shop manual 830E-1 A40851 & UP.PDF

CEBM027400

Shop Manual

DUMP TRUCK SERIAL NUMBERS

A40851 & UP

®

This material is proprietary to Komatsu America Corp (KAC), and is not to be reproduced, used, or disclosed except in accordance with written authorization 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 distributor for information on the latest revision.

Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel 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 problems. 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 properly disposed of in accordance with Local, State and Federal Laws at the end of their useful lives.

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 systems. Replacement parts manufactured and supplied by unauthorized sources may not be designed, manufactured or assembled to Komatsu's design specifications; accordingly, 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.

FOREWORD

This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck. The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model. This manual shows dimensioning of metric (SI) and U.S. standard units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator's normal seated position, unless specifically stated otherwise. Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 135 N·m (100 ft lbs) torque. All torque specifications have ±10% tolerance unless otherwise specified. A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating. The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 830E). The three numbers represent the basic truck model. The letter “E” designates an Electrical propulsion system. The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload. To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which includes all accessories, body liners, tailgates, etc.) and then weigh truck. Record this value and subtract from the GVW rating. The result is the allowable payload. NOTE: Accumulations of mud, frozen material, etc. become a part of the GVW and reduces allowable payload. To maximize payload and to keep from exceeding the GVW rating, these accumulations should be removed as often as practical.

Exceeding the allowable payload will reduce expected life of truck components.

A00046

Introduction

A-1

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.

A-2

Introduction

A00046

TABLE OF CONTENTS SUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B

ENGINE, FUEL, COOLING AND AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C

ELECTRIC SYSTEM (24 VDC. NON-PROPULSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D

ELECTRIC PROPULSION AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E

DRIVE AXLE, SPINDLES AND WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G

HYDRAIR® II SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H

BRAKE CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L

OPTIONS AND SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M

OPERATOR'S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N

LUBRICATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q

SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R

A00046

Introduction

A-3

KOMATSU MODEL 830E-AC TRUCK

A-4

Introduction

A00046

SECTION A GENERAL INFORMATION INDEX

MAJOR COMPONENTS & SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2

SAFETY AND OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3

WARNINGS AND CAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4

TORQUE TABLES AND CONVERSION CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5

STORAGE AND IDLE MACHINE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7

A01001 8/10

Index

A1-1

NOTES

A1-2

Index

8/10 A01001

MAJOR COMPONENT DESCRIPTION Truck And Engine

Operator's Cab

The 830E-AC Dump Truck is an off-highway, rear dump truck with AC Electric Drive. The gross vehicle weight is 385 852 kg (850,650 lbs.). The engine is a Komatsu SDA16V160 rated @ 1865 kW (2500 HP).

The operator cab has been engineered for operator comfort and to allow for efficient and safe operation of the truck. The cab provides wide visibility, with an integral 4-post ROPS/FOPS structure, and an advanced analog operator environment. It includes a tinted safety-glass windshield and power-operated side windows, a deluxe interior with a fully adjustable seat with lumbar support, a fully adjustable tilt/telescope steering wheel, controls mounted within easy reach of the operator, and an analog instrument panel which provides the operator with all instruments and gauges which are necessary to control and/or monitor the truck's operating systems.

Traction Alternator (G.E. GTA-41) The diesel engine drives an in-line alternator at engine speed. The alternator produces AC current which is rectified to DC within the main control cabinet. Cooling air for the control / power group and wheel motors, as well as the alternator itself, is provided by a fan mounted on the alternator shaft.

Main Control Cabinet Each phase module contains paired positive and negative semiconductor switches referred to as insulated gate bipolar transistors (IGBT). The IGBTs cycle on and off at varying frequencies to create an AC power signal from the DC supply. The AC power signal produced by each inverter is a variable-voltage, variable-frequency (VVVF) signal. Frequency and voltage are changed to suit the operating conditions.

AC Induction Traction Motorized Wheels The alternator output supplies electrical energy to the two wheel motors attached to the rear axle housing. The motorized wheels use three-phase AC induction motors with full-wave AC power. The two wheel motors convert electrical energy back to mechanical energy through built-in gear trains within the wheel motor assembly. The direction of the wheel motors is controlled by the directional control lever located on the center console.

Suspension HYDRAIR®II suspension cylinders located at each wheel provide a smooth and comfortable ride for the operator and dampens shock loads to the chassis during loading and operation.

A02089

Power Steering The truck is equipped with a full time power steering system which provides positive steering control with minimum operator effort. The system includes nitrogen-charged accumulators which automatically provide emergency power if the steering hydraulic pressure is reduced below an established minimum.

Dynamic Retarding The dynamic retarding is used to slow the truck during normal operation or control speed coming down a grade. The dynamic retarding ability of the electric system is controlled by the operator through the activation of the retarder pedal in the operators cab and by setting the RSC (Retarder Speed Control). Dynamic retarding is automatically activated, if the truck speed goes to a preset overspeed setting.

Brake System The braking system consists of an all hydraulic actuation system. Depressing the brake pedal actuates wheel-speed single disc front brakes and armaturespeed dual disc rear brakes. The brakes can also be activated by operating a switch on the instrument panel. The brakes will be applied automatically if system pressure decreases below a preset minimum. The parking brake is integral with the service brake caliper, and is spring-applied and hydraulicallyreleased. The park brake is applied by moving the directional control lever to the PARK position.

Major Component Description

A2-1

1. 2. 3. 4. 5. 6. 7.

Operator Cab Reserve Oil System Steps and Ladder Radiator Auto Lubrication Engine Suspension

A2-2

FIGURE 16-1. TRUCK COMPONENTS 14. Fuel Tank 15. Hoist Cylinder 10. Steering Linkage 16. Rear Axle Housing 11. Alternator 17. Disc Brake 12. Hoist Filters 18. Rear Tires 13. Steering Filter 19. Rear Suspension 8. Wheel Hub 9. Disc Brake

Major Component Description

20. Rear Axle Hatch 21. Hydraulic Tank 22. Hoist and Steering Pump 23. Steering Accumulators

A02089

SPECIFICATIONS These specifications are for the standard Komatsu 830E-AC Truck. Customer Options may change this listing. ENGINE Komatsu SDA16V160 (Optional SSDA16V160) No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Operating Cycle. . . . . . . . . . . . . . . . . . . . . . 4-Stroke Rated Brake HP. . . . 1865 kW (2500 hp)@ 1900 rpm Flywheel HP . . . . . 1761 kW (2360 hp) @ 1900 rpm Weight* (Wet) 8 558 kg (18,867 lbs) * Weight does not include Radiator, Sub-frame, or Alternator

AC ELECTRIC DRIVE SYSTEM (AC/DC Current)

SERVICE CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . Liters. (U.S. Gal.) Crankcase * . . . . . . . . . . . . . . . . . 280.0. . . . . (74.0) * Includes Lube Oil Filters Cooling System . . . . . . . . . . . . . . . . 568. . . . . (150) Fuel . . . . . . . . . . . . . . . . . . . . . . . . 4542. . . . (1200) Hydraulic System . . . . . . . . . . . . . . . 946. . . . . (250) Hydraulic Tank . . . . . . . . . . . . . . . . . 901. . . . . (238) Wheel Motor Gear Box (each) . . . . . . 38. . . . . . (10) HYDRAULIC SYSTEMS* Pumps Hoist . . . . . . . . . . . . . . . . . . . . . Tandem Gear Pump Rated @ . . . . . 851 lpm (225 gpm) @ 1900 rpm and . . . . . . . . . . . . . . . . . . . . . . . .17 240 kPa (2,500 psi) Steering/Brake . . . . . Pressure Compensating Piston Rated @ . . . . . . .246 lpm (65 gpm) @ 1900 rpm and . . . . . . . . . . . . . . . . . . . . . . . .18 961 kPa (2,750 psi) System Relief Pressures

Alternator . . . . . . . . . . . . .General Electric GTA - 41 Dual Impeller, In-Line Blower 255 m3/min (9000 cfm) Motorized Wheels . . . .GEB25 AC Induction Traction Motors Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.875:1 Maximum Speed* . . . . . . . . . 64.5 km/h (40 mph) (*w/40.00-57 Tires and 31.875:1 gear train) *NOTE: Wheel motor application depends upon GVW, haul road grade and length, rolling resistance, and other parameters. Komatsu & G.E. must analyze each job condition to assure proper application.

DYNAMIC RETARDING Electric Dynamic Retarding . . . . . . . . . . . . . Standard Maximum Rating . . . . . . . . . . . . . 3207 kW (4300 hp) 24 VDC ELECTRIC SYSTEM Batteries . . . . 4 x 8D 1450 CCA, 12 volt batteries in Series/Parallel w/Disconnect Switch Alternator . . . . . . . . . . . 24 Volt, 250 Ampere Output Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Volt Cranking Motors (2). . . . . . . . . . . . . . . . . . . . .24 Volt

Hoist . . . . . . . . . . . . . . . . . . . .17 240 kPa (2,500 psi) Steering/Brakes . . . . . . . . . . .27 580 kPa (4,000 psi) Hoist Cylinders (2) . . . . . . . . . . . . . . . . . . . . 3-Stage Tank (Vertical/Cylindrical) . . . . . . . . Non-Pressurized Filtration . . . . . . . . . . . . In-line replaceable elements Suction . . . . . . . . . . . .Single, Full Flow, 100 Mesh Hoist & Steering . . . . . . . . Full Flow, Dual In-Line, . . . . . . . . . . . High Pressure Beta 12 Rating =200 *With Quick Disconnects for powering disabled truck and system diagnostics. SERVICE BRAKES Actuation . . . . . . . . . . . . . . . . . . . . . . . .All Hydraulic Front . . . . . . . . . . . . . . . . Wheel Speed, Single Disc Inboard Mounted . . . . . . . . . . . . . . . . . 3 Calipers Disc Diameter, O.D. . . . . . . . 1213 mm (47.75 in.) Rear . . . . . . . . . . . . . . . Armature Speed, Dual Disc Disc Diameter, O.D. . . . . . . . . 635 mm (25.00 in.) Emergency Brake- Automatically Applied (Standard) Wheel Brake Lock . . . . . . Manual Switch on Panel . . . . . . . . . . . . . . . . . . . . . . . (Loading and Dumping) DISC PARKING BRAKE Each Rear Wheel . . . . . Integral with Service Caliper . . . . . . . . . . . Spring Applied, Hydraulically Released STEERING Turning Circle - Front Wheel Track. . . 28.4 m (93 ft.) Twin hydraulic cylinders with accumulator assist to provide constant rate steering. Emergency power steering automatically provided by accumulators.

A02089

Major Component Description

A2-3

DUMP BODY CAPACITIES AND DIMENSIONS Standard, Heaped @ 2:1 (SAE) . . 147 m3 (193 yd3) Struck . . . . . . . . . . . . . . . . . . . . . 117 m3 (153 yd3) Loading Height Empty . . . . . . . . 6.61 m (21 ft. 8 in.) Dumping Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Non-heated body w/exhaust mufflers . . . . . Standard TIRES Radial Tires (standard) . . . . . . . . . . . . . . . 40.00 R57 Optional Tires . . . . . . . . . . . . . . . . . . . . . . 46/90 R57 Rock Service, Deep Tread . . . . . . . . . . . . . Tubeless Rims, standard 5 piece. . Rated to 827 kPa (120 psi)

WEIGHT DISTRIBUTION Empty Vehicle . . . . Kilograms. . . . . . . . (Pounds) Front Axle . . . . . . . . . . . 82 747. . . . . . . . (182,426) Rear Axle. . . . . . . . . . . . 82 902. . . . . . . . (182,768) Total (100% fuel) . . . . . 165 649. . . . . . . . (365,194) Standard Komatsu body 27 669. . . . . . . . . (61,000) Standard tire weight. . . . 21 081. . . . . . . . . (46,476) Loaded Vehicle . . . Kilograms. . . . . . . . (Pounds) Front Axle . . . . . . . . . . 127 330. . . . . . . . (280,715) Rear Axle. . . . . . . . . . . 258 522. . . . . . . . (569,935) Total * . . . . . . . . . . . . . 385 852. . . . . . . . (850,650) Nominal Payload *. . . . 220 199. . . . . . . . (485,456) . . . . . . . . . . . . . (242 U.S. Ton) *Nominal payload is defined by Komatsu America Corporation’s payload policy documentation. In general, the nominal payload must be adjusted for the specific vehicle configuration and site application. The figures above are provided for basic product description purposes. Please contact your Komatsu distributor for specific application requirements.

OVERALL TRUCK DIMENSIONS (Empty with Standard Body)

Length . . . . . . . . . . . . . . . . . . . . . . . . . . Width . . . . . . . . . . . . . . . . . . . . . . . . . . . Height with Canopy . . . . . . . . . . . . . . . . Height with Dump Body Up . . . . . . . . . . Turning Circle (on front track) . . . . . . . .

A2-4

14.4 m (47 ft. 3 in.) 7.32 m (24 ft. 0 in.) 6.96 m (22 ft. 10 in.) 13.52 m (44 ft. 4 in.) 28.4 m (93 ft. 0 in.)

Major Component Description

A02089

SECTION A3 GENERAL SAFETY AND INDEX GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5 Truck Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5 Clothing And Personal Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5 Unauthorized Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5 Leaving The Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5 Mounting And Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6 Fire Extinguishers And First Aid Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6 Precautions For High Temperature Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6 Asbestos Dust Hazard Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6 Fire Prevention For Fuel And Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7 ROPS Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7 Preventing Injury From Work Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7 Precautions For Optional Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7 Precautions When Starting The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7 PRECAUTIONS FOR TRUCK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8 Safety Is Thinking Ahead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8 Safety At The Worksite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8 Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8 Preparing For Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8 Ventilation For Enclosed Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8 Mirrors, Windows, And Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9 In The Operator’s Cab - Before Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9 OPERATING THE MACHINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9 Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9 Truck Operation - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9 Traveling In The Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10

A03052

General Safety and Operating Instructions

A3-1

Precautions When Traveling In Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10 Traveling On Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10 Ensuring Good Visibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-11 Operating On Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-11 Avoid Damage To The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-11 Driving Near High Voltage Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-11 When Loading The Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-11 When Dumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-11 Working On Loose Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-12 Parking The Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-12 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-12 WORKING NEAR BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-13 Jump Starting With Booster Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14 Jump Starting With Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14 PRECAUTIONS FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15 BEFORE PERFORMING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15 Stopping The Engine Before Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15 Electrical Systems Isolation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15 Warning Tag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-17 Proper Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-17 Securing The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-17 DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-18 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-18 Attachments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-18 Working Under The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-18 Keeping The Machine Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-18 Rules To Follow When Adding Fuel Or Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-18 Radiator Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-18 Use Of Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-19 Precautions With The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-19

A3-2

General Safety and Operating Instructions

A03052

Handling High Pressure Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-19 Precautions With High Pressure Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-19 Maintenance Near High Temperatures And High Pressures . . . . . . . . . . . . . . . . . . . . . . . . . A3-19 Rotating Fan And Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-19 Waste Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-19 TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-20 Handling Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-20 Storing Tires After Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-21 ADDITIONAL JOB SITE RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-22 WHEN REPAIRS ARE NECESSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-23 SPECIAL PRECAUTIONS FOR WORKING ON AN 830E-1AC TRUCK . . . . . . . . . . . . . . . . . . . . . . A3-24 Preliminary Procedures before Welding or Performing Maintenance. . . . . . . . . . . . . . . . . . . A3-24 Engine Shutdown Procedure before Welding or Performing Maintenance . . . . . . . . . . . . . . A3-24 CAPACITOR DISCHARGE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-26 Necessary Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-26 MANUAL DC LINK CAPACITOR DISCHARGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . A3-28 CAPACITOR CHARGE LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-30 FAILURE OF DISCHARGE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-31 MANUAL DISCHARGE OF CAPACITORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-32 SHORT ISOLATED CAPACITOR TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-34 TRUCK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-36 PREPARING FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-36 Safety Is Thinking Ahead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-36 WALK AROUND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-36 RETRACTABLE LADDER SYSTEM (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-40 LADDER SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-40 LADDER SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-41 GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-41 IN-CAB CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-41

