gear bores until the backup ring and O-ring
NOTE: To ensure that the hoist pump is correctly timed are seated in the groove. Do not force the
during reassembly, place a mark on the end of the pressure plate down into the gear bores. If it
input shaft to indicate the location of the valley gets stuck, work the pressure plate back and
between any two gear teeth. Refer to Figure 50-19 forth until it slides freely into place.
which illustrates gear timing.
24. Lubricate the bearings in the gear plate, idler
gear (6) and drive gear (7) with clean type C-4
hydraulic oil.
25. Install idler gear (6) and rear drive gear (7). The
rear drive gear must be timed with the input drive
Do not drop the drive gear in the bore. Damage to gear by lining up a tooth on the rear drive gear
the bronze face of the pressure plate could result. with the valley of two teeth on the input drive gear
as shown in Figure 50-19.
14. Carefully insert the shaft of input drive gear (7,
Figure 50-13) through the shaft seals in the
flange until the drive gear is resting on pressure
plate (3).
15. Install idler gear (6).
16. Install the other pressure plate (3), backup ring
(2) and O-ring (1) into the gears. Ensure that the
O-ring and backup ring are facing upward and
oriented toward the discharge side of the gear
plate. Refer to Figure 50-18.
FIGURE 50-19. PUMP GEAR TIMING
15
CEN50110-00 50 Disassembly and assembly
26. Install the other pressure plate (3, Figure 50-10), 32. Lubricate the threads of the two of eight studs
backup ring (2) and O-ring (1) into the gears. that are 180 degrees apart. Install two flat
Ensure that the O-ring and backup ring are facing washers (2, Figure 50-9) and nuts (1). Tighten
upward and oriented toward the discharge side of the nuts to 325 - 339 N·m (240 - 250 ft lb).
the gear plate. Refer to Figure 50-18.
33. Turn over the pump so that the shaft of the input
27. Lubricate and install the O-ring in connector plate drive gear is facing upward. Use a 45 cm (18 in.)
(3, Figure 50-9). Lubricate the bearings in the adjustable wrench to check the pump driveshaft
connector plate, then install connector plate (3). If rotation (See Figure 50-20). The driveshaft will be
removed, install dowels (4). tight but should turn freely with a maximum
28. Lubricate and install the O-ring in transition plate torque of 7 - 14 N·m (5 - 10 ft lb) after the initial
(3, Figure 50-8). Use the capscrews to assemble surge.
bearing plate (4) onto the transition plate. Tighten 34. If the driveshaft will not turn properly,
the capscrews to the standard torque. disassemble the pump and inspect the parts for
29. Lubricate and install the O-ring in the bottom of burrs or foreign material that may be causing
bearing plate (4). Install assembled the bearing buildup or interference between parts.
plate/transition plate assembly onto the 35. When the driveshaft turns properly, install the
connector plate. remaining six flat washers (2, Figure 50-9) and
30. Install flat washers (2) and nuts (1). Tighten the nuts (1). Tighten the nuts to 325 - 339 N·m (240 -
nuts to the standard torque. 250 ft lb).
31. Install coupling (1, Figure 50-6).
A snap ring may have been installed previously
inside the coupling. This snap ring is not
necessary and must not be used. In some cases,
depending on tolerance stack-up, the snap ring
can cause excessive axial loading, leading to
premature pump failure.
FIGURE 50-20. CHECKING PUMP DRIVE
ROTATION
1. Wrench 3. Pump
2. Driveshaft
16
50 Disassembly and assembly CEN50110-00
Removal and installation of hoist valve 1. Refer to the "Hydraulic system bleeddown
procedure" in Testing and adjusting section
Removal Steering, hoist, brake cooling and auxiliary
hydraulic system.
2. Thoroughly clean the exterior of hoist valve (1,
Figure 50-21).
3. Disconnect six hydraulic tubes (2) and three
Hydraulic oil escaping under pressure can have hydraulic hoses (3) at the hoist valve. Disconnect
sufficient force to enter a person's body by three hydraulic hoses from pilot hose fittings (4).
penetrating the skin and cause serious injury, and 4. Plug the hydraulic lines and valve ports to help
possibly death, if proper medical treatment is not prevent contamination. Mark each hydraulic line
received immediately. to aid in correct installation.
Relieve pressure before disconnecting any
hydraulic lines. Tighten all connections securely
before applying pressure.
2 4 2
1 2 2
3
2
2 4
3
4
86435
FIGURE 50-21. HOIST VALVE & PIPING
1. Hoist Valve 3. Hose
2. Tube 4. Pilot Hose Fitting
17
CEN50110-00 50 Disassembly and assembly
10. Remove three nuts (1, Figure 50-22),
lockwashers (2), flat washers (3) and capscrews
(4) that secure hoist valve (5) to the mount.
11. Attach a lifting device to the hoist valve and
Use a lifting device with adequate capacity to remove it from the truck. Move the hoist valve to
remove and install the component. a clean work area for disassembly.
1 2
3 4
86436
FIGURE 50-22. HOIST VALVE REMOVAL & INSTALLATION
1. Nut 4. Capscrew
2. Lockwasher 5. Hoist Valve
3. Flat Washer
18
50 Disassembly and assembly CEN50110-00
Installation Disassembly and assembly of hoist valve
O-ring replacement
NOTE: It is not necessary to remove the individual
valve sections to accomplish repairs unless the O-
rings between the valve sections must be replaced to
Use a lifting device with adequate capacity to prevent leakage. Loosening and re-tightening the main
remove and install the component. valve tie rod nut could cause distortion, resulting in
1. Attach a suitable lifting device to hoist valve (5, binding or severely sticking plungers, poppet and
Figure 50-22). Move the hoist valve into position spools.
on top of the mount.
To replace the O-rings between the valve sections:
2. Secure the hoist valve with three nuts (1),
lockwashers (2), flat washers (3) and capscrews 1. Remove four nuts and washers (5, Figure 50-23)
(4). Tighten the nuts to the standard torque. from the tie rods on one end of the hoist valve.
Slide tie rods (6) from the valve and separate the
3. Unplug the hydraulic lines and valve ports. Install
valve sections.
new O-rings at the flange fittings, then connect
six hydraulic tubes (2, Figure 50-21) and three
hydraulic hoses (3) to the hoist valve. Tighten the
flange capscrews to the standard torque.
4. Connect three hydraulic hoses to pilot hose
fittings (4).
5. Check the hydraulic tank oil level and add oil, if
needed.
6. Start the engine. Raise the body and remove the
body-up retention cable. Lower and raise the
body to check for proper operation and leaks.
FIGURE 50-23. HOIST VALVE ASSEMBLY
1. Inlet Section (Rear) 4. Inlet Section (Front)
2. Spool Section (Work 5. Nuts and Washers
Ports) 6. Tie Rods
3. Spool Section 7. Tube
(Tank Ports) 8. Separator Plate
19
CEN50110-00 50 Disassembly and assembly
2. Inspect the machined sealing surfaces for 5. Use a torque wrench to tighten the nuts in the
scratches and nicks. If scratches or nicks are pattern shown in Figure 50-25. Tighten the tie rod
found, remove them by lapping on a smooth flat nuts evenly in the following sequence:
steel surface with fine lapping compound.
a. First, tighten the nuts to 20 N·m (15 ft lb) in
3. Lubricate the new O-rings lightly with order 1, 4, 2, 3.
multipurpose grease and install them between
b. Next, tighten the nuts to 43 N·m (32 ft lb) in
the valve sections. Stack the valve sections
order 1, 4, 2, 3.
together, making sure that the O-rings between
the sections are properly positioned. c. Finally, tighten the nuts to 142 N·m (105 ft lb)
4. Install the four tie rods with the dished washer in order 1, 4, 2, 3.
between the nut and housing (See Figure 50-24).
FIGURE 50-24. TIE ROD INSTALLATON
FIGURE 50-25. TIGHTENING SEQUENCE
20
50 Disassembly and assembly CEN50110-00
Disassembly of inlet section 2. Remove capscrews (1, Figure 50-26) and inlet
cover (2). Remove springs (3) and (5) and flow
NOTE: Match mark or identify each part when
control/main relief valve (4). Remove sleeve (6),
removed in respect to its location or mating bore to aid
low pressure relief valve (7) and O-rings (8).
in reassembly.
3. Remove capscrews (14) and cover (13). Remove
NOTE: The inlet section is shown removed from the springs (12), check valves (11) and O-rings (10).
main valve body for clarity.
1. Disconnect tube (7, Figure 50-23) from inlet
cover (2, Figure 50-26).
FIGURE 50-26. INLET SECTION DISASSEMBLY
1. Capscrew 6. Sleeve 10. O-Rings
2. Inlet Cover 7. Secondary Low Pressure 11. Check Valves
3. Spring (Orange) Relief Valve 12. Springs
4. Flow Control/Main Relief Valve 8. O-Rings 13. Cover
5. Spring 9. Inlet Valve Body 14. Capscrews
21
CEN50110-00 50 Disassembly and assembly
NOTE: If removal of the restrictor poppet in inlet cover Assembly of inlet section
(2) is required, proceed to the next step.
1. Discard all O-rings and backup rings. Clean all
4. Remove sleeve (9, Figure 50-27), backup ring parts in solvent and dry with compressed air.
(8), O-ring (7) and backup ring (6). Remove
2. Inspect all springs for breaks and distortion.
backup ring (5), O-ring (4), backup ring (3) and
Inspect poppet seating surfaces for nicks or
restrictor poppet (2).
excessive wear. All seats must be sharp and free
5. Repeat the procedure for the opposite inlet of nicks.
section if disassembly is required.
3. Inspect all bores and surfaces of sliding parts for
nicks, scores and excessive wear.
4. Inspect the poppets in their respective bore for
proper fit. Poppets should move freely through a
complete revolution without binding.
5. Inspect the fit and movement between the sleeve
and low pressure relief valve.
6. Coat all parts, including the housing bores, with
clean type C-4 hydraulic oil. Lightly lubricate new
O-rings with a multipurpose grease.
7. If restrictor poppet (2, Figure 50-27) was
removed, reassemble it in the order shown.
8. Install check valves (11, Figure 50-26) in their
respective bores. Install springs (12).
9. Install O-rings (10) and cover (13). Install and
tighten capscrews (14) to 81 N·m (60 ft lb).
10. Install low pressure relief valve (7) in sleeve (6),
then install the assembly in housing (9). Install
flow control/main relief valve (4), springs (3) and
(5), and inlet cover (2). Install and tighten
capscrews (1) to 81 N·m (60 ft lb).
11. Connect tube (7, Figure 50-23) and tighten the
nuts to 34 N·m (25 ft lb).
FIGURE 50-27. RESTRICTOR POPPET REMOVAL
(Inlet Cover)
1. Inlet Cover 6. Backup Ring
2. Restrictor Poppet 7. O-ring
3. Backup Ring 8. Backup Ring
4. O-Ring 9. Sleeve
5. Backup Ring
22
50 Disassembly and assembly CEN50110-00
Disassembly of rear spool section 5. Remove spool assembly (20, Figure 50-29). Note
the color of the lower spring (blue)(16) to ensure
NOTE: It is not necessary to remove inlet sections (1,
proper location during reassembly. Also note the
Figure 50-23) or (4) to disassemble spool sections (2)
“V” groove on the top end of the spool.
or (3).
6. Remove plug (3) from the end of the spool.
NOTE: Match mark or identify each part when Remove spring seat (2) and spring (11). Remove
removed in respect to its location or respect to its poppet (21) and spool end (15).
mating bore to aid reassembly.
NOTE: Pay special attention to poppets (12), (21) and
1. Remove the capscrews and lift spool cover (1, (22) during removal to ensure proper location during
Figure 50-29) from the housing. reassembly. Poppets may be identified with a colored
2. Remove poppet (6) from the spool cover. dot (red, green or white). If the poppets are not color
Remove and discard O-ring (8). coded, use the table below and the specified drill bit to
NOTE: The poppet contains a small steel ball (7). Do measure the orifice diameter for proper identification.
not misplace it.
3. Remove and discard O-rings (4) and (5). POPPET ORIFICE DRILL
4. Remove restrictor poppet (1, Figure 50-28). COLOR DIAMETER SIZE
Remove and discard O-ring (2) and backup ring Red 3.556 mm (.140 in.) #28
(3), if used. Note the position of the restrictor
Green 2.362 mm (.093 in.) #42
poppet when removed to ensure correct
reassembly. White 1.600 mm (.063 in.) #52
7. Repeat step 6 to disassemble the opposite end of
spool assembly (20). Note that there is no plug or
restrictor poppet in the opposite end and the
spring is blue (16).
8. Remove spool assembly (14). At the top end of
the spool, remove plug (3). Remove spring seat
(2) and spring (11). Remove restrictor poppet
(12) and spool end (15).
9. At the opposite end, remove plug (3), spring seat
(2) and spring (16). Remove restrictor poppet
(22) and spool end (15).
10. Remove spool cover (19) and O-rings (4), (5) and
(10). Remove poppet (18).
FIGURE 50-28. RESTRICTOR POPPET
1. Restrictor Poppet 4. O-Ring
2. O-Ring * 5. O-Ring
3. Backup Ring *
* Items 2 and 3 not used on all valves.
23
CEN50110-00 50 Disassembly and assembly
FIGURE 50-29. REAR SPOOL SECTION ASSEMBLY
1. Spool Cover 8. O-Ring 14. Spool Assembly 21. Restrictor Poppet
2. Spring Seat 9. Restrictor Poppet 15. Spool End (Green)
3. Plug 10. O-Ring 16. Spring (Blue) 22. Restrictor Poppet
4. O-Ring 11. Spring 17. O-Ring (White)
5. O-Ring 12. Restrictor Poppet 18. Poppet
6. Poppet (Red) 19. Spool Cover
7. Steel Ball 13. Spool Housing 20. Spool Assembly
24
50 Disassembly and assembly CEN50110-00
Assembly of rear spool section 11. Lubricate the assembled spool and install it in the
1. Discard all O-rings and backup rings. Clean all spool housing (See Figure 50-30). Make sure
parts in solvent and blow dry with compressed that “V” groove (1) in spool assembly (2) is
air. positioned up as noted.
2. Inspect all springs for breaks and distortion. NOTE: Spool assemblies (14, Figure 50-29) and (20)
Inspect the poppet seating surfaces for nicks and are physically interchangeable. Ensure that spool
excessive wear. All seats must be sharp and free assembly (14) is installed toward the base port of the
of nicks. spool housing.
3. Inspect all bores and surfaces of sliding parts for 12. If used, install O-ring (2, Figure 50-28) and
nicks, scores and excessive wear. backup ring (3) on restrictor poppet (1). Install the
4. Inspect all poppets in their respective bore for poppet in the spool housing as shown in Figure
proper fit. Poppets should move freely through a 50-29.
complete revolution without binding. 13. Install new O-rings (4, Figure 50-29), (5) and (10).
5. Lubricate O-rings (4, Figure 50-29), (5) and (10) 14. Install a new O-ring (and backup ring, if used) on
with clean hydraulic oil. Install the O-rings in poppet (6). Ensure that small steel ball (7) is
spool housing (13). Install poppet (18). Install installed in the poppet. Install the poppet in spool
spool cover (19) and secure it with the cover (1).
capscrews. Tighten the capscrews to 81 N·m (60
ft lb). 15. Position spool cover (1) over spool housing (13).
Install and tighten the capscrews to 81 N·m (60 ft
6. Install spring (11) in spool assembly (20). Install
lb).
spring seat (2). Apply Loctite to the threads of
spool end (15). Install the spool end and tighten it NOTE: The cover must be positioned according to the
to 34 N·m (25 ft lb). Install restrictor poppet (21). match marks that were made during disassembly. Do
Apply Dri-loc #204 to the threads of plug (3). not reverse the cover position.
Install and tighten the plug to 20 N·m (15 ft lb).
NOTE: Poppets (12), (21) and (22) may be color
coded and must be installed in their original location.
7. Repeat Step 6 for the opposite end of spool
assembly (20). Ensure that spring (16) is blue. A
poppet and plug are not installed in the lower
end.
8. Lubricate the spool assembly and carefully install
it in the spool housing (See Figure 50-30). Make
sure that “V” groove (1) in spool assembly (2) is
positioned up as noted.
9. Install spring (11, Figure 50-29) in the top
(grooved) end of remaining spool assembly (14).
Install spring seat (2). Apply Loctite to the threads
of spool end (15). Install spool end and tighten it
to 34 N·m (25 ft lb). Install red restrictor poppet
(12). Apply Dri-loc #204 to the threads of plug (3).
Install and tighten the plug to 20 N·m (15 ft lb). FIGURE 50-30. SPOOL INSTALLATION
10. Repeat Step 9 for the bottom end of spool
assembly (14). Ensure that spring (16) is blue. 1. “V” Groove 3. Work Ports Spool
2. Spool Assembly Section
25
CEN50110-00 50 Disassembly and assembly
Disassembly of front spool section 1. Remove the capscrews and lift spool cover (4,
Figure 50-31) from spool housing (1).
NOTE: It is not necessary to remove inlet sections (1,
Figure 50-23) or (4) to accomplish spool section 2. Remove and discard O-rings (5) and (6).
disassembly and repair. 3. Remove the capscrews and spool cover (9) from
spool housing (1). Remove and discard the O-
NOTE: Match mark or identify each spool in respect to
rings.
its mating bore when removed.
4. Remove springs (8). Push spools (7) out of the
housing bores.
FIGURE 50-31. FRONT SPOOL SECTION ASSEMBLY
1. Spool Housing 4. Spool Cover 7. Spool
2. Plug 5. O-Ring 8. Spring
3. O-Ring 6. O-Ring 9. Spool Cover
26
50 Disassembly and assembly CEN50110-00
Assembly of front spool section 6. Lubricate O-rings (5) and (6) and install them in
1. Discard all O-rings. Clean all parts in solvent and the top of the spool housing. Install top cover (4)
blow dry with compressed air. and secure it in place with capscrews. Tighten
the capscrews to 81 N·m (60 ft lb).
2. Inspect the springs for breaks and distortion.
7. If removed, install plugs (2) with new O-rings (3).
3. Inspect the housing bores and surfaces of the
spools for nicks, scoring and excessive wear. Overcenter manifold service
4. Lubricate spools (7, Figure 50-31) with clean
Overcenter manifold (1, Figure 50-32) is located at the
hydraulic oil and reinstall them in their original
rear of the hoist valve. The O-rings and backup rings
bores. Install springs (8).
on counterbalance valve (2), needle valve (3) and
5. Lubricate O-rings (5) and (6) with clean hydraulic check valves (4) may need to be replaced if leaking
oil. Install the O-rings in the bottom of the spool occurs.
housing. Install bottom cover (9) and secure it in
place with capscrews. Tighten the capscrews to
81 N·m (60 ft lb).
SEE
1 DETAIL A
2
DETAIL A 86521
FIGURE 50-32. OVERCENTER MANIFOLD VALVES
1. Overcenter Manifold 3. Needle Valve
2. Counterbalance Valve 4. Check Valve
27
CEN50110-00 50 Disassembly and assembly
Removal and installation of hoist pilot valve Installation
Removal 1. Place hoist pilot valve (1, Figure 50-33) into
position on the mounting bracket. Secure the
hoist pilot valve with mounting hardware (2).
2. Connect hydraulic lines (3) to the correct fittings.
Tighten the hydraulic line connections securely.
Hydraulic oil escaping under pressure can have 3. Place the hoist control lever in the spring-
sufficient force to enter a person's body by centered position. Adjust the pilot valve spool
penetrating the skin and cause serious injury, and until the centerline of the cable attachment hole
possibly death, if proper medical treatment is not extends 29.5 mm (1.16 in.) from the face of the
received immediately. valve body.
4. Align the eye of control cable (7) with the pilot
Relieve pressure before disconnecting any
valve spool hole, then insert pin (10). Secure the
hydraulic lines. Tighten all connections securely
pin with cotter pin (6).
before applying pressure.
5. Thread sleeve (9) upward until it contacts the
1. Refer to the "Hydraulic system bleeddown
valve body. Move flange (4) into position and
procedure" in Testing and adjusting section
secure it two machine screws (5).
Steering, hoist, brake cooling and auxiliary
hydraulic system. 6. Thread jam nut (8) against sleeve (9). Tighten
the jam nut securely.
2. Disconnect hydraulic lines (3, Figure 50-33) at
hoist pilot valve (1) located in the hydraulic brake 7. Start the engine and check for proper hoist
cabinet. Mark each line and its hoist pilot valve operation and leaks.
fitting to aid in proper installation. Plug the lines
to help prevent contamination from entering the
hydraulic system.
3. Remove two machine screws (5).
4. Loosen and unthread jam nut (8). Unthread
sleeve (9) until cotter pin (6) and pin (10) are
exposed. Remove the cotter pin and pin to
unhook control cable (7).
5. Remove mounting hardware (2) and hoist pilot
valve (1).
28
50 Disassembly and assembly CEN50110-00
1 3
29.5 mm 4 2
(1.16 in.)
5
10
FLOAT 6
Position
3
9
86522
FIGURE 50-33. HOIST PILOT VALVE & PIPING (EARLIER MODELS)
1. Hoist Pilot Valve 4. Flange 7. Control Cable 10. Pin
2. Mounting Hardware 5. Machine Screw 8. Jam Nut
3. Hydraulic Lines 6. Cotter Pin 9. Sleeve
29
CEN50110-00 50 Disassembly and assembly
3
1
29.5 mm
4
(1.16 in.) 2
5
10 3
FLOAT 6
Position
9 DETAIL A
DETAIL A
88018
FIGURE 50-34. HOIST PILOT VALVE & PIPING (LATER MODELS)
1. Hoist Pilot Valve 4. Flange 7. Control Cable 10. Pin
2. Mounting Hardware 5. Machine Screw 8. Jam Nut
3. Hydraulic Lines 6. Cotter Pin 9. Sleeve
30
50 Disassembly and assembly CEN50110-00
Disassembly and assembly of hoist pilot 8. Remove nuts (8, Figure 50-36) and (10) and
valve remove tie rods (9). Separate the valve housings.
Remove O-ring (11). Remove the poppet check
Disassembly and spring (located on the outlet housing side of
1. Thoroughly clean the exterior of the valve. Match the spool housing) from the spool housing.
mark inlet housing (18, Figure 50-36) and outlet
housing (7) in relation to spool housing (17) to
ensure proper reassembly.
2. Remove machine screws (15), seal plate (16),
wiper (13) and O-ring (12).
3. Remove snap ring (1), capscrews (6), cap (24),
spacer (23), and detent sleeve (22). Detent balls
(2) and (21) will fall free when the cap and detent
sleeve are removed. Separate cap (24), spacer
(23) and detent sleeve (22).
4. Carefully slide spool (14) out of spool housing
(17). Remove seal retainer (25), wiper (26) and
O-ring (27) from the spool.
5. Insert a rod in the cross holes of detent pin (3)
and unscrew it from spool (14). Exert slight
pressure against the detent pin as it disengages
and spring tension is released.
6. Remove spring seats (19), spring (4) and spacer
(5).
7. Remove relief valve (2, Figure 50-35) from spool
housing (1).
1
FIGURE 50-36. HOIST PILOT VALVE
1. Snap Ring 15. Machine Screw
2. Ball (4) 16. Seal Plate
3. Detent Pin 17. Spool Housing
4. Spring 18. Inlet Housing
5. Spacer 19. Spring Seat
6. Capscrew 20. Spring
7. Outlet Housing 21. Ball (1)
8. Nut 22. Detent Sleeve
86523 9. Tie Rod 23. Spacer
FIGURE 50-35. HOIST PILOT RELIEF VALVE 10. Nut 24. Cap
11. O-Ring 25. Seal Retainer
1. Spool Housing 2. Relief Valve
12. O-Ring 26. Wiper
13. Wiper 27. O-Ring
14. Spool
31
CEN50110-00 50 Disassembly and assembly
Cleaning and inspection 9. Install new O-ring (12) and wiper (13). Install seal
1. Clean all parts, including the housings, in solvent plate (16) and machine screws (15).
and blow dry with compressed air. 10. Install relief valve (2, Figure 50-35) with new O-
2. Inspect the seal counter bores. They must be rings in spool housing (1).
free of nicks and grooves.
3. Examine springs for breaks or distortion.
4. Inspect spool (14, Figure 50-36). The spool must
be free of longitudinal score marks, nicks or
grooves.
5. Test spool (14) in spool housing (17) for proper
fit. The spool must fit and rotate freely through a
complete revolution without binding.
NOTE: Spool housing (17), spool (14), inlet housing
(18) and outlet housing (7) are not serviced separately.
If any of these parts require replacement, the entire
hoist pilot valve must be replaced.
Assembly
1. Thoroughly coat all parts, including the housing
bores, with clean type C-4 hydraulic oil.
2. If the inlet and outlet housings were removed:
FIGURE 50-37. HOIST PILOT VALVE
a. Install check poppet (2, Figure 50-37) and
spring (3) in spool housing (1). 1. Spool Housing 4. O-Ring
2. Check Poppet 5. Outlet Housing
b. Install new O-ring (4) in spool housing. Place 3. Spring
the inlet and outlet housings on the spool
housing.
c. Install the tie rods and nut. Tighten the tie rod
nuts to the torques shown in Figure 50-38.
3. Install new O-ring (27, Figure 50-36) and wiper
(26). Install seal retainer (25).
4. Install spacer (5), spring seats (19), and spring
(4). Thread detent pin (3) into spool (14). Exert
slight pressure to compress the detent spring.
Tighten the detent pin to 9 - 11 N·m (84 - 96 in
lb). Install spring (20). Carefully install the spool
into the spool housing.
5. Apply grease to the cross holes of the detent pin
(3) to hold balls (2) and (21).
6. Slide detent sleeve (22) into cap (24) and place it
over a punch. Use the punch to depress ball (21)
and insert balls (2) in the cross holes.
7. While holding down ball (21), slide detent sleeve
(22) and cap (24) as an assembly over detent pin
(3). Continue to insert detent sleeve (22) until it FIGURE 50-38. TIE ROD NUT TORQUE
contacts spring seat (19). 1. Nut 4. Tie Rod
8. Secure cap (24) in place with capscrews (6). 2. Tie Rod 5. Outlet Housing
Tighten the capscrews to 7 N·m (5 ft lb). Install 3. Nut
spacer (23) and snap ring (1).
32
50 Disassembly and assembly CEN50110-00
Removal and installation of hoist cylinders
Removal 1
Hydraulic oil escaping under pressure can have
sufficient force to enter a person's body by
penetrating the skin and cause serious injury, and
possibly death, if proper medical treatment is not
received immediately.
Relieve pressure before disconnecting any
hydraulic lines. Tighten all connections securely
before applying pressure.
1. Refer to the "Hydraulic system bleeddown
procedure" in Testing and adjusting section
Steering, hoist, brake cooling and auxiliary
hydraulic system.
2. Disconnect lubrication lines (1, Figure 50-39) for
the upper and lower bearings of the hoist
cylinder.
86498
FIGURE 50-39. HOIST CYLINDER BEARING
LUBRICATION LINES
1. Lubrication Line
33
CEN50110-00 50 Disassembly and assembly
3. Remove capscrews (3, Figure 50-40),
lockwashers (4) and flange clamps (2).
Disconnect hydraulic hoses (1) from the bottom
of the hoist cylinder. Cap and plug all lines and
ports to prevent excessive spillage and
Use a lifting device with adequate capacity to
contamination.
remove and install the component.
NOTE: The cylinder should be secured to the frame to
prevent movement.
4. At the hoist cylinder upper mount, remove nut (6,
Figure 50-41), flat washer (5) and shoulder bolt
(4). Use a brass drift and hammer to drive pivot
pin (3) from upper pivot structure (1).
3 4
NOTE: Do not lose two spacers (2) between the
cylinder bearing and upper pivot structure (1).
2
4 3
1
2
86438
FIGURE 50-40. HOIST CYLINDER HOSES
1. Hydraulic Hose 3. Capscrew
2. Flange Clamps 4. Lockwasher
FIGURE 50-41. HOIST CYLINDER UPPER MOUNT
1. Upper Pivot Structure 4. Shoulder Bolt
2. Spacer 5. Flat Washer
3. Pivot Pin 6. Nut
34
50 Disassembly and assembly CEN50110-00
10. Carefully lower the hoist cylinder until it lies Installation
against the inner dual tire. Attach a suitable lifting
device to the upper cylinder mounting eye.
11. Install a retaining strap or chain to prevent the
cylinder from extending while handling.
12. At the lower mount, straighten the locking plate Use a lifting device with adequate capacity to
tabs on the locking plate (2, Figure 50-42) to remove and install the component.
allow removal of the capscrews. Remove 1. Install a retaining strap or chain to prevent the
capscrews (1), locking plate (2) and retaining cylinder from extending while handling.
plate (3). 2. Raise the cylinder into position over the pivot
13. Carefully remove the cylinder from the frame point on the frame. The cylinder should be
pivot by pulling it outward. Move the cylinder to a positioned so that the air bleed vent plug is on top
clean area for disassembly. and facing toward the front of the truck. Install
spacer (4, Figure 50-42). Align the bearing eye
NOTE: Do not lose spacer (4) between the cylinder with the pivot point and push the cylinder into
bearing and frame. place.
14. Clean the exterior of the cylinder thoroughly. 3. Install retaining plate (3), locking plate (2) and
capscrews (1). Tighten the capscrews to
standard torque. Bend the locking plate tabs over
the capscrew flats.
4. Align the hoist cylinder upper bearing eye
between the bores of upper pivot structure (1,
Figure 50-41).
5. Align the bolt hole in pivot pin (3) with the bolt
hole in upper pivot structure (1). Install the pivot
pin through the first spacer (2), then align the
second spacer with the bore on the other side of
hoist cylinder bearing eye. Finish installing the
pin through second spacer (2).
6. Install shoulder bolt (4) through each pin.
4 NOTE: Do not use a flat washer under the head of the
shoulder bolt. This will ensure that the shoulder bolt
3 does not run out of threads when tightening.
2 1
86499
7. Install flat washer (5) and nut (6) onto the
threaded end of each shoulder bolt. Tighten the
FIGURE 50-42. HOIST CYLINDER LOWER MOUNT nuts to 339 N·m (250 ft lb).
1. Capscrew 3. Retaining Plate 8. Install hydraulic hoses (1, Figure 50-40) with new
2. Locking Plate 4. Spacer O-rings at the bottom of the hoist cylinder. Secure
the flange clamps (2) with capscrews (3) and
lockwashers (4). Tighten the capscrews to the
standard torque.
9. Connect lubrication lines (1, Figure 50-39) at the
upper and lower hoist cylinder bearings.
10. Start the engine. Raise and lower the body
several times to bleed air from the hoist cylinders.
Check for proper operation and leaks.
11. Check the hydraulic tank oil level and fill if
necessary.
35
CEN50110-00 50 Disassembly and assembly
Disassembly and assembly of hoist 2. Mount the hoist cylinder in a fixture which will
cylinders allow it to be rotated 180 degrees.
3. Position the cylinder so that top cap (1, Figure
Disassembly
50-44) is at the top. Remove capscrews (2) and
1. If spherical bearings (2, Figure 50-43) require flat washers (3) that secure the top cap to
replacement, place the hoist cylinder on stands cylinder housing (7).
and secure it with a chain vise. Remove retainer 4. Install two 7/8" - 9NC X 4" capscrews into the two
rings (1) and press the bearing from the bore. threaded lifting holes in top cap (1). Thread the
NOTE: Do not use metal tools to strike the bearings. capscrews evenly until the top cap can be
removed. Lift the top cap straight up until quill
assembly (5) is clear of cylinder housing (7).
5. Remove O-ring (5) and backup ring (4) from top
cover (1).
Do not allow the bearings to fall to the ground.
Damage to the bearings and/or personal injury 2
could result.
1
3
1 4
2 6 5
1 7
86500
FIGURE 50-43. SPHERICAL BEARING REMOVAL
1. Retainer Ring 2. Spherical Bearing
NOTE: As internal parts are exposed during 86439
disassembly, protect machined surfaces from
scratches or nicks. FIGURE 50-44. HOIST CYLINDER TOP COVER
REMOVAL & INSTALLATION
1. Top Cap 5. O-ring
2. Capscrew 6. Quill Assembly
3. Flat Washer 7. Cylinder Housing
4. Backup Ring
36
50 Disassembly and assembly CEN50110-00
6. Remove capscrews (1, Figure 50-45), plate (2), NOTE: A retainer bar is required to prevent the first
snap ring (3) rod bearing retainer (4) and seal (5). and second stage cylinders from dropping out when
the housing is inverted.
7. Use a 25.4 x 76.2 x 508 mm (1" x 3" x 20") steel
1 flat to fabricate retainer bar (1, Figure 50-46). Drill
two 27.8 mm (1 3/32in.) diameter holes in the
retainer bar that align with a pair of tapped holes
spaced 180 degrees apart at the top of the
2
cylinder housing.
8. Use two top cap capscrews (2) to attach retainer
bar (1) to the cylinder housing.
3
4 2 1 2
86440
FIGURE 50-45. ROD BEARING RETAINER
REMOVAL
86441
1. 12 Pt. Capscrew 4. Rod Bearing Retainer
FIGURE 50-46. CYLINDER RETAINER BAR
2. Plate 5. Seal
INSTALLATION
3. Snap Ring
1. Retainer Bar 2. Capscrew
37
CEN50110-00 50 Disassembly and assembly
9. Rotate the cylinder assembly 180 degrees to 11. Fabricate a round disc to the following
position the lower mounting eye at the top. specifications:
10. Attach a lifting device through the mounting eye 328 mm (12.9 in.) diameter
on pivot rod (1, Figure 50-47). Lift the pivot rod
10 mm (0.38 in.) thick
out of cylinder housing (2).
14.27 - 14.53 mm (0.562 - 0.572 in.) hole in
the center
12. Rotate the cylinder housing 180 degrees.
Remove retainer bar (1, Figure 50-46).
13. Insert fabricated round disc (2, Figure 50-48) in
the bottom of the cylinder housing.
14. Insert threaded rod (1) - 13 mm (0.50 in.)
diameter x 1350 mm (53 in.) long - through the
top of the cylinder housing the hole in the round
disc. Thread nut (3) onto the bottom end of the
1 threaded rod below the disc.
2
86442
FIGURE 50-47. PIVOT ROD
REMOVAL 3 86443
1. Pivot Rod 2. Cylinder Housing FIGURE 50-48. FIRST & SECOND STAGE
REMOVAL & INSTALLATION
1. Threaded Rod 3. Nut
2. Round Disc
38
50 Disassembly and assembly CEN50110-00
15. Screw a lifting eye into the top end of the 16. Remove the lifting tools from the first and second
threaded rod. Attach it to a lifting device, then lift stage cylinders.
first and second stage cylinders (1, Figure 50-49)
17. Slide second stage cylinder (2, Figure 50-50)
out of cylinder housing (2) as one unit
down inside first stage cylinder (1). Remove snap
ring (3) from inside the first stage cylinder.
18. Remove second stage cylinder (2) from first
stage cylinder (3) by sliding it out the top.
19. Remove all bearings, O-rings, and seals from the
hoist cylinder components.
86444
FIGURE 50-49. FIRST & SECOND STAGE
REMOVAL & INSTALLATION
1. First & Second Stage 2. Cylinder Housing
Cylinders 86445
FIGURE 50-50. FIRST & SECOND STAGE
REMOVAL & INSTALLATION
1. First Stage Cylinder 3. Snap Ring
2. Second Stage Cylinder
39
CEN50110-00 50 Disassembly and assembly
Cleaning and inspection
NOTE: Use only fresh cleaning solvent, a lint-free
wiping cloth and dry, filtered compressed air when
cleaning and handling hydraulic cylinder parts.
Immediately after cleaning and inspection, coat all
surfaces and parts with clean Type C-4 hydraulic oil.
1. Thoroughly clean and dry all parts.
2. Inspect all parts for damage and excessive wear.
3. If the cylinder bores or plated surfaces are
excessively worn or grooved, the parts must be
replaced or, if possible, re-plated and machined
to original specifications.
4. Check the tightness of quill assembly (2, Figure
50-51) if it has not previously been tack welded.
a. Use special tightening tool SS1143 (see
Figure 50-51) to apply a tightening torque of 1
356 N·m (1,000 ft lb) to the quill.
b. If the quill moves, remove the quill and clean
the threads in the cover assembly and quill.
c. To install the quill, refer to "Installation of the
quill". FIGURE 50-51. QUILL ASSEMBLY TIGHTENING
5. When the cylinder assembly is dismantled, check 1. Cap Assembly
all capscrews carefully for distress. Replace the 2. Quill Assembly
capscrews if in doubt.
40
50 Disassembly and assembly CEN50110-00
Installation of the quill
NOTE: Use only new seals, bearings and O-rings
during reassembly. Thoroughly lubricate all parts and
seals with hydraulic oil to aid in assembly and to
provide lubrication during initial operation.
1. Inspect plugs (3, Figure 50-52) and check balls
(4) in the quill to ensure that the plugs are tight
and the ball seats are not damaged. Refer to
"Installation of check balls and plugs in quill" on
the next page.
2. Secure cap assembly (1) in a sturdy fixture.
Ensure that the threads in the cap and the
threads on the quill are clean, dry and free of oil
and solvent.
3. Spray the mating threads of both cap assembly
(1) and quill assembly (2) with LOCQUIC® Primer
T (Komatsu part number TL8753) or equivalent.
Allow the primer to dry for three to five minutes.
4. Apply Loctite® Sealant #277 (Komatsu part
number VJ6863) or equivalent to the mating
threads of both the cap assembly and quill
assembly.
5. Install the quill. Use SS1143 tool to tighten the
quill to 1 356 N·m (1,000 ft lb). Allow the parts to
cure for two hours before exposing the threaded
areas to oil.
NOTE: If LOCQUIC Primer T (TL8753) was not used,
the cure time will require 24 hours instead of two
hours.
6. Tack weld the quill in two places as shown in
Figure 50-52.
7. Remove all slag and foreign material from the
tack weld area before assembling the cylinder.
During future cylinder rebuilds, removal of the quill will
not be necessary unless it has loosened or is
damaged. Removal will require a break-loose force of
at least 2 712 N·m (2,000 ft lb) after the tack welds are
ground off.
FIGURE 50-52. QUILL ASSEMBLY INSTALLATION
1. Cap Assembly 3. Plug
2. Quill Assembly 4. Check Ball
41
CEN50110-00 50 Disassembly and assembly
Installation of check balls and plugs in quill 2. Spray the mating threads of both plugs (3, Figure
50-52) and quill assembly (2) with LOCQUIC
Check balls (4, Figure 50-52) in the side of quill
Primer T (Komatsu part number TL8753) or
assembly (2) are held in place with threaded plugs (3).
equivalent. Allow the primer to dry for 3 to 5
If a plug is missing and the check ball is not found in minutes.
the cylinder, inspect the opposite side hoist cylinder 3. Apply Loctite Sealant #277 (Komatsu part
and the plumbing leading to the hoist valve for number VJ6863) or equivalent to the mating
damage. Also, check the hoist valve itself to see threads of both plugs and the quill assembly.
whether the ball or plug has caused internal damage
4. Place check balls (4) in the quill tube and install
to the spool. Peening of the necked down sections of
plugs (3) with the concave side facing the ball.
the spool may result. Spool sticking may also occur.
Use the SS1158 plug installation and removal
NOTE: Refer to Figure 50-53 for SS1158 plug tool to tighten the plugs to 95 N·m (70 ft lb).
installation and removal tool that can be fabricated for Allow the parts to cure for two hours before
installing and removing the check ball plugs. exposing the threaded areas to oil.
Check the plugs during any cylinder repair to ensure NOTE: If LOCQUIC Primer T (TL8753) was not used,
that they are tight. If they move, remove the plugs and the cure time will require 24 hours instead of two
check whether the ball seat in the quill is deformed. hours.
• If deformation of the ball seat has occurred, the 5. Stake the plug threads in two places between the
quill should be replaced. holes, as shown in Figure 50-52, to prevent
loosening of the plug.
• If the ball seat area is not deformed, measure the
plug thickness as shown in Figure 50-52: NOTE: If removal of the plug is necessary in a later
Older plug: 6.35 ± 0.50 mm (0.25 ± 0.02 in.) rebuild, it will be necessary to carefully drill out the
Newer plug: 9.65 ± 0.50 mm (0.38 ± 0.02 in.) stake marks and destroy the plug. A new plug must be
installed and staked as previously detailed.
1. Use the newer plugs. Ensure that the threads in
the quill tube and on the plugs are clean, dry and
free of oil and solvent.
FIGURE 50-53. SS1158 PLUG INSTALLATION & REMOVAL TOOL
42
50 Disassembly and assembly CEN50110-00
Assembly 3. Mount the cylinder housing in a fixture which will
allow it to be rotated 180 degrees so that the top
NOTE: Lubricate all bearings and seals with clean type
cap end is positioned at the top.
C-4 hydraulic oil before installation.
4. Place a wood block beneath the cylinder housing
1. Install inner bearing (1), buffer seal (2), rod seal to help to locate the first and second stage
(3) and wiper seal (4) on the second stage cylinders.
cylinder (Figure 50-54), the first stage cylinder
(Figure 50-55) and the cylinder housing (Figure The wood block must not interfere with the lifting
50-56). tool that was fabricated during the disassembly
2. Install piston seal (6) on the second stage procedure.
cylinder (Figure 50-54) and the first stage
cylinder (Figure 50-55).
NOTE: Piston seal (6) consists of two pieces: an 5 6
expander and a nylon cap. Do not install the nylon cap
at this time.
5 6
2 1
2 1 3
3 4 86448
4 FIGURE 50-55. FIRST STAGE
86447
BEARING & SEAL INSTALLATION
FIGURE 50-54. SECOND STAGE
BEARING & SEAL INSTALLATION 1. Inner Bearing 4. Wiper Seal
2. Buffer Seal 5. Outer Bearing
1. Inner Bearing 4. Wiper Seal 3. Rod Seal 6. Piston Seal
2. Buffer Seal 5. Outer Bearing
3. Rod Seal 6. Piston Seal
43
CEN50110-00 50 Disassembly and assembly
5. Install the lifting tool (see Figure 50-48) that was 7. Lower the first stage cylinder until it is resting on
used during disassembly into the first stage the wood block. Remove the lifting tool and install
cylinder. it into the second stage cylinder.
6. Align and slide the first stage cylinder into the top NOTE: Seal installation rings (58B-98-40020) and
of the cylinder housing. See Figure 50-49. (58B-98-40030) will ease assembly of the first and
Allow the first stage cylinder to protrude far second stage cylinders, but it is not required.
enough to install the nylon cap on piston seal (6, 8. Lubricate the seal installation ring with clean type
Figure 50-55), then install outer bearings (5). C-4 hydraulic oil or petroleum jelly and install it in
the snap ring groove inside first stage cylinder (1,
Figure 50-50). The seal installation ring allows
the seals to glide over the snap ring groove
without being damaged.
9. Align and slide second stage cylinder (2) inside
first stage cylinder (1).
Allow the second stage cylinder to protrude far
enough to install the nylon cap on piston seal (6,
Figure 50-54), then install outer bearings (5).
10. Lower the second stage cylinder past the seal
installation ring. Remove the seal installation ring,
then install snap ring (3, Figure 50-50) on the
inside of the first stage cylinder.
11. Install two 7/8" - 9NC eye bolts in the lifting holes
on the top of the rod bearing retainer. Install O-
ring (4, Figure 50-57), backup rings (3), piston
seal (2), and bearings (1) on the rod bearing
retainer.
2 1
4
3 86450
2 1
FIGURE 50-57. ROD BEARING RETAINER
BEARING & SEAL INSTALLATION
3
1. Outer Bearing 3. Backup Ring
4 86449
2. Piston Seal 4. O-ring
FIGURE 50-56. CYLINDER HOUSING
BEARING & SEAL INSTALLATION
1. Inner Bearing 3. Rod Seal
2. Buffer Seal 4. Wiper Seal
44
50 Disassembly and assembly CEN50110-00
12. Lubricate the seal installation ring with clean type 15. Install retainer bar (1, Figure 50-46) with two top
C-4 hydraulic oil or petroleum jelly and install it in cap capscrews (2) on the top of the cylinder
the snap ring groove inside the second stage housing. Rotate the cylinder housing 180
cylinder. The seal installation ring allows the degrees.
seals to glide over the snap ring groove without
16. Attach a lifting device to the eye of pivot rod (1,
being damaged.
Figure 50-59) and align it over cylinder housing
13. Align and lower rod bearing retainer (2, Figure (4). Lubricate the pivot rod with clean type C-4
50-58) into the second stage cylinder until it is hydraulic oil.
past the snap ring groove in the second stage
cylinder.
14. Remove the seal installation ring and install snap
ring (1).
2 1
2
86501
3
FIGURE 50-58. ROD BEARING RETAINER
INSTALLATION
1. Snap Ring 2. Rod Bearing Retainer
86502
FIGURE 50-59. PIVOT ROD
REMOVAL
1. Pivot Rod 3. Seal
2. Guide Inserts 4. Cylinder Housing
45
CEN50110-00 50 Disassembly and assembly
17. Thread two 1" - 8NC X 4" guide inserts (2, Figure 21. Rotate the housing 90 degrees to position the top
50-59) in the bolt holes at the end of the pivot rod. cap end at the top. Install O-ring (5, Figure 50-44)
Install seal (3) on the end of the pivot rod. and backup ring (4) on top cap (1). Lower the
18. Lower the pivot rod into the cylinder housing. cover onto cylinder housing (7).
Align the guide inserts into the rod bearing 22. Lubricate capscrews (2) and flat washers (3) with
retainer capscrew holes. a lithium based grease. Install the capscrews and
19. Detach the lifting device from the pivot rod. flat washers, then tighten the capscrews in an
Rotate the cylinder assembly 90 degrees and alternating pattern to 1 017 N·m (750 ft lb).
remove the retainer bar. 23. If removed, install spherical bearings (2, Figure
50-43). Place the hoist cylinder on stands and
20. Lubricate 12-point capscrews (1, Figure 50-60)
secure it with a chain vise. Press the bearing into
with a lithium based grease. Install plate (2) and
the bore and install retainer rings (1).
eight of the capscrews. Remove the guide inserts
and install the remaining two capscrews. Tighten NOTE: Do not use metal tools to strike the bearings.
all ten capscrews in an alternating pattern to
24. After assembly is complete, refer to Testing and
1 166 N·m (860 ft lb).
Adjusting section Steering, brake cooling and
hoist hydraulic system for the hoist cylinder
leakage test requirements.
1 2 86504
FIGURE 50-60. ROD BEARING RETAINER
PLATE INSTALLATION
1. 12 Pt. Capscrew 2. Plate
46
50 Disassembly and assembly CEN50110-00
NOTES
47
CEN50110-00 50 Disassembly and assembly
980E Dump truck
Form No. CEN50110-00
48
CEN50105-00
DUMP TRUCK 1SHOP MANUAL
980E
Machine model Serial number
980E-5 A50137, A50138
50 Disassembly and assembly
Body and structures
Removal and installation of dump body ................................................................................................................ 3
Removal and installation of body pads ................................................................................................................. 6
Removal and installation of diagonal ladder/hood and grille assembly ................................................................ 8
Removal and installation of RH deck .................................................................................................................. 10
Removal and installation of LH deck................................................................................................................... 12
Removal and installation of fuel tank .................................................................................................................. 14
Removal and installation of fuel gauge sender ................................................................................................... 16
Removal and installation of hydraulic tank.......................................................................................................... 17
Removal and installation of hydraulic tank strainers ........................................................................................... 19
1
CEN50105-00 50 Disassembly and assembly
NOTES
2
50 Disassembly and assembly CEN50105-00
Removal and installation of dump body Removal
1. Park truck on a hard, level surface and block all
the wheels.
2. Place the directional control lever in PARK and
turn the rest switch ON. Turn the key switch OFF
Inspect the condition and rating of all lifting to shut down the engine and allow 90 seconds for
devices, slings, chains, and cables. Refer to the the steering system accumulators to bleed down.
manufacturer's manual for correct capacities and
3. Attach lifting cables (1, Figure 50-1) and a lifting
safety procedures when lifting components.
device to the dump body and take up the slack.
Replace any questionable items.
4. Remove the mud flaps from both sides of the
Ensure that the lifting device is rated for the dump body. Remove any electrical wiring and
appropriate capacity. Slings, chains, and cables hoses that are attached to the dump body.
used for lifting components must be rated to 5. Attach chains around the upper end of the hoist
supply a safety factor of approximately 2.5X the cylinders to support them after the mounting pins
weight being lifted. When in doubt as to the weight are removed.
of components or any service procedure, contact 6. At the hoist cylinder upper mounting bracket,
the Komatsu area representative for further remove locknut (6, Figure 50-2), flat washer (5)
information. and shoulder bolt (4). Use a brass drift and
hammer to drive pivot pin (3) from mounting
Lifting eyes and hooks must be fabricated from the bracket (1).
proper materials and rated to lift the load being
placed on them. NOTE: Do not lose two spacers (2) between the
cylinder bearing and mounting bracket (1).
Never stand beneath a suspended load. Use of guy
ropes are recommended for guiding and
positioning a suspended load.
Before raising or lifting the body, ensure that there
is adequate clearance between the body and
overhead structures or electric power lines.
FIGURE 50-2. HOIST CYLINDER UPPER MOUNT
1. Mounting Bracket 4. Shoulder Bolt
FIGURE 50-1. DUMP BODY REMOVAL
2. Spacer 5. Flat Washer
1. Lifting Cables 2. Guide Rope 3. Pin 6. Locknut
3
CEN50105-00 50 Disassembly and assembly
7. Remove shoulder bolt (1, Figure 50-3), flat Inspection
washer (2) and locknut (3) from both body pivot
1. Inspect body ears (6, Figure 50-3), the frame
pins (4).
pivot and the pivot bushings for excessive wear
8. Attach a body pivot pin support fixture to the or damage.
bracket on the underside the dump body to aid in
2. Inspect the body guide wear points. Body guide
supporting the pin as it is removed.
(2, Figure 50-4) should be centered between
9. Remove pivot pins (4) far enough to allow shims wear plates (3) with a maximum gap of 4.8 mm
(5) to drop out. Complete removal of the pins is (0.19 in.) at each side (new wear plates).
not necessary unless new pins are being
installed. If the gap becomes excessive, install new parts.
NOTE: To prevent the pivot pins from falling while
removing the dump body, use chains to secure the
pins to the truck frame.
10. Lift the dump body clear of the chassis and move
it to a work area. Block up the dump body to
prevent damage to the body guide.
FIGURE 50-4. BODY GUIDE
1. Dump Body 3. Body Guide Wear
2. Body Guide Plates
FIGURE 50-3. DUMP BODY PIVOT PINS
1. Shoulder Bolt 4. Pivot Pin
2. Flat Washer 5. Shims
3. Locknut 6. Body Ear
4
50 Disassembly and assembly CEN50105-00
Installation 8. Align the hoist cylinder bearing eye with the bore
1. Park truck on a hard, level surface and block all of hoist cylinder upper mounting bracket (1,
the wheels. Figure 50-2).
2. Place the directional control lever in PARK and 10. Align the bolt hole in pivot pin (3) with the bolt
turn the rest switch ON. Turn the key switch OFF hole in mounting bracket (1). Install the pivot pin
to shut down the engine and allow 90 seconds for through the first spacer (2), then align the second
the steering system accumulators to bleed down. spacer with the bore on the other side of hoist
cylinder bearing eye. Finish installing the pin
3. Attach lifting cables (1, Figure 50-1) and a lifting through second spacer (2).
device to the dump body and take up the slack.
11. Install shoulder bolt (4) through each pin. Install
4. Lower the body over the truck frame and align
flat washer (5) and locknut (6). The locknut must
the body pivots with the frame pivot holes.
be tight against the flat washer, and the flat
5. Install shims (5, Figure 50-3) in both body pivots, washer must be tight against the shoulder on the
as required, to fill the outside gaps and center the shoulder bolt. Ensure that the shoulder bolt has
body on the frame pivot. Do not install shims on some end play.
the inside. A minimum of one shim is required at
the outside end of both frame pivots. NOTE: Do not use a flat washer under the head of the
shoulder bolt. This will ensure that the shoulder bolt
6. Align the bolt hole in pivot pin (4) with the bolt
does not run out of threads when tightening.
hole in the pin retainer of body ear (6). Push the
pivot pin through shims (5) and into the frame NOTE: If locknut (6) is not a self-locking nut, tighten
pivot. Repeat this step for the other pivot pin. the nut to 339 N·m (250 ft lb).
7. Install shoulder bolt (1) through each pin. Install 12. Install all mud flaps, electrical wiring and hoses to
flat washer (2) and locknut (3). The locknut must the dump body.
be tight against the flat washer, and the flat
13. Adjust the body-up switch and hoist limit switch.
washer must be tight against the shoulder on the
Refer to Structure and functions section
shoulder bolt. Ensure that the shoulder bolt has
Electrical system, 24 volt for the correct
some end play.
dimensions.
NOTE: Do not use a flat washer under the head of the
shoulder bolt. This will ensure that the shoulder bolt
does not run out of threads when tightening.
NOTE: If locknut (3) is not a self-locking nut, tighten
the nut to 339 N·m (250 ft lb).
5
CEN50105-00 50 Disassembly and assembly
Removal and installation of body pads Installation
Removal 1. Install new body pads (4) with the same number
of shims (3) that were removed.
2. Install the mounting hardware. Tighten nuts (1) to
88 N·m (65 ft lb).
3. Remove the blocks from the frame. Lower the
dump body onto the frame.
To avoid serious personal injury or death, the
4. All pads (except the rear pad on each side)
body retention sling must be installed anytime
should contact the frame with approximately
personnel are required to perform maintenance on
equal compression of the rubber.
the truck with the dump body in the raised
position. A gap of approximately 1.9 mm (0.075 in.) is
required at each rear pad. This can be
NOTE: It is not necessary to remove the dump body to
accomplished by using one less shim at each
replace the body pads. Body pads should be inspected rear pad.
during scheduled maintenance inspections and
replaced if worn excessively. If pad contact appears to be unequal, refer to
"Body pad shimming procedure".
1. Raise the unloaded dump body to a height that is
sufficient to allow access to all of the body pads.
2. Install the body retention sling. Refer to “Securing
the dump body” in the Foreword, safety and
general information section for the body reten-
tion sling installation procedure.
3. Place blocks between the body and frame.
Secure the blocks in place.
4. Remove the pad mounting hardware.
5. Remove body pad (4, Figure 50-5) and shims (3).
Note the number of shims installed at each pad
location. The rear pad on each side should have
one less shim than the other pads.
FIGURE 50-5. BODY PAD INSTALLATION
1. Nut 4. Body Pad
2. Lockwasher 5. Flat Washer
3. Shim(s) 6. Capscrew
6
50 Disassembly and assembly CEN50105-00
Body pad shimming procedure 9. Subtract the body pad thickness of 39.7 mm
1. Park the truck on a flat, level surface. (1.56 in.) from each measurement that was
recorded in Step 8. There will be a total of eight
2. Raise the unloaded dump body to a height that is measurements “B” per side. Refer to Figure 50-6.
sufficient to allow access to all of the body pads.
“A” - 39.7 mm (1.56 in.) = “B”
10. Divide each measurement “B” by the single shim
thickness of 1.5 mm (0.06 in.) to determine the
number of shims required for each mounting
location.
To avoid serious personal injury or death, the “B” / 1.5 mm (0.06 in.) = number of shims
body retention sling must be installed anytime
11. Remove one shim from the calculation for the
personnel are required to perform maintenance on
most rearward body pad on both sides.
the truck with the dump body in the raised
position. NOTE: Using half shims is allowed if necessary. Half
3. Install the body retention sling. Refer to “Securing shims must be installed at the top of the stack.
the dump body” in the Foreword, safety and NOTE: The frame rail and the body bolster do not have
general information section for the body reten- to be parallel.
tion sling installation procedure.
4. Remove all of the body pads and shims.
5. Bolt one spacer block (XC2293) to each side of
the body. Use the pad mounting holes closest to
the front of the dump body.
6. Remove the body retention sling. Lower the
dump body onto the spacer blocks.
7. Check the dump body’s position and fit on the
truck. If there is any interference when the body
is on the spacer blocks, contact your local
Komatsu distributor to resolve the issue.
8. With the body lowered, measure the distance
from the frame rail to each pair of bolt holes at the
dump body’s pad mounting locations. There will
be a total of eight measurements “A” per side.
Refer to Figure 50-6.
FIGURE 50-6. MEASUREMENT DETAILS
1. Shims 2. Body Pad
7
CEN50105-00 50 Disassembly and assembly
Removal and installation of diagonal ladder/ Installation
hood and grille assembly
NOTE: It may be necessary to remove the dump body
to provide clearance for any lifting equipment. If body
removal is not required, the body must be raised and
properly secured with the body retention sling. Use a lifting device with adequate capacity to
remove and install the components.
Removal
1. Use an appropriate lifting device to lift grille and
hood assembly (4, Figure 50-7) into position on
the truck.
2. Align the mounting hardware holes with the
brackets attached to the radiator assembly. Install
Use a lifting device with adequate capacity to
hood mounting hardware (5). Tighten the
remove and install the components.
capscrews to the standard torque.
1. Park the truck on a flat, level surface. 3. Adjust and tighten both radiator bumpers.
2. Attach an appropriate lifting device to diagonal 4. Use an appropriate lifting device to lift diagonal
ladder (1, Figure 50-7). ladder (1) and support (2) into position over the
3. Remove ladder mounting hardware (3). mounting pads on the front bumper. Align the
4. Lift the structure off the truck. Collect shims (6). mounting holes and install shims (6) as needed to
level the structure.
5. Disconnect wiring harnesses and remove clamps
as necessary to allow removal of the grille and 5. Install ladder mounting hardware (3). Tighten the
hood assembly. capscrews to the standard torque.
6. Connect all cables, wiring harnesses, hoses and
NOTE: The secondary egress ladders on the sides of
clamps that were removed previously.
the hood and the front handrail on top of the hood do
not need to be removed unless desired. 7. If the secondary egress ladders on the sides of
the hood and/or the front handrail on top of the
6. Attach an appropriate lifting device to hood and
hood were removed, install them and tighten the
grille assembly (4).
mounting hardware to the standard torque.
7. Remove all hood mounting hardware (5) on both
sides of the hood.
8. Loosen the radiator bumpers on both decks.
9. Lift the grille and hood assembly from the truck
and move it to a work area.
8
50 Disassembly and assembly CEN50105-00
FIGURE 50-7. DIAGONAL LADDER, HOOD AND GRILLE REMOVAL & INSTALLATION
1. Diagonal Ladder 3. Ladder Mounting Hardware 5. Hood Mounting Hardware
2. Support 4. Hood and Grille Assembly 6. Shims
NOTE: The LH diagonal ladder configuration is shown
in Figure 50-7. Removal and installation of the RH
diagonal ladder option is the same.
9
CEN50105-00 50 Disassembly and assembly
Removal and installation of RH deck Installation
Removal
Use a lifting device with adequate capacity to
remove and install the components.
Use a lifting device with adequate capacity to
remove and install the components. Do not attach lifting slings or chains to the
handrails. Only use proper lifting points to attach
Do not attach lifting slings or chains to the the lifting device.
handrails. Only use proper lifting points to attach
the lifting device.
1. Clean all deck mount mating surfaces.
2. Install an appropriate lifting device to the lifting
1. Remove the access covers from retarding grid (1,
eyes at each corner of the deck and take up any
Figure 50-8). Tag and disconnect all electrical
slack. Do not attach the lifting device to the
leads in preparation for removal. Reinstall the
handrails.
access covers.
3. Carefully lift and position the deck on the deck
2. Remove retarding grid mounting hardware (2) at
supports. Ensure that any wiring harnesses,
six locations.
cables and hoses that may still be attached to the
3. Attach an appropriate lifting device to the lifting deck are moved out of the way.
eyes on the retarding grid. Lift the retarding grid
clear of deck structure (3) and move it to a work NOTE: Shimming may be necessary at the deck
area. mounting hardware locations to level the RH deck with
the center deck.
NOTE: If repairs to the grid assembly or cooling blower
4. Install deck mounting hardware (4) and any
are required, refer to the applicable service manual for
necessary shims at eight locations on the deck
the drive system manufacturer.
support and the front upright. Tighten the
4. Disconnect deck lighting harness (5). Inspect the capscrews to the standard torque.
underside of the deck. If necessary, remove any
5. Connect deck lighting harness (5) and any hoses
hoses or cables that remain connected to the
or cables that were disconnected from the deck.
deck.
Ensure that all electrical harnesses and clamps
NOTE: The lighting harness and clamps do not require are undamaged and reinstalled securely.
removal. Replace any components as necessary.
5. Install an appropriate lifting device to the lifting 6. Attach an appropriate lifting device to the lifting
eyes at each corner of the deck and take up any eyes on the retarding grid. Lift retarding grid (1)
slack. Do not attach the lifting device to the onto deck structure (3).
handrails. 7. Install retarding grid mounting hardware (2) at six
6. Remove deck mounting hardware (4) and any locations. Tighten the capscrews to the standard
shims at eight locations on the deck support and torque.
the front upright. 8. Remove the access covers from the retarding
7. Ensure that all wiring harnesses, cables and grid. Connect all electrical leads to their correct
hoses have been removed. Carefully lift the deck locations. Reinstall the access covers.
from the deck supports.
10
50 Disassembly and assembly CEN50105-00
4
4
4
5 87909
FIGURE 50-8. RH DECK AND RETARDING GRID REMOVAL & INSTALLATION
1. Retarding Grid 4. Deck Mounting Hardware
2. Retarding Grid Mounting Hardware 5. Deck Lighting Harness
3. Deck Structure
11
CEN50105-00 50 Disassembly and assembly
Removal and installation of LH deck Installation
Removal
Use a lifting device with adequate capacity to
remove and install the components.
If air conditioning system components must be
removed, refer to Testing and adjusting section Do not attach lifting slings or chains to the
Cab air conditioning for instructions on handrails. Only use proper lifting points to attach
discharging the air conditioning system before the lifting device.
disconnecting any air conditioning lines and
servicing the air conditioning system after 1. Clean all deck mount mating surfaces.
installation. 2. Install an appropriate lifting device to the lifting
eyes at each corner of the deck and take up any
slack. Do not attach the lifting device to the
handrails.
3. Carefully lift and position the deck on the deck
Use a lifting device with adequate capacity to supports. Ensure that any wiring harnesses,
remove and install the components. cables and hoses that may still be attached to the
deck are moved out of the way.
Do not attach lifting slings or chains to the
NOTE: Shimming may be necessary at the deck
handrails. Only use proper lifting points to attach
mounting hardware locations to level the LH deck with
the lifting device.
the center deck.
4. Install rear deck mounting hardware (3) and any
1. Remove the operator cab. Refer to Disassembly necessary shims.
and assembly section Operator cab for
instructions. 5. Install front deck mounting hardware (2) and any
necessary shims.
2. Disconnect deck lighting harness (1, Figure 50-
9). Inspect the underside of the deck. If 6. Tighten all of the deck mounting hardware to the
necessary, remove any hoses or cables that standard torque.
remain connected to the deck. 7. Connect deck lighting harness (1) and any hoses
or cables that were disconnected from the deck.
NOTE: The lighting harness and clamps do not require Ensure that all electrical harnesses and clamps
removal. are undamaged and installed securely. Replace
3. Install an appropriate lifting device to the lifting any components as necessary.
eyes at each corner of the deck and take up any
10. Install the operator cab. Refer to Disassembly
slack. Do not attach the lifting device to the
and assembly section Operator cab for
handrails.
instructions.
4. Remove rear deck mounting hardware (3) and
any shims at four locations on the deck support.
5. Remove front deck mounting hardware (2) and
any shims on the deck support.
6. Ensure that all wiring harnesses, cables and
hoses have been removed. Carefully lift the deck
from the deck supports.
12
50 Disassembly and assembly CEN50105-00
3
3 3 3
1 2
87908
FIGURE 50-9. LH DECK REMOVAL & INSTALLATION
1. Deck Lighting Harness 3. Rear Deck Mounting Hardware
2. Front Deck Mounting Hardware and Shim
and Shim
13
CEN50105-00 50 Disassembly and assembly
Removal and installation of fuel tank
Removal
Use a lifting device with adequate capacity to
remove and install the components.
10. Attach a lifting device to the lifting eyes on each
side of the tank.
To avoid serious personal injury or death, the 10. Remove capscrews (16), lockwashers (17), flat
body retention sling must be installed anytime washers (18), large washers (19) and rubber
personnel are required to perform maintenance on mounts (20).
the truck with the dump body in the raised
position. 11. Remove capscrews (1), lockwashers (2) and
mounting caps (3).
1. Park truck on a hard, level surface and block all
the wheels. 12. Lift the fuel tank from the upper mounting
brackets and move it to a work area.
2. Place the directional control lever in PARK.
13. Inspect rubber mounts (20) and replace if
3. Fully raise the dump body and install the body necessary.
retention sling. Refer to “Securing the dump
body” in the Foreword, safety and general
information section for the body retention sling
Cleaning and inspection
installation procedure.
4. Turn the key switch OFF to shut down the engine NOTE: If a tank has been damaged and requires
and after the engine has shut down allow 90 structural repair, perform the repairs before final
seconds for the steering accumulators to bleed cleaning.
down.
NOTE: When draining fuel or removing fuel lines, be
prepared to catch spilled fuel by having adequate
containers and cleanup equipment.
If a tank is to be weld repaired, special precautions
5. Loosen filler cap (4, Figure 50-10) and open drain are necessary to prevent fire or explosion. Consult
cock (15) on the bottom of the fuel tank to allow local authorities for safety regulations before
the fuel to drain from the tank into clean proceeding.
containers. Tighten the filler cap when the fuel is
completely drained. The fuel tank has a drain cock (15, Figure 50-10),
magnetic plug (14) and a cleaning port in the side that
6. Close fuel supply shutoff valve (8). Remove fuel
allow steam or solvent to be used for cleaning tanks
return hose (6), fuel supply hose (7) and quick fill
that have accumulated foreign material.
hose (13). Cap the hoses and tank fittings to
prevent contamination. It is not necessary to remove the tank from the truck
7. If equipped, remove mud flaps on both sides of for cleaning of sediment. However, rust and scale on
the fuel tank. the walls and baffles may require complete tank
removal. This allows cleaning solutions to be in
8. Disconnect the fuel tank harness from hoist filter
contact with all interior surfaces by rotating the tank in
assemblies (10), steering filter assembly (12) and
various positions.
the RH frame rail harness.
9. Remove hoist filter assemblies (10) and steering Before a cleaning procedure of this type, the fuel
filter assembly (12) from the fuel tank. Support gauge sender, vent assembly (5), breather filter (11)
the filter assemblies by placing a chain over the and all hose connections must be removed and
frame rail. It is not necessary to disconnect the temporarily sealed. After cleaning is complete, the
hydraulic hoses. temporary plugs can be removed.
If the tank is to remain out of service, a small amount
of light oil should be sprayed into the tank to prevent
rust. Seal all openings for rust prevention.
14
50 Disassembly and assembly CEN50105-00
6
7
5
SEE
UPPER MOUNT
4 DETAIL 1
UPPER MOUNT
DETAIL
SEE
LOWER MOUNT
DETAIL
10
19 13
17
11
20 12
18
LOWER MOUNT 16 14
DETAIL
15
87911
FIGURE 50-10. FUEL TANK REMOVAL & INSTALLATION
1. Capscrew 7. Fuel Supply Hose 13. Quick Fill Hose 19. Large Washer
2. Flat Washer 8. Shutoff Valve 14. Magnetic Plug 20. Rubber Mount
3. Mounting Cap 9. Fuel Tank 15. Drain Cock
4. Filler Cap 10. Hoist Filter Assemblies 16. Capscrew
5. Vent Assembly 11. Breather Filter 17. Lockwasher
6. Fuel Return Hose 12. Steering Filter Assembly 18. Flat Washer
15
CEN50105-00 50 Disassembly and assembly
Installation Removal and installation of fuel gauge
1. Thoroughly clean the frame mounting brackets sender
and the mounting hardware holes. Re-tap the Removal
threads if damaged.
1. Remove cover (1. Figure 50-11) from the top of
the fuel tank.
2. Disconnect the wiring harness from fuel gauge
sender (2).
Use a lifting device with adequate capacity to 3. Remove the sender mounting hardware.
remove and install the components. Carefully remove the fuel gauge sender and
2. Attach a lifting device to the lifting eyes on each gasket (3).
side of the tank. Lift the fuel tank into position
Installation
over the upper mounting brackets and lower the
tank into position. 1. Clean the mating surfaces. Install a new gasket
3. Install mounting caps (3, Figure 50-10), (3, Figure 50-11).
lockwashers (2) and capscrews (1). Do not 2. Install fuel gauge sender (2) into the fuel tank.
tighten the capscrews at this time. Ensure that the float moves freely.
4. Install rubber mounts (20), large washers (19), 3. Install the sender mounting hardware and tighten
flat washers (18), lockwashers (17) and the capscrews to the standard torque.
capscrews (16). Tighten the lower mounting 4. Connect the wiring harness to the fuel gauge
capscrews to 800 ± 80 N·m (590 ± 59 ft lb). sender.
5. Tighten the upper mounting capscrews to 712 ± 5. Install cover (1) on the top of the fuel tank.
72 N·m (525 ± 53 ft lb).
6. Install hoist filter assemblies (10) and steering
filter assembly (12) on the tank. Tighten the
capscrews to the standard torque.
7. Ensure that vent assembly (5) and breather filter
(11) are installed and that the hoses are
connected and clamped securely.
8. Connect fuel return hose (6), fuel supply hose (7)
and quick fill hose (13). Open fuel supply shutoff
valve (8). 1
9. Connect the fuel tank harness to hoist filter
assemblies (10), steering filter assembly (12),
and the RH frame rail harness. 2
10. If equipped, install mud flaps on both sides of the
fuel tank.
3
86314
FIGURE 50-11. FUEL GAUGE SENDER
1. Cover 3. Gasket
2. Fuel Gauge Sender
16
50 Disassembly and assembly CEN50105-00
Removal and installation of hydraulic tank
Removal
Be careful to avoid contact with hot oil if the truck
has been operating. Avoid spillage and
contamination.
If a component in the hydraulic system fails, 3. Open drain valve (1, Figure 50-12) to drain the
perform an oil analysis before replacing any hydraulic tank into suitable containers. Refer to
component. If foreign particles are evident, the the Operation and Maintenance Manual for the
system must be flushed. Refer to the Hydraulic capacity of the hydraulic tank.
System Flushing instructions. 4. Disconnect the hydraulic lines. Plug all lines to
prevent possible contamination to the system.
Close both suction line shutoff valves. Tag each
line at removal for proper identification during
installation.
Hydraulic oil escaping under pressure can have
sufficient force to enter a person's body by
penetrating the skin and cause serious injury, and
possibly death, if proper medical treatment is not
received immediately. Use a lifting device with adequate capacity to
remove and install the components.
Relieve pressure before disconnecting any
5. Attach a suitable lifting device to the lifting eyes
hydraulic lines. Tighten all connections securely
on the top of the hydraulic tank.
before applying pressure.
6. Disconnect ground wire (9) from the hydraulic
1. Refer to the "Hydraulic system bleeddown
tank.
procedure" in Testing and adjusting section
Steering, hoist, brake cooling and auxiliary 7. Remove two capscrews (5), lockwashers (6),
hydraulic system. large washers (7) and rubber mounts (8).
2. Thoroughly clean the outside of the hydraulic 8. Remove capscrews (3), flat washers (4) and
tank and attached equipment. mounting caps (2).
NOTE: If the oil is to be reused, clean containers must 9. Lift the hydraulic tank from the upper mounting
be used with a 3-micron filtering system available for brackets. Move the hydraulic tank to a clean work
refill. area.
NOTE: When draining oil or removing oil lines, be
prepared to catch spilled oil by having adequate
containers and cleanup equipment.
17
CEN50105-00 50 Disassembly and assembly
Installation
10 3 4
2
Use a lifting device with adequate capacity to
remove and install the components.
1. Lift the hydraulic tank into position on the frame.
2. Install mounting caps (2, Figure 50-12), flat
washers (4) and capscrews (3). Tighten the
capscrews to 622 ± 62 N·m (459 ± 45 ft lb).
3. Install two rubber mounts (7), flat washers (7),
lockwashers (5) and capscrews (5) at the rear of
the hydraulic tank. Tighten the capscrews to 800
± 80 N·m (590 ± 59 ft lb).
4. Connect ground wire (9) from the frame to the
hydraulic tank.
5. Uncap the hydraulic lines and attach them to the
proper connections on the hydraulic tank.
6. Replace breather filters (10), if required.
7. Close drain valve (1) and fill the hydraulic tank.
Refer to the Operation and Maintenance Manual
for the proper procedure.
8. Loosen the capscrews on the suction hoses at
the pump to bleed any trapped air, then loosen
1 the capscrews on the pressure hoses at the
pump to bleed any trapped air. Tighten all
capscrews securely.
8 5
NOTE: If trapped air is not bled from the steering
pump, possible pump damage and no output may
result.
6
7
9
86315
FIGURE 50-12. HYDRAULIC TANK
REMOVAL & INSTALLATION
1. Drain Valve 6. Lockwasher
2. Mounting Cap 7. Flat Washer
3. Capscrew 8. Rubber Mount
4. Flat Washer 9. Drain Valve
5. Capscrew 10. Breather Filters
18
50 Disassembly and assembly CEN50105-00
Removal and installation of hydraulic tank
strainers
Removal
Be careful to avoid contact with hot oil if the truck
has been operating. Avoid spillage and
contamination.
3. Open drain valve (1, Figure 50-12) to drain the
If a component in the hydraulic system fails, hydraulic tank into suitable containers. Refer to
perform an oil analysis before replacing any the Operation and Maintenance Manual for the
component. If foreign particles are evident, the capacity of the hydraulic tank.
system must be flushed. Refer to the Hydraulic 4. Disconnect the pump suction hoses from the
System Flushing instructions. hydraulic tank. Plug all lines to prevent possible
contamination to the system. Tag each line at
removal for proper identification during
installation.
5. Remove capscrews (2, Figure 50-13) and
Hydraulic oil escaping under pressure can have lockwashers (3). Remove suction cover plate (1).
sufficient force to enter a person's body by Discard the gasket.
penetrating the skin and cause serious injury, and 6. Remove capscrews (5), lockwashers (6) and flat
possibly death, if proper medical treatment is not washers (7). Remove both strainers (4).
received immediately.
Relieve pressure before disconnecting any
hydraulic lines. Tighten all connections securely
before applying pressure.
1. Refer to the "Hydraulic system bleeddown
procedure" in Testing and adjusting section
Steering, hoist, brake cooling and auxiliary
hydraulic system. 4
2. Thoroughly clean the outside of the hydraulic
tank and attached equipment. 7 6 5
NOTE: If the oil is to be reused, clean containers must
be used with a 3-micron filtering system available for
refill.
NOTE: When draining oil or removing oil lines, be
prepared to catch spilled oil by having adequate
containers and cleanup equipment.
1 2 3 86316
FIGURE 50-13. HYDRAULIC TANK STRAINER
REMOVAL & INSTALLATION
1. Suction Cover Plate 5. Capscrew
2. Capscrew 6. Lockwasher
3. Lockwasher 7. Flat Washer
4. Strainer
19
CEN50105-00 50 Disassembly and assembly
Cleaning and inspection Installation
1. Inspect the strainers thoroughly for metallic 1. Install both strainers (4, Figure 50-13). Install
particles and varnish build up (if oil has been capscrews (5), lockwashers (6) and flat washers
overheated). The quantity and size of any (7). Tighten the capscrews to standard torque.
particles may be an indication of excessive wear 2. Install suction cover plate (1) and a new gasket.
of components in the hydraulic system. Install capscrews (2) and lockwashers (3).
2. Clean the strainers from the inside out with fresh Tighten the capscrews to standard torque.
cleaning solvent. 3. Uncap the pump suction hoses and attach them
3. Inspect the strainers for cracks and wear. to the proper connections on the hydraulic tank.
Replace the strainers if necessary. 4. Close drain valve (1, Figure 50-12) and fill the
4. Clean any sediment from the bottom of the hydraulic tank. Refer to the Operation and
hydraulic tank. Maintenance Manual for the proper procedure.
5. Loosen the capscrews on the suction hoses at
the pump to bleed any trapped air, then loosen
the capscrews on the pressure hoses at the
pump to bleed any trapped air. Tighten all
capscrews securely.
NOTE: If trapped air is not bled from the steering
pump, possible pump damage and no output may
result.
20
50 Disassembly and assembly CEN50105-00
NOTES
21
CEN50105-00 50 Disassembly and assembly
980E Dump truck
Form No. CEN50105-00
22
CEN50108-00
DUMP TRUCK 1SHOP MANUAL
980E
Machine model Serial number
980E-5 A50052, A50053,
A50137, A50138
50 Disassembly and assembly
Operator cab
Removal and installation of operator cab.............................................................................................................. 3
Removal and installation of cab door .................................................................................................................... 6
Disassembly and assembly of cab door ............................................................................................................... 8
Adjustment of cab door ....................................................................................................................................... 16
Removal and installation of side window glass ................................................................................................... 18
Removal and installation of windshield and rear window glass .......................................................................... 21
Removal and installation of windshield wiper components ................................................................................. 22
Removal and installation of cab seats................................................................................................................. 24
Removal and installation of seat belts................................................................................................................. 26
1
CEN50108-00 50 Disassembly and assembly
NOTES
2
50 Disassembly and assembly CEN50108-00
Removal and installation of operator cab Removal
Hydraulic oil escaping under pressure can have
DO NOT attempt to modify or repair damage to the
sufficient force to enter a person's body by
ROPS structure without written approval from the
penetrating the skin and cause serious injury, and
manufacturer. Unauthorized repairs to the ROPS
possibly death, if proper medical treatment is not
structure will void certification. If modification or
received immediately.
repairs are required, contact the servicing
Komatsu distributor. Relieve pressure before disconnecting any
hydraulic lines. Tighten all connections securely
NOTE: It may be necessary to remove the body to
before applying pressure.
provide clearance for lifting equipment to be used. If
removal of the dump body is not required, the body 1. Refer to the "Hydraulic system bleeddown
must be raised and the body retention sling installed. procedure" in Testing and adjusting section
Refer to the topic "Securing the dump body" in Index Steering, hoist, brake cooling and auxiliary
and foreword section Foreword, safety and general hydraulic system.
information. 2. Remove cover (2, Figure 50-2). Disconnect all
NOTE: The base weight of the operator cab with the hydraulic hoses that are routed to the frame from
hydraulic brake cabinet attached is approximately the bottom of hydraulic brake cabinet (1). Cap all
2 767 kg (6,100 lb). However, due to options that may fittings and plug the hoses to prevent
be added, the weight of the operator cab may be as contamination.
much as 2 950 kg (6,500 lb). The rear portion of the
operator cab assembly is heavier than the front
portion.
NOTE: The angle of the lifting chains must be 45
degrees or greater. Refer to Figure 50-1. 1
45°
min.
2 86420
87605
FIGURE 50-2. REAR OF OPERATOR CAB
FIGURE 50-1. LIFTING THE OPERATOR CAB
1. Hydraulic Brake Cabinet 2. Cover
3
CEN50108-00 50 Disassembly and assembly
3. Close the shutoff valves for cab heater hoses (1,
Figure 50-3). Disconnect the hoses and drain the
water from the heater core.
Federal regulations prohibit venting air
conditioning system refrigerants into the
atmosphere. An approved recovery/recycle station
must be used to remove the refrigerant from the
air conditioning system.
4. Before removing the air conditioner hoses,
evacuate the air conditioning system. Refer to
Testing and adjusting section Cab air
conditioning for the correct procedure.
5. Disconnect all wiring harnesses (1, Figure 50-4)
and HVAC hoses (2) from the bottom of the
operator cab.
6. Check for any other clamps, hoses or wiring
which may interfere with cab removal. Remove
any additional components as needed.
1 RH SIDE VIEW
2 87563
1 FIGURE 50-4. BOTTOM OF OPERATOR CAB
FRONT RH SIDE VIEW 1. Wiring Harnesses 2. HVAC Hoses
87903
FIGURE 50-3. SHUTOFF VALVES
1. Cab Heater Hose
4
50 Disassembly and assembly CEN50108-00
8. Remove mount covers (2) at each corner of the
operator cab.
9. Remove capscrews (3), plate (4), bushings (5)
and sleeves (6) from the mounting pads.
Use a crane and lifting devices with adequate 10. Lift the operator cab off the truck and move it to a
capacity to remove and install the operator cab. work area for further service if needed.
The angle of the lifting chains must be 45 degrees
or greater. NOTE: Before the operator cab is lowered to the floor,
place blocking under each mounting pad (7) to prevent
7. Attach a lifting device to four lifting eyes (1,
damage to the floor pan and any components attached
Figure 50-5) provided on top of the operator cab.
to the bottom of the operator cab.
7 5
MOUNTING DETAIL 87912
FIGURE 50-5. OPERATOR CAB REMOVAL & INSTALLATION
1. Lifting Eye 4. Plate 7. Cab Mounting Pad
2. Mount Cover 5. Bushing
3. Capscrew 6. Sleeve
5
CEN50108-00 50 Disassembly and assembly
Installation Removal and installation of cab door
NOTE: To perform repairs on the door, it is usually
easier, but not necessary, to remove the door from the
operator cab and lower it to the floor for service.
Removal
Use a crane and lifting devices with adequate
capacity to remove and install the operator cab.
The angle of the lifting chains must be 45 degrees
or greater.
1. Install sleeve (6, Figure 50-5) and two bushings
(5) into each capscrew hole in cab mounting pads Use lifting device with adequate capacity to
(7) as shown. remove and install the component.
2. Attach a lifting device to lifting eyes (1) provided 1. Lower door glass (1, Figure 50-6) far enough to
on top of the operator cab. Lift the operator cab allow insertion of a lifting sling.
and align the cab mounting pad holes with the 2. Disconnect the window regulator harness from
deck mounting pad holes. connector (2).
3. Install plate (4) and at least one capscrew (3) at 3. Detach door check strap (4). Open the cab door.
each of the four cab mounting pads before
4. Insert a lifting sling through the open window and
lowering the cab onto the truck.
attach it to a hoist.