A03052

General Safety and Operating Instructions

A3-3

IN-CAB CONTROL PANEL FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-42 USING THE IN-CAB CONTROL PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-43 USING THE GROUND LEVEL CONTROL BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-45 ENGINE START-UP SAFETY PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-47 AFTER ENGINE HAS STARTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-48 PRE-SHIFT BRAKE CHECK (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-49 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-49 PERFORMING THE BRAKE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-50 EMERGENCY STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-53 MACHINE OPERATION SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-54 MACHINE OPERATION ON THE HAUL ROAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-55 STARTING ON A GRADE WITH A LOADED TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-56 PASSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-56 LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-56 DUMPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-56 Raising The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-56 Lowering The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-57 SUDDEN LOSS OF ENGINE POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-58 FUEL DEPLETION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-59 SAFE PARKING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-59 NORMAL ENGINE SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-60 DISABLED TRUCK CONNECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-61 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-61 STEERING AND BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-61 HOIST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-62 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-64 RESERVE ENGINE OIL SYSTEM (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-67

A3-4

General Safety and Operating Instructions

A03052

GENERAL SAFETY Safety records of most organizations will show that the greatest percentage of accidents are caused by unsafe acts of persons. The remainder are caused by unsafe mechanical or physical conditions. Report all unsafe conditions to the proper authority. The following safety rules are provided as a guide for the operator. However, local conditions and regulations 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 • Only trained and authorized personnel can operate and maintain the machine. • Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. • When working with another operator or a person on work site traffic duty, ensure all personnel understand all hand signals that are to be used. Truck Safety Features

Clothing And Personal Items • Avoid wearing loose clothing, jewelry, and loose long hair. They can catch on controls or in moving parts and cause serious injury or death. Additionally, never wear oily clothes as they are flammable. • Wear a hard hat, safety glasses, safety shoes, a mask and gloves when operating or maintaining a machine. Always wear safety goggles, a hard hat and heavy gloves if your job involves scattering metal chips or minute materials. This is particularly important when driving pins with a hammer or when cleaning air cleaner elements with compressed air. Also, ensure that the work area is free of other personnel during such tasks. Unauthorized Modification • Any modification made to this vehicle without authorization from Komatsu America Corp. can possibly create hazards. • Before making any modification, consult your authorized regional Komatsu America Corp. distributor. Komatsu will not be responsible for any injury or damage caused by any unauthorized modification.

• Ensure all guards and covers are in their proper position. Repair any damaged guards and covers. (Refer to Walk-Around Inspection, later in this section.)

Leaving The Operator’s Seat

• Learn the proper use of safety features such as safety locks, safety pins, and seat belts. Always use these safety features, properly.

While leaving the operator's seat, DO NOT touch any controls. To prevent accidental operations from occurring, always perform the following:

• Never remove any safety features. Always keep safety features in good operating condition.

• Move the directional control lever to the PARK position (this will apply the parking brake). DO NOT apply the wheel brake lock.

• Improper use of safety features may result in serious bodily injury or death.

• Lower the dump body, and move the hoist control lever to the FLOAT position. • Turn the key switch to the OFF position and wait for the engine to stop. • After the engine has stopped, wait two minutes before exiting the cab. If any warning lights are illuminated or warning horns are sounding, DO NOT leave the cab and notify maintenance personnel immediately. When exiting the machine, always lock compartments, and take the keys with you to prevent entry from unauthorized persons.

A03052

General Safety and Operating Instructions

A3-5

Precautions For High Temperature Fluids

Mounting And Dismounting • Never jump on or off the machine. Never climb on or off a machine while it is moving. • When climbing on or off a machine, face the machine and use the hand-hold and steps. • Never hold any control levers when getting on or off a machine. • Always maintain three-point contact with the hand-holds and steps to ensure that you support yourself. • When bringing tools up to the operating deck, always pass them by hand or pull them up by rope. • If there is any oil, grease, or mud on the handholds or steps, wipe them clean immediately. Always keep these components clean. Repair any damage and tighten any loose bolts. • Use the handrails and steps marked by arrows in the diagram below when getting on or off the machine. NOTE: Some trucks may be equipped with different boarding equipment than shown in the figure below. Refer to Options Section for additional information.

• Immediately after machine operation, engine coolant, engine oil, and hydraulic oil are at high temperatures and are pressurized. If the cap is removed, the fluids drained, the filters are replaced, etc., there is danger of serious burns. Allow heat and pressure to dissipate before performing such tasks and follow proper procedures as outlined in the service manual. • To prevent hot coolant from spraying: 1. Stop the engine and wait for the coolant temperature to decrease. 2. Depress the pressure relief button on the radiator cap. 3. Turn the radiator cap slowly to allow pressure to dissipate. • To prevent hot engine oil spray: 1. Stop the engine. 2. Wait for the oil temperature to cool down. 3. Turn the cap slowly to allow pressure to dissipate.

Asbestos Dust Hazard Prevention Asbestos dust is hazardous to your health when inhaled. If you handle materials containing asbestos fibers, follow the guidelines below: • Never use compressed air for cleaning. • Use water for cleaning and to control dust. Fire Extinguishers And First Aid Kits

• Operate the machine or perform tasks with the wind to your back, whenever possible. • Use an approved respirator, when necessary.

• Ensure fire extinguishers are accessible and proper usage techniques are known. • Provide a first aid kit at the storage point. • Know what to do in the event of a fire. • Keep the phone numbers of persons you must contact in case of an emergency on hand.

A3-6

General Safety and Operating Instructions

A03052

Fire Prevention For Fuel And Oil • Fuel, oil, and antifreeze can be ignited by a flame. These fluids are extremely flammable and hazardous. • Keep flames away from flammable fluids.

• When modifying or repairing the ROPS, always consult your nearest Komatsu distributor. • Even with the ROPS installed, the operator must always use the seat belt when operating the machine.

• Stop the engine while refueling. Preventing Injury From Work Equipment

• Never smoke while refueling • Tighten all fuel and oil tank caps securely. • Refuel and maintain oil in well ventilated areas. • Keep oil and fuel in a designated location. DO NOT allow unauthorized persons to enter.

• Never position any part of your body between movable parts such as the dump body, chassis or cylinders. If the work equipment is operated, clearances will change and may cause serious bodily injury or death.

Precautions For Optional Attachments • When installing and using optional equipment, read the instruction manual for the attachment and the information related to attachments in this manual. • DO NOT use attachments that are not authorized by Komatsu, or the authorized regional Komatsu distributor. Use of unauthorized attachments could create a safety problem and adversely affect the proper operation and useful life of the machine.

ROPS Precautions • The Rollover Protection Structure (ROPS) must be properly installed for machine operation. • The ROPS is intended to protect the operator if the machine rolls over. It is designed not only to support the load of the machine, but also to absorb the energy of the impact. • ROPS structures installed on equipment manufactured and designed by Komatsu fulfills all of the regulations and standards for all countries. If it is modified or repaired without authorization from Komatsu, or is damaged when the machine rolls over, the strength of the structure will be compromised and will not be able to fulfill its intended purpose. Optimum strength of the structure can only be achieved if it is repaired or modified as specified by Komatsu.

A03052

• Any injuries, accidents, and product failures resulting from the use of unauthorized attachments will not be the responsibility of Komatsu America Corp., or the authorized regional Komatsu distributor.

Precautions When Starting The Machine • Start the engine from the operator’s seat, only. • Never attempt to start the engine by shorting across the starter terminals. This may cause fire, or serious injury or death to anyone in the machine’s path.

General Safety and Operating Instructions

A3-7

PRECAUTIONS FOR TRUCK OPERATION Safety Is Thinking Ahead Prevention is the best safety program. Prevent a potential accident by knowing the employer's safety requirements and all necessary job site regulations. In addition, know the proper use and care of all the safety equipment on the truck. Only qualified operators or technicians may attempt to operate or maintain a Komatsu machine. Safe practices start before the operator gets to the equipment!

Fire Prevention • Remove all wood chips, leaves, paper and other flammable items accumulated in the engine compartment, as they could cause a fire. • Check fuel, lubrication, and hydraulic systems for leaks. Repair any leaks. Clean any excess oil, fuel or other flammable fluids, and dispose of properly. • Ensure a fire extinguisher is present and in proper working condition. • DO NOT operate the machine near open flames.

Safety At The Worksite • When walking to and from a truck, maintain a safe distance from all machines even when the operator is visible. • Before starting the engine, thoroughly check the area for any unusual conditions that could be dangerous. • Examine the road surface at the job site and determine the best and safest method of operation. • 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 position, the roads to be used, and existence of obstacles before starting operations. • Always determine the travel roads to be used at the work site. Travel roads must be maintained in order to ensure safe machine travel.

Preparing For Operation • Always mount and dismount while facing the truck. Never attempt to mount or dismount the truck while it is in motion. Always use handrails and ladders when mounting or dismounting the truck. • Check the deck areas for debris, loose hardware, and tools. Check for people and objects that remain on or around the truck. • Become familiar with and use all protective equipment devices on the truck and ensure that these items (anti-skid material, grab bars, seat belts, etc.) are securely in place.

Ventilation For Enclosed Areas • If it is necessary to start the engine in an enclosed area, provide adequate ventilation. Exhaust fumes from the engine can kill.

• If travel through wet areas is necessary, check the depth and flow of water before crossing the shallow parts. Never drive through water which exceeds the permissible water depth.

A3-8

General Safety and Operating Instructions

A03052

Mirrors, Windows, And Lights • Remove any dirt from the surface of the windshield, cab windows, mirrors and lights. Good visibility may prevent an accident. • Adjust the mirrors to a position where the operator can see best from the operator's seat. • Ensure headlights, work lights and taillights are in proper working order. Ensure that the machine is equipped with the proper work lamps needed for the operating conditions. • Replace any broken mirrors, windows or lights. In The Operator’s Cab - Before Starting The Engine • DO NOT leave tools or spare parts lying around or 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. • Read and understand the contents of the Operation & Maintenance manual. Read safety and operating instructions with special attention. Become thoroughly acquainted with all gauges, instruments and controls before attempting operation of the truck. • Read and understand the WARNING and CAUTION decals in the operator's cab. • Ensure the steering wheel, horn, controls and pedals are free of any oil, grease or mud. • Check operation of the windshield wiper, condition of wiper blades, and check the washer fluid reservoir level. • Be familiar with all steering and brake system controls, warning devices, road speeds and loading capabilities, before operating the truck. • If equipped, ensure the Retractable Ladder System (RLS) is raised. Seat Belts • On both driver and passenger seats, check the seat belt fabric, buckle, all belt retractors and hardware for damage or wear. Replace any worn or damaged parts immediately.

into the shoulder harness belt, near the retractor end.

OPERATING THE MACHINE Starting The Engine • NEVER ATTEMPT TO START THE MACHINE BY SHORTING ACROSS THE STARTER TERMINALS. This may cause fire, or serious injury or death to anyone in machine’s path. • NEVER start the engine if a warning tag has been attached to the controls. • When starting the engine, sound the horn as an alert. • Start and operate the machine only while seated in the operator’s seat. • DO NOT allow any unauthorized persons in the operator's compartment or any other place on the machine.

Truck Operation - General • WEAR SEAT BELTS AT ALL TIMES. • Only authorized persons are allowed to ride in the truck. Passengers must be in the cab and belted in the passenger seat. • DO NOT allow anyone to ride on the decks or on the steps of the truck. • DO NOT allow anyone to get on or off the truck while it is in motion. • DO NOT move the truck in or out of a building without a signal person present. • Know and obey hand signal communications between the operator and spotter. When other machines and personnel are present, the operator must move in and out of buildings, loading areas and through traffic, under the direction of a signal person. Courtesy at all times is a safety precaution! • Immediately report any adverse conditions on haul road, pit or dump area that may cause an operating hazard.

• Even if there are no signs of damage, replace both driver and passenger seat belts 5 years after seat belt manufacture, or every 3 years after start of use, whichever comes first. The passenger seat belt date of manufacture label is sewn into the seat belt near the buckle. The driver seat belt date of manufacture label is sewn

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General Safety and Operating Instructions

A3-9

• Check for flat tires periodically during a shift. If the truck has been operating on a “flat”, the truck must not be parked indoors until the tire cools. If the tire must be changed, DO NOT stand in front of the rim and locking ring when inflating a tire mounted on the machine. Observers must not be permitted in the area and must be kept away from the side of such tires.

• If the engine stops when the machine is in motion, the emergency steering system will be activated. Apply the brakes immediately and stop the machine as quickly and safely as possible (off of the haul road, if possible). Apply the parking brake. Precautions When Traveling In Reverse Before operating the machine or work equipment, do as follows:

A tire and rim assembly may explode if subjected to excessive heat. Personnel must move to a remote or protected location if there is a fire near the tire and wheel area or if the smell of burning rubber or excessively hot brakes is evident. If the truck must be approached, such as to fight a fire, those personnel must do so only while facing the tread area of the tire (front or back), unless protected by use of large heavy equipment as a shield. Stay at least 15 m (50 ft) from the tread of the tire. In the event of fire in the tire and wheel area (including brake fires), stay away from the truck for at least eight hours or until the tire and wheel are cool. • Keep serviceable fire fighting equipment on hand. Report used extinguishers for replacement or refilling. • Always move the directional control lever to PARK (this will apply the parking brake) when the truck is parked and unattended. DO NOT leave the truck unattended while the engine is running. NOTE: DO NOT use wheel brake lock when parking the truck. • Park the truck a safe distance away from other vehicles as determined by the supervisor. • Stay alert at all times! In the event of an emergency, be prepared to react quickly and avoid accidents. If an emergency arises, know where to get prompt assistance. Traveling In The Truck • When traveling on rough ground, travel at low speeds. When changing direction, avoid turning suddenly.

• Ensure the backup alarm works properly. • Sound the horn to warn people in the area. • Check for personnel near the machine. Do a thorough check behind the machine. • When necessary, designate a person to watch the area for the truck operator. This is particularly necessary when traveling in reverse. • When operating in hazardous areas and areas with poor visibility, designate a person to direct work site traffic. • DO NOT allow any one to enter the line of travel of the machine. This rule must be strictly obeyed even with machines equipped with a back-up alarm or rear view mirror. Traveling On Slopes • Traveling on slopes could result in the machine tipping over or slipping. • DO NOT change direction on slopes. To ensure safety, drive to level ground before turning. • DO NOT travel up and down on grass, fallen leaves, or wet steel plates. These materials may make the machine slip on even the slightest slope. Avoid traveling sideways, and always keep travel speed low. • When traveling downhill, use the retarder to reduce speed. DO NOT turn the steering wheel suddenly. DO NOT use the foot brake except in an emergency. • If the engine stops on a slope, apply the service brakes to fully stop the machine. Move the directional control lever to the PARK position (this will apply the parking brake).