4. After the cab is positioned, install the remaining
capscrews. Tighten the capscrews to 2 750 N·m
(2,028 ft lb).
5. Install HVAC hoses (2, Figure 50-4) and the
clamps to the underside of the operator cab.
1
6. Connect the other end of each cab heater hose
(1, Figure 50-3) to the fittings at heater hose
shutoff valves. Open the shutoff valves.
7. Route and connect all wiring harnesses (1,
Figure 50-4) to the connector plates on the
underside of the cab.
8. Remove the caps and plugs from the hydraulic
hoses and fittings. Install the hoses at the bottom
of hydraulic brake cabinet (1, Figure 50-2). 2
9. Reinstall any clamps, hoses and wiring as
needed.
10. Remove the caps and reinstall the air 3
conditioning system hoses to the compressor
and receiver/drier. Refer to Testing and adjusting
section Cab air conditioning for detailed 4
instructions about evacuation and recharging
with refrigerant. 87565
11. Start the engine and verify proper operation of all FIGURE 50-6. CAB DOOR REMOVAL &
controls. Ensure that the air conditioning system INSTALLATION
is properly recharged.
1. Door Glass 3. Inner Door Panel
2. Connector 4. Door Check Strap
6
50 Disassembly and assembly CEN50108-00
5. Remove capscrews (1, Figure 50-7) that secure 5. Refer to Figure 50-8. With the door closed,
door hinge (2) to the operator cab. Lift the door dimension "A" must be 6.1 mm (0.240 in.) in
from the operator cab. order to maintain a gap of 5.7 mm (0.225 in.)
6. Place the door on blocks or on a work bench to while opening the door. A stainless steel shim
protect the window glass and allow access to may be used between hinge (1) and ROPS frame
internal components for repair. (3) to maintain the proper gap.
Installation
1. Before installing the door, check the inner and A
outer door seals for damage. Replace the seals
as necessary.
1 3
Use lifting device with adequate capacity to
remove and install the component.
2. Insert a lifting sling through the open window and
attach it to a hoist.
3. Lift the cab door up to the deck and position the 2
door in the opening of the operator cab.
4. Align the door on door hinge (2, Figure 50-7) and
install capscrews (1).
1
87568
FIGURE 50-8. CAB DOOR HINGE CLEARANCE
1. Door Hinge 3. ROPS Frame
2. Door Frame
6. Attach door check strap (4, Figure 50-6).
7. Connect the window regulator harness to
2 connector (2). Verify proper operation of the
power window.
87566
FIGURE 50-7. CAB DOOR REMOVAL &
INSTALLATION
1. Capscrew 2. Door Hinge
7
CEN50108-00 50 Disassembly and assembly
Disassembly and assembly of cab door 5. Place a wood block under door glass (3, Figure
50-10) to prevent the glass from falling.
NOTE: The cab doors can be serviced without
removing the door from the operator cab. 6. Remove four window lift mounting screws (2).
7. Remove the mounting screws for all four
Removing the window regulator regulator brackets (1).
1. Lower door glass (1, Figure 50-9) at least 153 8. Remove regulator (4) from the door. All four of
mm (6 in.). the regulator brackets can be removed from
2. Disconnect the window regulator harness from regulator and reused.
connector (2).
3. Detach door check strap (4). Open the cab door.
4. Remove 10 door panel screws and inner door
panel (3).
1 1
1
2
2
1 4
3 1
87567
3 FIGURE 50-10. WINDOW REGULATOR
REMOVAL & INSTALLATION
1. Regulator Bracket 3. Door Glass
4 2. Window Lift Mounting 4. Window Regulator
Screws
87565
FIGURE 50-9. INNER DOOR PANEL
REMOVAL & INSTALLATION
1. Door Glass 3. Inner Door Panel
2. Connector 4. Door Check Strap
8
50 Disassembly and assembly CEN50108-00
Installing the window regulator
1. Loosely install all four regulator brackets (1,
Figure 50-10) onto window regulator (4). Tighten 9
the mounting hardware on the regulator motor,
but leave the other brackets loose. 2 3
2. Loosely install the regulator with the attached 4 5 6 7
brackets into the door. Do not tighten the
mounting hardware.
3. Use the window lift mounting hardware to attach
door glass (3) to the window lift bracket. Tighten
four window lift mounting screws (2) securely,
then remove the wood block that supports the
door glass.
NOTE: See Figure 50-11 for the correct installation of 1 3 2
the window lift mounting hardware.
6 8
4. Connect the window regulator harness to 87569
connector (2, Figure 50-9). FIGURE 50-11. WINDOW LIFT MOUNTING
5. Turn the engine start switch ON, then press the HARDWARE
window switch to test the operation of the window 1. Window Lift Bracket 6. Washer
regulator. 2. Gasket 7. Machine Screw -
6. With the door glass lowered, tighten the 3. Nylon Bushing M6 X 1.00 X 16
mounting hardware on both lower regulator 4. Window Stopper 8. Capscrew -
brackets. Bracket M6 X 1.00 X 12
7. With the door glass raised, tighten the mounting 5. Tube Sliding Bracket 9. Door Glass
hardware on both upper regulator brackets.
8. Install inner door panel (3, Figure 50-9). Tighten
the 10 door panel screws securely.
9. Attach door check strap (4).
9
CEN50108-00 50 Disassembly and assembly
Removing the door glass 4. Remove screw cover (1, Figure 50-13) from
1. Perform the procedure for "Removing the window window frame (2). Remove 22 screws that secure
regulator". Removal of the window regulator itself the window frame to the door.
is optional. NOTE: The screws along the bottom of the window
2. Lift the door glass and support it at the top of the frame should be shorter than the screws along the top
door frame. and sides.
3. Remove self-tapping screw (2, Figure 50-12) at
the lower end of both window channels (1).
2
NOTE: It may be necessary to pull the rubber felt
insert out of the channel to be able to remove the
screws.
1 2
87572
FIGURE 50-12. DOOR GLASS REMOVAL
1. Window Channel 2. Self-Tapping Screw
87573
FIGURE 50-13. WINDOW FRAME
1. Screw Cover 2. Window Frame
10
50 Disassembly and assembly CEN50108-00
5. Lift the door glass into the window frame so that it Installing the door glass
is near the top. While holding the glass in place,
1. Before installing the door glass, inspect glass
tilt the window frame outward and lift window
wipe (1, Figure 50-15) and frame filler (2) for
assembly (1, Figure 50-14) out of the door.
wear and damage. Replace components if
6. Move the window assembly to a work area where necessary.
the glass can be removed. Slide the glass down
2. Ensure that the rubber felt inserts in both window
and out of the window channels.
channels (3) are in good condition. Replace the
inserts if necessary.
1
1
87574
FIGURE 50-14. WINDOW ASSEMBLY REMOVAL
87575
1. Window Assembly 2. Window Inner Seal
FIGURE 50-15. WINDOW ASSEMBLY
1. Glass wipe 3. Window Channel
2. Frame Filler
11
CEN50108-00 50 Disassembly and assembly
3. Check the window frame seals and window inner
seal (2, Figure 50-14) for wear and damage.
Replace the seals if necessary.
4. Slide the new door glass into the window
2
channels. Move the door glass to the top of the
frame.
Do not allow the door glass to fall while installing
the window assembly. Damage to the glass will
occur if allowed to forcefully strike a hard surface.
5. While holding the door glass at the top of the
frame, lift window assembly (1) and lower the
window assembly into the door.
6. Carefully lower the door glass. Place a wood
block at the bottom of the door for support.
The screws along the bottom of the window frame
should be shorter than the screws along the top
and sides. The shorter screws must be used in this 87570
area to prevent possible damage to the door glass
during operation of the window. FIGURE 50-16. DOOR SEAL INSTALLATION
7. Install the 22 screws that secure window frame 1. Outer Door Seal 2. Inner Door Seal
(2, Figure 50-13) to the door. Install screw cover
(1) on the window frame.
8. Install self-tapping screw (1, Figure 50-12) at the Replacing the outer door seal
lower end of both window channels (2). Ensure
that the rubber felt insert is in place after the 1. Locate the seam of outer door seal (1, Figure 50-
screws are installed. 16) near the door check strap. Pull one end to
remove the seal from the door jamb.
9. Perform the procedure for "Installing the window
regulator". 2. Inspect the cab door channel for damage, dirt,
and oil. Repair or clean the cab door as
necessary. Remove all dirt and existing sealant.
Ensure that the entire perimeter of the cab door is
Replacing the inner door seal clean and free of burrs.
1. Inner door seal (2, Figure 50-16) is glued to the 3. Install the outer door seal in the door jamb all the
door. Peel the seal away from the door frame. way around the door frame. Starting near the
Use a suitable cleaner to remove any remaining door check strap, work the seal into the channel.
seal residue and glue from the door. Ensure that the seal fits tightly.
2. Ensure that the door frame is dry and free of dirt NOTE: It may be necessary to trim off some of the
and oil. Pull the backing paper off the new seal to seal.
expose a pressure sensitive adhesive, then press
the new seal into place. 4. Ensure that the door closes properly after the
seal is installed.
12
50 Disassembly and assembly CEN50108-00
Removing the interior door handle and door latch 2. Remove two screws (1, Figure 50-18) and detach
1. Remove 10 door panel screws and inner door push lever (2) to access the end of the latch
panel (1, Figure 50-17). cable (3).
3. Detach latch cable (3) from lever cam (4). Push
NOTE: There should be enough slack in the window and hold door latch lever (5) to loosen the cable
regulator harness so that disconnection of the harness as needed.
is not required.
2
1
1
5
4
3
1
2 87596
87595 FIGURE 50-18. REMOVING THE PUSH LEVER
FIGURE 50-17. INNER DOOR PANEL 1. Screw 4. Cam Lever
1. Inner Door Panel 2. Interior Door Handle 2. Push Lever 5. Door Latch Lever
3. Latch Cable
13
CEN50108-00 50 Disassembly and assembly
4. Detach the other end of latch cable (3, Figure 50- 5. Remove four screws (2, Figure 50-20), door
19) from plastic catch (2) at door latch lever (1). handle (1) and floating plates (3). Retain the
floating plates for proper installation of the door
Use the tip of a screwdriver to push up the latch
handle.
cable. Ensure that the plastic catch stays down.
The end of the cable will rotate at one end of the
plastic catch while the cable clears the clips. After
the cable is free of the clips, slide the cable out of 3
the plastic catch.
NOTE: Ensure that the plastic catch remains on the
door latch lever. The plastic catch can be replaced
only after the cable is removed.
2 1
87598
FIGURE 50-20. REMOVING THE DOOR HANDLE
1. Door Handle 3. Floating Plate
2 2. Screw
87597
FIGURE 50-19. REMOVING THE LATCH CABLE
1. Door Latch Lever 3. Latch Cable
2. Plastic Catch
14
50 Disassembly and assembly CEN50108-00
NOTE: Do not allow the door latch to slide down inside Installing the interior door handle and door latch
the door channel after the screws are removed.
1. Install door latch (3, Figure 50-21), external tooth
6. Remove four screws (1, Figure 50-21), external lockwashers (2) and four screws (1). Tighten the
tooth lockwashers (2) and door latch (3). screws securely.
2. To install door handle (1, Figure 50-20), first
secure the end of the handle that is closest to the
A door latch with two screws (2). Ensure that
floating plate (3) is installed first.
3. While installing the floating plate and two screws
2
1 at the other end of the handle, keep elbow
sections (2, Figure 50-22) of the handle pushed
into straight section (1) so that there are no gaps
between the handle sections. Tighten all four
screws securely.
A 2
1 87602
3 FIGURE 50-22. INSTALLING THE DOOR HANDLE
1. Straight Section 2. Elbow Section
4. Engage the end of latch cable (3, Figure 50-19)
VIEW A-A 87601
in plastic catch (2) of door latch lever (1). Rotate
FIGURE 50-21. REMOVING THE DOOR LATCH the cable downward to lock the end of the cable
into the clips of the plastic catch.
1. Screw 3. Door Latch
2. Lockwasher 5. Attach latch cable (3, Figure 50-18) to lever cam
(4). Push and hold door latch lever (5) to loosen
the cable as needed.
6. Attach push lever (2) with two screws (1).
7. Actuate the push lever several times to ensure
that the door latch is functioning properly.
8. Install inner door panel (1, Figure 50-17) and 10
door panel screws.
15
CEN50108-00 50 Disassembly and assembly
Adjustment of cab door 4. The door seal should firmly grip the paper all
along the top, front, and bottom edge of the door.
Door jamb bolt adjustment If the paper is loose all around, repeat Step 2. If
Over time, the door latch mechanism may wear. To the paper is firmly gripped, but can be removed
ensure proper latching of the door, the door jamb bolt without tearing it, open the door and tighten the
may need to be adjusted periodically. jamb bolt completely without affecting the
adjustment.
NOTE: Always check the condition of the door
5. If the paper slips out from the door seal easily
assembly seal before making adjustments.
along the top but the bottom (or vise versa), the
door itself will have to be adjusted.
a. If the seals are tight at the bottom of the door
but not at top, place a 4" x 4" block of wood at
the bottom edge of the door, below the handle.
Close the door on the wood block and press
firmly inward on the top corner of the door.
Press in one or two times, then remove the
wood block and check the seal tension again
using the paper method. Seal compression
should be equal all the way around the door. If
the seal is still loose at the top, repeat the
procedure again until seal compression is the
same all the way around.
b. If the seals are tight at the top of the door but
not at the bottom, place a 4" x 4" block of
wood at the top corner of the door and press
FIGURE 50-23. DOOR JAMB BOLT ADJUSTMENT firmly inward on the lower corner of the door.
Press in one or two times, then remove the
1. Washer 3. Frame
wood block and check seal compression again
2. Striker Bolt 4. Door Seal
using the paper method. Seal compression
should be equal all the way around the door. If
seal is still loose at the bottom, repeat the
procedure again until seal compression is the
If the door closes, but not tightly enough to give a same all the way around.
good seal between the door seal and the cab 1
If the door springs back when trying to close it 1
1. Mark washer location (1, Figure 50-23) portion of
the door jamb bolt with a marker, pen, or pencil Striker bolt (2, Figure 50-24) has probably loosened
by circumscribing the outside edge of the washer and slipped down from where the catch can engage
onto the jamb. with the bolt.
2. Loosen striker bolt (2). Move it straight inwards 1. Open the door and close both latches (3) and (5)
1.5 mm (1/16 inch) and retighten the bolt. on the catch until they are both fully closed.
3. Hold a piece of paper where door seal (4) will 2. Transfer the center of this opening onto the skin
contact the skin of the cab and firmly close the of the cab nearest where the door jamb bolt is
door on the paper. located. Use a T-square or other measuring
equipment and mark on the cab with a pencil.
NOTE: The door latch mechanism has a double catch
mechanism. Ensure that the door latches on the NOTE: Release the door catch before trying to close
second catch. the door.
16
50 Disassembly and assembly CEN50108-00
Exterior door handle release button adjustment
If the exterior door handle does not function, the
handle or latch mechanism may need to be replaced.
Often, the door handle release button may simply
need to be adjusted. The following is a procedure for
adjusting the release button.
1. To determine the amount of free play in the door
release plunger, push door handle release button
(1, Figure 50-25) until capscrew (2) just contacts
the latch mechanism. Measure the distance that
the plunger travels from this position to where the
plunger is fully released.
FIGURE 50-24. DOOR JAMB BOLT ADJUSTMENT
1. Cab 4. Door
2. Striker Bolt 5. Lower Latch 2 3 87579
3. Upper Latch
FIGURE 50-25. MEASURING TRAVEL DISTANCE
OF PLUNGER
3. Loosen and vertically align (center) the door jamb 1. Release Button 3. Locknut
bolt with the mark and tighten it firmly enough to 2. Capscrew
hold it in place but still allow some slippage.
4. Carefully try to close the door and determine
whether this adjustment has helped the
“springing” problem.
a. If the door latches but not firmly enough,
perform the procedure for "If the door closes,
but not tightly enough to give a good seal
between the door seal and the cab".
b. If the door latch does not catch, move the bolt
outward and try again. When corrected,
perform the procedure for "If the door closes,
but not tightly enough to give a good seal
between the door seal and the cab" to ensure
a good seal.
17
CEN50108-00 50 Disassembly and assembly
2. Remove the inner door panel. Removal and installation of side window
3. Remove three internal hex screws (1, Figure 50- glass
26) and plate (2) that secure the exterior door
Recommended tools and supplies
handle to the door.
• Cold knife, pneumatic knife, or a piano wire cutting
device, long knife. Cutout tools are available at an
auto glass supply store.
• Heavy protective gloves
• Safety eyeglass goggles
• Windshield adhesives, proper cleaners, primers
and application gun
• SM2897 glass installation bumpers
(9 for front side window, 11 for rear side window)
Recommended adhesives:
• SikaTack Ultrafast or Ultrafast II (both heated).
2 1 Vehicle can be put into service in 4 hours under
optimum conditions. Heated adhesives require a
Sika approved oven to heat adhesive to 80° C
(176° F).
87578 • Sikaflex 255FC or Drive (unheated). Vehicle can
be put into service in 8 hours under optimum
FIGURE 50-26. DOOR LATCH
conditions.
1. Internal Hex Screws 2. Plate Sika Corporation
30800 Stephenson Hwy.
Madison Heights, MI 48071
Toll Free Number: 1-800-688-7452
4. Adjust capscrew (2, Figure 50-25) Fax number: 248-616-7452
counterclockwise to increase the height of door http://www.sika.com or
handle release button (1). http://www.sikasolutions.com
5. To lock the capscrew in place, push in the
release button while tightening locknut (3). Apply
Loctite® to prevent the capscrew from loosening.
Due to the severe duty application of off-highway
vehicles, the cure times listed by the adhesive
manufacturer should be doubled before a truck is
moved. If the cure time is not doubled, vibration or
movement from a moving truck will weaken the
adhesive bond before it cures, and the glass may
fall off the cab.
If another adhesive manufacturer is used, follow
that manufacturer's instructions for use, including
the use of any primers, and double the allowances
for proper curing time.
18
50 Disassembly and assembly CEN50108-00
Removal Installation
1. Clean the metal with Sika Aktivator. Allow it to dry
for ten minutes. Then paint on a thin coat of Sika
Primer 206G+P and allow it to dry for ten
minutes.
The first concern with all glass replacement is 2. Using only the new side window(s) which are to
SAFETY! Wear heavy protective gloves and safety be bonded in place, center the new glass over
eyeglass goggles when working with glass. the opening in the cab. Use a permanent marker
to mark on the cab skin along all the edges of the
1. Use a cut-out tool to slice into the existing new glass that is to be installed. All edges must
urethane adhesive and remove the window be marked on the cab in order to apply the
glass. adhesive in the proper location.
2. Carefully clean and remove all broken glass 3. Use Sika Primer 206G+P to touch up any bright
chips from any remaining window adhesive. The metal scratches on the metal frame of the truck.
surface should be smooth and even. Use only Do not prime the existing urethane bed. Allow it
clean water. to dry for ten minutes.
NOTE: Removal of all old adhesive is not required. 4. Use a clean, lint free cloth to apply Sika Aktivator
Remove just enough to provide an even bedding base. to the black ceramic Frit surrounding the new
3. Use a long knife to cut the remaining urethane window. Use a clean, dry cloth and wipe off the
from the opening, leaving a bed 2 - 4 mm (0.08 - Sika Aktivator. Allow it to dry for ten minutes.
0.15 in.) thick. If the existing urethane is loose, 5. For front side windows (2, Figure 50-27), use
completely remove it. Leave the installation nine glass installation bumpers (SM2897). For
bumpers in place, if possible. rear side windows (3), use eleven glass
installation bumpers (SM2897). Space them
equally around the previously marked glass
perimeter, approximately 25 mm (1 in.) inboard
from where the edge of the glass will be when it is
installed.
The rubber bumpers are used to ensure a proper
adhesive installed thickness. If too thin, the glass
may break when the cab flexes. If too thick, both
improper sealing and the risk of glass not being
properly bonded are possible.
19
CEN50108-00 50 Disassembly and assembly
NOTE: Be careful not to place the adhesive too far 7. Immediately install the glass. Carefully locate the
inboard, as it will make any future glass replacement glass in place with the black masking side toward
more difficult. the adhesive. Press firmly, but not abruptly, into
6. Apply a continuous, even bead of adhesive place to ensure that the glass is properly seated.
[approximately 10 mm (0.38 in.) in diameter] to Do not pound the glass into place.
the cab skin at a distance of 13 - 16 mm (0.50 - 8. Use a wooden prop and duct tape to hold the
0.63 in.) inboard from the previously marked final glass in place for at least two hours or double the
location of the glass edges from Step 2. adhesive manufacturer’s curing time, whichever
time is longer.
9. Remove the tape or prop from the glass only after
the cure time has expired.
1 4
2 3 3 2
FRONT REAR 87576
FIGURE 50-27. CAB WINDOWS
1. Windshield 3. Rear Side Window
2. Front Side Window 4. Rear Window
20
50 Disassembly and assembly CEN50108-00
Removal and installation of windshield and Installation
rear window glass 1. If window seal (1, Figure 50-28) that was
NOTE: Two people are required to remove and install removed is broken, weathered, or damaged in
windshield (1, Figure 50-27) or rear window glass (4). any way, install a new window seal.
One person must be inside the cab, and the other
NOTE: Using a non-oily rubber lubricant or water-
person must be on outside the cab.
based hand cleaner on the weatherstrip material and
Special tools that are helpful in removing and installing cab opening will make the following installation easier.
automotive glass are available from local tool
a. Install the window seal around the window
suppliers.
opening. Start with one end of the seal at the
lower center part of the window opening and
Removal
press the seal over the edge of the opening.
NOTE: If the windshield is to be replaced, lift the
b. Continue installing the weatherstrip all around
windshield wiper arms out of the way first.
the opening. When the seal ends (2) meet at
1. Starting at the lower center of the glass, pull out the lower center part of the window opening,
window seal (1, Figure 50-28). Use a non-oily there must be 12.7 mm (0.5 in.) of overlapping
rubber lubricant and a screwdriver to release the material.
locking lip.
NOTE: The ends of the seal need to be square-cut to
2. Remove the glass from the window seal by assure a proper fit.
pushing it out from inside the cab.
c. Lift both ends so that they meet squarely.
3. Clean all dirt and old sealant from the seal
Then, while holding the ends together, force
grooves. Ensure that the perimeter of the window
them back over the lip of the opening.
opening is clean and free of burrs.
2. Lubricate the groove of the window seal where
the glass is to be seated.
3. Lower the glass into the groove along the bottom
of the window opening.
4. Have one person on the outside of the cab
pushing in on the glass against the opening,
while another person on the inside uses a soft flat
tool (such as a plastic knife) to work the seal over
the edge of the glass all the way around.
A 5. After the glass is in place, inspect around the
entire window seal to ensure that the glass is
A securely installed in the seal.
2 NOTE: If the windshield was replaced, lower the
windshield wiper arms back onto the glass.
GLASS
1 CAB SHEET
VIEW A-A 87594
FIGURE 50-28. WINDSHIELD AND REAR
WINDOW GLASS
1. Window Seal 2. Seal Ends
21
CEN50108-00 50 Disassembly and assembly
Removal and installation of windshield Installing the windshield wiper motor
wiper components 1. Place wiper motor (1, Figure 50-30) into position
Removing the windshield wiper motor on the mounting plate.
2. Install three capscrews (5), flat washers (6) and
1. Remove front access cover (1, Figure 50-29)
lockwashers (7). Tighten the capscrews to 8-9
from the operator cab.
N·m (71-79 in. lb).
3. Slide wiper linkage (3) onto the motor output
shaft. Hold the linkage stationary and tighten cap-
screw (4) to 22-24 N·m (16-18 ft lb).
4. Reconnect wiper motor harness (2).
NOTE: In case the wiper motor operates incorrectly, lift
the wiper arms off the windshield to avoid possible
damage.
5. Verify that the wipers operate properly and park
in the proper position (see Figure 50-29).
A
1 86676
FIGURE 50-29. ACCESSING THE WIPER MOTOR
1. Front Access Cover
2. Disconnect the wiper motor harness (2, Figure
50-30).
7 4 3
6 5
Some wiper linkage arms may have extremely
sharp edges. Wear protective gloves and long
sleeves when handling wiper linkage arms.
3. While holding wiper linkage (3) stationary, loosen 2
capscrew (4) and disconnect the wiper linkage
from wiper motor (1).
4. Remove three capscrews (5), flat washers (6)
1
and lock washers (7) that attach the wiper motor DETAIL A 87580
to the mounting plate. Remove the wiper motor
assembly. FIGURE 50-30. WIPER MOTOR REMOVAL &
INSTALLATION
1. Wiper Motor 5. Capscrew
2. Wiper Motor Harness 6. Flat Washer
3. Wiper Linkage 7. Lockwasher
4. Capscrew
22
50 Disassembly and assembly CEN50108-00
6. Install front access cover (1, Figure 50-29) on the 4. Loosen capscrew (5, Figure 50-32) that secures
operator cab. the wiper linkage drive arm to wiper motor (6).
NOTE: When installing the front access cover, ensure 5. Remove cover (1), nut (2), thin washer (3) and
that the bottom false hinge of the cover is engaging thick washer (4) from both wiper arm shafts.
into the bottom edge of the sheet metal panel of the 6. Remove capscrews and flat washers (7) from
cab front enclosure. both ends of wiper linkage (8).
7. Carefully remove the wiper linkage from the
Removing the windshield wiper arm and linkage
operator cab so as not to damage the washer
NOTE: Note the parked position of the wiper arms in fluid hoses.
Figure 50-31 for proper installation.
1. Lift wiper arm cover (2, Figure 50-31). Remove
flanged nut (3). 1
2. Disconnect washer fluid hose (5), then remove
wiper arm (4). 2
3. If the wiper linkage is also being serviced,
remove front access cover (1) from the operator 3
cab. 5
4 8
6
87582
FIGURE 50-32. WIPER LINKAGE REMOVAL &
INSTALLATION
1 1. Cover 6. Wiper Motor
2. Nut 7. Capscrew &
3. Washer (thin) Flat Washer
2 3 4. Washer (thick) 8. Wiper Linkage
5. Capscrew
5 4
DETAIL A 87581
FIGURE 50-31. WIPER ARM REMOVAL &
INSTALLATION
1. Front Access Cover 4. Wiper Arm
2. Wiper Arm Cover 5. Washer Fluid Hose
3. Flanged Nut
23
CEN50108-00 50 Disassembly and assembly
Installing the windshield wiper arm and linkage Removal and installation of cab seats
1. Carefully place wiper linkage (8, Figure 50-32) NOTE: Removal and installation instructions for the
into position in the operator cab so as not to passenger seat are identical to the instructions for the
damage the washer fluid hoses. Ensure that the operator seat.
wiper linkage drive arm is connected to the shaft
of wiper motor (6).
2. Install capscrews and flat washers (7) at both
ends of the wiper linkage.
3. Install thick washer (4), thin washer (3) and nut
(2) on both wiper arm shafts. Tighten the nuts to Do not remove the handrail from the deck to allow
18-20 N·m (160-177 in. lb). room to remove the operator seat from the cab.
There is a risk of personnel of falling off the truck if
the handrail is removed.
Removal
1. Disconnect the door check strap so the door can
Do not overtighten the nut. The threads on the swing open wider.
wiper arm shafts are easily stripped when
improperly tightened. If necessary, remove the door from the cab to
allow room to remove the seat. Refer to the topic
"Removal and installation of cab door".
4. Install cap (1) over both wiper arm shafts.
2. Remove cotter pins (4, Figure 50-33) so that seat
5. Tighten capscrew (5) to secure the wiper linkage
tethers (5) can be disconnected from the eye
drive arm to the shaft of wiper motor (6).
bolts in the cab floor.
NOTE: When the wiper motor is parked, the drive arm 3. Disconnect the seat harness on the floor of the
will be in the 3 o’clock position as shown in Figure 50- operator cab.
32.
4. Remove four capscrews (1), flat washers (2), and
6. Place wiper arm (4, Figure 50-31) into the parked lockwashers (3) that secure the seat to the riser.
position that was noted during removal. Install
flanged nut (3). Tighten the nut to 16-20 N·m
(142-177 in. lb). Close wiper arm cover (2).
7. Connect washer fluid hose (5) to the wiper arm.
8. Verify that the wipers operate properly and park
in the proper position. Use lifting device with adequate capacity to
remove and install the seat. Do not lift the seat by
9. Install front access cover (1) on the operator cab. using the arm rests as they could be damaged.
NOTE: When installing the front access cover, ensure 5. Remove the seat from the operator cab, then use
that the bottom false hinge of the cover is engaging a suitable lifting device to lift the seat from the
into the bottom edge of the sheet metal panel of the deck.
cab front enclosure.
24
50 Disassembly and assembly CEN50108-00
Servicing the seat Installation
Use lifting device with adequate capacity to
• Immediately repair or replace a damaged or
remove and install the seat. Do not lift the seat by
faulty seat.
using the arm rests as they could be damaged.
• Do not use a seat that has been dropped or in a
1. Use a suitable lifting device to lift the seat to the
truck accident.
deck.
• Only technicians who are experienced with 2. Position the seat in the operator cab. Install new
seat repairs may service the seat.
grade 5 capscrews (1, Figure 50-33), flat
• Welding is not permitted anywhere on the seat. washers (2) and lockwashers (3) that secure the
Modifying the seat is strictly prohibited. seat to the riser. Tighten the capscrews to the
• Use only OEM replacement parts for repairs. standard torque.
3. Connect the seat harness.
• To prevent a crush hazard, block up the seat to
prevent the seat from lowering during service. 4. Fasten seat tethers (5) to the eye bolts in the
floor of the operator cab. Install cotter pins (4).
• Suspension roller slides must not be oiled or
greased. Mechanisms other than sliding 5. Connect the door check strap. If the door was
suspension rollers may be lubricated as removed, install the door. Refer to the topic
required. "Removal and installation of cab door".
3
87583
FIGURE 50-33. CAB SEAT REMOVAL &
INSTALLATION
1. Capscrew 4. Cotter Pin
2. Flat Washer 5. Seat Tether
3. Lockwasher
25
CEN50108-00 50 Disassembly and assembly
Removal and installation of seat belts 3. Disconnect seat belt minder harness (1, Figure
50-35).
4. Remove capscrew (2) that secures seat belt latch
(3) and seat tether (4) to the seat.
Inspect the date of manufacture on the seat belt. If
the seat belt is over five years old, or if the seat
belt has been in service for more than three years,
replace the seat belt.
Removal 3
1. Remove capscrew (1, Figure 50-34) that secures
lap belt retractor (2) and seat tether (3) to the
seat.
2. Remove carriage bolt (4) that secures shoulder
belt retractor (5) to the mounting bracket. 4
1 87588
FIGURE 50-35. RH SEAT BELT MOUNT
1. Seat Belt Minder Harness 3. Seat Belt Latch
2. Capscrew 4. Seat Tether
5
5. Remove nut (3, Figure 50-36), the capscrew and
foam pad (2). Slide upper seat belt mount (1) off
2 the mounting bracket.
4
1 1 2
3 87587
FIGURE 50-34. LOWER SEAT BELT MOUNT
1. Capscrew 4. Carriage Bolt
2. Lap Belt Retractor 5. Shoulder Belt
3. Seat Tether Retractor
87586
FIGURE 50-36. UPPER SEAT BELT MOUNT
1. Upper Seat Belt Mount 3. Nut
2. Foam Pad
26
50 Disassembly and assembly CEN50108-00
Installation
NOTE: Use new hardware when installing the seat
belt.
1. Slide upper seat belt mount (1, Figure 50-36)
onto the mounting bracket. Install the capscrew,
foam pad (2) and nut (3). Tighten the nut to the
standard torque.
2. Install seat tether (4, Figure 50-35), seat belt
latch (3) and new capscrew (2) onto the seat.
Ensure that the seat tether is installed under the
seat belt latch. Tighten the capscrew to the
standard torque.
3. Connect seat belt minder harness (1).
4. Use carriage bolt (4, Figure 50-34) to secure
shoulder belt retractor (5) to the mounting
bracket.
5. Install seat tether (3), lap belt retractor (2) and
new capscrew (1) onto the seat. Ensure that the
seat tether is installed under the lap belt retractor.
Tighten the capscrew to the standard torque.
6. Ensure that the seat belt pulls out and retracts
smoothly and that the seat belt buckle clicks
securely into the seat belt latch. Ensure that the
seat tethers are secured properly to the eye bolts
on the cab floor.
27
CEN50108-00 50 Disassembly and assembly
980E Dump truck
Form No. CEN50108-00
28
CEN50138-00
DUMP TRUCK 1SHOP MANUAL
980E
Machine model Serial number
980E-5 A50137, A50138
50 Disassembly and assembly
Power module
Removal and installation of power module ........................................................................................................... 3
Removal and installation of alternator................................................................................................................. 18
Engine / alternator attachment checkout data sheet........................................................................................... 29
Additional engine measurements........................................................................................................................ 31
Removal and installation of the cooling module.................................................................................................. 35
Repairing the radiator ......................................................................................................................................... 40
Removal and installation of engine ..................................................................................................................... 43
1
CEN50138-00 50 Disassembly and assembly
NOTES
2
50 Disassembly and assembly CEN50138-00
Removal and installation of power module Read and observe the following instructions before
attempting any repairs.
General
The engine and alternator assemblies are mounted on
a roller-equipped subframe which is contained within
the truck’s main frame. This arrangement, referred to
as a "power module", permits removal and installation
of these components with a minimum amount of • Do not attempt to work in the deck area until
disconnect by utilizing the "roll in/roll out" feature. the body up retention cable or sling has been
installed.
Although the instructions in this section are primarily
based upon the "rollout" method for major component • Do not step on or use any power cable as a
removal, the radiator and fan drive components will handhold when the engine is running.
need to be removed as separate items. Optional • Do not open any control cabinet doors or
equipment may also be installed on the truck, requiring covers, and do not touch the retarding grid
additional removal and installation steps not listed. elements, until all shutdown procedures have
been completed.
The procedures outlined in this section of the manual
are general instructions for power module removal and • All removal, repair and installation of
installation. It may be necessary to perform some propulsion system electrical components and
procedures in a different order or use different cables must be performed by an electrical
maintenance technician who is properly
methods for component removal and installation,
trained to service the system.
depending on the lifting equipment available.
• In the event of a propulsion system
Prior to removal or repair procedures, it may be malfunction, a qualified technician must
necessary to remove the body to provide clearance for inspect the truck and verify that dangerous
lifting equipment to be used. If removal is not required, voltage levels are not present in the propulsion
the body should be raised and secured with the body system before repairs are started.
up retention cable or sling.
3
CEN50138-00 50 Disassembly and assembly
Removal
1. Park truck on a hard, level surface and block all
the wheels.
2. Place the directional control lever in PARK. Turn
the key switch OFF to shut down the engine and The system is charged with HFC-134A refrigerant.
allow 90 seconds for the steering system Federal regulations prohibit venting air
accumulators to bleed down. conditioning system refrigerants into the
atmosphere. An approved recovery/recycle station
must be used to remove the refrigerant from the
air conditioning system.
6. Evacuate the air conditioning system. Refer to
Testing and adjusting section Cab air
conditioning for the procedures that are
Use lifting equipment with adequate capacity to required to properly evacuate the refrigerant from
remove and install the components. the air conditioning system.
3. Remove the diagonal ladder and support from 7. Unclamp and disconnect refrigerant hoses (1,
truck. Refer to Disassembly and assembly Figure 50-2) from A/C compressor (2) and
section, Body and structures, for the removal condenser (3). Plug the hoses and ports. Move
procedure. the hoses away from engine compartment to
4. It is necessary to remove the radiator and fan prevent interference with power module removal.
drive components before removing the power Refer to "Removal and installation of the cooling
module. The coolant must be drained and the module" for details to remove the cooling module.
piping to the brake cooling heat exchanger must
be removed. Refer to the topic "Removal and
installation of the cooling module" for more
information.
2
5. Disconnect all electrical cables from the battery
box. Remove the mounting hardware from each
corner, then lift battery box assembly (1, Figure
50-1) from the truck.
1 3
89016
FIGURE 50-1. BATTERY BOX REMOVAL & 1
86691
INSTALLATION
FIGURE 50-2. REFRIGERANT HOSE REMOVAL
1. Battery Box Assembly
1. Refrigerant Hose 3. Condenser
2. A/C Compressor
4
50 Disassembly and assembly CEN50138-00
4 2
A
6
DETAIL A
6 1 3 87995
FIGURE 50-3. GRILLE INSTALLATION
1. Grille 4. Washer
2. Capscrew 5. Mounting Hardware
3. Lockwasher 6. Electrical Connectors
8. Remove the grille (1, Figure 50-3) from the
radiator by removing the mud flaps from both
sides of the grille and removing mounting bolts
from the sides and top of the grille.
1
9. Disconnect the electrical connectors (6) at the
bottom of the grille. Ensure all hoses and
harnesses are disconnected before lifting the
grille from the radiator.
10. Remove upper support rod (1, Figure 50-4) at
both sides of the radiator.
87926
FIGURE 50-4. UPPER SUPPORT ROD
1. Upper Support Rod
5
CEN50138-00 50 Disassembly and assembly
11. Drain the coolant from the radiator and 12. Disconnect the fan drive mounting structure bolts
disconnect all coolant hoses and tubes from the from the lower support arms (1, Figure 50-5) to
radiator (see Figure 50-40). the main frame.
DETAIL A
EB
DETAIL B
A
1
87997
FIGURE 50-5. FAN MOUNTING
INSTALLATION
1. Lower Support Arm
6
50 Disassembly and assembly CEN50138-00
13. Disconnect the fan drive shaft (1, Figure 50-6) 14. Attach lifting eyes and straps to the top of the
from the front of the engine. radiator and remove the radiator mounting bolts.
Remove the cooling module from the truck.
87998
FIGURE 50-6. FAN DRIVE SHAFT
1. Fan Drive Shaft
7
CEN50138-00 50 Disassembly and assembly
15. Open bottom drive shaft cover (1, Figure 50-7). 16. Remove the blower duct from the traction
Remove eight capscrews and lockwashers to alternator.
disconnect drive shaft (2) from traction alternator
a. Disconnect cables and hoses as required.
(3).
b. Remove alternator blower transition (1, Figure
50-8).
c. Cover all openings to prevent foreign material
from entering the system.
FIGURE 50-7. HOIST PUMP DRIVE SHAFT
REMOVAL
1. Bottom Drive Shaft Cover
2. Drive Shaft
3. Traction Alternator
89014
FIGURE 50-8. ALTERNATOR BLOWER DUCTS
1. Alternator Blower Transition
8
50 Disassembly and assembly CEN50138-00
17. Remove engine air intake duct support rods (2, 18. Install lifting bolts and attach an overhead hoist to
Figure 50-9) from the bottom of center deck (1). the center deck. Remove the deck mounting
Remove any hoses, electrical cables and ground hardware, then lift center deck (1) from truck.
straps that are attached to the center deck.
2 2
A
1
B
E
8
3
5
9
4 10
11
6 4
MOUNTING
7 DETAIL B
MOUNTING
DETAIL A 88888
FIGURE 50-9. CENTER DECK REMOVAL & INSTALLATION
1. Center Deck 8. Capscrew
2. Duct Support Rod 9. Washer
3. Capscrew 10. Structure Mount
4. Flat Washer 11. Nut
5. Structure Mount
6. Lockwasher
7. Nut
9
CEN50138-00 50 Disassembly and assembly
19. Disconnect the wiring harnesses from pressure 21. Disconnect air inlet tubes (3, Figure 50-10) at
switches (1, Figure 50-10) on the inlet ducts. each of the four turbochargers. Cover the
20. Loosen the clamps on hump hoses (2) between openings at the turbochargers and at both ends
the engine inlet ducts and the air cleaner outlet of the inlet ducts.
ducts.
2 3 3 2
B
2
2
3
1 1
DETAIL A DETAIL B
87931
FIGURE 50-10. ENGINE INLET DUCT REMOVAL & INSTALLATION
1. Pressure Switch 3. Air Inlet Tubes
2. Hump Hose
22. Remove the exhaust tube clamps connected to 2 1 1 2
exhaust tubes (1, Figure 50-11) from hanger rods
(2).
23. Remove the capscrews, lockwashers and nuts
that secure exhaust tubes (1) to the turbocharger
outlet flanges. Remove the exhaust tubes and
cover the turbocharger outlet openings on the
engine.
1
87916
FIGURE 50-11. ENGINE EXHAUST PIPING
1. Exhaust Tube 2. Hanger Rod
10
50 Disassembly and assembly CEN50138-00
24. Close fuel shutoff valve (1, Figure 50-12). 25. Close cab heater water shutoff valves (1, Figure
Disconnect and cap fuel hoses (2) at the 50-13). Disconnect the hoses and drain the water
mounting bracket. from the heater core. Secure the hoses away
from engine compartment to prevent interference
with power module removal.
2
89015
FIGURE 50-12. FUEL HOSES
1. Fuel Shutoff Valve 2. Fuel Hose
1 RH SIDE VIEW
1
FRONT RH SIDE VIEW 87903
FIGURE 50-13. SHUTOFF VALVES
1. Cab Heater Water Shutoff Valve
11
CEN50138-00 50 Disassembly and assembly
26. Disconnect service center hose (1, Figure 50-14) 28. Disconnect all power cables (1, Figure 50-16)
from engine oil pan (2). Plug the hose and port. and other wiring from the traction alternator.
Move the hose away from engine compartment to
prevent interference with power module removal.
NOTE: The hose may be connected to either side of
the engine depending on which side of the truck the 1
service center is located.
2 1 87904
FIGURE 50-14. ENGINE OIL HOSE
89017
1. Service Center Hose 2. Engine Oil Pan FIGURE 50-16. TRACTION ALTERNATOR
POWER CABLES
27. Disconnect service center hose (1, Figure 50-15) 1. Power Cables
from the coolant pipe beneath the radiator. Plug
the hose and port. Move the hose away from
engine compartment to prevent interference with
power module removal.
1 86692
FIGURE 50-15. SERVICE CENTER
COOLANT HOSE
1. Service Center Coolant Hose
12
50 Disassembly and assembly CEN50138-00
29. Remove the mounting hardware and subframe
rubber mounts on all four corners of the subframe
(see Figure 50-17 and Figure 50-18).
30. Install a safety chain around the engine subframe
cross member and the main frame to prevent the
power module from rolling when the subframe
rollers are installed.
31. Check the engine and the alternator to ensure
that all cables, wires, hoses, tubing and linkages
have been disconnected.
1 DETAIL A
7 2
4
5
6
DETAIL A DETAIL A
1 89019
FIGURE 50-18. REAR SUBFRAME
6 MOUNTS
2 1. Capscrew 4. Washer
5 2. Hardened Washer 5. Lockwasher
3 3. Rubber Mount 6. Nut
4
DETAIL A
89018
FIGURE 50-17. FRONT SUBFRAME MOUNTS
1. Capscrew 6. Hardened Washer
2. Rubber Mount 7. Front Subframe
3. Lockwasher Lifting Points
4. Nut
5. Washer
13
CEN50138-00 50 Disassembly and assembly
32. Place a jack under the rear of the power module NOTE: Pay special attention to ensure the engine
subframe. Raise the rear portion of engine does not hit the truck frame. Under no circumstance
subframe and install subframe rollers (1, Figure should the engine oil pan be used to support the
50-19) on both sides of the power module. Lower weight of the power module.
the rear portion of the subframe carefully until the
35. Place stands or blocking under the front of the
rollers rest on the main frame guide rail.
subframe. Lower the hoist until the front of the
NOTE: Subframe rollers are supplied in the optional subframe is supported. Install a safety chain to
tool group. prevent the subframe from rolling.
36. Attach lifting tool (1, Figure 50-20) to the hoist
and attach it to subframe lifting points (3) as
shown in Figure 50-20.
37. Raise the power module slightly to determine
whether the module is on an even plane. Move
the power module straight out of the truck to a
clean work area for further disassembly.
1 1
2 4
3 5 3
89020
FIGURE 50-19. SUBFRAME ROLLER
INSTALLATION
1. Subframe Roller
87984
33. Position the hoist at front subframe lifting points FIGURE 50-20. POWER MODULE LIFTING TOOL
(5, Figure 50-17). Raise the engine subframe INSTALLATION
until the engine is on a level plane. Remove the
safety chain that was installed in step 23. 1. Lifting Tool 4. Engine
2. Alternator 5. Power Module
3. Subframe Lifting Points Subframe
Lift the power module only at the lifting points on
the subframe structure. Refer to Figure 50-20.
Ensure that the lifting devices have adequate
capacity.
34. Roll the power module forward so that adequate
clearance is provided in front of the control
cabinet for the lifting device to be attached to
front subframe lifting points (5, Figure 50-17) and
rear subframe lifting points.
14
50 Disassembly and assembly CEN50138-00
Installation 8. Install a safety chain around the truck frame and
1. Inspect the subframe guide rails on the inside of the subframe to prevent the power module from
the main frame. Remove any debris that could rolling forward.
interfere with installation of the power module. 9. Place a small block behind each rear subframe
2. Clean the main frame rear support brackets. roller to prevent rolling.
3. Check subframe rollers (1, Figure 50-19) on both 10. Lower the hoist to allow the subframe to rest on
sides of the power module. Ensure that they are the stands and subframe rollers. Remove lifting
installed correctly and roll freely. tool (1, Figure 50-20).
11. Attach the hoist to front subframe lifting points (5,
Figure 50-17).
12. Remove the small blocks behind the subframe
rollers. Remove the safety chain and slowly roll
the power module into position over the front
Lift the power module only at the lifting points on
main frame mounts.
the subframe and engine/alternator cradle
structure. Refer to Figure 50-20. Ensure that the 13. Install rubber mounts (1, Figure 50-22) without
lifting devices have adequate capacity. the mounting hardware, then lower the hoist until
4. Attach lifting tool (1, Figure 50-20) to subframe front subframe mounts (2) are aligned with and
lifting points (3). seated on front main frame mounts (3). Reinstall
the safety chain.
5. Raise the power module and align the subframe
rollers onto the subframe guide rails.
6. Lower the power module to the subframe guide
rails. Relax the hoist slightly and roll the power
module into truck frame as far as possible before
the lifting chains contact the control cabinet (see
Figure 50-21).
7. Place stands or blocking under the front of the
subframe to support the power module while the
hoist is repositioned. 2
1
1
89021
FIGURE 50-22. FRONT SUBFRAME MOUNTS
1. Rubber Mount 3. Front Main Frame
2. Subframe Mount Mount
87988
FIGURE 50-21. POWER MODULE INSTALLATION
15
CEN50138-00 50 Disassembly and assembly
14. Place a jack under the rear of the subframe to 18. Install all ground straps between the frame and
support the power module. Raise the power subframe. Reconnect wire harnesses at the
module just enough to permit removal of the power module subframe connectors. Connect all
subframe rollers. Remove subframe rollers (1, power cables (1, Figure 50-16) and other wiring
Figure 50-19). to the traction alternator.
15. Lower the rear of the subframe until the isolation 19. Unplug and connect all service center hoses,
mounts align with the frame mount (see Figure engine oil hoses, fuel hoses and water lines. See
50-23). Figure 50-12 through Figure 50-15.
20. Uncover the exhaust tube openings and
turbocharger outlets. Install exhaust tubes (1,
Figure 50-11) on the turbocharger outlet flanges.
Tighten the capscrews to the standard torque.
21. Uncover the openings at the turbochargers and at
both ends of the inlet ducts. Install inlet ducts (3,
Figure 50-10) at each of the four turbochargers.
22. Install hump hoses (2) between the engine inlet
ducts and the air cleaner outlet ducts. Clamp the
ducts securely to ensure a positive seal is made.
Refer to Figure 50-24 for examples of correct
installation.
3
23. Install lifting bolts and attach an overhead hoist to
the center deck. Lift center deck (1, Figure 50-9)
3 into position, then install the mounting hardware
at each mounting bracket. Tighten the capscrews
2 to the standard torque.
24. Install all clamps and hangers that support the
1 87925 exhaust tubes and engine inlet ducts.
FIGURE 50-23. REAR SUBFRAME MOUNTS
25. Inspect the flexible transitions and gaskets and
1. Capscrew 3. Subframe Mount replace them if damaged. Install alternator blower
2. Washer (Isolation and Frame transition (1, Figure 50-8).
Mount) 26. Open bottom drive shaft cover (1, Figure 50-7).
Connect drive shaft (2) to traction alternator (3)
16. Install rubber mounts, capscrews, lockwashers by installing eight capscrews and lockwashers.
and nuts at the front and rear engine mounts on Tighten the capscrews to the standard torque.
both sides of the subframe (see Figure 50-18 and Close the bottom drive shaft cover.
Figure 50-17). Tighten the capscrews to 712 ± 72 27. Unplug and connect refrigerant hoses (1, Figure
N·m (525 ± 53 ft lb). 50-2) to A/C compressor (2) and condenser (3).
NOTE: Install the cooling module at this time. Refer to
"Removal and installation of the cooling module".
17. Install upper support rod (1, Figure 50-4) on both
sides of the radiator.
16
50 Disassembly and assembly CEN50138-00
28. Install the diagonal ladder and vertical support. 33. Ensure that all electrical wiring is connected to
Refer to Disassembly and assembly section, the power module components. Deactivate the
Body and structures, for the installation battery disconnect switches.
procedure.
34. Refill the radiator with coolant and service the
29. Attach an appropriate lifting device to the lifting engine with the appropriate fluids. Refer to the
eyes on the battery box, then lift battery box Operation and Maintenance Manual for the
assembly (1, Figure 50-1) into position at the cooling system capacity and fluid specifications.
front of the truck. Install the mounting hardware
35. Recharge the air conditioning system according
at each corner of the battery box and tighten the
to the instructions in Testing and adjusting
capscrews to the standard torque.
section Cab air conditioning.
30. Connect all electrical wiring to the battery box.
31. Connect air cleaner restriction indicator nylon
tubes (1, Figure 50-10) to the inlet ducts.
32. Open both water shutoff valves (1, Figure 50-13)
and fuel shutoff valve (1, Figure 50-12).
FIGURE 50-24. AIR INLET PIPING CONNECTIONS
17
CEN50138-00 50 Disassembly and assembly
Removal and installation of alternator
Removal
NOTE: The following instructions cover the removal of
the traction alternator from the engine after the power
module has been removed from the truck. Use lifting equipment with adequate capacity to
remove and install the components.
The power module must be placed on solid level
ground before removing the traction alternator. 1. Attach a hoist with two lifting chains to lifting eyes
(1, Figure 50-25) on top of the traction alternator.
Take up the slack in the lifting chains.
2. Block up the rear of the engine.
3. Loosen capscrews (2) that secure the traction
alternator to the subframe.
89022
FIGURE 50-25. TRACTION ALTERNATOR REMOVAL
1. Lifting Eyes
2. Capscrew & Lockwasher
18
50 Disassembly and assembly CEN50138-00
4. Remove access cover (1, Figure 50-26) on either hardened flat washers (2) that join engine
side of the flywheel housing. Reach through the flexplate to the alternator rotor adapter.
access opening to remove 20 capscrews and
2 1
89023
FIGURE 50-26. ENGINE DRIVE RING/ALTERNATOR ROTOR CONNECTION
1. Access Cover
2. Capscrew (5/8" - 11NC) & Hardened
Flat Washer
19
CEN50138-00 50 Disassembly and assembly
5. Remove 18 capscrews and flat washers (1, 7. Keep the alternator as level as possible and
Figure 50-27) that secure flywheel housing move it away from the engine.
adapter (2) to the alternator housing. 8. Note the location and quantity of the shims. Keep
6. Remove capscrews and lockwashers that secure the shims for possible reuse during installation.
the alternator to the subframe on both sides of
the traction alternator (see Figure 50-25).
3
89024
FIGURE 50-27. FLYWHEEL ADAPTER/ALTERNATOR HOUSING CONNECTION
1. Capscrew (5/8" - 11NC) & Hardened 3. Capscrew (M16 X 2.00) & Hardened
Flat Washer Flat Washer
2. Flywheel Housing Adapter
10. If removal of the flywheel housing adapter is NOTE: For further disassembly instructions for the
necessary, remove 16 capscrews and hardened traction alternator, refer to the appropriate GE service
flat washers (3, Figure 50-27) that secure manual.
flywheel housing adapter (2) to the engine
flywheel housing.
20
50 Disassembly and assembly CEN50138-00
Installation
1. If the flywheel housing adapter is removed, install
flywheel housing adapter (2, Figure 50-27) on the Table 1: Summary of Axial & Radial Runout
engine flywheel housing. Install 16 capscrews Limits
and hardened flat washers (3). Tighten the Description Specification
capscrews to 240 N·m (177 ft lb). Engine Crankshaft Endplay 0.15 mm (0.006 in.) -
0.80 mm (0.031 in.)
Flywheel Housing Radial 0.30 mm
Runout (0.012 in.)
Flywheel Housing Face 0.30 mm
The following instructions must be followed for
Runout (0.012 in.)
new or repower installations or whenever the
engine and/or alternator is not serviced. Failure to Flywheel/Flexplate Radial 0.13 mm
follow these instructions can result in serious Runout (0.005 in.)
damage to the engine and/or alternator. Flywheel/Flexplate Face 1.00 mm
• Remove fan driveshaft if already installed prior to Runout (0.040 in.)
measuring crankshaft end play to ensure crank
moves easily back and forth.
• When taking measurements always clean mating
surfaces and take four equally spaced readings,
then average all four.
• A reference to crank rotation - clockwise (CW) or
counterclockwise (CCW) - is the direction of
rotation when looking at the front (damper end) of
engine.
• All measurements are set to three decimal places
for standard and two decimal places for metric. 1 1 89010
FIGURE 50-28. SUBFRAME MOUNTS
• Ensure that a surface reference (such as a flat
steel bar) used for dial indicating is calibrated 1. Subframe mount
periodically for flatness and dimensional accuracy
to within +/-.0009 in. Also, ensure that all
instruments used for measurements are calibrated
on a periodic basis.
• Do not pry or hammer on engine vibration damper.
• Forward is defined as the front of truck and
rearward is defined as the rear of the truck.
• See Table 1 for summary of radial and axial runout
limits.
• It is assumed that these dimensions are within
specification from the supplier and are therefore
not required for new installations. However, these
measurements must be used for service rebuilds
and/or troubleshooting to confirm these
dimensions are within tolerance specification of
the engine manufacturer.
• The subframe and engine assembly must be
supported by the front and rear mounts used for
mounting the subframe to form a level plane, see
Figure 50-28.
21
CEN50138-00 50 Disassembly and assembly
Stator adapter face runout Engine Crankshaft Endplay
1. Thoroughly clean all mating surfaces: the 4. Mount a magnetic base on the front of the engine
alternator stator adapter, alternator rotor adapter, and a dial indicator on the front of the crankshaft.
engine flexplate, and engine flywheel housing. Measure total crankshaft endplay. Move
2. Install two M16 threaded rods, at least 300mm crankshaft forward and rearwards as far as
long, onto the engine flywheel housing. The rods possible. This is accomplished by removing a
will aid in installing the stator adapter under the hand-hole cover and prying gently on a
engine aftercooler with an overhead crane. crankshaft counterweight (Figure 50-30) or using
a rubber mallet on the crankshaft hub. Confirm
3. Install alternator stator adapter to the engine the measurement is equal in both forward and
flywheel housing. Torque bolts to 175 ft lbs (240 rear directions. Record values and confirm end
N·m). play is within engine manufacturer’s limits.
NOTE: Do not pry or hammer on engine vibration
damper.
Total Crankshaft Endplay =______________
Endplay limits: 0.15 - 0.80 mm (0.006 - 0.031 in.)
88034
FIGURE 50-29. DIAL INDICATOR SETUP
2
89009
FIGURE 50-30. CRANKSHAFT POSITIONING
1. Crankshaft hub
2. Crankshaft counterweight
22
50 Disassembly and assembly CEN50138-00
Alternator stator adapter to engine flexplate mat- 8. Move the crankshaft forward to its end travel.
ing surface - measurement “C” 9. Repeat the same procedure in three more
5. Move the crankshaft rearward to its end travel. locations, 90 degrees apart from each other in
6. Bolt a calibrated flat steel bar across the flywheel the perimeter, to find the values CF2, CF3, and
housing as a surface reference to measure the CF4.
distance between the alternator stator adapter
and the engine flexplate. See Figure 50-31. This
will be measurement CR1. 1st measurement - 12 o’clock (CF1): _____________
2nd measurement - 6 o’clock (CF2): _____________
3rd measurement - 3 o’clock (CF3): _____________
4th measurement - 9 o’clock (CF4): _____________
CavgF : (CF1+CF2+CF3+CF4) / 4 =___________
10. The total engine axial play is calculated as:
TEAP = (CavgF - CavgR) = ______________
11. The mean absolute value of the relative location
of the flywheel with respect to the flywheel
88036 housing is:
FIGURE 50-31. ENGINE FLYWHEEL TO
C = TEAP / 2 + CavgR = ________________
FLYWHEEL HOUSING MEASUREMENT
7. Repeat the same procedure in three more
locations, 90 degrees apart from each other in
the perimeter, to find the values CR2, CR3, and
CR4.
1st measurement - 12 o’clock (CR1): ____________
2nd measurement - 6 o’clock (CR2): _____________
3rd measurement - 3 o’clock (CR3): _____________
4th measurement - 9 o’clock (CR4): _____________
CavgR : (CR1+CR2+CR3+CR4) / 4 =___________
23
CEN50138-00 50 Disassembly and assembly
Alternator stator to rotor - measurement “A” 13. With the shipping rotor lock installed, bolt a
12. Place shims between the alternator rotor and calibrated flat steel bar to the rotor as a reference
stator to center the rotor on the stator, see Figure to measure the distance between the alternator
50-32. stator and rotor to determine the reading A1.
NOTE: Whenever alternator is removed from the NOTE: When taking the measurements, ensure that
engine for extended storage or transportation of the the readings are taken from the mating surfaces (see
alternator, rotor shipping locks must be installed. Figure 50-33).
88890
FIGURE 50-33. MEASURING DISTANCE
BETWEEN ALTERNATOR STATOR AND ROTOR
88037
FIGURE 50-32. ALTERNATOR ROTOR
SHIMMING
24
50 Disassembly and assembly CEN50138-00
14. Repeat the same procedure in three more 15. Alternators will have a tag from the manufacturer
locations, 90 degrees apart from each other in indicating rotor end play. See Figure 50-34 for
the perimeter, to find the values A2 , A3 , A4. example of tag. Use ½ the End Play in the
following calculation from the tag.
1st measurement - 45 degrees (A1): ____________
A = Aavg+ ½ End Play(Mfr tag) = ________________
2nd measurement - 135 degrees (A2): _____________
3rd measurement - 225 degrees (A3): _____________
4th measurement - 315 degrees (A4): _____________
Aavg: (A1+A2+A3+A4) / 4 =___________
89011
FIGURE 50-34. EXAMPLE OF
MANUFACTURER’S TAG
25
CEN50138-00 50 Disassembly and assembly
16. To determine the correct shims to use, compare
measurement “C” (step 11) to measurement “A” If A is greater than C, subtract C from A:
(step 15).
A - C = _______________Shim pack thickness
to be installed at stator (location “D”), Figure 50-
If C is greater than A, subtract A from C: 35.
C - A = ______________Shim pack thickness to
Table 3: Alternator-to-Flywheel Housing
be installed at rotor (location “B”), Figure 50-35.
Adapter
Location “D”
Table 2: Rotor-to-Flywheel
Location “B” Shim Part Number Shim Thickness
Shim Part Number Shim Thickness EJ1056 0.10 mm (0.004 in.)
58B-01-00620 0.10 mm (0.004 in.) EJ1055 0.18 mm (0.007 in.)
58B-01-00630 0.18 mm (0.007 in.)
89012
FIGURE 50-35. SHIM LOCATIONS
26
50 Disassembly and assembly CEN50138-00
Attaching traction alternator to engine subframe
23. Measure the height of both alternator side
mounting brackets in the center of the bracket.
Use a calibrated caliper and measue to three
Ensure the lifting device to be used has adequate decimal places in standard or two decimal places
capacity. Lift the traction alternator only at the in metric. Use a paint pen to label the brackets.
lifting eyes. Label the bracket that will be used on the LH side
with a "L". Label the RH bracket with a "R."
17. Remove shims placed between alternator rotor
and stator.
18. Carefully move the traction alternator into place BHeightLH =______________
and engage the engine drive end and the
alternator rotor.
BHeightRH =______________
19. Fasten the alternator stator adapter to the
alternator stator housing and tighten bolts to 240
N·m (175 ft lb).
24. Remove the lifting force from the overhead crane,
20. Install and torque the flexplate assembly to allowing the alternator to hang from the engine.
alternator rotor using the flywheel housing pass- Using a calibrated caliper measure, three
through openings between the starter motors decimal places for standard or two decimal
(openings are on both sides of flywheel housing). places for metric, the height from the top of the
Tighten bolts to 240 N·m (175 ft lb). subframe pad to the underside of the alternator
side mounting lip, in the center of the lip. Repeat
Measurements After Joining the Alternator and on both sides.
Engine
21. Mount a magnetic base on the front of the engine
and a dial indicator on the front of the crankshaft DHeightLH =______________
to measure the total crankshaft endplay.
NOTE: The total engine crankshaft endplay must
match the original measurement before the alternator DHeightRH =______________
was installed. If the new endplay measurement after
the alternator and engine are assembled is less than
the original measurement, re-shimming is required. 25. Using the numbers from step 23, subtract the
numbers from step 24 and add 0.034 in.
(0.87mm) (from manufacturer’s FEA). Then
Total Crankshaft Endplay =______________ divide the new number by 0.01 in. (0.254mm).
Round to the nearest whole number and add that
many 58B-80-03960 shims between the side
22. Rotate the crankshaft one full revolution and mount and the subframe.
listen for any unusual noise caused by moving
components contacting stationary parts.
H = BHeightLH - DHeightLH + 0.034 in. (0.87 mm) =
______________
NShimsLH = H / 0.01 in. (0.254 mm) = ____________
Number of shims for the LH = NShimsLH rounded
to the nearest whole number = ______________
27
CEN50138-00 50 Disassembly and assembly
H = BHeightRH - DHeightRH + 0.034 in. (0.87 mm) =
______________
NShimsRH = H / 0.01 in. (0.254 mm) = ____________
Number of shims for the LH = NShimsRH rounded
to the nearest whole number = ______________
26. Add shims from step 25. Attach the alternator
side mount to the corresponding side of the
alternator. Ensure the top of the mount is sitting
tightly on the alternator side mounting lip and
attach with six 1 in. bolts. Tighten the bolts to 750
ft lbs (1017 N·m). Repeat on the other side of the
alternator.
27. Attach side mount to the subframe with four M24
bolts, tighten to 590 ft lbs (800 N·m). Repeat on
the other side of the alternator.
28
50 Disassembly and assembly CEN50138-00
Engine / alternator attachment checkout
data sheet
Engine measurements
Step 4 = __________ Total Crankshaft Endplay
Step 7 = __________ CR1 (12 o’clock position)
__________ CR2 (3 o’clock position)
__________ CR3 (6 o’clock position)
__________ CR4 (9 o’clock position)
__________ CavgR (CR1 + CR2 + CR3 + CR4)
Step 9 = __________ CF1 (12 o’clock position)
__________ CF2 (3 o’clock position)
__________ CF3 (6 o’clock position)
__________ CF4 (9 o’clock position)
__________ CavgF (CF1 + CF2 + CF3 + CF4)
Step 10 =__________ TEAP = CavgR + CavgF
Step 11 =__________ C = TEAP / 2 + CavgR
Alternator measurements
Step 14 = __________ A1 (45°)
__________ A2 (135°)
__________ A3 (225°)
__________ A4 (315°)
__________ Aavg (A1 + A2 + A3 + A4)
Step 15 = __________ A = Aavg + ½ End playMfr tag
29
CEN50138-00 50 Disassembly and assembly
Shim calculation
Step 16 = __________ If C > A: shim = C - A; shim at rotor
__________ If A > C: shim = A - C; shim at housing
Engine measurement (after alternator attachment)
Step 21 = __________ Total Crankshaft Endplay
NOTE: The total engine crankshaft endplay must match the original measurement taken before the alternator was
installed. If the endplay after the alternator and engine are assembled is less than the original measurement, re-
shimming is required.
Attaching traction alternator to engine subframe
Step 23 = __________ BHeightLH
__________ BHeightRH
Step 24 = __________ DHeightLH
__________ DHeightRH
Step 25 = __________ H = BHeightLH - DHeightLH + 0.034 in. (0.87 mm)
__________ NShimsLH = H / 0.01 in. (0.254 mm)
__________ Number of shims for the LH = NShimsLH rounded to the nearest whole number
__________ H = BHeightRH - DHeightRH + 0.034 in. (0.87 mm)
__________ NShimsRH = H / 0.01 in. (0.254 mm)
__________ Number of shims for the RH = NShimsRH rounded to the nearest whole number
30
50 Disassembly and assembly CEN50138-00
Additional engine measurements
NOTE: It is assumed that the engine flywheel and flexplate runout dimensions are within specification from the
supplier and are therefore not required for new installations. However, these measurements must be used for
service rebuilds and/or troubleshooting to confirm these dimensions are within tolerance specification of the engine
manufacturer.
Flywheel Housing Face Runout
1. Locate the dial indicator base on the machined face of the flywheel/flexplate hub and zero the probe on
the flywheel housing face. See Figure 50-36. Using the engine barring device, slowly rotate the engine
crank through 2 full revolutions. When complete ensure dial indicator returns to zero. The difference
between the highest and lowest values is the face runout TIR (Total Indicated Reading). Limits are shown in
Table 4.
Table 4: Face Runout TIR Limits
FLYWHEEL Flywheel Housing Max Value
HOUSING Cummins "0" 0.25 mm (0.010 in.)
DIAL
Cummins "00" 0.30 mm (0.012 in.)
INDICATOR
SAE Standard J617 0.48 mm (0.019 in.)
FLYWHEEL/
FLEXPLATE
HUB
MAGNETIC
BASE
88042
FIGURE 50-36. FACE RUNOUT DIAL INDICATOR
SETUP
31
CEN50138-00 50 Disassembly and assembly
Flywheel Housing Radial Runout
1. Locate the dial indicator base on the machined face of the flywheel/flexplate hub and zero the probe on the ID
of the pilot bore of the flywheel housing. See Figure 50-37. Using the engine barring device, slowly rotate the
engine crank through 2 full revolutions. When complete insure dial indicator returns to zero. The difference
between the highest and lowest value is the radial runout TIR. Limits are shown Table 5.
Table 5: Radial Runout TIR Limits
FLYWHEEL Flywheel Housing Max Value
DIAL
HOUSING Cummins "0" 0.25 mm (0.010 in.)
INDICATOR
Cummins "00" 0.30 mm (0.012 in.)
SAE Standard J617 0.48 mm (0.019 in.)
NOTE: If the average of the two measurements
exceeds limits, contact your Komatsu representative
for further instructions
FLYWHEEL/
FLEXPLATE
HUB
MAGNETIC
BASE
88043
FIGURE 50-37. RADIAL RUNOUT DIAL
INDICATOR SETUP
32
50 Disassembly and assembly CEN50138-00
Flywheel/Flexplate Face Runout
1. Locate the dial indicator base on the machined face of the flywheel housing and zero the probe on the face of
the flywheel/flexplate. See Figure 50-38. Use an engine barring device to slowly rotate the engine crank
through two full revolutions. When complete, ensure dial indicator returns to zero. The difference between the
highest and lowest value is the face runout TIR. Limits are shown in Table 6 and Table 7.
Table 6: Face Runout TIR Limits
Flywheel Housing Max Value
0.25 mm typ
Cummins "0"
(0.001 in. x MR)
FLYWHEEL 0.30 mm typ
HOUSING Cummins "00"
(0.001 in. x MR)
SAE Standard J620 0.0005 in. x MR
DIAL
INDICATOR Table 7: Face Runout TIR Limits
Flywheel Housing Max Value mm (in.)
Cummins "0" 0.89 mm (0.035 in.)
FLYWHEEL Cummins "00" Flexplate 0.89 mm (0.001 in.)
SAE Standard J620
NOTE: If the average of the two measurements
exceeds limits, contact your Komatsu representative
88044
for further instructions. To measure maximum valve,
FIGURE 50-38. FLYWHEEL/FLEXPLATE FACE multiply value by Measured Radius (MR)
RUNOUT DIAL INDICATOR SETUP
33
CEN50138-00 50 Disassembly and assembly
Flywheel/Flexplate Radial Runout
1. Locate the dial indicator base on the machined face of the flywheel housing and zero the probe on the ID of
the flywheel/flexplate pilot bore. See Figure 50-39. Use an engine barring device to slowly rotate the engine
crankshaft through two full revolutions. When complete, ensure dial indicator returns to zero. The difference
between the highest and lowest value is the radial runout TIR. Limits are shown in Table 8.
FLYWHEEL FLYWHEEL Table 8: Radial Runout TIR Limits
HOUSING
Flywheel Housing Max Value
0.13 mm (0.005 in.)/
Cummins "0"
0.08mm (0.003 in.)
Cummins "00" Flexplate 0.13 mm (0.005 in.)
SAE Standard J620 0.13 mm (0.005 in.)
NOTE: If the average of the two measurements
exceeds limits, contact your Komatsu representative
for further instructions.
DIAL
INDICATOR
88045
FIGURE 50-39. FLYWHEEL/FLEXPLATE RADIAL
RUNOUT DIAL INDICATOR SETUP
34
50 Disassembly and assembly CEN50138-00
Removal and installation of the cooling 3. Evacuate the air conditioning system from the air
module conditioning system. Refer to Testing and
adjusting section Cab air conditioning.
Removal
4. Remove the diagonal ladder and the hood and
1. Park truck on a hard, level surface and block all grille assembly. Refer to Disassembly and
the wheels. assembly section Body and structures for the
2. Place the directional control lever in PARK. Turn removal instructions.
the engine start switch to OFF to shut down the
engine and allow 90 seconds for the steering
system accumulators to bleed down.
The cooling system is pressurized due to thermal
expansion of coolant. DO NOT remove the radiator
cap while the engine and coolant are hot. Severe
burns may result. Allow heat and pressure to
The system is charged with HFC-134A refrigerant.
dissipate before draining the cooling system.
Federal regulations prohibit venting air
conditioning system refrigerants into the 5. Remove the radiator cap, then open drain cocks
atmosphere. An approved recovery/recycle station (1, Figure 50-40). Allow the coolant to drain into
must be used to remove the refrigerant from the suitable containers below the radiator.
air conditioning system. 6. Remove outlet elbows (2, 3) and cap all coolant
lines to prevent contamination.
1 2
2 3
4
89025
FIGURE 50-40. RADIATOR PIPING - LOWER
1. Drain Cock 3. Outlet Elbow (Rear)
2. Outlet Elbow (Front) 4. Fuel Cooler Tube
35
CEN50138-00 50 Disassembly and assembly
NOTE: Refer to the Specification section for the 9. Disconnect top tank tube (3) from radiator.
cooling system capacity. Remove the tube and cap the port at the radiator
7. Disconnect, cap and unclamp two upper surge and engine.
tank hoses (1, Figure 50-41). Mark each hose for 10. Disconnect and unclamp the harness from
proper installation. coolant level switch (4). Remove the switch from
8. Disconnect and cap two lower surge tank hoses the surge tank
(2). Mark each hose for proper installation.
1
4
1
2
3
89048
FIGURE 50-41. RADIATOR PIPING - UPPER
1. Upper Surge Tank Hoses 3. Top Tank Tube
2. Lower Surge Tank Hoses 4. Coolant Level Switch
11. Remove the clamps and disconnect inlet hose (4, .
Figure 50-42) and outlet hose (5) at the
condenser.
12. Remove mounting hardware (3), then remove
condenser (2) from radiator assembly (1).
FIGURE 50-42. AIR CONDITIONER CONDENSER
1. Radiator Assembly 4. Inlet Hose
2. Condenser 5. Outlet Hose
3. Mounting Hardware
36
50 Disassembly and assembly CEN50138-00
13. Disconnect the cooling drive shaft cover and 14. Disconnect the cooling module drive shaft from
mounting hardware (see Figure 50-43). engine crankshaft (see Figure 50-6).
1 2 4
1 2 3
DETAIL A
DETAIL A
B
2
1 2 3
DETAIL B 87999
FIGURE 50-43. COOLING DRIVE SHAFT COVER
1. Capscrew 3. Nut
2. Flatwasher 4. Lockwasher
1
Use lifting equipment with adequate capacity to
remove and install the components.
15. Attach a hoist to the radiator and take up any
slack.
16. Remove upper support rods (1, Figure 50-44)
from both sides of the radiator.
87926
FIGURE 50-44. UPPER SUPPORT ROD
1. Upper Support Rod
37
CEN50138-00 50 Disassembly and assembly
17. Remove the eight bolts from the fan mounting 19. Ensure that all hoses, tubes and wiring have
structure to disconnect it from the main frame been removed. Use the hoist to lift radiator (1,
(see Figure 50-5). Figure 50-46) slightly and move the radiator
18. Remove capscrews (1, Figure 50-45), hardened forward until it is clear of engine fan (2). Move the
flat washers (2), lockwashers (3) and nuts (4) that radiator to a work area for service.
secure the radiator and to the mainframe at eight
locations.
2
3
4 1 87985
FIGURE 50-46. RADIATOR REMOVAL
DETAIL A 87989 1. Radiator 2. Engine Fan
FIGURE 50-45. RADIATOR MOUNTING
HARDWARE REMOVAL
1. Capscrew 3. Lockwasher
2. Flat Washer 4. Nut
38
50 Disassembly and assembly CEN50138-00
Installation 10. Install condenser (2, Figure 50-42) in front of
radiator assembly (1). Install and tighten
mounting hardware (3) to the standard torque.
11. Uncap and connect two upper surge tank hoses
(1, Figure 50-41), two lower surge tank hoses (2)
and two top tank tubes (3) between the radiator
Use lifting equipment with adequate capacity to and the engine. Ensure that the hoses and tubes
remove and install the components. are fully seated. Tighten the clamps securely.
1. Attach a hoist to cooling module (1, Figure 50- 12. Install coolant level switch (4) into the surge tank.
46) and lift it into position on the main frame. Be Connect the harness and tighten the clamps
careful when moving the cooling module back securely.
toward engine. 13. Uncap and install front outlet elbows (2, Figure
2. Install the radiator mounting hardware at the 50-40) and rear outlet elbows (3) at the bottom of
lower radiator mounting brackets. Do not tighten the radiator.
capscrews (1, Figure 50-45) at this time.
14. Connect inlet hose (4, Figure 50-42) and outlet
3. Inspect the rubber mounts for upper support rods hose (5) to the condenser. Install and tighten the
(1, Figure 50-44). Replace the mounts if wear or clamps securely.
damage is evident.
15. Recharge the air conditioning system according
4. Install the upper support rods and the mounting
to the instructions in Testing and adjusting
hardware on both sides of the radiator. Do not
section Cab air conditioning.
tighten the hardware at this time.
5. Adjust the upper support rods until the radiator is 16. Install the diagonal ladder and the hood and grille
positioned perpendicular to the main frame within assembly. Refer to Disassembly and assembly
± 3.0 mm (0.12 in.) measured at top of radiator. section Body and structures for the installation
When the position is established, tighten the instructions.
upper support rod locknuts and recheck the 17. Ensure that coolant drain cocks (1, Figure 50-40)
perpendicularity of the radiator. are closed, all pipe plugs are installed, and all
6. Tighten capscrews (1, Figure 50-45) at the lower hoses and tubes are connected securely. Fill the
radiator mounting brackets to the standard radiator with the recommended mixture and
torque. amount of coolant. Refer to the Operation and
Maintenance Manual for the filling procedure and
7. Reattach the fan mounting structure legs to the
cooling system capacity. Check for leaks and
main frame by installing capscrews (see Figure
repair as needed.
50-5). Tighten the mounting hardware to the
standard torque. 18. Start and operate the engine until the cooling
8. Attach the cooling module drive shaft to the system reaches normal operating temperature.
engine crankshaft (see Figure 50-6). Recheck for leaks during engine operation. Turn
off the engine and repair any leaks.
9. Install drive shaft cover attaching to the engine
dampener guard and fan mounting structure (see
Figure 50-43).
39
CEN50138-00 50 Disassembly and assembly
Repairing the radiator Disassembly
Internal inspection
If desired, an internal inspection can be performed on
the radiator before complete disassembly. The
inspection involves removing tubes from the radiator
core and cutting them open. This type of inspection To aid in removal of the tubes, clean the radiator
can indicate overall radiator condition as well as prior to disassembly. Heating the seals with hot
coolant and additive breakdown. water helps to loosen the grip on the tubes.
Cleaning the radiator prior to disassembly also
To perform this inspection, remove four random tubes
reduces the risk of internal contamination. After
from the air inlet side of the radiator. Remove tubes
cleaning, spray lubricating oil at the top end of the
from both the top and bottom cores and near each end
tubes.
of the radiator. Analyze any contaminant residue
inside the tube to determine the cause of
contamination. Flush the system before returning the
truck to service.
Contact your nearest L&M Radiator facility for further
instructions or visit the L&M website at
www.mesabi.com.
External cleaning
Many radiator shops use a hot alkaline soap, caustic
soda or chemical additives in their boil-out tanks,
which can attack solders. These tanks are generally
not recommended. Before such tanks are used for FIGURE 50-47. BREAKER TOOL (XA2307)
cleaning, ensure that the cleaning solutions are
not harmful to solder. Otherwise, damage to the
radiator will result. Completely rinse the cleaned 1. Start at the top row of tubes. Use breaker tool
(XA2307) to loosen the tube to be removed.
tube or core in clean water after removing it from the
When using the breaker tool, position it at the top
boil-out tank. or bottom of the tube. Never position it in the
As an alternative to boil-out tanks, radiators can be middle of the tube or damage may result. Use the
cleaned externally with a high pressure washer and breaker tool to lightly twist the tube back and forth
soap. In most cases, it may be best to blow out any dry within the seals to loosen the grip. Refer to Figure
dirt with a high pressure air gun prior to washing the 50-47.
core with the high pressure washer.
Pressure washers should not exceed 8 275 kPa
(1,200 psi). Unlike conventional cores, the spray
nozzle can be used right up next to the core. Starting
from the air exit side, place the high pressure washer
nozzle next to the fins. Concentrate on a small area,
slowly working from the top down. Spray straight into
the core, not at an angle. Continue washing until the
exit water is free of dirt. Repeat from the opposite side.
FIGURE 50-48. INSTALLATION TOOL (VJ6567)
40
50 Disassembly and assembly CEN50138-00
2. After the tube is loose, position installation tool Cleaning and inspection
(VJ6567) at the bottom of the tube to be
1. Use a drill with a 19 mm (3/4 in.) wire brush to
removed. Refer to Figure 50-48. The upper jaw of
remove any foreign material from the tube holes,
the installation tool should be positioned just
then wipe the holes clean.
below the rectangular section of the tube. The
bottom jaw should rest on the seal. Squeeze the 2. Clean the inside of the tanks and tubes. In most
installation tool just enough to allow the bottom of cases, just flushing the inside with soap and a
the tube to be removed from the bottom seal. high pressure hot water washer will be sufficient.
If not, contact an L&M manufacturing facility for
NOTE: To ease in the removal of tubes, use the further instructions or visit the L&M website at
breaker tool and installation tool simultaneously. www.mesabi.com.
3. Check for signs of internal blockage in the tubes
and tanks. If desired, you may cut open tubes for
inspection. If contamination is present, the tube
should be analyzed. The radiator must be
properly flushed of all contaminants and
corrective action must be taken to prevent such
contamination from occurring in the future. Refer
to Internal Inspection in this section.
4. Buff the tube ends with a polishing wheel and a
copper polishing compound. If any debris can not
be removed by buffing, using an emery cloth,
steel wool or a wire wheel with a wire size of 0.15
- 0.20 mm (0.006 - 0.008 in.) is acceptable. Be
careful not to mar the tube ends.
FIGURE 50-49. ANGLING TUBE DURING
3. Pull the tube from the top seal while
simultaneously twisting the tube. Angle the tube
only far enough to clear the radiator. Refer to
Figure 50-49. Removing the tube at an excessive
angle may cause damage to the tube.
4. Remove all the top tubes before removing the
bottom tubes. After all of the tubes are removed,
use pliers to remove the seals from the tanks.
Discard all seals. New seals must be used for
assembly.
41
CEN50138-00 50 Disassembly and assembly
Assembly 5. Inspect the seals and tube ends for damage
before trying to reinstall a tube. Replace as
NOTE: For easier installation, soak the seals in hot
necessary.
water before installing.
6. Working from the front of the radiator (opposite of
fan side), install the bottom row of tubes starting
with the fan side row.
When installing the tubes, center the top of the
tube in the top seal while angling the tube only as
much as necessary. Twist the tube while applying
upward force. Push the tube into the seal until
enough clearance is available to install the
bottom end of the tube into the bottom seal.
FIGURE 50-50. PROPER SEAL INSTALLATION
1. Install new tube seals onto the bottom tank and
the bottom side of the center tank. Do not install
seals in the top core at this time. Seals for the top
of the tubes do not have locking grooves; bottom
tube seals do. Ensure the correct seals are
installed in the proper position.
The seal holes must be dry during installation.
Use a rubber mallet and a flat metal plate to FIGURE 50-51. USING INSTALLATION TOOL
lightly tap the seals into place. Using excessive (VJ6567) TO INSTALL TUBE
force will drive the seals in too far. When installed
properly, the seals should be slightly convex.