• Lower the dump body and move the dump lever to the FLOAT position before traveling.

A3-10

General Safety and Operating Instructions

A03052

Ensuring Good Visibility

Driving Near High Voltage Cables

•

When working in dark places, install work lamps and head lamps.

•

•

Discontinue operations if visibility is poor, such as in mist, snow, or rain. Wait for the weather to improve to allow the operation to be performed safely.

Operating On Snow • When working on snowy or icy roads, there is danger that the machine may slip to the side on even the slightest slope. Always travel slowly and avoid sudden starting, turning, or stopping in these conditions. • Be extremely careful when clearing snow. The road shoulder and other objects are buried in the snow and cannot be seen.

Driving near high-voltage cables can cause electric shock. Always maintain the safe distances between the machine and the electric cable as listed below. Voltage

Minimum Safe Distance

6.6 kV

3m

10 ft.

33.0 kV

4m

14 ft.

66.0 kV

5m

17 ft.

154.0 kV

8m

27 ft.

275.0 kV

10 m

33 ft.

The following actions are effective in preventing accidents while working near high voltages: • Wear shoes with rubber or leather soles. • Use a signalman to give warning if the machine approaches an electric cable.

Avoid Damage To The Dump Body • When working in tunnels, on bridges, under electric cables, or when entering an enclosed area where there are height limits, always use extreme caution. The dump body must be completely lowered before driving.

Driving with a raised dump body or raising the dump body in an enclosed area, may result in serious damage and bodily injury or death. Always drive with the dump body resting on the frame.

• If the work equipment touches an electric cable, the operator must not leave the cab. • When performing operations near high voltage cables, DO NOT allow anyone to approach the machine. • Check with the electrical maintenance department about the voltage of the cables before starting operations. When Loading The Truck • Ensure the surrounding area is safe. If so, stop the machine in the correct loading position and evenly load the body. • DO NOT leave the operator's seat during the loading operation. When Dumping • Before dumping, check that there is no person or objects behind the machine. • Stop the machine in the desired location. Check again for persons or objects behind the machine. Give the determined signal, then slowly operate the dump body. If necessary, use blocks for the wheels or position a flagman. • When dumping on slopes, machine stability is poor and there is danger of tip over. Always perform such operations using extreme care. • Never travel with the dump body raised.

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General Safety and Operating Instructions

A3-11

Working On Loose Ground • Avoid operating the machine near cliffs, overhangs, and deep ditches. If these areas collapse, the machine could fall or tip over and result in serious injury or death. Remember that ground surfaces in these areas may be weakened after heavy rain or blasting. • Freshly laid soil and the soil near ditches is loose. It can collapse under the weight or vibration of the machine. Avoid these areas whenever possible.

• Turn the key switch to the OFF position and wait for the engine to stop. This could take up to three minutes for a hot engine to cool down. After the engine has stopped, wait two minutes before exiting the cab. If any warning lights are illuminated or warning horns are sounding, DO NOT leave the cab and notify maintenance personnel immediately. • When exiting the machine, always lock compartments, and take the keys with you to prevent entry from unauthorized persons. • Place wheel chocks around the wheels to prevent the truck from rolling.

Parking The Machine • Ensure the truck body is empty. Completely lower the dump body by placing the hoist control lever in the FLOAT position. • Choose a horizontal road surface to park the machine. If the machine must be parked on a slope, follow local regulations to secure the truck to prevent the machine from moving. • Move the directional control lever to PARK (this will apply the parking brake). NOTE: DO NOT apply the wheel brake lock.

TOWING Improper towing methods may lead to serious personal injury and/or damage. • Tow with a solid tow bar. DO NOT tow with a cable. • Use a towing device with ample strength for the weight of this machine. • Never tow a machine on a slope. • When connecting a machine to be towed, DO NOT allow anyone to go between the tow machine and the disabled machine. • Set the coupling of the disabled machine in a straight line with the towing portion of the tow machine, and secure it in position. • DO NOT stand next to the towing device while the truck is moving. (For towing method, refer to Operating Instructions Towing later in this section.)

A3-12

General Safety and Operating Instructions

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WORKING NEAR BATTERIES Battery Hazard Prevention Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If electrolyte comes in contact with skin, immediately flush the area with water. Battery acid can cause blindness if splashed into the eyes. If acid gets into the eyes, flush them immediately with large quantities of water and see a doctor immediately. • If acid is accidentally ingested, drink a large quantity of water, milk, beaten eggs or vegetable oil. Call a doctor or poison prevention center immediately. • Always wear safety glasses or goggles when working with batteries.

• When removing or installing a battery, positively identify the positive (+) terminal and negative (-) terminal and use precautions not to short circuit between the terminals. • This truck is equipped with a master disconnect switch (3, Figure 3-2) on the battery ground circuit. When disconnecting battery cables, always move the master disconnect switch to the OFF position (1, Figure 3-1). First, disconnect the positive (+) battery cables, then the negative (-) battery cables last. NOTE: If the master disconnect switch is OFF, and a wrench on the negative (-) terminal touches the battery box frame, a spark will occur if any electrical component on the truck was left in the ON position. • When connecting battery cables, always move the master disconnect switch (3, Figure 3-2) to the OFF position. Then connect the negative (-) cables first, then the positive cables (+) last. • Tighten battery terminals securely. Loose terminals can generate sparks and could lead to an explosion. • Tighten battery caps securely.

• Batteries generate hydrogen gas. Hydrogen gas is very EXPLOSIVE, and is easily ignited with a small spark or flame. • Before working with batteries, stop the engine and turn the key switch to the OFF position. Wait two minutes after the engine has stopped, and if no warning lights illuminate, then turn the battery disconnect switches to the OFF position.

FIGURE 3-1. MASTER DISCONNECT SWITCH 1. Off

2. On

• Avoid short-circuiting the battery terminals through accidental contact with metallic objects, such as tools, across the terminals.

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General Safety and Operating Instructions

A3-13

Jump Starting With Booster Cables

Jump Starting With Receptacles

• Always wear safety glasses or goggles when starting the machine with booster cables.

• Always wear safety glasses or goggles when starting the machine with booster cables.

• While jump starting with another machine, DO NOT allow the two machines to touch.

• While jump starting with another machine, DO NOT allow the two machines to touch.

• Ensure the parking brake is applied on both machines. The engine on the good machine is to be operating.

• Ensure the parking brake is applied on both machines. The engine on the good machine is to be operating.

• Ensure the size of the booster cables and clips are suitable for the battery size. Inspect the cables and clips for any damage or corrosion.

• Inspect the cables and connectors for any damage or corrosion.

• Ensure the key switch and master battery disconnect switch (3, Figure 3-2) on the disabled machine is in the OFF position. • Connect the batteries in parallel: positive to positive and negative to negative. • Connect the positive (24VDC +) cable from the good machine to the (24VDC +) on the disabled machine first. • Then connect the ground cable from the negative (-) battery terminal on the good machine to the frame of the disabled machine, as far away as possible from the batteries. This will prevent a spark from possibly starting a battery fire. • Move the master battery disconnect switch (3, Figure 3-2) to the ON position. Allow time for the batteries to charge. • If starting with a booster cable, perform the operation with two people. One person in the cab of the disabled machine, the other person working with the jumper cables. • If the batteries are low, DO NOT attempt starting the machine with only one set of jumper cables installed. Install the second set of jumper cables in the same way as already described. • Attempt starting the disabled machine. • For booster cable removal, disconnect the ground or negative (-) cable first, then the (24VDC +) cable last.

• Ensure the key switch and master battery disconnect switch (3, Figure 3-2) on the disabled machine is in the OFF position. • Connect the jumper cable to the receptacle on the good machine to the receptacle on the disabled machine. • Allow time for the batteries to charge. NOTE: The batteries will charge even with the master battery disconnect switch is in the OFF position. • If starting with a booster cable, perform the operation with two people. One person in the cab of the disabled machine, the other person working with the jumper cables. • If the batteries are low, DO NOT attempt starting the machine with only one set of jumper cables installed. Install the second set of jumper cables in the same way as already described. • Turn the master battery disconnect switch (3, Figure 3-2) to the ON position and attempt starting. • For booster cable removal, disconnect the cables from each machine. • If any tool touches between the positive (+) terminal and the chassis, it will cause sparks. Always use caution when using tools near the batteries.

• If any tool touches between the positive (+) terminal and the chassis, it will cause sparks. Always use caution when using tools near the batteries.

A3-14

General Safety and Operating Instructions

A03052

PRECAUTIONS FOR MAINTENANCE BEFORE PERFORMING MAINTENANCE Stopping The Engine Before Service • Before performing inspections or maintenance, stop the machine on firm, flat ground. Lower the dump body, place the directional control lever to the PARK position (this will apply the parking brake), and turn the key switch to the OFF position and wait for the engine to stop. • Wait two minutes after the engine has stopped, and if no warning lights illuminate, then turn the battery disconnect switches to the OFF position. Verify that the disconnects are functioning. • Place wheel chocks around the wheels to prevent the truck from rolling. • If the engine must be operated during maintenance, always move the directional control lever to the PARK position (this will apply the parking brake). Always perform this work with two people. One person must be in the operator's seat to stop the engine if necessary. Never move any controls not related to the task at hand during these situations. Apply the propel lockout lever (5, Figure 3-2) to prevent the truck from moving if the engine must operate during maintenance. When the propel lockout lever is in the OFF position and LED light (8) is illuminated, the drive system is locked out and the truck will not propel. When the propel lockout lever is in the ON position and LED light (7) is illuminated, the drive system is active and the truck can be driven. • When servicing the machine, use care not to touch any moving parts. Never wear loose clothing. • When performing service with the dump body raised, always place the dump lever in the HOLD position, and apply the lock (if equipped). Install the body-up safety cable securely.

A03052

Electrical Systems Isolation • Isolation box (6, Figure 3-2) contains master disconnect switch (3), starter disconnect switch (4) and propel lockout lever (5). The isolation box is located on top of the front bumper, on the left hand side. Move both disconnect switches and the propel lockout lever to the OFF position to disable the 24VDC electrical system, starters and the AC electric drive system. When the switches and propel lockout lever are in the OFF position, LED lights (8) will be illuminated. The battery disconnect switches and propel lockout lever can be padlocked in the OFF position to prevent unauthorized truck operation. When the switches and the propel lockout lever are in the ON position, LED lights (7) will be illuminated. Refer to the following table to ensure the correct disconnect is used to isolate a desired circuit or system. NOTE: This is the recommended usage of the battery disconnect and propel lockout switches. Local regulations may be different. Action

Recommended Isolation

24V Electrical Troubleshooting

Starter Lockout

24V Electrical Maintenance/Repair

Master Lockout

High Voltage/Propulsion Troubleshooting

None

High Voltage Maintenance/Repair

Master Lockout

Hydraulic Troubleshooting

Propel Lockout

Hydraulic Maintenance/Repair

Starter Lockout

Engine Troubleshooting

Propel Lockout

Engine Repair

Master Lockout

Mechanical Repair

Starter Lockout

Weld Repair

Master Lockout & Alternator Isolation

Fueling

Starter Lockout

Lube/General Maintenance

Starter Lockout

Shift Change Walk Around

Starter Lockout

Oil Sample Collection

Propel Lockout

General Safety and Operating Instructions

A3-15

FIGURE 3-2. ISOLATION BOX ASSEMBLY (COVERS REMOVED) 1. Engine Shutdown Switch 2. Access Ladder Light Switch

A3-16

3. Master Disconnect Switch 4. Starter Disconnect Switch 5. Propel Lockout Lever

General Safety and Operating Instructions

6. Isolation Box 7. LED Lights (on) 8. LED Lights (off)

A03052

Securing The Dump Body

Warning Tag • Never start the engine or operate the controls while a person is performing maintenance. Serious injury or death may result. • Always attach a warning tag to the control lever in the operator's cab to alert others that you are working on the machine. Attach additional warning tags around the machine, if necessary. • These tags are available from your Komatsu distributor. Part No. 09963-03001 Proper Tools

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 it's maximum height.

• Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools can cause personal injury.

2. Install two shackles (2, Figure 3-3) and body retention sling (3) between rear body ear (1) and the axle housing. 3. Secure the shackle pins with cotter pins.

• Extra precaution must be used when grinding, welding, and using a sledge-hammer.

4. Move the hoist lever to the FLOAT position to slowly lower the body until the cable is supporting the full weight of the body. Then move the hoist lever to the HOLD position. 5. After maintenance work is completed, return the sling to stored position.

FIGURE 3-3. SAFETY CABLE 1. Rear Body Ear 2. Shackle And Pin

A03052

General Safety and Operating Instructions

3. Body Retention Sling

A3-17

DURING MAINTENANCE Personnel • Only authorized personnel can service and repair the machine. Attachments • Place attachments that have been removed from the machine in a safe place and manner to prevent them from falling. Working Under The Machine • Always lower all movable work equipment to the ground or to their lowest position before performing service or repairs under the machine. • Always block the tires of the machine securely. • Never work under the machine if the machine is poorly supported. Keeping The Machine Clean

• 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 allow any water to enter the cooling air inlet duct above the electrical control cabinet. If water enters the control cabinet (through any opening or crevice) major damage to the electrical components may occur. • 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. Rules To Follow When Adding Fuel Or Oil • Spilled fuel and oil may cause slipping. Always clean up spills, immediately. • Always tighten the cap of the fuel and oil fillers securely. • Never use fuel for washing any parts. • Always stop the engine before adding fuel or oil. • Always add fuel and oil in a well-ventilated area.

If equipped, DO NOT aim high pressure spray equipment at or near the Retractable Ladder System (RLS) power pack, actuator box, bearings or electrical harnesses. Moisture introduced in the electrical harnesses may result in uncontrolled ladder movement. • Spilled oil, grease, scattered tools, etc. can cause you to slip or trip. Always keep your machine clean and tidy.

Radiator Coolant Level

• If water gets into the electrical system, there is danger that the machine 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.

• If it is necessary to coolant to the radiator, the engine. Allow engine and radiator to down before adding coolant.

add stop the cool the

• Depress the pressure relief button on the radiator cap to relieve any pressure. • Slowly loosen the cap to relieve pressure during removal.

A3-18

General Safety and Operating Instructions

A03052

Use Of Lighting • When checking fuel, oil, coolant, or battery electrolyte, always use lighting with antiexplosion specifications. If lighting without this protection is used, there is a danger of explosion.

• Small, high pressure pin-hole leaks are extremely dangerous. The jet stream of high-pressure oil can pierce the skin and eyes. Always wear safety glasses and thick gloves. Use a piece of cardboard or a sheet 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.

Maintenance Near High Temperatures And High Pressures

Precautions With The Battery • Before repairing the electrical system or when performing welding, turn the key switch to the OFF position. Wait two minutes after the engine has stopped, and if no warning lights illuminate, then turn the master disconnect switch (3, Figure 3-2) and starter disconnect switch (4) located in the isolation box (6) to the OFF position. When the switches are in the OFF position, LED lights (8) will be illuminated.

• Immediately after stopping the truck, the engine coolant and operating oils are at high temperature and under high pressure. In these conditions, opening the system or replacing filters may result in burns or other injury. Wait for the temperature to cool and pressure to subside before performing the inspection and/or maintenance as outlined in the service manual.

Rotating Fan And Belts Handling High Pressure Hoses • DO NOT bend high-pressure hoses or hit them with hard objects. DO NOT use any bent or cracked piping, tubes or hoses. They may burst during use.