Improperly installed seals are concave with a 7. Center the bottom end of the tube in the bottom
smaller diameter hole. Refer to Figure 50-50. seal. Push the tube downward until the formed
bead on the tube is seated inside the lock ring
2. Use a 13 mm (1/2 in.) diameter brush to lubricate groove in the seal. If necessary, use installation
the seals with lube/release agent (XA2308). tool (VJ6567) to pull the tube downward into the
3. Use a spray bottle to lubricate the tube ends with seal. The tool has a hooking device on the end of
the lube/release agent. one of the handles for aiding in installation. Refer
4. When installing tubes, start at one end and work to Figure 50-51.
toward the center. After you reach the center, 8. Ensure that all tube beads are seated in their
move to the opposite end, and again work toward respective bottom seals. Align and straighten all
the center. If any of the tubes are difficult to tubes during the installation of each row to allow
install, do not force the tube. Remove the tube maximum air flow through the radiator.
and determine the problem. Possible causes may 9. Install tube stay ends. Install the felt air baffles
be: behind the front and back rows while completing
• inadequate seal/tube lubrication tube installation.
• improperly installed seal 10. After all the tubes are installed, pressure test the
radiator.
• damaged seal or tube end
• tube angle excessive during installation and/or
tube not centered in seal.
42
50 Disassembly and assembly CEN50138-00
Pressure testing Removal and installation of engine
The radiator should be pressure tested at 103 kPa (15 Removal
psi) for 30 minutes. Various methods of pressure
testing include the following: NOTE: Refer to previous sections for removal
procedures for the power module, alternator and
• Pressurize the radiator and submerge into a test cooling module assembly.
tank. Watch for leaks.
• Lay the front side of the radiator on the floor. Cap
off ports, and fill the radiator with hot water.
Pressurize the radiator and check for leaks.
• Cap off radiator ports. Install an air pressure gauge
and pressurize to 103 kPa (15 psi). Remove the air Use lifting equipment with adequate capacity to
source and monitor the pressure gauge. remove and install the components.
• Pressurize the radiator with air, and spray sealed 1. Disconnect all hoses, cables, and harnesses
joints with soapy water.
from the engine, capping and covering everything
that was removed.
Additional service information can be found on the 2. Remove the thermal expansion engine mounting
L&M Radiator website at www.mesabi.com. capscrews that attach the engine to the subframe
Refer to Figure 50-52.
3. To ensure that the engine stays level while lifting,
attach a spreader bar with lifting straps to the
engine lifting eyes.
4. Lift the engine from the subframe and move it to
a clean work area.
Service
Complete instructions for the disassembly, assembly
and maintenance of the engine and its components
can be found in the engine manufacturer's service
manual.
43
CEN50138-00 50 Disassembly and assembly
2
3
DETAIL A
1
4
5
7
6 DETAIL A
8 DETAIL B
DETAIL B
89049
FIGURE 50-52. ENGINE MOUNTING
1. Capscrew 4. T-Spacer 7. Spacer Plate
2. Dowel Pin 5. Belleville Washer 8. Shims
3. Spacer Plate 6. Spacer Plate
Installation 2. At location 6 (see Figure 50-54), install dowel pin
1. Support the engine sub-frame at the front and (2, Figure 50-52), spacer plate (3), and capscrew
rear sub-frame mounts (1, Figure 50-53) to form (1). Tighten capscrew to 565 N·m (417 ft lb). At
a level plane. location 3, install spacer plate (3).
RIGHT
1 2 3
FRONT REAR
4 5 6
1 1 LEFT 89013
89010
FIGURE 50-53. ENGINE SUBFRAME MOUNTS FIGURE 50-54. ENGINE MOUNT LOCATIONS
1. Subframe Mount
44
50 Disassembly and assembly CEN50138-00
3. At location 4, place circular spacer plate (3, 7. At location 4, install the slip joint assembly as
Figure 50-55). The groove on the spacer must follows, install belleville washers (5, Figure 50-
face upwards. 52), and spacer plate (6) onto T-spacer (4). Make
4. Place the engine on the sub-frame. At location 4, sure the white dot on each belleville washer is
install dowel (1, Figure 50-55) through the engine facing up. Make sure the groove in the spacer
mount into tapped hole (2). This dowel and the plates are facing towards the engine foot. Place
dowel pin installed at location 6 are used to align slip joint assembly into the engine mounting foot
the engine to the sub-frame. center hole. Install capscrew (1) hand tight.
8. At locations 1, 2, and 5 install the slip joint
assembly as follows, install belleville washers (1,
Figure 50-56) and spacer plate (2) onto T-spacer
(3). Make sure that the white dot on each
1 belleville washer is facing up. Make sure the
groove in spacer plates face towards the engine
foot. Place slip joint assembly into the engine
mounting feet center holes. Install capscrew (4)
hand tight.
2
4
3
3 1
89050
FIGURE 50-55. DOWEL INSTALLATION
5 2
1. Dowel 3. Spacer Plate
2. Tapped Hole
6
5. Make sure that the engine mounting feet are in
contact with the spacer plates at locations 3, 4,
and 6. 89050
6. At locations 1, 2, and 5, place a circular spacer FIGURE 50-56. SLIP JOINT ASSEMBLY
plate (5, Figure 50-56). The groove on the spacer AND SHIMS
must face upwards. 1. Belleville Washers 4. Capscrew
2. Spacer Plate 5. Spacer Plate
3. T-spacer 6. Shims
45
CEN50138-00 50 Disassembly and assembly
9. Shimming will be required at locations 1, 2, and 12. Lower the engine and remove the lifting
5. Place shims (6) between circular spacer plates equipment.
(5) and the mounting surfaces of the sub-frame. 13. Retighten the capscrew at location 6 to 565 N·m
Begin with the thickest shims and progress to the (417 ft lb).
thinner shims until no more shims can be added.
14. Tighten capscrew at location 4 to 1 250 N·m (921
10. After the shimming process with the standard ft b).
shims, there are additional shims that must be
added to compensate for the engine block 15. Tighten the four capscrews at locations 3 and 6
sagging from its own weight. These shims are and the three capscrews at locations 1, 2, and 5
red. to 1 050 N·m (775 ft lb).
11. Raise the engine slightly so that it does not 16. Remove the dowel pin at location 4.
disengage from the alignment dowels. Add the 17. Add lithium base NLGI multipurpose grease to
red shims between the spacer plates and each engine foot grease port at locations 1, 2, 4
standard shim packs at the following locations and 5.
and the following quantities:
Location 5 - 1 shim
The final shim pack should be arranged as fol-
lows (from top to bottom):
1. Engine foot
2. Spacer plate
3. Red shim(s)
4. Standard shim pack
5. Sub-frame
46
50 Disassembly and assembly CEN50138-00
47
CEN50138-00 50 Disassembly and assembly
980E Dump truck
Form No. CEN50138-00
48
CEN90014-03
DUMP TRUCK 1SHOP MANUAL
980E
Machine model Serial number
980E-4 A40003 and up
980E-5 A50005 and up
90 Diagrams and drawings
Hydraulic circuit diagrams
Steering, hoist and brake cooling hydraulic circuit schematic...........................................................58B-60-21400
Brake hydraulic circuit schematic......................................................................................................58F-60-00841
Auxiliary system hydraulic circuit schematic .....................................................................................58E-60-01680
1
CEN90014-03 90 Diagrams and drawings
NOTES
2
58B-60-21400-03 JAN 19
STEERING, HOIST & BRAKE COOLING
HYDRAULICS SCHEMATIC
980E-4: A40003 & UP
980E-5: A50005 & UP
58F-60-00841-03 DEC 19
BRAKE HYDRAULICS SCHEMATIC
930E-5, 980E-4, 980E-5
58E-60-01680-03 FEB 21
AUXILIARY HYDRAULIC SCHEMATIC
CEN90014-03 90 Diagrams and drawings
980E Dump truck
Form No. CEN90014-03
4
CEN90033-01
DUMP TRUCK 1SHOP MANUAL
980E
Machine model Serial number
980E-5 A50052, A50053,
A50137, A50138
90 Diagrams and drawings
Electrical circuit diagrams
Electrical circuit diagram ...................................................................................................................58B-06-05901
HVAC circuit diagram ........................................................................................................................58B-06-06830
1
CEN90033-01 90 Diagrams and drawings
NOTES
2
SYMBOL LEGEND
HARNESS DESIGNATION TABLE CABLE DESIGNATION TABLE CIRCUIT INDEX
SWITCHES RELAYS OTHER
REFERENCE PART NUMBER DESCRIPTION ATTRIBUTE PART NO. DESCRIPTION CIRCUIT SHT
AA1 58E-06-04906 WIRING HARNESS, AUX INTERN AA24 58E-06-07590 CABLE, WABTECH GROUND 12VDC SUPPLY & CUSTOMER OPTIONAL ACCESSORY POWER 4
AA2 58E-06-04913 WIRING HARNESS, AUX INTERN PWR AA25 58E-06-07580 CABLE, WABTECH 24V POWER AHT CONNECTIONS OPTION 15
AA3 58E-06-04926 WIRING HARNESS, GE INTER AJ3 58B-06-23090 CABLE, AUX BOX GND AUTO LUBE 12 SPST NC SPST NO
AA4 58E-06-04603 WIRING HARNESS, PLM4 AK1 58B-06-23080 CABLE, AUX BOX POS AUX BOX DOME LIGHTS 4 T COIL TYPE T DIODE
ZENER RESISTOR
VARISTOR
AA5 58E-06-04932 WIRING HARNESS, CAN RPC EE4 58E-06-04461 WIRING HARNESS, PRELUBE POWER CABLE 1/0 RED AUX BOX FRAME GROUND CONNECTIONS 4 DIODE
SOLENOID TIMER
AA6 58E-06-05572 CABLE, CAT5E GE-SWITCH EE5 58F-06-02490 WIRING HARNESS, PRELUBE GND CABLE 1/0 BLK AUX BOX PANEL GROUNDS 4 PUSH BUTTON 7
SOLENOID
EE6 CH4517 CBL STR 2/0 BATTERY BLK MOMENTARY
AA7 XC2803 WIRING HARNESS, AHT PLUG1 BACKUP LAMPS 10 +
SWITCH, PUSH PULL SWITCH
AA8 58E-06-04960 WIRING HARNESS, AHT PLUG2 EE9 CH4605 CABLE, STR 2/0 RED PVC BATTERY BOX 2 PUSH TO TURN ON CONFIGURATION POLARIZED
CONTACT, NO CONTACT, NC CAPACITOR
AA9 58E-06-04972 WIRING HARNESS, CAN RPC EE11 CH4526 CABLE, STR 2/0 BLK PVC CAB ENTERTAINMENT RADIO 4 LIMIT SWITCH PULL TO TURN OFF POTENTIOMETER CAPACITOR
AA10 58E-06-04982 WIRING HARNESS, CAN J1939 EE13 58B-06-23240 CABLE, STR 2/0 BLK PVC CAN J1939 NETWORK 14
AA11 58E-06-04992 WIRING HARNESS, CAN J1939 EE14 58B-06-23230 CABLE, STR 2/0 RED PVC CAN RPC NETWORK 14
MOTOR
AA12 58E-06-05302 WIRING HARNESS, CAN RPC EJ1 58B-06-23200 CABLE, ALTERNATOR GND CAN THIRD PARTY NETWORK 14 TEMPERATURE
CONTACT, SPDT (+) (-)
SWITCH
AA13 58E-06-05712 WIRING HARNESS, CAN J1939 EK2 58B-06-23190 CABLE, ALTERNATOR POS CONNECTOR TABLE 21 FLOAT SWITCH
MOTOR SEN ANTENNA
AA14 58E-06-05722 WIRING HARNESS, CAN J1939 EN1 58B-06-23130 CABLE, STARTER POS DEVICE TABLE 20 ALTERNATOR
AA15 58E-06-05582 CABLE, CAT5E PLM-SWITCH EN2 58B-06-23120 CABLE, STARTER POS DIRECTIONAL SHIFTER/ PARK BRAKE 6 ANNUNCIATOR
PRESSURE SWITCH
AA16 58E-06-05591 CABLE, CAT5E SWITCH POWER EN3 58B-06-23160 CABLE, STARTER GND ENGINE INTERFACE 5
AA18 58E-06-08310 CABLE, GROUND EN4 58B-06-23150 CABLE, STARTER GND ENGINE OIL RESERVE SYSTEM OPTION 5
AA19 58E-06-08320 CABLE, GROUND EN5 58F-06-10970 CABLE, PRELUBE ENGINE SERVICE LAMPS 9
CONTACT, SPDT
AA20 58E-06-08331 CABLE, GROUND EN6 58B-06-23260 CABLE, PRELUBE ENGINE SHUTTERS/ ETHER START OPTIONS 15 GANGED
AA21 58E-06-07060 CABLE, CAT5E EN7 58B-06-23170 CABLE, STARTER GND ENGINE START CIRCUIT 2
AA22 58E-06-07060 CABLE, CAT5E EN8 58B-06-23140 CABLE, STARTER POS ETHERNET SWITCH WIRING 11
AA26 58E-06-07060 CABLE, CAT5E JN1 58B-06-23340 CABLE, 4/0 BLK PVC FOG LAMPS 8
AA28 58E-06-09290 CABLE, VID ETHERNET KK2 CH5828 CABLE, STR 4/0 RED PVC FRAME & OP-CAB HARNESS LAYOUT 1
AA29
AA30
AA31
58E-06-09960
58E-06-09971
58E-06-09980
WIRING HARNESS, AUX-CAB OP CNTRLS INT
WIRING HARNESS,AUX-CAB CONSOLE INTER
WIRING HARNESS,AUX-CAB DASH INTER
KK3
KK4
KK5
CH5827
CH5755
CH5756
CABLE, STR 4/0 RED PVC
CABLE, STR BATTERY BLACK
CABLE, STR 4/0 BATTERY BLACK
FRONT TURN/ CLEARANCE LAMPS, HAZARD SWITCH/ CAB DO...
FRONT VEHICLE HORN
HARNESS REFERENCE
8
10
1
LIGHTS POWER SENSORS SHIELDS
AA32 58E-06-09990 WIRING HARNESS, AUX-CAB BASIC INTER KK6 CH5829 CABLE STR 4/0 BATTERY RED HEADLIGHT LAMPS 7
- +
AA33 58E-06-09950 WIRING HARNESS, AUXB HYD INTER KK7 CH5829 CABLE STR 4/0 BATTERY RED HEATED MIRRORS 13 CIRCUIT
AA36 58F-98-50050 WIRING HARNESS, MEMS PWR KK8 58F-06-02901 CABLE, 2/0 RED PVC HOIST CONTROL 9 BATTERY BREAKER PRESSURE TEMPERATURE
LED INCANDESCENT SENSOR SENSOR
AB1 58F-06-02671 WIRING HARNESS, AUXB HYD KN1 58B-06-23000 CABLE, 4/0 RED PVC HOT START OPTION 15
LAMP MULTICONDUCTOR
AC1 58F-06-02613 WIRING HARNESS, AUX-CAB OP CONTROLS KN2 58B-06-23310 CABLE, 4/0 RED PVC HYD BRAKE CABINET 3 FUSE CABLE TO GROUND
KN3 58B-06-23320 INDICATOR TERMINATED
AC2 58B-06-23290 WIRING HARNESS, AUX-CAB CONSOLE CABLE, 4/0 BATT BLK HYD BRAKE CABINET 5
CHASSIS SHIELD
AC3 58F-06-02634 WIRING HARNESS, AUX-CAB DASH KN4 58B-06-23330 CABLE, 4/0 BATT BLK HYD CABINET LAMP 10 GROUND
AC4 58B-06-23370 WIRING HARNESS, AUX-CAB BASIC ST1 58F-06-02951 CABLE, F1 HYDRAULIC LADDER OPTION 18
AC51 58E-06-08651 WIRING HARNESS, ETHERNET EXT ST2 58F-06-03561 CABLE, F2 INTERFACE MODULE 3
AD1 58B-06-23070 WIRING HARNESS, REAR WHEEL SPD ST3 58B-06-23460 CABLE, T19 INTERFACE MODULE 12
AE1 58B-06-23040 WIRING HARNESS, AUX-QSK95 ST4 58B-06-23470 CABLE, T20 ISOLATION STATION 2
AF1 58B-06-23350 WIRING HARNESS, PLM ABOX TD1 58B-06-23400 CABLE, TM1 TA KEY SWITCH/ ENGINE SHUTDOWN 3
AG2
AH1
AH2
58B-06-23520
58B-06-23060
58B-06-23020
WIRING HARNESS, AUX-LEFT DECK
WIRING HARNESS, RIGHT FRONT
WIRING HARNESS, RH REAR
TD2
TD3
TD4
58B-06-23410
58B-06-23420
58B-06-23430
CABLE, TM1 TB
CABLE, TM1 TC
CABLE, TM2 TA
KOMTRAX PLUS MODULE/ ORBCOMM MODULE
KOMVISION AUTOLIV NETWORKS
KOMVISION CIRCUIT
11
16
17
WIRE LEGEND CONNECTOR / DEVICE
AJ1
AJ2
AR1
58B-06-23030
58B-06-23010
58B-06-23050
WIRING HARNESS, LEFT FRONT
WIRING HARNESS, LH REAR
WIRING HARNESS, FRONT WHEEL SPD
TD5
TD6
TT2
58B-06-23440
58B-06-23450
58B-06-23490
CABLE, TM2 TB
CABLE, TM2 TC
CABLE, WMB MAIN PHASE
KOMVISION SWITCH PANEL
LADDER LAMPS
MULTIFUNCTIONAL OPERTOR DISPLAY
16
8
7
WIRE DESIGNATION
11KS-002-AA1 (BRN 16ga)
WIRE GAUGE INSTANCES
UNIQUE IDENTIFIER WIRE COLOR
BB1 58F-06-02483 WIRING HARNESS, IND BRAKE HYD CABINET TT5 58B-06-23480 CABLE, CGB MAIN PHASE OP CAB WINDOW MOTORS 14 JACK PLUG DEVICE
BC1 58E-06-09231 WIRING HARNESS, WASHER OPERATOR CAB FANS 13 HARNESS ATTRIBUTE
CC1 58E-06-05884 WIRING HARNESS, OP CONTROLS OPERATOR CAB HVAC 5
CC2 58E-06-05896 WIRING HARNESS, CENTER CONSOLE OPERATOR CAB SEATS 6
SINGLE
HARNESS ATTRIBUTE LEGEND
CC3 58E-06-05906 WIRING HARNESS, CAB DASH PAYLOAD METER 4 13 SINGLE SINGLE
INSTANCE INSTANCE
INSTANCE
CC4 58E-06-05916 WIRING HARNESS, BASIC CAB REAR AXLE SERVICE LAMP 10
CC6 58E-06-12240 WIRING HARNESS, KOMVISION REAR TURN/ TAIL/ STOP LAMPS 10
AC3
CC9 58E-06-02193 WIRING HARNESS, DOOR DRIV ROTATING BEACON OPTION 13
MULTIPLE MULTIPLE MULTIPLE
CC10 58E-06-02203 WIRING HARNESS, DOOR PASS SHEET INDEX 1 INSTANCE INSTANCE INSTANCE
HARNESS ORIGIN HARNESS DESTINATION UNIQUE ID NO
CC12 58E-06-91304 WIRING HARNESS, ARCS CAB SPARE WIRES 7 SEE TABLE BELOW SEE TABLE BELOW
CC13 58E-06-91313 WIRING HARNESS, CAB CAM TERMINAL BOARD TABLE 20
CC14 58E-06-30410 WIRING HARNESS, BEACON VEC BLOCK/ GROUND/ POWER DISTRIBUTION 4
HARNESS DESIGNATION KEY
CC15 58D-06-01890 WIRING HARNESS, KVIS DISP WABTECH ALTERNATOR & WHEEL MOTOR POWER CIRCUIT 4
_______________________
CD2 58B-06-23540 WIRING HARNESS, RADAR 5-8 WABTECH INTERFACE 11
HARNESS TRUCK INSTANCES OF THE SAME DEVICE / CONNECTOR
CF1 58B-06-23560 WIRING HARNESS, CAM 2-4 WABTECH INTERFACE & WHEEL MOTOR SPEED SENSORS 9 MAY BE SPREAD ACROSS MULTIPLE SHEETS
CL1 58B-06-23550 WIRING HARNESS, CAM 1,5,6 WINDSHIELD WIPER/ WASHER 10
DESIGNATION LOCATION
CR1 58B-06-23530 WIRING HARNESS, RADAR 1-4 WIRE TABLE 19 _______________________
DD1 58F-06-01891 WIRING HARNESS, REAR AXLE HSG WRG A AUXILIARY CABINET
DD2 58E-06-08381 WIRING HARNESS, LIGHT BAR B BRAKE CABINET
DD3 58F-06-03030 WIRING HARNESS, REAR AXLE SERVICE LT C OPERATOR CAB
DD4 EL9925 HARNESS STR D REAR CASE
DD6 58F-06-03670 WIRING HARNESS, RADAR 5-6 E ENGINE
EE1 58B-06-23110 WIRING HARNESS, EXT QSK95
F RIGHT DECK
EE2 58B-06-23380 WIRING HARNESS, TITS JMPR
G LEFT DECK
EE12 58F-06-20690 WIRING HARNESS, FAN CLUTCH
EH2 58F-06-05330 WIRING HARNESS, DEF LH FILL
H RIGHT FRAME
EH3 58B-06-19501 WIRING HARNESS, DEF SYS
J LEFT FRAME
EH4 58F-06-21160 WIRING HARNESS, DEF RH SCR K BATTERY BOX
EH5 58E-06-21320 WIRING HARNESS, DEF SCR JMPR L RADIATOR GRILL
EH7 58B-06-19401 WIRING HARNESS, DEF SYS BANK 2 M BODY
EH9 58E-06-21300 WIRING HARNESS, DEF PUMP JMPR N ISOLATION STATION
EH10 58E-06-21330 WIRING HARNESS, DEF NOX JMPR P PANTOGRAPH
EH11 58E-06-21300 WIRING HARNESS, DEF PUMP JMPR R FRONT FRAME
EH12 58E-06-21340 WIRING HARNESS, DEF DOSER JMPR
S PROPULSION ALTERNATOR
EH13 58E-06-21300 WIRING HARNESS, DEF PUMP JMPR
T CONTROL CABINET
EH14 58E-06-21330 WIRING HARNESS, DEF NOX JMPR
U AHT ODS BOX
EH15 58E-06-21950 WIRING HARNESS, DEF DOSR JMPR
EH16 58E-06-21950 WIRING HARNESS, DEF DOSR JMPR
EJ4 58F-06-21170 WIRING HARNESS, DEF LH SCR
EJ9 58B-06-19301 WIRING HARNESS, DEF SYS BANK 1
EJ10 58E-06-21320 WIRING HARNESS, DEF SCR JMPR
EJ11 58E-06-21300 WIRING HARNESS, DEF PUMP JMPR
EJ12 58E-06-21300 WIRING HARNESS, DEF PUMP JMPR
EJ13 58E-06-21330 WIRING HARNESS, DEF NOX JMPR
EJ14 58B-06-21960 WIRING HARNESS, DEF DOSR JMPR
EJ15 58B-06-21960 WIRING HARNESS, DEF DOSR JMPR
ER1 58B-06-23180 WIRING HARNESS, RADIATOR
FF1 58B-06-23100 WIRING HARNESS, DECK RH
FF3 58F-06-02830 WIRING HARNESS, DIAGONAL LADDER LIGHT
FF4 58F-06-02790 WIRING HARNESS, DECK LIGHTS
FG1 58B-06-23360 WIRING HARNESS, PLM4 LH/RH
FH1 58B-06-23220 WIRING HARNESS, UPRIGHT RH
FT1 58B-06-23500 WIRING HARNESS, GB SPD SENSORS
GG1 58B-06-23000 WIRING HARNESS, DECK LH
GG3 58F-06-02840 WIRING HARNESS, DECK LIGHTS
GG5 58F-06-02890 WIRING HARNESS, DIAGONAL LADDER LIGHT
GJ1 58B-06-23210 WIRING HARNESS, UPRIGHT LH
HH1 58B-06-19031 WIRING HARNESS, DEF RELAY
HH3 EM7830 JUMPER HARNESS LLSW
HH4 58E-06-00032 WIRING HARNESS, FUEL TANK
HH5 58B-06-21970 WIRING HARNESS, ESDS JUMPER
HH8 58F-06-05570 WIRING HARNESS, MEMS JUMPER
HH9 58F-06-05570 WIRING HARNESS, MEMS JUMPER
HH10 58E-06-21310 WIRING HARNESS, DEF PUMP HEATER JMPR
HH12 58B-06-21310 WIRING HARNESS, DEF PUMP HEATER JMPR
HH13 58B-06-21310 WIRING HARNESS, DEF PUMP HEATER JMPR
HH14 58B-06-21310 WIRING HARNESS, DEF PUMP HEATER JMPR
HH15 58B-06-21310 WIRING HARNESS, DEF PUMP HEATER JMPR
HJ1 58B-06-23390 WIRING HARNESS, AUX MAN
HL1 58B-06-23280 WIRING HARNESS, RH HEADLIGHT
JJ1 58F-06-41880 WIRING HARNESS, AUTO LUBE
JJ2 58F-06-01791 WIRING HARNESS, LLSW
JJ5 58B-06-21270 WIRING HARNESS, ESDS JUMPER
JL1 58B-06-23270 WIRING HARNESS, LH HEADLIGHT
JR1 58F-06-02852 WIRING HARNESS, RLS
MM1 58F-06-02982 WIRING HARNESS, RIGHT BODY LTS
MM2 58F-06-02992 WIRING HARNESS, LEFT BODY LTS
NN1 58E-06-01311 WIRING HARNESS, ISO STATION IND
TT1 58B-06-23510 WIRING HARNESS, WM/CG SPD SENSORS
TT2 58F-06-03041 WIRING HARNESS, WMB MAIN PHASE
TT3 58E-06-13131 WIRING HARNESS, TRANS PRI
58B-06-05901-00 SEP 21
ELECTRICAL SCHEMATIC
980E-5
A50052, A50053, A50137, A50138
Sheet 1 of 21
BATTERY BOX / ISOLATION STATION BATTERY ISOLATION STATION
LAMP LED SYSTEM OPERATING 7
BAT(+)-015-NN1 (RED 16ga ) 1 RED
2 BLACK
SYS
58E-06-01990
TB27
74SB1-004-NN1 (DBL 16ga ) 4 4 74SB1-003-AJ1 (DBL 16ga ) 7 7 74SB1-002-AA1 (DBL 18ga ) N1 N2 74SB1-005-AA30 (DBL 18ga ) SH17:J-17
71GG-000-NN1 (YEL 16ga ) 3 3 71GG-001-AJ1 (YEL 16ga ) SH3:A-2 P12 AHT CONNECTION N3
J12
SWITCH PROPEL LOCKOUT (PLOS) SH7:G-18 74SB1-010-AA1 (DBL 18ga ) P1 P2 74SB1-016-AA31 (DBL 18ga ) SH11:G-17
71GG-000-NN1 (YEL 16ga ) 71GH-000-NN1 (ORG 16ga ) 2 2 71GH-001-AJ1 (ORG 16ga ) SH3:B-2 P3 74SB1-015-AA3 (DBL 20ga ) SH11:B-4
BAT(+)-015-NN1 (RED 16ga ) 71PS-000-NN1 (LBL 16ga ) D70
BAT(+)-013-NN1 (RED 16ga )
2 1 72RQ-000-NN1 (GRY 16ga ) 1 1 72RQ-001-AJ1 (GRY 16ga ) SH11:K-6
PC2528
CH5509 CH5510 D70 PC2834 D70 J537 P537
JUMPSTART1 JUMPSTART2
71PS-001-NN1 (LBL 16ga )
RELAY PROPEL LOCKOUT
1
2
1
2
(+) (-) LAMP LED PROPEL LOCKOUT ON
86 85
BATTERY BOX
BAT(-)-010-CH5509 (BLK 2/0 ) LW79257 RED 4/0 (NO)
1 RED
11-008-CH5509 (RED 2/0 ) 87 72RRQ-001-NN1 (DBL 16ga )
BATT5 BATT6
11-009-CH5510 (RED 2/0 ) LW79357 BLK 4/0 30 (C)
(NC)
0-032-NN1 (BLK 16ga ) 2 BLACK
87A PLON
- + - + BAT(+)-009-NN1 (RED 16ga )
1 1-002-KK1 (RED 4/0 ) 1 BAT(+)-002-KK9 (RED 4/0 ) 58E-06-01990
PLREL_K 58E-06-10020
58D-06-01190 58D-06-01190 PLREL_K
LAMP LED PROPEL LOCKOUT LOCKED OUT
BATT1 BATT2 RELAY STARTER LOCKOUT
- + - + (+) (-)
1-000-KK6 (RED 4/0 ) BAT(+)-000-KK2 (RED 4/0 ) BUS BAR 86 85 72RRQ-000-NN1 (DBL 16ga ) 1 RED
24VDC
58D-06-01190 58D-06-01190 BATT BOX 2 BLACK
0-033-NN1 (BLK 16ga )
XB3583 (NO) 87
PLLO
BAT(+)-009-NN1 (RED 16ga ) 30 (C) 58E-06-01990
BATT3 BATT4 1 (NC)87A
BAT(+)-007-KN1 (RED 4/0 ) BAT(+)-010-NN1 (RED 16ga ) 0-448-NN1 (BLK 16ga ) 8
- + - +
1-001-KK7 (RED 4/0 ) BAT(+)-001-KK3 (RED 4/0 ) 0-033-NN1 (BLK 16ga ) 7
1 58E-06-10020
BAT(+)-008-KN2 (RED 4/0 ) BAT(+)-011-NN1 (RED 16ga ) 0-032-NN1 (BLK 16ga ) 6
58D-06-01190 58D-06-01190 SLREL_K SLREL_K
BAT(+)-012-NN1 (RED 16ga ) 0-030-NN1 (BLK 16ga ) 5 56B-06-11530
BAT(+)-005-KK8 (RED 2/0 ) BAT(+)-0010-KN5 (RED 4/0 ) 0-031-NN1 (BLK 16ga ) 4
2
3
BAT(-)-020-CH5510 (BLK 2/0 ) STARTER DISCONNECT (SDISC) 2
EC1725 0-027-NN1 (BLK 16ga ) 1 LAMP LED STARTER
BAT(-)-001-KK4 (BLK 4/0 ) LOCKOUT OPEN
JB1
1
11ST-001-EN2 (RED 4/0 )
BAT(-)-000-KK5 (BLK 4/0 )
11ST-000-EN5 (RED 1/0 ) 1S-000-NN1 (DGR 16ga ) 1 RED
11ST-005-NN1 (RED 16ga )
11ST-002-EN1 (RED 4/0 ) 11ST-006-NN1 (RED 16ga ) 0-034-NN1 (BLK 16ga ) 2 BLACK
BUSS BAR BAT(-) RELAY MASTER SLLO
XB3617 11ST-007-EN8 (RED 4/0 ) DISCONNECT 58E-06-01990
(+) (-)
BAT(+)-014-NN1 (RED 16ga ) 86 85 LAMP LED STARTER LOCKOUT CLOSED
BAT(-)-006-KK10 (BLK 4/0 ) BAT(-)-002-KN3 (BLK 4/0 ) 1
1 (NO) 87 1 RED
BAT(-)-003-KN4 (BLK 4/0 )
30 (C)
(NC) 87A 2 BLACK
BAT(-)-005-KN6 (BLK 4/0 ) SWITCH MASTER 0-366-NN1 (BLK 16ga )
2
GROUND MLREL_K 58E-06-10020 SLON
DISCONNECT MLREL_K 58E-06-01990
(DISC-)
EC1725 LAMP LED MASTER DISCONNECT CLOSED
1
0-004-EN3 (BLK 4/0 )
0-003-EN4 (BLK 4/0 ) BAT(+)-011-NN1 (RED 16ga ) 1 RED
BATTERY BOX FUSE HOLDER 0-000-JN1 (BLK 4/0 ) 0-026-NN1 (BLK 16ga ) 0-026-NN1 (BLK 16ga ) 2 BLACK
AUX BOX
300A 0-027-NN1 (BLK 16ga ) MLLON
A1 B1 11-007-AK1 (RED 4/0 ) SH4:B-4 58E-06-01990
58E-06-07090
FH2-2
ALT 1
300A LAMP LED MASTER DISCONNECT OPEN
A2 B2
58E-06-07090
FH1-2 FH1-1
ALT 2
1M-000-NN1 (LTG 16ga ) 1 RED
300A
A3 B3
58E-06-07090
BAT(-)-004-NN1 (BLK 16ga ) 2 BLACK
58B-06-02580
MLLO
58E-06-01990
24VDC ALTERNATOR
SEN GB70 FRAME GND
A1 A2
11-027-EK2 (RED 4/0 ) (+) (-) 0-001-EJ1 (BLK 4/0 ) 0-000-JN1 (BLK 4/0 )
ALT(+) ALT(-) B2
0-002-AJ3 (BLK 4/0 ) SH4:F-6
B3
0-398-EE6 (BLK 2/0 )
GB3 ENG GND BLOCK
A1 0-010-EN7 (BLK 4/0 )
SINGLE
MOTOR STARTER 3 (STRT3)
1 2
21PT-013-EE1 (DBL 14ga )
BOTTOM
11ST-003-EE9 (RED 2/0 ) MOTOR STARTER 2 (STRT2) 3A 4
1 2
3B
TOP
MOTOR STARTER 1 (STRT1) 3A 4
1 2 5 6
3B 11
11ST-007-EN8 (RED 4/0 )
7A 10A
3A 4
MOTOR
5 6 7B 10B
3B 11
7A 10A 7C 10C
8 9
MOTOR
5 6 7B 10B 58F-06-11230
11
0-043-EE13 (BLK 2/0 )
7A 10A 7C 10C
8 9
MOTOR
7B 10B 58F-06-11230
7C 10C
8 9
0-028-EE11 (BLK 2/0 )
58F-06-11230
ENGINE STARTERS
11ST-008-EE14 (RED 2/0 )
IM2
TB28
D91 19 19 43 43 25 START MOTOR 2
11SM2-000-EE1 (DGR 14ga ) 11SM2-001-AE1 (DGR 14ga ) 11SM2-003-AA1 (DGR 14ga ) G2 G1 11SM2-002-AA1 (ORG 20ga )
11SM3-000-EE1 (YEL 14ga ) 2 1 11SM1-004-EE1 (GRY 14ga )
11SM1-003-AA1 (GRY 14ga ) F2 F1 11SM1-002-AA1 (PNK 20ga ) 14 START MOTOR 1
D90 PC2834 20 20 44 44
11SM1-000-EE1 (GRY 14ga ) 11SM1-001-AE1 (GRY 14ga ) IM2
11SM4-000-EE1 (PUR 14ga ) 2 1 11SM1-005-EE1 (GRY 14ga ) SP12515
PC2834
21PT-002-EE1 (DBL 14ga ) 22 22 21PT-007-AE1 (DBL 14ga ) 46 46 21PT-008-AA1 (DBL 14ga ) SH4:E-2
21PS-004-EE1 (BRN 14ga ) 21PS-002-EE1 (BRN 14ga ) 21 21 21PS-001-AE1 (BRN 14ga ) 45 45 21PS-006-AA1 (BRN 14ga ) SH3:K-11
SP108
ENGINE PRE LUBE OIL PRESS SW (PLPSW) GB31-B AUXBOX GND BLCK
NOTE: D1
SH5:K-4 0-087-EE1 (BLK 16ga ) 0-718-EE1 (BLK 14ga ) 23 23 0-719-AE1 (BLK 14ga ) 39 39 0-720-AA1 (BLK 14ga )
DIODE D87 PROVIDES CONTINUOUS
1 2 21PT-003-EE1 (DBL 14ga ) SH5:K-5 0-088-EE1 (BLK 14ga ) SP412
PRE-LUBE DURING CRANKING
PLPSW PLPSW D87 P17 J17
JB12F J808 P808
21PT-012-EE1 (DBL 14ga ) 2 1
1 21PT-013-EE1 (DBL 14ga )
2 PC2834
21PT-011-EE1 (DBL 14ga )
3 21PT-000-EE1 (DBL 14ga )
4 RELAY ENGINE PRE LUBE
5 86 85 0-042-EE1 (BLK 14ga )
6
7 21PT-005-EE1 (DBL 14ga )
8 21PT-004-EE1 (DBL 14ga ) 87
9 30 21PS-005-EE1 (BRN 14ga )
10 87A
11 P800
12 PC1146
P800 21PL-001-EE1 (DBL 14ga )
58E-06-02630
RELAY ENGINE PRE LUBE
MAG SWITCH (PLMS)
+ -
0-717-EE1 (BLK 14ga )
21PL-000-EE1 (DBL 14ga )
PRE LUBE HIGH VOLUME PUMP
FUSELINK1 (175A) 1 2 GB3 ENG GND BLOCK
PUMP B3
11PL-000-EN6 (RED 1/0 ) 11PF-000-EE4 (RED 1/0 ) + - 0-040-EE5 (BLK 1/0 )
175A
58E-06-09520 PLPM-(+) PLPM-(-)
ENGINE START PRE-LUBE 58B-06-05901-00 SEP 21
ELECTRICAL SCHEMATIC
980E-5
A50052, A50053, A50137, A50138
Sheet 2 of 21
7
SH2:C-19 71GG-001-AJ1 (YEL 16ga ) 31 31 71GG-002-AA1 (YEL 16ga )
SH2:D-19 71GH-001-AJ1 (ORG 16ga ) 30 30 71GH-002-AA1 (ORG 16ga )
P12 J12
TB34 VEC-90 F17 VEC-90
2E 2F GE CONTROL INTERFACE
SWITCH LEFT GROUND SH13:I-8 39G-001-AA4 (DBL 18ga ) T2 T1 39G-000-AA1 (DBL 16ga ) E F 11-010-AA1 (RED 16ga ) SH4:B-4
5 TB25
LEVEL SHUTDOWN (ESDS)
71GG-002-AA1 (YEL 16ga ) K1 K2 71GG-003-AA3 (YEL 20ga ) 26 PROPEL LOCKOUT Vout
F18 VEC-90
SP106
3C F15
4 3 11S-004-JJ5 (RED 16ga ) A A 11S-003-AJ1 (RED 16ga ) 21 21 11S-001-AA1 (RED 16ga ) 11S-000-AA1 (RED 16ga ) C 71GH-002-AA1 (ORG 16ga ) L1 L2 71GH-003-AA3 (ORG 20ga ) 27 PROPEL LOCKOUT Vin
15 71CK BUSS 86 85 3G
VEC-90
G 73S1-000-AA1 (DBL 18ga ) SH3:H-7
1 2 B B 23 23
58E-06-20051 5 58E-06-20051
11KS-001-AJ1 (BRN 16ga ) 11KS-002-AA1 (BRN 16ga ) P305
87 TB25
30 3H
H 510E-000-AA1 (DGR 18ga ) N1 N2 510E-001-AA3 (DGR 20ga ) 20 PARKING BRAKE
58E-06-13190 87a
J536 P536_CP P12 J12
PARK BRAKE SWITCH CAB SECONDARY ENGINE SHUTDOWN (ESS)
STATUS RELAY 28 P304
4C
11KS-005-JJ5 (BRN 16ga ) C SH7:K-8 49-003-CC3 (TAN 18ga ) 0-310-CC3 (BLK 18ga ) SH10:P-8
X1 X2
0 BUSS 85 86
1 2
1D 87 TB22 TB27
11KS-003-AA1 (BRN 16ga ) D
30 4G
G 34 34 34 34 3 4 35 35 35 35
23FA-000-AA1 (YEL 16ga ) 23F-000-AA1 (TAN 16ga ) L1 L4 23F-003-AA31 (TAN 16ga ) 23F-001-AC3 (TAN 16ga ) 23F-002-CC3 (TAN 16ga ) 72ES-000-CC3 (YEL 16ga ) 72ES-001-AC3 (YEL 16ga ) 72ES-002-AA31 (YEL 16ga ) R3 R1 72ES-003-AA1 (YEL 16ga ) SH5:A-10
87a
58E-06-50070
J702_JP J83 P83 P03 J03 P83 J83
R2 72ES-005-AA1 (YEL 20ga ) SH3:I-5
AHT
19 19
20 20
ENGINE
D1 INTERLOCK RELAY 19 P702 AUXBOX CONNECTOR J03 P03
1H
H (OPT)
TB30
1C J7-AA8 (BLK 16ga )
86 85 C 28 KEYSWITCH
712M-000-AA1 (PNK 20ga ) H2 H1 SH4:A-12 712-001-AA3 (ORG 20ga )
TB24
87 1A
SWITCH RIGHT GROUND H1 H2 A
30 P305
LEVEL SHUTDOWN (OPT TO VEC 90
48 48 87a
LOCATION) (ESDSR) H3 H4 11KS-010-AA31 (BRN 16ga ) RELAY 21 (30)
TIMED ENGINE
J83 P83 SHUTDOWN RELAY 20
4 3 11S-006-HH5 (RED 16ga ) A A 11S-005-AH1 (RED 16ga ) 51 51 11S-002-AA1 (RED 16ga ) 11KS-004-AC3 (BRN 16ga )
712K-002-AA1 (LBL 16ga ) SH4:C-6 11-035-AA25 (RED 1/0 ) BATTERY + INPUT
1 2 B B 52 52
11KS-007-AH1 (BRN 16ga ) 11KS-008-AA1 (BRN 16ga ) SWITCH KEY (KEYSW) BATFU
712K-004-CC3 (LBL 16ga ) SH10:B-10
OFF GB31-B AUXBOX GND BLCK
58E-06-13190 TB23 A1
GROUND
P11 J11 BATT 0-757-AA24 (BLK 1/0 )
J533 P533_CP 48 48 ON 49 49 49 49
11KS-006-CC3 (BRN 16ga ) 712K-000-CC3 (LBL 16ga ) 712K-001-AC3 (LBL 16ga ) 712K-005-AA31 (LBL 16ga ) N4 N2
RTN
START
21S-000-CC3 (YEL 16ga ) 23 23 21S-001-AC3 (YEL 16ga ) 23 23 21S-004-AA31 (YEL 16ga ) N3 AHT CONNECTION
P03 J03
11KS-009-HH5 (BRN 16ga )
08086-10000 N1 712K-010-AA1 (LBL 14ga )
J03 P03 P83 J83
Z2
Z1 712K-003-AA1 (LBL 20ga )
RELAY KEY SWITCH (KSWPR)
86 85
SH4:C-11 0-006-AA2 (BLK 16ga ) 712IM-000-AA1 (ORG 16ga )
SH7:K-9 0-014-AA2 (BLK 16ga )
TB22
88 88A
SH4:A-10 712-000-AA2 (ORG 10ga ) 11-004-AA2 (RED 8ga ) SH4:B-6 H4 H1 21S-003-AA1 (YEL 20ga )
SH4:A-10 712-006-AA2 (ORG 10ga )
88(2)
AHT CONNECTION H3 H2
KEY SWITCH / ENGINE SHUTDOWN
21S-002-AA1 (YEL 16ga )
58E-06-04150
TB33
SH18:B-19 73S-004-AA1 (LBL 16ga ) 73S-008-AA1 (LBL 16ga ) C1 C3 73S-007-AA33 (LBL 16ga ) 73S-009-AA33 (LBL 16ga )
SP414 SP413
HYD BRAKE CABINET
SWITCH PARK BRAKE RELEASE PRESSURE
73S-000-AA33 (LBL 14ga ) E E 73S-002-AB1 (LBL 16ga ) E E 73S-003-BB1 (LBL 16ga ) C
B
TB32 D72 F F A
SH3:C-13 73S1-000-AA1 (DBL 18ga ) M1 M3 73S1-002-AA33 (DBL 14ga ) 2 1 PBRPS
PBRPS 58E-06-60320
IM2 PC2834
0-051-BB1 (BLK 16ga )
H H H H SP408
0-312-AA33 (BLK 16ga ) 0-225-AB1 (BLK 16ga ) 0-456-BB1 (BLK 16ga ) 0-337-BB1 (BLK 16ga ) SH12:F-17
PARK BRAKE RELEASED 39 73S-001-AA1 (LBL 20ga ) 0-338-BB1 (BLK 16ga ) SH12:F-17
GB31-B AUXBOX GND BLCK
0-339-BB1 (BLK 16ga ) SH12:G-17
+24vout 48
E2
P P P P SP407
24VIM-011-AA1 (LBL 20ga ) 0-314-AA33 (BLK 16ga ) 0-226-AB1 (BLK 16ga ) 0-457-BB1 (BLK 16ga ) 0-444-BB1 (BLK 16ga ) SH10:P-11
VBATT 49 11INT-000-AA1 (PNK 20ga ) 0-445-BB1 (BLK 16ga ) SH10:O-11
VBATT2 50 11IM2-000-AA1 (WHT 20ga ) 0-755-BB1 (BLK 16ga ) SH9:J-20
0-761-BB1 (BLK 16ga ) SH9:J-17
0-317-AA33 (BLK 16ga ) O O 0-022-AB1 (BLK 16ga ) O O 0-455-BB1 (BLK 16ga ) SH6:N-18
IM1
J85 P85
P240 J240
CRANK REQUEST 6 21S-003-AA1 (YEL 20ga )
KEY SWITCH DIRECT 16 712K-003-AA1 (LBL 20ga )
ENGINE SHUTDOWN DELAY 26 21NSL-003-AA1 (LTG 20ga ) SH5:C-13
ENGINE SHUTDOWN DELAY RELAY 39 712M-001-AA1 (PNK 20ga )
SECONDARY ENGINE SHUT DOWN 45 72ES-005-AA1 (YEL 20ga ) SH3:D-21
START ENABLE 50 21SL-000-AA1 (TAN 20ga )
TB32
IM2
24VIM-011-AA1 (LBL 20ga ) H1 H2 24VIM-001-AA1 (LBL 18ga )
H3 H4 24VIM-002-AA1 (LBL 18ga ) SH12:B-20
58E-06-40220
SH7:D-15 24VIM-006-AA32 (LBL 16ga ) G4 G3 24VIM-007-AA29 (LBL 16ga ) SH7:F-13
SH12:J-14 24VIM-000-AA1 (LBL 20ga ) G1
VEC-91
4F 85 86 2D
F D
87
TB28 30 2C
C
3H 87a
SH2:M-19 21PS-006-AA1 (BRN 14ga ) H1 H2 21PS-000-AA1 (BRN 18ga ) H
TB28-H1 TB28-H2 START ENABLE
RELAY 30 VEC-91
58E-06-20062
F27
3G 11 BUSS
11INT-000-AA1 (PNK 20ga ) G
10
VEC-91
58E-06-20062
F28
4E 11 BUSS
11IM2-000-AA1 (WHT 20ga ) E
10
58E-06-20062
INTERFACE MODULE
58B-06-05901-00 SEP 21
ELECTRICAL SCHEMATIC
980E-5
A50052, A50053, A50137, A50138
Sheet 3 of 21
TB24
SH3:F-7 712-000-AA2 (ORG 10ga ) J3 J2 712-001-AA3 (ORG 20ga ) SH3:D-19
58E-06-40220
SH3:F-7 712-006-AA2 (ORG 10ga ) J4 K3
712-005-AA1 (ORG 16ga ) K1 K4 58E-06-02043
VEC-89 VEC-89 7
712 BUSS
24VDC AUXBOX BUS CB1-2 CB1 712-003-AA2 (ORG 10ga ) S5A
SP037
E1 11-016-AA1 (RED 1ga )
150A
SH6:B-14 712-008-AA1 (ORG 14ga ) 712-007-AA1 (ORG 10ga ) S5B
SH5:J-6 712-009-AA1 (ORG 10ga ) 0 BUSS
58B-06-06920
SH2:H-6 SH3:F-9
GE ALTERNATOR & WHEEL MOTOR POWER CIRCUIT
11-007-AK1 (RED 4/0 ) A2 C3 11-004-AA2 (RED 8ga ) 0-005-AA2 (BLK 10ga ) S7A
C4 D1 11-005-AA2 (RED 8ga ) S7B GE CONTROL CABINET WHEEL DRIVE MOTOR 1
71CK BUSS
SH3:B-9 11-010-AA1 (RED 16ga ) B1 D2 71CK-001-AA2 (PNK 8ga ) 1A TM1A-000-TD1 (ORG 535-MCM ) A
S6A TM1A
T1A
SH4:C-13 11-033-AA1 (RED 12ga ) B3 D3 1B TM1B-000-TD2 (ORG 535-MCM ) B
S6B
T1B TM1B
11 BUSS
B2 11-017-AA1 (RED 18ga ) SH18:C-22 11-012-AA2 (RED 8ga ) 1C TM1C-000-TD3 (ORG 535-MCM ) C
S8A
T1C TM1C
A1 11-035-AA25 (RED 1/0 ) SH3:E-19 S8B 58E-06-02043
IM2 WHEEL DRIVE MOTOR 2
2A TM2A-000-TD4 (ORG 535-MCM ) A
GE BATT+ 36 71GE-002-AA1 (BRN 20ga ) T2A TM2A
VEC-92 VEC-92 2B B
IM2
11-006-AA2 (RED 8ga ) TM2B-000-TD5 (ORG 535-MCM )
11 BUSS TM2B
SH4:B-4 11-033-AA1 (RED 12ga ) 6SA T2B
BATT + 31 11B1-003-AA1 (LBL 20ga ) 2C TM2C-000-TD6 (ORG 535-MCM ) C
CRANK SNS 41 T2C TM2C
VEC-91 RELAY KEY / GE CNTRL 6SB
IM3 D14 PWR (KCNPR) 71CK BUSS
712 BUSS 10H H 86 0-006-AA2 (BLK 16ga ) SH3:F-7 5SA
85 PROPULSION ALTERNATOR
71C-000-AA1 (ORG 16ga ) 0-007-AA2 (BLK 16ga )
F1APL F1-000-ST1 (ORG 1ga-MCM ) F1
TB24 D15 5SB F1 ALTF1
TB24 58E-06-09621
GE CONTROL INTERFACE G1 G2 71GE-001-AA1 (BRN 16ga ) G 10G F2APL F2-000-ST2 (ORG 1ga-MCM ) F2
88 88A F2
71CK-003-AA2 (PNK 10ga ) N3 N4 ALTF2
GE CONTROL POWER OUT 29 58E-06-20062 T19APL T19
71GE-000-AA3 (BRN 20ga ) G4 58E-06-40220 T19-000-ST3 (ORG 1ga-MCM )
88(2) T19 T19ALT
71CK-000-AA2 (PNK 10ga ) P3 P4
T20APL T20-000-ST4 (ORG 1ga-MCM ) T20
P305 58E-06-04150 VEC-90 VEC-90
P1 71CK-005-AA1 (PNK 12ga ) T20 T20ALT
71CK BUSS
71CK-001-AA2 (PNK 8ga ) S8A SENSOR GRID BLOWER 1 SPEED
71CK-002-AA2 (PNK 10ga ) MC115 MC115
71CK-006-AA2 (PNK 10ga ) GBI1P (+15V) 1 715P-000-FT1 (RED 18ga ) TW1 A +15V
S8B
0 BUSS
GBI1P (COMMON) 2 B COMMON
12VDC CONVERTER (12VCN) CB60 12V POWER RELAY (12VPR) 0-005-AA2 (BLK 10ga ) S7A 715G-000-FT1 (BLK 18ga ) TW1
24Va 86 85 GBI1P (V1) 3 C V1
11B5-000-AA2 (DBL 8ga ) 50A 0-012-AA2 (BLK 10ga ) 715B-000-FT1 (GRN 18ga ) TW2
S7B
24Vb PB8460 58E-06-20051
GBI1P (V2) 4 715DN-000-FT1 (BLK 18ga ) TW2 D V2
12Va 88 88A GBI1P (NOT V1) 5 E NOT V1
11B1-001-AA2 (LTG 8ga ) 715C-000-FT1 (WHT 18ga ) TW3
TB28 TB24
12Vb 88(2) GBI1P (NOT V2) 6 F NOT V2
SH2:M-19 21PT-008-AA1 (DBL 14ga ) J4 J2 21PT-010-AA1 (DBL 20ga ) 11B1-000-AA2 (LBL 10ga ) L2 L1 11B1-002-AA1 (LBL 10ga ) SH4:K-3 715DP-000-FT1 (BLK 18ga ) TW3
TB28-J4 TB28-J2 GNDa 58E-06-04150
0-009-AA2 (BLK 8ga ) L3 L4 11B1-004-AA1 (LBL 14ga ) SH17:J-22 GBI1P (SHIELD) 8 G SHIELD
VEC-91 SHIELD-100 SHIELD-100
GNDb 12V BUSS GBI1P GBM1P
12V-000-AA2 (ORG 8ga ) S7A SENSOR GRID BLOWER 2 SPEED
MC090 MC116 MC116
PC1110 GB31-B AUXBOX GND BLCK SH11:L-21 12V-001-AA16 (ORG 18ga ) GBI2P (+15V) 1 716P-000-FT1 (RED 18ga ) TW1 A +15V
GB31-B AUXBOX GND BLCK S7B
A2B1 0 BUSS
SH2:J-10 0-002-AJ3 (BLK 4/0 ) 0-012-AA2 (BLK 10ga ) GBI2P (COMMON) 2 716G-000-FT1 (BLK 18ga ) TW1 B COMMON
S6A
B3
0-011-AA2 (BLK 10ga ) GBI2P (V1) 3 716B-000-FT1 (GRN 18ga ) TW2 C V1
S6B
GB31-B AUXBOX GND BLCK 712 BUSS
712-004-AA2 (ORG 10ga ) GBI2P (V2) 4 716DN-000-FT1 (BLK 18ga ) TW2 D V2
S8A
GBI2P (NOT V1) 5 716C-000-FT1 (WHT 18ga ) TW3 E NOT V1
S8B
11 BUSS
11-011-AA2 (RED 8ga ) GBI2P (NOT V2) 6 716DP-000-FT1 (BLK 18ga ) TW3 F NOT V2
S5A
VEC BLOCK / GROUND / POWER DISTRIBUTION S5B 58E-06-20062
GBI2P (SHIELD) 8
SHIELD-101 SHIELD-101
G SHIELD
GBI2P GBM2P
WHEEL MOTOR/TRANSFORMER BLOWER
MC117 MC117
WTIP (+15V) 1 717P-000-TT1 (RED 18ga ) TW1 A +15V
WTIP (COMMON) 2 B COMMON
AUXBOX FRAME GROUND CONNECTIONS DL1 PC3010 717G-000-TT1 (BLK 18ga ) TW1
0-401-AA1 (BLK 14ga ) SH13:D-7
GB31-A AUXBOX GND BLCK WTIP (V1) 3 C V1
D2 0-421-AA1 (BLK 14ga ) SH9:F-16 VEC-91
0-018-AA2 (BLK 16ga ) B 717B-000-TT1 (GRN 18ga ) TW2
F55
0-416-AA1 (BLK 6ga ) 0-135-AA1 (BLK 16ga ) SH8:K-17 VEC-91 11 BUSS
F 9F WTIP (V2) 4 D V2
0-129-AA1 (BLK 16ga ) SH7:L-11 SP017 0-255-AA1 (BLK 14ga ) SH10:E-10 712L-001-AA2 (DBL 16ga ) A 717DN-000-TT1 (BLK 18ga ) TW2
GB31-A AUXBOX GND BLCK 58E-06-20062 5
0-128-AA1 (BLK 16ga ) SH7:L-11 0-403-AA1 (BLK 14ga ) SH13:B-8
A3 DL1 WTIP (NOT V1) 5 E NOT V1
0-413-AA1 (BLK 6ga ) 0-055-AA1 (BLK 16ga ) SH7:N-10 0-336-AA1 (BLK 16ga ) SH12:B-4 717C-000-TT1 (WHT 18ga ) TW3
SP026 0-053-AA1 (BLK 16ga ) SH7:P-10 DL2 PC3010
0-425-AA1 (BLK 16ga ) SH8:C-18 WTIP (NOT V2) 6 717DP-000-TT1 (BLK 18ga ) TW3 F NOT V2
SP104 WTIP (SHIELD) 8
0-424-AA1 (BLK 14ga ) SH9:G-16 0-222-AA1 (BLK 14ga ) SH5:O-8 SWITCH AUX BOX DOME LIGHT (DLS) 0-019-AA2 (BLK 16ga ) B SHIELD-099 WTBMP
GB31-A AUXBOX GND BLCK
E1 0-104-AA1 (BLK 16ga ) SH8:B-18 WTIP
2 3 712L-000-AA2 (DBL 16ga )
0-391-AA1 (BLK 18ga ) SH12:M-17 0-417-AA1 (BLK 6ga ) 0-127-AA1 (BLK 16ga ) SH7:M-11 712A-000-AA1 (WHT 16ga ) 712L-002-AA2 (DBL 16ga ) A
SP018 SP100
0-219-AA1 (BLK 14ga ) SH5:M-8 0-008-AA1 (BLK 16ga ) SH7:O-10 MC500 MC500
GB31-A AUXBOX GND BLCK DLS-2 SR8325 DLS-3 DL3 WMBI-T1/AO AI/ WMTB-A
B2 0-162-AA1 (BLK 16ga ) SH8:G-16 0-223-AA1 (BLK 14ga ) SH5:O-8 WMTBA-000-TT2 (BLK 6ga )
0-414-AA1 (BLK 6ga ) 0-163-AA1 (BLK 16ga ) SH8:F-16 0-420-AA1 (BLK 14ga ) SH9:G-16 WMBI-T1 WMTB-A
SP027 0-216-AA1 (BLK 14ga ) SH5:M-8 DL3 PC3010
0-080-AA1 (BLK 16ga ) SH15:C-5 WMBI-T2/AO WMTBB-000-TT2 (WHT 6ga ) AI/WMTB-B
GB31-B AUXBOX GND BLCK 0-020-AA2 (BLK 16ga )
B4
B WMBI-T2 WMTB-B
0-017-AA2 (BLK 16ga )
0-084-AA1 (BLK 16ga ) SH7:P-10 712L-003-AA2 (DBL 16ga ) A WMBI-T3/AO WMTBC-000-TT2 (RED 6ga ) AI/WMTB-C
0-699-AA1 (BLK 18ga ) SH12:M-16 0-165-AA1 (BLK 16ga ) SH8:E-16 WMBI-T3 WMTB-C
GB31-A AUXBOX GND BLCK DL4
0-023-AA1 (BLK 20ga ) SH6:I-16 A1 0-164-AA1 (BLK 16ga ) SH8:F-16
GB31-A AUXBOX GND BLCK
C2
0-024-AA1 (BLK 20ga ) SH6:I-16 0-130-AA1 (BLK 6ga ) 0-126-AA1 (BLK 16ga ) SH7:N-11 WMTBG1-000-TT2 (GRN 14ga )
0-160-AA1 (BLK 6ga ) 0-147-AA1 (BLK 16ga ) SH8:J-18 SP020 0-344-AA1 (BLK 16ga ) SH12:P-11 DL4 PC3010
SP028 0-334-AA1 (BLK 16ga ) SH12:D-5 0-075-AA1 (BLK 16ga ) SH15:B-7 WMBI-GND AI/WMTB-GND
0-333-AA1 (BLK 16ga ) SH12:C-5 0-021-AA2 (BLK 16ga ) B WMBI-GND WMTBG2-000-TT2 (GRN 14ga ) AI/WMTB-GND
AUX BOX DOME LIGHTS 712L-004-AA2 (DBL 16ga ) A
DL6
WMTBG3-000-TT2 (GRN 14ga )
0-422-AA1 (BLK 14ga ) SH10:M-11
GB31-A AUXBOX GND BLCK
0-679-AA1 (BLK 14ga ) SH10:H-6 A2 0-263-AA1 (BLK 14ga ) SH10:E-7
GB31-A AUXBOX GND BLCK
C4 0-240-AA1 (BLK 14ga ) SH10:C-21 0-131-AA1 (BLK 6ga ) 0-134-AA1 (BLK 16ga ) SH8:I-17
0-415-AA1 (BLK 6ga ) 0-146-AA1 (BLK 16ga ) SH8:L-17 SP025 0-426-AA1 (BLK 14ga ) SH9:F-16
SP029 0-241-AA1 (BLK 14ga ) SH10:E-21 0-402-AA1 (BLK 14ga ) SH13:D-7
0-325-AA1 (BLK 16ga ) SH12:E-10 0-407-AA1 (BLK 14ga ) SH13:C-8
0-376-AA1 (BLK 16ga ) SH12:H-5 AUXBOX PANEL GROUNDS CGIP (+15V) 1
MC118
718P-000-TT1 (RED 18ga ) TW1
MC118
CONTROL GROUP BLOWER MOTOR
A +15V
GB34 AUX FLOOR CGIP (COMMON) 2 B COMMON
2 718G-000-TT1 (BLK 18ga ) TW1
GB33 LH AUX PANEL CGIP (V1) 3 C V1
1 3 718B-000-TT1 (GRN 18ga ) TW2
0-697-AA19 (BLK 8ga )
CGIP (V2) 4 718DN-000-TT1 (BLK 18ga ) TW2 D V2
GB32 BACK AUX PANEL CGIP (NOT V1) 5 E NOT V1
1 718C-000-TT1 (WHT 18ga ) TW3
0-696-AA18 (BLK 8ga ) GB35 RH AUX PANEL CGIP (NOT V2) 6 718DP-000-TT1 (BLK 18ga ) TW3 F NOT V2
2 1
CGIP (SHIELD) 8
0-807-AA20 (BLK 8ga ) SHIELD-098 CBMP
CGIP
GB31-B AUXBOX GND BLCK GB35 RH AUX PANEL
D3 2
0-789-AA23 (BLK 8ga ) MC501 MC501
CGBI-T1 / AO CGBA-000-TT5 (BLK 6ga ) AI/CGB-A
11B1-002-AA1 (LBL 10ga ) SH4:E-9 CGBI-T1 CGB-A
CGBI-T2 / AO CGBB-000-TT5 (WHT 6ga ) AI/CGB-B
VEC-91
CGBI-T2 CGB-B
712 BUSS
CGBI-T3 / AO CGBC-000-TT5 (RED 6ga ) AI/CGB-C
0 BUSS 85 86 CGBI-T3 CGB-C
TB24
12F F
CGBG1-000-TT5 (GRN 14ga )
F23 87 4 4 4 4
CAB ENTERTAINMENT RADIO
65A-000-AA1 (WHT 16ga ) F1 F4 65A-005-AA32 (WHT 16ga ) 65A-003-AC4 (WHT 16ga ) 65A-004-CC4 (WHT 18ga )
10E 30
E
10 87a CGBI-GND AI/CGB-GND
D1 D4 65-009-AA32 (TAN 16ga ) 16 16 65-002-AC4 (TAN 16ga ) 16 16 65-003-CC4 (TAN 18ga ) CGBI-GND CGBG2-000-TT5 (GRN 14ga ) AI/CGB-GND
ENTERTAINMENT
RADIO RELAY 37 12E E J84 P84 P04 J04
65-000-AA1 (TAN 16ga ) ENTERTAINMENT RADIO CGBG3-000-TT5 (GRN 14ga )
12VREG-008-CC2 (LBL 16ga ) SH14:K-15
F22 TB21 7 (+) 12V SUPPLY
11G G 65-003-CC4 (TAN 18ga )
12VREG-000-AA1 (LBL 12ga ) B1 B3 12VREG-006-AA30 (LBL 14ga ) 34 34 12VREG-001-AC2 (LBL 14ga ) 34 34 12VREG-003-CC2 (LBL 14ga ) 12VREG-005-CC2 (LBL 12ga ) 3 ENTERTAINMENT RIGHT FRT SPEAKER 13 SPEAKER LEFT FRONT (+)
20 LF(+)-001-CC4 (WHT 18ga )
SP156 11 SPEAKER RIGHT FRONT (+)
VEC-91 CUSTOMER OP-CAB RF(+)-001-CC4 (WHT 18ga ) SECONDARY LINK TRANSFORMER
B4 12VREG-007-AA30 (LBL 14ga ) 35 35 12VREG-002-AC2 (LBL 14ga ) 35 35 12VREG-004-CC2 (LBL 14ga ) + A RF(+)-001-CC4 (WHT 18ga ) 4 IGNITION
F40 58E-06-20062 TB22 COMMUNICATION 65A-001-CC4 (TAN 18ga )
6 DIMMER AO (PRIMARY) / PB1 SLT-H1/AI
11 BUSS 11C RADIO CONNECTION SP162 65A-002-CC4 (TAN 18ga ) SLTH1-000-TT3 (ORG 3ga )
C 11ER-000-AA1 (RED 12ga ) D1 D3 11ER-006-AA30 (RED 14ga ) 36 36 11ER-001-AC2 (RED 14ga ) 36 36 11ER-003-CC2 (RED 14ga ) 11ER-005-CC2 (RED 12ga ) 1 - B RF(-)-001-CC4 (BLK 18ga )
20
SP155 PB1 SLT-H1
VEC-91 D4 37 37 37 37 RFSPK AO (PRIMARY) / PB2 SLT-H2/AI
TB22 11ER-007-AA30 (RED 14ga ) 11ER-002-AC2 (RED 14ga ) 11ER-004-CC2 (RED 14ga ) SLTH2-000-TT3 (ORG 3ga )
58E-06-20062
F41 12 SPEAKER RIGHT FRONT (-)
11 BUSS ENTERTAINMENT LEFT FRT SPEAKER RF(-)-001-CC4 (BLK 18ga )
11B PB2 SLT-H2
B 11FS-000-AA1 (RED 16ga ) F1 F4 0-211-CC2 (BLK 12ga ) 2 LF(-)-001-CC4 (BLK 18ga ) 14 SPEAKER LEFT FRONT (-)
5 GB31-A AUXBOX GND BLCK J82 P82 P02 J02 GB12-A GB12-B
+ A LF(+)-001-CC4 (WHT 18ga ) AI (SECONDARY) / SB1 SLTX1-000-TT4 (ORG 2/0-MCM ) SLT-X1/AO
A4 F4 A4
0-289-AA32 (BLK 8ga ) 1 1 0-203-AC4 (BLK 8ga ) 1 1 0-204-CC4 (BLK 8ga ) 0-212-CC2 (BLK 12ga ) 4 SH13:E-11 0-202-CC4 (BLK 18ga ) 8 GROUND
58E-06-20062 - B 15 SPEAKER LEFT REAR (+) SB1 SLT-X1
LF(-)-001-CC4 (BLK 18ga ) LR(+)-001-CC4 (WHT 18ga )
J601_CP 9 SPEAKER RIGHT REAR (+) AI (SECONDARY) / SB2 SLT-X2/AO
J84 P84 P04 J04 RR(+)-001-CC4 (WHT 18ga ) SLTX2-000-TT4 (ORG 2/0-MCM )
BUS17 LFSPK 10 SPEAKER RIGHT REAR (-)
0-704-CC2 (BLK 16ga ) SH14:K-15 RR(-)-001-CC4 (BLK 18ga ) SB2
16 SPEAKER LEFT REAR (-) SLT-X2
CUSTOMER ENTERTAINMENT LEFT REAR SPEAKER LR(-)-001-CC4 (BLK 18ga )
0-213-CC2 (BLK 16ga ) B
42 42 42 42 A OP-CAB FIRE + A LR(+)-001-CC4 (WHT 18ga )
11FS-003-AA30 (RED 16ga ) 11FS-001-AC2 (RED 16ga ) 11FS-002-CC2 (RED 16ga )
SUPPRESSION P737
C CONNECTION - B 58E-06-20500
J82 P82 P02 J02 LR(-)-001-CC4 (BLK 18ga )
GB12-B
GB12-B
B1 J602_CP LRSPK
0-384-CC2 (BLK 14ga )
58E-06-30050
0-383-CC2 (BLK 14ga )
ENTERTAINMENT RIGHT REAR SPEAKER NOTE: USE GE SCHEMATIC FOR ADDITIONAL CABLES TO ALTERNATOR
VEC-91 12VDC POWER PORT #1 (PWR1) A
+ RR(+)-001-CC4 (WHT 18ga )
F63 TB24
12V BUSS 9H 2 1
H 67C-000-AA1 (BRN 12ga ) V1 V4 67C-005-AA30 (BRN 14ga ) 66 66 67C-001-AC2 (BRN 14ga ) 66 66 67C-003-CC2 (BRN 14ga ) 1 1 - B RR(-)-001-CC4 (BLK 18ga )
20
RRSPK
V3 PC1374
58E-06-20062
12VDC POWER PORT #2 (PWR2)
68 68 68 68 1 1 2 1
67C-006-AA30 (BRN 14ga )
J82 P82
67C-002-AC2 (BRN 14ga )
P02 J02
67C-004-CC2 (BRN 14ga )
PC1374
58B-06-05901-00 SEP 21
ELECTRICAL SCHEMATIC
12VDC SUPPLY & CUSTOMER OPTIONAL ACCESSORY POWER 980E-5
A50052, A50053, A50137, A50138
Sheet 4 of 21
QSK95 - ENGINE INTERFACE TIER IV
KEYSWITCH 24V SIGNAL H 5 5 28 28 TB27 F36 VEC-91
72ES-004-EE1 (YEL 14ga ) 72ES-006-AE1 (YEL 16ga ) 72ES-003-AA1 (YEL 16ga ) SH3:D-21 11 BUSS
1 1 27 27 A 2A
11E1-003-EE1 (YEL 14ga ) 11E1-001-AE1 (YEL 14ga ) 11E1-006-AA1 (YEL 14ga ) A1 A2 11E1-000-AA1 (YEL 12ga )
SP112 20
BATTERY 24V UNSWITCHED (PARENT) A 11E1-005-EE1 (YEL 12ga ) 11E1-004-EE1 (YEL 14ga ) 7 7 11E1-007-AE1 (YEL 14ga ) 26 26 11E1-002-AA1 (YEL 14ga )
2 2 25 25 58E-06-20062
SP113 11E2-003-EE1 (LBL 14ga ) 11E2-006-AE1 (LBL 14ga ) 11E2-001-AA1 (LBL 14ga ) A4
F37 VEC-91
BATTERY 24V UNSWITCHED (CHILD 1) C 11E2-005-EE1 (LBL 12ga ) 11E2-004-EE1 (LBL 14ga ) 8 8 11E2-007-AE1 (LBL 14ga ) 24 24 11E2-002-AA1 (LBL 14ga ) 2B 11 BUSS
11E3-003-EE1 (DBL 14ga ) 3 3 11E3-006-AE1 (DBL 14ga ) 23 23 11E3-001-AA1 (DBL 14ga ) B1 B2 11E2-000-AA1 (LBL 12ga ) B
SP114 20
BATTERY 24V UNSWITCHED (CHILD 2) D 11E3-005-EE1 (DBL 12ga ) 11E3-004-EE1 (DBL 14ga ) 9 9 11E3-007-AE1 (DBL 14ga ) 22 22 11E3-002-AA1 (DBL 14ga )
B4
58E-06-20062
SP111 F38 VEC-91
BATTERY 24V UNSWITCHED (SERVICE) F 11E4-002-EE1 (BRN 12ga ) 11E4-004-EE1 (BRN 14ga ) 4 4 11E4-006-AE1 (BRN 14ga ) 21 21 11E4-001-AA1 (BRN 14ga ) 2H 11 BUSS
11E4-005-EE1 (BRN 14ga ) 6 6 11E4-007-AE1 (BRN 14ga ) 20 20 11E4-003-AA1 (BRN 14ga ) C1 C2 11E3-000-AA1 (DBL 12ga ) H
SP310 20
BATTERY 24V UNSWITCHED (NOx SENSORS) B 11E5-000-EE1 (PNK 12ga ) 11E5-001-EE1 (PNK 14ga ) 40 40 11E5-003-AE1 (PNK 14ga ) 49 49 11E5-005-AA1 (PNK 14ga )
58E-06-20062
SP311 11E5-002-EE1 (PNK 14ga ) 41 41 11E5-004-AE1 (PNK 14ga ) 50 50 11E5-006-AA1 (PNK 14ga ) SP312 C4
VEC-91
BATTERY 24V UNSWITCHED (CHILD 3) G 42 42 51 51 F39
11E6-000-EE1 (PUR 12ga ) 11E6-001-EE1 (PUR 14ga ) 11E6-003-AE1 (PUR 14ga ) 11E6-005-AA1 (PUR 14ga ) SP313 2G 11 BUSS 7
11E6-002-EE1 (PUR 14ga ) 43 43 11E6-004-AE1 (PUR 14ga ) 52 52 11E6-006-AA1 (PUR 14ga ) D1 D2 11E4-000-AA1 (BRN 12ga ) G
20
64 64 19 19 D4
58E-06-20062
SP115 0-063-EE1 (BLK 14ga ) 0-090-AE1 (BLK 14ga ) 0-069-AA1 (BLK 14ga ) D1
BATTERY GROUND (PARENT) J 0-060-EE1 (BLK 12ga ) 0-064-EE1 (BLK 14ga ) 65 65 0-070-AE1 (BLK 14ga ) 18 18 0-107-AA1 (BLK 14ga ) GB31-A AUXBOX GND BLCK
0-065-EE1 (BLK 14ga ) 66 66 0-152-AE1 (BLK 14ga ) 17 17 0-071-AA1 (BLK 14ga )
SP116 C3 VEC-92 F1
BATTERY GROUND (CHILD 1/SERVICE) K 0-061-EE1 (BLK 12ga ) 0-066-EE1 (BLK 14ga ) 67 67 0-072-AE1 (BLK 14ga ) 16 16 0-108-AA1 (BLK 14ga ) GB31-A AUXBOX GND BLCK
68 68 15 15 B 4B 11
SP117 0-067-EE1 (BLK 14ga ) 0-153-AE1 (BLK 14ga ) 0-073-AA1 (BLK 14ga ) 11E5-007-AA1 (PNK 12ga ) BUSS
ENGINE INTERFACE CIRCUITS
D4 20
BATTERY GROUND (CHILD 2) L 0-062-EE1 (BLK 12ga ) 0-068-EE1 (BLK 14ga ) 69 69 0-074-AE1 (BLK 14ga ) 14 14 0-109-AA1 (BLK 14ga ) GB31-A AUXBOX GND BLCK
58E-06-09621 VEC-92
BATTERY GROUND (NOx SENSORS) E 0-638-EE1 (BLK 12ga ) 0-639-EE1 (BLK 14ga ) 62 62 0-154-AE1 (BLK 14ga ) 13 13 0-641-AA1 (BLK 14ga )
SP109 B4 VEC-92 F2
63 63 12 12
0-640-EE1 (BLK 14ga ) 0-642-AE1 (BLK 14ga ) 0-148-AA1 (BLK 14ga ) GB31-A AUXBOX GND BLCK
11E6-007-AA1 (PUR 12ga ) G 4G 11
SP309 20 BUSS
BATTERY GROUND (CHILD 3) N 0-601-EE1 (BLK 12ga ) 0-661-EE1 (BLK 14ga ) 38 38 0-663-AE1 (BLK 14ga ) 47 47 0-665-AA1 (BLK 14ga ) SH12:N-15
39 39 48 48
58E-06-09621 VEC-92
P804 0-662-EE1 (BLK 14ga ) 0-664-AE1 (BLK 14ga ) 0-670-AA1 (BLK 14ga ) SH12:N-15