• Keep a safe distance from rotating parts such as the radiator fan and fan belts. • Serious bodily injury may result from direct or indirect contact with rotating parts and flying objects.

• Always repair any loose or broken hoses. Fuel and/or oil leaks may result in a fire. Waste Materials Precautions With High Pressure Oil • Always remember that work equipment circuits are always under pressure. • DO NOT add oil, drain oil, or perform maintenance or inspections before completely releasing the internal pressure.

• Never dump oil or other harmful fluids into a sewer system, rivers, etc. • Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, coolant, solvent, filters, batteries, and others. • Always put fluids drained from your machine in appropriate containers. Never drain fluids directly onto the ground. • The machine may be equipped with optional high intensity discharge lamps which contain mercury. These lamps must be reused, recycled or properly disposed of in accordance with applicable local, state and federal laws.

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General Safety and Operating Instructions

A3-19

TIRES Handling Tires Rim and tire maintenance can be hazardous unless the correct procedures are followed by trained personnel. Improperly maintained or inflated tires can overheat and burst due to excessive pressure. Improper inflation can also result in cuts in the tire caused by sharp stones. Both of these conditions can lead to tire damage, serious personal injury, or even death. To safely maintain a tire, adhere to the following conditions: • Before a tire is removed from a vehicle for tire repair, the valve core must be partially removed to allow deflation, and then the tire/rim assembly can be removed. During deflation, persons must stand outside of the potential trajectory of the locking ring of a multi-piece wheel rim. • After the tire/rim assembly is installed on the vehicle, inflate the tires to their specified pressure. Abnormal heat is generated, particularly when the inflation pressure is too low.

The tire inflation pressure 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, please consult the tire manufacturer. When the tires become overheated, a flammable gas is produced inside the tire which can ignite. It is particularly dangerous if the tires become overheated while the tires are pressurized. If the gas generated inside the tire ignites, the internal pressure will suddenly rise, and the tire will explode, resulting in danger and/or death to personnel in the area. Explosions differ from punctures or tire bursts because the destructive force of the explosion is extremely large. Therefore, the following operations are strictly prohibited when the tire is pressurized: • Welding the rim • Welding near the wheel or tire. • Smoking flames

or

creating

open

NOTE: To prevent injury from the wheel rims during tire inflation, use one of the following: 1. A wheel cage or other restraining device that will constrain all wheel rim components during an explosive separation of a multi-piece wheel rim, or during the sudden release of air. 2. A stand-off inflation device which permits a person to stand outside of the potential trajectory of the wheel components. • Use the specified tires.

A3-20

General Safety and Operating Instructions

A03052

Tire Maintenance

Storing Tires After Removal

If the proper procedure for performing maintenance 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 manufacturer.

• As a basic rule, store the tires in a warehouse in which unauthorized persons cannot enter. If the tires are stored outside, erect a fence around the tires with No Entry and other warning signs.

Refer to the Society of Automotive Engineers (SAE), SAE J1337, Off-Road Rim Maintenance Procedures and Service Precautions, Section 4.2 for additional information on demounting the tires and rim assemblies. Also, refer to Section 4.4 of SAE J1337 for assembly and inflation recommendations.

• If the tire falls, flee the area as quickly as possible. The tires for mining equipment are extremely heavy. DO NOT attempt to hold a tire upright when the tire is falling. The weight of these tires may lead to serious injury or death.

• Stand the tire on level ground, and block it securely so that it cannot roll or fall over.

The U.S. Department of Labor Mine Safety and Health Administration (MSHA) addresses tire repairs in its Title 30 Code of Federal Regulations, 30 CFR 57.14104.

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 mounted on the rim. Resulting gases inside the tire may ignite, causing explosion of the tire and rim.

A03052

Mounted tires stored as spares must be inflated to the minimum inflation pressure necessary to keep the tire beads properly seated. Maximum inflation pressure of the stored tire must, in no instance, exceed 15% of the tire’s cold inflation pressure.

General Safety and Operating Instructions

A3-21

ADDITIONAL JOB SITE RULES •

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A3-22

General Safety and Operating Instructions

A03052

WHEN REPAIRS ARE NECESSARY 1. Only qualified maintenance personnel who understand the systems being repaired must attempt repairs. 2. Many components on the Komatsu truck are large and heavy. Ensure that lifting equipment hoists, slings, chains, lifting eyes - are of adequate capacity to handle the lift. 3. DO NOT stand under a suspended load. DO NOT work under raised body unless body safety cables, props, or pins are in place to hold the body in up position. 4. DO NOT repair or service the truck while the engine is running, except when adjustments can only be made under such conditions. Keep a safe distance from moving parts. 5. When servicing any air conditioning system with refrigerant, wear a face shield and cold resistant gloves for protection against freezing. Ensure all current regulations for handling and recycling refrigerants are followed.

9. If a truck is to be towed for any reason, use a rigid tow bar. Check the truck cab for decals for special towing precautions. (Also refer to the Operation and Maintenance Manual, Operating Instructions - Towing.) 10. Drain, clean and ventilate fuel tanks and/or hydraulic tanks before making any welding repairs.

Any operating fluid, such as hydraulic oil or brake fluid escaping under pressure, can have sufficient force to enter a person's body by penetrating the skin. Serious injury and possibly death may result if proper medical treatment by a physician familiar with this injury is not received immediately.

6. Follow package directions carefully when using cleaning solvents.

11. Relieve pressure in lines or hoses before making any disconnects.

7. If an auxiliary battery assist is needed, refer to Jump Starting With Booster Cables or Jump Starting With Receptacles earlier in this section.

12. After adjustments or repairs, replace all shields, screens and clamps.

8. Before performing any welding on the truck, always turn the battery disconnect switches to the OFF position and disconnect the alternator positive cable. Failure to do so may seriously damage the battery and electrical equipment. It is not necessary to disconnect or remove any control circuit cards on electric drive dump trucks or any of the Alarm Indicating Device (AID) circuit control cards. Always fasten the welding machine ground (-) lead to the piece being welded; the grounding clamp must be attached as near as possible to the weld area. Never allow welding current to pass through ball bearings, roller bearings, suspensions, or hydraulic cylinders. Always avoid laying welding cables over or near the vehicle electrical harnesses. Welding voltage could be induced into the electrical harness and cause damage to components.

A03052

13. Working near tires can be dangerous. Use extreme caution when working around tires.

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 apply heat to the rim assembly with the tire mounted on the rim. Resulting gases inside the tire may ignite, causing explosion of the tire and rim. 14. Only a qualified operator or experienced maintenance personnel who are also qualified in operation can move the truck under its own power in the repair facility or during road testing after repairs are complete.

General Safety and Operating Instructions

A3-23

SPECIAL PRECAUTIONS FOR WORKING ON AN 830E-1AC TRUCK Preliminary Procedures before Welding or Performing Maintenance

Engine Shutdown Procedure before Welding or Performing Maintenance

Prior to welding and/or repairing an 830E-1AC dump truck, maintenance personnel must attempt to notify a Komatsu service representative. Only qualified personnel, specifically trained for servicing the AC drive system, must perform this service.

Normal operation of the drive system at shutdown leaves the system safe to maintain. However, in the event of a system failure, performing the following procedure prior to any maintenance activities will ensure that no hazardous voltages are present in the AC drive system.

If it is necessary to perform welding or repair to the truck without the field engineer present, the following procedures must be followed to ensure that the truck is safe for maintenance personnel to work on and to reduce the chance for damage to equipment.

Anytime the engine is operating: •

DO NOT open any of the cabinet doors or remove any covers.

•

DO NOT use any of the power cables for hand holds or foot steps.

•

DO NOT touch the retarding grid elements.

Before opening any cabinets or touching a grid element or a power cable, the engine must be shutdown and the red drive system warning lights must not be illuminated.

1. Before shutting down the engine, verify the status of all the drive system warning lights on the overhead display panel. Use the lamp test switch to verify that all lamps are functioning properly. If any of the red drive system warning lights remain on, DO NOT attempt to open any cabinets, disconnect any cables, or reach inside the retarder grid cabinet without a trained drive system technician present - even if engine is off. Only qualified personnel, specifically trained for servicing the AC drive system, must perform this service. 2. If all red drive system warning lights are off, follow all of the instructions for “Parking The Machine.” 3. After the engine has been off for at least five minutes, inspect the link voltage lights on the exterior of the main control cabinet and rear of the center console. If all lights are off, the retard grids, wheel motors, alternator, and related power cables are safe to work on. 4. Locate the GF cut-out switch in the front access panel on the left side of the main control cabinet. Place the switch in the CUTOUT position. This will prevent the alternator from re-energizing and creating system voltage until the switch is returned to the previous position. 5. Ensure both battery disconnect switches are in the OFF position. Verify that the battery disconnects are functioning. 6. Before doing any welding on the truck, always disconnect the battery charging alternator lead wire.

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7. DO NOT weld on the rear of the control cabinet! The metal panels on the back of the cabinet are part of capacitors and cannot be heated. 8. DO NOT weld on the retard grid exhaust louvers - they are made of stainless steel. Some power cable panels throughout the truck are also made of aluminum or stainless steel. They must be repaired with the same material or the power cables may be damaged. 9. 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 and prior to returning the truck to service. Discard cables with broken insulation. 10. Power cables and wiring harnesses must be protected from weld spatter and heat. Always fasten the welding machine ground (-) lead to the piece being welded; the grounding clamp must be attached as near as possible to the weld area.

11. If the red lights on the exterior of the control cabinet and/or the back wall of the center console continue to be illuminated after following the above procedure, a fault has occurred. Leave all cabinet doors in place; DO NOT touch the retard grid elements; DO NOT disconnect any power cables, or use them as hand or foot holds.

Notify your Komatsu service representative, immediately. Only qualified personnel, specifically trained for servicing the AC drive system, must perform this service. 12. Replace all covers and doors and place the GF cutout switch and battery disconnect switches in their original positions. Reconnect all harnesses prior to starting the truck. Leave the drive system in the rest mode until the truck is to be moved.

Always avoid laying welding cables over or near the vehicle electrical harnesses. Welding voltage could be induced into the electrical harness and cause damage to components. Never allow welding current to pass through ball bearings, roller bearings, suspensions, or hydraulic cylinders.

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CAPACITOR DISCHARGE SYSTEM The control cabinets are equipped with two capacitor charge lights, one on the exterior of the cabinet and one in the interior. The capacitor charge lights, when off, indicate to service personnel that the drive system is safe to work on. Certain drive system failures, however, can result in a condition where one or more capacitors can remain in a charged state even though the capacitor charge lights are off.

• Personal Protective Equipment (PPE) for working with 2000 VDC meter (safety shoes, high voltage gloves, and safety glasses) • Multimeter for ground resistance measurement

Because a danger can still exist with the capacitor charge lights off, it is necessary to adhere to the following instructions before touching or servicing drive system components. Only authorized service personnel are allowed to service the drive system. Refer in this section for rules when servicing the drive system. Adhere to the proper procedures for disabling the drive system.

Necessary Tools

• 2000 VDC Meter Kit (Figure 3-4 and Figure 3-5) (Komatsu p/n 58B-06-00800)

FIGURE 3-5. DISCHARGE STICKS

FIGURE 3-4. VOLT METER

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Warnings And Cautions All applicable local mine, government, and industry rules for working with high voltage must be followed. Required personal protective equipment, including but not limited to safety shoes, high voltage gloves, and safety glasses must be worn. Safety cautions and warnings appear throughout the instructions. WARNING indicates the potential for personal injury and CAUTION indicates the potential for equipment damage. Read the following warnings prior to working on this drive system.

Hazardous voltages are present in this equipment. Ensure that the Control Power Switch (CPS) is in the OFF position and that the Generator Field Contactor (GFCO) switch is in the CUTOUT position before attempting any work on the drive system components. Check that Capacitor Charge Lights (CCL’s) are not illuminated. Use measurement and protective equipment rated for 2000 VDC minimum to verify that no voltage is present before touching any terminal. 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.

Failure to observe these precautions may result in death or serious personal injury.

Hazardous voltages are present in this equipment. Avoid touching any energized equipment when the door to the low voltage area is open. Failure to do so may result in personal injury and equipment damage.

Hazardous voltages may be present in this equipment even if the engine and capacitor charge lights are off. Use measurement and protective equipment rated for 2000 VDC minimum to verify that no voltage is present before touching any terminal. 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.

Verify that the Capacitor Charge Light (CCL) above the high voltage contactor area is not illuminated before opening the doors to the high voltage area or the high voltage contactor area.

Voltages in excess of 1500 VDC may be present. Any measurement and/or protective equipment used must be rated at 2000 VDC minimum.

Use measurement and protective equipment rated for 2000 VDC minimum to verify that no voltage is present before touching any terminal.

Verify functionality of the measurement equipment using site-approved procedures both before and after performing control group measurements.

Verify functionality of the measurement equipment using site-approved procedures both before and after performing control group measurements.

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Failure to observe these precautions may result in death or serious personal injury.

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MANUAL DC LINK CAPACITOR DISCHARGE PROCEDURE Preparation Follow any and all local and site specific procedures and requirements for working on off-highway mining equipment.

Verify that: 1. The engine is off and the parking brake is on.

2. Verify that the generator field contactor (GF) switch (2, Figure 3-6) in the low voltage area of the control cabinet is in the CUTOUT position. NOTE: The generator field is cut out via GF cutout switch (2, Figure 3-6) in the low voltage area of the control cabinet. 3. Apply control power for a minimum of 30 seconds. Then, turn off control power using control power switch (1) on the switch panel. With control power on, an RP contactor closes and discharges the DC link through the retarding grids in less than 10 seconds.

FIGURE 3-6. INFORMATION DISPLAY PANEL 1. Control Power Switch 2. GF Cutout Switch

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3. Capacitor Charge Light

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In most control cabinets, RP2 is the normal discharge path. In groups containing an RP3 contactor, RP2 and RP3 are alternated as the normal discharge path. Refer to Figure 3-7.

FIGURE 3-7. DISCHARGE PATHS

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CAPACITOR CHARGE LIGHTS Observe both capacitor charge lights (CCL1, CCL2). CCL1 is on the outside of the contactor box. CCL2 is on the switch panel inside the low voltage area. The lights will stay illuminated as long as the voltage on the DC link is greater than 50 VDC. Refer to Figure 3-8.

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.

Hazardous voltages may be present in this equipment even if the engine and capacitor charge lights are off. Use measurement and protective equipment rated for 2000 VDC minimum to verify that no voltage is present before touching any terminal.

FIGURE 3-8. CAPACITOR CHARGE LIGHTS 1. Exterior Capacitor Charge Light (CCL2) 2. Interior Capacitor Charge Light (CCL1)

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3. Information Display Panel 4. DC Link Capacitors

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FAILURE OF DISCHARGE SYSTEM If the capacitor charge lights remain illuminated, a failure of the normal (fast) capacitor discharge system (RP discharge path) has likely occurred. The slow discharge resistors that are hard wired across the DC link should then discharge the capacitors. The slow discharge resistors will discharge the DC link to less than 1 VDC in under 7.5 minutes. If after 7.5 minutes, the capacitor charge lights are still illuminated, it must be assumed that the automatic discharge system is not working and that high voltage is present in the high voltage area. Measuring Dc Voltage On Capacitors 1. Use volt meter tester (58B-06-00770), test the volt meter for proper operation. Voltage should read 100 VDC. If the voltmeter fails the test, repair or replace the volt meter. Do not proceed to Step 3 unless the volt meter is functioning properly. 2. Open the high voltage area doors.