TB27
SHUTTER CONTROL A 65S-002-EE1 (BRN 16ga ) 25 25 65S-001-AE1 (BRN 16ga ) 11 11 65S-003-AA1 (BRN 16ga ) M1 M2 65S-000-AA1 (BRN 16ga ) G 12G VEC-91
58E-06-20062
TB27 0 BUSS 85 86
ENGINE DELAY SHUTDOWN E 12 12 10 10 R51
21NSL-000-EE1 (LTG 16ga ) 21NSL-002-AE1 (LTG 16ga ) 21NSL-001-AA1 (LTG 16ga ) E1 E2 21NSL-003-AA1 (LTG 20ga ) SH3:I-5 58B-06-00130 12H H
F25 87
COOLANT LEVEL SWITCH 712 BUSS 65SR-000-AA1 (ORG 16ga ) SH15:B-2
2 1 30
E4 21NSL-004-AA2 (LTG 18ga )
COOLANT LEVEL SWITCH 15V SUPPLY J 1 1 A + V SUPPLY R51 1KΩ 2W
R51 10 87a
924-000-EE1 (PNK 16ga ) 924-001-ER1 (PNK 18ga )
COOLANT LEVEL SIGNAL W 926-000-EE1 (WHT 16ga ) 2 2 926-001-ER1 (WHT 18ga ) B SIGNAL LOW
SHUTTER CONTROL
COOLANT LEVEL SWITCH RETURN X 925-000-EE1 (TAN 16ga ) 3 3 925-001-ER1 (TAN 18ga ) C GROUND
TB27 (OPT) RELAY 39
J812 P812_CP P802 9 9 D 12D VEC-91
28EC-003-AA1 (DBL 16ga ) H1 H2 28EC-000-AA1 (DBL 18ga )
58E-06-20062
0 BUSS 85 86
ETHER START CONTROL C 28EC-001-EE1 (DBL 16ga ) 18 18 28EC-002-AE1 (DBL 16ga ) 8 8 21OR-003-AA1 (YEL 16ga ) K1 K2 21OR-005-AA1 (LBL 16ga ) SH5:N-8
F21 87 12C C
K4 21OR-002-AA1 (LBL 16ga ) SH5:P-8 11 BUSS 28E-000-AA1 (DBL 16ga ) SH15:C-5
P805 30
7 7 10 87a
21ORR-001-AA1 (WHT 16ga ) L1 L2 21ORR-005-AA1 (DGR 16ga ) SH5:N-8
ETHER START
L4 21ORR-003-AA1 (DGR 16ga ) SH5:P-8 (OPT) RELAY 36
TB27
11A
W1 0-388-AA2 (BLK 18ga ) A
C1
W2 0-235-AA2 (BLK 16ga ) GB31-B AUXBOX GND BLCK
TB25 GE CONTROL INTERFACE
W3 0-013-AA36 (BLK 25ga ) SH18:O-7 T1 T2 74X1K-003-AA3 (LTG 20ga ) 7 ALTERNATE IDLE 1180 RPM
W4 0-238-AA2 (BLK 16ga ) SH6:J-11 U1 U2 531SC-003-AA3 (DGR 20ga ) 46 ALTERNATE SPEED 1830 RPM
TURBO COMP INLET TEMP SENSOR TB29
MC3293 MC3293
COMPRESSOR INTAKE TEMP SIGNAL 1 29CS-000-EE2 (WHT 18ga ) A COMPRESSOR INTAKE TEMP SIGNAL 63 63 74X1K-002-AA1 (LTG 18ga ) SH6:N-5 79RD-000-AA1 (BRN 18ga ) S1 S2
P304
COMPRESSOR INTAKE TEMP RETURN 2 29CR-000-EE2 (BLK 18ga ) B COMPRESSOR INTAKE TEMP RETURN 64 64 531SC-002-AA1 (DGR 18ga )
P815 AHT CONNECTION S3 79RD-001-AA3 (BRN 18ga ) 2 REVERSE TRUE
TITS
ALTERNATE IDLE 1180 RPM 27 13 13 TB22 7 FORWARD TRUE
74X1K-000-EE1 (LTG 16ga ) 74X1K-001-AE1 (LTG 16ga ) FAN ON FULL SH6:N-5 72FD-000-AA1 (WHT 18ga ) R1 R2 72FD-001-AA3 (WHT 18ga )
ALTERNATE SPEED 1830 RPM 25 14 14 6 6
HYD BRAKE CABINET
531SC-000-EE1 (DGR 16ga ) 531SC-001-AE1 (DGR 16ga ) 22FO-002-AA1 (TAN 16ga ) K1
ENGINE TEST
AHT CONNECTION R3
P302
ENGINE TEST / FAN CLUTCH 2 17 17 GB31-A AUXBOX GND BLCK SWITCH SERVICE BRAKE PRESSURE TB35
22FO-000-EE1 (TAN 16ga ) 22FO-001-AE1 (TAN 16ga )
E2
CHASSIS GROUND RETURN 22 0-085-EE1 (BLK 14ga ) 70 70 0-086-AE1 (BLK 14ga ) 5 5 0-155-AA1 (BLK 14ga ) C 44R-004-BB1 (GRY 16ga ) K K 44R-005-AB1 (GRY 16ga ) K K 44R-006-AA33 (GRY 16ga ) F3 F4 44R-000-AA3 (GRY 20ga ) 9 SERVICE BRAKE
71BC-006-BB1 (DGR 16ga ) B
FAN CLUTCH ON FULL 5 22C-002-EE1 (GRY 16ga ) A SH10:F-2 44R-003-AA1 (GRY 18ga ) F1 F2 44R-001-AA1 (GRY 20ga ) SH6:K-16
5V PULL-UP 9 22C-003-EE1 (GRY 16ga ) SBPS
58E-06-60340 SBPS
P806 JB41 J J J J
71BC-007-BB1 (DGR 16ga ) 71BC-003-AB1 (DGR 16ga ) 71BC-008-AA33 (DGR 16ga ) SH6:G-6
1 SOLENOID PARK BRAKE
2 TB27 SP462 SP161
3 31 31 4 4 FAN ON FULL 2 1 G G G G
22C-001-EE1 (GRY 16ga ) 22C-005-AE1 (GRY 16ga ) 22C-004-AA1 (GRY 16ga ) G1 71BC-005-BB1 (DGR 16ga ) 52CS-004-BB1 (GRY 16ga ) 52CS-006-BB1 (GRY 16ga ) 52CS-003-AB1 (GRY 16ga ) 52CS-007-AA33 (GRY 16ga ) SH6:J-7
4 22C-000-EE1 (GRY 16ga ) TEST POINT
XA3347
PC1150 PBS PBS J240 P240 P85 J85
WIF
WATER IN FUEL SENSOR SIGNAL 1 1 1 ENGINE D2 IM2 TB24
27WS-000-EE1 (WHT 16ga )
WATER IN FUEL SENSOR RETURN 2 2 2 WATER IN 1 2 GE CPU RUNNING 11 41 SYS RUNNING OUTPUT
27WR-000-EE1 (BLK 16ga ) 71BC-004-BB1 (DGR 16ga ) 52CS-005-BB1 (GRY 16ga ) 72CPU-001-AA1 (BLK 20ga ) Z1 Z2 72CPU-000-AA3 (BLK 20ga )
FUEL SENSOR
P826 PC2834 IM1 AHT CONNECTION Z3
MC204 MC204 MC202 MC202 MC258 MC258 P304
CAN J1939 HIGH A 939YE-000-EE1 (YEL 20ga ) 57 57 939YE-003-AE1 (YEL 20ga ) 1 1 939YE-001-AA1 (YEL 20ga ) SH14:F-1
CAN J1939 LOW B 939GE-000-EE1 (GRN 20ga ) 58 58 939GE-003-AE1 (GRN 20ga ) 2 2 939GE-001-AA1 (GRN 20ga ) SH14:F-1
CAN J1939 SHLD C 59 59 3 3
VEC-92 F10
SHIELD-208 SHIELD-208 SHIELD-209 SHIELD-209 SHIELD-270 71CK 3A A
ENG_1939 BUS 5
58E-06-09621 VEC-92
FAN CLUTCH CONTROLLER
32 32 22D-004-AA1 (LTG 18ga )
MC1105 MC1105
SH14:G-3 939YE-007-AA1 (YEL 20ga ) 3 3 939YE-024-AA99 (YEL 18ga ) C CAN HI
SH14:G-3 939GE-007-AA1 (GRN 20ga ) 4 4 939GE-024-AA99 (DGR 18ga ) D CAN LO
5
SHIELD-136
71CKC-000-AA1 (YEL 20ga ) 2 2 71CKC-001-AA99 (YEL 18ga ) A 24V SUPPLY
GB31-A AUXBOX GND BLCK
C1
0-634-AA1 (BLK 20ga ) 1 1 0-637X-AA99 (BLK 18ga ) 71CKC-002-AA99 (YEL 18ga )
FAN CLUTCH INTERFACE SHIELD-137 29 29 SHIELD-119
MC854 MC854 MC853 MC851 MC850 0-190-AA1 (BLK 14ga ) SH5:L-8
CLUTCH COIL 3 23C-003-ER1 (WHT 18ga ) 4 4 23C-002-EE1 (WHT 18ga ) 36 36 23C-001-AE1 (WHT 18ga ) 33 33 23C-000-AA1 (WHT 18ga ) 0-638X-AA99 (BLK 18ga ) B 24V RETURN
POWER RETURN 1 5 5 26 26 0C-001-AE1 (BLK 18ga ) 70 70 0C-000-AA1 (BLK 18ga )
0C-003-ER1 (BLK 18ga ) 0C-002-EE1 (BLK 18ga ) DI1
6 6 MC853 MC851
SHIELD2736 SHIELD-137 SHIELD-119 SP905 SP394 SHIELD-943 MC1103
65 65
MC1098 MC1098 MC1099 MC1099 MC1102 SHIELD-117 SHIELD-972-AE1 (BLK 18ga ) SHIELD-971-AA1 (BLK 18ga ) SHIELD-118
SPEED SENSOR SUPPLY 2 5VFCS-003-ER1 (RED 18ga ) 7 7 5VFCS-001-EE1 (RED 18ga ) 55 55 5VFCS-000-AE1 (RED 18ga ) 66 66 5VFCS-002-AA1 (RED 18ga )
SPEED SENSOR RETURN 4 5VFCR-003-ER1 (BLK 18ga ) 8 8 5VFCR-001-EE1 (BLK 18ga ) 56 56 5VFCR-000-AE1 (BLK 18ga ) 67 67 5VFCR-002-AA1 (BLK 18ga )
CLUTCH SPEED FEEDBACK 5 9 9 60 60 33FS-000-AE1 (WHT 18ga ) 68 68 33FS-002-AA1 (WHT 18ga )
33FS-003-ER1 (WHT 18ga ) 33FS-001-EE1 (WHT 18ga )
FCI_CP 10 10 MC1102 MC850
SHIELD2738 SHIELD-116 54 54 12 12 E CLUTCH COIL PWM-
0C-000-AA1 (BLK 18ga ) 0C-002x-AA99 (BLK 18ga ) 0C-003X-AA99 (BLK 18ga )
SHIELD-116 SHIELD-117
J808 P808 23C-000-AA1 (WHT 18ga ) 11 11 23C-004-AA99 (WHT 18ga )
P812_CP J812 P17 J17
23C-005-AA99 (WHT 18ga ) F CLUTCH COIL PWM+
MC1103
VEC-91 5VFCS-002-AA1 (RED 18ga ) 6 6 5VFCS-002X-AA99 (RED 18ga ) B +5V SPEED SNSR SUPP
F59 TB21 HVAC MODULE 7 7 A SPEED SNSR RETURN
5VFCR-002-AA1 (BLK 18ga ) 5VFCR-002X-AA99 (BLK 18ga )
1A 1B
SH4:B-11 712-009-AA1 (ORG 10ga ) A B 12H-006-AA1 (YEL 10ga ) Z1 Z4 12H-010-AA31 (YEL 14ga ) 2 2 12H-005-AC3 (YEL 14ga ) 2 2 12H-000-CC3 (YEL 14ga ) 1 +24V 33FS-002-AA1 (WHT 18ga ) 9 9 33FS-002X-AA99 (WHT 18ga ) C FAN SPEED INPUT
25
3 3 3 3 2 +24 V GB21 PLM GND
Z3 12H-009-AA31 (YEL 14ga ) 12H-007-AC3 (YEL 14ga ) 12H-008-CC3 (YEL 14ga ) SP015
58E-06-20062 A4
0-817-AA1 (BLK 18ga ) SHIELD-118
18FC2-000-AA1 (DGR 20ga ) 10
TB30 SPR_21
22C-006-ER1 (GRY 16ga ) 3 3 22C-000-EE1 (GRY 16ga )
SWITCH A/C X1 X4 65T-003-AA31 (DBL 18ga ) 1 1 65T-006-AC3 (DBL 18ga ) 1 1 65T-004-CC3 (DBL 18ga ) 3 A/C COMPRESSOR CLUTCH 8 8 22D-004X-AA99 (LTG 18ga ) D FAN CLUTCH INPUT
RECEIVER DRYER SH10:P-8 0-703-CC3 (BLK 14ga ) 4 GROUND
FCC_CP JFCC DI2
65T-002-AE1 (DBL 14ga ) 29 29 SH15:B-2 5 GROUND_
J03 SH11:E-15 0-888-CC3 (BLK 14ga )
65T-005-AA1 (DBL 14ga ) X2 65T-000-AA1 (DBL 16ga )
NO2 J83 P83 P03
3 4 0-096-ER1 (BLK 16ga ) 4 4 0-087-EE1 (BLK 16ga ) SH2:M-14
C2 TB28 P137
OPERATOR CAB HVAC
SOLENOID A/C 36-001-AE1 (YEL 14ga ) 30 30 36-003-AA1 (YEL 14ga ) A1 A2 36-002-AA1 (YEL 18ga ) SH6:H-2
1 2 65C-001-ER1 (LBL 14ga ) 2 2 COMPRESSOR CLUTCH
C1 NC1
AHT CONNECTION A4 A3
PC1804 65C-000-EE1 (LBL 14ga ) 1 2 0-088-EE1 (BLK 14ga ) SH2:N-14
RECDR RECDR
65T-007-ER1 (DBL 14ga ) 1 1 XB7317
P803 P803
P813_CP J813 32 32
65T-001-EE1 (DBL 14ga )
31 31 0-190-AA1 (BLK 14ga ) SH5:I-16
36-000-EE1 (YEL 14ga ) 33 33
SWITCH ENGINE RUN OIL PRESSURE (EOPSW) 34 34 34 34
0-215-AE1 (BLK 14ga ) 18AZ-002-AA1 (DGR 14ga )
1 2 SPR_3
0-092-EE1 (BLK 14ga )
37 37 18AZ-001-AE1 (DGR 14ga )
8 PSI P17 J17
PC2979
QSK95 ENGINE INTERFACE J808 P808
RELAY ORS (ORS)
86 85
11HH-002-AA1 (PNK 18ga ) 36-004-AA1 (YEL 18ga )
11POR-003-AA1 (GRY 14ga ) 55 55
VEC-91 F31 TB28 TB28
SH4:H-4 0-216-AA1 (BLK 14ga ) 56 56 44 44 0-733-AE1 (BLK 14ga ) 53 53 0-743-AA1 (BLK 14ga )
11 BUSS 4C 88 88A
C 11ORS-002-AA1 (LBL 14ga ) D1 D2 11ORS-001-AA1 (LBL 14ga ) 11POR-001-AA1 (GRY 14ga ) E1 E2 45 45 0-734-AE1 (BLK 14ga ) 54 54 0-744-AA1 (BLK 14ga )
15 TB28-E2 F1
46 46 0-735-AE1 (BLK 14ga ) 55 55 0-745-AA1 (BLK 14ga )
58E-06-20062 TB28-D1 TB28-D2 88(2) TB28-E1 GB31-A AUXBOX GND BLCK
E4 57 57 47 47 0-736-AE1 (BLK 14ga ) 56 56 0-746-AA1 (BLK 14ga ) F2
SH4:H-4 0-219-AA1 (BLK 14ga ) 58 58 48 48 0-737-AE1 (BLK 14ga ) 57 57 0-747-AA1 (BLK 14ga )
58E-06-04150 TB28-E4 49 49 58 58
GB31-A AUXBOX GND BLCK
0-738-AE1 (BLK 14ga ) 0-748-AA1 (BLK 14ga ) F3
50 50 0-739-AE1 (BLK 14ga ) 59 59 0-749-AA1 (BLK 14ga ) GB31-A AUXBOX GND BLCK
SH5:D-13 21OR-005-AA1 (LBL 16ga ) 59 59 51 51 0-740-AE1 (BLK 14ga ) 60 60 0-750-AA1 (BLK 14ga ) F4
SH5:D-13 21ORR-005-AA1 (DGR 16ga ) 60 60 52 52 0-741-AE1 (BLK 14ga ) 61 61 0-751-AA1 (BLK 14ga )
53 53 62 62
GB31-A AUXBOX GND BLCK
0-742-AE1 (BLK 14ga ) 0-752-AA1 (BLK 14ga )
VEC-91 F32 TB28-L1 TB28 TB28-L2
11 BUSS 4A A
11RCNT-000-AA1 (TAN 14ga ) L1 L2 11RCNT-001-AA1 (TAN 14ga )
15
MC011 J808 P808 P17 J17
58E-06-20062
SH18:N-7 11RCNT-005-AA36 (BRN 25ga ) L3 L4 11RCNT-003-AA1 (TAN 14ga )
MC011 TB28-L3 TB28-L4 SP777
65TS-006-AA1 (DBL 16ga ) 65TS-009-AA1 (DBL 16ga ) 34 34
RELAY HEATED HOSE (TSW) 35 35
VEC-92 F5 VEC-92
86
11PHH-000-AA1 (RED 14ga )
85 36 36 10 10 35 35 B 1B 11
SH5:P-4 0-766-AA1 (BLK 14ga ) 11DFP-000-AE1 (PNK 16ga ) 11DFP-006-AA1 (PNK 16ga )
15 BUSS
58E-06-09621
VEC-92 F8
71CK 2C C 88 88A VEC-92 F6 VEC-92
BUSS
11HH-000-AA1 (PNK 12ga ) 11PHH-001-AA1 (RED 14ga ) J12 P12
20
SP780 15 15 11NOX-000-AE1 (PNK 16ga ) 36 36 11NOX-006-AA1 (PNK 16ga ) D 4D 11
58E-06-09621 VEC-92 88(2) 15 BUSS
58E-06-09621
58E-06-04150 J808 P808 P17 J17
29 29
SH4:H-8 0-223-AA1 (BLK 14ga ) 30 30
SH4:H-8 0-222-AA1 (BLK 14ga ) 28 28
11POR-002-AA1 (GRY 14ga ) 27 27
GB31-B AUXBOX GND BLCK
E3 0-766-AA1 (BLK 14ga )
0-764-AA1 (BLK 18ga )
SH5:O-8 65TS-008-AA1 (DBL 16ga )
11PHH-004-AA1 (RED 14ga )
31 31
32 32 58B-06-05901-00 SEP 21
0-765-AA1 (BLK 14ga ) 0-765-AA1 (BLK 14ga ) 33 33
SH5:D-13
SH5:E-13
21OR-002-AA1 (LBL 16ga )
21ORR-003-AA1 (DGR 16ga )
25 25
26 26 AFTERTREATMENT WIRING ELECTRICAL SCHEMATIC
J11 P11
980E-5
ENGINE OIL RESERVE SYSTEM OPTION A50052, A50053, A50137, A50138
Sheet 5 of 21
7
GE CONTROL INTERFACE
BRAKE LOCK SOL ON IN 1 F60 VEC-91 TB24
52B-010-AA3 (PUR 16ga ) SH6:M-9
OPERATOR
F
2F 3F F 49 49 49 49
SH4:B-11 712-008-AA1 (ORG 14ga ) 712DS2-000-AA1 (BRN 14ga ) U1 U2 712DS2-003-AA30 (BRN 14ga ) 712DS2-001-AC2 (BRN 14ga )
15
P302
BRAKE LOCK SW POWER SUPPLY IN 40 712BL-007-AA3 (DGR 20ga ) SH6:K-8
VEC-92 58E-06-09621
VEC-89
CAB SEATS
TB27 GB31-B AUXBOX GND BLCK F56 TB24
1H 86 85 2D D E4 712 BUSS 4B
HILL START BRAKE APPLY OUT 39 52GE-001-AA3 (ORG 20ga ) J1 J2 52GE-002-AA1 (ORG 18ga ) H 0-901-AA1 (BLK 18ga ) B 712DS-000-AA1 (ORG 14ga ) C1 C4 712DS-002-AA30 (ORG 14ga ) 2 2 712DS-001-AC2 (ORG 14ga ) 2 2
15
87 2E VEC-89 58E-06-02043
E 52B-009-AA1 (PUR 16ga ) SH6:M-12
30 J82 P82
SH6:K-6 712BL-005-AA1 (DGR 16ga ) A 1A
87a P02 J02
BRAKE LOCK SW OFF IN 36 52B1-004-AA3 (PUR 20ga ) SH6:M-9 VEC92-P2
VEC92-P1 F
DRIVE SYSTEM 3F P03 J03 TB10 AIR SEAT DRIVER
P304 ABM VEC-92
VEC92-P3 65 65 712CCD-007-CC3 (RED 14ga ) P1 P2 712CCD-001-CC2 (RED 14ga ) 1 1 C 12V + 1 1 1 712DS-003-CC2 (ORG 14ga )
0-025-CC2 (BLK 14ga ) 2 2 C 12V -
66 66 712CCD-010-CC3 (RED 14ga ) P3 P4 712CCD-003-CC2 (RED 14ga ) 3 3 L 12V + 2 2 2 0-309-CC2 (BLK 14ga )
0-029-CC2 (BLK 14ga ) 4 4 L 12V -
GB12-B
SP12944 P227 J227
A2 J228_CP P228
0-049-CC2 (BLK 12ga )
GE ASSISTED BRAKE MANAGEMENT AIR SEAT PASSENGER
1 1 1 712DS2-002-CC2 (BRN 14ga )
GB12-B
A3
2 2 2 0-308-CC2 (BLK 14ga )
P230 J230
0-266-CC2 (BLK 14ga )
DIRECTIONAL SHIFTER / PARK BRAKE
J3-AA7 (BLK 18ga )
J2-AA7 (BLK 18ga )
J1-AA7 (BLK 18ga ) TB23
VEC-89 F43 VEC-89
71CK BUSS 4A
1
2
3
10
11
12
AHT P701 A 71SS-000-AA1 (LBL 20ga ) T1 T4 71SS-003-AA30 (LBL 20ga ) 3 3 71SS-001-AC2 (LBL 20ga ) 3 3
AUXBOX CONNECTOR 5
(OPT) J701_JP 58E-06-02043
VEC89-P4 J82 P82 P02 J02
10
11
12
1
2
3
GE CONTROL INTERFACE
72AF-000-AA3 (GRY 20ga ) 17 FORWARD DIRECTION INPUT
TB23
72RA-001-AA3 (YEL 18ga ) X4 X1 72RA-002-AA1 (YEL 18ga ) SH10:C-4
X3 72RA-000-AA3 (YEL 20ga ) 16 REVERSE DIRECTION INPUT
TB25
V2 71BC-008-AA33 (DGR 16ga ) SH5:F-17 72N-003-AA3 (PNK 18ga ) 34 NEUTRAL REQUEST
TB24 DIRECTION SELECTOR
SHIFTER CONTROLLER
SH12:M-17 71BC-010-AA1 (DGR 16ga ) V4 V1 71BC-000-AA1 (DGR 16ga ) 72PA-001-AA3 (BRN 18ga ) E2 E1 72PA-003-AA1 (BRN 20ga ) SH6:L-16 SP365
P304 GND 6 0-260-CC2 (BLK 20ga )
TB21
72P-002-AA3 (BRN 18ga ) K1 K4 72P-003-AA30 (BRN 20ga ) 13 13 72P-001-AC2 (BRN 20ga ) 13 13 72P-000-CC2 (BRN 20ga ) 2 PARK VBATT 7 71SS-002-CC2 (LBL 20ga )
L1 L3 72R-004-AA30 (YEL 20ga ) 14 14 72R-001-AC2 (YEL 20ga ) 14 14 72R-000-CC2 (YEL 20ga ) 1 REVERSE
DIRECTION SELECTOR SHIFTER
72R-003-AA3 (YEL 18ga ) L2 72N-004-AA30 (PNK 20ga ) 15 15 72N-001-AC2 (PNK 20ga ) 15 15 72N-000-CC2 (PNK 20ga ) 12 NEUTRAL PWM 4 72PWM-000-CC2 (TAN 20ga ) 4 PWM OUTPUT DIMMER INPUT 9 49-004-CC2 (TAN 20ga ) SH7:K-7
F19
71CK BUSS VEC-90 9B
B 72N-002-AA1 (PNK 18ga ) M1 M4 72F-004-AA30 (GRY 20ga ) 16 16 72F-001-AC2 (GRY 20ga ) 16 16 72F-000-CC2 (GRY 20ga ) 11 FORWARD VSHIFT 8 71SR-000-CC2 (LTG 20ga ) 6 VBATT GND 5 0-418-CC2 (BLK 20ga )
10
D14 9 9 9 9 3 TROLLEY FAULT 10 47 47 SW B NO 11
VEC-90
M2 72T-002-AA30 (YEL 20ga ) 72T-001-AC2 (YEL 20ga ) 72T-000-CC2 (YEL 20ga ) 72IM-000-CC2 (YEL 20ga ) 72IM-003-AC2 (YEL 20ga ) P108 71H-002-CC2 (LBL 20ga ) SH9:J-7
H 9H 85 86
SH5:K-10 36-002-AA1 (YEL 18ga )
58E-06-20051 SW B COM 12
72F-002-AA1 (GRY 18ga ) N1 N4
J82 P82 P109 J02 P02 71P-003-CC2 (BRN 20ga ) SH9:I-12
87 D2
30 TO VEC90 1G P02 J02 58E-06-06390 P109 58E-06-20300 IM2
G 72F-003-AA3 (GRY 18ga ) N2
87a RELAY 20 (87A) P108
D3 9 IM2 MAIN GROUND 1
1F SH6:K-14 72T-007-AA1 (YEL 18ga ) P3 P4 SH4:I-4 0-024-AA1 (BLK 20ga )
ENGINE RUNNING F SH4:I-4 0-023-AA1 (BLK 20ga ) 10 IM2 MAIN GROUND 2
RELAY 21 52CS-001-AA1 (GRY 20ga ) 20 PARK BRAKE SOLENOID
D4 TB22 30 PARK BRAKE PROTECTION (OPT)
1E
E 72R-002-AA1 (YEL 18ga ) 47 47 72IM-002-AA30 (YEL 20ga ) G4 G1 72IM-001-AA1 (YEL 20ga ) 35 SHIFTER FAULT
D13
85 86
P82 J82 IM1
TB24
87 11B
B 52PB-000-AA1 (PUR 16ga ) B1 B2
30
87a 11D
D
TB21
PARK BRAKE R18
58B-06-00290 SH12:B-14 0-229-AA2 (BLK 16ga ) X3
REQUEST RELAY 22 TB32
SH5:G-17 52CS-007-AA33 (GRY 16ga ) K3 K4 52CS-002-AA2 (GRY 18ga ) 1 2 0-231-AA2 (BLK 18ga ) X4
0 BUSS 58E-06-40220
85 86
K1 K2 SH5:E-12 0-238-AA2 (BLK 16ga ) Y3
87 11A
A 52CS-000-AA1 (GRY 16ga ) SH12:N-13 0-345-AA2 (BLK 18ga ) Y4 Y1 0-936-AA1 (BLK 18ga ) SH12:J-14
0 BUSS 30
87a 7 BRAKE LOCK
712BL-001-AA1 (DGR 20ga ) 15 BRAKE LOCK SWITCH POWER SUPPLY
PARK BRAKE 12D
D 17 SELECTOR SW (NOT IN PARK)
RELEASE RELAY 23 35 PARK BRAKE RELEASE REQUEST
52PB-003-AA1 (PUR 20ga )
TB24 44 SERVICE BRAKE PRESS SW
SH5:F-18 44R-001-AA1 (GRY 20ga )
72FNR-000-AA1 (DBL 16ga ) M1 M2 72FNR-001-AA1 (DBL 20ga )
D11 IM2
0 BUSS 85 86
AHT CONNECTION M3 M4 72FNR-002-AA1 (DBL 18ga ) 1 2 72T-007-AA1 (YEL 18ga ) SH6:I-8
D5 TB23
87 12A PC2834
A 712BL-000-AA1 (DGR 16ga ) 712BL-006-AA1 (DGR 16ga ) L1 L2
30
SP778
87a
SH6:B-4 712BL-007-AA3 (DGR 20ga ) L3 L4 712BL-004-AA30 (DGR 16ga ) 70 70 712BL-002-AC2 (DGR 16ga )
PARK BRAKE SH6:C-5 712BL-005-AA1 (DGR 16ga )
SWITCH RELAY 24 J82 P82
S1 52ABA-000-AA1 (TAN 20ga )
0 BUSS
S2
86 85 SWITCH BRAKE LOCK 42 SELECTOR SWITCH PARK
SH6:H-10 72PA-003-AA1 (BRN 20ga )
D6
0-818-CC2 (BLK 18ga ) SH9:I-11
87 9 7 0-095-CC2 (BLK 16ga ) SH18:C-22 IM3
30
87a 44 44 44 44 3
9D 52B1-003-AA30 (PUR 16ga ) 52B1-001-AC2 (PUR 16ga ) 52B1-002-CC2 (PUR 16ga )
D 52B-000-AA1 (PUR 16ga ) 2B 712BL-003-CC2 (DGR 16ga ) 70 70
TRUCK MOVING 1
RELAY 25 D7
J02 P02
39HA-002-AA30 (YEL 16ga ) 45 45 39HA-001-AC2 (YEL 16ga ) 45 45 39HA-000-CC2 (YEL 16ga ) 6 0-450-CC2 (BLK 18ga )
5B
D8 TB23 46 46 46 46 4
0 BUSS 9C 39H-001-AC2 (YEL 16ga ) 39H-000-CC2 (YEL 16ga )
85 86 C 52B1-000-AA1 (PUR 16ga ) B1 B4
10 8 0-059-CC2 (BLK 16ga )
87 J82 P82 P02 J02
B2 52B1-004-AA3 (PUR 20ga ) SH6:C-4
30
P39 P39
87a 58F-06-60921
VEC-92 VEC-92
PARK BRAKE 58E-06-09621
2F
SH6:C-8 52B-009-AA1 (PUR 16ga )
D9 LATCH RELAY 26 F 86 85 2B B
52ABA-001-AA1 (TAN 20ga )
E 9E
87 2G
G 52B-002-AA1 (PUR 16ga ) 52B-011-AA1 (PUR 16ga ) 52B-001-AA1 (PUR 20ga )
D10 86 85 30
SP779
F 9F 87a 2A A TB32
87
SH6:B-4 52B-010-AA3 (PUR 16ga ) J1 J2 SOLENOID BRAKE LOCK
30 RELAY 4
PARK BRAKE PROTECTION SP453
87a L L L L 2 1
J3 52B-007-AA33 (PUR 16ga ) 52B-003-AB1 (PUR 16ga ) 52B-004-BB1 (PUR 16ga ) 52B-005-BB1 (PUR 16ga ) 0-098-BB1 (BLK 16ga ) 0-455-BB1 (BLK 16ga ) SH3:I-13
SP160
INTERFACE RELAY XA3347
27 TB32 J85 P85 P240 J240 BLS BLS
T1
R14 D3
71ABA-000-AA1 (YEL 16ga ) 58B-06-02020
52B-006-BB1 (PUR 16ga ) 1 2 0-239-BB1 (BLK 16ga )
79RD-000-AA1 (BRN 18ga ) SH5:E-15 71ABA-002-AA1 (YEL 16ga ) T4 T2 71ABA-003-AA1 (YEL 18ga ) 1 2 0-281-AA1 (BLK 18ga ) SH15:B-6
PC2834
J8-AA8 (BLK 18ga )
R14 R14
AHT
72FD-000-AA1 (WHT 18ga ) SH5:F-15 P702
1
AUXBOX CONNECTOR TB23
(OPT) J702_JP
1
AHT CONNECTION V1 V4
TB23
SH13:J-8 39H1-001-AA4 (YEL 18ga ) P4 P1 39H1-000-AA1 (YEL 18ga ) 39H-002-AA1 (YEL 18ga ) A1 A4 39H-003-AA30 (YEL 16ga )
A3
58B-06-05901-00 SEP 21
ELECTRICAL SCHEMATIC
980E-5
A50052, A50053, A50137, A50138
Sheet 6 of 21
ELECTRONIC GAUGE DISPLAY
7
IM2
TB26
42 42 55B-003-AA31 (DBL 16ga ) P2 P1 55B-002-AA1 (DBL 20ga ) 14 MODE SW OK
41 41 55A-003-AA31 (LBL 16ga ) N2 N1 55A-002-AA1 (LBL 20ga ) 3 MODE SW LEFT ARROW
45 45 55D-003-AA31 (PUR 16ga ) S2 S1 55D-002-AA1 (PUR 20ga ) 16 MODE SW UP ARROW
44 44 55C-003-AA31 (YEL 16ga ) R2 R1 55C-002-AA1 (YEL 20ga ) 4 MODE SW DOWN ARROW
IM1
SP200
SH8:C-6 71LS-006-CC3 (DGR 16ga ) 71LS-003-CC3 (DGR 16ga ) P83 J83
SWITCH DISPLAY INPUT
SH11:E-15 0-041-CC3 (BLK 18ga ) 7 9
TB10
3 55K-001-CC3 (YEL 16ga ) R1 R2
71LS-007-CC3 (DGR 16ga ) 2B SP364 D9
1 24SON-002-AA32 (LBL 16ga ) 1 2 712G-001-AA32 (LTG 16ga ) SH7:F-14
6 PC2834
5B D10
SONALERT
4 24SON-003-AA32 (LBL 16ga ) 1 2 24VIM-006-AA32 (LBL 16ga ) SH3:K-10
+ 24SON-000-CC4 (LBL 16ga ) 18 18 24SON-004-AC4 (LBL 16ga ) 18 18 24SON-005-AA32 (LBL 16ga )
8 10 D27 PC2834
SH7:G-8 11RWL-004-CC3 (PUR 16ga )
P26 P26 - 31ML-004-CC4 (BRN 16ga ) 2 1 31IML-006-CC4 (BRN 16ga ) 17 17 31IML-002-AC4 (BRN 16ga ) 17 17 31IML-005-AA32 (BRN 16ga )
58F-06-08400 PC2834
PB1951 J04 P04 P84 J84 R16 TB34
24SON-001-AA32 (LBL 16ga ) 2 1 31IML-003-AA32 (BRN 16ga ) 31IML-001-AA32 (BRN 16ga ) N4 N1 31IML-000-AA1 (BRN 20ga ) 19 SONALERT
470Ω 2W
ELECTRONIC DASH DISPLAY PANEL(MOD) SP252 30 IM ON SIGNAL
R16 R16
58B-06-00190 IM2
OK SWITCH 1 55K-000-CC1 (YEL 16ga ) 31 31 31 31 SH8:J-8
MC3199 MC3199 45L-005-AC1 (DGR 16ga ) 45L-006-AA29 (DGR 16ga )
SH14:F-20 939YE-022-CC1 (YEL 20ga ) 6 CAN J1939 HI 30 30 45R-005-AC1 (LBL 16ga ) 30 30 45R-006-AA29 (LBL 16ga ) SH8:J-8
5 CAN J1939 LOW TB10 D28
SH14:F-20 939GE-022-CC1 (GRN 20ga )
SONALERT 22 31-000-CC1 (YEL 16ga ) J1 J2 31-001-CC4 (YEL 16ga ) 1 2 31ML-007-CC4 (BRN 16ga ) VEC-91
19 CAN DISPLAY HI
TB23 F54
R4 PC2834 9C 712 BUSS
18 CAN DISPLAY LOW 6 6 712G-002-AC1 (LTG 16ga ) 6 6 712G-004-AA29 (LTG 16ga ) Y4 Y1 712G-000-AA1 (LTG 16ga ) C
58B-06-02020 5
P900 1 2 0-194-CC1 (BLK 16ga ) SH7:G-7 Y3 712G-001-AA32 (LTG 16ga ) SH7:D-15
TB35
45L-011-CC1 (DGR 16ga ) SP10 R4 R4
LEFT TURN 12 45L-010-CC1 (DGR 16ga ) 45L-008-CC1 (DGR 16ga ) 11RWL-001-AC1 (PUR 16ga ) 3 3 11RWL-003-AA29 (PUR 16ga ) P2 P1 11RWL-002-AA1 (PUR 20ga ) 40 RED WARNING LAMP
RIGHT TURN 20 45R-010-CC1 (LBL 16ga ) 45R-008-CC1 (LBL 16ga )
SP11 R5 4 4 IM1
45R-011-CC1 (LBL 16ga )
58B-06-02020
24VIM-007-AA29 (LBL 16ga ) SH3:K-13
1 2 0-193-CC1 (BLK 16ga ) SH7:H-7
TB23 VEC-91 F26
2E 11 BUSS
R5 R5 11DISP-001-AC1 (YEL 16ga ) 1 1 11DISP-000-AA29 (YEL 16ga ) G4 G1 11DISP-002-AA1 (YEL 16ga ) E
15
HIGH BEAM 13 TB35
41H-006-CC1 (TAN 16ga ) SH7:J-13
IGNITION 15 712G-003-CC1 (LTG 16ga ) 2 2 11ONS-002-AA29 (LBL 16ga ) T2 T1 11ONS-004-AA1 (LBL 20ga )
TB10 T3 11ONS-003-AA1 (LBL 18ga )
3 3 VEC-92 4E E
SH7:E-4 11RWL-004-CC3 (PUR 16ga ) M1 M2 11RWL-000-CC1 (PUR 16ga ) VEC-92 11CMX-001-AA1 (TAN 14ga ) SH17:K-21
F3
11
BATTERY 7 11DISP-003-CC1 (YEL 16ga ) 1 1 F 4F 85 86
15 BUS
GB12-A 87 D34
SP12
C4 30 4H H
GROUND 8 0-186-CC1 (BLK 16ga ) 0-185-CC1 (BLK 16ga ) 74SBD-000-AA1 (LBL 18ga ) 1 2 74SB1-010-AA1 (DBL 18ga ) SH2:C-20
87a
SH7:F-9 0-194-CC1 (BLK 16ga )
P900 PC2834
SH7:F-9 0-193-CC1 (BLK 16ga ) J01 P01 P81 J81 RELAY 1
IM SYSTEM BUSY 58E-06-09621
HEADLIGHT LAMP SWITCH
SWITCH HEADLIGHTS SPARE WIRES - AUXB TO CAB
SH13:E-1 0-320-CC3 (BLK 18ga )
SH13:A-2 0-446-CC3 (BLK 16ga ) 7 9
VEC-89 F64 VEC-89 TB22
3 SPR1-002-AA31 (DGR 14ga ) 59 59 SPR1-000-AC3 (DGR 14ga ) 59 59 SPR1-001-CC3 (DGR 14ga ) OP-CAB
71CK BUSS 2D D 11D-000-AA1 (PNK 16ga ) A1 A4 11D-004-AA31 (PNK 16ga ) 5 5 11D-001-AC3 (PNK 16ga ) 5 5 11D-002-CC3 (PNK 16ga ) 2B 41L-002-CC3 (LBL 16ga ) SH7:L-2 SH7:K-2 41H-004-CC3 (TAN 16ga ) CENTER CONSL
5 SWITCH COMBO
1 SP004 SPR2-002-AA31 (DGR 14ga ) 60 60 SPR2-000-AC3 (DGR 14ga ) 60 60 SPR2-001-CC3 (DGR 14ga ) SPARE WIRES
58E-06-02043 6 4 3
VEC89-P2 J83 P83 P03 J03 41L-000-CC3 (LBL 16ga ) 41L-001-CC3 (LBL 16ga ) 41H-000-CC3 (TAN 16ga )
11D-003-CC3 (PNK 16ga ) 5B SP016
4 TB10 DIMMER SW
41L-003-CC3 (LBL 16ga ) D1
P121 PC1709 P121 61 61 61 61 OP-CAB
SPR3-002-AA31 (DGR 14ga ) SPR3-000-AC3 (DGR 14ga ) SPR3-001-CC3 (DGR 14ga )
SH8:B-8 0-159-CC3 (BLK 18ga ) 8 10 11L-010-CC3 (YEL 18ga ) SH8:K-4
LOWER DASH
SPR4-002-AA31 (DGR 14ga ) 62 62 SPR4-000-AC3 (DGR 14ga ) 62 62 SPR4-001-CC3 (DGR 14ga ) SPARE WIRES
TB10
P20 58F-06-60801 P20 AUX BOX
41H-006-CC1 (TAN 16ga )
SH7:G-8 E2 E1 41H-005-CC3 (TAN 16ga )
SPARE
TB34
11 11 11 11 WIRES 63 63 63 63 OP-CAB
SH8:H-9 41TS-005-AA1 (DGR 18ga ) A1 A2 41TS-007-AA31 (DGR 16ga ) 41TS-003-AC3 (DGR 16ga ) 41TS-000-CC3 (DGR 16ga ) 41TS-002-CC3 (DGR 16ga ) SPR5-002-AA31 (DGR 14ga ) SPR5-000-AC3 (DGR 14ga ) SPR5-001-CC3 (DGR 14ga )
SP301 LOWER FRT
SPR6-002-AA31 (DGR 14ga ) 64 64 SPR6-000-AC3 (DGR 14ga ) 64 64 SPR6-001-CC3 (DGR 14ga ) SPARE WIRES
J83 P83 P03 J03 TB10 DISPLAY PANEL DIMMER
41TS-006-CC3 (DGR 16ga ) G1 G2 41TS-009-CC1 (DGR 16ga ) 1
J83 P83 P03 J03
49-001-CC1 (TAN 16ga ) 2
3 SPR7-002-AA32 (DGR 14ga ) 6 6 SPR7-000-AC4 (DGR 14ga ) 6 6 SPR7-001-CC4 (DGR 14ga ) OP-CAB
GB12-A OVERHEAD
P18 A2
0-178-CC1 (BLK 16ga ) SPR8-002-AA32 (DGR 14ga ) 7 7 SPR8-000-AC4 (DGR 14ga ) 7 7 SPR8-001-CC4 (DGR 14ga ) SPARE WIRES
SH6:H-18 49-004-CC2 (TAN 20ga )
R27
TB10
SP008 SP285 J84 P84 P04 J04
SH17:E-8 49-009-CC2 (TAN 20ga ) 49-007-CC2 (TAN 20ga ) N1 N2 49-008-CC1 (TAN 20ga ) 49-005-CC1 (TAN 16ga ) 1 2 0-187-CC1 (BLK 16ga )
SH3:C-15 49-003-CC3 (TAN 18ga ) N3
58B-06-00290
TB34
RELAY HI-BEAM HEADLIGHT
AHT CONNECTION B3
(HBHR) GB31-B AUXBOX GND BLCK
86 0-014-AA2 (BLK 16ga ) SH3:F-7 C2
18 18 18 18 85
SH7:I-14 41H-004-CC3 (TAN 16ga ) 41H-001-AC3 (TAN 16ga ) 41H-003-AA31 (TAN 16ga ) B2 B1 41H-002-AA1 (TAN 18ga ) 0-015-AA2 (BLK 16ga )
VEC-89 F6 VEC-89 TB34 LAMP HIGH MOUNT LEFT HI-BEAM
11 BUSS 12F 88 88A
F 11HL-000-AA1 (BRN 10ga ) 41HB-000-AA2 (LTG 10ga ) F4 F1 41HB-001-AA1 (LTG 16ga ) 41 41 41HB-005-AJ1 (LTG 16ga ) 5 5 41HB-006-JL1 (LTG 16ga ) 1
25
58E-06-02043 88(2) 42 42 6 6 2
VEC89-P12 F2 SH4:G-4 0-129-AA1 (BLK 16ga ) 0-110-AJ1 (BLK 16ga ) 0-054-JL1 (BLK 16ga )
TB34 HMLHB
58E-06-04150 G1
58D-06-10920
SH7:I-12 41L-002-CC3 (LBL 16ga ) 4 4 41L-004-AC3 (LBL 16ga ) 4 4 41L-007-AA31 (LBL 16ga ) C2 C1 41L-005-AA1 (LBL 16ga ) LAMP LOW MOUNT LEFT HI-BEAM
G2
AHT CONNECTION C3 41HB-002-AA1 (LTG 16ga ) 43 43 41HB-007-AJ1 (LTG 16ga ) 7 7 41HB-008-JL1 (LTG 16ga ) 1
J03 P03 P83 J83
SH4:G-4 0-128-AA1 (BLK 16ga ) 44 44 0-112-AJ1 (BLK 16ga ) 8 8 0-121-JL1 (BLK 16ga ) 2
LMLHB
58D-06-10920
J12 P12 J542 P542
LAMP HIGH MOUNT RIGHT HI-BEAM
41HB-003-AA1 (LTG 16ga ) 41 41 41HB-009-AH1 (LTG 16ga ) 5 5 41HB-010-HL1 (LTG 16ga ) 1
SH4:H-8 0-127-AA1 (BLK 16ga ) 42 42 0-122-AH1 (BLK 16ga ) 6 6 0-123-HL1 (BLK 16ga ) 2
HMRHB
58D-06-10920
LAMP LOW MOUNT RIGHT HI-BEAM
41HB-004-AA1 (LTG 16ga ) 43 43 41HB-011-AH1 (LTG 16ga ) 7 7 41HB-012-HL1 (LTG 16ga ) 1
RELAY HEADLIGHT LOW
MOUNT (HLMR) SH4:I-8 0-126-AA1 (BLK 16ga ) 44 44 0-124-AH1 (BLK 16ga ) 8 8 0-125-HL1 (BLK 16ga ) 2
0-016-AA2 (BLK 16ga ) SH8:G-14 LMRHB
86 85 58D-06-10920
41L-006-AA1 (LBL 16ga ) 0-543-AA2 (BLK 16ga )
J11 P11 J543 P543
VEC-89 F4 VEC-89 LAMP LOW MOUNT LEFT LOW-BEAM
11 BUSS 9A 88 88A
A 11LL-000-AA1 (GRY 10ga ) 41LM-000-AA1 (GRY 16ga ) 39 39 41LM-002-AJ1 (GRY 16ga ) 3 3 41LM-003-JL1 (GRY 16ga ) 1
15
58E-06-02043 88(2) 40 40 4 4 2
VEC89-P9 SH4:H-4 0-055-AA1 (BLK 16ga ) 0-114-AJ1 (BLK 16ga ) 0-113-JL1 (BLK 16ga )
LMLLB
58E-06-04150 58D-06-10930
J12 P12 J542 P542 LAMP LOW MOUNT RIGHT LOW-BEAM
41LM-001-AA1 (GRY 16ga ) 39 39 41LM-004-AH1 (GRY 16ga ) 3 3 41LM-005-HL1 (GRY 16ga ) 1
SH4:H-8 0-008-AA1 (BLK 16ga ) 40 40 0-116-AH1 (BLK 16ga ) 4 4 0-115-HL1 (BLK 16ga ) 2
RELAY HEADLIGHT HIGH MOUNT (HHMR) LMRLB
86 85 58D-06-10930
0-157-AA2 (BLK 16ga ) SH10:D-11
J11 P11 J543 P543
VEC-89 F5 VEC-89 LAMP HIGH MOUNT LEFT LOW-BEAM
11 BUSS 9G 88 88A
G 11LR-000-AA1 (PNK 10ga ) 41HM-000-AA1 (PNK 16ga ) 45 45 41HM-002-AJ1 (PNK 16ga ) 9 9 41HM-003-JL1 (PNK 16ga ) 1
15
58E-06-02043 88(2) 46 46 10 10 2
VEC89-P9 SH4:H-4 0-053-AA1 (BLK 16ga ) 0-118-AJ1 (BLK 16ga ) 0-117-JL1 (BLK 16ga )
HMLLB
58E-06-04150 58D-06-10930
41HM-001-AA1 (PNK 16ga )
J12
45 45
P12
41HM-004-AH1 (PNK 16ga )
J542
9 9
P542
41HM-005-HL1 (PNK 16ga )
LAMP HIGH MOUNT RIGHT LOW-BEAM
1
58B-06-05901-00 SEP 21
HEADLIGHT LAMPS
SH4:H-8 0-084-AA1 (BLK 16ga ) 46 46 0-119-AH1 (BLK 16ga ) 10 10 0-120-HL1 (BLK 16ga )
HMRLB
2
58D-06-10930
ELECTRICAL SCHEMATIC
J11 P11 J543 P543 980E-5
A50052, A50053, A50137, A50138
Sheet 7 of 21
FOG LAMPS
SWITCH FOG LAMP
7 9
LAMP RIGHT FOG
SH7:I-8 0-159-CC3 (BLK 18ga )
TB34 48LF-001-AA1 (GRY 16ga ) 37 37 48LF-003-AH1 (GRY 16ga ) 1 1 48LF-005-HL1 (GRY 16ga ) 1
3 55 55 55 55 B 1B VEC-89 VEC-89
48F-000-CC3 (GRY 16ga ) 48F-001-AC3 (GRY 16ga ) 48F-003-AA31 (GRY 16ga ) E2 E1 48F-002-AA1 (GRY 18ga ) 7
SH13:D-1 71LS-011-CC3 (DGR 16ga ) 2B SH4:H-8 0-104-AA1 (BLK 16ga ) 38 38 0-103-AH1 (BLK 16ga ) 2 2 0-102-HL1 (BLK 16ga ) 2
VEC-89 F44 VEC-89 TB23 TB10 1
0 BUSS 85 86
J03 P03 P83 J83 RFLT
71CK BUSS 4D F62 58D-06-10940
D 71LS-000-AA1 (DGR 16ga ) M1 M4 71LS-004-AA31 (DGR 16ga ) 36 36 71LS-001-AC3 (DGR 16ga ) 36 36 71LS-002-CC3 (DGR 16ga ) A1 A2 71LS-008-CC3 (DGR 16ga )
5 11 BUSS 87 TB34 J11 P11 J543 P543
6
58E-06-02043 5B 15 30 1D D
J83 P83 P03 J03 71LS-006-CC3 (DGR 16ga ) A3 48LF-000-AA1 (GRY 12ga ) D1 D2
4
87a LAMP LEFT FOG
D4 48LF-002-AA1 (GRY 16ga ) 37 37 48LF-004-AJ1 (GRY 16ga ) 1 1 48LF-006-JL1 (GRY 16ga ) 1
8 10 FOG LAMP (OPT)
SH7:C-3 SH10:B-10 0-268-CC3 (BLK 18ga ) RELAY 40 58E-06-02043
SH4:H-4 0-425-AA1 (BLK 16ga ) 38 38 0-106-AJ1 (BLK 16ga ) 2 2 0-105-JL1 (BLK 16ga ) 2
P23 P23 LFLT
58F-06-60831 58D-06-10940
J12 P12 J542 P542
LAMP DIAGONAL LADDER LIGHT #1 (OPT LOCATION)
1 48-025-FF3 (DBL 14ga ) 1
2 0-770-FF3 (BLK 14ga ) 2
RDLLT 58D-06-02940
LADDER LAMPS
J545B
RIGHT DECK LAMPS
LAMP DECK LIGHT #1
SWITCH LADDER LIGHT GND LVL (LLSW) 48-001-AA1 (DBL 16ga ) 47 47 48-006-AH1 (DBL 16ga ) 11 11 48-023-HL1 (DBL 16ga ) 1 1 1
48-024-FF4 (DBL 16ga )
48C-007-JJ2 (ORG 16ga ) A A 48C-004-AJ1 (ORG 16ga )
SH4:I-8 0-165-AA1 (BLK 16ga ) 48 48 0-166-AH1 (BLK 16ga ) 12 12 0-167-HL1 (BLK 16ga ) 2 2 2
2 0-800-FF4 (BLK 16ga )
B B
48A-007-JJ2 (YEL 16ga ) 48A-003-AJ1 (YEL 16ga ) RDLT1
1 58D-06-02940
3
C C
LAMP DECK LIGHT #2
48B-007-JJ2 (PUR 16ga ) 48B-003-AJ1 (PUR 16ga )
VA2828 P535 J535_CP 49 49 13 13 3 3 1
48-002-AA1 (DBL 16ga ) 48-009-AH1 (DBL 16ga ) 48-010-HL1 (DBL 16ga ) 48-018-FF4 (DBL 16ga )
SWITCH CAB LADDER LIGHT 50 50 14 14 4 4 2
SH4:I-8 0-164-AA1 (BLK 16ga ) 0-168-AH1 (BLK 16ga ) 0-169-HL1 (BLK 16ga ) 0-801-FF4 (BLK 16ga )
7 9 RDLT2 58D-06-02940
SH10:C-10 0-056-CC3 (BLK 18ga )
TB34
3 53 53 53 53 K4 K1 26 26
J11 P11 J543 P543 P545 J545 LEFT DECK LAMPS
48B-000-CC3 (PUR 18ga ) 48B-001-AC3 (PUR 18ga ) 48B-006-AA31 (PUR 18ga ) 48B-002-AA1 (PUR 18ga ) 48B-003-AJ1 (PUR 16ga ) LAMP DIAGONAL LADDER LIGHT #1
2B GB31-B AUXBOX GND BLCK
SH8:K-4 11L-008-CC3 (YEL 18ga ) B2
1 48A-000-CC3 (YEL 18ga ) 54 54 K2 48A-002-AA1 (YEL 18ga ) 25 25 48A-003-AJ1 (YEL 16ga ) 0-237-AA2 (BLK 16ga )
48-003-AA1 (DBL 16ga ) 47 47 48-011-AJ1 (DBL 16ga ) 11 11 48-012-JL1 (DBL 16ga ) 1 1 48-020-GG5 (DBL 16ga ) 1
6 48A-001-AC3 (YEL 18ga ) 54 54 48A-006-AA31 (YEL 18ga ) J4 J1
J12 P12 TB34
5B SH4:H-4 0-163-AA1 (BLK 16ga ) 48 48 0-170-AJ1 (BLK 16ga ) 12 12 0-171-JL1 (BLK 16ga ) 2 2 0-802-GG5 (BLK 16ga ) 2
J03 P03
4 J2 48C-004-AJ1 (ORG 16ga ) 27 27 48C-001-AA1 (ORG 18ga ) L1 LDLLT
P83 J83 58D-06-02940
RELAY ACCESS LADDER LIGHT TB26 LAMP DECK LIGHT #1 (OPT LOCATION)
SH8:K-6 0-318-CC3 (BLK 18ga ) 8 10 48C-002-AA1 (ORG 18ga ) L4 L2
(ALLR)
T2
P12 J12 86 85
P21 P21 48C-000-AA1 (ORG 18ga ) 0-016-AA2 (BLK 16ga ) SH7:N-8 48-004-AA1 (DBL 16ga ) 49 49 48-013-AJ1 (DBL 16ga ) 13 13 48-017-JL1 (DBL 16ga ) 3 3 1 48-019-GG3 (DBL 16ga ) 1
58F-06-60811 T1 T4
48A-004-AA1 (YEL 18ga ) 22 22 48A-005-AH1 (YEL 16ga ) 58E-06-40220 SH4:H-4 0-162-AA1 (BLK 16ga ) 50 50 0-172-AJ1 (BLK 16ga ) 14 14 0-803-JL1 (BLK 16ga ) 4 4 2 0-449-GG3 (BLK 16ga ) 2
88 88A
U1
LDLT1
48B-004-AA1 (PUR 18ga ) 23 23 48B-005-AH1 (PUR 16ga ) 11DSL-000-AA1 (RED 12ga ) 48-000-AA1 (DBL 12ga ) 58D-06-02940
U2
VEC-89 F10 VEC-89 88(2) J12 P12 J542 P542 P544 J544 LAMP DECK LIGHT #2 (OPT LOCATION)
J11 P11 11 BUSS 12G
G
SWITCH RIGHT LADDER LIGHT GND LVL (OPT LOCATION) (RLSW) P534 J534_CP 20 58E-06-04150 3 48-022-GG3 (DBL 16ga ) 1
58E-06-02043
48B-008-HH3 (PUR 16ga ) C C
3 24 24 4 2
1 48C-003-AH1 (ORG 16ga ) 0-767-GG3 (BLK 16ga )
48A-008-HH3 (YEL 16ga ) B B LDLT2
2 58D-06-02940
VA2828 J544B
48C-008-HH3 (ORG 16ga ) A A P11 J11
F 11F VEC-89 VEC-89
SH7:J-2 41TS-005-AA1 (DGR 18ga )
0 BUSS 85 86
F8
11 BUSS 87 TB35
FRONT TURN / CLEARANCE LAMPS / HAZARD SWITCH / DOME LIGHTS 15
87a
30 11G G 41T-000-AA1 (TAN 14ga ) E1 E2
E4
MARKER LAMP
RELAY 8 58E-06-02043 58E-06-40220 LAMP MARKER/TURN LEFT SIDE DECK
D1
VEC-89 VEC-89
0 BUSS
D2 45LL-009-GG1 (BRN 16ga ) A C
45LL-001-AA1 (BRN 16ga ) 1 1 45LL-004-AG2 (BRN 16ga ) 1 1 45LL-017-GG1 (BRN 16ga ) SP144 AMB
F11
11 BUSS PWR SP143 LCL1
TB10 2 2 2 2 B
GND 41T-001-AA1 (TAN 16ga ) 41T-005-AG2 (TAN 16ga ) 41T-009-GG1 (TAN 16ga ) 41T-006-GG1 (TAN 16ga )
15
45L-009-CC3 (DGR 16ga ) B1
LOAD AMB
SH4:I-8 0-134-AA1 (BLK 16ga ) 3 3 0-783-AG2 (BLK 16ga ) 3 3 0-138-GG1 (BLK 16ga ) 58E-06-00830
TB22 LCL1
SP142
45L-000-CC3 (DGR 16ga ) 45L-001-CC3 (DGR 18ga ) 17 17 45L-003-AC3 (DGR 16ga ) 17 17 45L-007-AA31 (DGR 16ga ) P4 P1 45L-004-AA1 (DGR 18ga ) SH13:I-19 0-363-GG1 (BLK 16ga ) 0-139-GG1 (BLK 16ga )
SWITCH COMBO FLASHER
SP035 J80 P80 P503 J503
TURN SW RELAY 13 LAMP MARKER/TURN LEFT FRT DECK
L 9 SH7:E-13 45L-006-AA29 (DGR 16ga ) P3 P2 AHT CONNECTION 12D
56 56 712T-001-AC3 (BRN 16ga ) 56 56 712T-002-CC3 (BRN 16ga ) 10 SP036 D
R 11 45R-000-CC3 (LBL 16ga ) 45R-001-CC3 (LBL 18ga ) 19 19 45R-003-AC3 (LBL 16ga ) 19 19 45R-007-AA31 (LBL 16ga ) R4 R1 45R-004-AA1 (LBL 18ga ) 45LL-010-GG1 (BRN 16ga ) A C
0 BUSS 85 86
J83 P83 P03 J03 P121 AMB
P121 J03 P03 P83 J83 SH7:E-13 45R-006-AA29 (LBL 16ga ) R3 R2 AHT CONNECTION LCL2
87 TB35 B
12C 41T-007-GG1 (TAN 16ga )
TB10 30 C 12 12 B
45LL-000-AA1 (BRN 14ga ) J1 J2 41T-013-AA1 (TAN 16ga ) 41T-014-AJ2 (TAN 16ga ) AMB
87a
45R-009-CC3 (LBL 16ga ) C1 58E-06-40220 OPTIONAL 58E-06-00830
TB23 VEC-91 D13 F52 LCL2
K1 45LL-007-AA1 (BRN 16ga ) 24 24 45LL-011-AJ2 (BRN 16ga ) A LEFT SIDE
H 11H
712 BUSS LEFT TURN R31
712T-003-AA31 (BRN 16ga ) R4 R1 712T-000-AA1 (BRN 16ga ) RELAY 11 MARKER/ 0-140-GG1 (BLK 16ga )
5 2 1 1 1 C
45R-002-CC3 (LBL 18ga ) 12B 0-887-AA32 (BLK 16ga ) 45LL-002-AA32 (BRN 16ga ) K3 K2 SH4:I-4 0-147-AA1 (BLK 16ga ) 0-149-AJ2 (BLK 16ga ) TURN
58E-06-20062 D4 B
VEC-91 F35 1 2 58B-06-00140 P732_CP
45L-002-CC3 (DGR 18ga ) 45LR-002-CC3 (LTG 18ga )
A 3A 11 BUSS 0 BUSS 85 86 LAMP MARKER/TURN RIGHT FRT DECK
11L-000-AA1 (YEL 14ga ) VEC89-P12 J14 P14
15 PC2834 SP145
58E-06-20062 SWITCH HAZARD LIGHTS 87 TB35 A C
12A 45RL-004-FF1 (DBL 16ga ) 45RL-007-FF1 (DBL 16ga )
30 A 1 1 A A
45RL-000-AA1 (DBL 14ga ) X1 X2 45RL-001-AA1 (DBL 16ga ) 45RL-002-AH1 (DBL 16ga ) AMB
87a
SH8:G-1 0-318-CC3 (BLK 18ga ) 7 9 58E-06-40220 SP146
R32 RCL1
SH7:I-11 11L-010-CC3 (YEL 18ga ) VEC89-P12 Y3 Y1 41T-002-AA1 (TAN 16ga ) 2 2 41T-008-AH1 (TAN 16ga ) B B 41T-010-FF1 (TAN 16ga ) 41T-011-FF1 (TAN 16ga ) B
3 RIGHT TURN A3
2 1
SH13:D-1 11L-003-CC3 (YEL 14ga ) 0-886-AA32 (BLK 16ga ) 45RL-003-AA32 (DBL 16ga ) AMB
RELAY 12 58E-06-02043
SH8:F-1 11L-008-CC3 (YEL 18ga ) 11L-009-CC3 (YEL 16ga ) 2B SH4:G-8 0-135-AA1 (BLK 16ga ) 3 3 0-141-AH1 (BLK 16ga ) C C 0-143-FF1 (BLK 16ga ) 58E-06-00830
TB22 GB31-B AUXBOX GND BLCK 58B-06-00140 RCL1
SP248 1 SP147
C1 C4 11L-015-AA31 (YEL 14ga ) 9 9 11L-001-AC3 (YEL 14ga ) 9 9 11L-002-CC3 (YEL 14ga ) SH13:G-19 0-364-FF1 (BLK 16ga ) 0-144-FF1 (BLK 16ga )
6
J11 P11 P502 J502 LAMP MARKER/TURN RIGHT SIDE DECK
C3 11L-006-CC3 (YEL 18ga ) 5B
J83 P83 P03 J03 TB10 4
L1 11L-016-CC3 (YEL 16ga ) 45RL-009-FF1 (DBL 16ga ) A C
SH11:L-10 0-136-CC3 (BLK 18ga ) 8 10 AMB
RCL2
P33 P33 41T-012-FF1 (TAN 16ga ) B
58F-06-60901 14 14 C
LAMP CAB DOME PASSENGER SH4:I-4 0-146-AA1 (BLK 16ga ) 0-156-AH2 (BLK 16ga ) AMB
D30 OPTIONAL 58E-06-00830
DOOR (-) SP149 RCL2
SP281 0DL1-000-CC4 (BRN 16ga ) 2 1 0DL-000-CC4 (GRY 16ga ) 41T-015-AA1 (TAN 16ga ) 15 15 41T-016-AH2 (TAN 16ga ) 41T-017-AH2 (TAN 16ga ) B RIGHT SIDE
+ OFF
11L-004-AA32 (YEL 16ga ) 2 2 11L-007-AC4 (YEL 16ga ) 2 2 11L-005-CC4 (YEL 18ga ) 11L-011-CC4 (YEL 16ga ) CDL1(D) SP148 MARKER/ 0-145-FF1 (BLK 16ga )
PC2834
CDL1(+) 0-176-CC4 (BLK 16ga ) 45RL-008-AA1 (DBL 16ga ) 19 19 45RL-010-AH2 (DBL 16ga ) 45RL-011-AH2 (DBL 16ga ) A TURN
ON (-) GB12-A
J84 P84 P04 J04 CDL1(-) C2 P731_CP
45LL-008-AA1 (BRN 16ga ) 18 18
41T-018-AH2 (TAN 16ga ) SH10:F-7 TO REAR AXLE
J16 P16 TURN /
45RL-012-AH2 (DBL 16ga ) SH10:F-14
CLEARANCE
LIGHTING
LAMP CAB DOME CENTER FRONT 45LL-012-AH2 (BRN 16ga ) SH10:I-13
D31
DOOR (-)
0DL2-000-CC4 (BRN 16ga ) 2 1 0DL-001-CC4 (GRY 16ga )
+ OFF
11L-012-CC4 (YEL 16ga ) CDL2(D) PC2834
CDL2(+) ON (-) 0-316-CC4 (BLK 16ga ) SWITCH DOOR PIN (DPSW2)
CDL2(-) 1 2
0DL-005-CC4 (GRY 14ga ) 3 3 0DL-006-CC10 (GRY 14ga ) 0-897-CC10 (BLK 14ga ) 4 4 0-899-CC4 (BLK 14ga )
P51 J51 J51 P51
LAMP CAB DOME CENTER REAR
D32 SWITCH DOOR PIN (DPSW1) GB12-A
DOOR (-) 1 2 C3
0DL3-000-CC4 (BRN 16ga ) 2 1 0DL-002-CC4 (GRY 16ga ) 0DL-004-CC4 (GRY 14ga ) 3 3 0DL-007-CC9 (GRY 14ga ) 0-359-CC9 (BLK 14ga ) 4 4 0-898-CC4 (BLK 14ga )
+ OFF SP294
11L-013-CC4 (YEL 16ga ) CDL3(D) PC2834
CDL3(+) ON (-) 0-360-CC4 (BLK 16ga )
CDL3(-) P50 J50 J50 P50
D33
0DL4-000-CC4 (BRN 16ga ) 2 1 0DL-003-CC4 (GRY 16ga )
LAMP CAB DOME DRIVER
PC2834
DOOR (-)
+ OFF
11L-014-CC4 (YEL 16ga ) CDL4(D)
CDL4(+) ON (-) 0-528-CC4 (BLK 16ga )
CDL4(-)
58B-06-05901-00 SEP 21
ELECTRICAL SCHEMATIC
980E-5
A50052, A50053, A50137, A50138
Sheet 8 of 21
GE INTERFACE AND WHEEL MOTOR SPEED SENSORS
AHT RH WHEEL
15RFWS-003-AA1 (RED 18ga ) 1 SPD RESISTOR
TB33 2 (OPT) R56
GE CONTROL INTERFACE SP251
M4 M1 15RFWS-002-AA1 (RED 18ga ) SENSOR RIGHT FRONT WHEEL SPEED
P56_CP
MC242 MC242 P501 XC2387
RIGHT FRONT WHEEL (+15V) 23 AHT CONNECTION
15RFWS-004-AA3 (RED 18ga ) L3 L1 33RF-003-AA1 (WHT 18ga ) MC239 MC239 MC232 MC232
15RFWS-001-AA1 (RED 18ga ) 1 1 15RFWS-000-AR1 (RED 16ga ) A +V SUPPLY
RIGHT FRONT WHEEL (SIGNAL) 37 33RF-002-AA3 (WHT 18ga ) L4 L2
2 2 7
33RF-001-AA1 (WHT 18ga ) 33RF-000-AR1 (WHT 16ga ) B SIGNAL
RIGHT FRONT WHEEL (COMMON) 11 0RF-002-AA3 (BLK 18ga ) K4 K1
0RF-001-AA1 (BLK 18ga ) 3 3 0RF-000-AR1 (BLK 16ga ) C GROUND
ENGINE SERVICE LAMPS
SS4T04 39 0RF-003-AA3 (BLK 18ga ) K3
4 4
SHIELD-240 SHIELD-230 SHIELD-230 D SHIELD
RIGHT FRONT WHEEL (SHIELD) 24 J4 J1
SHIELD-245 SHIELD-245 SHIELD-240
AHT LH WHEEL
J3 AHT CONNECTION SPD RESISTOR
TB33 (OPT) R57
SP250
S4 S1 15LFWS-003-AA1 (RED 18ga ) 15LFWS-002-AA1 (RED 18ga ) 1
2
MC244 MC244
LEFT FRONT WHEEL (+15V) 30 15LFWS-004-AA3 (RED 18ga ) AHT CONNECTION R3 R1 33LF-003-AA1 (WHT 18ga )
P57_CP
SENSOR LEFT FRONT WHEEL SPEED
LEFT FRONT WHEEL (SIGNAL) 45 33LF-002-AA3 (WHT 18ga ) R4 R2 33LF-001-AA1 (WHT 18ga ) P507 XC2387
MC238 MC238 MC234 MC234
LEFT FRONT WHEEL (COMMON) 17 0LF-002-AA3 (BLK 18ga ) P4 P1 0LF-001-AA1 (BLK 18ga ) 5 5 15LFWS-000-AR1 (RED 16ga ) A +V SUPPLY
15LFWS-001-AA1 (RED 18ga )
SS3T04 43 AHT CONNECTION 6 6 VEC-91 F34 TB24
0LF-003-AA3 (BLK 18ga ) P2 P3 33LF-000-AR1 (WHT 16ga ) B SIGNAL 11 BUSS 4D D
11SL-000-AA1 (DBL 14ga ) A1
LEFT FRONT WHEEL (SHIELD) 29 7 7 15
SHIELD-246 SHIELD-246 N4 N1
SHIELD-239 0LF-000-AR1 (BLK 16ga ) C GROUND
58E-06-20062
A2
8 8
SHIELD-239 SHIELD-233 SHIELD-233 D SHIELD
11SL-001-AA1 (DBL 14ga )
J13 P13
ENGINE SERVICE LAMP (2HR) TIMER (ESLT)
3 25 25 25 25 7 7
T 42SL-000-AA1 (ORG 16ga ) 42SL-003-AG2 (ORG 16ga ) 42SL-004-GG1 (ORG 16ga )
SENSOR LEFT REAR WHEEL SPEED
TB29
MC228 MC228 MC217 MC217 MC205 MC205 NO
LEFT REAR WHEEL (+15V) 33 15LRW-002-AA3 (RED 18ga ) TW1 A2 A1 15LRW-001-AA1 (RED 18ga ) TW1 1 1 15LRW-000-AD1 (RED 18ga ) TW1 A A
C J80 P80 P503 J503 P540_CP J540
42SL-002-GJ1 (ORG 16ga )
LEFT REAR WHEEL (COMMON) 47 2 2 B B NC
77G-003-AA3 (BLK 18ga ) TW1 B2 B1 77G-001-AA1 (BLK 18ga ) TW1 77G-000-AD1 (BLK 18ga ) TW1
SWITCH RIGHT ENGINE SERVICE LAMP (RESLS)
LEFT REAR WHEEL (V1) 19 3 3 C C PC2644 SWITCH LEFT ENGINE SERVICE LAMP (LESLS)
77C-003-AA3 (WHT 18ga ) TW2 C2 C1 77C-001-AA1 (WHT 18ga ) TW2 77C-000-AD1 (WHT 18ga ) TW2 2 2
42A-000-GJ1 (LTG 16ga ) 5 5 42A-001-GG1 (LTG 16ga ) 23 23 42A-006-AG2 (LTG 16ga ) 23 23 42A-002-AA1 (LTG 16ga ) 19 19 42A-003-AH1 (LTG 16ga ) N N 42A-005-FF1 (LTG 16ga ) 1 1 42A-004-FH1 (LTG 16ga )
LEFT REAR WHEEL (NOT V1) 18 4 4 F F 1 1
77DP-003-AA3 (BLK 18ga ) TW2 D2 D1 77DP-001-AA1 (BLK 18ga ) TW2 77DP-000-AD1 (BLK 18ga ) TW2 3 3
42B-000-GJ1 (BRN 16ga ) 6 6 42B-001-GG1 (BRN 16ga ) 24 24 42B-006-AG2 (BRN 16ga ) 24 24 42B-002-AA1 (BRN 16ga ) 20 20 42B-003-AH1 (BRN 16ga ) O O 42B-005-FF1 (BRN 16ga ) 2 2 42B-004-FH1 (BRN 16ga )
LEFT REAR WHEEL (NOT V2) 31 77B-003-AA3 (GRN 18ga ) TW3 E2 E1 77B-001-AA1 (GRN 18ga ) TW3 5 5 77B-000-AD1 (GRN 18ga ) TW3 G G
VA2828 VA2828
LEFT REAR WHEEL (V2) 46 77DN-003-AA3 (BLK 18ga ) TW3 F2 F1 77DN-001-AA1 (BLK 18ga ) TW3 6 6 77DN-000-AD1 (BLK 18ga ) TW3 D D
J540 P540_CP J503 P503 P80 J80 J11 P11 P502 J502 P541_CP J541
SP140 SHIELD-211 SP139 SP138 SHIELD-211
G2 G1 7 7 E E
SHIELD-227 SHIELD-217 TB35
LEFT REAR WHEEL (SHIELD) 32 SHIELD-981-AA1 (BLK 18ga ) SHIELD-995-AD1 (BLK 18ga ) SHIELD-994-AD1 (BLK 18ga )
SHIELD-227 P721
42-000-AA2 (BRN 12ga ) M3 M1 42-001-AA1 (BRN 14ga )
XA4256
M2 M4 42-002-AA1 (BRN 14ga )
42-013-AA1 (BRN 12ga )
SP304
SENSOR RIGHT REAR WHEEL SPEED LAMP LEFT UPPER ENGINE SERVICE
TB29 LUESL
MC221 MC221 MC213 MC213 MC209 MC209
RIGHT REAR WHEEL (+15V) 20 H2 H1 15RRW-001-AA1 (RED 18ga ) TW1 13 13 15RRW-000-AD1 (RED 18ga ) TW1 A A 1 42-012-GJ1 (BRN 14ga ) 1 1 42-009-GG1 (BRN 14ga ) 19 19 42-016-AG2 (BRN 14ga ) 19 19 42-008-AA1 (BRN 14ga )
15RRW-002-AA3 (RED 18ga ) TW1 LAMP RIGHT UPPER ENGINE SERVICE
RIGHT REAR WHEEL (COMMON) 35 J2 J1 714G-001-AA1 (BLK 18ga ) TW1 14 14 714G-000-AD1 (BLK 18ga ) TW1 B B 2 0-277-GJ1 (BLK 14ga )
714G-003-AA3 (BLK 18ga ) TW1
15 15 42-003-AH1 (BRN 14ga ) T T 42-014-FF1 (BRN 14ga ) 3 3 42-006-FH1 (BRN 14ga ) 1
RIGHT REAR WHEEL (V1) 9 K2 K1 714A-001-AA1 (WHT 18ga ) TW2 15 15 714A-000-AD1 (WHT 18ga ) TW2 C C 58D-06-02940 2 2 0-276-GG1 (BLK 14ga ) 20 20 0-786-AG2 (BLK 14ga ) 20 20 0-426-AA1 (BLK 14ga ) SH4:I-8
714A-003-AA3 (WHT 18ga ) TW2 LAMP LEFT LOWER ENGINE SERVICE 2
RIGHT REAR WHEEL (NOT V1) 10 16 16 F F LLESL
714DP-003-AA3 (BLK 18ga ) TW2 L2 L1 714DP-001-AA1 (BLK 18ga ) TW2 714DP-000-AD1 (BLK 18ga ) TW2 42-007-AA1 (BRN 14ga ) RUESL
1 42-011-GJ1 (BRN 14ga ) 3 3 42-010-GG1 (BRN 14ga ) 21 21 42-017-AG2 (BRN 14ga ) 21 21 SH4:G-8 0-421-AA1 (BLK 14ga ) 16 16 0-282-AH1 (BLK 14ga ) U U 0-804-FF1 (BLK 14ga ) 4 4 0-283-FH1 (BLK 14ga ) 58D-06-02940
RIGHT REAR WHEEL (NOT V2) 22 17 17 G G
LAMP RIGHT LOWER ENGINE SERVICE
714B-003-AA3 (GRN 18ga ) TW3 M2 M1 714B-001-AA1 (GRN 18ga ) TW3 714B-000-AD1 (GRN 18ga ) TW3
2 0-280-GJ1 (BLK 14ga )
RIGHT REAR WHEEL (V2) 36 N2 N1 714DN-001-AA1 (BLK 18ga ) TW3 18 18 714DN-000-AD1 (BLK 18ga ) TW3 D D 17 17 42-004-AH1 (BRN 14ga ) V V 42-015-FF1 (BRN 14ga ) 5 5 42-005-FH1 (BRN 14ga ) 1
714DN-003-AA3 (BLK 18ga ) TW3
SHIELD-214 SP136 58D-06-02940 4 4 0-279-GG1 (BLK 14ga ) 22 22 0-787-AG2 (BLK 14ga ) 22 22 0-424-AA1 (BLK 14ga ) SH4:H-4
SP158 SP137 SHIELD-214
P2 P1 19 19 E E 0-287-FH1 (BLK 14ga ) 2
SHIELD-223 SHIELD-213
RIGHT REAR WHEEL (SHIELD) 21 SHIELD-982-AA1 (BLK 18ga ) SHIELD-984-AD1 (BLK 18ga ) SHIELD-983-AD1 (BLK 18ga )
SHIELD-223 P720 J540 P540_CP RLESL
58D-06-02940
XA4256 J503 P503 P80 J80
SH4:H-8 0-420-AA1 (BLK 14ga ) 18 18 0-285-AH1 (BLK 14ga ) W W 0-805-FF1 (BLK 14ga ) 6 6 0-286-FH1 (BLK 14ga ) 0-288-FH1 (BLK 16ga )
P301 J15 P15
SP165
EXTERNAL RETARD LIGHTS 31 74ZA-000-AA3 (DGR 20ga ) SH10:G-2 J11 P11 P502 J502 P541_CP J541
SENSOR GE ALTERNATOR SPEED
P304 TB33
MC250 MC250 MC252 MC252 MC201 MC201
ENGINE/ALT SPEED SENSOR (SIGNAL) 15 74X-002-AA3 (WHT 18ga ) T4 T1 74X-001-AA1 (WHT 18ga ) 40 40 74X-003-AE1 (WHT 16ga ) A REF
ENGINE/ALT SPEED SENSOR (RETURN) 27 74Z-002-AA3 (BLK 18ga ) W4 W1 74Z-001-AA1 (BLK 18ga ) 41 41 74Z-003-AE1 (BLK 16ga ) B COM
ENGINE/ALT SPEED SENSOR (SHIELD) 42 V4 V1 42 42 G SHIELD
SHIELD-257 SHIELD-257 SHIELD-260 SHIELD-260 SHIELD-261 SHIELD-261
P700 VEC-91
P301 TB26 TB23 F51
SHIELD-251 J17 P17 TB23 10F 712 BUSS
A1 A2 AHT CONNECTION 712H-004-AA1 (LBL 16ga ) W2 W1 712H-003-AA1 (LBL 16ga ) F
10
MC246 MC246 SH11:B-5 71P-005-AA1 (BRN 16ga ) J1
BUFFERED RIGHT REAR WHEEL (SIGNAL) 16 714Z-000-AA3 (WHT 18ga ) B1 B2 AHT CONNECTION W4 AHT CONNECTION
TB10 58E-06-20062
J2 AHT CONNECTION
BUFFERED RIGHT REAR WHEEL (RETURN) 15 714Y-000-AA3 (BLK 18ga ) C1 C2 AHT CONNECTION 71P-018-AA31 (BRN 16ga ) 71P-007-CC2 (BRN 16ga ) K1
MC248 MC248
J4 H2 71P-021-AA30 (BRN 16ga ) SH11:F-6
BUFFERED LEFT REAR WHEEL (RETURN) 4 77Y-000-AA3 (BLK 18ga ) D1 D2 AHT CONNECTION 58E-06-40220
H1 H4 71P-008-AA30 (BRN 14ga ) 10 10 10 10
VEC-89 F45 VEC-89 71P-001-AC2 (BRN 14ga ) 71P-006-CC2 (BRN 14ga ) 71P-003-CC2 (BRN 20ga ) SH6:H-17
BUFFERED LEFT REAR WHEEL (SIGNAL) 5 77Z-000-AA3 (WHT 18ga ) E1 E2 AHT CONNECTION SP366 HYDRAULIC TAP
71CK BUSS 2E
E 71P-000-AA1 (BRN 14ga ) MANIFOLD SOLENOID
SHIELD-251 15 J82 P82 SWITCH AUX HYD PRESS
F1 F2 AHT CONNECTION SP810
SHIELD-252 SHIELD-252 58E-06-02043 P02 J02 NO
BUFFERED LEFT REAR WHEEL (SHIELD) 17 SHIELD-999-AA3 (BLK 18ga ) VEC89-P2 C 39SU-032-HJ1 (TAN 16ga ) C C 39SU-000-AH2 (TAN 16ga ) 39SU-001-AH2 (TAN 16ga ) 1 2 0-813-AH2 (BLK 16ga ) SH12:E-14
TB26 B B B C
SP001 712H-009-AH2 (LBL 16ga ) 712H-010-HJ1 (LBL 16ga )
SHIELD-253 NC A
M1
SWITCH DATA STORE (DSSW) AHPS JAHPS JAHPS AHPS HTM HTM
MC249 MC249 AHPS-
BUFFERED LEFT FRONT WHEEL (RETURN) 8 SWITCH HOIST LIMIT 58E-06-30610 D1
0BLF-000-AA3 (BLK 20ga ) G1 AHPS-
3 1
9 7 0-818-CC2 (BLK 18ga ) SH6:L-14 30 30 712H-001-AH2 (LBL 16ga ) 712H-002-AH2 (LBL 16ga ) 3 1 39SU-002-AH2 (TAN 16ga ) 1 2 0-814-AH2 (BLK 16ga ) SH12:E-14
4 2
BUFFERED LEFT FRONT WHEEL (SIGNAL) 20 33BLF-000-AA3 (WHT 20ga ) H1 7 7 71P-017-AC3 (BRN 16ga ) 7 7 SP809 4 2
3 22 22 PC2834
MC251 MC251 53H-001-AA1 (PNK 16ga ) PC2818
BUFFERED RIGHT FRONT WHEEL (SIGNAL) 10 2B D6
33BRF-000-AA3 (WHT 20ga ) J1
J83 P83 P03 J03 71P-002-CC2 (BRN 16ga ) HLS HLS
1 53H-008-BB1 (PNK 16ga ) 1 2 0-755-BB1 (BLK 16ga ) SH3:H-14
BUFFERED RIGHT FRONT WHEEL (RETURN) 11 0BRF-000-AA3 (BLK 20ga ) K1 53H-002-AH2 (PNK 16ga )
SHIELD-253 J16 P16 PC2834
6
SHIELD-254 5B
L1
BUFFERED RIGHT FRONT WHEEL (SHIELD) 9 SP002 SHIELD-254 4
SHIELD-992-AA3 (BLK 18ga ) TB21 TB35
P302 SP794
ABS CONNECTION R3 R2 AHT CONNECTION 10 8 N1 N4 53H-004-AA33 (PNK 16ga ) R R 53H-003-AB1 (PNK 16ga ) R R 53H-009-BB1 (PNK 16ga ) 53H-010-BB1 (PNK 16ga ) 2
SH3:H-14 0-761-BB1 (BLK 16ga ) 1
WEAK RESET/DUMP BODY OVERRIDE 21 71H-000-AA3 (LBL 20ga ) R1 R4 71H-003-AA30 (LBL 20ga ) 11 11 71H-001-AC2 (LBL 20ga ) 11 11 71H-002-CC2 (LBL 20ga ) SH6:H-17 DSSW DSSW N2
58F-06-60991 J85 P85 P240 J240 HS_CP
DATA STORE 13 73DS-000-AA3 (TAN 20ga ) S1 S4 73DS-006-AA30 (TAN 16ga ) 12 12 73DS-001-AC2 (TAN 16ga ) 12 12 73DS-002-CC2 (TAN 16ga ) SOLENOID HOIST LIMIT
SWITCH SPEED CONTROL ROCKER
S3 73DS-004-AA31 (TAN 16ga ) SH11:G-17 53H-006-AA1 (PNK 16ga ) 3 3 53H-011-AJ2 (PNK 16ga ) 53H-012-AJ2 (PNK 16ga ) 1 2 0-756-AJ2 (BLK 16ga ) SH12:D-1
J82 P82 P02 J02
9 7 0-052-CC3 (BLK 16ga ) SH11:L-10 SP900
TB31 HS HS
D88
HOIST CONTROL
CRUISE CONTROL 19 31RR-002-AA3 (LTG 20ga ) E1 E2 31RR-003-AA31 (LTG 16ga ) 40 40 31RR-001-AC3 (LTG 16ga ) 40 40 31RR-000-CC3 (LTG 16ga ) 3
J14 P14
2B 71P-004-CC3 (BRN 16ga ) SH11:J-10 53H-013-AJ2 (PNK 16ga ) 1 2 0-754-AJ2 (BLK 16ga ) SH12:D-1