3. With a suitable high voltage meter rated for at least 2000 VDC, such as PC3186 or equivalent, plus suitable protective equipment, measure the voltage across each of the DC link capacitors. Place one meter lead on the positive (+) capacitor terminal, and the other meter lead on the negative (-) capacitor terminal, and observe the voltage. See Figure 3-9 and Figure 3-10. 4. After checking all DC link capacitors, test the volt meter again using the volt meter tester (58B-06-00770). Voltage should read 100 VDC. If the voltmeter does not indicate 100 VDC, repair or replace the volt meter. Do not proceed beyond this step unless the volt meter is functioning properly. 5. If the voltage is less than 1.0 V the capacitor is sufficiently discharged. Repeat on all DC Link capacitors. If the voltage of any capacitor is above 1.0 V, manually discharge the capacitor as described in MANUAL DISCHARGE OF CAPICTORS.

FIGURE 3-9. DC METER ON CAPACITOR

FIGURE 3-10. CAPACITOR TERMINAL POLARITY

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MANUAL DISCHARGE OF CAPACITORS If the voltage is greater than 1V on any of the capacitors, the capacitor must be manually discharged. With a suitable capacitor discharge device, such as ground stick pair (PC3299) or (58B-06-00800), discharge the capacitors where needed per the following instructions:

Voltages in excess of 1500 VDC may be present. Any measurement and/or protective equipment used must be rated at 2000 VDC minimum.

1. Determine which capacitors must be discharged by check for voltage starting at MANUAL DC LINK CAPACITOR DISCHARGE PROCEDURE.

Verify functionality of the measurement equipment using site-approved procedures both before and after performing control group measurements.

2. With the control cabinet high voltage compartment doors closed, connect the ground stick pair ground lead to ground. The most convenient location is the middle top bolt that attaches the door center post to the control cabinet frame. 3. Verify the ground connection and ground stick resistance levels. Measure the resistance between each individual ground stick tip to either the GND1 or GND2 ground block in the low voltage compartment of the control cabinet using a multimeter (Figure 3-11). Ensure that the resistance is within the manufacturer’s specifications for the ground sticks. If the readings are not within specifications, repair or replace the grounding sticks. Do not proceed any further until the grounding sticks are within specifications. For (PC3299) or (58B-06-00800) grounding sticks, the valid range is 80 to 125 ohms per stick.

Failure to observe these precautions may result in death or serious personal injury. 4. Discharge the relevant capacitors. Open the door(s) and place one grounding stick on one of the positive (+) capacitor terminals and the other on the diagonally located negative (-) terminal. Refer to Figure 3-10 and Figure 3-12. Attempt to minimize the time between application of the positive stick and the negative stick so that the current flow will be positive to negative rather than either to ground. Leave sticks in place until capacitors are discharged. Refer to Figure 3-12. NOTE: On the capacitors located behind the door post, it is difficult to access diagonal terminals on the same capacitor. If using adjacent terminals, use care to keep the tips separated while discharging or else use a positive terminal on one capacitor and negative terminal of the adjacent capacitor on the same bus bar. For (PC3299) or (58B-06-00800) grounding sticks, the discharge times from 2000 volts are:

Hazardous voltages are present in this equipment. Avoid touching any energized equipment when the door to the low voltage area is open. Failure to do so may result in personal injury and equipment damage.

• 15 seconds (maximum) for 2 capacitors • 75 seconds (maximum) for 10 capacitors 5. To ensure the discharge tool is working properly, verify the ground connection and ground stick resistance levels. Measure the resistance between each individual ground stick tip to either the GND1 or GND2 ground block in the low voltage compartment of the control cabinet using a multimeter (Figure 3-11). Ensure that the resistance is within the manufacturer’s specifications for the ground sticks. For grounding sticks (PC3299) or (58B-0600800), the valid range is 80 to 125 ohms per stick.

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FIGURE 3-11. GROUNDING STICK LEAD CONNECTION AND CHECK

Voltages in excess of 1500 VDC may be present. Any measurement and/or protective equipment used must be rated at 2000 VDC minimum. 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. 6. Re-test for voltage on all capacitors as described in MANUAL DC LINK CAPACITOR DISCHARGE PROCEDURE. The discharge procedure must be repeated on all capacitors that indicated 1 VDC or higher.

FIGURE 3-12. APPLICATION OF GROUNDING STICKS TO CAPACITOR TERMINALS

7. After it is confirmed that all capacitors are fully discharged, proceed to SHORT ISOLATED CAPACITOR TERMINALS.

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SHORT ISOLATED CAPACITOR TERMINALS

Hazardous voltages may be present in this equipment even if the engine and Capacitor Charge lights are off.

1. Before performing and service work, any capacitor that is isolated from the DC link and confirmed discharged must have its terminals electrically shorted together to prevent static charge build up. Use bare wire to jumper all four terminals on the capacitor. See Figure 3-13. 2. Proceed to troubleshoot and repair the control group to restore it to original functionality. 3. After repairs are completed, remove the bare wires before starting the engine.

Use measurement and protective equipment rated for 2000 VDC minimum to verify that no voltage is present before touching any terminal. 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.

FIGURE 3-13. JUMPER ALL TERMINALS ON ISOLATED CAPACITOR

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TRUCK OPERATION PREPARING FOR OPERATION The safest trucks are those which have been properly prepared for operation. At the beginning of each shift, a careful check of the truck must be made by the operator before starting the engine.

Local work practices may prevent an operator from performing all tasks suggested here. To the extent permitted, the operator must follow this or a similar routine.

Safety Is Thinking Ahead Prevention is the best safety program. Prevent a potential accident by knowing the employer's safety requirements, all necessary job site regulations, as well as use and care of the safety equipment on the truck. Only qualified operators or technicians can operate or maintain a Komatsu truck. Safe practices start before the operator gets to the equipment! • Wear the proper clothing. Loose fitting clothing, unbuttoned sleeves and jackets, jewelry, etc., can catch on a protrusion and cause a potential hazard. • Always use the personal safety equipment provided for the operator such as hard hats, safety shoes, safety glasses or goggles. There are some conditions when protective hearing devices must also be worn for operator safety. • When walking to and from the truck, maintain a safe distance from all machines, even if the operator is visible.

WALK AROUND INSPECTION At the beginning of each shift, a careful walk around inspection of the truck must be performed before the operator attempts engine start-up. A walk around inspection is a systematic ground level inspection of the truck and its components to ensure that the truck is safe to operate before entering the operator's cab. Start at the left front corner of the truck (see illustration, next page), and move in a counter-clockwise direction. Move front-to-rear, across the rear, and continuing forward up the opposite side of the truck to the original starting point. If these steps are performed in sequence, and are repeated from the same point and in the same direction before every shift, many potential problems may be avoided, or scheduled for maintenance. Unscheduled downtime and loss of production can be reduced as a result.

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High voltage may be present on this truck! DO NOT open any electrical cabinet doors on the truck while the engine is operating! Never climb on any power cables or use power cables for hand holds or footholds, unless the engine has been shut off and the system has been verified as at rest!

1. Start at left front of the truck. While performing the walk around inspection, visually inspect all lights and safety equipment for external damage from rocks or misuse. Ensure lenses are clean and unbroken. Empty the dust pans on the air cleaners located on the left side of the truck. Ensure the ground level engine shutdown button is pulled up. If equipped, inspect the fire control actuator to ensure the safety pin is in place and the plastic tie that prevents accidental actuation is in place and in good condition. Ensure the battery disconnect switches and propel lockout lever are ON. 2. Move behind the front of the left front tire. Inspect the hub and brake assemblies for leaks and any abnormal conditions. 3. Check that all suspension attaching hardware is secure and inspect the mounting key area for evidence of wear. Check that the suspension rod extension is correct, and that there are no leaks. Ensure the suspension protective boot is in good condition. 4. Inspect the anchor end of the steering cylinder for proper greasing and all parts are secure. 5. With the engine stopped, check the engine oil level. To obtain an accurate measurement, remove the dipstick and wipe it off. Then reinsert the dipstick and remove it again to check the oil level. Use the service light if necessary.

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FIGURE 3-14. WALK AROUND INSPECTION

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FIGURE 3-1. WALK AROUND INSPECTION 1. 2. 3. 4. 5. 6. 7. 8. 9.

Operator Cab Reserve Oil System Steps and Ladder Radiator Auto Lubrication Engine Suspension Wheel Hub Disc Brake

10. Steering Linkage 11. Alternator 12. Hoist Filters 13. Steering Filter

14. Fuel Tank 15. Hoist Cylinder 16. Rear Axle Housing 17. Disc Brake 18. Rear Tires 19. Rear Suspension 20. Rear Axle Hatch 21. Hydraulic Tank 22. Hoist and Steering Pump 23. Steering Accumulators

6. Inspect air conditioner belts for correct tension, obvious wear, and tracking. Inspect fan guard security and condition. When leaving this point, ensure the service light is off, if used. 7. Move outboard of the front wheel. Inspect attaching lugs/wedges to ensure all are tight and complete. Inspect the tires for cuts, damage or bubbles. Check tire inflation pressure. Check sight glass for front wheel oil level. 8. Move behind the front wheel and inspect the steering cylinder. Check for proper greasing and inspect the mounting hardware to ensure it is all in place. Inspect all steering linkage joints (10) for proper greasing. Inspect the suspension mounting hardware to ensure it is all in place. Ensure the suspension protective boot is in good condition. Inspect the hub and brakes for any unusual conditions. Check the entire area for leaks. 9. Inspect the sight glass on hydraulic tank (21). With the engine stopped and body down, hydraulic fluid must be visible in the upper sight glass. 10. Verify all hydraulic tank shut off valves are locked in their fully open positions. 11. Move around the hydraulic tank and in front of the rear dual tires. Inspect hoist cylinder (15) for any damage and leaks. Inspect both upper and lower hoist cylinder pins for integrity and for proper greasing.

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12. Before leaving this position, look under the lower edge of the chassis to ensure the flexible duct that carries the air from the blower to the final drive housing is in good condition with no holes or breakage. Also, look up at the main hydraulic pumps (22) to see that there is no leakage or any other unusual condition with the pumps or the pump drive shafts. 13. Move around the dual tires, and check to see that all lugs/wedges are in place and tight. Inspect latches on the wheel cover to be sure they are properly latched. Inspect the wheel for any oil that would indicate brake leakage or wheel motor leakage. Check the dual tires (18) for cuts, damage or bubbles. Verify that inflation appears to be correct. If the truck has been operating on a flat tire, the tire must be cool before moving the truck inside a building. Check for any rocks that might be lodged between the dual tires. Inspect the rock ejector condition and straightness so that it can not damage a tire. 14. Inspect the left rear suspension (19) for damage and for correct rod extension. Check for leaks. Ensure that the covers over the chrome piston rod are in good condition. Inspect for proper greasing. 15. Open the rear hatch cover (20), turn on the work light if necessary. Inspect for leaks around wheel motor mounting to rear housing, and also brake hoses and fittings. Ensure that covers on wheel motor sump are in place, and that there are no rags or tools left behind. Inspect condition of hatch cover gasket, report any bad gasket to maintenance. Turn off work light if used, close and latch hatch. 16. While standing in front of the rear hatch, look up to see that rear lights are in good condition, along with the back-up horns. Look up at the panhard rod to see that it is getting proper greasing. Also look at both body hinge pins for greasing and any abnormal condition. Check hoist limit switch and clear any mud/debris from contacts. 17. Perform the same inspection on the right rear suspension (19) as done on the left.

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18. Move around the right dual tires. Inspect between the tires for rocks, and check the condition of the rock ejector. Inspect the tires for cuts or damage, and for correct inflation. 19. Perform the same inspection for wheel lugs/ wedges, wheel cover latches, and wheel leaks that was done on the left hand dual wheels. 20. Move in front of the right dual tires and inspect hoist cylinder (15) in the same manner as the left side. Check integrity and condition of the body-up limit switch. Remove any mud/dirt accumulation from the switch. 21. Move around fuel tank (14). Inspect the fuel sight gauge, (this must agree with the gauge in the cab). Inspect the attaching hardware for the fuel tank at the upper saddles, and then at the lower back of the tank for the security and condition of the mounts. Check the hoist filters for leaks. 22. Move behind the right front wheel, and inspect the steering cylinder and linkage (10). Check for proper greasing and inspect the mounting hardware. Check the suspension mounting hardware and suspension extension. Ensure the suspension protective boot is in good condition. Inspect the hub and brakes for any unusual conditions. Check the entire area for leaks. 23. Move around the right front wheel; check that all lugs/wedges are in place and tight. 24. Move in behind the front of the right front wheel, check the hub and brakes for leaks and any unusual condition. Inspect the steering cylinder for secureness and for proper greasing. Inspect the engine compartment for any leaks and unusual conditions. Inspect the fan guard and belts. Check for any rags or debris behind the radiator. 25. Inspect the auto lube system and reservoir (5). Refer to Automatic Lubrication System in Section P, for specific details concerning the auto lube system. 26. Move around to the right front of the truck, drop the air cleaner pans and empty. Ensure the battery box covers are in place and secure.

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27. While in front of radiator (4), inspect for any debris in the radiator and remove. Check for any coolant leaks. Inspect headlights and fog lights. Inspect the battery box cover for damage and ensure it is in place and secure. 28. Always use grab rails and the ladder when mounting or dismounting the truck. Clean ladder and steps (3) and hand rails of any foreign material, such as ice, snow, oil or mud. If the truck is equipped with a reserve engine oil tank, check the oil level with the reserve tank dipstick. 29. If equipped with the retractable ladder system: a. Visually inspect the ladder for mechanical damage. If movement is impaired in any way, the ladder must be repaired. b. Visually inspect for cleanliness. Ensure the ladder is dry and free from grease and oil. c. Ensure correct oil level is maintained in the reservoir. d. Raise and lower the ladder system. Check for loose parts or any adverse noise conditions. e. Ensure the movement alarm and both UP and DOWN LEDs operate correctly. f. Check for any change in equipment appearance, especially that which will effect ladder system stability. 30. Use the stairs and handrails while climbing from the first level to the cab deck.

Always mount and dismount ladders facing the truck. Never attempt to mount or dismount while the truck is in motion.

31. When checking the coolant level in the radiator, use the coolant level sight gauge. If it is necessary to remove the radiator cap, relieve coolant pressure by depressing the pressure relief button, and then slowly removing the radiator cap.

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1. The in-cab control panel is a microprocessor that controls, monitors, stores and reports ladder system operational data.

If the engine has been running, allow the coolant to cool before removing the fill cap or draining the radiator. Serious burns may result if skin comes in contact with hot coolant.

2. The electro-hydraulic power pack is in a ground level stainless steel cabinet. It houses the main control hydraulics and electrical components that lower and raise the ladder. 3. The RLS also contains wiring harnesses, hydraulic hoses and an emergency down valve.

32. Inspect the covers over the retarding grids and ensure they are secure. Inspect the main air inlet to ensure it is clear. Ensure all cabinet door latches are secure. 33. Move to the back of the cab. Open the doors to the brake cabinet and inspect for leaks. 34. Clean the cab windows and mirrors. Clean out the cab floor as necessary. Ensure steering wheel, controls and pedals are free of any oil, grease or mud. 35. Stow personal gear in the cab in a manner that does not interfere with truck operation. Dirt or trash buildup, specifically in the operator's cab, must be cleaned. DO NOT carry tools or supplies in the cab of the truck or on the decks. 36. Adjust the seat and the steering wheel for use. 37. Read and understand the description of all operator controls. Become familiar with all control locations and functions before operating the truck. 38. If equipped, raise the retractable ladder using the in cab control panel.

RETRACTABLE LADDER SYSTEM (If equipped) LADDER SYSTEM DESCRIPTION The RLS is an electro-hydraulic ladder powered by the truck’s 24VDC electrical system. The RLS provides a safe means to mount and dismount the truck under normal and emergency conditions. The RLS consists of two main control components, the in-cab control panel and the power pack that operates the ladder.

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FIGURE 3-15. RETRACTABLE LADDER SYSTEM

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LADDER SYSTEM OPERATION

IN-CAB CONTROL PANEL

Normal Operation

In-cab control panel (1, Figure 3-16) is located on the left side of the dash and contains a microprocessor that controls, displays, monitors, stores and reports ladder system operational data. The in-cab control panel provides real time position of the ladder to the operator.

During normal operation, a person can lower or raise the RLS by using the: • In-cab control panel • Ground level control box located next to the battery isolation box • Control switches in the power pack. NOTE: The master disconnect switch located in the isolation box and the isolation switch in the power pack must both be in the ON position for the RLS to operate. As an added safety measure, the RLS uses a parking brake interlock that requires the parking brake to be set before the ladder can be operated under normal conditions. The RLS will automatically raise the ladder if the operator releases the parking brake and fails to press the [UP] button on the in-cab control panel before attempting to drive the truck.

GENERAL SAFETY The following safety procedures, at a minimum, must be followed to ensure safe operation and use of the Retractable Ladder System (RLS). 1. DO NOT run or jump on the ladder. 2. DO NOT overload the ladder. Use the ladder one person at a time. 3. Hold onto the handrail when using the ladder. 4. Always face the ladder when ascending or descending. 5. DO NOT attempt to ride on the ladder while it is being raised or lowered or while the truck is in motion. 6. Always visually check the ladder before use to ensure the unit has not been damaged. 7. Ensure the ladder is in the fully down position before boarding. 8. Keep hands and fingers away from pinch points while the ladder is in motion. 9. Always check to ensure no personnel are on or in the immediate vicinity of the ladder while it is in motion.

FIGURE 3-16. CAB CONTROLS (OPERATOR VIEW) 1. In-cab Control Panel

10. The ladder must be kept clean and free of moisture, grease and oil 11. When in the truck’s cab, always use the in-cab control panel to raise the ladder. 12. Report defects immediately.

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IN-CAB CONTROL PANEL FEATURES The in-cab control panel features a digital display screen, command buttons ([UP], [DOWN], [ENTER], [EXIT], [LEFT], [RIGHT]) for operating the ladder and navigating through the various menu display screens, a USB key port and RS 232 port for downloading ladder system operational data to a laptop computer for troubleshooting. Refer to Figure 3-17. Digital Display Screen In-cab control panel display screen (1, Figure 3-17) provides the user with system status, error/fault messages and a visual indicator of the ladder’s position (lowered, raised, in motion). Command Buttons [UP] button (2, Figure 3-17) is a dual function control that is used to raise the ladder during normal operation and scroll through the menu displays. Pressing this button and holding it briefly will cause the ladder to raise. Pressing and releasing this button one time will scroll up one line of menu display, and holding it will result in continuous menu scrolling. [DOWN] button (3, Figure 3-17) is a dual function control that is used to lower the ladder during normal operation and scroll through the menu displays. Pressing this button and holding it briefly will cause the ladder to lower. Pressing and releasing this button one time will scroll down one line of menu dis-

play, and holding it will result in continuous menu scrolling. [DOWN] button (3, Figure 3-17) is a dual function control that is used to lower the ladder during normal operation and scroll through the menu displays. Pressing this button and holding it briefly will cause the ladder to lower. Pressing and releasing this button one time will scroll down one line of menu display, and holding it will result in continuous menu scrolling. [ENTER] button (6, Figure 3-17) is a multi-function button used for ladder system alarm acknowledgement and menu access when in Display Mode. This button is also used to confirm or accept changes shown on the display screen. Press this button to confirm or accept changes listed on the display screen. [EXIT] button (7, Figure 3-17) is a multi-function button used for ladder system alarm acknowledgement and menu access when in Display Mode. This button is also used to exit from the menu screens. Press this button to exit from menu screens. [LEFT] button (4, Figure 3-17) is for scrolling left when entering a password. [RIGHT] button (5, Figure 3-17) is for scrolling right when entering a password.

FIGURE 3-17. IN-CAB CONTROL PANEL (FRONT VIEW) 1. Display Screen 4. [LEFT] Button 7. [EXIT] Button 2. [UP] Button 5. [RIGHT] Button 8. USB Port 3. [DOWN] Button 6. [ENTER] Button 9. 15-Pin Harness Plug

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USING THE IN-CAB CONTROL PANEL

Raising the Ladder

While the ladder is in motion, the direction (up or down) can be changed by pressing the opposite direction ([UP] or [DOWN]) button on the control panel.

The ladder will typically be in the lowered position on a stationary truck. The in-cab control panel will indicate that the access is DOWN, as shown here:

If the IN CAB LOCKOUT message is displayed on the control panel screen, then the RLS can only be operated from the ground level control box mounted next to the battery isolation box. All other control panel functionality is still available including fault indication and audible alarms.

When in the operator’s cab, always use the [UP] button on the control panel to raise the ladder instead of releasing the parking brake. The automatic operation of the ladder when the parking brake is released is an emergency feature only. DO NOT release the parking brake to raise the ladder as part of normal operation.

To raise the ladder, press and hold (temporarily) the [UP] button located on the in-cab control panel. The illustrated ladder on the screen will animate and begin to rise to the UP position and the UP arrow (on the control panel button) will flash. When the ladder is completely raised, the [UP] button will remain illuminated continuously. When the ladder has reached its raised travel position and strikes the limit switch, the control panel will indicate that the access is UP, as shown here:

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General Safety and Operating Instructions

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The RLS power pack will continue to operate for three more seconds to charge hydraulic accumulator. During this time, the UP arrow will continue to flash until the cycle is complete. The RLS uses a limit switch to monitor ladder travel to the UP position. If the ladder fails to strike the limit switch or the limit switch fails to close, a fault alarm will activate after a short delay and the in-cab control panel will display this message, as shown here:

Lowering the Ladder NOTE: The parking brake must be applied before the ladder can be lowered. To lower the ladder, press and hold (temporarily) the [DOWN] button located on the in-cab control panel. The illustrated ladder on the screen will animate and begin to lower to the DOWN position and the [DOWN] button will flash. When the ladder has reached its lowered travel position, the control panel will indicate that the access is DOWN, as shown here:

NOTE: The fault alarm must be acknowledged by pressing the [EXIT] or [ENTER] buttons on the control panel. Once the alarm has been acknowledged, the fault message will be replaced by a FAULT IN SYSTEM message. A defective limit switch will prevent normal RLS operation and must be corrected immediately.

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When the ladder is completely lowered, the [DOWN] button will remain illuminated continuously.

General Safety and Operating Instructions

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USING THE GROUND LEVEL CONTROL BOX Ground level control box (1, Figure 3-18) is located next to the battery isolation box and contains toggle switch (2) that lowers and raises the ladder. NOTE: The parking brake must be applied before the ladder can be lowered. If toggle switch (2) is held in either position for more than ten seconds, a fault will be activated and will need to be acknowledged by pressing either the [EXIT] or [ENTER] buttons located on the in-cab control panel.

Raising the Ladder To raise the ladder, push toggle switch (2, Figure 318) to the LADDER UP position and release. Ladder operation via this switch is the same as using the incab control panel. Any ladder movement will be shown on the in-cab control panel. Lowering the Ladder To lower the ladder, push toggle switch (2, Figure 318) to the LADDER DOWN position and release. Ladder operation via this switch is the same as using the in-cab control panel. Any ladder movement will be shown on the in-cab control panel.

FIGURE 3-18. GROUND LEVEL CONTROL BOX 1. Ground Level Control Box

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2. Toggle Switch

General Safety and Operating Instructions

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Emergency Operation In an emergency, the RLS ladder can be lowered by using the emergency down valve (1, Figure 3-19) mounted on the frame above the left hand side headlight assembly. The emergency down valve relieves ladder system hydraulic pressure and allows the ladder to smoothly lower to the ground. To lower the ladder, rotate the handle on the emergency down valve clockwise. The ladder will lower smoothly until it reaches the ground. To reset the ladder, rotate the handle counterclockwise to its original position and, with power restored to the power pack, press the [UP] button to raise the ladder. NOTE: The handle on the emergency down valve must be in the original position before re-activating the ladder.

FIGURE 3-19. EMERGENCY DOWN VALVE 1. Emergency Down Valve

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General Safety and Operating Instructions

2. Grille

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ENGINE START-UP SAFETY PRACTICES

Never attempt to start the engine by shorting across the cranking motor terminals. This may cause a fire, or serious injury or death to anyone in the machine’s path. Start the engine from the operator’s seat only. 1. Ensure all personnel are clear of the truck before starting the engine. Always sound the horn as a warning before actuating any operational controls. If the truck is in an enclosure, ensure there is adequate ventilation before start-up. Exhaust fumes are dangerous! 2. The directional control lever must be in the PARK position before starting. NOTE: The park brake will always be applied whenever the directional control lever is in the park position and the truck is moving slower than 0.5 mph. Move the rest switch to the ON position to put the drive system in rest mode of operation. Refer to discussion of the rest switch in Section N, Operator Cab Controls. 3. If the truck is equipped with auxiliary cold weather heater system(s), DO NOT attempt to start the engine while the heaters are in operation. Damage to coolant heaters will result!

a. Turn key switch to the RUN (not START) position. b. With the directional control lever in PARK, rotate the key switch fully clockwise to the START position, and hold this position until the engine starts (see NOTE below). The START position is spring-loaded and will return to RUN when the key is released. NOTE: This truck is equipped with an engine prelube system. With this feature, a noticeable time delay may occur (while engine lube oil passages are being filled and pressurized) before engine cranking will begin. c. After the engine has started, place the rest switch in the OFF position to enable the drive system. Refer to the discussion on the rest switch in Section N, Operator Cab Controls. NOTE: In cold ambient conditions and when the engine is cold, the engine rpm will not increase above low idle speed until the engine controller determines it is safe to do so. This time delay will vary from 30 seconds to 11 minutes which allows the coolant and engine oil to warm up. A warning light will also be illuminated indicating that the engine is too cold for truck operation.

NOTE: The electric cranking motors have a 30 second time limit. If the 30 second limit is reached, cranking will be prohibited for two minutes. After two minutes, cranking will be allowed. If the 30 second limit is reached seven consecutive times, the key switch must be turned to the OFF position. This will allow the interface module to power down and reset, which requires seven minutes to complete. The cranking motor warning light in the overhead panel will also illuminate if the 30 second time limit or seven attempts is reached.

4. The key switch is a four position (ACC, OFF, RUN, START) switch. (The ACC position is not currently used.) When the switch is rotated one position clockwise, it is in the RUN position and all electrical circuits (except START) are activated.

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General Safety and Operating Instructions

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AFTER ENGINE HAS STARTED 1. Become thoroughly familiar with steering and emergency controls. After the engine has been started, DO NOT accelerate engine speed or drive truck until low pressure and warning systems are normal, and the coolant temperature is at least 71°C (160°F). 2. Test the truck steering in extreme right and left directions. If the steering system is not operating properly, shut the engine off immediately. Determine the steering system problem and have it repaired before resuming operation. 3. Operate each of the truck's brake circuits at least twice prior to operating and moving the truck. These circuits include individual activation from the operator's cab of the service brake, parking brake, and wheel brake lock. With the engine running and with the hydraulic circuit fully charged, activate each circuit individually.

4. If any application or release of any brake circuit appears sluggish or improper, or if warning alarms are activated on application or release, shut the engine off and notify maintenance personnel. DO NOT operate the truck until the brake circuit in question is fully operational. 5. Check the gauges, warning lights and instruments before moving the truck to ensure proper system operation and proper instrument functioning. Pay special attention to braking and steering circuit hydraulic warning lights. If warning lights come on, shut off the engine immediately and determine the cause. 6. Ensure the headlights, work lights and taillights are in proper working order. Good visibility may prevent an accident. Check operation of the windshield wipers.

a. Park the truck on level ground. b. To operate the park brake, place the directional control lever in the PARK position. c. To operate the wheel brake lock, apply the service brake and move directional control lever to neutral. Release service brakes, and apply wheel brake lock. Turn the wheel brake lock OFF, then back ON again. d. Release wheel brake lock and apply service brakes several times. e. With service brakes applied, move directional control lever to PARK.

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General Safety and Operating Instructions

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PRE-SHIFT BRAKE CHECK (if equipped) NOTE: Komatsu recommends that operators perform static brake tests to verify that the braking systems are adequate at the beginning of each shift before operating the truck. The static brake test allows the operator to check the service brake, parking brake and the dynamic retarder. The purpose of these tests is to verify the functionality of the service brake, parking brake and retarder systems at the time they are tested. After performing each test, it is the operator’s responsibility to determine if the truck passed each test and if the truck is safe for operation. The order of performing the brake tests, (service brake, parking brake or retard system) does not matter. Each brake test is a separate test, where one brake system or all three can be tested at any time. If an operator has questions during brake testing, refer to the drive system Diagnostic Information Display (DID) panel, located on the back wall of the cab for guidance.

OPERATION The static brake test utilizes a momentary switch and a check light located in the overhead display panel.

Brake Test Switch Pre-shift brake test switch is used to initiate a brake test. Press on the momentary switch to enter the brake test mode. If certain conditions are met, the operator can enter a brake test sequence.

The amber light in the top of the switch is used to indicate when the truck is in brake test mode, and is referred to as the brake check light. When illuminated, a brake test is ready. When flashing, the brake test is at the validation point, or the retard system test is finished.

Description If the truck fails any brake test, notify maintenance personnel immediately. Do not resume operation unless the truck passes all brake tests.

Events The following events have been added to the drive system software to support the brake test feature. • 645-1 Service Brake test Performed • 645-2 Parking Brake Test Performed • 645-3 Retard Test Performed • 645-4 Brake Test Switch stuck closed

The operator can choose which brake test to perform, and will set the truck controls based on the settings in Table 1. The drive system will detect the position of the directional control lever, and will prepare for the appropriate test. The operator will then press the brake test switch. If the brake check light is illuminated solid after pressing the brake test switch, the system is in brake test mode and is ready for the chosen test to be initiated by the operator. After testing, the operator will then determine if the truck passed the brake tests, and if it is safe for operation. If the brake check light does not illuminate immediately after pressing the brake test switch, there is most likely a problem with the setup. Refer to the setup conditions and take action to prepare the truck for a brake test.

The Events Log will record when and which brake tests have been performed.

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General Safety and Operating Instructions

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PERFORMING THE BRAKE TESTS

If there is a problem with the truck setup, the DID panel will display the problem.

Setup

For example if the engine is off:

Before performing any brake test, the following conditions must be met:

ERROR Entering Brake Test Engine not running

• Dump body empty If the Truck is loaded:

NOTE: The drive system will not enter any brake test if the truck is loaded.