1
P304 J83 P83 P03 J03 PC2834
RET PEDAL REF (RETURN) 21 0RET-001-AA3 (BLK 20ga ) 6
RET PEDAL REF (SUPPLY) 20 10V-005-AA3 (RED 20ga ) 5B
TB31 4
ACC PEDAL REF (SUPPLY) 19 10V-002-AA3 (RED 20ga ) N1 N4
10 8 0-151-CC3 (BLK 16ga ) SH11:J-10
ACC PEDAL REF (RETURN) 18 N3 N2
0ACL-000-AA3 (BLK 20ga ) 10V-003-AA29 (RED 18ga ) SWITCH SPEED CONTROL MODULE
P29 P29
CRUISE CONTROL REF (SUPPLY) 31 L1 L4
58F-06-60961
32RS-000-AA3 (DBL 20ga )
71P-016-CC3 (BRN 16ga ) SET
CRUISE CONTROL REF (RETURN) 30 32OR-000-AA3 (LTG 20ga ) L2 L3 AHT CONNECTION
P305 H2 H4 MC253 MC253 MC300 MC300 MC256 MC256 CANCEL
32RS-002-AA29 (RED 18ga ) 15 15 32RS-004-AC1 (RED 18ga ) 15 15 32RS-003-CC1 (RED 18ga ) A EP
MC272 MC272
CRUISE CONTROL (SWEEP) 34 32RS-001-AA3 (BLK 20ga ) H1 32OR-003-AA29 (BLK 18ga ) 16 16 32OR-005-AC1 (BLK 18ga ) 16 16 32OR-004-CC1 (BLK 18ga )
58B-06-00280 TB31 220.0
DOWN
CRUISE CONTROL (COMMON) 16 32OR-001-AA3 (WHT 20ga ) F4 F3 32OR-002-AA1 (LTG 18ga ) 1 2 32RR-000-AA1 (LTG 18ga ) D1 D2 32RR-001-AA29 (WHT 18ga ) 17 17 32RR-003-AC1 (WHT 18ga ) 17 17 32RR-002-CC1 (WHT 18ga )
2 KΩ 1W
CRUISE CONTROL (SHIELD) 33
R21 130.0
F2 F1 R21 R21 UP
SHIELD-298
X1 X2
SHIELD-298 SHIELD-255 68.0
MC269 MC269 CCS
ACCELERATOR PEDAL (COMMON) 17 0ACL-003-AA3 (BLK 18ga ) 0ACL-004-AA3 (BLK 18ga ) W1 18 18 18 18 C
SHIELD-255 SHIELD-265 SHIELD-265 SHIELD-256
SP246 58E-06-40220
V1 V4 B CMS
ACCELERATOR PEDAL (SWEEP) 35 P022
525A-000-AA3 (WHT 18ga ) SP245 58E-06-60200
ACCELERATOR PEDAL (SHIELD) 18 SHIELD-295 10 10 10 10
SHIELD-295 MC266 SHIELD-286 SHIELD-266 SHIELD-266 SHIELD-282 ACCELERATOR PEDAL
MC266 MC301 MC301 MC265 MC265
10V-001-AA29 (RED 18ga ) 7 7 10V-006-AC1 (RED 18ga ) 7 7 10V-000-CC1 (RED 18ga ) A C +VDC SUPPLY
0ACL-001-AA29 (BLK 18ga ) 9 9 0ACL-005-AC1 (BLK 18ga ) 9 9 0ACL-002-CC1 (BLK 18ga ) C B GROUND
TB31
525-002-AA3 (WHT 18ga ) T1 T4 525-001-AA29 (WHT 18ga ) 8 8 525-003-AC1 (WHT 18ga ) 8 8 525-000-CC1 (WHT 18ga ) B A PEDAL SIGNAL
SHIELD-853-AA3 (BLK 18ga )
S1 S4 P236 58F-06-20390
SHIELD-286
SHIELD-296
RETARD PEDAL (SHIELD) 9 AHT CONNECTION S3
J701_JP
4
P701
4
14 14 14 14
SHIELD-287 SHIELD-267 SHIELD-267 SHIELD-281 RETARD/SERVICE BRAKE COMBO PEDAL
MC270 MC267 MC267 MC302 MC302
MC270 MC264 MC264
RETARD PEDAL (COMMON) 22 0RET-004-AA3 (BLK 18ga ) AHT 11 11 10V-007-AC1 (RED 18ga ) 11 11 10V-004-CC1 (RED 18ga ) C C +VDC SUPPLY
AUXBOX
CONNECTOR 0RET-006-AA29 (BLK 18ga ) 13 13 0RET-007-AC1 (BLK 18ga ) 13 13 0RET-008-CC1 (BLK 18ga ) A B GROUND
TB31
(OPT)
RETARD PEDAL (SWEEP) 21 R1 R4 12 12 12 12 B A PEDAL SIGNAL
74N-002-AA3 (WHT 18ga ) 74N-001-AA29 (WHT 18ga ) 74N-003-AC1 (WHT 18ga ) 74N-000-CC1 (WHT 18ga )
P235
P1 P4
58E-61-50020
SHIELD-296 SHIELD-287 J81 P81
TB31 P01 J01
SHIELD-122-AA3 (BLK 18ga ) A1
SHIELD-297
SP901
RETARD LEVER (SHIELD) 8 AHT CONNECTION A3
SHIELD-297 GB31-B AUXBOX GND BLCK
MC271
MC271 D2
RETARD LEVER (COMMON) 20 0LEV-002-AA3 (BLK 18ga ) 0LEV-003-AA3 (BLK 18ga ) B1 B2 0-707-AA3 (BLK 18ga )
SP902
RETARD LEVER (SWEEP) 19 52RA-000-AA3 (WHT 18ga )
AHT
AUXBOX CONNECTOR
AHT CONNECTION
52R-002-AA3 (WHT 18ga )
B3
C1
58B-06-05901-00 SEP 21
P303
MC2798 MC2798
TB22 (OPT)
J701_JP RETARD LEVER ELECTRICAL SCHEMATIC
5
DRIVE SYSTEM HEARTBEAT TO AHT DRIVE CONTROLLER 29 90DS-003-AA3 (WHT 18ga ) X1 X2 AHT CONNECTION CONNECTION
P701
5
POINTS
DRIVE SYSTEM HEARTBEAT RETURN 30 0DS-003-AA3 (BLK 18ga ) Y1 Y2 AHT CONNECTION
AHT
J6-AA7 (BLK 18ga ) 980E-5
A50052, A50053, A50137, A50138
Z1 Z2 AHT CONNECTION AUXBOX
SHIELD-822
P304 CONNECTOR
(OPT)
Sheet 9 of 21
BACKUP LAMPS SWITCH MANUAL BACKUP LIGHT
BACKUP HORN RIGHT
79A-002-DD2 (DBL 16ga ) - 0-248-DD2 (BLK 16ga )
+
9 7
TB23
0-268-CC3 (BLK 18ga ) SH8:C-8
TB10 RRBH-(+) 736131C2 RRBH-(-)
U1 U4 47S-003-AA31 (LBL 16ga ) 51 51 47S-001-AC3 (LBL 16ga ) 51 51 47S-000-CC3 (LBL 16ga ) 3 712K-006-CC3 (LBL 16ga ) F1
BACKUP HORN LEFT
2B 712K-004-CC3 (LBL 16ga ) SH3:E-11
1 7
J83 P83 P03 J03 SP343 SP344
29 29 79A-001-AH2 (DBL 14ga ) 4 4 79A-004-DD2 (DBL 16ga ) 79A-003-DD2 (DBL 16ga ) - 0-249-DD2 (BLK 16ga ) 0-694-DD2 (BLK 14ga ) 6 6 0-243-AH2 (BLK 14ga ) 1 1 0-240-AA1 (BLK 14ga ) SH4:I-4
+
6
LRBH-(+) 736131C2 LRBH-(-)
5B
4
B
11B VEC-89
SH6:G-10 72RA-002-AA1 (YEL 18ga )
LAMP BACKUP REAR RIGHT LED
10 8 0-056-CC3 (BLK 18ga ) SH8:F-1
0 BUSS 85 86
SP346
F3 13 13 5 5 1
P22 P22 47-002-AA1 (GRY 14ga ) 47-004-AH2 (GRY 14ga ) 47-016-DD2 (GRY 16ga ) 47-006-DD2 (GRY 16ga )
11 BUSS 87 58F-06-60821
15 30 11C C 2
87a
79A-000-AA1 (DBL 14ga )
LEDBLR
D14 TB33 J16 P16 P73 J73 58D-06-10351
11D RELAY BACKUP LIGHT
BACKUP HORN D 47A-000-AA1 (PNK 16ga ) X1
RELAY 3 (BULR)
86 85
0-251-DD2 (BLK 16ga )
D15
VEC89-P11 0-157-AA2 (BLK 16ga ) SH7:O-9 X3 Y2
E
11E LAMP BACKUP REAR LEFT LED
47S-002-AA1 (LBL 16ga ) 58E-06-40220
VEC-89 58E-06-02043
Y1
VEC-89 F2 VEC-89
47-007-DD2 (GRY 16ga ) 1
11 BUSS 9C 88 88A
VEC89-P11 C 47B-000-AA1 (TAN 10ga ) 47-000-AA2 (GRY 10ga )
25 2
58E-06-02043 88(2) LEDBLL
LAMP RIGHT DECK BACKUP 58D-06-10351
58E-06-04150
1 47-011-FF1 (GRY 14ga ) H H 47-009-AH1 (GRY 14ga ) 8 8 47-008-AA1 (GRY 14ga ) 0-252-DD2 (BLK 16ga )
- LAMP STOP/TAIL LEFT
2 0-258-FF1 (BLK 14ga ) J J 0-256-AH1 (BLK 14ga ) 9 9 0-255-AA1 (BLK 14ga ) SH4:G-8 SP347
44-004-DD2 (GRY 16ga ) A C 0-264-DD2 (BLK 16ga ) 0-698-DD2 (BLK 16ga ) 7 7 0-244-AH2 (BLK 14ga ) 2 2 0-241-AA1 (BLK 14ga ) SH4:J-4
XA6208 RBUL RED
LRSTL
J502 P502 P11 J11 J73 P73 P16 J16
41T-019-DD2 (TAN 16ga ) B
RED
LAMP LEFT DECK BACKUP LRSTL 58D-06-00821
1 8 8 8 8
LAMP STOP/TAIL RIGHT
-
47-015-GG1 (GRY 14ga ) 47-017-AG2 (GRY 14ga ) 47-012-AA1 (GRY 14ga )
SP348
2 0-259-GG1 (BLK 14ga ) 9 9 0-691-AG2 (BLK 14ga ) 9 9 0-263-AA1 (BLK 14ga ) SH4:I-8 44-005-DD2 (GRY 16ga ) A C 0-265-DD2 (BLK 16ga )
RED
XA6208 LBUL SP3814 SP345 RRSTL
SH8:M-19 41T-018-AH2 (TAN 16ga ) 41T-030-AH2 (TAN 16ga ) 3 3 41T-029-DD2 (TAN 16ga ) 41T-020-DD2 (TAN 16ga ) B
J503 P503 P80 J80
RED
RRSTL 58D-06-00821
P73 J73
LAMP BODY RIGHT REAR TURN
11H VEC-89
SH5:F-16 44R-003-AA1 (GRY 18ga ) H SH8:M-19 45RL-012-AH2 (DBL 16ga ) A A 45RL-017-MM1 (DBL 16ga ) A C
41T-022-AH2 (TAN 16ga ) B B 41T-036-MM1 (TAN 16ga )
0 BUSS 85 86
VEC89-P11 0-300-AH2 (BLK 16ga ) C C 0-460-MM1 (BLK 16ga ) RSTL
TB35 B
F9 87 12E E 16 16 1 1
11 BUSS
44-000-AA1 (GRY 14ga ) G1 G2 44-001-AA1 (GRY 14ga ) 44-003-AH2 (GRY 14ga ) 44-007-DD2 (GRY 16ga ) P55_CP J55
30
RSTL 58D-06-00831
10 87a
74ZA-000-AA3 (DGR 20ga ) SH9:G-4 VEC89-P12 G4
J16 P16 P73 J73 0-463-MM1 (BLK 16ga )
SERVICE BRAKE 0-253-DD2 (BLK 16ga ) LAMP BODY RIGHT SIDE MARKER
LAMP RELAY 9
VEC-89 58E-06-02043 LAMP RETARD LEFT REAR A C
A C
1C VEC-89
74ZA-001-AA1 (DGR 18ga ) C
A C
TB21 71CK BUSS 86 85 B RSCL1
VEC89-P1 AMB 41T-031-MM1 (TAN 16ga ) B
TB35
D1 D2 LRL SP716
F13 87 1F
F 17 17 B
44D-000-AA1 (LBL 16ga ) SP349 RSCL1 58D-06-00821
H1 H2 44D-001-AA1 (LBL 16ga )
11 BUSS 30
D4 44D-003-AH2 (LBL 14ga ) 2 2 44D-007-DD2 (LBL 16ga ) 44D-005-DD2 (LBL 16ga ) AMB 0-461-MM1 (BLK 16ga )
10 87a 8 8
VEC89-P1 AHT CONNECTION H3 H4 0-680-AH2 (BLK 14ga ) 44D-006-DD2 (LBL 16ga ) LRL 58D-06-00831 SP717
LAMP BODY RIGHT REAR MARKER
RETARD LAMPS J16 P16 SP350
P73 J73 0-311-DD2 (BLK 14ga ) 0-254-DD2 (BLK 16ga ) LAMP RETARD RIGHT REAR
VEC-89 RELAY 15 58E-06-02043 A
A C
C
SP3823
SH4:I-4 0-679-AA1 (BLK 14ga ) 3 3 0-678-AH2 (BLK 14ga ) 0-301-AH2 (BLK 16ga ) A C
B RSCL2
AMB 41T-032-MM1 (TAN 16ga ) B
J16 P16 RRL
B 58D-06-00821
LAMP SERVICE BRAKE OP-CAB (SBL) RSCL2
AMB
RRL 58D-06-00831 0-462-MM1 (BLK 16ga )
44-008-AA32 (GRY 16ga ) 10 10 44-002-AC4 (GRY 16ga ) 10 10 44-006-CC4 (GRY 16ga ) LAMP BODY LEFT REAR TURN
IM2 GB12-A
0-091-CC4 (BLK 16ga )
74ZA-002-AA1 (DGR 20ga ) 24 RETARD SWITCH INPUT
E1 RED A A A C
0-137-CC4 (BLK 16ga ) SH8:M-19 45LL-012-AH2 (BRN 16ga ) 45LL-018-MM2 (BRN 16ga )
0-671-CC4 (BLK 16ga ) SH10:N-6 58E-06-06041
IM2 41T-021-AH2 (TAN 16ga ) B B 41T-033-MM2 (TAN 16ga ) LSTL
LAMP RETARD OP-CAB (DRL) C C B
0-464-MM2 (BLK 16ga )
44D-008-AA32 (LBL 16ga ) 5 5 44D-002-AC4 (LBL 16ga ) 5 5 44D-004-CC4 (LBL 16ga ) LSTL 58D-06-00831
J54_CP P54
0-465-MM2 (BLK 16ga )
J84 P84 P04 J04 AMB LAMP BODY LEFT SIDE MARKER
58E-06-06051
A C
A C
B LSCL1
41T-034-MM2 (TAN 16ga ) B
SP719
58D-06-00821
LSCL1
0-466-MM2 (BLK 16ga )
SP720
LAMP BODY LEFT REAR MARKER
REAR TURN / TAIL / STOP LAMPS
A C
A C
B LSCL2
41T-035-MM2 (TAN 16ga ) B
LSCL2 58D-06-00821
0-467-MM2 (BLK 16ga )
VEC-91 F50 TB24
712 BUSS 10C C
63-009-AA1 (PNK 14ga ) R1 R4 63-010-AA31 (PNK 14ga ) 58 58 63-000-AC3 (PNK 14ga )
10
TB10
58E-06-20062 J83 P83
H1 63-011-CC3 (PNK 16ga )
SWITCH HORN BUTTON
58 58 TB22
63-002-CC3 (PNK 16ga ) 63-001-CC3 (PNK 14ga )
JB6G 50 50 50 50 5 A
SP030 11H-000-AA1 (DGR 16ga ) B1 B4 11H-003-AA31 (DGR 16ga ) 11H-001-AC3 (DGR 16ga ) 11H-002-CC3 (DGR 16ga )
1
RELAY VEHICLE HORN POWER (HPR)
B
63-003-CC3 (PNK 14ga ) J03 P03 86 85
2 63-004-CC3 (PNK 16ga ) 11A-011-AA1 (TAN 16ga ) B2 AHT CONNECTION P121
J83 P83 P03 J03
3 63-005-CC3 (PNK 16ga ) PC1621
4 63-006-CC3 (PNK 16ga )
5 63-007-CC3 (PNK 16ga ) VEHICLE HORN
6 TIMER WASHER DELAY MOD (WADT) 88 88A 13 13 13 13 1
63-008-CC3 (PNK 16ga ) 11HS-000-AA1 (DBL 14ga ) 11HS-003-AG2 (DBL 14ga ) 11HS-006-GG1 (DBL 14ga )
1
56B-06-11510 TIMER WIPER DELAY MOD 63L1-002-CC3 (BRN 16ga )
88(2)
WADT-1 0-422-AA1 (BLK 14ga ) 14 14 0-292-AG2 (BLK 14ga ) 14 14 0-781-GG1 (BLK 14ga ) 2
86 63-007-CC3 (PNK 16ga ) 2
58F-54-20452
X
WADT-2 58E-06-04150 AHS
3 SH4:I-8
T
63T1-000-CC3 (PUR 16ga ) 87 0-380-CC3 (BLK 16ga ) J80 P80 P503 J503
P
WADT-3
4 TB35
L
85
P10 11A-001-AA1 (TAN 12ga ) A1 A2 11A-002-AA1 (TAN 16ga ) 4 4
PC0566 5
58E-06-40220
WADT-5 B4
SWITCH COMBO VEC-91
63W-002-CC3 (GRY 16ga ) 6
WASHER SW F33 J16 P16
B1 B2
PWR PC1838 11 BUSS 4B
8 7 63W-001-CC3 (GRY 16ga ) B 11A-000-AA1 (TAN 12ga )
63W-000-CC3 (GRY 16ga ) 15
SP460 MOTOR WINDSHIELD WASHER
HI
1 63H1-000-CC3 (LTG 16ga ) PUMP
LO
2 1 1 A A + -
58E-06-20062
63W-004-CC4 (GRY 16ga ) 63W-003-BC1 (GRY 16ga )
INT
12 SH14:G-17 11A-012-CC3 (TAN 18ga ) 33 33 11A-004-AC3 (TAN 18ga ) 33 33 11A-009-AA31 (TAN 18ga )
WW+ WW-
P65 J65 XA4584
OFF P121 C C
J03 P03 P83 J83
HI D15 C C
11A-003-AB1 (TAN 16ga ) 11A-010-AA33 (TAN 16ga )
FRONT VEHICLE HORN
LO
63L2-000-CC3 (LBL 16ga ) 2 1 SH10:I-11 0-671-CC4 (BLK 16ga ) B B 0-377-BC1 (BLK 16ga )
PARK
6 INT
PC2834 JWW PWW P85 J85
P121 OFF
PC1709
RELAY WIPER MOTOR LOW SWITCH HYDRAULIC LAMP
(+) (-)
86 85 MOTOR WINDSHIELD WIPER C C 2 1
5 11A-008-BB1 (TAN 16ga )
5 4 4
63L1-000-CC3 (BRN 16ga ) 63L-000-CC3 (DGR 16ga )
SP461 HLSW-2 SR8325 HLSW-1
63L1-001-CC3 (BRN 16ga ) 6 1 1
(NO) 87 6 MOTOR 11A1-000-BB1 (LBL 16ga )
P240 J240
63L1-003-CC3 (BRN 16ga ) 30 (C)
(NC) 87A LAMP HYDRAULIC CABINET #1
63P-000-CC3 (DBL 16ga ) 2 2 11A1-001-BB1 (LBL 16ga ) A
P09_K PC1730 3 3
P09_K SP171
63P-000-CC3 (DBL 16ga ) SH3:H-14 0-445-BB1 (BLK 16ga ) B
P07 PB9923
P07 HL1 PC3010
RELAY WIPER MOTOR HIGH
(+) (-)
86 85 LAMP HYDRAULIC CABINET #2
0-378-CC3 (BLK 16ga )
SP363 11A1-002-BB1 (LBL 16ga ) A
0-390-CC3 (BLK 16ga ) 0-315-CC3 (BLK 18ga ) SH14:J-14
(NO) 87 B
63H-000-CC3 (TAN 16ga ) SH3:H-14 0-444-BB1 (BLK 16ga )
30 (C)
HYD CABINET LAMP
(NC) 87A HL2 PC3010
P08_K PC1730
P08_K
GB12-B
E2 0-278-CC3 (BLK 18ga )
0-346-CC3 (BLK 14ga )
SH14:G-14
58B-06-05901-00 SEP 21
WINDSHIELD WIPER / WASHER GB12-B
B3 0-703-CC3 (BLK 14ga ) SH5:K-13
0-382-CC3 (BLK 16ga )
0-310-CC3 (BLK 18ga ) SH3:C-18 ELECTRICAL SCHEMATIC
980E-5
A50052, A50053, A50137, A50138
Sheet 10 of 21
GE CONTROL INTERFACE
TB28
MC1699 MC1699
MMS RS232 RECEIVE 3 90MMR-000-AA3 (WHT 20ga ) TB28-S1 S1
MMS RS232 TRANSMIT 5 90MMT-000-AA3 (RED 20ga ) TB28-T1 T1
SWITCH TRACTION MOTOR PRESSURE (BPSW)
MMS RS232 GND 1 TB28-U1 NO C C
90MMG-000-AA3 (BLK 20ga ) U1 75A2-002-DD4 (WHT 18ga )
C
MMS RS232 SHIELD 4 V1
NC A A
SHIELD-1001 SHIELD-1001 75A1-000-DD4 (RED 18ga )
TB28-V1 58F-06-01860
71P-014-DD4 (BLK 18ga ) B B
P303
TB35 J703 P703
MC122 MC122
TRACTION MOTOR PRESSURE SWITCH 2 75A2-000-AA3 (BRN 20ga ) V2 V1 75A2-001-AA1 (BRN 16ga ) 28 28 75A2-003-AH2 (BRN 16ga ) 1 1 75A2-004-DD1 (GRN 18ga )
SH9:H-7 71P-005-AA1 (BRN 16ga ) 26 26 71P-010-AH2 (BRN 14ga )
SP180
71P-011-AH2 (BRN 16ga ) 2 2 71P-013-DD1 (WHT 18ga )
ANTENNA GPS KOMTRAX PLUS MODULE KOMTRAX PLUS MODULE / ORBCOMM MODULE
MC695 MC695 7
COMM_CAN_H_1 32 939YP-010-CC3 (YEL 20ga ) SH14:C-17
SYSTEM BUSY 15 74SB1-015-AA3 (DBL 20ga ) SH2:D-22 P72 J72 T1
71P-012-AH2 (BRN 16ga ) COMM_CAN_L_1 31 939GP-010-CC3 (GRN 20ga ) SH14:C-17
MC696 MC696
COMM_CAN_H_0 42 939YE-010-CC3 (YEL 20ga ) SH14:F-14
TB35 SWITCH BODY-UP PROXIMITY
3 1
DUMP BODY DOWN 3 71F-000-AA3 (LTG 20ga ) S4 S1 71F-005-AA1 (LTG 18ga ) 71F-001-AA1 (LTG 18ga ) 25 25 71F-004-AH2 (LTG 16ga ) 3 1 COMM_CAN_L_0 41 939GE-010-CC3 (GRN 20ga ) SH14:F-14
4 2
SP503 4 2
MC100 MC100
SH13:J-8 71F-002-AA4 (LTG 18ga ) S3 S2 AHT CONNECTION COMM_CAN_H_2 22 939YK-006-CC3 (YEL 20ga ) SH14:H-13
P304 PC2818
J16 P16 BUSW BUSW
COMM_CAN_L_2 21 939GK-006-CC3 (GRN 20ga ) SH14:H-13
71F-003-AA1 (LTG 20ga ) SH12:F-6
TB26 DOS_L_UPDATE 27
VEC-90 F47 VEC-90
MC2421 MC2421 MC2468 MC2468 76-000-CC3 (LBL 18ga ) SH14:G-15
RS232 GROUND WITH PTU CONN 25 5 TB28 TB28-B1 B
1B 71CK BUSS
90CAG-000-AA3 (BLK 20ga ) W1 W2 90CAG-001-AA3 (BLK 20ga ) TB28-B4 71VHM-000-AA1 (DGR 16ga )
10 10 10 10 5
71VHM-002-CC3 (DGR 16ga ) 71VHM-001-AC3 (DGR 16ga ) 71VHM-006-AA31 (DGR 16ga ) B4 B1
GE - DSC AUX BOX 58E-06-20051
W3 3 3RD PARTY DIAG 49 13B-000-CC3 (YEL 18ga ) SH14:I-15
DIAGNOSTIC F30 VEC-91
14 14 85-001-AC3 (GRY 14ga ) 14 14 85-009-AA31 (GRY 14ga ) C4 C1
CONNECTOR 4G 11 BUSS
RS232 RECEIVE FROM PTU 12 90CAR-000-AA3 (WHT 20ga ) 2 G
X1 X2 90CAR-001-AA3 (WHT 20ga ) TB28-C4 TB28-C1
85-000-AA1 (GRY 14ga )
20
SP187 58E-06-20062
X3 PWR_CTR_KEY_1 4 71VHM-003-CC3 (DGR 18ga )
DIAG5 J03 P03 P83 J83
RS232 TRANSMIT TO PTU CONN 27 90CAT-000-AA3 (RED 20ga ) Y1 Y2 90CAT-001-AA3 (RED 20ga ) PWR_CTR_KEY_2 5 71VHM-004-CC3 (DGR 18ga )
RS232 SHIELD TO PTU CONN 26
SHIELD-050 JB8A
Y3
P303 85-002-CC3 (GRY 14ga ) 1
SHIELD-050 PWR_IN_BATT_1 8 2
MC098 MC098 Z1 Z2 85-003-CC3 (GRY 18ga )
E2TP F SHIELD-051 3
94ET1-000-AA6 (W-OR 24ga ) SH11:J-21
E2TN E 94ET2-000-AA6 (ORG 24ga ) SH11:J-21 MC2469 MC2469 MC2470 PWR_IN_BATT_2 9 85-004-CC3 (GRY 18ga ) 4
Z3
MC207 MC207 MC2470
E2RP C 94ER1-000-AA6 (W-GR 24ga ) SH11:J-21 90CAG-004-AA30 (BLK 20ga ) 56 56 90CAG-002-AC2 (BLK 20ga ) 56 56 90CAG-003-CC2 (BLK 20ga ) 5 85-006-CC3 (GRY 18ga ) 5
E2RN B 94ER2-000-AA6 (GRN 24ga ) SH11:J-21 PWR_IN_BATT_3 18 85-005-CC3 (GRY 18ga ) 6
GE - DSC CAB 85-007-CC3 (GRY 18ga )
57 57 57 57 3 7 ANTENNA SATELLITE
ETC2 90CAR-004-AA30 (WHT 20ga ) 90CAR-002-AC2 (WHT 20ga ) 90CAR-003-CC2 (WHT 20ga ) DIAGNOSTIC 71VHM-005-CC3 (DGR 18ga )
PWR_IN_BATT_4 19 85-008-CC3 (GRY 18ga ) 8 (OPT)
CONNECTOR GB12-B
90CAT-004-AA30 (RED 20ga ) 58 58 90CAT-002-AC2 (RED 20ga ) 58 58 90CAT-003-CC2 (RED 20ga ) 2 0-412-CC3 (BLK 16ga ) SH11:N-8
B4 56B-06-11530
SHIELD-276 0-347-CC3 (BLK 14ga )
59 59 59 59 0-888-CC3 (BLK 14ga ) SH5:K-13
SHIELD-276 SHIELD-052 SHIELD-052 SHIELD-053 DIAG6 JB8D SATELLITE MODEM (OPT)
1
J82 P82
GND_PWR_1 6 0-348-CC3 (BLK 18ga ) 2 6 PWR_IN_BATT1
P02 J02
GND_PWR_2 7 0-349-CC3 (BLK 18ga ) 3
GND_PWR_3 16 0-350-CC3 (BLK 18ga ) 4 7 PWR_IN_BATT2
GND_PWR_4 17 0-351-CC3 (BLK 18ga ) 5
VID ETHERNET SHIELD G SH SH SH SH VID PANEL 6 3 POWER_CTR_KEY
SHIELD-133 SHIELD-133 SHIELD-134 MC1998 MC1998 SHIELD-134 SHIELD-135 MC1082 SH7:D-5 0-041-CC3 (BLK 18ga )
EN4 TX DATA + F 97ET1-000-AA28 (W-OR 24ga ) 6 6 97ET1-003-AC51 (W-OR 24ga ) 6 6 97ET1-002-CC24 (W-OR 24ga ) 1 TX(+) 7
EN4 TX DATA - E 97ET2-000-AA28 (ORG 24ga ) 4 4 97ET2-003-AC51 (ORG 24ga ) 4 4 97ET2-002-CC24 (ORG 24ga ) 2 TX(-) 8
EN4 RX DATA + C 97ER1-000-AA28 (W-GR 24ga ) 5 5 97ER1-003-AC51 (W-GR 24ga ) 5 5 97ER1-002-CC24 (W-GR 24ga ) 3 RX(+)
KP-B 56B-06-11530
EN4 RX DATA - B 97ER2-000-AA28 (GRN 24ga ) 8 8 97ER2-003-AC51 (GRN 24ga ) 8 8 97ER2-002-CC24 (GRN 24ga ) 6 RX(-) 0-353-CC3 (BLK 18ga ) 1 GROUND2
MC1080 MC1080 MC1082 2 GROUND1
0-352-CC3 (BLK 18ga )
ETC4 PENET7 JENET7 JENET8 PENET8 VID_ENET
PANEL MOUNT 8 PIN M12 FEMALE CNB
DIS_HL_7 5 7KTS-000-CC3 (PUR 18ga ) 9 DOS_L_0
SH9:H-9 71P-021-AA30 (BRN 16ga ) 1 1 71P-019-AC2 (BRN 16ga ) 1 1 71P-020-CC2 (BRN 16ga ) 24VDC +
VID(+) KP-A 7KTWU-001-CC3 (YEL 18ga ) SH14:G-15
J82 P82 P02 J02 SP280
PWR_CTR_EXT 3 7KTWU-000-CC3 (YEL 18ga ) 7KTWU-002-CC3 (YEL 18ga ) 14 PWR_CTR_EXT
SH12:B-12 0-812-CC2 (BLK 16ga ) 0-815-CC2 (BLK 16ga ) 24VDC -
SP825 KOMTRAX STARTUP 26 7MSU-000-CC3 (ORG 18ga ) 6 KOMTRAX MODEM STARTUP
VID(-)
SYS_BUSY 10 74SB1-012-CC3 (DBL 18ga ) 74SB1-013-CC3 (DBL 18ga ) 15 SYS_BUSY
CHASSIS GROUND SP807
0-816-CC2 (BLK 16ga ) 74SB1-014-CC3 (DBL 18ga ) SH14:G-15 MC112 MC112
SNAPSHOT IN PROGRESS 29 74DS-000-CC3 (GRY 18ga ) SH12:I-17 SH14:F-12 10 COMM_CAN_H
VIDGND 939YE-016-CC3 (YEL 20ga )
SH14:F-12 939GE-016-CC3 (GRN 20ga ) 11 COMM_CAN_L
KP-B
MC1296 MC1296
5 93CAG-000-CC3 (BLK 20ga ) 2 RS232 GND
74SB1-011-CC3 (DBL 18ga ) 47 47 74SB1-000-AC3 (DBL 18ga ) 47 47 74SB1-016-AA31 (DBL 18ga ) SH2:C-22 2 93CAT-000-CC3 (RED 20ga ) 3 RS232 TX
3 93CAR-000-CC3 (WHT 20ga ) 4 RS232 RX
DIS_HL_0 19 73DS-005-CC3 (TAN 18ga ) 12 12 73DS-003-AC3 (TAN 16ga ) 12 12 73DS-004-AA31 (TAN 16ga ) SH9:K-5
DIAG7
KP-A J03 P03 P83 J83 ANTENNA WIRELESS (OPT) CNA
WIRELESS ACCESS
KOMTRAX
MC600 MC600 SHIELD-143 SH SH SHIELD-142 MC599 MC599
+12VDC 2 5 100-000-CC23 (W-BL 24ga ) 1 1 100-001-CG3 (W-BL 24ga ) 5 +12VDC2
+12VDC 1 4 101-000-CC23 (BLU 24ga ) 7 7 101-001-CG3 (BLU 24ga ) 4 +12VDC
GND 8 0-777-CC23 (BRN 24ga ) 3 3 0-779-CG3 (BRN 24ga ) 8 GND2
GND 2 7 0-778-CC23 (W-BR 24ga ) 2 2 0-780-CG3 (W-BR 24ga ) 7 GND
TX (+) 1 90ET1-003-CC23 (W-OR 24ga ) 6 6 90ET1-002-CG3 (W-OR 24ga ) 1 TX(+)
TX (-) 2 90ET2-003-CC23 (ORG 24ga ) 4 4 90ET2-002-CG3 (ORG 24ga ) 2 TX(-)
RX (+) 3 90ER1-003-CC23 (W-GR 24ga ) 5 5 90ER1-002-CG3 (W-GR 24ga ) 3 RX(+)
RX (-) 6 90ER2-003-CC23 (GRN 24ga ) 8 8 90ER2-002-CG3 (GRN 24ga ) 6 RX(-)
CN5 J608 P608
KWB_K+
58B-06-05980
MC096
TX(+) 1 93ET1-000-CC22 (W-OR 24ga )
TX(-) 2 93ET2-000-CC22 (ORG 24ga )
RX(+) 3 93ER1-000-CC22 (W-GR 24ga )
RX(-) 6 93ER2-000-CC22 (GRN 24ga )
CN4
SWITCH TRACTION CONTROL
ETHERNET SWITCH
9 7 0-151-CC3 (BLK 16ga ) SH9:K-12
TB22
WHEEL SPIN/SLIDE 22 72TC-000-AA3 (YEL 20ga ) J1 J4 72TC-003-AA31 (YEL 18ga ) 6 6 72TC-001-AC3 (YEL 18ga ) 6 6 72TC-002-CC3 (YEL 18ga ) 3 SHIELD-126
2B SH9:K-12 SH SH SH SH SH SH
71P-004-CC3 (BRN 16ga ) SHIELD-131 SHIELD-124 MC093 MC093 SHIELD-124 SHIELD-125 MC121 MC121 SHIELD-125 MC098 MC098
1 1 1 93ET1-002-AC51 (W-OR 24ga ) 1 1 93ET1-001-AA22 (W-OR 24ga ) 1 KOMTRAX TX(+) DRIVE SYS TX(+) 1 94ET1-000-AA6 (W-OR 24ga ) SH11:D-4
3 3 93ET2-002-AC51 (ORG 24ga ) 3 3 93ET2-001-AA22 (ORG 24ga ) 3 KOMTRAX TX(-) DRIVE SYS TX(-) 3 94ET2-000-AA6 (ORG 24ga ) SH11:D-4
6 2 2 93ER1-002-AC51 (W-GR 24ga ) 2 2 93ER1-001-AA22 (W-GR 24ga ) 2 KOMTRAX RX(+) DRIVE SYS RX(+) 2 94ER1-000-AA6 (W-GR 24ga ) SH11:D-4
5B 4 4 93ER2-002-AC51 (GRN 24ga ) 4 4 93ER2-001-AA22 (GRN 24ga ) 4 KOMTRAX RX(-) DRIVE SYS RX(-) 4 94ER2-000-AA6 (GRN 24ga ) SH11:D-4
4 MC096
JENET6 PENET6 PENET3 JENET3 PORT8 PORT0
MODULAR MINING DISPLAY
TB23 10 8 0-132-CC3 (BLK 16ga ) SH11:N-8 (PTX-C)
REST MODE 18 72RQ-003-AA3 (GRY 20ga ) K2 K1 72RQ-002-AA1 (GRY 14ga ) 29 29 72RQ-001-AJ1 (GRY 16ga ) SH2:D-19 MC094 SH SH SH SH SH
P30 P30 MC094 SHIELD-128 SHIELD-121 MC091 MC091 SHIELD-121 SHIELD-123 MC119 MC119 SHIELD-123
58F-06-60881 SHIELD-127
TX(+) 6 91ET1-000-CC11 (W-OR 24ga ) 1 1 91ET1-002-AC51 (W-OR 24ga ) 1 1 91ET1-001-AA26 (W-OR 24ga ) 1 MMS TX(+) SH
MC099
J12 P12 MC099
TX(-) 4 91ET2-000-CC11 (ORG 24ga ) 3 3 91ET2-002-AC51 (ORG 24ga ) 3 3 91ET2-001-AA26 (ORG 24ga ) 3 MMS TX(-) PAYLOAD TX(+) 1 95ET1-000-AA15 (W-OR 24ga ) SH13:N-17
RX(+) 5 91ER1-000-CC11 (W-GR 24ga ) 2 2 91ER1-002-AC51 (W-GR 24ga ) 2 2 91ER1-001-AA26 (W-GR 24ga ) 2 MMS RX(+) PAYLOAD TX(-) 3 95ET2-000-AA15 (ORG 24ga ) SH13:N-17
RX(-) 8 91ER2-000-CC11 (GRN 24ga ) 4 4 91ER2-002-AC51 (GRN 24ga ) 4 4 91ER2-001-AA26 (GRN 24ga ) 4 MMS RX(-) PAYLOAD RX(+) 2 95ER1-000-AA15 (W-GR 24ga ) SH13:N-17
27 27 27 27 PAYLOAD RX(-) 4 SH13:N-17
MMS_ENET JENET4 PENET4 PENET1 JENET1 PORT6 95ER2-000-AA15 (GRN 24ga )
SWITCH ENGINE WARMING PORT2
9 7 USER PC
0-136-CC3 (BLK 18ga ) SH8:L-6 MC095
TB23 SH SH SH SH SH
MC095 SHIELD-129 SHIELD-122 MC092 MC092 SHIELD-122 SHIELD-120 MC120 MC120 SHIELD-120
ENGINE WARMUP MODE 28 72GD-000-AA3 (TAN 20ga ) S1 S4 72GD-003-AA31 (TAN 18ga ) 8 8 72GD-001-AC3 (TAN 18ga ) 8 8 72GD-002-CC3 (TAN 18ga ) 3 TX(+) 1 92ET1-000-CC21 (W-OR 24ga ) 1 1 92ET1-002-AC51 (W-OR 24ga ) 1 1 92ET1-001-AA21 (W-OR 24ga ) 1 PC TX(+) MC090 MC090
2B 71P-009-CC3 (BRN 16ga ) TX(-) 2 92ET2-000-CC21 (ORG 24ga ) 3 3 92ET2-002-AC51 (ORG 24ga ) 3 3 92ET2-001-AA21 (ORG 24ga ) 3 PC TX(-) V(+) 4 12V-001-AA16 (ORG 18ga ) SH4:F-13
1 RX(+) 3 2 2 2 2 2 PC RX(+) GB31-B AUXBOX GND BLCK
92ER1-000-CC21 (W-GR 24ga ) 92ER1-002-AC51 (W-GR 24ga ) 92ER1-001-AA21 (W-GR 24ga ) C3
RX(-) 6 92ER2-000-CC21 (GRN 24ga ) 4 4 92ER2-002-AC51 (GRN 24ga ) 4 4 92ER2-001-AA21 (GRN 24ga ) 4 PC RX(-) V(-) 2 0-177-AA16 (BLK 18ga )
6
PC_ENET JENET5 PENET5 PENET2 JENET2 PORT4
5B
ENET_PWR
4
GB31-B AUXBOX GND BLCK
GB31-B AUXBOX GND BLCK C4
10 8 0-052-CC3 (BLK 16ga ) SH9:K-12 GND SCREW 1 0-550-AA1 (BLK 16ga )
E1
BRAKE TEST LIGHT RETURN 25 0-900-AA3 (BLK 20ga )
P31 P31
58F-06-60931 SH MC010
SHIELD-085 MC010
712P-003-CC3 (YEL 18ga ) TPMS TX(+) 1 98ET1-000-AA35 (W-OR 24ga ) SH18:M-6
TPMS TX(-) 3 98ET2-000-AA35 (ORG 24ga ) SH18:M-6
SWITCH BRAKE TEST TPMS RX(+) 2 98ER1-000-AA35 (W-GR 24ga ) SH18:M-6
TB25 TPMS RX(-) 4 98ER2-000-AA35 (GRN 24ga ) SH18:M-6
BRAKE TEST SYSTEM LIGHT 1 24 33SBA-000-AA3 (YEL 20ga ) 37 37 37 37 7 9
W1 W4 33SBA-003-AA31 (YEL 18ga ) 33SBA-001-AC3 (YEL 18ga ) 33SBA-002-CC3 (YEL 18ga ) PORT3
BRAKE TEST 23 72SBT-000-AA3 (DBL 20ga ) X1 X4 72SBT-003-AA31 (DBL 18ga ) 43 43 72SBT-001-AC3 (DBL 18ga ) 43 43 72SBT-002-CC3 (DBL 18ga ) 3
2B
1
SH
P304
6 SHIELDS ARE IM TX(+) 1
SHIELD999 MC999
100ET1-000-AA41 (W-OR 24ga ) SH12:N-5
5B
4 GROUNDED TO THE IM TX(-)
IM RX(+)
3
2
100ET2-000-AA41 (ORG 24ga )
100ER1-000-AA41 (W-GR 24ga )
SH12:O-5
SH12:O-5
SH11:K-10 0-132-CC3 (BLK 16ga ) SHELL OF THE M12 IM RX(-) 4 100ER2-000-AA41 (GRN 24ga ) SH12:O-5
OPERATOR CAB
MC999
SH11:E-15 0-412-CC3 (BLK 16ga ) 8 10
PORT5
PLUGS AT THE
P25 P25
58F-06-60911 ETHERNET SWITCH
VEC-89 F57 VEC-89 TB35
712 BUSS 4G
AUX BOX
G 712P-000-AA1 (YEL 16ga ) U1 U2 712P-004-AA31 (YEL 16ga ) 15 15 712P-001-AC3 (YEL 16ga ) 15 15 712P-002-CC3 (YEL 16ga )
10
58E-06-02043
VEC89-P4 J83 P83
ETHERNET SWITCH WIRING
P03 J03
TB25 SENSOR TRANSFORMER SEC LINK RTD
MC760 MC760 MC761 MC761 MC759 MC759
TSLRTD1 PIN 1 12 SLT1A-000-AA3 (WHT 18ga ) E2 E1 SLT1A-001-AA1 (WHT 18ga ) 65 65 SLT1A-002-AH1 (WHT 18ga ) 1 RTD1 +
TSLRTD1 PIN 2 13 SLT1B-000-AA3 (BLK 18ga ) F2 F1 SLT1B-001-AA1 (BLK 18ga ) 66 66 SLT1B-002-AH1 (BLK 18ga ) 2
3
RTD1 -
RTD1 SHIELD
58B-06-05901-00 SEP 21
SHIELD-114
TSLRTD1 SHIELD 14
TSLRTD2 PIN 1 3
SHIELD-110
MC754
SLT2A-000-AA3 (WHT 18ga )
SHIELD-110
MC754
G2 G1
P2 P1
SHIELD-112
MC762
SLT2A-001-AA1 (WHT 18ga )
SHIELD-112
MC762
67 67
68 68
SHIELD-114
MC758
SLT2A-002-AH1 (WHT 18ga )
MC758
6 RTD2 +
ELECTRICAL SCHEMATIC
TSLRTD2 PIN 2 6 SLT2B-000-AA3 (BLK 18ga ) R2 R1 SLT2B-001-AA1 (BLK 18ga ) 69 69 SLT2B-002-AH1 (BLK 18ga ) 7
8
RTD2 -
RTD2 SHIELD
980E-5
GE INTERFACE A50052, A50053, A50137, A50138
SHIELD-115
TSLRTD2 SHIELD 18 S2 S1 70 70 RTD
SHIELD-111 SHIELD-111 SHIELD-113 SHIELD-113 SHIELD-115
P302 J11 P11
Sheet 11 of 21
IM2
TB28 SWITCH DRIVERS SEAT BELT
SEAT BELT 43 4 4 4 4 3 3 2 2 1 1
62SB-000-AA1 (ORG 20ga ) X1 X4 62SB-004-AA30 (ORG 18ga ) 62SB-001-AC2 (ORG 18ga ) 62SB-002-CC2 (ORG 18ga )
TB28-X1 TB28-X4 XK1267
HYD PUMP FILTER PRESS 44 39-003-AA1 (TAN 20ga )
SWITCH ACCUMULATOR LOW PRECHARGE PRESSURE #1 (ACCP1) J82 P82 P02 J02 P212 P212
C TB30 FUEL SENSOR 26 GB12-B 4 4
51A2-000-AR1 (BRN 16ga ) 38G-000-AA1 (GRY 20ga ) A1
0-329-CC2 (BLK 18ga )
B 51A1-001-AR1 (LBL 16ga ) 19 19 51A1-000-AA1 (LBL 20ga ) G1 G2
A IM3 0-812-CC2 (BLK 16ga ) SH11:F-7 J227 P227
ACCP1 ACCP1
58E-06-60330 VEC-89 VEC-89
A 2A 85 86 2G G
62A-000-AA1 (YEL 20ga ) 24VIM-002-AA1 (LBL 18ga ) SH3:K-13
SWITCH ACCUMULATOR LOW PRECHARGE PRESSURE #2 (ACCP2)
C TB30 R19 62SBA-000-AA1 (ORG 14ga ) H 2H 87 F63
SEAT BELT ALARM TB32 30 71CK BUSS
B 0-335-AR1 (BLK 16ga ) 20 20 0-336-AA1 (BLK 16ga ) SH4:H-8 33JB-000-AA1 (LTG 20ga ) D1 D4 33JB-005-AA2 (LTG 18ga ) 1 2 0-229-AA2 (BLK 16ga ) SH6:J-11
A CUSTOMER ATTACHMENT 87a 15 7
L1
ACCP2 D2
58B-06-00290 (OPT)
ACCP2 58E-06-60330
SEAT BELT ALARM
P13 J13 (OPT) RELAY 41
SWITCH LOW STEERING PRESSURE 58E-06-02043
33JB-001-AA1 (GRY 16ga ) 71CK BUSS
C
GB31-A AUXBOX GND BLCK R2 VEC-89 VEC-89
D3 0-690-AA1 (BLK 16ga ) SH18:E-17
B 33F-000-AJ2 (DBL 16ga ) 6 6 10 10 0-614-AA1 (BLK 16ga ) 1 2 33J-005-AA1 (GRY 16ga )
6800.0 86 85 0 BUSS
A
R2 R2
58E-06-60350 LSPSW SOLENOID STEERING BLEED DOWN 58B-06-02020 87 F12
LSPSW J14 P14 30 11 BUSS
SP184 1E 87a 10
0-331-AJ2 (BLK 16ga ) 2 2 0-333-AA1 (BLK 16ga ) SH4:I-4 33JB-002-AJ2 (LTG 16ga ) 33JB-003-AJ2 (LTG 16ga ) 2 1 33J-002-AJ2 (GRY 16ga ) 33J-001-AJ2 (GRY 16ga ) 7 7 33J-000-AA1 (GRY 16ga ) 33J-004-AA1 (GRY 16ga ) E
SP019 SP507
SWITCH STEERING BLEED PRESSURE STEERING BLEED
BF4493 VEC89-P1
SBDSOL SBDSOL PWR RELAY 14
C 9 9 33JA-001-AA1 (YEL 20ga )
D26 P14 J14 58E-06-02043
B
A 2 1
VEC-89 F42 VEC-89
33JA-000-AJ2 (YEL 16ga ) 33JB-004-AJ2 (LTG 16ga ) 33J-003-AJ2 (GRY 16ga ) 4H 71CK BUSS
300A/255R H
BLDPS 58E-06-60310 PC2834 TB21 5
BLDPS SP799
34 34 58E-06-02043
0-753-AJ2 (BLK 16ga ) 0-332-AJ2 (BLK 16ga ) 0-334-AA1 (BLK 16ga ) SH4:I-4 87-001-AA1 (TAN 20ga ) J1 J2 87-000-AA1 (TAN 18ga )
560Ω 5W
SH9:K-18 0-754-AJ2 (BLK 16ga ) 87-002-AA2 (TAN 18ga ) J4
TB35 R15
SH9:K-18 0-756-AJ2 (BLK 16ga )
38G-000-AA1 (GRY 20ga ) C1 C4 38G-002-AA2 (GRY 18ga ) 2 1
P14 J14 560.0 FUEL SENDER
58E-06-40020 11 11 1 1 1 + VDC SIGNAL
C2 38G-001-AA1 (GRY 16ga ) 38G-003-AH2 (GRY 14ga ) 38G-004-HH4 (GRY 16ga )
0-330-AH2 (BLK 16ga ) 2 2 0-327-HH4 (BLK 16ga )
52AA2-000-AA1 (BRN 20ga ) 21 21 2 GROUND
TB30 J16 P16 J730 P730
AHT
15 15 FLS 58B-06-03300
39-003-AA1 (TAN 20ga ) F1 F2 39-000-AA1 (TAN 20ga ) AUXBOX CONNECTOR
(OPT)
16 16 J9-AA8 (BLK 16ga )
J702_JP P702
SEATBELT WARNING LAMP 40 62A-000-AA1 (YEL 20ga ) SWITCH HYDRAULIC FILTER #1 SWITCH HYDRAULIC FILTER #2 SWITCH STEERING FILTER
PARK BRAKE APPLY PSW 31 33-002-AA1 (BRN 20ga )
MAN MODE AUTO APPLY PRES SW 11 52AA2-000-AA1 (BRN 20ga ) 39AP-000-AA1 (YEL 16ga ) 12 12 39AP-001-AH2 (YEL 16ga ) 2 1 39HP-000-AH2 (LBL 16ga ) 2 1 39SP-000-AH2 (BRN 16ga ) 2 1 0-328-AH2 (BLK 16ga )
HFSW1_CP HFSW1_CP HFSW2_CP HFSW2_CP SFSW_CP SFSW_CP
58B-06-50900 58B-06-50900 58B-06-50900
IM2
SH9:I-21 0-814-AH2 (BLK 16ga ) SP135
SH4:J-4 0-325-AA1 (BLK 16ga ) 21 21 0-326-AH2 (BLK 16ga ) 0-330-AH2 (BLK 16ga )
SH9:I-21 0-813-AH2 (BLK 16ga )
TB33 J16 P16 SWITCH PARK BRAKE SET
B1 72MAN-000-AA1 (LTG 20ga ) 38 MANUAL MODE C
15 STEERING BLEED PRESSURE SW TB32 B 0-337-BB1 (BLK 16ga ) SH3:H-14
B2 AHT CONNECTION 33-002-AA1 (BRN 20ga ) D1 D4 33-003-AA33 (BRN 16ga ) D D 33-001-AB1 (BRN 16ga ) D D 33-000-BB1 (BRN 16ga ) A
PBPSW
AHT CONNECTION IM1 58E-06-60340
A2 E1 E4 33BP-003-AA33 (WHT 16ga ) PBPSW
43 AUTO MODE 33T-003-AA33 (DBL 16ga ) SWITCH LOW BRAKE ACCUM PRESSURE
A1 72AT-000-AA1 (PNK 20ga ) F1 F4
SH11:C-8 71F-003-AA1 (LTG 20ga ) 5 BODY DOWN SWITCH S S 33BP-001-AB1 (WHT 16ga ) S S 33BP-000-BB1 (WHT 16ga ) C
51A1-002-AA1 (LBL 20ga ) 1 LOW STEERING PRECHARGE B 0-338-BB1 (BLK 16ga ) SH3:H-14
AIR RESTRICTION SWITCH 1
33F-001-AA1 (DBL 20ga ) 21 LOW STEERING PRESSURE A
ARS1 LBPS
2 NC C 1 8 8 26 26 26 26 3 ENGINE AIR FILTER MC322 58E-06-60360
25AF-000-GJ1 (TAN 16ga ) 25AF-002-GG1 (TAN 16ga ) 25AF-003-AG2 (TAN 16ga ) 25AF-001-AA1 (TAN 20ga ) MC322 LBPS
CAN 3RD PARTY-HI 42 939YK-011-AA1 (YEL 20ga ) SH14:H-5
IM2 CAN 3RD PARTY-LO 32 SWITCH SERVICE BRAKE DEGRADE PRESSURE
ARS1 939GK-011-AA1 (GRN 20ga ) SH14:H-5
58E-06-05290 CAN 3RD PARTY-SHLD 22 N N 33T-001-AB1 (DBL 16ga ) N N 33T-000-BB1 (DBL 16ga ) C
J540 P540_CP J503 P503 P80 J80
B (BLK 16ga )
0-339-BB1 SH3:H-14
J85 P85 A
GB20 IM GND P240 J240
MC703 MC703 BDS
25AF1-000-GJ1 (WHT 16ga ) J1939 MONITOR BUS HI 43 SH14:B-5
A1
SH12:J-18 58E-06-60370
939YP-008-AA1 (YEL 20ga ) SHIELD-936-AA1 (BLK 18ga ) BDS
J1939 MONITOR BUS LOW 33 939GP-008-AA1 (GRN 20ga ) SH14:C-5 SHIELD-935-AA1 (BLK 18ga ) SHIELD-896
J1939 MONITOR BUS GND 23 SHIELD-934-AA1 (BLK 18ga ) SP906 SP734
SHIELD-834
AIR RESTRICTION SWITCH 2 TB28
MC705 MC705 MC720 MC206 MC206 MC718 MC718 MC717 MC717
ARS2 J1939 ENGINE BUS HI 44 939YE-008-AA1 (YEL 20ga ) SH14:G-6 90IMT-000-AA1 (RED 20ga ) M1 M4 52 52 52 52 2
90IMT-004-AA30 (RED 18ga ) 90IMT-002-AC2 (RED 18ga ) 90IMT-003-CC2 (RED 20ga ) OP-CAB IM
2 NC C 1 J1939 ENGINE BUS LOW 34 SH14:G-6
939GE-008-AA1 (GRN 20ga )
J1939 ENGINE BUS GND 24 DIAGNOSTIC
90IMT-001-AA1 (RED 20ga ) M2
ARS2 DIAG-1
58E-06-05290 53 53 53 53 3 CONNECTOR
90IMR-000-AA1 (WHT 20ga ) N1 N4 90IMR-004-AA30 (WHT 18ga ) 90IMR-002-AC2 (WHT 18ga ) 90IMR-003-CC2 (WHT 20ga )
0-806-GJ1 (BLK 16ga ) 9 9 0-788-GG1 (BLK 16ga ) 27 27 0-234-AG2 (BLK 16ga ) 27 27 0-376-AA1 (BLK 16ga ) SH4:J-4 AUTO LUBE SOL 5 68-000-AA1 (DBL 20ga )
STEERING BLEED VLV 18 33JB-000-AA1 (LTG 20ga ) 90IMR-001-AA1 (WHT 20ga ) N2
BRAKE ACCUMULATOR PRESSURE 6 33BP-002-AA1 (WHT 20ga )
BRAKE PRESSURE DEGREDATION 17 33T-002-AA1 (DBL 20ga ) 90IMG-000-AA1 (BLK 20ga ) P1 P4 90IMG-004-AA30 (BLK 18ga ) 54 54 90IMG-002-AC2 (BLK 18ga ) 54 54 90IMG-003-CC2 (BLK 20ga ) 5
J540 P540_CP J503 P503 P80 J80
DIAG RS232 GND 26 90IMG-000-AA1 (BLK 20ga ) 55 55 55 55
SHIELD-268 SHIELD-894 SHIELD-894 SHIELD-893
DIAG RS232 RECIEVE 36 90IMR-000-AA1 (WHT 20ga ) 90IMG-001-AA1 (BLK 20ga ) P2
DIAG RS232 TRANS 46 DIAG1
90IMT-000-AA1 (RED 20ga ) J82 P82
TB21 MC720 R1 R4
SHIELD-268 P02 J02
SH18:C-16 510E2-005-AJ1 (DGR 16ga ) 33 33 510E2-004-AA1 (DGR 16ga ) A1 A2 510E2-000-AA1 (DGR 20ga ) 49 HYD LADDER UP LOW HYD TANK LEVE 13 34LL-001-AA1 (WHT 16ga )
SNAPSHOT IN PROGRESS 2 74DS-002-AA1 (GRY 20ga ) R2
TB30 KEYSWITCH OR 28
AHT CONNECTION A3 87-001-AA1 (TAN 20ga )
18VIM-000-AA1 (WHT 20ga ) E1 E2 18VIM-011-AA1 (WHT 20ga ) 1 +18 SENSOR
P12 J12 IM1
SHIELD-130
13CA-003-AA1 (YEL 20ga ) 36 HYD LADDER ALARM MC719 MC719
11 STEERING PRESSURE 90IMT-001-AA1 (RED 20ga ) 2
TB21 MC650 AUXBOX IM
SP342 12 BRAKE PRESSURE
28 28 21 HOIST PRESSURE 2 3
DIAGNOSTIC
SH18:G-17 13CA-002-AJ1 (YEL 16ga ) 13CA-005-AA1 (YEL 16ga ) C1 C2 90IMR-001-AA1 (WHT 20ga )
22 HOIST PRESSURE 1 CONNECTOR
90IMG-001-AA1 (BLK 20ga ) 5
IM3
SENSOR STEERING PRESSURE P12 J12 J372
MC653 MC654 MC654
1 27 27 HYD BRAKE TEMP-RF 24 TB25
1 18VIM-002-AJ2 (WHT 18ga ) 18VIM-001-AA1 (WHT 20ga ) 34BT2-000-AA1 (BLK 20ga )
HYD TANK TEMPERATURE 27 34BT4-001-AA1 (BLK 20ga ) 74DS-002-AA1 (GRY 20ga ) M1 M4 74DS-003-AA31 (GRY 18ga ) 13 13 74DS-001-AC3 (GRY 18ga ) 13 13 74DS-000-CC3 (GRY 18ga ) SH11:G-13
2
2 26 26 HYD BRAKE TEMP- LR 28 TB30
33SP-002-AJ2 (BLK 18ga ) 33SP-001-AA1 (BLK 20ga ) 34BT3-000-AA1 (BLK 20ga )
+5V SENSOR 50 5VIM-001-AA1 (ORG 20ga ) C1 C2 5VIM-000-AA1 (ORG 20ga ) SWITCH HYDRAULIC TANK LVL
58B-06-20320 SPS J83 P83 SHIELD-636 SP735 MC3292 MC3292
28 28 AMBIENT TEMP 23 34AT-001-AA1 (BLK 20ga ) SHIELD-936-AA1 (BLK 18ga ) SH12:G-12 SPR-008-JJ20 (GRY 18ga ) 5 SPR2
SHIELD-734 SHIELD-735 P03 J03
HYD OIL TEMP-LF 25 34BT1-000-AA1 (BLK 20ga ) MC635 2 SPR1
SHIELD-735 SP132 MC636 MC635 SPR-009-JJ20 (WHT 18ga )
SH3:K-10 24VIM-000-AA1 (LBL 20ga ) 24VIM-008-AA1 (RED 16ga ) 29 29 24VIM-009-AJ2 (RED 16ga ) A A 24VIM-010-JJ20 (BRN 18ga ) 1 V+
IM3 SP736 31 31 B B 3 GROUND
P14 J14 SH6:J-14 0-936-AA1 (BLK 18ga ) 0-354-AA1 (BLK 16ga ) 0-340-AJ2 (BLK 16ga ) 0-341-JJ20 (BLU 18ga )
34LL-001-AA1 (WHT 16ga ) 34LL-001-AA1 (WHT 16ga ) 30 30 34LL-002-AJ2 (WHT 16ga ) C C 34LL-003-JJ20 (BLK 18ga ) 4 OUTPUT
32 32
MC636 SHIELD-636 SHIELD-701 P712 J712 HTLS 58E-06-50240
SENSOR HOIST PRESSURE #1
MC651 MC652 MC652 SENSOR BRAKE TEMP RH REAR
1 1 18VIM-004-AH2 (WHT 18ga ) 31 31 18VIM-003-AA1 (WHT 20ga ) MC639 MC639 MC634 MC634
MC652
18 18 34BT4-000-AJ2 (WHT 16ga ) 1
2
2 33HP1-002-AH2 (BLK 18ga ) 32 32 33HP1-001-AA1 (BLK 20ga ) 7861-93-3320
GB20 IM GND 20 20 2
SP298 SHIELD-709 5VIM-006-AA1 (WHT 20ga ) 5VIM-005-AJ2 (BLK 16ga )
58B-06-20290 HPS1 33 33
A4
SHIELD-003-AA1 (BLK 16ga ) SHIELD-700 P710
SHIELD-732 SHIELD-733 SHIELD-710
SHIELD-733 B1 SP299 SHIELD-711 SHIELD-709 SENSOR BRAKE TEMP LH REAR
SP247 SHIELD-004-AA1 (BLK 14ga ) SHIELD-997-AA1 (BLK 18ga ) 19 19 SHIELD-998-AJ2 (BLK 16ga ) SP791 MC755
A2 SHIELD-725
GB20 IM GND SHIELD-001-AA1 (BLK 16ga ) SP302 1
GB20 IM GND
SP296 SHIELD-710 7861-93-3320
A3 SHIELD-712 15 15 2
GB20 IM GND SHIELD-002-AA1 (BLK 16ga ) 34BT3-002-AJ2 (WHT 16ga )
MC640 MC755 P709
5VIM-002-AA1 (WHT 20ga ) 14 14 5VIM-009-AJ2 (BLK 16ga )
SENSOR HOIST PRESSURE #2 MC640 SENSOR BRAKE TEMP RH FRONT
MC649 MC650 SHIELD-731 MC757
1 1 18VIM-006-AH2 (WHT 18ga ) 5 5 18VIM-005-AA1 (WHT 20ga ) 40 40 34BT2-002-AJ2 (WHT 16ga ) 1
MC641 MC757 7861-93-3320
2
2 33HP2-002-AH2 (BLK 18ga ) 6 6 33HP2-001-AA1 (BLK 20ga ) 5VIM-004-AA1 (WHT 20ga ) 39 39 5VIM-010-AJ2 (BLK 16ga ) 2
MC641 SHIELD-977
P708
58B-06-20290 HPS2 7 7 SHIELD-711 SHIELD-980-AA1 (BLK 18ga ) 38 38 SHIELD-996-AJ2 (BLK 16ga ) SP789
SHIELD-730 SENSOR BRAKE TEMP LH FRONT
SP303 MC756
37 37 SHIELD-976 1
P16 J16 34BT1-000-AA1 (BLK 20ga ) 34BT1-002-AJ2 (WHT 16ga )
MC756 7861-93-3320
5VIM-003-AA1 (WHT 20ga ) 36 36 5VIM-011-AJ2 (BLK 16ga ) 2
SENSOR BRAKE PRESSURE
MC648 MC222 TB24 MC998 MC642 MC642 P707
MC647 MC647 MC648 MC222
1 1 18VIM-008-BB1 (WHT 20ga ) A A 18VIM-007-AB1 (WHT 20ga ) A A 18VIM-010-AA33 (WHT 20ga ) W4 W1 18VIM-009-AA1 (WHT 20gaMC998
) 23 23
SHIELD-725 SHIELD-723 SENSOR DUCT AIR TEMPERATURE
2
MC645 MC645
2 33BPS-002-BB1 (BLK 20ga ) B B 33BPS-001-AB1 (BLK 20ga ) B B 33BPS-003-AA33 (BLK 20ga ) X4 X1 33BPS-000-AA1 (BLK 20ga ) 34AT-001-AA1 (BLK 20ga ) 21 21 34AT-000-AJ2 (WHT 16ga ) A 1
M M MC998
SHIELD-728 SHIELD-729 SHIELD-289
58B-06-20290 BPS M M 22 22 B 2
SP130 SHIELD-289
Y4 Y1
SHIELD-736
5VIM-008-AA1 (WHT 20ga ) 5VIM-007-AJ2 (BLK 16ga )
SHIELD-993-BB1 (BLK 16ga ) SHIELD-729 MC646 MC646
P85 J85 ATS AK7339
SH6:H-3 71BC-010-AA1 (DGR 16ga ) 4 4
J240 P240
1
2
3
4
5
6
7
8
AUTO LUBE PRESSURE SW 33 68P-003-AA1 (PUR 20ga ) JB8F R3
TB30 1 2 5 5
56B-06-11530 58S-005-AA1 (GRY 18ga ) 0-699-AA1 (BLK 18ga ) SH4:I-4 58S-003-AA1 (GRY 16ga )
AUTO LUBE LEVEL 42 68LS-002-AA1 (DGR 20ga ) A3
GB20 IM GND SHIELD-736 16 16
B2
57TPU-001-AA1 (WHT 18ga )
SHIELD-006-AA1 (BLK 18ga ) BRAKE COOLING SOLENOID 46 58S-004-AA1 (GRY 20ga ) 58S-004-AA1 (GRY 20ga ) A1 A2
SH4:H-4 0-391-AA1 (BLK 18ga ) 17 17
SP314
HOIST CYL BASE PRESSURE SW 32 57TPU-002-AA1 (WHT 20ga ) 57TPU-002-AA1 (WHT 20ga ) B1 B2
IM2
J14 P14
SWITCH AUTO LUBE PRESSURE
TB35 C D7
68P-003-AA1 (PUR 20ga ) W1 W2 68P-002-AA1 (PUR 16ga ) 23 23 68P-001-AH2 (PUR 14ga ) B 68ES-006-JJ1 (DBL 14ga ) 1 2 68-007-JJ1 (TAN 14ga )
A
GB31-A AUXBOX GND BLCK 24 24 PC2834
SP401 0-693-AA1 (BLK 16ga ) 0-692-AH2 (BLK 14ga ) LLPS
E3 58E-06-60390
0-695-AA1 (BLK 8ga ) 0-665-AA1 (BLK 14ga ) SH5:C-10 LLPS
TB35
0-670-AA1 (BLK 14ga ) SH5:C-10
R1 SOLENOID AUTO LUBE
R30 J16 P16
R2 R4 68-001-AA2 (DBL 18ga ) 1 2 0-345-AA2 (BLK 18ga ) SH6:J-11 68ES-004-AA1 (DBL 16ga ) 53 53 68ES-001-AJ1 (DBL 14ga ) E E 68ES-002-JJ1 (DBL 14ga ) 68ES-005-JJ1 (DBL 14ga ) 2 1 68-008-JJ1 (TAN 14ga )
MC999 SH SP305 SP306
SHIELD999
SH11:M-21 100ET1-000-AA41 (W-OR 24ga ) 1 ENET TX(+) PC2436
58B-06-00290 LLSOL LLSOL
SH11:M-21 100ET2-000-AA41 (ORG 24ga ) 3 ENET TX(-) 68-005-AA1 (TAN 16ga ) 54 54 68-003-AJ1 (TAN 14ga ) B B 68-004-JJ1 (TAN 14ga )
SH11:N-21 100ER1-000-AA41 (W-GR 24ga ) 2 ENET RX(+)
4 ENET RX(-) VEC-89 2B
B
SWITCH AUTOLUBE LEVEL (OPT)
SH11:N-21 100ER2-000-AA41 (GRN 24ga ) 68ES-003-AA1 (DBL 16ga )
MC999 F20 55 55 C C C NO
4C 71CK BUSS 68LS-003-AA1 (DGR 16ga ) 68LS-001-AJ1 (DGR 16ga ) 68LS-000-JJ1 (DGR 16ga )
85 86 C B
IM_ENET VEC89-P2
10 A NC
87
30 4F XA3247 ALLSW
4E 87a ALLSW
0-771-AA1 (BLK 16ga ) 56 56 0-342-AJ1 (BLK 16ga ) A A 0-343-JJ1 (BLK 16ga )
AUTO LUBE J11 P11 J511 P511
RELAY 29 58E-06-02043 VEC-89 66 66
68ES-000-AA1 (DBL 16ga )
SP3801
68-006-AA1 (TAN 16ga )
SP3802
68-002-AA1 (TAN 16ga ) 67 67 58B-06-05901-00 SEP 21
68LS-002-AA1 (DGR 20ga )
SP3803
68LS-004-AA1 (DGR 16ga ) 68 68
ELECTRICAL SCHEMATIC
980E-5
INTERFACE MODULE SH4:I-8 0-344-AA1 (BLK 16ga )
SP3804
0-769-AA1 (BLK 16ga ) 69 69
A50052, A50053, A50137, A50138
J12 P12
Sheet 12 of 21
SWITCH HEATED MIRROR
SH7:I-8 0-446-CC3 (BLK 16ga ) 7 9
3 69MA-000-CC3 (YEL 16ga ) 39 39 69MA-001-AC3 (YEL 16ga ) 39 39 69MA-003-AA31 (YEL 16ga )
TB28-W4
TB28
W4 W1
TB28-W1 HEATED MIRRORS
71LS-005-CC3 (DGR 16ga ) 2B
1
J03 P03 P83 J83
6
5B
4
8 10
RIGHT DECK HEATED MIRROR
P28 P28 69M-001-AA1 (YEL 14ga ) 6 6 69M-003-AH1 (YEL 14ga ) F F 69M-007-FF1 (YEL 14ga ) 1 1
58F-06-60941 7 7 G G
SH4:G-8 0-403-AA1 (BLK 14ga ) 0-404-AH1 (BLK 14ga ) 0-406-FF1 (BLK 14ga )
69MA-002-AA1 (YEL 18ga ) 2 2 7
MIRROR1_CP PC2930
J11 P11 P502 J502
G 1G VEC-89
VEC-89
0 BUSS 85 86
VEC89-P1
TB23
F53 87 1H
H 69M-000-AA1 (YEL 12ga ) F1 F2
11 BUSS 30 LEFT DECK HEATED MIRROR
20 87a 6 6 6 6 1 1
VEC89-P1 F4 69M-002-AA1 (YEL 14ga ) 69M-008-AG2 (YEL 14ga ) 69M-011-GG1 (YEL 14ga )
SH4:J-8 0-407-AA1 (BLK 14ga ) 7 7 0-410-AG2 (BLK 14ga ) 7 7 0-785-GG1 (BLK 14ga )
HEATED MIRROR 2 2
RELAY 39 58E-06-02043
MIRROR2_CP PC2930
J80 P80 P503 J503
4 4 D D 1
RIGHT DECK
11RB-002-AA1 (DGR 14ga ) 11RB-005-AH1 (DGR 14ga ) 11RB-009-FF1 (DGR 14ga )
5 5 E E 2 ROTATING BEACON
SH4:G-8 0-401-AA1 (BLK 14ga ) 0-395-AH1 (BLK 14ga ) 0-397-FF1 (BLK 14ga )
SWITCH ROTATING BEACON (OPT) OPTION
P548_CP
7 9
TB22 J11 P11 P502 J502
3 E1
SH8:B-8 71LS-011-CC3 (DGR 16ga ) 2B
1 4 4 4 4 1
LEFT DECK
E2 11RB-003-AA1 (DGR 14ga ) 11RB-010-AG2 (DGR 14ga ) 11RB-012-GG1 (DGR 14ga )
5 5 5 5 2 ROTATING BEACON
SH4:J-8 0-402-AA1 (BLK 14ga ) 0-400-AG2 (BLK 14ga ) 0-784-GG1 (BLK 14ga )
6 11RB-000-CC3 (DGR 14ga ) 38 38 11RB-001-AC3 (DGR 14ga ) 38 38 11RB-006-AA31 (DGR 14ga ) E4 E3 OPTION
5B P549_CP
SH8:K-4 11L-003-CC3 (YEL 14ga )
4
J03 P03 P83 J83 J80 P80 P503 J503
8 10 JIFFY SPLICE 1 ROTATING BEACON CAB
SH7:I-8 0-320-CC3 (BLK 18ga )
11RB-007-AA32 (DGR 14ga ) 14 14 11RB-004-AC4 (DGR 14ga ) 14 14 11RB-011-CC4 (DGR 14ga ) 1 2 11RB-014-CC14 (DGR 14ga ) 1
P24 P24 RRBB1 1259564H1 JS1
58F-06-60951 2
J84 P84 P04 J04 0-497-CC14 (BLK 14ga )
GB12-A JIFFY SPLICE 2
F1 CRB 58F-06-83101
0-428-CC4 (BLK 14ga ) 1 2
SH4:M-14 RRBB2 1259564H1 JS2
ROTATING BEACON OPTION
0-202-CC4 (BLK 18ga )
LAMP RED PAYLOAD RIGHT
PAYLOAD METER 4 39AA-001-AA1 (DGR 16ga ) 10 10 39AA-002-AH1 (DGR 16ga ) K K 39AA-005-FF1 (DGR 16ga ) 1 2 0-189-FF1 (BLK 16ga )
RED
EK9380
RPLR_CP RPLR_CP
2G VEC-90 LAMP AMBER PAYLOAD RIGHT
39A-001-AA1 (LTG 18ga ) G
TB23
0 BUSS 85 86
SP195
C1 39BA-001-AA1 (LBL 16ga ) 11 11 39BA-002-AH1 (LBL 16ga ) L L 39BA-005-FF1 (LBL 16ga ) 1 2 0-199-FF1 (BLK 16ga )
3A YEL
F14 87 VEC-90
A 39AA-000-AA1 (DGR 16ga ) C2 EK9381
71CK BUSS 30 58E-06-20051 RPLA_CP RPLA_CP
5 87a LAMP GREEN PAYLOAD RIGHT
C4
TB34 PAYLOAD RED 12 12 M M 1 2
LAMP RELAY 16
39CA-001-AA1 (YEL 16ga ) 39CA-002-AH1 (YEL 16ga ) 39CA-005-FF1 (YEL 16ga ) 0-158-FF1 (BLK 16ga )
S2 S1 GRN
3B
B EK9382
2D RPLG_CP RPLG_CP
R2 R1 39B-001-AA1 (BRN 18ga ) D
TB23
0 BUSS 85 86 J11 P11 P502 J502
P2 P1 D1 SH8:K-19 0-364-FF1 (BLK 16ga )
87 2C
C 39BA-000-AA1 (LBL 16ga ) D2
30 LAMP RED PAYLOAD LEFT
87a
D4
39AA-006-AA1 (DGR 16ga ) 10 10 39AA-009-AG2 (DGR 16ga ) 10 10 39AA-010-GG1 (DGR 16ga ) 1 2 0-367-GG1 (BLK 16ga )
PAYLOAD AMBER
RED
LAMP RELAY 17
EK9380
2B LPLR_CP LPLR_CP
39C-001-AA1 (DBL 18ga ) B
TB23 LAMP AMBER PAYLOAD LEFT
0 BUSS 85 86
E1
11 11 11 11 1 2
SP196
2A 39BA-006-AA1 (LBL 16ga ) 39BA-009-AG2 (LBL 16ga ) 39BA-010-GG1 (LBL 16ga ) 0-368-GG1 (BLK 16ga )
87 A 39CA-000-AA1 (YEL 16ga ) E2 YEL
30
EK9381
87a LPLA_CP LPLA_CP
E4
LAMP GREEN PAYLOAD LEFT
PAYLOAD GREEN
LAMP RELAY 18 12 12 12 12 1 2
39CA-006-AA1 (YEL 16ga ) 39CA-009-AG2 (DGR 16ga ) 39CA-010-GG1 (DGR 16ga ) 0-369-GG1 (BLK 16ga )
GRN
PAYLOAD METER 4 EK9382
LPLG_CP LPLG_CP
J80 P80 P503 J503
39C-000-AA4 (DBL 18ga ) 44 GREEN LAMP
45 AMBER LAMP GND-DECK
39B-000-AA4 (BRN 18ga ) SH8:I-19 0-363-GG1 (BLK 16ga )
43 RED LAMP SHIELD-929 1
39A-000-AA4 (LTG 18ga )
SCORE BOARD RIGHT (OPT) SCORE BOARD LEFT (OPT)
SH3:B-3 39G-001-AA4 (DBL 18ga ) 31 BATTERY DIRECT
MC606 MC606
PWR & COMM GND 1 A 0-370-FG1 (BLK 16ga ) A PWR & COMM GND 2
VEC-90 F46 VEC-90 TB34 N/C 1 B B PWR & COMM GND 3
71CK BUSS 4D
D 712PL-000-AA1 (LTG 16ga ) V1 V2 712PL-001-AA4 (LTG 18ga ) 50 KEYSWITCH SIGN TX C C N/C 2
5 SIGN RX D D SIGN TX2 REBROADCAST
58E-06-20051 35L10-000-FG1 (WHT 16ga )
24 VDC PWR IN E 712S1-002-FG1 (RED 16ga ) E 24 VDC PWR OUT
GB31-A AUXBOX GND BLCK
E4
37 GROUND 2 PC1137 CNRIN CNLO
0-365-AA4 (BLK 18ga )
B N/C 1
TB30
0-375-AA4 (BLK 18ga ) SH13:K-16 MC607 MC607
712S1-000-AA1 (DGR 16ga ) P1 P2 712S1-001-AF1 (RED 16ga ) E 24 VDC PWR IN
SH6:O-4 39H1-001-AA4 (YEL 18ga ) 49 BRAKE LOCK ON
MC605 MC605
RS232-TRANSMIT 2 25 35L8-000-AA4 (WHT 18ga ) S1 S2 35L8-001-AF1 (WHT 16ga ) D SIGN RX
RS232-RECEIVE 2 24 35L9-000-AA4 (RED 18ga ) Y1 Y2 35L9-001-AF1 (BRN 16ga ) C SIGN TX
SH11:C-3 71F-002-AA4 (LTG 18ga ) 46 BODY UP
RS232-GROUND 2 34 35L7-000-AA4 (BLK 18ga ) R1 R2 35L7-001-AF1 (BLK 16ga ) A PWR & COMM GND 1
SHIELD-671 CNLIN
R4 0-375-AA4 (BLK 18ga ) SH13:J-9
GB21 PLM GND PC1137
GB21A1
PLM GND
SHIELD-005-AA4 (BLK 16ga ) SP300 T1 T2
EC3034 SHIELD-671 SHIELD-673
T3 T4
SHIELD-670 SHIELD-670 SHIELD-656
MC601 MC601 MC290 MC290
RS232 GND 23 35L2-000-AA4 (BLK 20ga ) L1 L2 35L2-001-AA4 (BLK 20ga ) 5
AUXBOX
RS232 R 15 35L3-000-AA4 (RED 20ga ) M1 M2 35L3-001-AA4 (RED 20ga ) 3 PLM4
DIAGNOSTIC
RS232 T 21 35L4-000-AA4 (WHT 20ga ) N1 N2 35L4-001-AA4 (WHT 20ga ) 2
CONNECTOR
J362
SENSOR PAYLOAD PRESSURE RIGHT FRONT MC712
1 14 14 MC295 MC295
1 39F-007-AR1 (BLK 16ga ) 39F-001-AA1 (BLK 16ga )
TB27
2
MC603 MC603 0-389-AA4 (BLK 18ga )
2 39FC-003-AR1 (WHT 16ga ) 15 15 39FC-001-AA1 (WHT 16ga ) X1 X3 39FC-000-AA4 (BLK 18ga ) 2 RF PRESSURE
SP293
CAN/THIRD PARTY-SHLD 22
58E-06-10051 P150 13 13 Y1 Y3 1 LF PRESSURE
SHIELD-877 SHIELD-661 39FD-000-AA4 (WHT 18ga ) SHIELD-054
SHIELD-259 MC101 MC101
SHIELD-661
SHIELD-1001-AA1 (BLK 18ga ) Z1 Z3 SHIELD-1002-AA4 (BLK 18ga ) 39F-000-AA4 (RED 18ga ) 40 +18V CAN/THIRD PARTY-HI 12 939YK-001-AA4 (YEL 20ga ) SH14:H-3 TO THIRD PARTY
SP898 SHIELD-669
CAN/THIRD PARTY-LO 13 939GK-001-AA4 (GRN 20ga ) SH14:H-3 NETWORK
SHIELD-660
SP899 CONNECTOR
SENSOR PAYLOAD PRESSURE LEFT FRONT GB21 PLM GND
MC713 MC294 MC294 MC711 MC711
1 17 17
A3
CAN/RPC-HI 5 TO RPC
1 39F-008-AR1 (BLK 16ga ) 39F-002-AA1 (BLK 16ga ) SHIELD-663 SHIELD-669 939YP-007-AA4 (YEL 20ga ) SH14:B-3
CAN/RPC-LO 11 939GP-007-AA4 (GRN 20ga ) SH14:C-3
NETWORK
2
2 16 16 TB27 CAN/RPC-GND 14 CONNECTOR
39FD-003-AR1 (WHT 16ga ) 39FD-001-AA1 (WHT 16ga ) SHIELD-860
S1 S3
58E-06-10051 P151 18 18
SHIELD-878 SHIELD-660
S2
SHIELD-1000 MC714
T2
P13 J13 39F-006-AA1 (RED 18ga ) 58E-06-40220 PLM4 COMMUNICATION BOX
MC114 MC114
39F-009-AA1 (GRN 18ga ) T1 USB_PS_2 26 5VUSB-000-AA4 (BLU 24ga ) 1 USB_PS_2
SHIELD-821 9 9 SHIELD-950 USB_PS_1 36 2 USB_PS_1
SENSOR PAYLOAD PRESSURE LEFT REAR SHIELD-950 USBV-000-AA4 (BRN 24ga )
MC2483 MC2483 MC743 USB_PORT2--DM 29 USBDMH-000-AA4 (GRN 24ga ) 3 USB_PORT2--DM
1 1 39F-005-DD1 (BLK 16ga ) 7 7 39F-003-AH2 (BLK 16ga ) USB_PORT2--DP 39 USBDPH-000-AA4 (W-GR 24ga ) 4 USB_PORT2--DP
USB_PORT1--DM 27 USBDMD-000-AA4 (ORG 24ga ) 5 USB_PORT1--DM
2
2 8 8 GB21 PLM GND USB_PORT1--DP 28 6 USB_PORT1--DP
39FB-005-DD1 (WHT 16ga ) A2 USBDPD-000-AA4 (W-OR 24ga )
58E-06-10051 P152 SHIELD-951 SHIELD-1000 SHIELD-663 COMMA
SHIELD-979-AH2 (BLK 18ga ) 40 40
J72 P72 SP354
38 38 HEARTBEAT 8 72HC-000-AA4 (ORG 20ga ) 1 HEARTBEAT
TB27 MC297 HAUL CYCLE 10 2 HAUL CYCLE
MC297 74HB-000-AA4 (PNK 20ga )
39FB-003-AH2 (WHT 16ga ) 37 37 U1 U3 39FB-000-AA4 (BLK 18ga ) 3 LR PRESSURE ETHERNET LINK 9 74LA-000-AA4 (LTG 20ga ) 3 ETHERNET LINK
39FB-001-AA1 (BLK 18ga )
SENSOR PAYLOAD PRESSURE RIGHT REAR MC113 MC113 MC099 MC099
MC744 ETHERNET TX1 20 ENTX1-000-AA4 (W-OR 24ga ) 4 ETHERNET TX1 TX(+) 1 95ET1-000-AA15 (W-OR 24ga ) SH11:K-21
1 1 39F-004-AH2 (BLK 16ga ) 8 8 ETHERNET TX2 19 ENTX2-000-AA4 (ORG 24ga ) 5 ETHERNET TX2 RX(+) 2 95ET2-000-AA15 (ORG 24ga ) SH11:K-21
TB27 ETHERNET RX2 17 8 ETHERNET RX2 TX(-) 3
ENRX2-000-AA4 (GRN 24ga ) 95ER1-000-AA15 (W-GR 24ga ) SH11:K-21
2
2 39FA-004-AH2 (WHT 16ga ) 39 39 39FA-002-AA1 (WHT 18ga ) V1 V3 39FA-000-AA4 (WHT 18ga ) 4 RR PRESSURE ETHERNET RX1 18 ENRX1-000-AA4 (W-GR 24ga ) 9 ETHERNET RX1 RX(-) 6 95ER2-000-AA15 (GRN 24ga ) SH11:K-21
MC714
58E-06-10051 P153 5V 7 5VPL-000-AA4 (RED 20ga ) 6 5V PLM4_ENET
P16 J16
GND 30 0-313-AA4 (BLK 20ga ) 7 GND
P264 COMMB
P264
58B-06-05901-00 SEP 21
ELECTRICAL SCHEMATIC
980E-5
A50052, A50053, A50137, A50138
Sheet 13 of 21
PLM4 RPC TEE IM RPC TEE DRIVE SYSTEM RPC TEE KOMVISION RPC TEE
T1 P20T1B1 T2 P20T2B1 T3 T4 TR2