ERROR Entering Brake Test Truck is NOT Empty

• Truck located outside on a flat area, where truck movement is allowed.

If all of the conditions are correct, except the brakes are not set correctly, an error message will be displayed. For example, if the service brake and parking brake are both applied together:

•

ERROR Entering Brake Test Set Brakes for Test

Ensure the area around the truck is free of personnel and objects. Some truck movement could occur during brake testing.

Brake Test Exit Criteria The drive system is unable to determine if the truck is on a hill or in a parking ditch. Testing during these conditions will affect test results.

Numerous conditions can occur which may interrupt a brake test, including the following: • Any of the setup conditions becoming false • Drive system fault which restricts the LINK or Propel mode

Before performing any brake test, the truck must be in the following state:

• Truck Speed greater than 3.2 kph (2.0 mph)

• Engine on (low idle)

• Drive system at torque level for more than 30 seconds

• Drive system ready (Ready Mode) • Dump body down

• Brake test requested, but not initiated by the operator within 60 seconds after pressing the brake test switch

• No drive system warning lights ON (Can not be in LIMP mode.) • Zero ground speed

TABLE 1: BRAKE TEST SETTINGS Test Type

Wheel Brake Lock

Service Brake Pedal

Directional Control Lever

Service Brake

OFF

FULLY APPLIED

NEUTRAL

Parking Brake

OFF

RELEASED

PARK

Retard Test

OFF

RELEASED

PARK

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General Safety and Operating Instructions

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Service Brake Test 1. Firmly depress the service brake pedal.

9. Release the accelerator pedal and the torque will be reduced, the test will stop and the brake check light will turn off.

2. Place the directional control lever in the NEUTRAL position. Ensure the wheel brake lock switch is OFF.

10. Place the directional control lever in the PARK position. Release the service brake pedal.

3. Press the brake test switch and wait for the brake check light to be on solid.

11. If the truck failed the service brake test, notify maintenance personnel immediately.

4. Fully depress the service brake pedal. Ensure full brake application is reached. Failure to reach full brake application will affect the service brake test results. 5. The DID panel will display: Service Brake Test READY Press Accel Pedal to Start 6. With the service brake pedal still fully applied, fully depress the accelerator pedal. The drive system controller will enter propel mode and generate torque up to the service brake limit. Maintain full service brake pressure during the test. NOTE: The drive system can only detect if the service brakes are applied. It can not detect the percentage of application. It is up to the operator to press hard enough on the service brake pedal to achieve a full brake application. 7. The DID panel will display: Service Brake Test ACTIVE Check Truck Movement when Light Flashes 8. Once torque has reached the limit for the service brake test, the brake check light will begin to flash. This is the indication for the operator to make a determination as to the status of the service brake system.

If the truck fails the service brake test, notify maintenance personnel immediately. Do not resume operation unless the truck passes all brake tests.

NOTE: If the operator partially or fully releases the accelerator pedal during the test, torque will be reduced and the brake check light will go back on solid when torque falls below the test set point. The operator can re-apply the accelerator pedal to increase torque and the brake check light will again flash when the torque is at the test limit.

If the test exits abnormally, or if the operator simply does not press the accelerator pedal far enough to achieve the torque level for the service brake test, the DID panel will display: Brake Test ERROR Test did NOT complete

• If the truck did not move: The service brake system passed the test. • If the truck moved during the test: The service brake system failed the test.

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General Safety and Operating Instructions

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Retard System Test:

Parking Brake Test 1. Place the directional control lever in the PARK position.

1. Place the directional control lever in the PARK position.

2. Press the brake test switch and wait for the brake check light to be on solid.

2. Press the brake test switch and wait for the brake check light to be on solid.

3. The DID panel will display:

3. The DID panel will display:

Parking Brake or Retard Test READY Press Accel or Retard Pedal to Start 4. Fully depress the accelerator pedal. The drive system controller will enter propel mode and generate torque up to the park brake limit. 5. The DID panel will display: Park Brake Test ACTIVE Check Truck Movement when Light Flashes 6. Once the torque has reached the limit for the parking brake test, the brake check light will begin to flash. This is the indication for the operator to make a determination as to the status of the parking brake system. • If the truck did not move: The park brake system passed the test. • If the truck moved during the test: The park brake test has failed. Release the accelerator pedal. If the truck starts to roll, apply the service brakes to hold the truck stationary. Notify maintenance personnel immediately.

Parking Brake or Retard Test READY Press Accel or Retard Pedal to Start 4. Fully depress the retard pedal. The drive system controller will ramp up the engine speed, close CM1, close CM2, close CM3 close CM4, turn on the choppers, and test the retarding system. The system will verify current flow through each grid leg and the grid blower motor. 5. The DID panel will display the current status of the test. Retard System Test ACTIVE CM1 CM2 CM3 CM4 CHOP (Elements are added as the test progresses.) 6. Upon successful completion of the test, the light will flash for 10 seconds indicating a successful test. The DID panel will display: Retard System Test PASSED or Retard System Test FAILED or Incomplete NOTE: If the brake check light never flashes, but turns off, the test has failed.

If the truck fails the parking brake test, notify maintenance personnel immediately. Do not resume operation unless the truck passes all brake tests. 7. When the operator releases the accelerator pedal, torque will be reduced, the test will stop and the brake check light will turn off.

If the truck fails the retard system test, notify maintenance personnel immediately. Do not resume operation unless the truck passes all brake tests. 7. When the operator releases the retard pedal, the test will stop and the brake check light will turn off. 8. If the retard system failed the test, notify maintenance personnel immediately. Do not resume operation unless the truck passes all brake tests.

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General Safety and Operating Instructions

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EMERGENCY STEERING SYSTEM Operation This truck is equipped with an emergency steering system. This system is a backup in the event of loss of oil supply to the main steering system. The emergency steering system was designed to meet or exceed SAE J1511 and ISO 5010 standards. If the low steering system pressure indicator light and alarm are activated, a failure in the hydraulic oil supply to the steering and brake system exists. When the alarm is activated, typically there is enough hydraulic pressure stored in the brake and steering accumulators to allow brief operation of the steering and brake functions. However, this oil supply is limited. Therefore, it is important to stop the truck as quickly and safely as possible after the alarm is first activated. If the oil supply pressure drops to a predetermined level, the low brake pressure warning light will also illuminate. If the oil pressure continues to decrease, the brake auto-apply feature will activate the service brakes to stop the truck. Pre-Operation Testing NOTE: Komatsu recommends that operators perform this test to verify that the steering accumulator precharge pressure is adequate at the beginning of each shift before operating the truck.

2. Wait at least 90 seconds to verify that all hydraulic pressure has been relieved from the steering accumulators. Turn the steering wheel from stop to stop. If the front wheels do not move, there is no hydraulic pressure. 3. Check the hydraulic tank oil level. The oil level must be visible in the center of the upper sight glass and must not cover the entire upper sight glass. Add oil if necessary. DO NOT overfill. 4. Turn the key switch to the ON position, but DO NOT start the engine. a. Steering system pressure: Verify that the low steering pressure warning light is illuminated. If it is not illuminated, immediately notify maintenance personnel. DO NOT operate the truck until the problem is corrected. b. Steering accumulator precharge: Verify that the low accumulator precharge warning light is not illuminated and the warning buzzer is not sounding. If the warning light is illuminated and the buzzer is sounding, immediately notify maintenance personnel. DO NOT operate the truck until the problem is corrected. 5. Start the engine and allow the steering accumulators to fully charge. Turn the steering wheel so that the front wheels are straight. 6. Check the hydraulic tank oil level while the engine is on.

Ensure no one is near the front tires during this test. All personnel are warned that the clearances change when the truck is steered and this could cause serious injury. This test can only be performed with an empty truck. 1. Park the empty truck on flat, level ground. Lower the dump body onto the frame and stop the engine. Ensure that the key switch is in the OFF position.

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a. If the oil level is visible in center of the lower sight glass and does not cover the entire lower sight glass, the steering accumulators are adequately charged. Proceed to Step 7. b. If the oil level is below the lower sight glass, the steering accumulators are not adequately charged. Turn the key switch to the OFF position and stop the engine. Immediately notify maintenance personnel. DO NOT operate the truck until the problem is corrected.

General Safety and Operating Instructions

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7. Shut the engine off by using the engine stop button located on the center console. Leave the key switch in the ON position. This allows the steering accumulators to retain their hydraulic charge.

MACHINE OPERATION SAFETY PRECAUTIONS After the truck engine is started and all systems are functioning properly, the operator must follow all local safety rules to ensure safe machine operation.

a. If the warning light and buzzer do activate, turn the key switch OFF and notify maintenance personnel. DO NOT operate the truck until the problem is corrected. b. If the steering accumulators are adequately charged, the low steering pressure warning light and the low accumulator precharge warning light will not illuminate. Continue to the next step. 8. Turn the steering wheel from stop to stop. The front wheels must turn fully to the left and to the right. Eventually, the low steering pressure warning light will illuminate and the warning buzzer will sound. This is normal. If the front wheels cannot be turned fully to the left and right, or if the warning light and buzzer do not activate, immediately notify maintenance personnel. DO NOT operate the truck until the problem is corrected. If the truck passes this test, the emergency steering system is functioning properly.

If any of the red warning lights illuminate or if any gauge reads in the red area during truck operation, a malfunction is indicated. Stop the truck as soon as safety permits, and stop the engine. Have the problem corrected before resuming truck operation.

The truck is equipped with "slip/slide" control. If this function becomes inoperative, operating the truck with stalled or free spinning wheel motors may cause serious damage to wheel motors! If the truck does not begin to move within ten seconds after depressing the throttle pedal (directional control lever in a drive position), release the throttle pedal and allow wheels to regain traction before accelerating again.

1. When the truck body is raised, DO NOT allow anyone below it unless the body-up retaining cable is in place.

1. Always look to the rear before reversing the truck. Watch for and obey the ground spotter's hand signals before traveling in reverse. Sound the horn (three blasts). The spotter will have a clear view of the total area at the rear of the truck.

2. DO NOT use the fire extinguisher for any purpose other than putting out a fire! If an extinguisher is discharged, report the occurrence so the used unit can be refilled or replaced.

2. Operate the truck only while properly seated with seat belt fastened. Keep hands and feet inside the cab compartment while the truck is in operation.

Additional Guidelines

3. DO NOT allow unauthorized personnel to ride in the truck. DO NOT allow anyone to ride on the ladder or outside of the truck cab. Passengers must be belted into the passenger seat during travel. 4. DO NOT leave the truck unattended while the engine is running. Move the directional control lever to PARK, then shut the engine off before getting out of the cab.

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General Safety and Operating Instructions

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4. Observe all regulations pertaining to the job site's traffic patterns. Be alert to any unusual traffic patterns. Obey the spotter's signals.

4. Before traveling in reverse, give a back-up signal of three blasts on the horn. Before starting forward, signal with two blasts on the horn. These signals must be given each time the truck is moved forward or backward.

5. Match the truck speed to haul road conditions and slow the truck in congested areas. Keep a firm grip on the steering wheel at all times.

5. Use extreme caution when approaching a haul road intersection. Maintain a safe distance from oncoming vehicles.

6. DO NOT allow the engine to run at idle for extended periods of time.

6. Maintain a safe distance when following another vehicle. Never approach another vehicle from the rear, in the same lane, closer than 15 m (50 ft). When driving on a down grade, this distance must not be less than 30 m (100 ft).

3. Check gauges and instruments frequently during operation for proper readings.

7. Check the brake lock performance periodically to ensure safe loading and dumping.

DO NOT use the brake lock for parking. When the engine is turned off, hydraulic pressure will bleed down, allowing the brakes to release! 8. Proceed slowly on rough terrain to avoid deep ruts or large obstacles. Avoid traveling close to soft edges and near the edges of a fill area. 9. Truck operation requires a concentrated effort by the driver. Avoid distractions of any kind while operating the truck.

MACHINE OPERATION ON THE HAUL ROAD 1. Always stay alert! If unfamiliar with the haul road, drive with extreme caution. Cab doors must remain closed at all times if the truck is in motion or unattended. 2. Obey all road signs. Keep the truck under control at all times. Govern truck speed by the road conditions, weather and visibility. Report poor haul road conditions immediately. Muddy or icy roads, pot holes or other obstructions can present hazards. 3. Initial propulsion with a loaded truck must begin from a level surface whenever possible. At times, starting on a hill or grade cannot be avoided. Refer to Starting On A Grade With A Loaded Truck later in this section.

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7. DO NOT stop or park on a haul road unless unavoidable. If the truck must be stopped on a haul road, park in a safe place, move the directional control lever to PARK, and shut the engine off before leaving the cab. Block the wheels securely and notify maintenance personnel for assistance. 8. While driving on a slope, maintain a speed that will ensure safe driving and provide effective retarding under all conditions (Refer to Dynamic Retarding, in Section 32 Operator Cab Controls.) Refer to the grade/speed retard chart in the operator's cab to determine maximum safe truck speeds for descending various grades with a loaded truck. 9. When operating the truck in darkness, or when visibility is poor, DO NOT move the truck unless all headlights, clearance lights, and tail lights are on. DO NOT back the truck if the back-up horn or lights are inoperative. Always dim the headlights when approaching oncoming vehicles. 10. If the emergency steering light and/or low brake pressure warning light illuminate during operation, immediately steer the truck to a safe stopping area, away from other traffic if possible. Refer to item 7 above. 11. Check the tires for proper inflation during each shift. If the truck has been operating on a flat or under-inflated tire, the truck must remain outside of any buildings until the tire cools.

General Safety and Operating Instructions

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STARTING ON A GRADE WITH A LOADED TRUCK Initial propulsion with a loaded truck must begin from a level surface whenever possible. There are circumstances when starting on a hill or grade cannot be avoided. In these instances use the following procedure: 1. Fully depress the service brake pedal (DO NOT use retarder lever) to hold the truck on the grade. With the service brakes fully applied, move the directional control lever to a drive position (FORWARD/REVERSE) and increase engine rpm with the throttle pedal. 2. As engine rpm approaches maximum, and when propulsion effort is felt working against the brakes, release the brakes and allow truck movement. Ensure the service brake pedal is completely released. As truck speed increases above 5-8 kph (3-5 mph) the PSC will drop propulsion if the retarder is still applied.

5. During loading, the operator must stay in the truck cab with the engine running. Place the directional control lever in NEUTRAL and apply the brake lock. 6. When loaded, pull away from the shovel as quickly as possible with extreme caution.

DUMPING Raising The Dump Body 1. Approach the dump area with extreme caution. Ensure the area is clear of persons and obstructions, including overhead utility lines. Obey signals as directed by the spotter, if present. 2. Avoid unstable areas. Keep a safe distance from the edge of the dump area. Position the truck on a solid, level surface before dumping.

NOTE: Releasing and reapplying dynamic retarding during a hill start will result in loss of propulsion. As the body raises, the truck center of gravity will move. The truck must be on level surface to prevent tipping/rolling!

PASSING 1. DO NOT pass another truck on a hill or on a blind curve! 2. Before passing, ensure the road ahead is clear. If a disabled truck is blocking your lane, slow down and pass with extreme caution. 3. Use only the areas designated for passing.