MC203 MC203 P20T2B2 P20T3B2 P20T3B1 P20T4B2 MC709 TR2
A A1 MC704 MC704 MC210 MC210 MC706 MC706 MC707 MC707 MC709 SP323 MC737 MC737
A2 A A A1 A2 A A A1 A2 A 20 20 20 20 A A1 A2 A
939YP-013-CC3 (YEL 20ga ) A A
TERM#1 939YP-012-AA9 (YEL 20ga ) 939YP-000-AA5 (YEL 20ga ) 939YP-017-AA31 (YEL 20ga ) 939YP-002-AC3 (YEL 20ga ) 939YP-003-CC3 (YEL 20ga ) 939YP-005-CC3 (YEL 20ga )
SP324
B B1 B2 B B B1 B2 B B B1 B2 B 21 21 21 21 B B1 B2 B
939GP-009-CC3 (GRN 20ga ) B B PC0618
939GP-012-AA9 (GRN 20ga ) 939GP-000-AA5 (GRN 20ga ) 939GP-017-AA31 (GRN 20ga ) 939GP-002-AC3 (GRN 20ga ) 939GP-003-CC3 (GRN 20ga ) 939GP-005-CC3 (GRN 20ga ) SP325
PC0618 C C1 C2 C C C1 C2 C C C1 C2 C 22 22 22 22 C C1 C2 C C C
SHIELD-959 SHIELD-959 SHIELD-835 SHIELD-835 SHIELD-278 SHIELD-278 SHIELD-842 SHIELD-842 SHIELD-843 SHIELD-843 SHIELD-845 SHIELD-845 SHIELD-042 SHIELD-042
MC711 MC711 MC703 MC703 MC750 P20T4B1 MC753 7
SEE NOTE #1 A3 A A3 A A3 A A3 A
939YP-007-AA4 (YEL 20ga ) SH13:M-13 939YP-008-AA1 (YEL 20ga ) SH12:G-9 J83 P83 P03 J03
FOR AHT OPT B3 B B3 B B3 B B3 B
939GP-007-AA4 (GRN 20ga ) SH13:M-13 939GP-008-AA1 (GRN 20ga ) SH12:G-9 MC695
C3 C C3 C C3 C C3 C
SHIELD-860 SHIELD-834 SHIELD-965 MC750 SHIELD-820 939YP-010-CC3 (YEL 20ga ) SH11:B-14
939YP-016-AA11 (YEL 20ga ) A SH11:B-14 TO KOMTRAX PLUS
P20T1D P20T2D P20T3D GE CAN RPC P20T4D
939GP-010-CC3 (GRN 20ga )
PC0616 PC0616 PC0616 939GP-016-AA11 (GRN 20ga ) B
CONNECTION PC0616
SHIELD-816
C
SHIELD-965
NOTE: GE_RPC
1) OPTIONAL AHT CONNECTION TO CAN RPC REMOVES TERM
#1 RESISTOR FROM RPC CAN TEE #1 AND AHT CONNECTOR
P20T3B2 CONNECTS TO RPC CAN TEE #1
MC753
939YP-011-CC12 (YEL 20ga ) SH17:G-5
939GP-011-CC12 (GRN 20ga ) SH17:G-5
CAN RPC NETWORK CAN RPC NETWORK
(YELLOW) OPERATOR CAB CAN RPC (YELLOW)
KOMVISION J1939 TEE
PTX EDP J1939 TEE
T17 P30T17B2 T5 P30T5B2 P30T8B1 T8 TERM #8
MC212 MC691 MC692 MC692 MC111 MC734 MC734 MC995 MC995 P30T5B1
24 24
MC691
24 24 A A1 A2 A MC109 MC109 SP327 MC111 SP330 SP333 SP336 MC997 MC997
A A1 A2 A MC3198 MC3198
A A2 A1 A
939YE-021-AA31 (YEL 20ga ) 939YE-004-AC3 (YEL 20ga ) 939YE-005-CC3 (YEL 20ga ) 939YE-009-CC3 (YEL 20ga ) 939YE-015-CC3 (YEL 20ga ) 939YE-002-CC3 (YEL 20ga ) 939YE-017-CC3 (YEL 20ga ) 939YE-019-CC3 (YEL 20ga ) 939YE-013-CC1 (YEL 20ga )
25 25 25 25 B B1 B2 B SP328 SP331 SP334 SP337 B B1 B2 B B B2 B1 B PC0618
939GE-021-AA31 (GRN 20ga ) 939GE-004-AC3 (GRN 20ga ) 939GE-005-CC3 (GRN 20ga ) 939GE-009-CC3 (GRN 20ga ) 939GE-015-CC3 (GRN 20ga ) 939GE-002-CC3 (GRN 20ga ) 939GE-017-CC3 (GRN 20ga ) 939GE-019-CC3 (GRN 20ga ) 939GE-013-CC1 (GRN 20ga )
26 26 26 26 C C1 C2 C SP329 SP332 SP335 SP338 C C1 C2 C C C2 C1 C
SHIELD-280 SHIELD-802 SHIELD-802 SHIELD-805 SHIELD-805 SHIELD-242 SHIELD-242 SHIELD-262 SHIELD-262 SHIELD-043 SHIELD-043 SHIELD-272 SHIELD-272 SHIELD-274 SHIELD-274 SHIELD3198 SHIELD3198
P30T17B1 MC752 SHIELD-273
A3 A A3 A MC3199 A A3
J83 P83 939YE-018-CC3 (YEL 20ga )
B3 B B3 B PTX DROP B B3
P03 J03 SHIELD-264 939GE-018-CC3 (GRN 20ga )
C3 C
SHIELD-244 MC996 C3 C CONNECTOR C C3
SHIELD-819 MC112 MC112 SHIELD3199
939GE-016-CC3 (GRN 20ga ) SH11:G-18 MC110 MC110
PC0616 P30T17D 10 PC0616 P30T5D P30T8D PC0616
939GE-021-AA31 (GRN 20ga ) 939YE-016-CC3 (YEL 20ga ) SH11:G-18 939GE-014-CC3 (GRN 20ga )
939YE-021-AA31 (YEL 20ga ) SHIELD-817 C
TO KOMTRAX PLUS MC3199
TO ORBCOMM MODEM MC696 939YE-014-CC3 (YEL 20ga ) 3 D SH7:E-4 939YE-022-CC1 (YEL 20ga )
FROM ENGINE MC696
IM J1939 TEE DRIVE SYSTEM J1939 TEE 939GE-010-CC3 (GRN 20ga ) SH11:B-14 E SH7:E-4 939GE-022-CC1 (GRN 20ga )
CAN J1939 1 SHIELD-273 OP-CAB
T6 P30T6B2 P30T7B2 939YE-010-CC3 (YEL 20ga ) SH11:B-14 SH14:I-13 11TP-004-CC3 (YEL 18ga ) KOM-NET
T7 CONNECTOR ELECTRONIC
MC258 MC258 SP819 MC1104 MC1104 MC749 MC749 SERVICE
A A1 A2 A A A1 A2 A 9 DISPLAY PANEL
SH5:H-10 939YE-001-AA1 (YEL 20ga )
SP820 939YE-006-AA1 (YEL 20ga ) 939YE-011-AA10 (YEL 20ga ) 939YE-021-AA31 (YEL 20ga ) MC752 0-271-CC3 (BLK 18ga ) CONNECTOR ENGINE DATALINK
939GE-001-AA1 (GRN 20ga ) B B1 B2 B B B1 B2 B CONNECTOR
SH5:H-10 SP821
939GE-006-AA1 (GRN 20ga ) 939GE-011-AA10 (GRN 20ga ) 939GE-021-AA31 (GRN 20ga ) 939YE-020-CC12 (YEL 20ga ) SH17:G-5 TIER 4
C C1 C2 C C C1 C2 C MC212 2
SHIELD-132 SHIELD-132 SHIELD-962 SHIELD-962 939GE-020-CC12 (GRN 20ga ) SH17:G-5 SH14:I-13 712TP-004-CC3 (RED 18ga ) DIAGNOSTIC
SHIELD-270 B
MC705 MC751 MC751 KOMVISION SH10:N-10 11A-012-CC3 (TAN 18ga ) DIAG4
P30T6B1 A3 A P30T7B1 A3 A A 12 A
SHIELD-136
939YE-012-AA12 (YEL 20ga )
CONNECTION SH10:P-8 0-278-CC3 (BLK 18ga ) 0-272-CC3 (BLK 18ga ) 0-362-CC3 (BLK 18ga )
B3 B B3 B B GE CAN J1939 SP191
MC1105 MC705 939GE-012-AA12 (GRN 20ga )
939GE-007-AA1 (GRN 20ga ) C3 C C3 C C CONNECTION 6 H
SH5:H-16 SHIELD-836
939YE-008-AA1 (YEL 20ga ) SH12:G-9 SHIELD-966 SHIELD-966 SH11:F-16 7KTWU-001-CC3 (YEL 18ga )
939YE-007-AA1 (YEL 20ga ) SH5:H-16 939GE-008-AA1 (GRN 20ga ) SH12:H-9
MC1105 PC0616 P30T6D PC0616 P30T7D GE_1939 7
FAN CLUTCH CONTROLLER SH11:C-14 76-000-CC3 (LBL 18ga )
IM2 CONNECTION DIAG4_CP
CONNECTION
SH11:G-15 74SB1-014-CC3 (DBL 18ga ) 4
CAN J1939 NETWORK (RED) OPERATOR CAB CAN J1939 DIAG3_CP
OPERATOR CAB CAN J1939
THIRD PARTY
PLM4 THIRD PARTY TEE IM THIRD PARTY TEE DRIVE SYSTEM THIRD PARTY TEE MODULAR MINING THIRD PARTY TEE
T11 P40T11B2 P40T12B1 T12 P40T12B2 P40T13B2 T13 P40T13B1 T16 TERM#5
MC323 MC323 MC104 MC104 MC211 MC211 MC943 MC943 MC106 MC106 MC105 MC105 MC108 MC108
TERM#4 A A1 A2 A A A1 A2 A A A1 A2 A 28 28 28 28
SP397 SP339 A A1 A2 A
939YK-010-AA17 (YEL 20ga ) 939YK-000-AA14 (YEL 20ga ) 939YK-009-AA31 (YEL 20ga ) 939YK-002-AC3 (YEL 20ga ) 939YK-004-CC3 (YEL 20ga ) 939YK-005-CC3 (YEL 20ga ) 939YK-008-CC3 (YEL 20ga )
PC0618 B B1 B2 B B B1 B2 B B B1 B2 B 29 29 29 29 SP396 SP340 B B1 B2 B PC0618
939GK-010-AA17 (GRN 20ga ) 939GK-000-AA14 (GRN 20ga ) 939GK-009-AA31 (GRN 20ga ) 939GK-002-AC3 (GRN 20ga ) 939GK-004-CC3 (GRN 20ga ) 939GK-005-CC3 (GRN 20ga ) 939GK-008-CC3 (GRN 20ga )
C C1 C2 C C C1 C2 C C C1 C2 C 30 30 30 30 SP395 SP341 C C1 C2 C
SHIELD323 SHIELD323 SHIELD-249 SHIELD-249 SHIELD-279 SHIELD-279 SHIELD-084 SHIELD-084 SHIELD-247 SHIELD-247 SHIELD-248 SHIELD-248 SHIELD-241 SHIELD-241
MC103 MC103 MC100 MC100
A3 A MC101 A3 A MC322 A3 A SHIELD-250 P40T16B1 A3 A
939YK-001-AA4 (YEL 20ga ) SH13:L-14 939YK-011-AA1 (YEL 20ga ) SH12:G-9 939YK-003-AA13 (YEL 20ga ) A GE CAN THIRD 939YK-006-CC3 (YEL 20ga ) SH11:C-14
B3 B B3 B B3 B B B3 B
939GK-001-AA4 (GRN 20ga ) SH13:L-14 939GK-011-AA1 (GRN 20ga ) SH12:G-9 939GK-003-AA13 (GRN 20ga ) PARTY 939GK-006-CC3 (GRN 20ga ) SH11:C-14
C3 C C3 C MC322 C3 C C C3 C
SHIELD-259 MC101 CONNECTION
SHIELD-322 SHIELD-258 SHIELD-258
PC0616 P40T11D PC0616 P40T12D PC0616 P40T13D GE_TP PC0616 P40T16D
SHIELD-271
MC107 MC107
939GK-007-CC3 (GRN 20ga ) 10
11TP-004-CC3 (YEL 18ga ) SH14:F-15 939YK-007-CC3 (YEL 20ga ) 3
VEC-91 F29 TB32 11
11 BUSS 4H SHIELD-271 DATA PORT
H 11TP-000-AA1 (YEL 16ga ) P1 P2 11TP-006-AA31 (YEL 16ga ) 16 16 11TP-001-AC3 (YEL 16ga ) 16 16 11TP-002-CC3 (YEL 16ga ) 11TP-003-CC3 (YEL 18ga ) 1
10 7
SP249 SH11:C-14 13B-000-CC3 (YEL 18ga )
58E-06-20062
VEC-90 712TP-004-CC3 (RED 18ga ) SH14:F-15
F48 TB32 6
SP278 712TP-006-CC3 (RED 18ga )
71CK BUSS 4E
E 712TP-000-AA1 (RED 18ga ) R1 R2 712TP-008-AA31 (RED 18ga ) 31 31 712TP-001-AC3 (RED 18ga ) 31 31 712TP-002-CC3 (RED 18ga ) 712TP-003-CC3 (RED 18ga ) 712TP-007-CC3 (RED 18ga ) 2
5 9 GB12-B
SP3813
58E-06-20051 VEC-90 12
D1
J83 P83 0-362-CC3 (BLK 18ga )
P03 J03 DIAG2_CP
0-274-CC3 (BLK 18ga )
0-273-CC3 (BLK 18ga )
SH10:P-8 0-315-CC3 (BLK 18ga ) B MODULAR MINING
712TP-005-CC3 (RED 18ga ) C DISPLAY PWR IN
11TP-005-CC3 (YEL 18ga ) A CONNECTION
CAN J1939 THIRD PARTY NETWORK
PTX_CP
SH4:L-10 1
(BLACK)
12VREG-008-CC2 (LBL 16ga )
SH4:M-9 0-704-CC2 (BLK 16ga ) 2
MMWIFI_CP
SWITCH LEFT WINDOW
0-192-CC4 (BLK 18ga ) 7 9
GB12-A
B2
0-275-CC4 (BLK 12ga ) 0-191-CC4 (BLK 12ga ) 3
VEC-91 F56 TB24 2B 2 2
SP806 SP009 67L-001-CC4 (PNK 14ga ) 67L-002-CC9 (PNK 14ga ) MOTOR WINDOW LH
11 BUSS
712 BUS 9E E 67P-000-AA1 (YEL 12ga ) T1 T2 67P-004-AA32 (YEL 14ga ) 13 13 67P-001-AC4 (YEL 14ga ) 13 13 67P-012-CC4 (YEL 14ga ) 67P-005-CC4 (YEL 12ga ) 1
20 6 1
67P-006-CC4 (YEL 12ga ) MOTOR
T3 67P-003-AA32 (YEL 14ga ) 9 9 67P-002-AC4 (YEL 14ga ) 9 9 67P-010-CC4 (YEL 14ga ) 5B 67M-000-CC4 (GRY 14ga ) 1 1 67M-001-CC9 (GRY 14ga ) 2
0-195-CC4 (BLK 12ga ) 4
P059 58E-54-31700
P50 J50
8 10
P072 P072
58F-06-60861
67P-015-CC4 (YEL 18ga )
SWITCH RIGHT WINDOW
0-197-CC4 (BLK 18ga ) 7 9
GB12-A
C1
0-522-CC4 (BLK 12ga ) 0-198-CC4 (BLK 12ga ) 3
VEC-91 F62 TB24 2B 2 2
SP006 SP007 67T-001-CC4 (LBL 14ga ) 67T-002-CC10 (LBL 14ga )
712 BUS
11 BUSS 9G G 11 11 11 11 1 MOTOR WINDOW RH
67R-000-AA1 (PUR 12ga ) S1 S4 67R-001-AA32 (PUR 14ga ) 67R-011-AC4 (PUR 14ga ) 67R-013-CC4 (PUR 14ga ) 67R-005-CC4 (PUR 12ga )
20 6 1
58E-06-20062 67R-006-CC4 (PUR 12ga ) MOTOR
S3 67R-002-AA32 (PUR 14ga ) 12 12 67R-012-AC4 (PUR 14ga ) 12 12 67R-029-CC4 (PUR 14ga ) 5B 67S-000-CC4 (DBL 14ga ) 1 1 67S-001-CC10 (DBL 14ga ) 2
0-200-CC4 (BLK 12ga ) 4 P058 58E-54-31710
J84 P84 P04 J04
P51 J51
8 10
P071 P071
58F-06-60861
67R-016-CC4 (PUR 18ga )
OP-CAB WINDOW MOTOR
58B-06-05901-00 SEP 21
ELECTRICAL SCHEMATIC
980E-5
A50052, A50053, A50137, A50138
Sheet 14 of 21
7
ENGINE SHUTTERS / ETHER START OPTIONS
VEC-92 GB31-A AUXBOX GND BLCK
VEC-92
E 1E 86 85 1C C B1
SH5:K-10 65T-000-AA1 (DBL 16ga ) 0-079-AA1 (BLK 18ga )
58E-06-09621
87 SOLENOID ENGINE SHUTTER (OPT)
SH6:N-10 0-281-AA1 (BLK 18ga )
SH5:D-19 65SR-000-AA1 (ORG 16ga ) D 1D 30
87a 1F F 58 58 1 1 2 1
65SS-000-AA1 (LBL 16ga ) 65SS-001-AH1 (LBL 16ga ) 65SS-003-HL2 (LBL 16ga ) 65SS-004-HL2 (LBL 16ga ) 0-480-HL2 (BLK 16ga )
SH4:I-8 0-075-AA1 (BLK 16ga ) 59 59 0-076-AH1 (BLK 16ga ) 2 2 SP3825
RELAY 2
PC0436
SHUTTER CONTROL P520_CP J520 ESSOL ESSOL
D14
J11 P11
65SS-005-HL2 (LBL 16ga ) 1 2 0-481-HL2 (BLK 16ga )
SP3824
0-078-HL2 (BLK 16ga )
SOLENOID ETHER START (OPT)
SP3826
SH5:D-19 28E-000-AA1 (DBL 16ga ) 51 51 28E-001-AJ1 (DBL 16ga ) 15 15 28E-002-JL1 (DBL 16ga ) 1 1 28E-003-JL2 (DBL 16ga ) 28E-004-JL2 (DBL 16ga ) 2 1 0-431-JL2 (BLK 16ga )
SH4:H-4 0-080-AA1 (BLK 16ga ) 52 52 0-081-AJ1 (BLK 16ga ) 16 16 0-082-JL1 (BLK 16ga ) 2 2
PC0436
ETHER_CP ETHER ESOL ESOL
D13
J12 P12 J542 P542
28E-005-JL2 (DBL 16ga ) 1 2 0-430-JL2 (BLK 16ga )
SP3827
0-429-JL2 (BLK 16ga )
HOT START OPTION 87-501-HH7 (BLK 14ga )
HEATER COOLANT LH
46GA-005-AA1 (LBL 14ga ) 61 61 46GA-006-AH1 (LBL 14ga ) P P 46GA-008-FF1 (LBL 14ga ) 1
0-501-HH7 (DGR 14ga )
86-501-HH7 (BLK 14ga ) AHT CONNECTIONS OPTION 46YA-005-AA1 (TAN 14ga )
46RA-005-AA1 (LTG 14ga )
62 62
63 63
46YA-006-AH1 (TAN 14ga )
46RA-006-AH1 (LTG 14ga )
Q
R
Q
R
46YA-008-FF1 (TAN 14ga )
46RA-008-FF1 (LTG 14ga )
2
3
AHT RIGHT DECK
MODE LAMPS
64 64 S S 4
XB7268
0-438-AA1 (BLK 14ga ) 0-439-AH1 (BLK 14ga ) 0-441-FF1 (BLK 14ga ) CONNECTOR (OPT)
HEATER COOLANT RH THERMOSTAT OIL RESERVE TANK RDML_CP
TB-HTST 87-502-JJ8 (BLK 14ga ) 90-510-JJ8 (BLK 14ga ) A A
PB4110 J11 P11 P502 J502
0-502-JJ8 (DGR 14ga ) 86-511-JJ8 (BLK 14ga ) B B
C1 86-502-JJ8 (BLK 14ga ) C C
46GA-004-AA1 (LBL 14ga ) 15 15 46GA-010-AG2 (LBL 14ga ) 15 15 46GA-012-GG1 (LBL 14ga ) 1 AHT LEFT DECK
XB7269 ECHTR1 EG1968 16 16 16 16 2
C2
GB31-A AUXBOX GND BLCK
46YA-004-AA1 (TAN 14ga ) 46YA-010-AG2 (TAN 14ga ) 46YA-012-GG1 (TAN 14ga ) MODE LAMPS
17 17 17 17 3
D4
HEATER OIL RESERVE TANK B3 46RA-004-AA1 (LTG 14ga ) 46RA-010-AG2 (LTG 14ga ) 46RA-012-GG1 (LTG 14ga ) CONNECTOR (OPT)
D2 0-434-AA1 (BLK 14ga ) 18 18 0-437-AG2 (BLK 14ga ) 18 18 0-782-GG1 (BLK 14ga ) 4
87-510-JJ7 (PNK 14ga ) A A 87-511-JJ8 (BLK 14ga ) A A
E1 B B B B LDML_CP
86-510-JJ7 (TAN 14ga ) 90-510-JJ8 (BLK 14ga )
0-514-JJ7 (BLK 14ga ) C C 0-515-JJ8 (BLK 14ga ) C C
J80 P80 P503 J503
E2
CON3 CON4 ECHTR2 EG1966 TB32
SERIES
46GA-005-AA1 (LBL 14ga ) A1 A2 0-432-AA1 (BLK 14ga )
JUNCTION
BLOCK THERMOSTAT ENGINE OIL A3 A4 46GA-002-AA1 (LBL 14ga )
87-503-EJ3 (BLK 14ga ) A A
90-500-EJ3 (BLK 14ga ) B B 46RA-005-AA1 (LTG 14ga ) B1 B2
0-505-EJ3 (BLK 14ga ) 0-504-EJ3 (BLK 14ga ) C C
SP259 B3 B4 46RA-002-AA1 (LTG 14ga )
POWER RECEPTACLE ON EOTS HEATER ENGINE OIL LH 27 27 3 3 4 AHT REAR AXLE
0-433-AH2 (BLK 14ga ) 0-442-DD1 (BLK 14ga )
FRONT LH BUMPER A A 12 12 34 34 4 4 1 MODE LAMPS
TB-HTST 86-504-EJ3 (BLK 14ga ) 46GA-000-AA1 (LBL 14ga ) 46YA-005-AA1 (TAN 14ga ) C1 C2 46GA-001-AH2 (LBL 14ga ) 46GA-011-DD1 (LBL 14ga )
PB4110 B B 13 13 35 35 46RA-001-AH2 (LTG 14ga ) 5 5 46RA-011-DD1 (LTG 14ga ) 2 CONNECTOR
SUPPLY POWER 90-501-EJ3 (BLK 14ga ) 46RA-000-AA1 (LTG 14ga )
G1 PARALLEL 0-507-EJ3 (BLK 14ga ) C C 14 14 46YA-000-AA1 (TAN 14ga ) C3 C4 46YA-002-AA1 (TAN 14ga ) 36 36 46YA-001-AH2 (TAN 14ga ) 6 6 46YA-011-DD1 (TAN 14ga ) 3 (OPT)
SINGLE PHASE 240 VAC
JUNCTION
FULL LOAD AMPS: 35 EOH1 PC0292 RBML2_CP
G2 BLOCK
MC723 HEATER ENGINE OIL RH
MC723 F4
J16 P16 P72 J72
4 0-500-JJ6 (BLK 8ga ) G3 86-503-EJ3 (BLK 14ga ) 86-505-EJ3 (BLK 14ga ) A A
2 86-500-JJ6 (GRN 8ga ) SP256 B B
90-500-EJ3 (BLK 14ga ) 90-502-EJ3 (BLK 14ga )
3 H1
SP257 C C 4 4 SHIELD-918
0-506-EJ3 (BLK 14ga ) 0-508-EJ3 (BLK 14ga ) MC728 MC726
1 87-500-JJ6 (WHT 8ga ) SP258 AHT 5 5 8 8 MC726 1 1
33PG-000-AA1 (BLK 18ga ) 33PG-004-AD1 (BLK 18ga )
H2
EOH2 PC0292 AUXBOX CONNECTOR 6 6 9 9 2 2
33PP-000-AA1 (RED 18ga ) 33PP-002-AD1 (RED 18ga )
J713 (OPT) 7 7 10 10 3 3
33PRR-000-AA1 (WHT 18ga ) 33PRR-001-AD1 (WHT 18ga )
THERMOSTAT HYDRAULIC OIL MC728 11 11 4 4
SHIELD-918 SHIELD-914 SHIELD-914
TB-HTST 90-503-JJ3 (BLK 14ga ) A A AHT REAR BRAKE
PB4110 B B
87-507-JJ3 (BLK 14ga ) PRESSURE SENSOR
C C
J1
CONNECTOR (OPT)
EG1968 MC727 MC727 MC725 MC725
J2 8 8 33PG-001-AA1 (BLK 18ga ) 20 20 33PG-003-AD1 (BLK 18ga ) 9 9
K4 9 9 33PP-001-AA1 (RED 18ga ) 21 21 33PP-003-AD1 (RED 18ga ) 10 10
J3
HEATER HYDRAULIC OIL #1 10 10 22 22 11 11
SP260 33PLR-000-AA1 (WHT 18ga ) 33PLR-001-AD1 (WHT 18ga )
86-506-JJ7 (PNK 14ga ) A A 86-507-JJ3 (BLK 14ga ) 86-508-JJ3 (BLK 14ga ) A A 11 11 23 23 12 12
SP261 SHIELD-917 SHIELD-917 SHIELD-913 SHIELD-913
K1 87-506-JJ7 (TAN 14ga ) B B 87-507-JJ3 (BLK 14ga ) 90-506-JJ3 (BLK 14ga ) B B
C C
SP253 C C
0-509-JJ7 (BLK 14ga ) 0-510-JJ3 (BLK 14ga ) 0-511-JJ3 (BLK 14ga ) J15 P15 P74_CP J74
K2
CON1 CON2 HOHTR1 EG1966
HEATER HYDRAULIC OIL #2 58E-06-15000
A A JUMPER PLUG
86-509-JJ3 (BLK 14ga ) AHT
90-507-JJ3 (BLK 14ga ) B B 18 18 39-001-AA1 (TAN 16ga ) 11 11 39-002-AJ2 (TAN 16ga ) 2 2
C C 1 1
STEERING FILTER SWITCH
0-512-JJ3 (BLK 14ga ) J27-000-JJ20 (BLK 18ga ) (OPT)
17 17 39AP-003-AA1 (YEL 16ga ) 8 8
HOHTR2 EG1966 SFSW_JP
P702 J702_JP J14 P14
39L-000-AJ2 (YEL 16ga )
SWITCH BRAKE FILTER PRESSURE
39AP-004-AJ2 (YEL 16ga ) 1 2
BFSW BFSW
58B-06-50900 AHT REAR BRAKE
PRESSURE SENSOR
CONNECTOR (OPT)
58B-06-05901-00 SEP 21
ELECTRICAL SCHEMATIC
980E-5
A50052, A50053, A50137, A50138
Sheet 15 of 21
KOMVISION DISPLAY
VLED X2+ X1- GND
GND 1-NC 2-NC 2 2
8X002 8X002-000-CC6 (LTG 20ga ) SH17:F-11
3-NO 4-NO
FRONT
VLED X2+ X1- GND
GND 1-NC 2-NC 3 3
8X003 8X003-000-CC6 (PUR 20ga ) SH17:F-11
3-NO 4-NO
RH FRONT
VLED X2+ X1- GND
GND 1-NC 2-NC 4 4
8X004 8X004-000-CC6 (YEL 20ga ) SH17:E-11
3-NO 4-NO
RH REAR
VLED X2+ X1- GND
GND 1-NC 2-NC 5 5
8X005 8X005-000-CC6 (BLK 20ga ) SH17:E-11
3-NO 4-NO
REAR
VLED X2+ X 1 - GND
GND 1-NC 2-NC 6 6
8X006 8X006-000-CC6 (LBL 20ga ) SH17:F-11
3-NO 4-NO
U1 LH REAR
NCV317BD2TR4G
VLED
SH17:E-11 49-011-CC6 (TAN 20ga ) 13 13 VIN Vin Vout VLED X2+ X1- GND
8X013
ADJ
C2 GND 7 7
R1 1-NC 2-NC
C1 1uF 8X007 8X007-000-CC6 (GRY 20ga ) SH17:F-11
243
1uF 100V
1/4w 3-NO 4-NO
100V
5mA LH FRONT
MOV1
ERZ-V10D390 R5 R5 R5 R5 VLED X2+ X1- GND
20k 20k 20k 20k
R6 1/4w 1/4w 1/4w 1/4w
GND 1-NC 2-NC 8 8
4.12K 8X008 8X008-000-CC6 (TAN 20ga ) SH17:E-11
1/4W 8 7 6 5 S1
3-NO 4-NO
76SB04T MODE
1 2 3 4
VLED X2+ X1- GND
SH17:E-11 0-590-CC6 (BLK 20ga ) 1 1 GND GND 1-NC 2-NC 9 9
8X009-000-CC6 (WHT 20ga ) SH17:E-11
0 8X009
3-NO 4-NO
P1
GRIDLINE
VLED X2+ X1- GND
GND 1-NC 2-NC 10 10
8X010 8X010-000-CC6 (DBL 20ga ) SH17:E-11
3-NO 4-NO
BODY
VLED X2+ X1- GND
GND 1-NC 2-NC 11 11
8X011 8X011-000-CC6 (ORG 20ga ) SH17:E-11
3-NO 4-NO
CANCEL
VLED X2+ X1- GND
GND 1-NC 2-NC 12 12
8X012 8X012-000-CC6 (BRN 20ga ) SH17:F-11
3-NO 4-NO
LOCK
VLED X2+ X1- GND
GND 1-NC 2-NC
3-NO 4-NO 14 14
8X016 8X016-000-CC6 (YEL 20ga ) SH17:F-11
BRIGHT
VLED X2+ X1- GND
GND 1-NC 2-NC
3-NO 4-NO 15 15
8X017 8X017-000-CC6 (DBL 20ga ) SH17:F-11
DIM
VLED X2+ X1-
GND
CHASSIS
X1- X2+ 16 16
GND 8X045 8X045-002-CC6 (PUR 20ga ) SH17:F-11
POWER
GND P1
58E-54-27300
TERMX1 TX0
P21TX0B2 MC823 MC823 MC821 MC821 MC813 MC813 SP049 MC815 MC815 SP056 MC817 MC817
A A1 A2 A 9 9
SP046
939YX1-010-CC12 (YEL 20ga ) 939YX1-009-CR1 (YEL 20ga ) 939YX1-002-CR1 (YEL 20ga ) 939YX1-003-CR1 (YEL 20ga )
SP057 939YX1-005-CR1 (YEL 20ga ) SH17:C-20
PC0618 B B1 B2 B 10 10 SP050
939GX1-010-CC12 (GRN 20ga ) 939GX1-009-CR1 (GRN 20ga ) 939GX1-002-CR1 (GRN 20ga ) 939GX1-003-CR1 (GRN 20ga ) 939GX1-005-CR1 (GRN 20ga ) SH17:C-20
C C1 C2 C 11 11 SP047
SHIELD-024 SHIELD-024 SHIELD-023 SP048 SP055 SP058
A3 A SHIELD-023 SHIELD-030 SHIELD-030 SHIELD-028 SHIELD-028 HIELD-026
SHIELD-029S
SHIELD-025
SHIELD-027
B3 B
C3 C J01X_CP P01X
SHIELD-039
PC0616 P21TX0D
MC818 MC816 MC814
MC803 MC818 MC816 MC814
939YX1-000-CC12 (YEL 20ga ) SH17:K-4 939GX1-008-CR1 (GRN 20ga ) SH17:E-19 939GX1-007-CR1 (GRN 20ga ) SH17:E-19 939GX1-006-CR1 (GRN 20ga ) SH17:D-19
939GX1-000-CC12 (GRN 20ga ) SH17:K-4 939YX1-008-CR1 (YEL 20ga ) SH17:E-19 939YX1-007-CR1 (YEL 20ga ) SH17:D-19 939YX1-006-CR1 (YEL 20ga ) SH17:D-19
OPERATOR CAB
AUTOLIV NETWORK (BLUE)
TERMX3 TX9 P22TX9B2
MC824 MC824 MC822 MC822 MC806 MC806 MC807 MC807 MC852 MC852 MC809 MC809
A A1 A2 A 9 9
SP059 SP066 5 5 SP069
939YX2-010-CC12 (YEL 20ga ) 939YX2-009-CD2 (YEL 20ga ) 939YX2-002-CD2 (YEL 20ga ) 939YX2-003-CD2 (YEL 20ga ) 939YX2-001-DD6 (YEL 20ga ) 939YX2-005-DD6 (YEL 20ga ) SH17:G-19
PC0618 B B1 B2 B 10 10 SP060 SP067 6 6 SP070
939GX2-010-CC12 (GRN 20ga ) 939GX2-009-CD2 (GRN 20ga ) 939GX2-002-CD2 (GRN 20ga ) 939GX2-003-CD2 (GRN 20ga ) 939GX2-001-DD6 (GRN 20ga ) 939GX2-005-DD6 (GRN 20ga ) SH17:G-19
C C1 C2 C 11 11 7 7
SHIELD-035 SHIELD-035 SHIELD-022 SP065 SP068 SHIELD-036 SHIELD-000
A3 A SHIELD-022 SHIELD-037 SHIELD-037 SHIELD-036 SHIELD-000 SHIELD-034
SP075
SHIELD-031
SHIELD-032
SHIELD-033
B3 B P16X J16X
C3 C J09X_CP P09X
SHIELD-038
PC0616 P22TX9D
MC812 MC811 MC810
MC804 MC812 MC811 MC810
939YX2-000-CC12 (YEL 20ga ) SH17:K-4 939GX2-008-CD2 (GRN 20ga ) SH17:I-19 939GX2-007-CD2 (GRN 20ga ) SH17:H-19 939GX2-006-DD6 (GRN 20ga ) SH17:H-19
939GX2-000-CC12 (GRN 20ga ) SH17:K-4 939YX2-008-CD2 (YEL 20ga ) SH17:I-19 939YX2-007-CD2 (YEL 20ga ) SH17:H-19 939YX2-006-DD6 (YEL 20ga ) SH17:H-19
OPERATOR CAB
AUTOLIV NETWORK (GREEN)
58B-06-05901-00 SEP 21
ELECTRICAL SCHEMATIC
980E-5
A50052, A50053, A50137, A50138
Sheet 16 of 21
7
SH17:G-10 8X013-028-CC12 (RED 20ga ) OPERATOR CAB RADAR 1 KOMVISION
SH17:I-10 8X013-029-CC12 (RED 20ga ) MC817 MC817
SH16:J-14 939YX1-005-CR1 (YEL 20ga ) 2 2
3 3 SHORT RANGE RADAR
SH16:K-14 939GX1-005-CR1 (GRN 20ga )
4 4 LOCATED ON BUMPER
SH17:K-10 8X013-030-CC12 (RED 14ga ) 12VR-003-CR1 (RED 16ga )
1 1 FRONT FORWARD LH
0-565-CR1 (BLK 20ga )
5 5 (AIMING FRONT RH)
8X013-011-CC12 (RED 20ga ) 0-566-CR1 (BLK 20ga )
JB9X 6 6
8X013-026-CC12 (RED 20ga ) 0-567-CR1 (BLK 20ga )
SH17:J-12 0-716-CC2 (BLK 14ga ) 7 7 0-534-CC12 (BLK 14ga ) 1 12VR-020-CC12 (RED 16ga ) 1 1 SP3806
8
7
6
5
4
3
2
1
2 2 2 J119
12VR-000-CC12 (RED 16ga ) 12VR-021-CR1 (RED 16ga )
8X013-020-CC12 (RED 18ga ) 2 3 3 3 RADAR 2 KOMVISION
12VR-001-CC12 (RED 16ga ) 12VR-022-CR1 (RED 16ga ) MC814 MC814
SH17:K-8 11CAM-007-CC12 (YEL 18ga ) 1 4 12VR-002-CC12 (RED 16ga ) 4 4 SH16:K-14 939YX1-006-CR1 (YEL 20ga ) 2 2
PX07_CP JX07 JB8C
SH17:J-3 8X001-000-CC12 (ORG 18ga ) 6 5 12VR-004-CC12 (RED 16ga ) SH16:K-14 939GX1-006-CR1 (GRN 20ga ) 3 3
JB10X SHORT RANGE RADAR
6 12VR-021-CR1 (RED 16ga ) 4 4
56B-06-11530 12VR-005-CC12 (RED 16ga ) LOCATED ON BUMPER
SH17:J-6 74SB1-009-CC12 (DBL 18ga ) 4 7 12VR-006-CC12 (RED 16ga ) 1 0-637-CC12 (BLK 16ga ) 5 5 0-035-CR1 (BLK 16ga ) 0-568-CR1 (BLK 16ga ) 1 1
FRONT FORWARD RH
8 12VR-009-CC12 (RED 16ga ) 2 0-036-CC12 (BLK 16ga ) 6 6 0-589-CR1 (BLK 16ga ) 0-569-CR1 (BLK 16ga ) 5 5
KOMVISION CONTROLLER SP3807 (AIMING FRONT LH)
9 12VR-017-CC12 (RED 14ga ) SH17:J-11 3 0-037-CC12 (BLK 16ga ) 7 7
0-616-CR1 (BLK 16ga ) 6 6
SH17:I-5 0-536-CC12 (BLK 20ga ) 0-539-CC12 (BLK 18ga ) 9 10 4 0-038-CC12 (BLK 16ga ) 8 8
KEY SLG-1 4 12 11 5 J122
SH17:I-5 0-537-CC12 (BLK 20ga ) 0-540-CC12 (BLK 18ga ) 0-039-CC12 (BLK 16ga )
KEY SLG-2 5 12 6 RADAR 3 KOMVISION
SH17:I-10 0-538-CC12 (BLK 20ga ) 0-560-CC12 (BLK 16ga ) J01X_CP P01X MC816 MC816
GND PWR-1 6 J251X_CP 7 2 2
0-529-CC12 (BLK 20ga ) 0-044-CC12 (BLK 16ga ) SH16:K-12 939YX1-007-CR1 (YEL 20ga )
GND PWR-2 7 58E-06-02630 8 3 3 LONG RANGE RADAR
0-530-CC12 (BLK 20ga ) 0-045-CC12 (BLK 16ga ) SH16:K-12 939GX1-007-CR1 (GRN 20ga )
GND PWR-3 16 0-531-CC12 (BLK 20ga ) 9 4 4 LOCATED ON BUMPER
GND PWR-4 17 0-532-CC12 (BLK 20ga ) 0-533-CC12 (BLK 20ga ) 10 0-571-CR1 (BLK 16ga ) 1 1 FRONT RIGHT CORNER
6 6 11 GB12-A 5 5
SH7:K-7 49-009-CC2 (TAN 20ga ) P0178X J0178X SP3808
12
11
10
9
8
7
6
5
4
3
2
1
D3
JB12A 12 0-714-CC12 (BLK 14ga ) 0-573-CR1 (BLK 16ga ) 6 6
KVIS-B
58E-06-02630 PX07_CP JX07 49-010-CC12 (TAN 20ga ) 13 13 49-011-CC6 (TAN 20ga ) SH16:D-1
58E-06-02640 J123
1 1 0-590-CC6 (BLK 20ga ) SH16:E-1
SWITCH CANCEL 36 RADAR 4 KOMVISION
8X011-001-CC12 (ORG 20ga ) 11 11 8X011-000-CC6 (ORG 20ga ) SH16:F-7 MC818 MC818
SWITCH BODY 37 8X010-001-CC12 (DBL 20ga ) 10 10 8X010-000-CC6 (DBL 20ga ) SH16:F-7 SH16:K-9 939YX1-008-CR1 (YEL 20ga ) 2 2
SWITCH LINE 38 8X009-001-CC12 (WHT 20ga ) 9 9 8X009-000-CC6 (WHT 20ga ) SH16:E-7 SH16:K-9 939GX1-008-CR1 (GRN 20ga ) 3 3 SHORT RANGE RADAR
SWITCH MODE 39 8X008-001-CC12 (TAN 20ga ) 8 8 8X008-000-CC6 (TAN 20ga ) SH16:E-7 12VR-019-CR1 (RED 16ga ) 4 4 LOCATED ON RIGHT
SWITCH REAR 47 8X005-001-CC12 (BLK 20ga ) 5 5 8X005-000-CC6 (BLK 20ga ) SH16:C-7 0-636-CR1 (BLK 16ga ) 1 1 UPRIGHT REAR
SWITCH RH REAR 48 8X004-001-CC12 (YEL 20ga ) 4 4 8X004-000-CC6 (YEL 20ga ) SH16:C-7 5 5
SWITCH RH FRONT 49 8X003-001-CC12 (PUR 20ga ) 3 3 8X003-000-CC6 (PUR 20ga ) SH16:B-7 6 6
J124
KVIS-A 18 18 8X045-002-CC6 (PUR 20ga ) SH16:I-7
12 12 8X012-000-CC6 (BRN 20ga ) SH16:G-7
INDICATOR POWER 48 8X045-003-CC12 (PUR 20ga ) 2 2 8X002-000-CC6 (LTG 20ga ) SH16:A-7 MC99 MC99
7 7 8X007-000-CC6 (GRY 20ga ) SH16:D-7 2 939YX1-RR72 (YEL 20ga ) 2
6 6 8X006-000-CC6 (LBL 20ga ) SH16:D-7 3 939GX1-RR72 (GRN 20ga ) 3
KVIS-B
17 17 8X017-000-CC6 (DBL 20ga ) SH16:H-7 1 1 12VR-010-CD2 (RED 16ga ) 1 1 12VR-007-DD6 (RED 16ga ) 4 12VR-RR72 (RED 16ga ) 4
SWITCH LOCK 30 8X012-001-CC12 (BRN 20ga ) 16 16 8X016-000-CC6 (YEL 20ga ) SH16:H-7 2 2 12VR-011-CD2 (RED 16ga ) 2 2 12VR-008-DD6 (RED 16ga ) 1 0-1-RR72 (BLK 20ga ) 1
SWITCH FRONT 50 8X002-001-CC12 (LTG 20ga ) 3 3 12VR-014-CD2 (RED 16ga ) 5 0-2-RR72 (BLK 20ga ) 5
SWITCH LH FRONT 40 8X007-001-CC12 (GRY 20ga ) 4 4 12VR-015-CD2 (RED 16ga ) 6 0-3-RR72 (BLK 20ga ) 6
SWITCH LH REAR 46 8X006-001-CC12 (LBL 20ga ) P119 RADAR
5 5 0-046-CD2 (BLK 16ga ) 3 3 0-541-DD6 (BLK 16ga )
6 6 0-047-CD2 (BLK 16ga ) 4 4 0-542-DD6 (BLK 16ga )
KVIS-A
7 7
8 8
MC753 MC753 P16X J16X RADAR 5 KOMVISION
CAN 1 H 42 939YP-011-CC12 (YEL 20ga ) SH14:C-15 MC809 MC809
CAN 1 L 41 939GP-011-CC12 (GRN 20ga ) SH14:C-15 SH16:M-15 939YX2-005-DD6 (YEL 20ga ) 2 2
KOMVISION DISPLAY MONITOR J09X_CP P09X
SH16:M-15 939GX2-005-DD6 (GRN 20ga ) 3 3
MC752 MC752 SHORT RANGE RADAR
CAN 2 H 32 939YE-020-CC12 (YEL 20ga ) SH14:F-12 8X016-001-CC12 (YEL 20ga ) 3 BRIGHTNESS + 4 4
LOCATED ON REAR AXLE
CAN 2 L 31 939GE-020-CC12 (GRN 20ga ) SH14:F-12 8X017-001-CC12 (DBL 20ga ) 4 BRIGHTNESS - SP3809 0-577-DD6 (BLK 20ga ) 1 1
RH (AIMING REAR LH)
0-578-DD6 (BLK 20ga ) 5 5
DISPLAY ON/OFF 38 8X046-000-CC12 (ORG 20ga ) 8X046-000-CC12 (ORG 20ga ) 2 DISPLAY ON/OFF 0-579-DD6 (BLK 20ga ) 6 6
SH17:C-4 8X013-028-CC12 (RED 20ga ) 6 LIGHT
J125
KVIS-B RADAR 6 KOMVISION
MC810 MC810
GND SLG D-2 8 0CAM-000-CC12 (BLK 20ga ) 5 SIGNAL GND SH16:N-15 939YX2-006-DD6 (YEL 20ga ) 2 2
SH16:M-15 939GX2-006-DD6 (GRN 20ga ) 3 3
P44 4 4
KVIS-A 12VR-008-DD6 (RED 16ga ) LONG RANGE RADAR
0-580-DD6 (BLK 16ga ) 1 1 LOCATED ON REAR AXLE
MC2329 SP3810 5 5
MC2329 0-581-DD6 (BLK 16ga ) LH (AIMING REAR RH)
HSYNC A 910-000-CC15 (WHT 18ga ) 4 VSYNC 6 6
GND SIG SYNC J 0GSS-000-CC15 (BLK 18ga ) 11 GND SIG SYNC J126
VSYNC B 911-000-CC15 (RED 18ga ) 5 RGB R RADAR 7 KOMVISION
MC2324 MC2324 MC811 MC811
RGB R C 912-000-CC15 (RED 20ga ) MC2326 9 RGB B 2 2
SH16:N-11 939YX2-007-CD2 (YEL 20ga )
GND R D GNDR-000-CC15 (BLK 20ga ) MC2326 10 GND B 3 3 SHORT RANGE RADAR
SH16:M-11 939GX2-007-CD2 (GRN 20ga )
RGB G E 913-000-CC15 (GRN 20ga ) MC2328 8 GND G 4 4 LOCATED ON LH UPRIGHT
12VR-014-CD2 (RED 16ga )
GND G F GNDG-000-CC15 (WHT 20ga ) MC2328 3 HSYNC 1 1 REAR
MC2325
0-544-CD2 (BLK 16ga ) 0-583-CD2 (BLK 16ga )
RGB B G 914-000-CC15 (W-RD 20ga ) 6 GND R SP3811 5 5
GND B H MC2325 7 RGB G 6 6
GNDB-000-CC15 (W-BK 20ga ) 0-585-CD2 (BLK 16ga )
RGB J127
ALARM KOMVISION ERROR (ESON)
D77 1 1 1 PWR IN BATT RADAR 8 KOMVISION
11CAM-011-CC15 (YEL 20ga ) MC812 MC812
INDICATOR ERROR 46 8X048-000-CC12 (LBL 20ga ) 2 1 31ALD-001-CC12 (LTG 20ga ) + 1 SH17:C-4 8X013-029-CC12 (RED 20ga ) 2 2 8X013-032-CC15 (RED 20ga ) 12 PWR CTR KEY SH16:N-9 939YX2-008-CD2 (YEL 20ga ) 2 2
SHIELD-2223
2 SH17:D-5 0-538-CC12 (BLK 20ga ) 3 3 0-558-CC15 (BLK 20ga ) 2 GND PWR SH16:M-9 939GX2-008-CD2 (GRN 20ga ) 3 3
PC2834 SHIELD-2226
SH17:D-5 0-536-CC12 (BLK 20ga ) - 3 12VR-015-CD2 (RED 16ga ) 4 4 LONG RANGE RADAR
PC0251 SHIELD-2224 PX06 JX06 P45 7831-47-6000
4 0-545-CD2 (BLK 16ga ) 1 1 LOCATED ON FRONT
SHIELD-2227 5 5 5 BUMPER LEFT CORNER
ALARM KOMVISION RADAR (RSON)
D79 2
6 2 2 6 6
0-910-CC15 (BLK 16ga ) 8X050-002-CC12 (DBL 14ga ) 8X050-001-CC2 (DBL 14ga )
INDICATOR RADAR 47 8X047-000-CC12 (DBL 20ga ) 2 1 31FALD-001-CC12 (DGR 20ga ) + JB6H_CP J128
GB30 CAB SHIELD GND
PC2834 -
SH17:D-5 0-537-CC12 (BLK 20ga ) PB1951
RELAY RADAR POWER (RPR)
(+) (-)
RADAR POWER CTRL 39 8X049-002-CC12 (PNK 18ga ) 86 85 0-713-CC12 (BLK 18ga )
PWR CTR EXT 3 8X001-000-CC12 (ORG 18ga ) SH17:D-8
(NO) 87 12VR-017-CC12 (RED 14ga ) SH17:D-12
TB25 VEC-92 F11 AUX BOX
30 (C) 6 6 8X050-000-AC2 (DBL 14ga ) 6 6 8X050-004-AA30 (DBL 14ga ) J1 J2 8X050-003-AA1 (DBL 14ga ) B 3B 3C C
11B1-004-AA1 (LBL 14ga ) SH4:E-9
(NC) 87A 20
5 5 38 38 38 38
58E-06-09621 VEC-92
RPR_K PC1730 74SB1-006-CC2 (DBL 18ga ) 74SB1-001-AC2 (DBL 18ga ) 74SB1-005-AA30 (DBL 18ga ) SH2:C-22
SP005 RPR_K
SYSTEM BUSY 10 GB12-B SWITCH KOMVISION ON/OFF (KOMV)
74SB1-008-CC12 (DBL 18ga ) 74SB1-007-CC12 (DBL 18ga ) SH17:D-2 0-716-CC2 (BLK 14ga ) VEC-92
4 4
D4 1 TB25 F9
74SB1-009-CC12 (DBL 18ga ) SH17:D-8 0-535-CC2 (BLK 18ga )
PWR IN BATT-1 8 TB25 2 71CKM-000-AA2 (BRN 14ga )
H1 H2 H 3H 71CK
11CAM-002-CC12 (YEL 18ga ) 11CAM-001-CC12 (YEL 20ga ) 71CKM-001-AA1 (BRN 14ga ) BUSS
PWR IN BATT-2 9 1 1 8 8 8 8 3 15
11CAM-003-CC12 (YEL 18ga ) SH17:C-4 8X013-030-CC12 (RED 14ga ) 8X013-031-CC2 (RED 14ga ) 8X013-034-AC2 (RED 14ga ) 8X013-036-AA30 (RED 14ga ) Z1 Z2 8X013-035-AA2 (RED 14ga ) 58E-06-09621 VEC-92
PWR IN BATT-3 18 11CAM-004-CC12 (YEL 18ga )
PWR IN BATT-4 19 4 TB25
11CAM-005-CC12 (YEL 18ga ) 11CAM-000-CC12 (YEL 18ga ) TB26 5
11CAM-007-CC12 (YEL 18ga ) SH17:D-8 11CMX-000-AA2 (TAN 14ga ) Y1 Y2 11CMX-001-AA1 (TAN 14ga ) SH7:G-17
3 3 7 7 7 7 6
11CAM-006-CC2 (YEL 18ga ) 11CAM-008-AC2 (YEL 14ga ) 11CAM-010-AA30 (YEL 14ga ) V1 V2 11CAM-009-AA2 (YEL 14ga )
MC803
8
7
6
5
4
3
2
1
CAN 4 L 11 939GX1-000-CC12 (GRN 20ga ) SH16:K-4
CAN 4 H 12 1258403H1
939YX1-000-CC12 (YEL 20ga ) SH16:K-4 JB12B JB12C J02 P02
MC804 JB8B 58E-06-02630 58E-06-02640 P82 J82
CAN 5 H 2 SH16:M-4
939YX2-000-CC12 (YEL 20ga ) 56B-06-11530 JX07 PX07_CP
CAN 5 L 1 SH16:N-4
939GX2-000-CC12 (GRN 20ga ) SP254
GND COMM-3 35 0COMX-000-CC12 (BLK 18ga )
12
11
10
12
11
10
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
KVIS-B SHIELD-039
SHIELD-038
MC2331 13 13 CAMERA 1
MC2330 MC2331 SHIELD-2233 SHIELD-2247 MC2342 MC2340
AV NTSC 0 C 1 1 MC2342 2 SIGNAL
26AV-000-CC13 (W-RD 20ga ) 26AV-001-CL1 (WHT 20ga )
GND NTSC 0 D 8X073-000-CC13 (W-BK 20ga ) 12 12 8X073-001-CL1 (GRN 20ga ) 4 RETURN
MC2341 MC2341 LOCATED ON ACCESS LADDER
0DOS-009-CC13 (BLK 16ga ) 2 2 0DOS-001-CL1 (BLK 20ga ) 3 MIRROR
24CAM-009-CC13 (PNK 16ga ) 3 3 24CAM-001-CL1 (RED 20ga ) 1 VCC
MC2340
J10X_CP P10X
CAM1
MC2332 CAMERA 2
13 13
MC2332 SHIELD-2234 SHIELD-2248 MC2345 MC2343 MC2345
AV NTSC 1 E 26AV1-000-CC13 (RED 20ga ) 1 1 26AV1-001-CF1 (WHT 20ga ) 2 SIGNAL
GND NTSC 1 F 8X074-000-CC13 (BLK 20ga ) 4 4 8X074-001-CF1 (GRN 20ga ) 4 RETURN
0DOS-008-CC13 (BLK 16ga ) 2 2 MC2344 MC2344 3 MIRROR LOCATED ON RIGHT DECK
0DOS-002-CF1 (BLK 20ga )
24CAM-008-CC13 (PNK 16ga ) 3 3 24CAM-002-CF1 (RED 20ga ) 1 VCC FACING FORWARD
MC2343
14 14 CAM2 CAMERA 3
MC2334 SHIELD-2236 SHIELD-2249 MC2346
AV NTSC 2 G 5 5 MC2348 MC2348 2 SIGNAL
26AV2-000-CC13 (WHT 20ga ) 26AV2-001-CF1 (WHT 20ga )
GND NTSC 2 H 8X075-000-CC13 (GRN 20ga ) 8 8 8X075-001-CF1 (GRN 20ga ) 4 RETURN
MC2347 MC2347 LOCATED ON RIGHT DECK
0DOS-007-CC13 (BLK 16ga ) 6 6 0DOS-003-CF1 (BLK 20ga ) 3 MIRROR
FACING RIGHT OF TRUCK
POWER OUT CAMERA A 24CAM-000-CC13 (PNK 20ga ) 24CAM-007-CC13 (PNK 16ga ) 7 7 24CAM-003-CF1 (RED 20ga ) 1 VCC
DOS L MR B 0DOS-000-CC13 (BLK 20ga ) MC2346
MC2336 15 15 CAM3 CAMERA 4
SHIELD-2237 SHIELD-2250 MC2349
AV NTSC 3 J MC2336 9 9 MC2351 MC2351 2 SIGNAL
26AV3-000-CC13 (W-RD 20ga ) 26AV3-001-CF1 (WHT 20ga )
GND NTSC 3 K 8X076-000-CC13 (W-BK 20ga ) 12 12 8X076-001-CF1 (GRN 20ga ) 4 RETURN
0DOS-006-CC13 (BLK 16ga ) 10 10 MC2350 MC2350 3 MIRROR LOCATED ON REAR AXLE
0DOS-010-CF1 (BLK 20ga )
24CAM-006-CC13 (PNK 16ga ) 11 11 24CAM-010-CF1 (RED 20ga ) 1 VCC
J11X_CP MC2349
CAM4
MC2337 14 14 CAMERA 5
SHIELD-2238 SHIELD-2251 MC2352
AV NTSC 4 L MC2337 4 4 MC2354 MC2354 2 SIGNAL
26AV4-000-CC13 (RED 20ga ) 26AV4-001-CL1 (WHT 20ga )
GND NTSC 4 M 8X077-000-CC13 (BLK 20ga ) 7 7 8X077-001-CL1 (GRN 20ga ) 4 RETURN LOCATED ON LEFT DECK
0DOS-005-CC13 (BLK 16ga ) 5 5 MC2353 MC2353 3 MIRROR
0DOS-011-CL1 (BLK 20ga ) FACING LEFT OF TRUCK
24CAM-005-CC13 (PNK 16ga ) 6 6 24CAM-011-CL1 (RED 20ga ) 1 VCC
MC2352
MC2339 15 15 CAM5 CAMERA 6
SHIELD-2240 SHIELD-2252 MC2355
AV NTSC 5 N MC2339 26AV5-000-CC13 (WHT 20ga ) 8 8 MC2357 MC2357 2 SIGNAL
26AV5-001-CL1 (WHT 20ga )
GND NTSC 5 P 8X078-000-CC13 (GRN 20ga ) 11 11 4 RETURN
8X078-001-CL1 (GRN 20ga ) LOCATED ON LEFT DECK
MC2335 0DOS-004-CC13 (BLK 16ga ) 9 9 MC2356 MC2356 3 MIRROR
0DOS-012-CL1 (BLK 20ga ) FACING FORWARD
24CAM-004-CC13 (PNK 16ga ) 10 10 24CAM-012-CL1 (RED 20ga ) 1 VCC
NTSC1 MC2355
CAM6
J10X_CP P10X
KOMVISION
58B-06-05901-00 SEP 21
ELECTRICAL SCHEMATIC
980E-5
A50052, A50053, A50137, A50138
Sheet 17 of 21
HYDRAULIC LADDER OPTION OPTIONAL HYD ACCESS LADDER
JUMPER PLUG NEEDED WHEN NO
LADDER IS PRESENT 7
73S-006-JR1 (LBL 20ga ) 8 8 8 73S-005-AJ1 (LBL 16ga ) 1 1 73S-004-AA1 (LBL 16ga ) SH3:G-5
POWER LADDER CONTROLLER
56B-06-11530
PARKING BRAKE SWITCH 10
P12 J12
JB8E TB21 VEC-91 F58
7
8
6
5
4
3
2
1
11LAD-009-JR1 (BRN 16ga ) 2 2 2 11LAD-004-AJ1 (BRN 16ga ) 2 2 11LAD-007-AA1 (BRN 16ga ) F1 F2 11LAD-008-AA1 (BRN 18ga ) D 1D 1C C
11-017-AA1 (RED 18ga ) SH4:B-6
VBAT 7 5
11LAD-000-JR1 (BRN 20ga ) 58E-06-20062
11LAD-001-JR1 (BRN 16ga ) F4
11LAD-002-JR1 (BRN 16ga ) P12 J12
11LAD-005-JR1 (BRN 16ga ) SENSOR POWER LADDER UP SWITCH LADDER CONTROL
11LAD-006-JR1 (BRN 16ga )
A A
11LAD-013-CC2 (BRN 18ga ) 9 7 0-095-CC2 (BLK 16ga ) SH6:L-14
SP308
UP POSITION SENSOR 4 510E3-005-JR1 (DGR 20ga ) 510E3-007-JR1 (DGR 16ga ) B B C C 0-304-JR1 (BLK 16ga ) J9-000-JJ10 (BLK 18ga ) 1 1 510E2-005-AJ1 (DGR 16ga ) SH12:H-1 3
510E2-006-JR1 (DGR 16ga ) 1 2B
56B-06-15610 1
UPS UPS
6
SENSOR POWER LADDER DOWN 21 21 21 21 5B
11LAD-011-AA30 (BRN 16ga ) 11LAD-010-AC2 (BRN 16ga ) 11LAD-012-CC2 (BRN 16ga )
A A 4
J82 P82 P02 J02
SP463 12DP-001-JR1 (BRN 16ga ) 9 9 9 12DP-003-AJ1 (BRN 16ga ) 3 3 12DP-004-AA1 (BRN 16ga ) 3 3
DOWN POSITION SENSOR 5 12DP2-000-JR1 (GRY 20ga ) 12DP2-001-JR1 (GRY 16ga ) B B C C 0-094-JR1 (BLK 16ga ) 10 8
56B-06-15610 AHT AUX BOX
DPS DPS CONNECTOR P35 P35
58F-06-60971
12DP2-002-JR1 (GRY 16ga ) (OPT)
RELAY AHT LADDER DOWN 10 10 10 8 8 22 22
(+) (-) 12DP3-000-JR1 (WHT 16ga ) 12DP3-001-AJ1 (WHT 16ga ) 12DP3-002-AA1 (WHT 18ga )
11LAD-014-JR1 (BRN 16ga ) 86 85
J702_JP P702
0-688-JR1 (BLK 16ga ) 3 3 3 0-689-AJ1 (BLK 16ga ) 4 4 0-690-AA1 (BLK 16ga ) SH12:B-13
(NO) 87
30 (C)
JB12D
(NC) 87A
58E-06-02630
P12 J12
ALDR
58E-06-10020
ALDR
12
11
10
9
8
7
6
5
4
3
2
1
0-797-JR1 (BLK 16ga )
GND 6 0-089-JR1 (BLK 20ga )
510E3-000-JR1 (DGR 16ga ) RELAY AHT LADDER UP
(+) (-)
11LAD-003-JR1 (BRN 16ga ) 86 85
(NO) 87 0-058-JR1 (BLK 16ga )
30 (C) 0-111-JR1 (BLK 16ga )
(NC) 87A
ALUR
58E-06-10020
ALUR
0-217-JR1 (BLK 16ga )
6 6 6
0-101-JR1 (BLK 16ga )
RELAY CAB LADDER ALARM
(+) (-)
CAB ALARM 1 12CA-000-JR1 (YEL 20ga ) 86 85 0-097-JR1 (BLK 16ga )
(NO) 87 7 7 7
13CA-001-JR1 (YEL 16ga ) 13CA-002-AJ1 (YEL 16ga ) SH12:I-1
30 (C)
(NC) 87A
CAR 58E-06-10020
CAR
RELAY LADDER UP
(+) (-) SWITCH GROUND LEVEL
SOLENOID 11 12HS-000-JR1 (LBL 20ga ) 86 85 LADDER OVERRIDE
SOLENOID HYDRAULIC LADDER
SP399
(NO) 87 4 3 1 2
13HS-000-JR1 (BRN 16ga ) 13LS-000-JR1 (LBL 16ga ) 13LS-002-JR1 (LBL 16ga ) 0-676-JR1 (BLK 16ga )
30 (C) SP400
(NC) 87A 1 2 LSOL LSOL
LUR 58E-06-10020
LUR GLORS GLORS
58E-06-13190
ALARM GROUND
RELAY GROUND LEVEL ALARM LEVEL LADDER D5
(+) (-)
GROUND ALARM 2 12GLA-000-JR1 (PNK 20ga ) 86 85 0-093-JR1 (BLK 16ga ) 13LS-001-JR1 (LBL 16ga ) 1 2 0-677-JR1 (BLK 16ga )
1 +
PC2834
(NO) 87 2 -
13GLA-000-JR1 (LTG 16ga )
30 (C)
(NC)
GLA
87A
58E-06-08400
GLAR 58E-06-10020 GLAR TB21
0-100-JR1 (BLK 16ga )
DN SWITCH 9 12LD-000-JR1 (LBL 20ga ) 4 4 4 12LD-001-AJ1 (LBL 16ga ) 5 5 12LD-002-AA1 (LBL 16ga ) G1 G4 12LD-006-AA30 (LBL 16ga ) 28 28 12LD-004-AC2 (LBL 16ga ) 28 28 12LD-005-CC2 (LBL 16ga )
UP SWITCH 8 12LU-000-JR1 (DBL 20ga ) 5 G2
AHT CONNECTION
5 5 12LU-001-AJ1 (DBL 16ga ) 6 6 12LU-002-AA1 (DBL 16ga ) H1 H4 12LU-006-AA30 (DBL 16ga ) 29 29 12LU-004-AC2 (DBL 16ga ) 29 29 12LU-005-CC2 (DBL 16ga )
P7 J538
J538B P538_JP H2
AHT CONNECTION
P12 J12 J82 P82 P02 J02
ACTIVE ANTENNA 1
MC002 SHIELD-087 1 1 SHIELD-089 41 41 SHIELD-091 SHIELD-091 1 1 SHIELD-093 SHIELD-093 1 A
SHIELD-089 B
12VTM-001-AA34 (RED 20ga ) 2 2 12VTM-004-AA1 (RED 20ga ) 42 42 12VTM-005-AH2 (RED 16ga ) 2 2 12VTM-007-HH8 (RED 20ga ) 2 TR8
0TM-001-AA34 (BLK 20ga ) 3 3 43 43 3 3 3 C
0TM-004-AA1 (BLK 20ga ) 0TM-005-AH2 (BLK 16ga ) 0TM-007-HH8 (BLK 20ga )
939YA-001-AA34 (YEL 20ga ) 4 4 939YA-004-AA1 (YEL 20ga ) 44 44 939YA-005-AH2 (YEL 20ga ) 4 4 939YA-007-HH8 (YEL 20ga ) 4
SHIELD-087
939GA-001-AA34 (GRN 20ga ) 5 5 45 45 5 5 5
ANTENNA TPMS GPS 939GA-004-AA1 (GRN 20ga )
MC004 MC006
939GA-005-AH2 (GRN 20ga )
MC006 MC008
939GA-007-HH8 (GRN 20ga )
MC002 MC004 MC008
J100 P100 P102_CP J102 JANT1
CONTROLLER TIRE MONITORING
ACTIVE ANTENNA 2
SHIELD 1 SHIELD-086 SHIELD-086 SHIELD-088 SHIELD-088 1 1 SHIELD-090 MC005 46 46
SHIELD-092 SHIELD-092 1 1 SHIELD-094 SHIELD-094 1 A
SHIELD-090 B
+12VDC 2 12VTM-000-AA34 (RED 20ga ) 12VTM-002-AA34 (RED 20ga ) 2 2 12VTM-003-AA1 (RED 20ga ) 47 47 12VTM-006-AH2 (RED 16ga ) 2 2 12VTM-008-HH9 (RED 20ga ) 2 TR9
GND 3 0TM-002-AA34 (BLK 20ga ) 3 3 48 48 3 3 3 C
0TM-000-AA34 (BLK 20ga ) 0TM-003-AA1 (BLK 20ga ) 0TM-006-AH2 (BLK 16ga ) 0TM-008-HH9 (BLK 20ga )
ANTENNA TPMS 4G WIFI CAN HI 4 939YA-000-AA34 (YEL 20ga ) 939YA-002-AA34 (YEL 20ga ) 4 4 939YA-003-AA1 (YEL 20ga ) 49 49 939YA-006-AH2 (YEL 20ga ) 4 4 939YA-008-HH9 (YEL 20ga ) 4
CAN LO 5 939GA-000-AA34 (GRN 20ga ) 939GA-002-AA34 (GRN 20ga ) 5 5 939GA-003-AA1 (GRN 20ga ) 50 50 939GA-006-AH2 (GRN 20ga ) 5 5 939GA-008-HH9 (GRN 20ga ) 5
MC001 MC001 MC003 MC003 MC005 MC007 MC007 MC009 MC009
TMS-5 J101 P101 P103_CP J103 JANT2
J16 P16
SH
SHIELD-085
MC010
TX+ 1 98ET1-000-AA35 (W-OR 24ga ) SH11:M-21
TX- 3 98ET2-000-AA35 (ORG 24ga ) SH11:M-21
RX+ 2 98ER1-000-AA35 (W-GR 24ga ) SH11:M-21
RX- 4 98ER2-000-AA35 (GRN 24ga ) SH11:M-21
MC010
TMS-3
MC011 MC011
+24V 1 SH5:N-4
11RCNT-005-AA36 (BRN 25ga )
SENSE 2 SPR-000-AA36 (BLU 25ga )
SPR
GROUND 3 0-013-AA36 (BLK 25ga ) SH5:E-12
TMS-1
TIRE MONITOR
58B-06-05901-00 SEP 21
ELECTRICAL SCHEMATIC
980E-5
A50052, A50053, A50137, A50138
Sheet 18 of 21
WIRE LOCATOR TABLE
WIRE SHEET-ZONE WIRE SHEET-ZONE WIRE SHEET-ZONE WIRE SHEET-ZONE WIRE SHEET-ZONEWIRE SHEET-ZONE WIRE SHEET-ZONE WIRE SHEET-ZONE WIRE SHEET-ZONE WIRE SHEET-ZONE WIRE SHEET-ZONE WIRE SHEET-ZONE WIRE SHEET-ZONE WIRE SHEET-ZONE WIRE SHEET-ZONE WIRE SHEET-ZONE WIRE SHEET-ZONE WIRE SHEET-ZONE WIRE SHEET-ZONE WIRE SHEET-ZONE WIRE SHEET-ZONE WIRE SHEET-ZONE
0-000 2-I9 0-127 4-H8 0-288 9-G21 0-455 3-I13 0-751 5-N13 5VFCS-002X 5-J18 11B1-002 4-E9 11LAD-009 18-C3 12VREG-006 4-L5 24VIM-001 3-J12 34BT1-000 12-J8 41L-003 7-I11 45R-008 7-F6 52B-007 6-N11 67R-002 14-N3 71VHM-003 11-D12 74Z-002 9-H2 93CAG-000 11-G18 712M-000 3-D11 939GP-011 17-G5 BAT(+)-012 2-F14 WMTBG3-000 4-I18
7
0-001 2-I7 0-127 7-M11 0-289 4-M5 0-455 6-N18 0-752 5-N13 5VFCS-003 5-I1 11B1-002 4-K3 11LAD-010 18-D18 12VREG-007 4-M5 24VIM-002 3-K13 34BT1-002 12-L18 41L-004 7-L2 45R-009 8-J5 52B-009 6-C8 67R-005 14-N7 71VHM-004 11-D12 74Z-003 9-H7 93CAR-000 11-G18 712M-001 3-I4 939GP-012 14-B2 BAT(+)-013 2-E15
0-1 17-F20 0-128 4-G4 0-292 10-L13 0-456 3-H12 0-753 12-C1 5VIM-000 12-J10 11B1-003 4-C3 11LAD-011 18-C17 12VREG-008 4-L10 24VIM-002 12-B20 34BT2-000 12-I8 41L-005 7-L5 45RL-000 8-K13 52B-009 6-M12 67R-006 14-N7 71VHM-005 11-D15 74ZA-000 9-G4 93CAT-000 11-G18 712P-000 11-N4 939GP-016 14-C6 BAT(+)-014 2-G15
0-002 2-J10 0-128 7-L11 0-300 10-H9 0-457 3-H12 0-754 9-K18 5VIM-001 12-J8 11B1-004 4-E9 11LAD-012 18-D20 12VREG-008 14-K15 24VIM-006 3-K10 34BT2-002 12-K18 41L-006 7-O7 45RL-001 8-K16 52B-010 6-M9 67R-011 14-N5 71VHM-006 11-C17 74ZA-000 10-G2 93ER1-000 11-I12 712P-001 11-N6 939GP-017 14-B6 BAT(+)-015 2-D16
0-002 4-F6 0-129 4-G4 0-301 10-H9 0-460 10-F15 0-754 12-D1 5VIM-002 12-M11 11B1-004 17-J22 11LAD-013 18-D21 12VREG-009 4-L10 24VIM-006 7-D15 34BT3-000 12-J8 41L-007 7-L4 45RL-002 8-K18 52B-010 6-B4 67R-012 14-N5 72AF-000 6-G7 74ZA-001 10-G2 93ER1-001 11-J16 712P-002 11-N7 939GX1 17-F20 BAT(-)-000 2-E1
0-2 17-F20 0-129 7-L11 0-304 18-C5 0-461 10-H17 0-755 3-H14 5VIM-003 12-M11 11B5-000 4-E5 11LAD-014 18-C3 12VREG-009 6-D17 24VIM-007 3-K13 34BT3-002 12-K18 41LM-000 7-N8 45RL-003 8-K14 52B-011 6-M11 67R-013 14-N6 72AT-000 12-F3 74ZA-002 10-G2 93ER1-002 11-J14 712P-003 11-M9 939GX1-000 16-K4 BAT(-)-001 2-F1
0-003 2-L10 0-130 4-I6 0-308 6-D20 0-462 10-H17 0-755 9-J20 5VIM-004 12-M11 11CAM-000 17-K7 11LL-000 7-N5 12VTM-000 18-L5 24VIM-007 7-F13 34BT4-000 12-J18 41LM-001 7-N8 45RL-004 8-K19 52B1-000 6-M6 67R-016 14-N7 72CPU-000 5-G18 75A1-000 11-A9 93ER2-000 11-I12 712P-004 11-N5 939GX1-000 17-K4 BAT(-)-002 2-G5
0-3 17-F20 0-131 4-I6 0-309 6-C20 0-463 10-H17 0-756 9-K18 5VIM-005 12-J18 11CAM-001 17-K7 11LR-000 7-O5 12VTM-001 18-L7 24VIM-008 12-J15 34BT4-001 12-I8 41LM-002 7-N12 45RL-007 8-K20 52B1-001 6-L11 67R-029 14-N6 72CPU-001 5-G16 75A2-000 11-B2 93ER2-001 11-J16 712PL-000 13-I6 939GX1-002 16-K7 BAT(-)-003 2-G5
0-004 2-K12 0-132 11-K10 0-310 3-C18 0-464 10-I15 0-756 12-D1 5VIM-006 12-M11 11CAM-002 17-J2 11NOX-000 5-O11 12VTM-002 18-L7 24VIM-009 12-J18 34LL-001 12-H8 41LM-003 7-N13 45RL-008 8-K16 52B1-002 6-L12 67S-000 14-N12 72ES-000 3-D17 75A2-001 11-B4 93ER2-002 11-J14 712PL-001 13-I8 939GX1-003 16-K10 BAT(-)-004 2-G14
0-005 4-D15 0-132 11-N8 0-310 10-P8 0-465 10-J16 0-757 3-E19 5VIM-007 12-L18 11CAM-003 17-K2 11NOX-006 5-O13 12VTM-003 18-L9 24VIM-010 12-J20 34LL-002 12-J18 41LM-004 7-O12 45RL-009 8-K20 52B1-003 6-M8 67S-001 14-N14 72ES-001 3-D18 75A2-002 11-A9 93ET1-000 11-I12 712S1-000 13-G12 939GX1-005 16-K14 BAT(-)-005 2-G4
0-006 3-F7 0-134 4-I8 0-311 10-H10 0-466 10-J16 0-761 3-H14 5VIM-008 12-M11 11CAM-004 17-K2 11ONS-002 7-G12 12VTM-004 18-K9 24VIM-011 3-H4 34LL-003 12-J20 41LM-005 7-O13 45RL-010 8-L18 52B1-004 6-M9 67T-001 14-N12 72ES-002 3-D19 75A2-003 11-B6 93ET1-001 11-J16 712S1-001 13-J15 939GX1-005 17-C20 BAT(-)-006 2-E1
0-006 4-C11 0-134 8-I17 0-312 3-H8 0-467 10-J16 0-761 9-J17 5VIM-009 12-K18 11CAM-005 17-K2 11ONS-003 7-G13 12VTM-005 18-K11 25AF-000 12-G2 35L2-000 13-K11 41T-000 8-H13 45RL-011 8-L18 52B1-004 6-C4 67T-002 14-N14 72ES-003 3-D21 75A2-004 11-B9 93ET1-002 11-J14 712S1-002 13-J14 939GX1-006 16-K14 BAT(-)-010 2-G5
0-007 4-C10 0-135 4-G8 0-313 13-O11 0-480 15-B12 0-764 5-P3 5VIM-010 12-K18 11CAM-006 17-K12 11ONS-004 7-G13 12VTM-006 18-L11 25AF-001 12-G5 35L2-001 13-K15 41T-001 8-H16 45RL-012 8-M19 52CS-000 6-J6 68-000 12-H8 72ES-003 5-A10 76-000 11-C14 93ET2-000 11-I12 712T-000 8-J2 939GX1-006 17-D19 BAT(-)-020 2-G5
0-008 4-H8 0-135 8-K17 0-314 3-H8 0-481 15-B12 0-765 5-P3 5VIM-011 12-L18 11CAM-007 17-D8 11ORS-001 5-M3 12VTM-007 18-K13 25AF-002 12-G3 35L3-000 13-K11 41T-002 8-I16 45RL-012 10-F14 52CS-001 6-J9 68-001 12-N11 72ES-004 5-A2 76-000 14-G15 93ET2-001 11-J16 712T-001 8-J1 939GX1-007 16-K12 CGBA-000 4-K18
0-008 7-O10 0-136 8-L6 0-315 10-P8 0-497 13-E12 0-766 5-O8 5VPL-000 13-O11 11CAM-007 17-K8 11ORS-002 5-M2 12VTM-008 18-L13 25AF-003 12-G4 35L3-001 13-K15 41T-005 8-I18 45RL-017 10-F15 52CS-002 6-J9 68-002 12-P14 72ES-005 3-D21 77B-000 9-E9 93ET2-002 11-J14 712T-002 8-J2 939GX1-007 17-E19 CGBB-000 4-K18
0-009 4-E5 0-136 11-L10 0-315 14-J14 0-500 15-J1 0-766 5-P4 5VUSB-000 13-M11 11CAM-008 17-K14 11PF-000 2-O12 13B-000 11-C14 25AF1-000 12-H1 35L4-000 13-K11 41T-006 8-I20 46GA-000 15-J12 52CS-003 5-G15 68-003 12-P16 72ES-005 3-I5 77B-001 9-E4 94ER1-000 11-D4 712T-003 8-J1 939GX1-008 16-K9 CGBC-000 4-K18
0-010 2-H14 0-137 10-I10 0-316 8-M6 0-501 15-H3 0-767 8-G20 7KTS-000 11-F12 11CAM-009 17-K17 11PHH-000 5-O6 13B-000 14-I15 26AV-000 17-L2 35L4-001 13-K15 41T-007 8-I20 46GA-001 15-J17 52CS-004 5-G13 68-004 12-O18 72ES-006 5-A6 77B-003 9-E2 94ER1-000 11-J21 712TP-000 14-I4 939GX1-008 17-E19 CGBG1-000 4-L18
0-011 4-F7 0-138 8-I19 0-317 3-H8 0-502 15-H3 0-769 12-P14 7KTWU-000 11-F12 11CAM-010 17-K16 11PHH-001 5-O5 13CA-001 18-G5 26AV-001 17-L12 35L7-000 13-J11 41T-008 8-K18 46GA-002 15-I15 52CS-005 5-G13 68-005 12-P14 72F-000 6-H11 77C-000 9-E9 94ER2-000 11-J21 712TP-001 14-I8 939GX1-009 16-K4 CGBG2-000 4-L18
0-012 4-F15 0-139 8-I20 0-318 8-K6 0-504 15-I5 0-770 8-D20 7KTWU-001 11-F16 11CAM-011 17-I11 11PHH-004 5-O6 13CA-002 12-I1 26AV1-000 17-L2 35L7-001 13-J15 41T-009 8-I19 46GA-004 15-I15 52CS-006 5-G14 68-006 12-N11 72F-001 6-H10 77C-001 9-E4 94ER2-000 11-D4 712TP-002 14-I9 939GX1-010 16-K2 CGBG3-000 4-L18
0-013 5-E12 0-140 8-I20 0-318 8-G1 0-505 15-I3 0-771 12-P14 7KTWU-001 14-G15 11CMX-000 17-K18 11PL-000 2-O10 13CA-002 18-G17 26AV1-001 17-L12 35L8-000 13-J11 41T-010 8-K19 46GA-005 15-I14 52CS-007 5-G17 68-007 12-N20 72F-002 6-I6 77C-003 9-E2 94ET1-000 11-J21 712TP-003 14-I11 939GX2-000 16-N4 ENRX1-000 13-N11
0-013 18-O7 0-141 8-K18 0-320 7-I8 0-506 15-I5 0-777 11-H12 7KTWU-002 11-F15 11CMX-001 7-G17 11POR-001 5-M5 13CA-003 12-I4 26AV2-000 17-M2 35L8-001 13-J15 41T-011 8-K20 46GA-006 15-H16 52CS-007 6-J7 68-008 12-N20 72F-003 6-G7 77DN-000 9-E9 94ET1-000 11-D4 712TP-004 14-F15 939GX2-000 17-K4 ENRX2-000 13-N11
0-014 3-F7 0-143 8-K19 0-320 13-E1 0-507 15-J6 0-778 11-H12 7MSU-000 11-F12 11CMX-001 17-K21 11POR-002 5-M7 13CA-005 12-I2 26AV2-001 17-M12 35L9-000 13-J11 41T-012 8-K20 46GA-008 15-H19 52GE-001 6-C3 68ES-000 12-O14 72F-004 6-H9 77DN-001 9-E4 94ET2-000 11-J21 712TP-004 14-I13 939GX2-001 16-M11 ENTX1-000 13-N11
0-014 7-K9 0-144 8-K20 0-325 4-J4 0-508 15-J6 0-779 11-H14 8X001-000 17-J3 11D-000 7-I4 11POR-003 5-M7 13GLA-000 18-H5 26AV3-000 17-M2 35L9-001 13-J15 41T-013 8-I16 46GA-010 15-H16 52GE-002 6-C5 68ES-001 12-O16 72FD-000 5-F15 77DN-003 9-E2 94ET2-000 11-D4 712TP-005 14-I11 939GX2-002 16-M7 ENTX2-000 13-N11
0-015 7-K8 0-145 8-K20 0-325 12-E10 0-509 15-I3 0-780 11-H14 8X001-000 17-D8 11D-001 7-I7 11RB-000 13-D3 13HS-000 18-G5 26AV3-001 17-M12 35L10-000 13-J14 41T-014 8-J19 46GA-011 15-J19 52PB-000 6-I6 68ES-002 12-N18 72FD-000 6-N5 77DP-000 9-E9 95ER1-000 11-K21 712TP-006 14-I15 939GX2-003 16-M9 F1-000 4-D18
0-016 7-N8 0-146 4-I4 0-326 12-E11 0-510 15-K5 0-781 10-L15 8X002-000 16-A7 11D-002 7-I8 11RB-001 13-D4 13LS-000 18-G8 26AV4-000 17-N2 36-000 5-L1 41T-015 8-I16 46GA-012 15-H18 52PB-003 6-I9 68ES-003 12-O13 72FD-001 5-F17 77DP-001 9-E4 95ER1-000 13-N17 712TP-007 14-I15 939GX2-005 16-M15 F2-000 4-D18
0-016 8-G14 0-146 8-L17 0-327 12-D18 0-511 15-K6 0-782 15-I18 8X002-000 17-F11 11D-003 7-I9 11RB-002 13-D6 13LS-001 18-G9 26AV4-001 17-N12 36-001 5-L6 41T-016 8-L18 46RA-000 15-J12 52R-002 9-P5 68ES-004 12-O14 72FNR-000 6-J6 77DP-003 9-E2 95ER2-000 11-K21 712TP-008 14-I5 939GX2-005 17-G19 GNDB-000 17-I2
0-017 4-H10 0-147 4-I4 0-328 12-E15 0-512 15-K6 0-783 8-I18 8X002-001 17-F2 11D-004 7-I5 11RB-003 13-D6 13LS-002 18-G9 26AV5-000 17-N2 36-002 5-K10 41T-017 8-L18 46RA-001 15-J17 52RA-000 9-O2 68ES-005 12-N19 72FNR-001 6-K11 77G-000 9-D9 95ER2-000 13-N17 714A-000 9-F9 939GX2-006 16-M15 GNDG-000 17-H2
0-018 4-H12 0-147 8-J18 0-329 12-A11 0-514 15-I3 0-784 13-D11 8X003-000 16-B7 11DFP-000 5-O11 11RB-004 13-E8 15LFWS-000 9-C10 26AV5-001 17-N12 36-002 6-H2 41T-018 8-M19 46RA-002 15-J15 53H-001 9-J13 68ES-006 12-N19 72FNR-002 6-K11 77G-001 9-D4 95ET1-000 11-K21 714A-001 9-F4 939GX2-006 17-H19 GNDR-000 17-H2
0-019 4-H12 0-148 5-C9 0-330 12-E16 0-515 15-I6 0-785 13-C11 8X003-000 17-F11 11DFP-006 5-O13 11RB-005 13-D9 15LFWS-001 9-C8 27WR-000 5-G2 36-003 5-K7 41T-018 10-F7 46RA-004 15-I15 53H-002 9-I14 68LS-000 12-O18 72GD-000 11-L2 77G-003 9-D2 95ET1-000 13-N17 714A-003 9-F2 939GX2-007 16-M11 J1 6-F7
0-020 4-H12 0-149 8-J19 0-331 12-B1 0-522 14-N8 0-786 9-F15 8X003-001 17-F2 11DISP-000 7-G12 11RB-006 13-D5 15LFWS-002 9-C8 27WS-000 5-G2 36-004 5-M5 41T-019 10-F14 46RA-005 15-I14 53H-003 9-J14 68LS-001 12-P16 72GD-001 11-L6 77Y-000 9-I2 95ET2-000 11-K21 714B-000 9-G9 939GX2-007 17-H19 J2 6-F7
0-021 4-H12 0-151 9-K12 0-332 12-D3 0-528 8-O6 0-787 9-G15 8X004-000 16-C7 11DISP-001 7-G10 11RB-007 13-D6 15LFWS-003 9-C5 28E-000 5-D19 38G-000 12-A8 41T-020 10-F14 46RA-006 15-H16 53H-004 9-J13 68LS-002 12-M8 72GD-002 11-L7 77Z-000 9-I2 95ET2-000 13-N17 714B-001 9-G4 939GX2-008 16-M9 J3 6-F7
0-022 3-I10 0-151 11-J10 0-333 4-I4 0-529 17-D2 0-788 12-H2 8X004-000 17-E11 11DISP-002 7-G13 11RB-009 13-D11 15LFWS-004 9-C2 28E-000 15-C5 38G-001 12-D11 41T-021 10-F8 46RA-008 15-H19 53H-006 9-J13 68LS-003 12-P14 72GD-003 11-L4 79A-000 10-C8 96ER1-000 11-M16 714B-003 9-G2 939GX2-008 17-I19 J4 9-N6
0-023 4-I4 0-152 5-B6 0-333 12-C5 0-530 17-E2 0-789 4-K12 8X004-001 17-E2 11DISP-003 7-G6 11RB-010 13-D10 15LRW-000 9-D9 28E-001 15-C7 38G-002 12-D11 41T-022 10-F8 46RA-010 15-I16 53H-008 9-J17 68LS-004 12-P14 72HC-000 13-N11 79A-001 10-C13 96ER1-001 11-M14 714DN-000 9-G9 939GX2-009 16-M4 J6 9-P5
0-023 6-I16 0-153 5-C6 0-334 4-I4 0-531 17-E2 0-797 18-E5 8X005-000 16-C7 11DSL-000 8-G11 11RB-011 13-E9 15LRW-001 9-D4 28E-002 15-C8 38G-003 12-D15 41T-029 10-F10 46RA-011 15-J19 53H-009 9-J16 68P-001 12-N16 72IM-000 6-H13 79A-002 10-C16 96ER2-000 11-M16 714DN-001 9-G4 939GX2-010 16-M2 J7 3-D12
0-024 4-I4 0-154 5-C6 0-334 12-D5 0-532 17-E2 0-800 8-E20 8X005-000 17-E11 11E1-000 5-A12 11RB-012 13-D11 15LRW-002 9-D2 28E-003 15-C10 38G-004 12-D18 41T-030 10-F8 46RA-012 15-I18 53H-010 9-J17 68P-002 12-N11 72IM-001 6-I16 79A-003 10-C16 96ER2-001 11-M14 714DN-003 9-G2 939YA-000 18-L5 J8 6-N7
0-024 6-I16 0-155 5-F9 0-335 12-B2 0-533 17-E6 0-801 8-F20 8X005-001 17-E2 11E1-001 5-A6 11RB-014 13-E12 15RFWS-000 9-B10 28E-004 15-C11 39-000 12-D14 41T-031 10-G17 46YA-000 15-J12 53H-011 9-K15 68P-003 12-M8 72IM-002 6-I15 79A-004 10-C14 96ET1-000 11-M16 714DP-000 9-F9 939YA-001 18-L7 J9 12-E15
0-025 6-C17 0-156 8-L18 0-336 4-H8 0-534 17-D3 0-802 8-F20 8X006-000 16-D7 11E1-002 5-A9 11RCNT-000 5-N2 15RFWS-001 9-B8 28E-005 15-C11 39-001 15-L12 41T-032 10-G17 46YA-001 15-J17 53H-012 9-K16 69M-000 13-C6 72IM-003 6-H14 79RD-000 5-E15 96ET1-001 11-M14 714DP-001 9-F4 939YA-002 18-L7 J9-000 18-E15
0-026 2-H14 0-157 7-O9 0-336 12-B4 0-535 17-J12 0-803 8-G18 8X006-000 17-F11 11E1-003 5-A3 11RCNT-001 5-N6 15RFWS-002 9-B5 28EC-000 5-D11 39-002 15-L14 41T-033 10-I15 46YA-002 15-J15 53H-013 9-K16 69M-001 13-C7 72MAN-000 12-F3 79RD-000 6-N5 96ET2-000 11-M16 714DP-003 9-F2 939YA-003 18-L9 J27-000 15-L16
0-027 2-H14 0-157 10-D11 0-337 3-H14 0-536 17-I5 0-804 9-F19 8X006-001 17-F2 11E1-004 5-A3 11RCNT-003 5-N6 15RFWS-003 9-B8 28EC-001 5-D2 39-003 12-A8 41T-034 10-J17 46YA-004 15-J15 55A-002 7-C17 69M-002 13-C7 72N-000 6-H11 79RD-001 5-E17 96ET2-001 11-M14 714G-000 9-F9 939YA-004 18-K9 LF(+)-001 4-M12
0-028 2-L10 0-158 13-G19 0-337 12-F17 0-536 17-D5 0-805 9-G19 8X007-000 16-D7 11E1-005 5-A2 11RCNT-005 5-N4 15RFWS-004 9-B2 28EC-002 5-D6 39A-000 13-G8 41T-035 10-J17 46YA-005 15-J14 55A-003 7-C15 69M-003 13-B9 72N-001 6-H10 85-000 11-C18 97ER1-000 11-F2 714G-001 9-F4 939YA-005 18-K11 LF(-)-001 4-M12
0-029 6-C17 0-159 7-I8 0-338 3-H14 0-537 17-D5 0-806 12-H1 8X007-000 17-F11 11E1-006 5-A9 11RCNT-005 18-N7 15RRW-000 9-F9 28EC-003 5-D9 39A-001 13-G8 41T-036 10-F15 46YA-006 15-H16 55B-002 7-C17 69M-007 13-B11 72N-002 6-I6 85-001 11-C16 97ER1-002 11-F8 714G-003 9-F2 939YA-006 18-L11 LR(+)-001 4-N12
0-030 2-D16 0-159 8-B8 0-338 12-F17 0-537 17-I5 0-807 4-K12 8X007-001 17-F2 11E1-007 5-A6 11RWL-000 7-F9 15RRW-001 9-F4 29CR-000 5-E2 39AA-000 13-G12 41TS-000 7-J6 46YA-008 15-H19 55B-003 7-C15 69M-008 13-C10 72N-003 6-H8 85-002 11-C16 97ER1-003 11-F5 714Y-000 9-H2 939YA-007 18-K13 LR(-)-001 4-N12
0-031 2-E16 0-160 4-I2 0-339 3-H14 0-538 17-D5 0-812 11-F7 8X008-000 16-E7 11E2-000 5-B12 11RWL-001 7-F10 15RRW-002 9-F2 29CS-000 5-E2 39AA-001 13-G13 41TS-002 7-J7 46YA-010 15-H16 55C-002 7-C17 69M-011 13-C11 72N-004 6-H9 85-003 11-D12 97ER2-000 11-F2 714Z-000 9-H2 939YA-008 18-L13 RF(+)-001 4-M12
0-032 2-F17 0-161 7-J12 0-339 12-G17 0-538 17-I10 0-812 12-B12 8X008-000 17-E11 11E2-001 5-A9 11RWL-002 7-F15 18AZ-001 5-L6 31-000 7-F6 39AA-002 13-F15 41TS-003 7-J5 46YA-011 15-J19 55C-003 7-C15 69MA-000 13-A3 72P-000 6-H11 85-004 11-D12 97ER2-002 11-F8 715B-000 4-E18 939YE-000 5-H2 RF(-)-001 4-M12
0-033 2-F17 0-162 4-H4 0-340 12-J18 0-539 17-E6 0-813 9-I21 8X008-001 17-E2 11E2-002 5-A9 11RWL-003 7-F12 18AZ-002 5-L7 31-001 7-F8 39AA-005 13-F18 41TS-005 7-J2 46YA-012 15-H18 55D-002 7-C17 69MA-001 13-A4 72P-001 6-H10 85-005 11-D12 97ER2-003 11-F5 715C-000 4-E18 939YE-001 5-H10 RR(+)-001 4-N12
0-034 2-F17 0-162 8-G16 0-341 12-J20 0-540 17-E6 0-813 12-E14 8X009-000 16-E7 11E2-003 5-A3 11RWL-004 7-E4 18FC2-000 5-K16 31ALD-001 17-I5 39AA-006 13-G13 41TS-005 8-H9 47-000 10-D10 55D-003 7-C15 69MA-002 13-B3 72P-002 6-G7 85-006 11-D19 97ET1-000 11-E2 715DN-000 4-E18 939YE-001 14-F1 RR(-)-001 4-N12
0-035 17-D15 0-163 4-H4 0-342 12-P16 0-541 17-F17 0-814 9-I21 8X009-000 17-E11 11E2-004 5-A3 11RWL-004 7-F8 18VIM-000 12-I4 31FALD-001 17-I5 39AA-009 13-H15 41TS-006 7-J7 47-002 10-D12 55K-000 7-E6 69MA-003 13-A6 72P-003 6-H9 85-007 11-D19 97ET1-002 11-E8 715DP-000 4-E18 939YE-002 14-E13 SEAT-000 6-C19
0-036 17-D13 0-163 8-F16 0-343 12-O18 0-542 17-G17 0-814 12-E14 8X009-001 17-E2 11E2-005 5-A2 11S-000 3-B5 18VIM-001 12-I3 31IML-000 7-E16 39AA-010 13-H17 41TS-007 7-J3 47-004 10-C13 55K-001 7-D6 71ABA-000 6-N7 72PA-001 6-G7 85-008 11-E12 97ET1-003 11-E5 715G-000 4-D18 939YE-003 5-H6 SEAT-001 6-C19
0-037 17-D13 0-164 4-I8 0-344 4-I8 0-543 7-O7 0-815 11-F8 8X010-000 16-F7 11E2-006 5-A6 11S-001 3-B4 18VIM-002 12-I1 31IML-001 7-E15 39AP-000 12-E11 41TS-009 7-J10 47-006 10-C15 57TPU-001 12-M13 71ABA-002 6-J6 72PA-003 6-L16 85-009 11-C17 97ET2-000 11-E2 715P-000 4-D18 939YE-004 14-E6 SEAT-002 6-C19
0-038 17-D13 0-164 8-F16 0-344 12-P11 0-544 17-G15 0-816 11-F8 8X010-000 17-E11 11E2-007 5-A6 11S-002 3-E4 18VIM-003 12-J3 31IML-002 7-E11 39AP-001 12-E11 42-000 9-D14 47-007 10-C15 57TPU-002 12-M8 71ABA-003 6-N7 72PA-003 6-H10 86-500 15-J1 97ET2-002 11-E8 716B-000 4-F18 939YE-005 14-E8 SEAT-003 6-C19
0-039 17-D13 0-165 4-I8 0-345 6-J11 0-545 17-G15 0-817 5-J16 8X010-001 17-E2 11E3-000 5-B12 11S-003 3-B3 18VIM-004 12-J1 31IML-003 7-E14 39AP-003 15-L12 42-001 9-E16 47-008 10-D8 58S-003 12-M13 71BC-000 6-H5 72PWM-000 6-H13 86-501 15-J3 97ET2-003 11-E5 716C-000 4-F18 939YE-006 14-F2 SEAT-004 6-C20
0-040 2-O14 0-165 8-E16 0-345 12-N13 0-550 11-L20 0-818 6-L14 8X011-000 16-F7 11E3-001 5-B9 11S-004 3-B2 18VIM-005 12-K3 31IML-005 7-E12 39AP-004 15-L14 42-002 9-E16 47-009 10-D6 58S-004 12-M8 71BC-003 5-F15 72R-000 6-H11 86-502 15-J3 98ER1-000 11-M21 716DN-000 4-F18 939YE-007 5-H16 SEAT-005 6-C20
0-041 7-D5 0-166 8-E17 0-346 10-P7 0-558 17-I11 0-818 9-I11 8X011-000 17-E11 11E3-002 5-B9 11S-005 3-E3 18VIM-006 12-K1 31IML-006 7-E10 39B-000 13-G8 42-003 9-F17 47-011 10-D3 58S-005 12-M13 71BC-004 5-G11 72R-001 6-H10 86-503 15-J3 98ER1-000 18-M6 716DP-000 4-F18 939YE-007 14-G3 SEAT-006 6-D20
0-041 11-E15 0-167 8-E18 0-347 11-E14 0-560 17-D13 0-886 8-K13 8X011-001 17-E2 11E3-003 5-B3 11S-006 3-E2 18VIM-007 12-L2 31ML-004 7-E8 39B-001 13-G8 42-004 9-G17 47-012 10-E6 62A-000 12-E8 71BC-005 5-G11 72R-002 6-I6 86-504 15-J6 98ER2-000 11-M21 716G-000 4-F18 939YE-008 12-G9 SEAT-007 6-D20
0-042 2-N10 0-168 8-F17 0-348 11-E12 0-565 17-C19 0-887 8-K13 8X012-000 16-G7 11E3-004 5-B3 11SL-000 9-C14 18VIM-008 12-L1 31ML-007 7-E8 39BA-000 13-H12 42-005 9-G20 47-015 10-E3 62SB-000 12-A8 71BC-006 5-G11 72R-003 6-G7 86-505 15-J6 98ER2-000 18-M6 716P-000 4-F18 939YE-008 14-G6 SHIELD-001 12-K4
0-043 2-L12 0-169 8-F18 0-349 11-E12 0-566 17-C19 0-888 5-K13 8X012-000 17-F11 11E3-005 5-B2 11SL-001 9-D13 18VIM-009 12-I4 31RR-000 9-K6 39BA-001 13-G13 42-006 9-F20 47-016 10-C14 62SB-001 12-A11 71BC-007 5-G11 72R-004 6-H9 86-506 15-J3 98ET1-000 11-M21 717B-000 4-G18 939YE-009 14-E9 SHIELD-002 12-K4
0-044 17-D13 0-170 8-F17 0-350 11-E12 0-567 17-C19 0-888 11-E15 8X012-001 17-F2 11E3-006 5-B6 11SM1-000 2-M14 18VIM-010 12-L4 31RR-001 9-K5 39BA-002 13-G15 42-007 9-F16 47-017 10-E4 62SB-002 12-A12 71BC-008 5-F17 72RA-000 6-G9 86-507 15-K5 98ET1-000 18-M6 717C-000 4-H18 939YE-010 11-B14 SHIELD-003 12-K10
0-045 17-E13 0-171 8-F18 0-351 11-E12 0-568 17-D19 0-897 8-M13 8X013-011 17-D2 11E3-007 5-B6 11SM1-001 2-M16 18VIM-011 12-I6 31RR-002 9-K2 39BA-005 13-G18 42-008 9-F16 47A-000 10-D8 62SB-003 12-A13 71BC-008 6-G6 72RA-001 6-G7 86-508 15-K6 98ET2-000 11-M21 717DN-000 4-G18 939YE-010 14-F14 SHIELD-004 12-K10
0-046 17-F15 0-172 8-G17 0-352 11-E16 0-569 17-D19 0-898 8-N14 8X013-020 17-D7 11E4-000 5-B12 11SM1-002 2-M19 21NSL-000 5-C2 31RR-003 9-K4 39BA-006 13-H13 42-009 9-F14 47B-000 10-D7 62SB-004 12-A10 71BC-010 6-H3 72RA-002 6-G10 86-509 15-K6 98ET2-000 18-M6 717DP-000 4-H18 939YE-011 14-F4 SHIELD-005 13-K11
0-047 17-G15 0-173 7-K12 0-353 11-E16 0-571 17-E19 0-899 8-M14 8X013-026 17-D2 11E4-001 5-B9 11SM1-003 2-M17 21NSL-001 5-C9 32OR-000 9-L2 39BA-009 13-H15 42-010 9-F14 47S-000 10-B8 62SBA-000 12-B15 71BC-010 12-M17 72RA-002 10-C4 86-510 15-J3 100-000 11-H12 717G-000 4-G18 939YE-012 14-G7 SHIELD-006 12-M5
0-049 6-C16 0-176 8-L6 0-354 12-J15 0-573 17-E19 0-900 11-L2 8X013-028 17-C4 11E4-002 5-B2 11SM1-004 2-M13 21NSL-002 5-C6 32OR-001 9-L2 39BA-010 13-H17 42-011 9-F13 47S-001 10-B6 63-000 10-K5 71C-000 4-C8 72RQ-000 2-D17 86-511 15-I6 100-001 11-H14 717P-000 4-G18 939YE-013 14-E19 SHIELD-122 9-O4
0-051 3-H13 0-177 11-L20 0-359 8-N13 0-577 17-G19 0-901 6-C7 8X013-028 17-G10 11E4-003 5-B9 11SM1-005 2-M11 21NSL-003 3-I5 32OR-002 9-L5 39C-000 13-G8 42-012 9-F13 47S-002 10-B5 63-001 10-L4 71CK-000 4-D10 72RQ-001 2-D19 87-000 12-D14 101-000 11-H12 718B-000 4-J18 939YE-014 14-E14 SHIELD-853 9-M3
0-052 9-K12 0-185 7-G6 0-360 8-N6 0-578 17-G19 0-910 17-I8 8X013-029 17-I10 11E4-004 5-B3 11SM2-000 2-L15 21NSL-003 5-C13 32OR-003 9-L5 39C-001 13-G8 42-013 9-E16 47S-003 10-B5 63-002 10-M1 71CK-001 4-D15 72RQ-001 11-K6 87-001 12-I8 101-001 11-H14 718C-000 4-J18 939YE-015 14-E11 SHIELD-934 12-G11
0-052 11-L10 0-189 13-F19 0-362 14-J17 0-579 17-G19 0-936 6-J14 8X013-029 17-C4 11E4-005 5-B3 11SM2-001 2-M16 21NSL-004 5-D11 32OR-004 9-L12 39CA-000 13-H12 42-014 9-F19 48-000 8-G13 63-003 10-L2 71CK-002 4-D11 72RQ-002 11-K4 87-002 12-D13 510E-000 3-C11 718DN-000 4-J18 939YE-016 11-G18 SHIELD-935 12-G11
0-053 4-H4 0-190 5-I16 0-363 8-I19 0-580 17-H19 0-936 12-J14 8X013-030 17-C4 11E4-006 5-B6 11SM2-002 2-M19 21OR-002 5-D13 32OR-005 9-L10 39CA-001 13-H13 42-015 9-G19 48-001 8-G14 63-004 10-L2 71CK-003 4-D10 72RQ-003 11-K2 87-500 15-J1 510E-001 3-C20 718DP-000 4-K18 939YE-016 14-F12 SHIELD-936 12-J18
0-053 7-P10 0-190 5-L8 0-363 13-I19 0-581 17-H19 0ACL-000 9-K2 8X013-030 17-K10 11E4-007 5-B6 11SM2-003 2-M17 21OR-002 5-P8 32RR-000 9-L6 39CA-002 13-G15 42-016 9-F15 48-002 8-G14 63-005 10-L2 71CK-005 4-D11 72RRQ-000 2-E16 87-501 15-K3 510E2-000 12-H4 718G-000 4-J18 939YE-017 14-E14 SHIELD-936 12-G12
0-054 7-L13 0-191 14-L10 0-364 8-K19 0-583 17-H19 0ACL-001 9-L5 8X013-031 17-K12 11E5-000 5-B2 11SM3-000 2-L12 21OR-003 5-D9 32RR-001 9-L8 39CA-005 13-G18 42-017 9-F15 48-003 8-G14 63-006 10-L2 71CK-006 4-D11 72RRQ-001 2-E16 87-502 15-K3 510E2-004 12-H2 718P-000 4-J18 939YE-018 14-E16 SHIELD-971 5-I9
0-055 4-H4 0-192 14-L10 0-364 13-G19 0-585 17-H19 0ACL-002 9-M12 8X013-032 17-I11 11E5-001 5-B3 11SM4-000 2-L9 21OR-005 5-D13 32RR-002 9-L12 39CA-006 13-H13 42A-000 9-E15 48-004 8-G14 63-007 10-L2 71CKC-000 5-H15 72SBT-000 11-M2 87-503 15-K3 510E2-005 12-H1 910-000 17-H2 939YE-019 14-E16 SHIELD-972 5-I8
0-055 7-N10 0-195 14-L10 0-365 13-J8 0-589 17-D15 0ACL-003 9-M2 8X013-034 17-K14 11E5-002 5-B3 11ST-000 2-O9 21OR-005 5-N8 32RR-003 9-L10 39CA-009 13-I15 42A-001 9-E16 48-006 8-E17 63-008 10-L2 71CKC-001 5-I18 72SBT-001 11-M6 87-506 15-K3 510E2-005 18-C16 911-000 17-H2 939YE-020 14-F12 SHIELD-979 13-N5
0-056 8-F1 0-197 14-N10 0-366 2-F17 0-590 16-E1 0ACL-004 9-M3 8X013-035 17-K17 11E5-003 5-B6 11ST-001 2-L9 21ORR-001 5-D9 32RS-000 9-L2 39CA-010 13-I17 42A-002 9-E18 48-009 8-E17 63-009 10-K2 71CKC-002 5-I20 72SBT-002 11-M7 87-507 15-K5 510E2-006 18-F5 912-000 17-H2 939YE-020 17-G5 SHIELD-980 12-L17
0-056 10-C10 0-198 14-N10 0-367 13-H19 0-590 17-E11 0ACL-005 9-M10 8X013-036 17-K16 11E5-004 5-B6 11ST-002 2-K11 21ORR-003 5-P8 32RS-001 9-L2 39F-000 13-M8 42A-003 9-E19 48-010 8-E18 63-010 10-K4 71CKM-000 17-J18 72SBT-003 11-M4 87-510 15-K3 510E3-000 18-C3 913-000 17-H2 939YE-021 14-E6 SHIELD-981 9-E9
0-058 18-G5 0-199 13-G19 0-368 13-H19 0-601 5-C2 0BLF-000 9-I2 8X016-000 16-H7 11E5-005 5-B9 11ST-003 2-L9 21ORR-003 5-E13 32RS-002 9-L5 39F-001 13-L3 42A-004 9-E21 48-011 8-F17 63-011 10-L3 71CKM-001 17-J20 72T-000 6-H11 87-511 15-I6 510E3-005 18-C2 914-000 17-H2 939YE-022 7-E4 SHIELD-982 9-G9
0-059 6-M13 0-200 14-N10 0-369 13-I19 0-614 12-C12 0BRF-000 9-J2 8X016-000 17-F11 11E5-006 5-B9 11ST-005 2-G14 21ORR-005 5-N8 32RS-003 9-L12 39F-002 13-M3 42A-005 9-E20 48-012 8-F18 63H-000 10-P6 71F-000 11-B2 72T-001 6-H10 90-500 15-I6 510E3-007 18-C3 924-000 5-D2 939YE-022 14-F20 SHIELD-983 9-G11
0-060 5-B2 0-202 4-M14 0-370 13-I14 0-616 17-D15 0C-000 5-I9 8X016-001 17-F10 11E5-007 5-B10 11ST-006 2-G14 21ORR-005 5-D13 32RS-004 9-L10 39F-003 13-M3 42A-006 9-E17 48-013 8-G17 63H1-000 10-M2 71F-001 11-B5 72T-002 6-I9 90-501 15-J6 525-000 9-N12 924-001 5-D3 939YE-024 5-H18 SHIELD-984 9-G9
0-061 5-C2 0-202 13-E11 0-375 13-J9 0-634 5-I15 0C-001 5-I6 8X017-000 16-H7 11E6-000 5-B2 11ST-007 2-G14 21PL-000 2-O9 33-000 12-F14 39F-004 13-N2 42B-000 9-E15 48-017 8-G18 63L-000 10-O6 71F-002 11-C3 72T-007 6-K14 90-502 15-J6 525-001 9-N7 925-000 5-D2 939YK-000 14-H4 SHIELD-992 9-J2
0-062 5-C2 0-203 4-M6 0-375 13-K16 0-636 17-D15 0C-002 5-I3 8X017-000 17-F11 11E6-001 5-B3 11ST-008 2-L11 21PL-001 2-O12 33-001 12-F13 39F-005 13-M1 42B-001 9-E16 48-018 8-E20 63L1-000 10-O4 71F-002 13-J8 72T-007 6-I8 90-503 15-K6 525-002 9-N6 925-001 5-D3 939YK-001 13-L14 SHIELD-993 12-L2
0-063 5-B3 0-204 4-M7 0-376 4-J4 0-637 17-D13 0C-002x 5-J18 8X017-001 17-F10 11E6-002 5-B3 11TP-000 14-I4 21PS-000 3-K12 33-002 12-E8 39F-006 13-N6 42B-002 9-E18 48-019 8-G20 63L1-001 10-O4 71F-003 11-C8 72TC-000 11-J2 90-506 15-K6 525-003 9-N10 926-000 5-D2 939YK-001 14-H3 SHIELD-994 9-E11
0-064 5-B3 0-211 4-M9 0-376 12-H5 0-637X 5-I18 0C-003 5-I1 8X045-002 16-I7 11E6-003 5-B6 11TP-001 14-I8 21PS-001 2-M16 33-003 12-F12 39F-007 13-L1 42B-003 9-E19 48-020 8-F20 63L1-002 10-O4 71F-003 12-F6 72TC-001 11-J6 90-507 15-K6 525A-000 9-M2 926-001 5-D3 939YK-002 14-H8 SHIELD-995 9-E9
0-065 5-C3 0-212 4-M9 0-377 10-N8 0-638 5-C2 0C-003X 5-J20 8X045-002 17-F11 11E6-004 5-B6 11TP-002 14-I9 21PS-002 2-M11 33BLF-000 9-I2 39F-008 13-M1 42B-004 9-E21 48-022 8-G20 63L1-003 10-O4 71F-004 11-B6 72TC-002 11-J7 90-510 15-I7 531SC-000 5-F2 939GA-000 18-L5 939YK-003 14-H6 SHIELD-996 12-L18
0-066 5-C3 0-213 4-N7 0-378 10-O6 0-638X 5-I20 0CAM-000 17-H2 8X045-003 17-F2 11E6-005 5-B9 11TP-003 14-I11 21PS-004 2-N6 33BP-000 12-F14 39F-009 13-N6 42B-005 9-E20 48-023 8-E18 63L2-000 10-M2 71F-005 11-B4 72TC-003 11-J4 90CAG-000 11-C2 531SC-001 5-F6 939GA-001 18-L7 939YK-004 14-H9 SHIELD-997 12-K17
0-067 5-C3 0-215 5-L6 0-380 10-N6 0-639 5-C3 0COMX-000 17-K2 8X046-000 17-G2 11E6-006 5-B9 11TP-004 14-I13 21PS-005 2-N10 33BP-001 12-F13 39FA-000 13-N8 42B-006 9-E17 48-024 8-E20 63P-000 10-N1 71GE-000 4-D3 73DS-000 9-J2 90CAG-001 11-C5 531SC-002 5-E9 939GA-002 18-L7 939YK-005 14-H11 SHIELD-998 12-K18
0-068 5-C3 0-216 4-H4 0-382 10-P7 0-640 5-C3 0DL-000 8-L9 8X047-000 17-I2 11E6-007 5-B10 11TP-004 14-F15 21PS-006 2-M19 33BP-002 12-H8 39FA-002 13-N6 42SL-000 9-D14 48-025 8-D20 63T1-000 10-N2 71GE-001 4-D5 73DS-001 9-J5 90CAG-002 11-D7 531SC-003 5-E18 939GA-003 18-L9 939YK-006 11-C14 SHIELD-999 9-I2
0-069 5-B9 0-216 5-M8 0-383 4-N7 0-641 5-C9 0DL-001 8-M9 8X048-000 17-I2 11ER-000 4-M3 11TP-005 14-I11 21PS-006 3-K11 33BP-003 12-F12 39FA-004 13-N2 42SL-002 9-E14 48A-000 8-F3 63W-000 10-M3 71GE-002 4-C3 73DS-002 9-J7 90CAG-003 11-D9 712-000 3-F7 939GA-004 18-K9 939YK-006 14-H13 SHIELD-1001 13-L5
0-070 5-B6 0-217 18-F5 0-384 4-N7 0-642 5-C6 0DL-002 8-N9 8X049-002 17-J2 11ER-001 4-M7 11TP-006 14-I5 21PT-000 2-N7 33BPS-000 12-L5 39FB-000 13-N8 42SL-003 9-D15 48A-001 8-F4 63W-001 10-M2 71GG-000 2-D15 73DS-003 11-G15 90CAG-004 11-C5 712-000 4-A10 939GA-005 18-K11 939YK-007 14-H14 SHIELD-1002 13-L7
0-071 5-B9 0-219 4-H4 0-388 5-E11 0-661 5-C3 0DL-003 8-N9 8X050-000 17-J14 11ER-002 4-M7 12CA-000 18-F2 21PT-002 2-N7 33BPS-001 12-L2 39FB-001 13-N6 42SL-004 9-D16 48A-002 8-F6 63W-002 10-M3 71GG-001 2-C19 73DS-004 9-K5 90CAR-000 11-C2 712-001 3-D19 939GA-006 18-L11 939YK-008 14-H14 SLT1A-000 11-O2
0-072 5-C6 0-219 5-M8 0-389 13-K11 0-662 5-C3 0DL-004 8-N10 8X050-001 17-I12 11ER-003 4-M8 12DP-001 18-F5 21PT-003 2-N6 33BPS-002 12-L1 39FB-003 13-N3 44-000 10-G6 48A-003 8-F7 63W-003 10-M8 71GG-001 3-A2 73DS-004 11-G17 90CAR-001 11-C5 712-001 4-A12 939GA-007 18-K13 939YK-009 14-H6 SLT1A-001 11-O4
0-073 5-C9 0-222 4-H8 0-390 10-O6 0-663 5-C6 0DL-005 8-N10 8X050-002 17-J9 11ER-004 4-M8 12DP-003 18-D15 21PT-004 2-N7 33BPS-003 12-L4 39FB-005 13-N1 44-001 10-G7 48A-004 8-F6 63W-004 10-M6 71GG-002 3-A3 73DS-005 11-G12 90CAR-002 11-D7 712-003 4-A11 939GA-008 18-L13 939YK-010 14-H2 SLT1A-002 11-O6
0-074 5-C6 0-222 5-O8 0-391 4-H4 0-664 5-C6 0DL-006 8-M11 8X050-003 17-J18 11ER-005 4-M9 12DP-004 18-D16 21PT-005 2-N7 33BRF-000 9-J2 39FC-000 13-L7 44-002 10-H8 48A-005 8-G7 65-000 4-L4 71GG-003 3-B15 73DS-006 9-J4 90CAR-003 11-D9 712-004 4-A11 939GE-000 5-H2 939YK-011 12-G9 SLT1B-000 11-P2
0-075 4-I8 0-223 4-H8 0-391 12-M17 0-665 5-C10 0DL-007 8-N11 8X050-004 17-J16 11ER-006 4-M5 12DP2-000 18-D2 21PT-007 2-M16 33F-000 12-C2 39FC-001 13-L3 44-003 10-G11 48A-006 8-F5 65-002 4-L9 71GH-000 2-D15 73S-000 3-G8 90CAR-004 11-D5 712-005 4-E10 939GE-001 5-H10 939YK-011 14-H5 SLT1B-001 11-P4
0-075 15-B7 0-223 5-O8 0-395 13-D9 0-665 12-N15 0DL1-000 8-L6 8X073-000 17-L2 11ER-007 4-M5 12DP2-001 18-D3 21PT-008 2-M19 33F-001 12-C4 39FC-003 13-L1 44-004 10-E14 48A-007 8-E6 65-003 4-L10 71GH-001 2-D19 73S-001 3-H4 90CAT-000 11-D2 712-006 3-F7 939GE-001 14-F1 939YP-000 14-B4 SLT1B-002 11-P6
0-076 15-B8 0-225 3-H10 0-397 13-D11 0-670 5-C10 0DL2-000 8-M6 8X073-001 17-L12 11FS-000 4-M3 12DP2-002 18-D3 21PT-008 4-E2 33FS-000 5-I6 39FD-000 13-L7 44-005 10-E14 48A-008 8-H6 65-009 4-L8 71GH-001 3-B2 73S-002 3-H10 90CAT-001 11-D5 712-006 4-A10 939GE-002 14-E13 939YP-002 14-B8 SLT2A-000 11-P2
0-078 15-B10 0-226 3-H10 0-398 2-J9 0-670 12-N15 0DL3-000 8-N6 8X074-000 17-L2 11FS-001 4-N6 12DP3-000 18-E5 21PT-010 4-C3 33FS-001 5-I3 39FD-001 13-M3 44-006 10-H10 48B-000 8-F3 65A-000 4-L4 71GH-002 3-B3 73S-003 3-H12 90CAT-002 11-E7 712-007 4-B12 939GE-003 5-H6 939YP-003 14-B11 SLT2A-001 11-P4
0-079 15-B4 0-229 6-J11 0-400 13-D10 0-671 10-I11 0DL4-000 8-O6 8X074-001 17-L12 11FS-002 4-N7 12DP3-001 18-D15 21PT-011 2-N7 33FS-002 5-I9 39FD-003 13-M1 44-007 10-G12 48B-001 8-F4 65A-001 4-M14 71GH-003 3-B15 73S-004 3-G5 90CAT-003 11-E9 712-008 4-B11 939GE-004 14-E6 939YP-005 14-B13 SLT2A-002 11-P6
0-080 4-H4 0-229 12-B14 0-401 4-G8 0-671 10-N6 0DOS-000 17-M2 8X075-000 17-M2 11FS-003 4-M4 12DP3-002 18-D16 21PT-012 2-N7 33FS-002X 5-J18 39G-000 3-B5 44-008 10-G7 48B-002 8-F6 65A-002 4-M14 71H-000 9-J2 73S-004 18-B19 90CAT-004 11-D5 712-008 6-B14 939GE-005 14-E8 939YP-007 13-M13 SLT2B-000 11-P2
0-080 15-C5 0-231 6-J11 0-401 13-D7 0-676 18-G10 0DOS-001 17-L12 8X075-001 17-M12 11H-000 10-L12 12GLA-000 18-H2 21PT-013 2-N7 33FS-003 5-I1 39G-001 3-B3 44D-000 10-G6 48B-003 8-F7 65A-003 4-L9 71H-001 9-J5 73S-005 18-B15 90DS-003 9-P2 712-009 4-B11 939GE-006 14-F2 939YP-007 14-B3 SLT2B-001 11-P4
0-081 15-C7 0-234 12-H3 0-402 4-J8 0-677 18-H10 0DOS-002 17-L12 8X076-000 17-M2 11H-001 10-L15 12H-000 5-J12 21S-000 3-E9 33HP1-001 12-J3 39G-001 13-I8 44D-001 10-G7 48B-004 8-F6 65A-004 4-L10 71H-002 6-H17 73S-006 18-B2 90ER1-002 11-H14 712-009 5-J6 939GE-007 5-H16 939YP-008 12-G9 SLT2B-002 11-P6
0-082 15-C8 0-235 5-E11 0-402 13-D7 0-678 10-H7 0DOS-003 17-M12 8X076-001 17-M12 11H-002 10-L16 12H-005 5-J11 21S-001 3-E10 33HP1-002 12-J1 39H-000 6-L12 44D-002 10-I8 48B-005 8-G7 65A-005 4-L8 71H-002 9-J7 73S-007 3-G7 90ER1-003 11-H12 712A-000 4-G10 939GE-007 14-G3 939YP-008 14-B5 SLTH1-000 4-M18
0-084 4-H8 0-237 8-F12 0-403 4-G8 0-679 4-I4 0DOS-004 17-K9 8X077-000 17-N2 11H-003 10-L14 12H-006 5-J9 21S-002 3-F14 33HP2-001 12-K3 39H-001 6-L11 44D-003 10-G9 48B-006 8-F5 65C-000 5-K3 71H-003 9-J4 73S-008 3-G6 90ER2-002 11-H14 712BL-000 6-K6 939GE-008 12-H9 939YP-010 11-B14 SLTH2-000 4-M18
0-084 7-P10 0-238 5-E12 0-403 13-B8 0-679 10-H6 0DOS-005 17-K9 8X077-001 17-N12 11HH-000 5-O2 12H-007 5-J11 21S-003 3-I4 33HP2-002 12-K1 39H-002 6-N7 44D-004 10-I10 48B-007 8-E6 65C-001 5-K1 71LS-000 8-B2 73S-009 3-G8 90ER2-003 11-H12 712BL-001 6-K9 939GE-008 14-G6 939YP-010 14-C17 SLTX1-000 4-M18
0-085 5-F2 0-238 6-J11 0-404 13-B9 0-680 10-H9 0DOS-006 17-K9 8X078-000 17-N2 11HH-002 5-O4 12H-008 5-J12 21S-004 3-E11 33J-000 12-C14 39H-003 6-O8 44D-005 10-H11 48B-008 8-G6 65S-000 5-C13 71LS-001 8-B5 73S1-000 3-H7 90ET1-002 11-H14 712BL-002 6-K14 939GE-009 14-E9 939YP-011 14-C15 SLTX2-000 4-M18
0-086 5-F6 0-239 6-N16 0-406 13-B11 0-688 18-E8 0DOS-007 17-K9 8X078-001 17-N12 11HL-000 7-L6 12H-009 5-J10 21SL-000 3-J4 33J-001 12-C13 39H1-000 6-O6 44D-006 10-H11 48C-000 8-G11 65S-001 5-C6 71LS-002 8-B6 73S1-000 3-C13 90ET1-003 11-H12 712BL-003 6-L13 939GE-010 11-B14 939YP-011 17-G5 SPR-000 18-N5
0-087 2-M14 0-240 4-I4 0-407 4-J8 0-689 18-E15 0DOS-008 17-K9 10V-000 9-M12 11HS-000 10-L12 12H-010 5-J10 22C-000 5-K3 33J-002 12-C12 39H1-001 6-O4 44D-007 10-H10 48C-001 8-F10 65S-002 5-C2 71LS-003 7-C4 73S1-002 3-H8 90ET2-002 11-H14 712BL-004 6-K9 939GE-010 14-F14 939YP-012 14-B2 SPR-008 12-J20
0-087 5-K4 0-240 10-C21 0-407 13-C8 0-690 12-B13 0DOS-009 17-K9 10V-001 9-K5 11HS-003 10-L13 12HS-000 18-G2 22C-001 5-G4 33J-003 12-C12 39H1-001 13-J8 44D-008 10-H7 48C-002 8-G10 65S-003 5-C9 71LS-004 8-B3 74DS-000 11-G13 90ET2-003 11-H12 712BL-005 6-K6 939GE-011 14-F4 939YP-013 14-B16 SPR-009 12-J20
0-088 2-N14 0-241 4-J4 0-410 13-C10 0-690 18-E17 0DOS-010 17-M12 10V-002 9-K2 11HS-006 10-L15 12LD-000 18-I2 22C-002 5-F2 33J-004 12-C15 39HA-000 6-L12 44R-000 5-F18 48C-003 8-H7 65SR-000 5-D19 71LS-005 13-D2 74DS-000 12-I17 90IMG-000 12-H8 712BL-005 6-C5 939GE-012 14-G7 939YP-016 14-B6 SPR1-000 7-I18
0-088 5-K5 0-241 10-E21 0-412 11-N8 0-691 10-E4 0DOS-011 17-N12 10V-003 9-K5 11IM2-000 3-H4 12LD-001 18-I15 22C-003 5-F2 33J-005 12-C14 39HA-001 6-L11 44R-001 5-F18 48C-004 8-E7 65SR-000 15-B2 71LS-006 7-C3 74DS-001 12-I14 90IMG-001 12-H13 712BL-006 6-K7 939GE-013 14-E19 939YP-017 14-B6 SPR1-001 7-I19
0-089 18-E2 0-243 10-C19 0-412 11-E15 0-692 12-N16 0DOS-012 17-N12 10V-004 9-N12 11INT-000 3-H4 12LD-002 18-I16 22C-004 5-G9 33JA-000 12-C2 39HA-002 6-N8 44R-001 6-K16 48C-007 8-E6 65SS-000 15-B4 71LS-006 8-C6 74DS-002 12-H8 90IMG-002 12-H15 712BL-007 6-B4 939GE-014 14-E14 939YX1 17-F20 SPR1-002 7-I17
0-090 5-B6 0-244 10-E19 0-413 4-H2 0-693 12-N14 0DS-003 9-P2 10V-005 9-K2 11KS-001 3-C3 12LD-004 18-I20 22C-005 5-G6 33JA-001 12-C4 39HP-000 12-E12 44R-003 5-F16 48C-008 8-G5 65SS-001 15-B8 71LS-007 7-C4 74DS-003 12-I13 90IMG-003 12-H17 712BL-007 6-K8 939GE-015 14-E11 939YX1-000 16-K4 SPR2-000 7-I18
0-091 10-I10 0-248 10-B17 0-414 4-H2 0-694 10-C18 0GSS-000 17-H2 10V-006 9-M10 11KS-002 3-C4 12LD-005 18-I21 22C-006 5-K1 33JB-000 12-H8 39L-000 15-L15 44R-003 10-F2 48F-000 8-B9 65SS-003 15-B10 71LS-008 8-B7 74HB-000 13-N11 90IMG-004 12-H13 712CCD-001 6-C17 939GE-016 11-G18 939YX1-000 17-K4 SPR2-001 7-I19
0-092 5-L2 0-249 10-C17 0-415 4-I2 0-695 12-N13 0LEV-002 9-O2 10V-007 9-N10 11KS-003 3-D6 12LD-006 18-I18 22D-004 5-H9 33JB-001 12-C10 39SP-000 12-E14 44R-004 5-F13 48F-001 8-B11 65SS-004 15-B11 71LS-011 8-B8 74LA-000 13-N11 90IMR-000 12-H8 712CCD-007 6-C16 939GE-016 14-F12 939YX1-002 16-J7 SPR2-002 7-I17
0-093 18-H5 0-251 10-C16 0-416 4-G6 0-696 4-J12 0LEV-003 9-O4 11-004 3-F9 11KS-004 3-D7 12LU-000 18-I2 22D-004X 5-K18 33JB-002 12-C10 39SU-000 9-I18 44R-005 5-F15 48F-002 8-B13 65SS-005 15-B11 71LS-011 13-D1 74N-000 9-O12 90IMR-001 12-H13 712CCD-010 6-C16 939GE-017 14-E14 939YX1-003 16-J10 SPR3-000 7-I18
0-094 18-D5 0-252 10-D16 0-417 4-H6 0-697 4-J12 0LF-000 9-C10 11-004 4-B6 11KS-005 3-B1 12LU-001 18-I15 22FO-000 5-F2 33JB-003 12-C11 39SU-001 9-I19 44R-006 5-F16 48F-003 8-B12 65T-000 5-K10 71P-000 9-I7 74N-001 9-O7 90IMR-002 12-H15 712DS-000 6-C17 939GE-018 14-E16 939YX1-005 16-J14 SPR3-001 7-I19
0-095 6-L14 0-253 10-H11 0-418 6-H16 0-698 10-E17 0LF-001 9-C5 11-005 4-B5 11KS-006 3-E7 12LU-002 18-I16 22FO-001 5-F6 33JB-004 12-C11 39SU-002 9-I19 45L-000 8-J4 48LF-000 8-B16 65T-000 15-B2 71P-001 9-I9 74N-002 9-O2 90IMR-003 12-H17 712DS-001 6-C19 939GE-019 14-E16 939YX1-005 17-C20 SPR3-002 7-I17
0-095 18-C22 0-254 10-H11 0-420 4-H8 0-699 4-I4 0LF-002 9-C2 11-006 4-B5 11KS-007 3-E3 12LU-004 18-I20 22FO-002 5-F9 33JB-005 12-B11 39SU-032 9-I17 45L-001 8-I5 48LF-001 8-B18 65T-001 5-L3 71P-002 9-J9 74N-003 9-O10 90IMR-004 12-H13 712DS-002 6-C18 939GE-020 14-F12 939YX1-006 16-K14 SPR4-000 7-I18
0-096 5-K1 0-255 4-G8 0-420 9-G16 0-699 12-M16 0LF-003 9-C2 11-007 2-H6 11KS-008 3-E4 12LU-005 18-I21 23C-000 5-I9 33LF-000 9-C10 41H-000 7-I14 45L-002 8-I5 48LF-002 8-C18 65T-002 5-L6 71P-003 6-H17 74SB1-000 11-G15 90IMT-000 12-H8 712DS-003 6-C20 939GE-020 17-G5 939YX1-006 17-D19 SPR4-001 7-I19
0-097 18-F5 0-255 10-E10 0-421 4-G8 0-703 5-K13 0RET-001 9-K2 11-007 4-B4 11KS-009 3-E1 12LU-006 18-I18 23C-001 5-I6 33LF-001 9-C5 41H-001 7-K2 45L-003 8-I6 48LF-003 8-B19 65T-003 5-K9 71P-003 9-I12 74SB1-001 17-J14 90IMT-001 12-H13 712DS2-000 6-B17 939GE-021 14-E6 939YX1-007 16-K12 SPR4-002 7-I17
0-098 6-N16 0-256 10-E6 0-421 9-F16 0-703 10-P8 0RET-004 9-N2 11-008 2-E6 11KS-010 3-D6 12V-000 4-E10 23C-002 5-I3 33LF-002 9-C2 41H-002 7-K5 45L-004 8-I9 48LF-004 8-C19 65T-004 5-K12 71P-004 9-K12 74SB1-002 2-C20 90IMT-002 12-G15 712DS2-001 6-B19 939GE-022 7-E4 939YX1-007 17-D19 SPR5-000 7-J18
0-100 18-H8 0-258 10-E3 0-422 4-I8 0-704 4-M9 0RET-006 9-M5 11-009 2-E6 11L-000 8-K1 12V-001 4-F13 23C-003 5-I1 33LF-003 9-C5 41H-003 7-K4 45L-005 7-E10 48LF-005 8-B21 65T-005 5-K7 71P-004 11-J10 74SB1-003 2-C18 90IMT-003 12-G17 712DS2-002 6-D20 939GE-022 14-F20 939YX1-008 16-K9 SPR5-001 7-J19
0-101 18-G5 0-259 10-E3 0-422 10-M11 0-704 14-K15 0RET-007 9-N10 11-010 3-B9 11L-001 8-K3 12V-001 11-L21 23C-004 5-J18 33PG-000 15-J12 41H-004 7-K2 45L-006 7-E13 48LF-006 8-C21 65T-006 5-K11 71P-005 9-H7 74SB1-004 2-C18 90IMT-004 12-G13 712DS2-003 6-B18 939GE-024 5-H18 939YX1-008 17-E19 SPR5-002 7-J17
0-102 8-B21 0-260 6-H13 0-424 4-H4 0-707 9-O7 0RET-008 9-N12 11-010 4-B4 11L-002 8-K4 12VR 17-F20 23C-005 5-J20 33PG-001 15-K12 41H-004 7-I14 45L-006 8-J8 49-001 7-K10 65T-007 5-K1 71P-005 11-B5 74SB1-005 2-C22 90MMG-000 11-A2 712G-000 7-F13 939GK-000 14-H4 939YX1-009 16-J4 SPR6-000 7-J18
0-103 8-B19 0-263 4-I8 0-424 9-G16 0-713 17-J10 0RF-000 9-B10 11-011 4-B5 11L-003 8-K4 12VR-000 17-D11 23F-000 3-D12 33PG-003 15-K15 41H-005 7-J15 45L-007 8-I7 49-003 3-C15 65TS-006 5-O4 71P-006 9-I10 74SB1-005 17-J17 90MMR-000 11-A2 712G-001 7-D15 939GK-001 13-L14 939YX1-010 16-J2 SPR6-001 7-J19
0-104 4-H8 0-263 10-E7 0-425 4-H4 0-714 17-E13 0RF-001 9-B5 11-012 4-B5 11L-003 13-D1 12VR-001 17-D11 23F-001 3-D15 33PG-004 15-J15 41H-006 7-J13 45L-008 7-F6 49-003 7-K8 65TS-008 5-N7 71P-007 9-I11 74SB1-006 17-J12 90MMT-000 11-A2 712G-001 7-F14 939GK-001 14-H3 939YX2-000 16-M4 SPR6-002 7-J17
0-104 8-B18 0-264 10-E16 0-425 8-C18 0-716 17-J12 0RF-002 9-B2 11-016 4-B5 11L-004 8-K1 12VR-002 17-D11 23F-002 3-D16 33PLR-000 15-K12 41H-006 7-F8 45L-009 8-I5 49-004 6-H18 65TS-009 5-N7 71P-008 9-I8 74SB1-007 17-J4 91ER1-000 11-K12 712G-002 7-F10 939GK-002 14-H8 939YX2-000 17-K4 SPR7-000 7-J18
0-105 8-C21 0-265 10-E16 0-426 4-I8 0-716 17-D2 0RF-003 9-B2 11-017 4-B6 11L-005 8-L3 12VR-003 17-D15 23F-003 3-D14 33PLR-001 15-K15 41HB-000 7-L8 45LL-000 8-J13 49-004 7-K7 67C-000 4-N3 71P-009 11-L9 74SB1-008 17-J2 91ER1-001 11-K16 712G-003 7-F6 939GK-003 14-H6 939YX2-001 16-M11 SPR7-001 7-J19
0-106 8-C19 0-266 6-H19 0-426 9-F16 0-717 2-O12 0TM-000 18-L5 11-017 18-C22 11L-006 8-K7 12VR-004 17-D11 23FA-000 3-D11 33PP-000 15-J12 41HB-001 7-L9 45LL-001 8-J16 49-005 7-K10 67C-001 4-N6 71P-010 11-B6 74SB1-009 17-D8 91ER1-002 11-K14 712G-004 7-F12 939GK-004 14-H9 939YX2-002 16-M7 SPR7-002 7-J17
0-107 5-B9 0-268 8-C8 0-428 13-E10 0-718 2-M15 0TM-001 18-L7 11-027 2-H5 11L-007 8-L2 12VR-005 17-D11 24CAM-000 17-M2 33PP-001 15-K12 41HB-002 7-L9 45LL-002 8-J14 49-007 7-K8 67C-002 4-O6 71P-011 11-B7 74SB1-009 17-J6 91ER2-000 11-K12 712H-001 9-I14 939GK-005 14-H11 939YX2-003 16-M9 SPR8-000 7-K18
0-108 5-C9 0-268 10-B10 0-429 15-C10 0-719 2-M16 0TM-002 18-L7 11-033 4-C13 11L-008 8-F1 12VR-006 17-D11 24CAM-001 17-L12 33PP-002 15-J15 41HB-003 7-L9 45LL-004 8-I18 49-008 7-K9 67C-003 4-N7 71P-012 11-B7 74SB1-010 2-C20 91ER2-001 11-K16 712H-002 9-I14 939GK-006 11-C14 939YX2-005 16-M15 SPR8-001 7-K19
0-109 5-C9 0-271 14-G15 0-430 15-C12 0-720 2-M17 0TM-003 18-L9 11-033 4-B4 11L-008 8-K4 12VR-007 17-F17 24CAM-002 17-L12 33PP-003 15-K15 41HB-004 7-L9 45LL-007 8-J16 49-009 7-K7 67C-004 4-O7 71P-013 11-B9 74SB1-010 7-G18 91ER2-002 11-K14 712H-003 9-H15 939GK-006 14-H13 939YX2-005 17-G19 SPR8-002 7-K17
0-110 7-L12 0-272 14-G15 0-431 15-C12 0-733 5-M11 0TM-004 18-K9 11-035 3-E19 11L-009 8-K6 12VR-008 17-F17 24CAM-003 17-M12 33PRR-000 15-K12 41HB-005 7-L12 45LL-008 8-J16 49-009 17-E8 67C-005 4-N4 71P-014 11-A8 74SB1-011 11-G14 91ET1-000 11-K12 712H-004 9-I13 939GK-007 14-H14 939YX2-006 16-N15 T19-000 4-D18
0-111 18-E9 0-273 14-J16 0-432 15-I14 0-734 5-M11 0TM-005 18-K11 11-035 4-C6 11L-010 7-I11 12VR-009 17-D11 24CAM-004 17-K8 33PRR-001 15-K15 41HB-006 7-L13 45LL-009 8-I20 49-010 17-E9 67C-006 4-O4 71P-016 9-I7 74SB1-012 11-G12 91ET1-001 11-K16 712H-009 9-I14 939GK-008 14-H14 939YX2-006 17-H19 T20-000 4-D18
0-112 7-L12 0-274 14-J16 0-433 15-J17 0-735 5-M11 0TM-006 18-L11 11A-000 10-M11 11L-010 8-K4 12VR-010 17-F15 24CAM-005 17-K8 33RF-000 9-B10 41HB-007 7-L12 45LL-010 8-I20 49-011 16-D1 67L-001 14-L12 71P-017 9-I6 74SB1-013 11-G14 91ET1-002 11-K14 712H-010 9-I16 939GK-009 14-H6 939YX2-007 16-N11 TM1A-000 4-B18
0-113 7-N13 0-275 14-L8 0-434 15-I14 0-736 5-M11 0TM-007 18-K13 11A-001 10-L11 11L-011 8-L4 12VR-011 17-F15 24CAM-006 17-K8 33RF-001 9-B5 41HB-008 7-L13 45LL-011 8-J19 49-011 17-E11 67L-002 14-L14 71P-018 9-I6 74SB1-014 11-G15 91ET2-000 11-K12 712IM-000 3-F8 939GK-010 14-H2 939YX2-007 17-H19 TM1B-000 4-B18
0-114 7-N12 0-276 9-F14 0-437 15-I16 0-737 5-M11 0TM-008 18-L13 11A-002 10-M13 11L-012 8-L4 12VR-014 17-F15 24CAM-007 17-K8 33RF-002 9-B2 41HB-009 7-M12 45LL-012 8-M19 51A1-000 12-A4 67M-000 14-L12 71P-019 11-F7 74SB1-014 14-G15 91ET2-001 11-K16 712K-000 3-E9 939GK-011 12-G9 939YX2-008 16-N9 TM1C-000 4-B18
0-115 7-O13 0-277 9-F13 0-438 15-I14 0-738 5-N11 1-000 2-E2 11A-003 10-N10 11L-013 8-L4 12VR-015 17-F15 24CAM-008 17-K8 33RF-003 9-B5 41HB-010 7-M13 45LL-012 10-I13 51A1-001 12-A3 67M-001 14-L14 71P-020 11-F8 74SB1-015 2-D22 91ET2-002 11-K14 712K-001 3-E10 939GK-011 14-H5 939YX2-008 17-I19 TM2A-000 4-C18
0-116 7-O12 0-278 10-P8 0-439 15-H16 0-739 5-N11 1-001 2-F2 11A-004 10-N11 11L-014 8-L4 12VR-017 17-D12 24CAM-009 17-K8 33SBA-000 11-M2 41HB-011 7-N12 45LL-017 8-I19 51A1-002 12-A5 67P-000 14-L2 71P-021 9-H9 74SB1-015 11-B4 92ER1-000 11-L12 712K-002 3-D9 939GP-000 14-B4 939YX2-009 16-M4 TM2B-000 4-C18
0-117 7-P13 0-278 14-G14 0-441 15-H19 0-740 5-N11 1-002 2-E2 11A-008 10-N10 11L-015 8-K1 12VR-017 17-J11 24CAM-010 17-M12 33SBA-001 11-M6 41HB-012 7-N13 45LL-018 10-I15 51A2-000 12-B2 67P-001 14-L5 71P-021 11-F6 74SB1-016 2-C22 92ER1-001 11-L16 712K-003 3-I4 939GP-002 14-B8 939YX2-010 16-M2 TM2C-000 4-C18
0-118 7-P12 0-279 9-G14 0-442 15-J19 0-741 5-N11 1M-000 2-G16 11A-009 10-N12 11L-016 8-L4 12VR-019 17-D15 24CAM-011 17-N12 33SBA-002 11-M7 41HM-000 7-O7 45LR-002 8-K7 52AA2-000 12-E8 67P-002 14-L5 71PS-000 2-D16 74SB1-016 11-G17 92ER1-002 11-L14 712K-004 3-E11 939GP-003 14-B11 BAT(+)-000 2-E3 USBDMD-000 13-N11
0-119 7-P12 0-280 9-G13 0-444 3-H14 0-742 5-N11 1S-000 2-F16 11A-010 10-N11 11LAD-000 18-C2 12VR-020 17-D11 24CAM-012 17-N12 33SBA-003 11-M4 41HM-001 7-O7 45R-000 8-J4 52ABA-000 6-K8 67P-003 14-L3 71PS-001 2-D15 74SBD-000 7-G16 92ER2-000 11-L12 712K-004 10-B10 939GP-005 14-B13 BAT(+)-001 2-F3 USBDMH-000 13-M11
0-120 7-P13 0-281 6-N10 0-444 10-P11 0-743 5-M13 5VFCR-000 5-I6 11A-011 10-L11 11LAD-001 18-C3 12VR-021 17-D15 24SON-000 7-E8 33SP-001 12-J3 41HM-002 7-O12 45R-001 8-J5 52ABA-001 6-M8 67P-004 14-L3 71SR-000 6-H13 74X-001 9-H4 92ER2-001 11-L16 712K-005 3-E11 939GP-007 13-M13 BAT(+)-002 2-E3 USBDPD-000 13-N11
0-121 7-L13 0-281 15-B6 0-445 3-H14 0-744 5-M13 5VFCR-001 5-I3 11A-012 10-N10 11LAD-002 18-C3 12VR-022 17-D15 24SON-001 7-D13 33SP-002 12-J1 41HM-003 7-O13 45R-002 8-J5 52B-000 6-L6 67P-005 14-L7 71SS-000 6-F14 74X-002 9-H2 92ER2-002 11-L14 712K-006 10-B9 939GP-007 14-C3 BAT(+)-005 2-H4 USBDPH-000 13-M11
0-122 7-M12 0-282 9-F17 0-445 10-O11 0-745 5-M13 5VFCR-002 5-I9 11A-012 14-G17 11LAD-003 18-C3 12VREG-000 4-L4 24SON-002 7-D13 33T-000 12-G14 41HM-004 7-P12 45R-003 8-J6 52B-001 6-M13 67P-006 14-L7 71SS-001 6-F16 74X-003 9-H7 92ET1-000 11-L12 712K-010 3-F12 939GP-008 12-G9 BAT(+)-007 2-E6 USBV-000 13-M11
0-123 7-M13 0-283 9-F20 0-446 7-I8 0-746 5-M13 5VFCR-002X 5-J18 11A1-000 10-O11 11LAD-004 18-C15 12VREG-001 4-L7 24SON-003 7-D13 33T-001 12-G13 41HM-005 7-P13 45R-004 8-J9 52B-002 6-M8 67P-010 14-L6 71SS-002 6-H13 74X1K-000 5-F2 92ET1-001 11-L16 712L-000 4-H10 939GP-008 14-C5 BAT(+)-008 2-E6 WMTBA-000 4-H18
0-124 7-N12 0-284 12-A13 0-446 13-A2 0-747 5-M13 5VFCR-003 5-I1 11A1-001 10-O11 11LAD-005 18-C3 12VREG-002 4-M7 24SON-004 7-E11 33T-002 12-H8 41L-000 7-I10 45R-005 7-E10 52B-003 6-N12 67P-012 14-L6 71SS-003 6-F15 74X1K-001 5-F6 92ET1-002 11-L14 712L-001 4-H12 939GP-009 14-B16 BAT(+)-009 2-F14 WMTBB-000 4-H18
0-125 7-N13 0-285 9-G17 0-448 2-G16 0-748 5-N13 5VFCS-000 5-I6 11A1-002 10-O11 11LAD-006 18-C3 12VREG-003 4-L8 24SON-005 7-E12 33T-003 12-F12 41L-001 7-I11 45R-006 7-E13 52B-004 6-N13 67P-015 14-L7 71VHM-000 11-C18 74X1K-002 5-E9 92ET2-000 11-L12 712L-002 4-H12 939GP-010 11-B14 BAT(+)-010 2-F14 WMTBC-000 4-H18
0-126 4-I8 0-286 9-G20 0-449 8-G20 0-749 5-N13 5VFCS-001 5-I3 11B1-000 4-E5 11LAD-007 18-C16 12VREG-004 4-M8 24VIM-000 3-K10 34AT-000 12-L18 41L-002 7-L2 45R-006 8-J8 52B-005 6-N14 67R-000 14-N2 71VHM-001 11-C16 74X1K-003 5-E18 92ET2-001 11-L16 712L-003 4-H12 939GP-010 14-C17 BAT(+)-0010 2-E6 WMTBG1-000 4-I18
0-126 7-N11 0-287 9-G21 0-450 6-L13 0-750 5-N13 5VFCS-002 5-I9 11B1-001 4-E5 11LAD-008 18-C17 12VREG-005 4-L9 24VIM-000 12-J14 34AT-001 12-J8 41L-002 7-I12 45R-007 8-J7 52B-006 6-N14 67R-001 14-N3 71VHM-002 11-D15 74Z-001 9-H4 92ET2-002 11-L14 712L-004 4-H12 939GP-011 14-C15 BAT(+)-011 2-F14 WMTBG2-000 4-I18
58B-06-05901-00 SEP 21
ELECTRICAL SCHEMATIC
980E-5
A50052, A50053, A50137, A50138
Sheet 19 of 21
DEVICE TABLE SPLICE AND TERMINAL BOARD TABLE
DEVICE SHEET-ZONE DEVICE SHEET-ZONE DEVICE SHEET-ZONE DEVICE SHEET-ZONE CONN WIRE ID'S SHEET-ZONE CONN WIRE ID'S SHEET-ZONE CONN WIRE ID'S SHEET-ZONE CONN WIRE ID'S SHEET-ZONE CONN WIRE ID'S SHEET-ZONE CONN WIRE ID'S SHEET-ZONE CONN WIRE ID'S SHEET-ZONE CONN WIRE ID'S SHEET-ZONE
12V POWER RELAY (12VPR) 4-E10 GB20 IM GND 12-M5 LAMP LOW MOUNT LEFT HI-BEAM 7-L15 SWITCH HOIST LIMIT 9-I16 SP001 SHIELD 9-I4 SP333 939YE 14-E14 TB10-P1 712CCD 6-C17 TB23-N4 712K 3-E12 TB26-G1 0BLF 9-I4 TB29-A2 15LRW 9-D4 TB32-H3 3-K12 TB35-N4 53H 9-J13
12VDC CONVERTER (12VCN) 4-E5 GB20 IM GND 12-K10 LAMP LOW MOUNT LEFT LOW-BEAM 7-N15 SWITCH HORN BUTTON 10-L18 SP002 SHIELD 9-J3 SP334 939GE 14-E14 TB10-P2 712CCD 6-C17 TB23-P1 39H1 6-O6 TB26-H1 33BLF 9-I4 TB29-B1 77G 9-D4 TB32-H4 24VIM 3-K12 TB35-P1 11RWL 7-F15
12VDC POWER PORT #1 (PWR1) 4-N9 GB20 IM GND 12-K4 LAMP LOW MOUNT RIGHT HI-BEAM 7-N15 SWITCH HYDRAULIC FILTER #1 12-E12 SP004 41H 7-I16 SP335 SHIELD 14-E15 TB10-P3 712CCD 6-C17 TB23-P4 39H1 6-O5 TB26-J1 33BRF 9-J4 TB29-B2 77G 9-D4 TB32-J1 52B 6-M10 TB35-P2 11RWL 7-F15
12VDC POWER PORT #2 (PWR2) 4-O9 GB21 PLM GND 5-J16 LAMP LOW MOUNT RIGHT LOW-BEAM 7-O15 SWITCH HYDRAULIC FILTER #2 12-E13 SP005 74SB1 17-J4 SP336 939YE 14-E16 TB10-P4 712CCD 6-C17 TB23-R1 712T 8-J2 TB26-K1 0BRF 9-J4 TB29-C1 77C 9-E4 TB32-J2 52B 6-M11 TB35-R1 68 12-N11 7
24VDC ALTERNATOR 2-I7 GB21 PLM GND 13-K11 LAMP MARKER/TURN LEFT FRT DECK 8-J21 SWITCH HYDRAULIC LAMP 10-N11 SP006 67R 14-N7 SP337 939GE 14-E16 TB10-R1 55K 7-D7 TB23-R4 712T 8-J2 TB26-L1 SHIELD 9-J4 TB29-C2 77C 9-E4 TB32-J3 52B 6-N11 TB35-R2 68 12-N11
24VDC AUXBOX BUS 4-C5 GB21 PLM GND 13-N9 LAMP MARKER/TURN LEFT SIDE DECK 8-I21 SWITCH HYDRAULIC TANK LVL 12-J21 SP007 0 14-N10 SP338 SHIELD 14-E16 TB10-R2 55K 7-D8 TB23-S1 72GD 11-L3 TB26-M1 SHIELD 9-I4 TB29-D1 77DP 9-E4 TB32-K1 52CS 6-J9 TB35-R4 68 12-N11
24VDC AUXBOX BUS 4-B5 GB21 PLM GND 13-M9 LAMP MARKER/TURN RIGHT FRT DECK 8-K21 SWITCH KEY (KEYSW) 3-E9 SP008 49 7-K8 SP339 939YK 14-H14 TB21-A1 510E2 12-H4 TB23-S4 72GD 11-L4 TB26-N1 55A 7-C17 TB29-D2 77DP 9-E4 TB32-K2 52CS 6-J9 TB35-S1 71F 11-B4
24VDC AUXBOX BUS 4-B5 GB30 CAB SHIELD GND 17-I8 LAMP MARKER/TURN RIGHT SIDE DECK 8-L21 SWITCH KOMVISION ON/OFF (KOMV) 17-K18 SP009 0 14-L10 SP340 939GK 14-H14 TB21-A2 510E2 12-H4 TB23-T1 71SS 6-F15 TB26-N2 55A 7-C16 TB29-E1 77B 9-E4 TB32-K3 52CS 6-J9 TB35-S2 11-C4
24VDC AUXBOX BUS 4-B5 GB31-A AUXBOX GND BLCK 4-H2 LAMP RED PAYLOAD LEFT 13-H19 SWITCH LADDER CONTROL 18-D21 SP10 45L 7-F7 SP341 SHIELD 14-H14 TB21-A3 12-I4 TB23-T2 71SS 6-F15 TB26-P1 55B 7-C17 TB29-E2 77B 9-E4 TB32-K4 52CS 6-J9 TB35-S3 71F 11-C4
24VDC AUXBOX BUS 4-B5 GB31-A AUXBOX GND BLCK 4-H6 LAMP RED PAYLOAD RIGHT 13-F19 SWITCH LADDER LIGHT GND LVL (LLSW) 8-E6 SP11 45R 7-F7 SP342 18VIM 12-I4 TB21-B1 12VREG 4-L5 TB23-U1 47S 10-B5 TB26-P2 55B 7-C16 TB29-F1 77DN 9-E4 TB32-L1 62SBA 12-B15 TB35-S4 71F 11-B4
24VDC AUXBOX BUS 4-B5 GB31-A AUXBOX GND BLCK 4-I6 LAMP RETARD LEFT REAR 10-G13 SWITCH LEFT ENGINE SERVICE LAMP (LESLS) 9-E14 SP12 0 7-G8 SP343 79A 10-C16 TB21-B3 12VREG 4-L5 TB23-U4 47S 10-B5 TB26-R1 55C 7-C17 TB29-F2 77DN 9-E4 TB32-M1 73S1 3-H8 TB35-T1 11ONS 7-G13
24VDC AUXBOX BUS 4-B5 GB31-A AUXBOX GND BLCK 4-H2 LAMP RETARD OP-CAB (DRL) 10-I12 SWITCH LEFT GROUND LEVEL SHUTDOWN (ESDS) 3-C2 SP015 0, SHIELD 5-J17 SP344 0 10-C18 TB21-B4 12VREG 4-M5 TB23-V1 6-N8 TB26-R2 55C 7-C16 TB29-G1 SHIELD 9-E4 TB32-M3 73S1 3-H8 TB35-T2 11ONS 7-G13
24VDC AUXBOX BUS 4-B5 GB31-A AUXBOX GND BLCK 4-I2 LAMP RETARD RIGHT REAR 10-H13 SWITCH LEFT WINDOW 14-M11 SP016 41L 7-I11 SP345 41T 10-F14 TB21-C1 13CA 12-I3 TB23-V4 39HA 6-N8 TB26-S1 55D 7-C17 TB29-G2 SHIELD 9-E4 TB32-P1 11TP 14-I5 TB35-T3 11ONS 7-G13
24VDC AUXBOX BUS 4-B5 GB31-A AUXBOX GND BLCK 4-M5 LAMP RIGHT DECK BACKUP 10-E3 SWITCH LOW BRAKE ACCUM PRESSURE 12-F16 SP017 0 4-G7 SP346 47 10-C15 TB21-C2 13CA 12-I4 TB23-W1 712H 9-H15 TB26-S2 55D 7-C16 TB29-H1 15RRW 9-F4 TB32-P2 11TP 14-I5 TB35-U1 712P 11-N5
24VDC AUXBOX BUS 4-B5 GB31-A AUXBOX GND BLCK 4-I6 LAMP RIGHT FOG 8-B22 SWITCH LOW STEERING PRESSURE 12-C1 SP018 0 4-H7 SP347 0 10-E17 TB21-D1 74ZA 10-G2 TB23-W2 712H 9-H15 TB26-T1 48 8-G14 TB29-H2 15RRW 9-F4 TB32-R1 712TP 14-I5 TB35-U2 712P 11-N5
24VDC AUXBOX BUS 4-B5 GB31-A AUXBOX GND BLCK 4-I2 LAMP RIGHT LOWER ENGINE SERVICE 9-G22 SWITCH MANUAL BACKUP LIGHT 10-C9 SP019 33JB 12-C11 SP348 44 10-E14 TB21-D2 74ZA 10-G2 TB23-W4 9-H15 TB26-T2 48 8-G14 TB29-J1 714G 9-F4 TB32-R2 712TP 14-I5 TB35-V1 75A2 11-B4
ACCELERATOR PEDAL 9-N15 GB31-A AUXBOX GND BLCK 4-G6 LAMP RIGHT UPPER ENGINE SERVICE 9-F22 SWITCH MASTER GROUND DISCONNECT (DISC-) 2-H14 SP020 0 4-I7 SP349 44D 10-H11 TB21-D4 74ZA 10-H2 TB23-X1 72RA 6-G9 TB26-T4 48 8-G14 TB29-J2 714G 9-F4 TB32-S1 52ABA 6-K8 TB35-V2 75A2 11-B4
ACTIVE ANTENNA 1 18-K15 GB31-A AUXBOX GND BLCK 5-M14 LAMP SERVICE BRAKE OP-CAB (SBL) 10-I12 SWITCH PARK BRAKE RELEASE PRESSURE 3-H13 SP025 0 4-I7 SP350 0 10-H11 TB21-F1 11LAD 18-C17 TB23-X3 72RA 6-G9 TB26-U1 48 8-G14 TB29-K1 714A 9-F4 TB32-S2 52ABA 6-L8 TB35-W1 68P 12-N11
ACTIVE ANTENNA 2 18-L15 GB31-A AUXBOX GND BLCK 5-N14 LAMP STOP/TAIL LEFT 10-E15 SWITCH PARK BRAKE SET 12-F16 SP026 0 4-H3 SP354 SHIELD 13-N5 TB21-F2 11LAD 18-C17 TB23-X4 72RA 6-G9 TB26-U2 48 8-G14 TB29-K2 714A 9-F4 TB32-T1 71ABA 6-N7 TB35-W2 68P 12-N11
AIR RESTRICTION SWITCH 1 12-G2 GB31-A AUXBOX GND BLCK 5-I15 LAMP STOP/TAIL RIGHT 10-F15 SWITCH PROPEL LOCKOUT (PLOS) 2-D15 SP027 0 4-H3 SP363 0 10-P7 TB21-F4 11LAD 18-C17 TB23-Y1 712G 7-F13 TB26-V1 11CAM 17-K17 TB29-L1 714DP 9-F4 TB32-T2 71ABA 6-N7 TB35-X1 45RL 8-K15
AIR RESTRICTION SWITCH 2 12-H1 GB31-A AUXBOX GND BLCK 5-N14 LEFT DECK HEATED MIRROR 13-C14 SWITCH RIGHT ENGINE SERVICE LAMP (RESLS) 9-E22 SP028 0 4-I3 SP364 24SON 7-D13 TB21-G1 12LD 18-I17 TB23-Y3 712G 7-F13 TB26-V2 11CAM 17-K17 TB29-L2 714DP 9-F4 TB32-T4 71ABA 6-N7 TB35-X2 45RL 8-K16
AIR SEAT DRIVER 6-C19 GB31-A AUXBOX GND BLCK 5-F11 MODULAR MINING DISPLAY (PTX-C) 11-K12 SWITCH RIGHT GROUND LEVEL SHUTDOWN (OPT LOCATION) ... 3-E2 SP029 0 4-I3 SP365 0 6-H19 TB21-G2 18-I18 TB23-Y4 712G 7-F13 TB26-W1 90CAG 11-C5 TB29-M1 714B 9-G4 TB33-A1 72AT 12-F3 TB35-Y1 45RL 8-K16
AIR SEAT PASSENGER 6-D20 GB31-A AUXBOX GND BLCK 5-C10 MOTOR STARTER 1 (STRT1) 2-L9 SWITCH RIGHT LADDER LIGHT GND LVL (OPT LOCATION) (... 8-G5 SP030 63 10-L4 SP366 71P 9-I11 TB21-G4 12LD 18-I18 TB23-Z1 712K 3-F12 TB26-W2 90CAG 11-C5 TB29-M2 714B 9-G4 TB33-A2 12-F3 TB35-Y3 45RL 8-K15
ALARM GROUND LEVEL LADDER 18-H8 GB31-A AUXBOX GND BLCK 5-C10 MOTOR STARTER 2 (STRT2) 2-L11 SWITCH RIGHT WINDOW 14-N11 SP035 45L 8-I5 SP394 SHIELD 5-I10 TB21-H1 12LU 18-I17 TB23-Z2 712K 3-F12 TB26-W3 90CAG 11-C5 TB29-N1 714DN 9-G4 TB33-B1 72MAN 12-F3
ALARM KOMVISION ERROR (ESON) 17-I7 GB31-A AUXBOX GND BLCK 5-B10 MOTOR STARTER 3 (STRT3) 2-K14 SWITCH ROTATING BEACON (OPT) 13-E2 SP036 45R 8-J5 SP395 SHIELD 14-H11 TB21-H2 18-I18 TB24-A1 11SL 9-C15 TB26-X1 90CAR 11-C5 TB29-N2 714DN 9-G4 TB33-B2 12-F3
ALARM KOMVISION RADAR (RSON) 17-I7 GB31-A AUXBOX GND BLCK 5-M14 MOTOR WINDOW LH 14-L16 SWITCH SERVICE BRAKE DEGRADE PRESSURE 12-G16 SP037 712 4-B12 SP396 939GK 14-H11 TB21-H4 12LU 18-I18 TB24-A2 11SL 9-D15 TB26-X2 90CAR 11-C5 TB29-P1 SHIELD 9-G4 TB33-C1 73S 3-G7
ANTENNA SATELLITE (OPT) 11-E21 GB31-A AUXBOX GND BLCK 5-C10 MOTOR WINDOW RH 14-N17 SWITCH SERVICE BRAKE PRESSURE 5-F12 SP046 939YX1 16-J7 SP397 939YK 14-H11 TB21-J1 87 12-D14 TB24-B1 52PB 6-I9 TB26-X3 90CAR 11-D5 TB29-P2 SHIELD 9-G4 TB33-C3 73S 3-G7
ANTENNA TPMS 4G WIFI 18-L1 GB31-A AUXBOX GND BLCK 12-N13 MOTOR WINDSHIELD WASHER 10-M9 SWITCH SPEED CONTROL MODULE 9-M15 SP047 939GX1 16-K7 SP399 13LS 18-G9 TB21-J2 87 12-D14 TB24-B2 52PB 6-I9 TB26-Y1 90CAT 11-D5 TB29-R1 72FD 5-F16 TB33-J1 SHIELD 9-B5
ANTENNA TPMS GPS 18-K1 GB31-A AUXBOX GND BLCK 12-C12 MOTOR WINDSHIELD WIPER 10-O8 SWITCH SPEED CONTROL ROCKER 9-K10 SP048 SHIELD 16-K8 SP400 0 18-G12 TB21-J4 87 12-D14 TB24-C1 712DS 6-C18 TB26-Y2 90CAT 11-D5 TB29-R2 72FD 5-F17 TB33-J3 9-B5
ANTENNA WIRELESS (OPT) 11-H18 GB31-A AUXBOX GND BLCK 13-J8 PAYLOAD METER 4 13-N9 SWITCH STEERING BLEED PRESSURE 12-C1 SP049 939YX1 16-J10 SP401 0 12-N14 TB21-K1 72P 6-H8 TB24-C4 712DS 6-C18 TB26-Y3 90CAT 11-D5 TB29-R3 5-F16 TB33-J4 SHIELD 9-B5
BACKUP HORN LEFT 10-C16 GB31-A AUXBOX GND BLCK 15-B7 PLM4 COMMUNICATION BOX 13-O14 SWITCH STEERING FILTER 12-E15 SP050 939GX1 16-K10 SP407 0 3-H13 TB21-K4 72P 6-H9 TB24-D1 65 4-L7 TB26-Z1 SHIELD 11-D5 TB29-S1 79RD 5-E16 TB33-K1 0RF 9-B5
BACKUP HORN RIGHT 10-B16 GB31-A AUXBOX GND BLCK 15-I14 POWER LADDER CONTROLLER 18-I2 SWITCH TRACTION CONTROL 11-K8 SP055 SHIELD 16-K10 SP408 0 3-H13 TB21-L1 72R 6-H8 TB24-D4 65 4-L8 TB26-Z2 SHIELD 11-D5 TB29-S2 79RD 5-E17 TB33-K3 0RF 9-B5
BATT1 2-E2 GB31-B AUXBOX GND BLCK 2-M19 PRE LUBE HIGH VOLUME PUMP 2-O14 SWITCH TRACTION MOTOR PRESSURE (BPSW) 11-A8 SP056 939YX1 16-J13 SP412 0 2-M15 TB21-L2 72R 6-H8 TB24-E1 72PA 6-H8 TB26-Z3 SHIELD 11-D5 TB29-S3 5-F16 TB33-K4 0RF 9-B5
BATT2 2-E3 GB31-B AUXBOX GND BLCK 3-H8 PROPULSION ALTERNATOR 4-D21 T1 14-B1 SP057 939GX1 16-K13 SP413 73S 3-G8 TB21-L3 72R 6-H9 TB24-E2 72PA 6-H8 TB27-A1 11E1 5-A12 TB30-A1 58S 12-M13 TB33-L1 33RF 9-B5
BATT3 2-F2 GB31-B AUXBOX GND BLCK 3-E19 QSK95 - ENGINE INTERFACE TIER IV 5-H2 T2 14-B4 SP058 SHIELD 16-K13 SP414 73S 3-G6 TB21-M1 72N 6-H8 TB24-F1 65A 4-L7 TB27-A2 11E1 5-A12 TB30-A2 58S 12-M13 TB33-L2 33RF 9-B5
BATT4 2-F3 GB31-B AUXBOX GND BLCK 4-F7 R2 12-C14 T3 14-B6 SP059 939YX2 16-M7 SP453 0 6-N17 TB21-M2 72N 6-H8 TB24-F4 65A 4-L8 TB27-A4 11E1 5-A12 TB30-A3 58S 12-M13 TB33-L3 9-B5
BATT5 2-E2 GB31-B AUXBOX GND BLCK 4-F7 R3 12-M14 T4 14-B13 SP060 939GX2 16-M7 SP460 63W 10-M3 TB21-M4 72N 6-H9 TB24-G1 71GE 4-D5 TB27-B1 11E2 5-B12 TB30-B1 57TPU 12-M13 TB33-L4 33RF 9-B5
BATT6 2-E3 GB31-B AUXBOX GND BLCK 4-F7 R4 7-F8 T5 14-E18 SP065 SHIELD 16-M7 SP461 63L1 10-O4 TB21-N1 72F 6-H8 TB24-G2 71GE 4-D5 TB27-B2 11E2 5-B12 TB30-B2 57TPU 12-M13 TB33-M1 15RFWS 9-B5
BATTERY BOX FUSE HOLDER 2-I5 GB31-B AUXBOX GND BLCK 4-K12 R5 7-F8 T6 14-F4 SP066 939YX2 16-M9 SP462 71BC 5-G11 TB21-N2 72F 6-I8 TB24-G4 71GE 4-D5 TB27-B4 11E2 5-B12 TB30-C1 5VIM 12-J10 TB33-M4 15RFWS 9-B5
BUS BAR 24VDC BATT BOX 2-E6 GB31-B AUXBOX GND BLCK 4-H10 R14 6-N8 T7 14-F6 SP067 939GX2 16-M9 SP463 12DP2 18-D3 TB21-N4 72F 6-H9 TB24-H1 11KS 3-D6 TB27-C1 11E3 5-B12 TB30-C2 5VIM 12-J10 TB33-N1 SHIELD 9-C5
BUS17 4-M8 GB31-B AUXBOX GND BLCK 5-P3 R15 12-D12 T8 14-F21 SP068 SHIELD 16-M10 SP503 71F 11-B5 TB21-P3 72T 6-I8 TB24-H2 11KS 3-D6 TB27-C2 11E3 5-B12 TB30-D1 33JB 12-B11 TB33-N3 SHIELD 9-C5
BUSS BAR BAT(-) 2-G4 GB31-B AUXBOX GND BLCK 5-E12 R16 7-E13 T11 14-H1 SP069 939YX2 16-M13 SP507 33J 12-C15 TB21-P4 72T 6-I9 TB24-H3 11KS 3-D6 TB27-C4 11E3 5-B12 TB30-D2 33JB 12-B11 TB33-P1 0LF 9-C5
BUSS_BAR_0 2-H14 GB31-B AUXBOX GND BLCK 6-C8 R18 6-J10 T12 14-H3 SP070 939GX2 16-M13 SP716 41T 10-G17 TB21-R1 71H 9-J3 TB24-H4 11KS 3-D6 TB27-D1 11E4 5-B12 TB30-D4 33JB 12-B11 TB33-P2 0LF 9-C5
BUSS_BAR_11 2-F14 GB31-B AUXBOX GND BLCK 7-K10 R19 12-B12 T13 14-H5 SP075 SHIELD 16-M13 SP717 0 10-H17 TB21-R2 9-J4 TB24-J2 712 4-A11 TB27-D2 11E4 5-B12 TB30-E1 18VIM 12-I5 TB33-P3 9-C5
BUSS_BAR_11ST 2-G14 GB31-B AUXBOX GND BLCK 8-K13 R21 9-L6 T16 14-H17 SP100 712L 4-H12 SP719 41T 10-J17 TB21-R3 9-J3 TB24-J3 712 4-A11 TB27-D4 11E4 5-B12 TB30-E2 18VIM 12-I6 TB33-P4 0LF 9-C5
BUSS_BAR_BAT- 2-G14 GB31-B AUXBOX GND BLCK 8-F12 R27 7-K12 T17 14-E9 SP104 0 4-H12 SP720 0 10-J16 TB21-R4 71H 9-J4 TB24-J4 712 4-A11 TB27-E1 21NSL 5-C11 TB30-F1 39 12-D13 TB33-R1 33LF 9-C5
CAMERA 1 17-L15 GB31-B AUXBOX GND BLCK 9-O8 R30 12-N12 TERM #8 14-E22 SP106 11S 3-B5 SP734 SHIELD 12-G12 TB21-S1 73DS 9-J3 TB24-K1 712 4-A11 TB27-E2 21NSL 5-C11 TB30-F2 39 12-D14 TB33-R2 33LF 9-C5
CAMERA 2 17-L15 GB31-B AUXBOX GND BLCK 11-L3 R31 8-J14 TERM#1 14-B1 SP108 21PS 2-M11 SP735 SHIELD 12-J17 TB21-S3 73DS 9-K4 TB24-K3 712 4-A11 TB27-E4 21NSL 5-D11 TB30-G1 51A1 12-A4 TB33-R3 9-C5
CAMERA 3 17-M15 GB31-B AUXBOX GND BLCK 11-L21 R32 8-K14 TERM#4 14-H1 SP109 0 5-C3 SP736 0 12-J15 TB21-S4 73DS 9-J4 TB24-K4 712 4-A11 TB27-G1 22C 5-G10 TB30-G2 51A1 12-A5 TB33-R4 33LF 9-C5
CAMERA 4 17-M15 GB31-B AUXBOX GND BLCK 11-L21 R51 5-D13 TERM#5 14-H17 SP111 11E4 5-B3 SP777 65TS 5-N7 TB21-X3 0 6-J12 TB24-L1 11B1 4-E8 TB27-H1 28EC 5-D11 TB30-H1 712M 3-D13 TB33-S1 15LFWS 9-C5
CAMERA 5 17-N15 GB32 BACK AUX PANEL 4-K12 RADAR 1 KOMVISION 17-C21 TERMX1 16-K1 SP112 11E1 5-A3 SP778 712BL 6-K7 TB21-X4 0 6-J12 TB24-L2 11B1 4-E8 TB27-H2 28EC 5-D11 TB30-H2 712M 3-D12 TB33-S4 15LFWS 9-C5
CAMERA 6 17-N15 GB32 BACK AUX PANEL 4-J12 RADAR 2 KOMVISION 17-D21 TERMX3 16-M1 SP113 11E2 5-A3 SP779 52B 6-M13 TB21-Y1 0 6-J13 TB24-L3 11B1 4-E8 TB27-J1 52GE 6-C5 TB30-L1 35L2 13-K14 TB33-T1 74X 9-H4
CB1 4-B8 GB33 LH AUX PANEL 4-J12 RADAR 3 KOMVISION 17-E21 THERMOSTAT ENGINE OIL 15-I6 SP114 11E3 5-B3 SP780 11PHH 5-O6 TB21-Y3 0 6-J12 TB24-L4 11B1 4-E8 TB27-J2 52GE 6-C5 TB30-L2 35L2 13-K15 TB33-T4 74X 9-H4
CB60 4-E6 GB34 AUX FLOOR 4-J13 RADAR 4 KOMVISION 17-F21 THERMOSTAT HYDRAULIC OIL 15-K7 SP115 0 5-B3 SP789 SHIELD 12-L19 TB21-Y4 0 6-J12 TB24-M1 72FNR 6-K11 TB27-K1 21OR 5-D11 TB30-M1 35L3 13-K14 TB33-V1 SHIELD 9-H4
CONTROL GROUP BLOWER MOTOR 4-L21 GB34 AUX FLOOR 4-J13 RADAR 5 KOMVISION 17-G21 THERMOSTAT OIL RESERVE TANK 15-H7 SP116 0 5-C3 SP791 SHIELD 12-K19 TB21-Z1 12H 5-J10 TB24-M2 72FNR 6-K11 TB27-K2 21OR 5-D11 TB30-M2 35L3 13-K15 TB33-V4 SHIELD 9-H4
CONTROLLER TIRE MONITORING 18-O5 GB35 RH AUX PANEL 4-K13 RADAR 6 KOMVISION 17-H21 TIMER WASHER DELAY MOD (WADT) 10-M8 SP117 0 5-C3 SP794 53H 9-J17 TB21-Z3 12H 5-J10 TB24-M3 6-K11 TB27-K4 21OR 5-D11 TB30-N1 35L4 13-K14 TB33-W1 74Z 9-H4
COOLANT LEVEL SWITCH 5-D5 GB35 RH AUX PANEL 4-K13 RADAR 7 KOMVISION 17-I21 TIMER WIPER DELAY MOD 10-M5 SP130 SHIELD 12-L2 SP799 0 12-D3 TB21-Z4 12H 5-J10 TB24-M4 72FNR 6-K11 TB27-L1 21ORR 5-D11 TB30-N2 35L4 13-K15 TB33-W4 74Z 9-H4
D1 9-I20 GB70 FRAME GND 2-I9 RADAR 8 KOMVISION 17-I21 TR2 14-B18 SP132 24VIM 12-J15 SP806 67P 14-L7 TB22-A1 11D 7-I5 TB24-N3 71CK 4-D11 TB27-L2 21ORR 5-D11 TB30-P1 712S1 13-J14 TB33-X1 47 10-D12
D2 5-G12 GB70 FRAME GND 2-J9 RELAY ACCESS LADDER LIGHT (ALLR) 8-G12 TR8 18-K15 SP135 0 12-E16 SP807 74SB1 11-G14 TB22-A4 11D 7-I5 TB24-N4 71CK 4-D11 TB27-L4 21ORR 5-E11 TB30-P2 712S1 13-J15 TB33-X3 47 10-D12
D3 6-N15 GB70 FRAME GND 2-I9 RELAY AHT LADDER DOWN 18-E5 TR9 18-L15 SP136 SHIELD 9-G10 SP809 712H 9-I14 TB22-B1 11H 10-L13 TB24-P1 71CK 4-D11 TB27-M1 65S 5-C13 TB30-R1 35L7 13-J14 TB33-Y1 47 10-D12
D4 8-K7 GB70 FRAME GND 2-J9 RELAY AHT LADDER UP 18-F5 TURBO COMP INLET TEMP SENSOR 5-E5 SP137 SHIELD 9-G11 SP810 39SU 9-I19 TB22-B2 10-L14 TB24-P3 71CK 4-D11 TB27-M2 65S 5-C13 TB30-R2 35L7 13-J15 TB33-Y2 47 10-D12
D5 18-H10 GE CONTROL CABINET 4-M18 RELAY BACKUP LIGHT (BULR) 10-D9 TX0 16-K1 SP138 SHIELD 9-E11 SP819 939YE 14-F2 TB22-B4 11H 10-L14 TB24-P4 71CK 4-D11 TB27-N1 74SB1 2-C21 TB30-R4 0 13-K15 TB34-A1 41TS 7-J3
D6 9-J19 GE CONTROL INTERFACE 3-E21 RELAY CAB LADDER ALARM 18-G5 TX9 16-M1 SP139 SHIELD 9-E10 SP820 939GE 14-F2 TB22-C1 11L 8-K1 TB24-R1 63 10-K3 TB27-N2 74SB1 2-C21 TB30-S1 35L8 13-J14 TB34-A2 41TS 7-J3
D7 12-N20 GE CONTROL INTERFACE 4-D2 RELAY ENGINE PRE LUBE 2-O9 USER PC 11-L12 SP140 SHIELD 9-E9 SP821 SHIELD 14-F2 TB22-C3 11L 8-K1 TB24-R4 63 10-K4 TB27-N3 2-C21 TB30-S2 35L8 13-J15 TB34-B1 41H 7-K5
D9 7-D14 GE CONTROL INTERFACE 5-G19 RELAY ENGINE PRE LUBE MAG SWITCH (PLMS) 2-O12 VEC-89 4-C15 SP142 0 8-I20 SP825 0 11-F8 TB22-C4 11L 8-K1 TB24-S1 67R 14-N3 TB27-P1 74SB1 2-C21 TB30-T1 SHIELD 13-K14 TB34-B2 41H 7-K5
D10 7-D14 GE CONTROL INTERFACE 6-C3 RELAY GROUND LEVEL ALARM 18-H5 VEC-89 6-C17 SP143 41T 8-I20 SP898 SHIELD 13-L5 TB22-D1 11ER 4-M5 TB24-S3 67R 14-N3 TB27-P2 74SB1 2-C21 TB30-T2 SHIELD 13-K15 TB34-B3 7-K5
D11 6-K13 GE CONTROL INTERFACE 6-G11 RELAY HEADLIGHT HIGH MOUNT (HHMR) 7-P7 VEC-89 6-F14 SP144 45LL 8-I20 SP899 SHIELD 13-L8 TB22-D3 11ER 4-M5 TB24-S4 67R 14-N3 TB27-P3 74SB1 2-D21 TB30-T3 SHIELD 13-K14 TB34-C1 41L 7-L5
D13 15-C12 GE CONTROL INTERFACE 9-P2 RELAY HEADLIGHT LOW MOUNT (HLMR) 7-N7 VEC-89 7-L6 SP145 45RL 8-K20 SP900 53H 9-K16 TB22-D4 11ER 4-M5 TB24-T1 67P 14-L3 TB27-R1 72ES 3-D20 TB30-T4 SHIELD 13-K15 TB34-C2 41L 7-L5
D14 15-B12 GE CONTROL INTERFACE 11-P2 RELAY HEATED HOSE (TSW) 5-O4 VEC-89 7-N5 SP146 41T 8-K20 SP901 SHIELD 9-O4 TB22-E1 11RB 13-D6 TB24-T2 67P 14-L3 TB27-R2 72ES 3-D20 TB30-X1 65T 5-K9 TB34-C3 7-L5
D15 10-N5 GND-DECK 13-I18 RELAY HI-BEAM HEADLIGHT (HBHR) 7-L7 VEC-89 7-I4 SP147 0 8-K20 SP902 0LEV 9-O4 TB22-E2 11RB 13-D6 TB24-T3 67P 14-L3 TB27-R3 72ES 3-D20 TB30-X2 65T 5-K9 TB34-D1 48LF 8-B18
D26 12-C12 HEATER COOLANT LH 15-H5 RELAY KEY / GE CNTRL PWR (KCNPR) 4-D9 VEC-89 7-O5 SP148 45RL 8-L18 SP905 SHIELD 5-I8 TB22-E3 11RB 13-D6 TB24-U1 712DS2 6-B18 TB27-S1 39F 13-M8 TB30-X4 65T 5-K9 TB34-D2 48LF 8-B18
D27 7-E9 HEATER COOLANT RH 15-H5 RELAY KEY SWITCH (KSWPR) 3-F8 VEC-89 8-B14 SP149 41T 8-L18 SP906 SHIELD 12-G12 TB22-E4 11RB 13-D6 TB24-U2 712DS2 6-B18 TB27-S2 39F 13-M8 TB30-Y1 35L9 13-J14 TB34-D4 48LF 8-C18
D28 7-F9 HEATER ENGINE OIL LH 15-J7 RELAY LADDER UP 18-H5 VEC-89 8-J10 SP155 11ER 4-M9 SP3801 68ES 12-O14 TB22-F1 11FS 4-M4 TB24-V1 67C 4-N4 TB27-S3 39F 13-M8 TB30-Y2 35L9 13-J15 TB34-E1 48F 8-B13
D30 8-L9 HEATER ENGINE OIL RH 15-J7 RELAY MASTER DISCONNECT 2-G15 VEC-89 8-H10 SP156 12VREG 4-L9 SP3802 68 12-P14 TB22-F4 11FS 4-M4 TB24-V3 67C 4-O4 TB27-T1 39F 13-M8 TB31-A1 SHIELD 9-O6 TB34-E2 48F 8-B13
D31 8-M9 HEATER HYDRAULIC OIL #1 15-K7 RELAY ORS (ORS) 5-M5 VEC-89 8-B2 SP158 SHIELD 9-G9 SP3803 68LS 12-P14 TB22-G1 72IM 6-I16 TB24-V4 67C 4-N4 TB27-T2 39F 13-M8 TB31-A3 9-O6 TB34-F1 41HB 7-L9
D32 8-N9 HEATER HYDRAULIC OIL #2 15-L7 RELAY PROPEL LOCKOUT 2-E15 VEC-89 8-G11 SP160 52B 6-N14 SP3804 0 12-P14 TB22-G4 72IM 6-I16 TB24-W1 18VIM 12-L5 TB27-U1 39FB 13-N8 TB31-B1 0LEV 9-O6 TB34-F2 41HB 7-L9
D33 8-N9 HEATER OIL RESERVE TANK 15-I7 RELAY RADAR POWER (RPR) 17-J9 VEC-89 9-I7 SP161 52CS 5-G14 SP3806 0 17-C19 TB22-H1 21S 3-F14 TB24-W4 18VIM 12-L5 TB27-U3 39FB 13-N8 TB31-B2 0 9-O7 TB34-F4 41HB 7-L9
D34 7-G17 HVAC MODULE 5-K14 RELAY STARTER LOCKOUT 2-F15 VEC-89 10-D5 SP162 65A 4-M14 SP3807 0 17-D19 TB22-H2 21S 3-F14 TB24-X1 33BPS 12-L5 TB27-V1 39FA 13-N8 TB31-B3 9-O6 TB34-G1 41HB 7-L9
D70 2-D17 HYDRAULIC TAP MANIFOLD SOLENOID 9-I20 RELAY VEHICLE HORN POWER (HPR) 10-L11 VEC-89 10-F3 SP165 0 9-G21 SP3808 0 17-E19 TB22-H3 3-F13 TB24-X4 33BPS 12-L5 TB27-V3 39FA 13-N8 TB31-C1 52R 9-P6 TB34-G2 41HB 7-L9
D72 3-H9 IM2 2-M20 RELAY WIPER MOTOR HIGH 10-P6 VEC-89 10-D7 SP171 11A1 10-O11 SP3809 0 17-G19 TB22-H4 21S 3-F13 TB24-Y1 SHIELD 12-L5 TB27-W1 0 5-E11 TB31-D1 32RR 9-L7 TB34-J1 48A 8-F6
D77 17-I4 IM2 3-J4 RELAY WIPER MOTOR LOW 10-O6 VEC-89 10-G3 SP180 71P 11-B7 SP3810 0 17-H19 TB22-J1 72TC 11-J3 TB24-Y4 SHIELD 12-L5 TB27-W2 0 5-E11 TB31-D2 32RR 9-L8 TB34-J2 48A 8-F6
D79 17-I4 IM2 4-C2 RETARD/SERVICE BRAKE COMBO PEDAL 9-O15 VEC-89 11-N4 SP184 33J 12-C13 SP3811 0 17-H19 TB22-J4 72TC 11-J4 TB24-Z1 72CPU 5-G17 TB27-W3 0 5-E11 TB31-E1 31RR 9-K3 TB34-J4 48A 8-F5
D87 2-N13 IM2 5-G16 RIGHT DECK HEATED MIRROR 13-B14 VEC-89 12-C17 SP187 71VHM 11-D15 SP3813 712TP 14-I15 TB22-K1 22FO 5-F10 TB24-Z2 72CPU 5-G18 TB27-W4 0 5-E11 TB31-E2 31RR 9-K4 TB34-K1 48B 8-F6
D88 9-K17 IM2 6-L17 ROTATING BEACON CAB 13-E13 VEC-89 12-C18 SP191 0 14-G15 SP3814 41T 10-F8 TB22-L1 23F 3-D13 TB24-Z3 5-G17 TB27-X1 39FC 13-L6 TB31-F1 32OR 9-L5 TB34-K2 48B 8-F6
D90 2-M10 IM2 7-F18 SATELLITE MODEM (OPT) 11-G19 VEC-89 12-B17 SP195 0 13-G20 SP3823 0 10-H9 TB22-L4 23F 3-D14 TB25-E1 SLT1A 11-O4 TB27-X3 39FC 13-L7 TB31-F2 32OR 9-L4 TB34-K4 48B 8-F5
D91 2-M13 IM2 10-I3 SCORE BOARD LEFT (OPT) 13-J17 VEC-89 12-O10 SP196 0 13-H20 SP3824 0 15-B13 TB22-P1 45L 8-I9 TB25-E2 SLT1A 11-O4 TB27-Y1 39FD 13-L6 TB31-F3 32OR 9-L5 TB34-L1 48C 8-F11
DEV104 2-C21 IM2 12-O7 SCORE BOARD RIGHT (OPT) 13-J14 VEC-89 13-B3 SP200 71LS 7-C4 SP3825 65SS 15-B11 TB22-P2 8-J9 TB25-F1 SLT1B 11-P4 TB27-Y3 39FD 13-L7 TB31-F4 32OR 9-L4 TB34-L2 48C 8-G11
DEV300 6-J13 JB1 2-F17 SECONDARY LINK TRANSFORMER 4-M21 VEC-90 3-B7 SP245 SHIELD 9-M3 SP3826 28E 15-C11 TB22-P3 45L 8-J9 TB25-F2 SLT1B 11-P4 TB27-Z1 SHIELD 13-L6 TB31-H1 32RS 9-L4 TB34-L4 48C 8-G11
DEV400 4-A11 JB6G 10-L2 SENSOR BRAKE PRESSURE 12-L1 VEC-90 3-D9 SP246 0ACL 9-M3 SP3827 0 15-C13 TB22-P4 45L 8-I9 TB25-G1 SHIELD 11-P4 TB27-Z3 SHIELD 13-L7 TB31-H2 32RS 9-L4 TB34-N1 31IML 7-E16
DEV401 9-M5 JB8A 11-E19 SENSOR BRAKE TEMP LH FRONT 12-L21 VEC-90 4-E15 SP247 SHIELD 12-K5 SP12494 12VTM 18-L7 TB22-R1 45R 8-J9 TB25-G2 SHIELD 11-P4 TB28-A1 36 5-K8 TB31-H4 32RS 9-L5 TB34-N4 31IML 7-E16
DEV402 3-K12 JB8B 17-K6 SENSOR BRAKE TEMP LH REAR 12-K21 VEC-90 6-M3 SP248 11L 8-K6 SP12495 0TM 18-L7 TB22-R2 8-J9 TB25-H1 71CKM 17-J19 TB28-A2 36 5-K9 TB31-L1 0ACL 9-L4 TB34-P1 39C 13-G8
DEV403 7-L9 JB8C 17-D7 SENSOR BRAKE TEMP RH FRONT 12-K21 VEC-90 11-C19 SP249 11TP 14-I11 SP12496 939YA 18-L7 TB22-R3 45R 8-J9 TB25-H2 71CKM 17-J20 TB28-A3 36 5-K9 TB31-L2 0ACL 9-L4 TB34-P2 39C 13-G8
DEV3396 9-I8 JB8D 11-E16 SENSOR BRAKE TEMP RH REAR 12-J21 VEC-90 13-H9 SP250 15LFWS 9-C8 SP12497 939GA 18-L7 TB22-R4 45R 8-J9 TB25-J1 8X050 17-J18 TB28-A4 5-K8 TB31-L3 9-L5 TB34-R1 39B 13-G8
DEV3597 4-D11 JB8E 18-B3 SENSOR DUCT AIR TEMPERATURE 12-L21 VEC-90 13-I6 SP251 15RFWS 9-B8 SP12498 SHIELD 18-K7 TB22-X1 90DS 9-P4 TB25-J2 8X050 17-J18 TB28-B1 71VHM 11-C18 TB31-L4 0ACL 9-L5 TB34-R2 39B 13-G8
DEV3598 8-G14 JB8F 12-M11 SENSOR GE ALTERNATOR SPEED 9-H9 VEC-90 14-I4 SP252 31IML 7-E15 SP12515 11SM1 2-M14 TB22-X2 9-P4 TB25-K1 71GG 3-B15 TB28-B4 71VHM 11-C18 TB31-N1 10V 9-K4 TB34-S1 39A 13-G8
DEV3601 10-D12 JB9X 17-D11 SENSOR GRID BLOWER 1 SPEED 4-E21 VEC-91 3-L14 SP253 0 15-K6 SP12944 0 6-C17 TB22-Y1 0DS 9-P4 TB25-K2 71GG 3-B15 TB28-C1 85 11-C18 TB31-N2 10V 9-K5 TB34-S2 39A 13-G8
DEV3603 10-M13 JB10X 17-E13 SENSOR GRID BLOWER 2 SPEED 4-F21 VEC-91 3-L14 SP254 0COMX, SHIELD 17-K5 TB-HTST-C1 0 15-H3 TB22-Y2 9-P4 TB25-L1 71GH 3-B15 TB28-C4 85 11-C18 TB31-N3 10V 9-K4 TB34-T1 39G 3-B5
DEV3604 8-I16 JB12A 17-E5 SENSOR HOIST PRESSURE #1 12-J1 VEC-91 3-K14 SP256 86 15-J6 TB-HTST-C2 0 15-H3 TB22-Z1 SHIELD 9-P4 TB25-L2 71GH 3-B15 TB28-D1 11ORS 5-M3 TB31-N4 10V 9-K5 TB34-T2 39G 3-B5
DEV3605 8-J16 JB12B 17-K7 SENSOR HOIST PRESSURE #2 12-K1 VEC-91 4-N3 SP257 90 15-J6 TB-HTST-D2 0 15-I3 TB22-Z2 9-P4 TB25-M1 74DS 12-I12 TB28-D2 11ORS 5-M3 TB31-P1 SHIELD 9-O7 TB34-V1 712PL 13-I7
DEV3606 8-K16 JB12C 17-K8 SENSOR LEFT FRONT WHEEL SPEED 9-D12 VEC-91 4-D6 SP258 0 15-J6 TB-HTST-D4 0 15-I3 TB23-A1 39H 6-O8 TB25-M4 74DS 12-I13 TB28-E1 11POR 5-M7 TB31-P4 SHIELD 9-O7 TB34-V2 712PL 13-I8
DEV3643 11-B11 JB12D 18-E8 SENSOR LEFT REAR WHEEL SPEED 9-E12 VEC-91 4-M3 SP259 0 15-I5 TB-HTST-E1 0 15-I3 TB23-A4 39H 6-O8 TB25-N1 510E 3-C19 TB28-E2 11POR 5-M7 TB31-R1 74N 9-O7 TB35-A1 11A 10-M12
DEV4419 13-M8 JB12F 2-O7 SENSOR PAYLOAD PRESSURE LEFT FRONT 13-M1 VEC-91 4-F15 SP260 86 15-K6 TB-HTST-E2 0 15-I3 TB23-B1 52B1 6-M7 TB25-N2 510E 3-C20 TB28-E4 11POR 5-M7 TB31-R4 74N 9-O7 TB35-A2 11A 10-M13
DEV5613 5-I20 JB41 5-G4 SENSOR PAYLOAD PRESSURE LEFT REAR 13-N1 VEC-91 4-G10 SP261 90 15-K6 TB-HTST-F4 86 15-J3 TB23-B2 52B1 6-M8 TB25-P1 SLT2A 11-P4 TB28-F1 11SM1 2-M19 TB31-S1 SHIELD 9-N7 TB35-B1 11A 10-M12
DEV5614 5-J20 JIFFY SPLICE 1 13-E11 SENSOR PAYLOAD PRESSURE RIGHT FRONT 13-L1 VEC-91 4-L1 SP278 712TP 14-I11 TB-HTST-G1 86 15-J3 TB23-B4 52B1 6-M8 TB25-P2 SLT2A 11-P4 TB28-F2 11SM1 2-M19 TB31-S3 9-N7 TB35-B2 11A 10-M13
DIRECTION SELECTOR SHIFTER 6-H15 JIFFY SPLICE 2 13-E11 SENSOR PAYLOAD PRESSURE RIGHT REAR 13-N1 VEC-91 4-M3 SP280 7KTWU 11-F15 TB-HTST-G2 86 15-J3 TB23-C1 39AA 13-G13 TB25-R1 SLT2B 11-P4 TB28-G1 11SM2 2-M19 TB31-S4 SHIELD 9-N7 TB35-B4 11A 10-M13
DIRECTION SELECTOR SHIFTER CONTROLLER 6-H12 JUMPSTART1 2-D7 SENSOR POWER LADDER DOWN 18-D5 VEC-91 5-A14 SP281 11L 8-L4 TB-HTST-G3 86 15-J3 TB23-C2 39AA 13-G13 TB25-R2 SLT2B 11-P4 TB28-G2 11SM2 2-M19 TB31-T1 525 9-N7 TB35-C1 38G 12-D11
DISPLAY PANEL DIMMER 7-J12 JUMPSTART2 2-D7 SENSOR POWER LADDER UP 18-C5 VEC-91 5-J7 SP285 49 7-K10 TB-HTST-H1 86 15-J3 TB23-C4 39AA 13-G13 TB25-S1 SHIELD 11-P4 TB28-H1 21PS 3-K12 TB31-T4 525 9-N7 TB35-C2 38G 12-D11
DL1 4-G14 KOMTRAX PLUS MODULE 11-I12 SENSOR RIGHT FRONT WHEEL SPEED 9-B12 VEC-91 5-D15 SP293 0, SHIELD 13-L12 TB-HTST-H2 86 15-J3 TB23-D1 39BA 13-G13 TB25-S2 SHIELD 11-P4 TB28-H2 21PS 3-K12 TB31-V1 0RET 9-M4 TB35-C4 38G 12-D11
DL3 4-H14 KOMVISION CONTROLLER 17-N2 SENSOR RIGHT REAR WHEEL SPEED 9-G12 VEC-91 5-B14 SP294 0DL 8-N10 TB-HTST-J1 87 15-K3 TB23-D2 39BA 13-H13 TB25-T1 74X1K 5-E17 TB28-J2 21PT 4-E4 TB31-V2 0RET 9-M5 TB35-D1 41T 8-I16
DL4 4-H14 KOMVISION DISPLAY 16-E2 SENSOR STEERING PRESSURE 12-J1 VEC-91 5-N2 SP296 SHIELD 12-K5 TB-HTST-J2 87 15-K3 TB23-D4 39BA 13-H13 TB25-T2 74X1K 5-E18 TB28-J4 21PT 4-E3 TB31-W1 0RET 9-M5 TB35-D2 41T 8-I16
DL6 4-I14 KOMVISION DISPLAY MONITOR 17-I13 SENSOR TRANSFORMER SEC LINK RTD 11-P8 VEC-91 5-B14 SP298 SHIELD 12-K12 TB-HTST-J3 87 15-K3 TB23-E1 39CA 13-H13 TB25-U1 531SC 5-E17 TB28-L1 11RCNT 5-N5 TB31-X1 SHIELD 9-M4 TB35-E1 41T 8-H15
ELECTRONIC DASH DISPLAY PANEL(MOD) 7-F5 LAMP AMBER PAYLOAD LEFT 13-H19 SOLENOID A/C COMPRESSOR CLUTCH 5-K4 VEC-91 5-B14 SP299 SHIELD 12-K12 TB-HTST-K1 87 15-K3 TB23-E2 39CA 13-H13 TB25-U2 531SC 5-E18 TB28-L2 11RCNT 5-N6 TB31-X2 SHIELD 9-M5 TB35-E2 41T 8-H16
ENGINE PRE LUBE OIL PRESS SW (PLPSW) 2-N6 LAMP AMBER PAYLOAD RIGHT 13-G19 SOLENOID AUTO LUBE 12-N20 VEC-91 5-C15 SP300 SHIELD 13-K12 TB-HTST-K2 87 15-K3 TB23-E4 39CA 13-H13 TB25-V1 71BC 6-H5 TB28-L3 11RCNT 5-N5 TB32-A1 46GA 15-I14 TB35-E4 41T 8-I16
ENGINE SERVICE LAMP (2HR) TIMER (ESLT) 9-D13 LAMP BACKUP REAR LEFT LED 10-D16 SOLENOID BRAKE LOCK 6-N15 VEC-91 5-M2 SP301 41TS 7-J7 TB-HTST-K4 87 15-K3 TB23-F1 69M 13-C7 TB25-V2 71BC 6-G5 TB28-L4 11RCNT 5-N6 TB32-A2 46GA 15-I15 TB35-F1 44R 5-F17
ENGINE WATER IN FUEL SENSOR 5-G4 LAMP BACKUP REAR RIGHT LED 10-C16 SOLENOID ENGINE SHUTTER (OPT) 15-B12 VEC-91 6-B15 SP302 SHIELD 12-K17 TB10-A1 71LS 8-B7 TB23-F2 69M 13-C7 TB25-V4 71BC 6-H5 TB28-M1 90IMT 12-G13 TB32-A3 46GA 15-I14 TB35-F2 44R 5-F18
ENTERTAINMENT LEFT FRT SPEAKER 4-M12 LAMP BODY LEFT REAR MARKER 10-J19 SOLENOID ETHER START (OPT) 15-C12 VEC-91 7-F15 SP303 SHIELD 12-L17 TB10-A2 71LS 8-B7 TB23-F4 69M 13-C7 TB25-W1 33SBA 11-M3 TB28-M2 90IMT 12-H13 TB32-A4 46GA 15-I15 TB35-F3 44R 5-F17
ENTERTAINMENT LEFT REAR SPEAKER 4-N12 LAMP BODY LEFT REAR TURN 10-I19 SOLENOID HOIST LIMIT 9-K17 VEC-91 7-G14 SP304 42 9-F16 TB10-A3 71LS 8-B7 TB23-G1 11DISP 7-G13 TB25-W4 33SBA 11-M4 TB28-M4 90IMT 12-G13 TB32-B1 46RA 15-I14 TB35-F4 44R 5-F18
ENTERTAINMENT RADIO 4-N15 LAMP BODY LEFT SIDE MARKER 10-J19 SOLENOID HYDRAULIC LADDER 18-G10 VEC-91 8-K3 SP305 68ES 12-N19 TB10-B1 45L 8-I6 TB23-G4 11DISP 7-G13 TB25-X1 72SBT 11-M3 TB28-N1 90IMR 12-H13 TB32-B2 46RA 15-I15 TB35-G1 44 10-G7
ENTERTAINMENT RIGHT FRT SPEAKER 4-M12 LAMP BODY RIGHT REAR MARKER 10-H19 SOLENOID PARK BRAKE 5-G12 VEC-91 8-J3 SP306 68 12-N21 TB10-C1 45R 8-J6 TB23-H1 71P 9-I8 TB25-X4 72SBT 11-M4 TB28-N2 90IMR 12-H13 TB32-B3 46RA 15-J14 TB35-G2 44 10-G7
ENTERTAINMENT RIGHT REAR SPEAKER 4-N12 LAMP BODY RIGHT REAR TURN 10-G19 SOLENOID STEERING BLEED DOWN 12-C12 VEC-91 9-C14 SP308 510E3 18-C3 TB10-D1 41L 7-I12 TB23-H2 71P 9-H8 TB25-Y1 11CMX 17-K19 TB28-N4 90IMR 12-H13 TB32-B4 46RA 15-J15 TB35-G4 44 10-G7
ETHERNET SWITCH 11-L19 LAMP BODY RIGHT SIDE MARKER 10-G19 SONALERT 7-E8 VEC-91 9-H16 SP309 0 5-C3 TB10-E1 41H 7-J15 TB23-H4 71P 9-I8 TB25-Y2 11CMX 17-K20 TB28-P1 90IMG 12-H13 TB32-C1 46YA 15-J14 TB35-H1 44D 10-G7
FAN CLUTCH CONTROLLER 5-K21 LAMP CAB DOME CENTER FRONT 8-M6 STARTER DISCONNECT (SDISC) 2-F14 VEC-91 10-K2 SP310 11E5 5-B3 TB10-E2 41H 7-J14 TB23-J1 71P 9-H8 TB25-Z1 8X013 17-K17 TB28-P2 90IMG 12-H13 TB32-C2 46YA 15-J15 TB35-H2 44D 10-G7
FAN CLUTCH INTERFACE 5-I1 LAMP CAB DOME CENTER REAR 8-N6 SWITCH A/C RECEIVER DRYER 5-K1 VEC-91 10-M11 SP311 11E6 5-B3 TB10-F1 712K 10-B11 TB23-J2 9-H8 TB25-Z2 8X013 17-K17 TB28-P4 90IMG 12-H13 TB32-C3 46YA 15-J14 TB35-H3 10-H7
FUEL SENDER 12-D20 LAMP CAB DOME DRIVER 8-O6 SWITCH ACCUMULATOR LOW PRECHARGE PRESSURE #1 (ACCP... 12-B2 VEC-91 11-C19 SP312 11E5 5-B10 TB10-G1 41TS 7-J10 TB23-J4 71P 9-H8 TB26-A1 SHIELD 9-H4 TB28-R1 12-H13 TB32-C4 46YA 15-J15 TB35-H4 44D 10-H7
FUSELINK1 (175A) 2-O9 LAMP CAB DOME PASSENGER 8-L6 SWITCH ACCUMULATOR LOW PRECHARGE PRESSURE #2 (ACCP... 12-B2 VEC-91 14-I4 SP313 11E6 5-B10 TB10-G2 41TS 7-J10 TB23-K1 72RQ 11-K4 TB26-A2 9-H4 TB28-R2 SHIELD 12-H13 TB32-D1 33 12-F12 TB35-J1 45LL 8-J15
GB3 ENG GND BLOCK 2-O15 LAMP DECK LIGHT #1 8-E21 SWITCH AUTO LUBE PRESSURE 12-N17 VEC-91 14-L2 SP314 SHIELD 12-M6 TB10-H1 63 10-L3 TB23-K2 72RQ 11-K3 TB26-B1 714Z 9-H4 TB28-R4 SHIELD 12-H13 TB32-D4 33 12-F12 TB35-J2 45LL 8-J16
GB3 ENG GND BLOCK 2-J10 LAMP DECK LIGHT #1 (OPT LOCATION) 8-G21 SWITCH AUTOLUBE LEVEL (OPT) 12-O19 VEC-91 14-N2 SP323 939YP 14-B16 TB10-J1 31 7-F7 TB23-L1 712BL 6-K9 TB26-B2 9-H4 TB28-S1 90MMR 11-A5 TB32-E1 33BP 12-F12 TB35-K1 45LL 8-J16
GB12-A 4-M8 LAMP DECK LIGHT #2 8-F21 SWITCH AUX BOX DOME LIGHT (DLS) 4-H10 VEC-91 18-C20 SP324 939GP 14-B16 TB10-J2 31 7-F8 TB23-L2 712BL 6-K9 TB26-C1 714Y 9-H4 TB28-T1 90MMT 11-A5 TB32-E4 33BP 12-F12 TB35-K2 45LL 8-J16
GB12-A 7-G9 LAMP DECK LIGHT #2 (OPT LOCATION) 8-G21 SWITCH AUX HYD PRESS 9-I17 VEC-92 4-D15 SP325 SHIELD 14-B15 TB10-K1 71P 9-H12 TB23-L3 712BL 6-K9 TB26-C2 9-H4 TB28-U1 90MMG 11-A5 TB32-F1 33T 12-F12 TB35-K3 45LL 8-J15
GB12-A 7-K13 LAMP DIAGONAL LADDER LIGHT #1 8-F21 SWITCH BODY-UP PROXIMITY 11-C7 VEC-92 5-C14 SP327 939YE 14-E11 TB10-L1 11L 8-L4 TB23-L4 712BL 6-K9 TB26-D1 77Y 9-I4 TB28-V1 SHIELD 11-A5 TB32-F4 33T 12-F12 TB35-M1 42 9-E16
GB12-A 8-L9 LAMP DIAGONAL LADDER LIGHT #1 (OPT LOCATION) 8-D21 SWITCH BRAKE FILTER PRESSURE 15-M16 VEC-92 5-H15 SP328 939GE 14-E11 TB10-M1 11RWL 7-G9 TB23-M1 71LS 8-B3 TB26-D2 9-I4 TB28-W1 69MA 13-A7 TB32-G1 24VIM 3-K12 TB35-M2 42 9-E16
GB12-A 8-N15 LAMP GREEN PAYLOAD LEFT 13-I19 SWITCH BRAKE LOCK 6-M13 VEC-92 5-O2 SP329 SHIELD 14-E11 TB10-M2 11RWL 7-G9 TB23-M4 71LS 8-B3 TB26-E1 77Z 9-I4 TB28-W4 69MA 13-A7 TB32-G3 24VIM 3-K12 TB35-M3 42 9-E16
GB12-A 10-I10 LAMP GREEN PAYLOAD RIGHT 13-G19 SWITCH BRAKE TEST 11-N9 VEC-92 5-O14 SP330 939YE 14-E13 TB10-N1 49 7-K9 TB23-N1 712K 3-E12 TB26-E2 9-I4 TB28-X1 62SB 12-A10 TB32-G4 24VIM 3-K12 TB35-M4 42 9-E16
GB12-A 13-E10 LAMP HIGH MOUNT LEFT HI-BEAM 7-L15 SWITCH CAB LADDER LIGHT 8-G2 VEC-92 5-C14 SP331 939GE 14-E13 TB10-N2 49 7-K9 TB23-N2 712K 3-E12 TB26-F1 SHIELD 9-I4 TB28-X4 62SB 12-A10 TB32-H1 24VIM 3-J12 TB35-N1 53H 9-J13
GB12-A 14-N8 LAMP HIGH MOUNT LEFT LOW-BEAM 7-P15 SWITCH CAB SECONDARY ENGINE SHUTDOWN (ESS) 3-D17 VEC-92 5-O14 SP332 SHIELD 14-E13 TB10-N3 49 7-K9 TB23-N3 3-E12 TB26-F2 9-I4 TB29-A1 15LRW 9-D4 TB32-H2 24VIM 3-J12 TB35-N2 53H 9-J13
GB12-A 14-L8 LAMP HIGH MOUNT RIGHT HI-BEAM 7-M15 SWITCH COMBO 7-I13 VEC-92 6-C6
GB12-A 17-E14 LAMP HIGH MOUNT RIGHT LOW-BEAM 7-P15 SWITCH COMBO 8-J4 VEC-92 6-M7
GB12-B 4-N7 LAMP HYDRAULIC CABINET #1 10-O13 SWITCH COMBO 10-N1 VEC-92 7-G14
GB12-B 4-M9 LAMP HYDRAULIC CABINET #2 10-P13 SWITCH DATA STORE (DSSW) 9-J9 VEC-92 15-B3
GB12-B 6-C16 LAMP LED MASTER DISCONNECT CLOSED 2-H18 SWITCH DISPLAY INPUT 7-E6 VEC-92 17-J19
GB12-B 6-D22 LAMP LED MASTER DISCONNECT OPEN 2-I18 SWITCH DOOR PIN (DPSW1) 8-N12 VEC-92 17-J21
GB12-B 10-P7 LAMP LED PROPEL LOCKOUT LOCKED OUT 2-E18 SWITCH DOOR PIN (DPSW2) 8-M12 VEHICLE HORN 10-L18
GB12-B 10-P7 LAMP LED PROPEL LOCKOUT ON 2-E18 SWITCH DRIVERS SEAT BELT 12-A14 VID PANEL 11-G9
GB12-B 11-E14 LAMP LED STARTER LOCKOUT CLOSED 2-G18 SWITCH ENGINE RUN OIL PRESSURE (EOPSW) 5-L1 WHEEL DRIVE MOTOR 1 4-B21
GB12-B 12-A11 LAMP LED STARTER LOCKOUT OPEN 2-G18 SWITCH ENGINE WARMING 11-L8 WHEEL DRIVE MOTOR 2 4-C21
GB12-B 14-J17 LAMP LED SYSTEM OPERATING 2-C18 SWITCH FOG LAMP 8-C9 WHEEL MOTOR/TRANSFORMER BLOWER 4-I21
GB12-B 17-J14 LAMP LEFT DECK BACKUP 10-E3 SWITCH GROUND LEVEL LADDER OVERRIDE 18-H8 WIRELESS ACCESS KOMTRAX 11-H17
GB20 IM GND 12-K10 LAMP LEFT FOG 8-C22 SWITCH HAZARD LIGHTS 8-L7
GB20 IM GND
GB20 IM GND
12-K4
12-G11
LAMP LEFT LOWER ENGINE SERVICE
LAMP LEFT UPPER ENGINE SERVICE
9-G13
9-F13
SWITCH HEADLIGHTS
SWITCH HEATED MIRROR
7-I9
13-B3
58B-06-05901-00 SEP 21
ELECTRICAL SCHEMATIC
980E-5
A50052, A50053, A50137, A50138
Sheet 20 of 21
CONNECTOR TABLE
CONN SHEET-ZONE CONN SHEET-ZONE CONN SHEET-ZONE CONN SHEET-ZONE CONN SHEET-ZONE CONN SHEET-ZONE CONN SHEET-ZONE
CONN SHEET-ZONE CONN SHEET-ZONE CONN SHEET-ZONE CONN SHEET-ZONE CONN SHEET-ZONE
J812 5-J3 P03 3-E10 P22TX9D 16-M2 P101 18-L9 PENET6 11-J14 STRT2-10B 2-K12 VEC92-P2 6-M7
12VCN-12VA 4-E5 D4 8-K7 GB21-A4 5-J16 J03 3-E10 J82 6-K14
J812 5-D3 P03 3-E7 P23 8-C9 P108 6-H15 PENET7 11-F5 STRT2-10C 2-L12 VEC92-P3 5-H15
12VCN-12VB 4-E5 D5 18-H10 GB30-2 17-I8 J03 5-K12 J82 6-F16
J813 5-L3 P03 3-D16 P23 8-C9 P108 6-H16 PENET8 11-F8 STRT3-1 2-J14 VEC92-P3 6-C7
12VCN-24VA 4-E5 D5 18-H10 GB31A-A1 4-I6 J03 6-C16 J82 6-I15
JAHPS 9-I18 P03 5-K12 P24 13-E3 P109 6-H12 PLLO 2-E18 STRT3-7A 2-K14 VEC92-P3 17-J21
12VCN-GND 4-E5 D6 9-J18 GB31A-A2 4-I6 J03 7-I8 J82 9-I9 7
JAHPS 9-I16 P03 6-C16 P24 13-E2 P109 6-H13 PLM4_ENET 13-N15 STRT3-7B 2-K14 VEC92-P3 17-J19
12VPR-85 4-E10 D6 9-J19 GB31A-A3 4-H2 J03 7-J6 J82 9-J5
JANT1 18-K15 P03 7-J19 P25 11-N9 P119 17-F20 PLMS-(+) 2-O12 STRT3-8 2-L15 VEC92-P3 17-J21
12VPR-86 4-E10 D7 12-N20 GB31A-A4 4-M5 J03 7-J19 J82 11-E7
JANT2 18-L15 P03 7-L2 P25 11-N9 P121 7-I13 PLMS-(-) 2-O12 STRT3-10A 2-K15 VEC92-P4 5-C14
12VPR-88 4-E10 D7 12-N20 GB31A-B1 15-B7 J03 7-L2 J82 11-F7
JB1 2-F17 P03 7-I8 P26 7-E6 P121 7-I14 PLMS-1 2-O12 STRT3-10B 2-K15 VEC92-P4 5-C14
12VPR-88A 4-E10 D9 7-D14 GB31A-B2 4-H2 J03 8-K4 J82 12-H15
JB6G 10-L2 P03 7-J6 P26 7-E6 P121 8-J4 PLMS-2 2-O12 SYS 2-C18 VEC92-P4 5-O14
24VDC-A1 4-C5 D9 7-D14 GB31A-B3 15-I14 J03 8-B10 J82 12-A11
JB8A 11-E19 P03 8-B11 P28 13-B3 P121 8-J3 PLON 2-E18 T1A 4-B18 VEC92-P4 7-G16
24VDC-A2 4-B5 D10 7-D14 GB31A-B4 5-C10 J03 8-J2 J82 17-K16
JB8B 17-K6 P03 8-J2 P28 13-B3 P121 10-L17 PLOS-B1 2-D16 T1B 4-B18 VEC92-P4 7-G14
24VDC-B1 4-B5 D10 7-D14 GB31A-C1 5-I15 J03 8-F3 J82 18-D18
JB8C 17-D7 P03 8-K4 P29 9-K10 P121 10-N2 PLOS-B2 2-D16 T1C 4-B18 VEC92-S5B 4-D15
24VDC-B2 4-B5 D11 6-K13 GB31A-C2 4-I2 J03 8-J6 J82 18-I19
JB8D 11-E16 P03 8-F4 P29 9-K11 P121 10-N1 PLOS-F1 2-D15 T2A 4-C18 VEC92-S6A 4-C15
24VDC-B3 4-B5 D11 6-K13 GB31A-C3 5-C10 J03 8-B6 J83 3-D7
JB8E 18-C3 P03 8-J6 P30 11-K8 P137 5-K14 PLOS-F2 2-D15 T2B 4-C18 VID(+) 11-F9
24VDC-C3 4-B5 D13 15-C12 GB31A-C4 4-I2 J03 9-K6 J83 3-E11
JB8F 12-M11 P03 8-B6 P30 11-K9 P150 13-L1 PLPM-(+) 2-O14 T2C 4-C18 VID(-) 11-F9
24VDC-C4 4-B5 D13 15-C12 GB31A-D1 5-B10 J03 9-I7 J83 3-D14
JB9X 17-D11 P03 9-I7 P30T5B1 14-E18 P151 13-M1 PLPM-(-) 2-O14 T19 4-D18 VIDGND 11-G9
24VDC-D1 4-B5 D14 15-B12 GB31A-D2 4-G6 J03 10-B8 J83 3-D19
JB10X 17-E13 P03 9-K6 P30T5B2 14-E19 P152 13-N1 PLPSW 2-N6 T19ALT 4-D20 VID_ENET 11-F9
24VDC-D2 4-B5 D14 15-B12 GB31A-D3 12-C12 J03 10-L6 J83 5-K11
JB12A 17-E5 P03 10-B8 P30T5D 14-F19 P153 13-N2 PLPSW 2-N6 T20 4-D18 WADT-1 10-L8
24VDC-D3 4-B5 D15 10-N5 GB31A-D4 5-C10 J03 10-N11 J83 7-J18
JB12B 17-K7 P03 10-N11 P30T6B1 14-F4 P0178X 17-F10 PLREL_K 2-E16 T20ALT 4-D20 WADT-2 10-L8
24VDC-E1 4-B5 D15 10-N5 GB31A-E1 4-H6 J03 10-L16 J83 7-L4
JB12C 17-K8 P03 10-L16 P30T6B2 14-F4 P212 12-A14 PLREL_K 2-E15 TITS 5-E5 WADT-3 10-M8
ACCP1 12-B2 D26 12-C12 GB31A-E2 5-F10 J03 11-N7 J83 7-C15
JB12D 18-E8 P03 10-L6 P30T6D 14-G4 P212 12-A15 PORT0 11-J20 TM1A 4-B20 WADT-5 10-M8
ACCP1 12-A3 D26 12-C12 GB31A-E3 12-N13 J03 11-C16 J83 7-J4
JB12F 2-O7 P03 11-N7 P30T7B1 14-F6 P227 6-C20 PORT2 11-K20 TM1B 4-B20 WIF 5-G4
ACCP2 12-B2 D27 7-E9 GB31A-E4 13-J8 J03 11-G15 J83 7-I7
JB41 5-G4 P03 11-C16 P30T7B2 14-F7 P227 12-A13 PORT3 11-M20 TM1C 4-B20 WMBI-GND 4-I18
ACCP2 12-B2 D27 7-E10 GB31A-F1 5-M14 J03 12-I16 J83 8-J7
JENET1 11-K16 P03 11-G15 P30T7D 14-G7 P228 6-C19 PORT4 11-L19 TM2A 4-C20 WMBI-T1 4-H18
AHPS 9-I18 D28 7-F9 GB31A-F2 5-M14 J03 13-D4 J83 8-B12
JENET2 11-L16 P03 12-I16 P30T8B1 14-E21 P230 6-D20 PORT5 11-N20 TM2B 4-C20 WMBI-T2 4-H18
AHPS 9-I15 D28 7-F9 GB31A-F3 5-N14 J03 13-A4 J83 8-B4
JENET3 11-J16 P03 13-D4 P30T8D 14-F21 P235 9-O15 PORT6 11-K19 TM2C 4-C20 WMBI-T3 4-H18
AHPS- 9-I17 D30 8-L9 GB31A-F4 5-N14 J03 14-I9 J83 8-K2
JENET4 11-K14 P03 13-A4 P30T17B1 14-E9 P236 9-N15 PORT8 11-J19 TMS-1 18-O5 WMTB-A 4-H20
AHPS- 9-I17 D30 8-L9 GB31B-A1 3-E19 J03 14-E8 J83 8-F5
JENET5 11-L14 P03 14-B11 P30T17B2 14-E9 P240 3-I11 PWR1-1 4-N9 TMS-3 18-M5 WMTB-B 4-H20
AHS 10-L18 D31 8-M9 GB31B-A2 4-F7 J03 14-B11 J83 8-J1
JENET6 11-J14 P03 14-E8 P30T17D 14-F9 P240 5-G15 PWR1-2 4-N9 TMS-5 18-L5 WMTB-C 4-H20
AI/CGB-GND 4-L20 D31 8-M9 GB31B-A3 8-K13 J04 4-L10 J83 9-K5
JENET7 11-F5 P03 14-I9 P31 11-L8 P240 6-N13 PWR2-1 4-O9 TR2 14-B18 WTBMP 4-H20
AI/WMTB-GND 4-I20 D32 8-N9 GB31B-B1 4-F7 J04 4-M7 J83 9-I6
JENET8 11-F7 P04 4-L10 P31 11-L9 P240 9-J16 PWR2-2 4-O9 TSW-85 5-O5 WTIP 4-H18
ALDR 18-E5 D32 8-N9 GB31B-B2 8-F12 J04 7-E10 J83 10-B6
JFCC 5-K18 P04 4-M7 P33 8-L8 P240 10-N10 PWW 10-N8 TSW-86 5-O4 WW+ 10-M9
ALDR 18-E5 D33 8-N9 GB31B-B3 4-F7 J04 7-K19 J83 10-L15
JS1 13-E12 P04 7-K19 P33 8-L7 P240 12-G14 PX06 17-I11 TSW-88 5-O4 WW- 10-M9
ALLR-85 8-G13 D33 8-N9 GB31B-B4 4-H10 J04 8-L3 J83 10-N12
JS2 13-E12 P04 7-E11 P35 18-D21 P240 12-L2 R2 12-C14 TSW-88A 5-O5
ALLR-86 8-G12 D34 7-G17 GB31B-C1 5-E12 J04 10-I10 J83 10-K5
JWW 10-N8 P04 8-L3 P35 18-D21 P264 13-O11 R2 12-C14 UPS 18-C5
ALLR-88 8-G12 D34 7-G17 GB31B-C2 7-K10 J04 13-E9 J83 11-C17
JX06 17-I11 P04 10-I10 P39 6-M13 P264 13-N9 R3 12-M14 UPS 18-C5
ALLR-88A 8-G13 D70 2-D17 GB31B-C3 11-L21 J04 14-N6 J83 11-N6
JX07 17-K11 P04 13-E9 P39 6-M13 P301 9-H2 R3 12-M15 VEC89-P1 8-B14
ALLSW 12-O20 D70 2-D17 GB31B-C4 11-L21 J11 3-E4 J83 11-G16
JX07 17-D3 P04 14-N6 P40T11B2 14-H2 P301 9-G2 R4 7-F8 VEC89-P1 8-B16
ALLSW 12-O19 D72 3-H9 GB31B-D1 2-M19 J11 5-P9 J83 12-I14
JX07 17-E9 P07 10-O8 P40T11D 14-I2 P302 5-F19 R4 7-F8 VEC89-P1 10-G6
ALT(+) 2-I7 D72 3-H9 GB31B-D2 9-O8 J11 7-P11 J83 13-A6
KCNPR-85 4-C10 P07 10-O8 P40T12B1 14-H3 P302 6-B3 R5 7-F8 VEC89-P1 10-G3
ALT(-) 2-I7 D77 17-I5 GB31B-D3 4-K12 J11 7-O11 J83 13-D5
KCNPR-86 4-C9 P7 18-I2 P40T12B2 14-H4 P302 9-J2 R5 7-F8 VEC89-P1 12-C17
ALTF1 4-D20 D77 17-I4 GB31B-E1 11-L3 J11 7-N12 J83 14-B8
KCNPR-88 4-D9 P08_K 10-P6 P40T12D 14-I4 P302 11-P2 R14 6-N8 VEC89-P1 13-C6
ALTF2 4-D20 D79 17-I5 GB31B-E2 3-H8 J11 8-B19 J83 14-E6
18-F5 17-I4 5-P3 8-G7 14-I8 KCNPR-88A 4-D10 P08_K 10-P6 P40T13B1 14-H6 P303 9-O2 R14 6-N9 VEC89-P1 13-B3
ALUR D79 GB31B-E3 J11 J83
KEYSW-B 3-E8 P09X 16-M4 P40T13B2 14-H5 P303 11-D2 R15 12-D12 VEC89-P2 7-I4
ALUR 18-F5 D87 2-N13 GB31B-E4 6-C8 J11 8-K18 J84 4-M6
12-G2 2-N13 4-J12 8-G10 4-L9 KEYSW-BR 3-E9 P09X 17-G15 P40T13D 14-I6 P303 11-A2 R15 12-D13 VEC89-P2 9-I7
ARS1 D87 GB32-1 J11 J84
KEYSW-C 3-E9 P09_K 10-O6 P40T16B1 14-H17 P304 3-C21 R16 7-E13 VEC89-P2 12-O13
ARS1 12-G2 D88 9-K17 GB32-2 4-K12 J11 8-F17 J84 7-E12
KOMV-2 17-J18 P09_K 10-O6 P40T16D 14-I17 P304 5-G19 R16 7-E14 VEC89-P2 12-B17
ARS2 12-H1 D88 9-K17 GB33-1 4-J12 J11 9-E19 J84 7-K18
KOMV-3 17-K18 P10 10-M5 P44 17-H13 P304 5-E19 R18 6-J10 VEC89-P2 12-B19
ARS2 12-H1 D90 2-M10 GB34-2 4-J13 J11 9-G17 J84 8-L2
KOMV-5 17-K18 P10X 17-N12 P45 17-I13 P304 6-C3 R18 6-J11 VEC89-P4 6-F14
ATS 12-L21 D90 2-M11 GB34-3 4-J13 J11 10-E8 J84 10-I8
KOMV-6 17-K18 P10X 17-L12 P50 8-N14 P304 6-G11 R19 12-B13 VEC89-P4 6-C17
BAT(-)-1 2-G4 D91 2-M13 GB35-1 4-K13 J11 11-P6 J84 13-E8
KP-A 11-G12 P11 3-E4 P50 8-N11 P304 9-P2 R19 12-B12 VEC89-P4 8-B2
BAT(-)-2 2-G5 D91 2-M13 GB35-2 4-K13 J11 12-O15 J84 14-N5
KP-A 11-F12 P11 5-P9 P50 14-L14 P304 9-K2 R21 9-L6 VEC89-P4 11-N4
BAT(-)-3 2-G5 DI1 5-I21 GB70-A1 2-I9 J11 13-D9 J85 3-I10
KP-B 11-E12 P11 7-O12 P51 8-M14 P304 9-G2 R21 9-L6 VEC89-P4 12-C18
BAT(-)-4 2-G4 DI2 5-K21 GB70-A2 2-I9 J11 13-B9 J85 5-G16
KP-B 11-G12 P11 7-N12 P51 8-M11 P304 11-B2 R27 7-K12 VEC89-P9 7-O5
BAT(-)-5 2-G5 DIAG1 12-H19 GB70-B2 2-J9 J11 13-G15 J85 6-N12
KSWPR-85 3-F8 P11 7-P12 P51 14-N14 P304 11-M2 R27 7-K12 VEC89-P9 7-N5
BAT(-)-6 2-G5 DIAG5 11-C9 GB70-B3 2-J9 J11 15-H16 J85 9-J14
KSWPR-86 3-F8 P11 8-G7 P54 10-I15 P305 3-D21 R30 12-N12 VEC89-P9 10-D7
BAT(-)-7 2-G4 DIAG6 11-E10 GBI1P 4-E18 J11 15-B8 J85 10-N11
KSWPR-88 3-F8 P11 8-K18 P058 14-N16 P305 3-B21 R30 12-N12 VEC89-P11 8-H10
BAT(-)-8 2-G4 DIAG7 11-G18 GBI2P 4-F18 J12 2-C20 J85 12-G13
2-E2 2-G14 4-E20 3-B3 12-L4 KSWPR-88A 3-F8 P11 8-B19 P059 14-L16 P305 4-D3 R31 8-J14 VEC89-P11 8-H13
BAT1(+) DISC(-)-1 GBM1P J12 J85
KVIS-A 17-F2 P11 8-F17 P65 10-M6 P305 9-L2 R31 8-J14 VEC89-P11 10-D8
BAT1(-) 2-E1 DISC(-)-2 2-G14 GBM2P 4-F20 J12 3-C4 J100 18-K9
KVIS-A 17-H2 P11 8-G9 P071 14-N11 P501 9-B11 R32 8-K14 VEC89-P11 10-D5
BAT2(+) 2-E3 DISC(-)-3 2-H14 GE_1939 14-G8 J12 5-O9 J101 18-L9
KVIS-A 17-F2 P11 9-G17 P071 14-N12 P502 8-K19 R32 8-K14 VEC89-P11 10-F3
BAT2(-) 2-E3 DISC(-)-4 2-H14 GE_RPC 14-C9 J12 7-P11 J102 18-K13
KVIS-B 17-K2 P11 9-E19 P72 11-B9 P502 9-E20 R51 5-D13 VEC89-P12 7-L6
BAT3(+) 2-F2 DISC(-)-5 2-H14 GE_TP 14-I7 J12 7-L12 J103 18-L13
KVIS-B 17-E2 P11 10-E8 P72 13-N3 P502 9-G18 R51 5-D13 VEC89-P12 8-K13
BAT3(-) 2-F1 DISC(-)-6 2-G14 GLA 18-H8 J12 7-N11 J119 17-C21
KVIS-B 17-G2 P11 11-P6 P72 15-J18 P502 10-E6 RADAR 17-F22 VEC89-P12 8-G11
BAT4(+) 2-F3 DISC(-)-7 2-H14 GLAR 18-H5 J12 8-F7 J122 17-D21
KVIS-B 17-F2 P11 12-O15 P072 14-M11 P502 13-G17 RBUL 10-E3 VEC89-P12 8-J10
BAT4(-) 2-F3 DISC(-)-8 2-H14 GLAR 18-H5 J12 8-G17 J123 17-E21
KWB_K+ 11-H17 P11 13-B9 P072 14-M12 P502 13-B11 RCL1 8-K22 VEC89-P12 10-G6
BAT5(+) 2-E2 DISC(-)-9 2-G14 GLORS 18-H8 J12 8-C19 J124 17-F21
LBPS 12-F16 P11 13-D9 P73 10-E19 P502 13-D11 RCL1 8-K21 VEC89-S5A 4-B15
BAT5(-) 2-E1 DL1 4-G14 GLORS 18-H8 J12 8-F10 J125 17-G21
LBPS 12-F16 P11 13-G15 P73 10-C14 P502 15-H19 RCL2 8-L22 VEC89-S5B 4-B15
BAT6(+) 2-E3 DL2 4-H14 GND 13-I18 J12 11-K5 J126 17-H21
LBUL 10-E3 P11 15-B8 P73 10-G12 P503 8-I19 RCL2 8-L21 VEC89-S6A 4-B15
BAT6(-) 2-E3 DL3 4-H14 GND-SWITCH 11-L20 J12 12-I2 J127 17-I21
LCL1 8-I21 P11 15-H16 P73 10-F10 P503 9-D16 RDLLT 8-D21 VEC89-S7A 4-B15
BATFU 3-E21 DL4 4-I14 HBHR-85 7-K8 J12 12-P16 J128 17-I21
LCL1 8-I22 P11X 17-M12 P73 10-H10 P503 9-E17 RDLT1 8-E21 VEC89-S8A 4-B15
BDS 12-G16 DLS-2 4-H10 HBHR-86 7-K7 J12 12-H2 J0178X 17-F10
LCL2 8-J22 P12 2-C20 P80 8-I18 P503 9-G15 RDLT2 8-F21 VEC90-P1 3-D11
BDS 12-G16 DLS-3 4-H10 HBHR-88 7-L7 J12 15-C7 J227 6-C20
LCL2 8-J21 P12 3-B3 P80 9-G16 P503 10-L14 RECDR 5-K1 VEC90-P1 3-D9
BFSW 15-M15 DPS 18-D5 HBHR-88A 7-L8 J12 18-I16 J227 12-A13
LDLLT 8-F21 P12 3-C4 P80 9-E18 P503 10-E4 RECDR 5-K1 VEC90-P1 6-I6
BFSW 15-M16 DPS 18-D5 HHMR-85 7-O7 J12 18-B18 J230 6-D20
LDLT1 8-G21 P12 5-O9 P80 9-D15 P503 12-H3 RESLS-1 9-E22 VEC90-P1 11-C19
BLDPS 12-C2 DPSW1-1 8-N12 HHMR-86 7-O7 J12 18-C16 J240 3-I12
LDLT2 8-G21 P12 7-P12 P80 10-L13 P503 12-G4 RESLS-2 9-E22 VEC90-P2 3-B8
BLDPS 12-C1 DPSW1-2 8-N13 HHMR-88 7-O7 J12 18-E16 J240 5-G14
LEDBLL 10-D16 P12 7-L12 P80 10-E5 P503 13-D11 RESLS-3 9-E22 VEC90-P2 3-B6
BLS 6-N16 DPSW2-1 8-M12 HHMR-88A 7-O7 J13 9-D10 J240 6-N13
LEDBLR 10-C16 P12 7-N12 P80 12-H4 P503 13-I17 RFLT 8-B22 VEC90-P2 13-H12
BLS 6-N15 DPSW2-2 8-M13 HL1 10-O13 J13 12-B4 J240 9-J16
LESLS-1 9-E14 P12 8-G17 P80 12-G5 P503 13-C11 RFSPK 4-M12 VEC90-P2 13-H9
BPS 12-L1 DRL(+) 10-I12 HL2 10-P13 J13 13-M3 J240 10-N10
LESLS-2 9-E15 P12 8-F9 P80 13-I15 P503 15-I18 RGB 17-I2 VEC90-P3 3-B6
BPSW-COM 11-A8 DRL(-) 10-I12 HLMR-85 7-N8 J14 8-J19 J240 12-L2
LESLS-3 9-E15 P12 8-C19 P80 13-C10 P507 9-D11 RLESL 9-G22 VEC90-P3 3-C11
BPSW-NC 11-A9 DSSW 9-J9 HLMR-86 7-N7 J14 9-K14 J240 12-G14
LFLT 8-C22 P12 8-F7 P80 13-D10 P511 12-O18 RLSW-1 8-G5 VEC90-P3 13-G12
BPSW-NO 11-A9 DSSW 9-J9 HLMR-88 7-N7 J14 12-D4 J362 13-K17
LFSPK 4-M12 P12 11-K5 P80 15-I16 P534 8-H7 RLSW-2 8-H6 VEC90-P4 3-D11
BULR-85 10-D10 ECHTR1 15-H7 HLMR-88A 7-N8 J14 12-J3 J372 12-I15
LLESL 9-G13 P12 12-H2 P81 7-G12 P535 8-E7 RLSW-3 8-G6 VEC90-P4 13-I6
BULR-86 10-D9 ECHTR2 15-I7 HLS 9-I16 J14 12-C10 J502 8-K19
LLPS 12-N18 P12 12-I2 P81 9-O10 P537 2-D18 RPR_K 17-J10 VEC90-P4 14-I4
BULR-88 10-D9 ENET_PWR 11-L20 HLS 9-I16 J14 12-M18 J502 9-E20
LLPS 12-N17 P12 12-P16 P82 4-N6 P538_JP 18-I15 RPR_K 17-J9 VEC90-P9 6-H6
BULR-88A 10-D10 ENG_1939 5-H2 HLSW-1 10-N12 J14 12-C14 J502 9-G19
LLSOL 12-N20 P12 15-C7 P82 4-O6 P542 7-L13 RRBB1 13-E11 VEC90-P9 6-M6
BUS24V-1 2-E6 EOH1 15-J7 HLSW-2 10-N11 J14 15-L14 J502 10-E5
LLSOL 12-N20 P12 18-I16 P82 4-M7 P542 7-P13 RRBB2 13-E11 VEC90-P9 6-M3
BUS24V-2 2-E6 EOH2 15-J7 HMLHB 7-L15 J15 9-G9 J502 13-D11
LLSW-1 8-E6 P12 18-C16 P82 6-F16 P542 7-N13 RRBH-(+) 10-B16 VEC90-P11 6-J6
BUS24V-3 2-E6 EOPSW 5-L1 HMLLB 7-P15 J15 15-K14 J502 13-G18
LLSW-2 8-E6 P12 18-E16 P82 6-I15 P542 8-C21 RRBH-(-) 10-B17 VEC90-P12 6-K6
BUS24V-4 2-E6 EOPSW 5-L2 HMRHB 7-M15 J16 8-L17 J502 13-B11
LLSW-3 8-E6 P12 18-B18 P82 6-C19 P542 8-G18 RRL 10-H13 VEC90-S7A 4-D15
BUS24V-6 2-E6 EOTS 15-I6 HMRLB 7-P15 J16 9-I13 J502 15-H19
LMLHB 7-L15 P13 9-D10 P82 6-K14 P542 15-C8 RRL 10-H14 VEC90-S7B 4-E15
BUS24V-8 2-E6 ESDS 3-C1 HOHTR1 15-K7 J16 10-C13 J503 8-I19
LMLLB 7-N15 P13 12-B3 P82 6-H10 P543 7-N13 RRSPK 4-N12 VEC90-S8A 4-D15
BUS24V-10 2-E6 ESDS 3-C2 HOHTR2 15-L7 J16 10-G11 J503 9-E17
LMRHB 7-N15 P13 13-M3 P82 6-L11 P543 7-P13 RRSTL 10-E16 VEC90-S8B 4-D15
BUS24V-11 2-E6 ESDSR 3-E1 HOSTAT 15-K7 J16 10-H7 J503 9-G15
LMRLB 7-O15 P14 8-J19 P82 9-J5 P543 7-O13 RRSTL 10-F15 VEC91-P1 5-J9
BUS24V-12 2-E6 ESDSR 3-E2 HPR-85 10-L12 J16 10-M15 J503 9-D16
LRBH-(+) 10-C16 P14 9-K15 P82 9-I9 P543 8-F18 RSCL1 10-G19 VEC91-P1 5-J7
BUSW 11-C7 ESLT-3 9-D14 HPR-86 10-L11 J16 10-G8 J503 10-E4
LRBH-(-) 10-C17 P14 12-D4 P82 11-E7 P543 8-B21 RSCL1 10-G19 VEC91-P1 18-C20
BUSW 11-C8 ESLT-C 9-D13 HPR-88 10-L11 J16 10-E20 J503 10-L15
LRL 10-G13 P14 12-M18 P82 11-F7 P544 8-G19 RSCL2 10-H19 VEC91-P1 18-C21
CAM1 17-L15 ESLT-NO 9-D14 HPR-88A 10-L12 J16 11-B6 J503 12-H3
LRL 10-G14 P14 12-C10 P82 12-H15 P545 8-F19 RSCL2 10-H19 VEC91-P2 3-K15
CAM2 17-L15 ESOL 15-C12 HPS1 12-J1 J16 12-D15 J503 12-G4
LRSPK 4-N12 P14 12-C14 P82 12-A11 P608 11-H14 RSON(+) 17-I7 VEC91-P2 5-B14
CAM3 17-M15 ESOL 15-C12 HPS2 12-K1 J16 12-N16 J503 13-I17
LRSTL 10-E15 P14 12-J3 P82 17-K16 P700 9-H9 RSON(-) 17-I7 VEC91-P2 5-A14
CAM4 17-M15 ESON(+) 17-I7 HS 9-K17 J16 12-E11 J503 13-C11
LRSTL 10-E16 P14 15-L14 P82 18-D18 P701 6-F7 RSTL 10-F19 VEC91-P2 5-B14
CAM5 17-N15 ESON(-) 17-I7 HS 9-K17 J16 12-L3 J503 13-D11
LSCL1 10-J19 P15 9-G9 P82 18-I20 P701 9-N6 RSTL 10-G19 VEC91-P2 5-B14
CAM6 17-N15 ESS-3 3-D17 HTLS 12-J21 J16 13-N6 J503 15-I18
LSCL1 10-I19 P15 15-K15 P83 3-E11 P701 9-P5 RTD 11-P8 VEC91-P2 6-B15
CAR 18-G5 ESS-4 3-D17 HTM 9-I20 J16 15-J17 J511 12-O18
LSCL2 10-J19 P16 8-L18 P83 3-D19 P702 3-D12 RTN 3-E21 VEC91-P2 7-G14
CAR 18-G5 ESS-X1 3-C17 HTM 9-I20 J16 18-L11 J520 15-B10
LSCL2 10-J19 P16 9-I14 P83 3-D15 P702 6-N7 RUESL 9-F22 VEC91-P3 3-L14
CB1-2 4-B8 ESS-X2 3-C17 IM1 3-H4 J16X 16-M11 J533 3-E3
LSOL 18-G10 P16 10-M15 P83 3-D7 P702 12-E15 SB1 4-M18 VEC91-P3 3-K14
CB60-1 4-E7 ESSOL 15-B12 IM1 5-G16 J16X 17-G17 J536 3-C3
LSOL 18-G10 P16 10-G9 P83 5-K11 P702 15-L12 SB2 4-M18 VEC91-P3 6-B17
CB60-2 4-E6 ESSOL 15-B12 IM1 6-I17 J17 2-M17 J537 2-D18
LSPSW 12-C1 P16 10-C13 P83 7-I7 P702 18-D18 SBDSOL 12-C12 VEC91-P3 8-K3
CBMP 4-K20 ETC2 11-D2 IM1 7-F18 J17 5-L7 J538 18-I13
LSPSW 12-C2 P16 10-H7 P83 7-L3 P703 11-A10 SBDSOL 12-C12 VEC91-P4 3-L14
CDL1(+) 8-L6 ETC4 11-F2 IM1 7-C18 J17 5-I9 J538B 18-I15
LSTL 10-I19 P16 10-E20 P83 7-C15 P707 12-L21 SBL(+) 10-H12 VEC91-P4 3-K14
CDL1(-) 8-L6 ETHER 15-C10 IM1 12-F7 J17 5-O13 J540 9-E16
LSTL 10-I19 P16 10-G11 P83 7-J5 P708 12-K21 SBL(-) 10-I12 VEC91-P4 5-N2
CDL1(D) 8-L6 F1 4-D18 IM1 12-I8 J17 5-N13 J540 9-G14
LUESL 9-F13 P16 11-B6 P83 7-J18 P709 12-K21 SBPS 5-F13 VEC91-P4 5-M2
CDL2(+) 8-M6 F2 4-D18 IM2 2-M20 J17 9-H7 J540 9-D17
LUR 18-H5 P16 12-E11 P83 8-F4 P710 12-J21 SBPS 5-F12 VEC91-P4 9-C14
CDL2(-) 8-M6 FH1-1 2-H5 IM2 3-J4 J50 8-N14 J540 12-H2
LUR 18-H5 P16 12-L3 P83 8-B12 P712 12-J19 SDISC-1 2-F14 VEC91-P4 10-M11
CDL2(D) 8-M6 FH1-2 2-H4 IM2 4-C3 J50 8-N11 J540 12-G3
MLLO 2-I18 P16 12-D15 P83 8-J7 P720 9-G11 SDISC-2 2-F14 VEC91-P4 11-C19
CDL3(+) 8-N6 FH2-2 2-H5 IM2 6-K17 J50 14-L14 J541 9-E21
MLLON 2-H18 P16 12-N16 P83 8-K3 P721 9-E11 SDISC-3 2-F14 VEC91-P4 14-I4
CDL3(-) 8-N6 FLS 12-D20 IM2 7-E18 J51 8-M11 J541 9-G20
MLREL_K 2-G16 P16 13-N6 P83 8-B5 P730 12-D18 SDISC-4 2-F14 VEC91-P9 4-N3
CDL3(D) 8-N6 FUS-1 2-O9 IM2 10-I3 J51 8-M14 J542 7-L13
MLREL_K 2-G15 P16 15-J17 P83 8-J1 P737 4-N15 SDISC-5 2-G14 VEC91-P9 4-G10
CDL4(+) 8-O6 FUS-2 2-O10 IM2 12-G7 J51 14-N14 J542 7-P13
8-O6 2-J10 12-E8 10-F15 7-N13 MMS_ENET 11-K12 P16 18-L11 P83 9-I6 P800 2-O9 SDISC-6 2-F14 VEC91-P9 7-F15
CDL4(-) GB3-A1 IM2 J55 J542
NTSC1 17-N2 P16X 16-M11 P83 9-K5 P800 2-N10 SDISC-7 2-F14 VEC91-P9 14-L2
CDL4(D) 8-O6 GB3-B3 2-O15 IM2 12-M8 J65 10-M6 J542 8-C20
ORS-85 5-M5 P16X 17-G17 P83 10-B6 P802 5-D5 SDISC-8 2-G14 VEC91-P9 14-N2
CGB-A 4-K20 GB12A-A2 7-K13 IM3 4-C3 J72 11-B9 J542 8-G18
ORS-86 5-M5 P17 2-M17 P83 10-K5 P803 5-K4 SDISC-9 2-G14 VEC91-P10 4-L1
CGB-B 4-K20 GB12A-B2 14-L8 IM3 6-L17 J72 13-N3 J542 15-C8
ORS-88 5-M5 P17 5-L7 P83 10-L15 P803 5-K4 SDISC-10 2-F14 VEC91-P10 4-C8
CGB-C 4-K20 GB12A-C1 14-N8 IM3 12-I7 J72 15-J19 J543 7-O13
ORS-88A 5-M5 P17 5-I9 P83 10-N12 P804 5-C2 SFSW2 15-L16 VEC91-P10 4-D6
CGBI-GND 4-L18 GB12A-C2 8-L8 IM3 12-J8 J73 10-H10 J543 7-P13
P01 7-G10 P17 5-O13 P83 11-G16 P805 5-D2 SFSW_JP 15-L15 VEC91-P10 9-H16
CGBI-T1 4-K18 GB12A-C3 8-N14 IM3 12-A8 J73 10-C14 J543 7-N13
P01 9-O12 P17 5-N13 P83 11-C17 P806 5-F2 SLLO 2-G18 VEC91-P10 10-K2
CGBI-T2 4-K18 GB12A-C4 7-G9 IM_ENET 12-O7 J73 10-G12 J543 8-F18
P1 16-I6 P17 9-H7 P83 11-N6 P808 2-M16 SLON 2-G18 VEC91-P11 4-M3
CGBI-T3 4-K18 GB12A-D3 17-E14 J01 7-G10 J73 10-E19 J543 8-B20
P1 16-E2 P18 7-J12 P83 12-I14 P808 5-N11 SLREL_K 2-F15 VEC91-P11 4-L4
CGIP 4-K18 GB12A-E1 10-I10 J01 9-O12 J73 10-F10 J544 8-G20
P01X 16-K4 P20 7-I9 P83 13-D5 P808 5-J6 SLREL_K 2-F16 VEC91-P11 4-M3
CN4 11-I12 GB12A-F1 13-E10 J02 4-O7 J74 15-K17 J544B 8-G20
P01X 17-D15 P20 7-I10 P83 13-A6 P808 5-L6 SLT-H1 4-M20 VEC91-P11 5-E17
CN5 11-H12 GB12A-F4 4-M8 J02 4-N7 J80 8-I18 J545 8-F20
P02 4-M8 P20T1B1 14-B2 P83 14-I8 P808 5-O11 SLT-H2 4-M20 VEC91-P11 8-J3
CNA 11-G19 GB12B-A1 12-A11 J02 4-M8 J80 9-G16 J545B 8-D20
P02 4-O7 P20T1D 14-C2 P83 14-B8 P815 5-E2 SLT-X1 4-M20 VEC91-P12 4-L4
CNB 11-F19 GB12B-A2 6-C16 J02 6-H14 J80 9-D15 J608 11-H14
P02 4-N7 P20T2B1 14-B4 P83 14-E6 P826 5-G2 SLT-X2 4-M20 VEC91-P12 5-D15
CNLIN 13-J17 GB12B-A3 6-D22 J02 6-F17 J80 9-E18 J701_JP 6-G7
P02 6-F17 P20T2B2 14-B4 P84 4-L9 P900 7-G6 SONA(+) 7-E8 VEC91-P12 5-D17
CNLO 13-J17 GB12B-A4 4-M9 J02 6-L12 J80 10-L13 J701_JP 9-N6
P02 6-C21 P20T2D 14-C4 P84 4-M6 P900 7-F5 SONA(-) 7-E8 VEC91-P12 5-D17
CNRIN 13-J14 GB12B-B1 4-N7 J02 6-H11 J80 10-E6 J701_JP 9-P5
P02 6-H14 P20T3B1 14-B6 P84 7-E12 PB1 4-M18 SPR 18-N7 VEC91-P12 5-C15
COMMA 13-N14 GB12B-B3 10-P7 J02 6-L15 J80 12-G5 J702_JP 3-D12
P02 6-L12 P20T3B2 14-B6 P84 7-K18 PB2 4-M18 SPS 12-J1 VEC91-S5A 4-F15
COMMB 13-O14 GB12B-B4 11-E14 J02 6-C21 J80 12-H4 J702_JP 6-N7
P02 6-H11 P20T3D 14-C6 P84 8-L2 PBPSW 12-F16 STRT1-1 2-K9 VEC91-S6A 4-F15
CON1 15-K5 GB12B-D1 14-J17 J02 9-I10 J80 13-D10 J702_JP 12-E15
P02 6-L15 P20T4B1 14-B12 P84 10-I8 PBPSW 12-F16 STRT1-7A 2-L9 VEC91-S6B 4-F15
CON2 15-K5 GB12B-D4 17-J14 J02 9-J7 J80 13-C10 J702_JP 15-L12
P02 9-J7 P20T4B2 14-B13 P84 13-E8 PBRPS 3-H13 STRT1-7B 2-L9 VEC91-S7A 4-E15
CON3 15-I6 GB12B-E2 10-P7 J02 11-F8 J80 13-I15 J702_JP 18-D18
P02 9-I10 P20T4D 14-C13 P84 14-N5 PBRPS 3-H13 STRT1-8 2-L9 VEC91-S7B 4-F15
CON4 15-I6 GB20-A1 12-G11 J02 11-E9 J80 15-I16 J703 11-A9
P02 11-E8 P21 8-G3 P85 3-I10 PBS 5-G13 STRT1-10A 2-L10 VEC91-S8A 4-F15
CRB 13-E13 GB20-A2 12-K4 J02 12-A12 J81 7-G12 J712 12-J20
P02 11-F8 P21 8-G2 P85 5-G16 PBS 5-G12 STRT1-10B 2-L10 VEC92-P1 5-O14
D1 9-I20 GB20-A3 12-K4 J02 12-H17 J81 9-O10 J713 15-J1
P02 12-A12 P21TX0B2 16-K2 P85 6-N12 PC_ENET 11-L12 STRT2-1 2-K11 VEC92-P1 6-C6
D1 9-I20 GB20-A4 12-K10 J02 17-K14 J82 4-M7 J730 12-D18
P02 12-H17 P21TX0D 16-K2 P85 9-J14 PENET1 11-K16 STRT2-7A 2-K11 VEC92-P1 15-B4
D2 5-G13 GB20-B1 12-K10 J02 18-D20 J82 4-N6 J808 2-M16
P02 17-K14 P022 9-M14 P85 10-N11 PENET2 11-L16 STRT2-7B 2-K11 VEC92-P1 15-B3
D2 5-G12 GB20-B2 12-M5 J02 18-I21 J82 4-O6 J808 5-N11
P02 18-I21 P22 10-C9 P85 12-L3 PENET3 11-J16 STRT2-7C 2-L11 VEC92-P2 5-O2
D3 6-N15 GB21-A1 13-K11 J03 3-D16 J82 6-L11 J808 5-J6
D3
D4
6-N16
8-K7
GB21-A2
GB21-A3
13-N9
13-M9
J03
J03
3-E7
3-D18
J82
J82
6-C19
6-H10
J808
J808
5-L6
5-O11
P02
P03
18-D19
3-D18
P22 10-C9
P22TX9B2 16-M2
P85
P100
12-G13
18-K9
PENET4
PENET5
11-K14
11-L14
STRT2-8
STRT2-10A
2-L12
2-K12
VEC92-P2
VEC92-P2
6-C7
6-M8
58B-06-05901-00 SEP 21
ELECTRICAL SCHEMATIC
980E-5
A50052, A50053, A50137, A50138
Sheet 21 of 21
58B-06-06830-00 OCT 18
HVAC ELECTRICAL SCHEMATIC
90 Diagrams and drawings CEN90033-01
3
CEN90033-01 90 Diagrams and drawings
980E Dump truck
Form No. CEN90033-01
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