LOADING 1. Approach the loading area with caution. Remain at a safe distance while the truck ahead is being loaded. 2. DO NOT drive over unprotected power cables. 3. When approaching or leaving a loading area, watch for other vehicles and for personnel working in the area. 4. When pulling in under a loader or shovel, follow the spotter’s or the shovel operator’s signals. The truck operator may speed up loading by observing the location and loading cycle of the truck being loaded ahead, and then following a similar pattern.

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3. Carefully maneuver the truck into the dump position. When backing the truck into the dump position, use only the brake pedal to stop and hold the truck; DO NOT rely on the brake lock to stop the truck; this control is not modulated and applies the rear service brakes only. 4. When the truck is stopped and in dump position, apply the brake lock and move the directional control lever to the NEUTRAL position.

The dumping of very large rocks (10% of payload, or greater) or sticky material (loads that do not flow freely from the body) may allow the material to move too fast and cause the body to move RAPIDLY and SUDDENLY. This sudden movement may jolt the truck violently and cause possible injury to the operator, and/or damage to the hoist cylinders, frame, and/or body hinge pins. If it is necessary to dump this kind of material, slowly accelerate engine rpm while raising the body. When the material starts to move, release the hoist lever to the HOLD position. If the material does not continue moving and clear the body, repeat this procedure until the material has been dumped.

General Safety and Operating Instructions

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5. Pull the lever (Figure 3-20) to the rear (to RAISE position) to actuate the hoist circuit. (Releasing the lever anywhere during the raise cycle will hold the body at that position.)

2. Move the hoist lever forward to the DOWN position and release. Releasing the lever places the hoist control valve in the FLOAT position allowing the body to return to the frame. NOTE: If dumped material builds up at the rear of the body and the body cannot be lowered, perform Steps a & b below:

a. Move the hoist lever back to the RAISE position to fully raise the dump body. Then, release the hoist lever so it returns to the HOLD position. b. Move the directional control lever to FORWARD, release the brake lock, depress the override button and drive forward to clear the material. Stop, move the directional control lever to NEUTRAL, apply the brake lock and lower the body, again. FIGURE 3-20. HOIST LEVER POSITION 1. Raise 2. Hold

3. Float 4. Lower

NOTE: When an attempt to lower the body is unsuccessful because of material obstruction, raise the body back up. This will help to prevent the body from suddenly dropping when pulling away from the obstruction.

6. Raise engine rpm to accelerate hoist speed. 7. Reduce the engine rpm as the last stage of the hoist cylinder begins to extend. Keep engine speed at low idle as the last stage reaches halfextension. 8. Release the hoist lever as the last stage of the hoist cylinder reaches full extension. NOTE: If the directional control lever is in REVERSE when the dump body is raised, reverse propel is inhibited. To deactivate, lower the dump body and move the directional control lever out of REVERSE.

The truck is not to be moved with the dump body raised except for emergency purposes only. Failure to lower the body before moving the truck may cause damage to the hoist cylinders, frame and/or body hinge pins. 3. With the body returned to the frame, move the directional control lever to FORWARD, release the brake lock, and carefully leave the dump area.

Lowering The Dump Body

Lowering The Dump Body

(When dumping on flat ground):

(When dumping over a berm or into a crusher):

It is very likely when dumping on flat ground that the dumped material will build up enough to prevent the body from lowering. In this case, the truck will have to be driven forward a short distance (just enough to clear the material) before the body can be lowered. 1. Shift the directional control lever to FORWARD, release the brake lock, depress the override button and drive just far enough forward for the body to clear the material. Stop, shift the directional control lever to NEUTRAL, and apply the brake lock.

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1. Move the hoist lever to the DOWN position and release. Releasing the lever places the hoist control valve in the FLOAT position allowing the body to return to the frame. NOTE: If dumped material builds up at the rear of the body and the body cannot be lowered, perform Steps a & b below:

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a. Move the hoist lever back to the HOIST position to fully raise the dump body. Release the hoist lever to return it to the HOLD position. NOTE: DO NOT drive forward if the tail of the body will not clear the crusher wall in the fully raised position. b. Move the directional control lever to FORWARD, release the brake lock. Depress the override button and drive forward to clear the material. Stop, shift the directional control lever to NEUTRAL, apply the brake lock and lower the body again.

NOTE: When an attempt to lower the body is unsuccessful because of material obstruction, raise the body back up. This will help to prevent the body from suddenly dropping when pulling away from the obstruction.

CAUTION! DO NOT move the truck with the dump body raised except for emergency purposes only. Failure to lower the body before moving the truck may cause damage to the hoist cylinders, frame and/or body hinge pins. 2. With the body returned to the frame, move the directional control lever to FORWARD, release the brake lock, and carefully leave the dump area.

SUDDEN LOSS OF ENGINE POWER If the engine suddenly stops, there is enough hydraulic pressure stored in the brake and steering accumulators to allow the operation of the steering and brake functions. However, this oil supply is limited so it is important to stop the truck as quickly and safely as possible after the loss of engine power. If the brake supply pressure drops to a pre-determined level, the low brake pressure warning light will illuminate and a buzzer will sound. If the brake pressure continues to decrease, the auto-apply feature will activate and the service brakes will apply automatically to stop the truck. 1. Bring the truck to a safe stop as quickly as possible by using the foot pedal to apply the service brakes. If possible, safely steer the truck to the side of the road while braking.

Dynamic retarding will not be available! DO NOT use the service brakes for continuous retarding purposes. 2. As soon as the truck has stopped moving, shift the directional control lever to PARK. This will apply the parking brake. 3. Slowly release the service brakes to check the capacity of the parking brake. If the parking brake can not hold the truck stationary, apply the service brakes and hold them ON. DO NOT turn the key switch OFF, and DO NOT release the service brakes. 4. Notify maintenance personnel immediately. 5. If the truck is on level ground, or if the parking brake can hold the truck stationary and the truck is in a stable condition, it is then OK to turn the key switch OFF. 6. If safe to do so, have maintenance personnel place wheel chocks or other mechanisms in front or behind the wheels to reduce the risk of the truck rolling. 7. If traffic is heavy near the disabled machine, mark the truck with warning flags during daylight hours or use flares at night. Adhere to local regulations.

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General Safety and Operating Instructions

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FUEL DEPLETION

SAFE PARKING PROCEDURES

The high pressure injection (HPI) fuel system uses fuel to adjust fuel delivery timing by creating a hydraulic link between the upper plunger and the timing plunger. Metered fuel is also used for lubricating the injector plunger and barrel. The maximum demand for metered fuel is required during high speed / low load conditions.

The operator must continue to use safety precautions when preparing for parking and stopping the engine. In the event that the equipment is being used in consecutive shifts, any questionable truck performance the operator may have noticed must be checked by maintenance personnel before the truck is released to another operator. 1. Park the truck on level ground, if possible. If it is necessary to park on a grade, the truck must be positioned at right angles to the grade.

Operating the truck to fuel depletion forces the injector train into a no-follow* condition. No fuel flow between the plungers may cause damage to the injectors and the overhead due to adhesive wear, resulting in costly repairs and unnecessary downtime.

Allowing the Komatsu truck to operate until fuel depletion can lead to unsafe operating conditions possibly resulting in an uncontrollable vehicle and/or personal injury.

2. Stop the truck using the service brakes. Place the directional control lever in the PARK position. This will apply the parking brake. Slowly release the service brakes. If the truck starts to roll, apply the service brakes and notify maintenance personnel immediately. NOTE: If the engine is running, and the truck is stationary and no brakes are applied, the red indicator light (D5) will illuminate and the warning buzzer will sound. Also, parking brake light (A3) and service brake light (B3) will start flashing. The operator must apply one of the following braking systems: the service brakes, the wheel brake lock or the parking brake to prevent truck roll away and to silence the alarms. 3. If the truck is stationary with only the parking brake applied, place chocks fore/aft of the wheels to reduce the risk of the truck rolling. Each truck must be parked at a reasonable distance from other trucks/equipment. 4. Haul roads are not safe parking areas. In an emergency, pick the safest spot most visible to other machines in the area. If the truck becomes disabled where traffic is heavy, mark the truck with warning flags in daylight, or flares at night. 5. Proceed to Normal Engine Shutdown procedure.

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General Safety and Operating Instructions

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NORMAL ENGINE SHUTDOWN PROCEDURE The following procedure must be followed to shut the engine off. 1. Stop the truck out of the way of other traffic. Park on a level surface, free of overhead power lines or other objects that could prevent raising the dump body. a. Reduce engine speed to idle. b. Place the directional control lever in PARK. This will apply the parking brake. DO NOT apply the wheel brake lock. NOTE: If the truck starts to roll, apply the service brakes and notify maintenance personnel immediately. c. Ensure the parking brake applied indicator light in the overhead display panel is illuminated. 2. Place the rest switch in the ON position to put the AC drive system in rest mode. Ensure the rest indicator light in the overhead panel is illuminated. 3. Turn the key switch counterclockwise to the OFF position to stop the engine. The engine may continue to run for up to three minutes after the key switch is turned OFF, if the parking brake has been set. The engine may stop before three minutes has elapsed if the engine coolant is not too hot, and the engine rpm’s and fuel delivery has been low for a period of time before the key switch was placed in the OFF position. The engine shutdown light in the overhead panel will be illuminated during the shutdown sequence.

NOTE: If the engine must be shut down immediately, stop the truck, shift the directional control lever to PARK, turn the key switch OFF, then pull up on the engine stop switch located in the operator cab center console. Push the switch back down to enable engine operation.

NOTE: There is also an engine stop switch located at ground level at the left front corner of the truck. When this switch is activated, the engine will stop immediately, with no cooling off time. 4. With the key switch OFF and engine stopped, wait at least two minutes. If any warning lights are illuminated, notify maintenance personnel immediately. NOTE: When the key switch is turned OFF, the parking brake will automatically be set, even if it was not set already by the operator. The wheel brake lock will be disabled, even if it was set by the operator. 5. Ensure the steering circuit is completely bled down by turning the steering wheel back and forth several times. No front wheel movement will occur when hydraulic pressure is relieved. If the front tires continue to steer after the engine is stopped, notify maintenance personnel. 6. Verify all link voltage lights are off (one on the back side of the center console inside the operator cab, two on the electrical cabinet), and notify maintenance personnel if the lights remain illuminated longer than five minutes after the engine has been stopped. 7. If equipped, lower the retractable ladder with the in cab control panel. 8. Close and lock all windows. Remove the key from the key switch and lock the cab to prevent possible unauthorized truck operation. Properly dismount the truck. Put wheel chocks in place.

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General Safety and Operating Instructions

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DISABLED TRUCK CONNECTORS GENERAL Refer to Section L for repair and troubleshooting procedures for the hoist system components and steering system components. Refer to Section J for repair and troubleshooting procedures for the hydraulic brake system components.

6. To disconnect the hoses, stop the engine(s). Wait two minutes for the hydraulic system to bleed down. Ensure all hydraulic pressure has been relieved before disconnecting the hoses. 7. Ensure the brake system jumper hose is removed when the supply and return hoses are disconnected from the truck.

STEERING AND BRAKE SYSTEM Ports are provided on the bleeddown manifold to allow operation of the steering and brake circuits for temporary truck operation if the steering/brake pump is not operational. To use this feature, two hoses (supply and return) from the disabled truck must be connected to a hydraulic source (such as an operational truck or an auxiliary power unit). Hookup 1. When the good truck is in position, stop the engine and wait two minutes to allow the hydraulic system to bleed down. Ensure hydraulic pressure has bled off before connecting any hoses. NOTE: Maximum hydraulic pressure is not to exceed 24 304 kPa (3,525 psi). 2. Connect the hydraulic supply hose from the good truck to the supply port (4, Figure 3-20). NOTE: Failure to attach the return hose from the disabled truck to the hydraulic pressure source could cause the disabled truck hydraulic tank to overflow, or potentially damage the hydraulic power source due to lack of oil. 3. Connect the return hose from the good truck to the return port (3). NOTE: Because there are check valves incorporated into the bleed down manifold, the pressurized fluid supplied by the hydraulic source using supply port (4) will not supply oil to the brake system. To enable brake system operation, a jumper hose must be installed between the brake ports (1 & 2). Once the jumper hose is installed, pressurized oil from the hydraulic pressure source will be supplied to both the steering and the brake circuits. 4. If operable brakes are needed on the disabled truck, connect a jumper hose from brake port (1) to brake port (2). 5. Start the engine on the good truck and check the operation of the steering and brake system before moving the disabled truck.

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FIGURE 3-21. BLEEDDOWN MANIFOLD 1. Brake Port( # 1) 2. Brake Port (# 2)

General Safety and Operating Instructions

3. Return Port 4. Supply/Inlet Port

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HOIST SYSTEM

Hookup

Sometimes it is necessary to dump a load from the body of a truck when the hoist system is inoperable. To use this feature, two hoses (supply and return) must be connected to a hydraulic source (such as an operational truck or an auxiliary power unit).

Ensure there is an adequate, clear area to dump the loaded box. When the good truck is in position, stop the engine and wait two minutes to allow the hydraulic system to bleed down. Ensure hydraulic pressure has bled off before connecting hoses.

Quick disconnect fittings (1 & 2, Figure 3-22) are provided on the overcenter valve to allow operation of the hoist circuit for temporary truck operation if the hoist pump, hoist valve or other hoist system component is not operational. This will allow maintenance personnel to raise the truck body to dump the load before moving the disabled truck.

1. With the good truck parked as close as possible to the disabled truck, attach a hose from the power up quick disconnect (1, Figure 3-22) to the power down circuit of the disabled truck. (Hose must be rated to withstand 17 237 kPa (2,500 psi) or greater pressure.

In the example, Figure 3-22 illustrates a typical hookup from the good truck. The disabled truck may be another Model 830E, or a different Komatsu electric drive truck model. The hoist circuit relief valves are adjusted to 17 240 kPa (2,500 psi).

NOTE: The power down circuit will use a smaller diameter hose (tube) than the power up circuit. 2. Connect another hose from the power down quick disconnect (2) to the power up circuit of the disabled truck. NOTE: If both trucks are a Model 830E, the hoses will be installed at the quick disconnects but will be crossed when connected.

Dumping Procedure Raising the Body: 3. On the disabled truck, move the hoist control lever to power up and then release it to place the hoist pilot valve in the HOLD position (leave in this position during entire procedure). 4. Start the engine on the good truck, place the hoist control in the power down position and increase engine RPM to high idle to dump the disabled truck. If the body of the disabled truck fails to raise, increase the good truck power down relief pressure as follows: a. Stop the engine and wait two minutes to allow the hydraulic system pressure to bleed down.

FIGURE 3-22. HOIST CONNECTIONS 1. Power Up Quick Disconnect 2. Power Down Quick Disconnect 3. Over Center Valve

b. Remove the cap from the hoist pilot valve relief valve located in the hydraulics components cabinet behind the cab. While counting the number of turns, slowly screw the relief valve adjustment screw clockwise until it bottoms. 5. Repeat Step 4 to dump the disabled truck.

NOTE: The matching quick disconnect couplings for items (1 & 2) is PB4684.

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General Safety and Operating Instructions

A03052

Lowering the Body: 6. Place the hoist lever of the good truck in FLOAT to lower the body. If necessary, momentarily place the hoist control in POWER UP until the body is able to descend in FLOAT. Do not accelerate the engine. 7. After body is lowered, stop the engine and wait two minutes to allow the hydraulic system to bleeddown. Then disconnect the hoses.

A03052

8. Reduce power down relief valve pressure to normal on good truck by turning the adjustment counterclockwise the same number of turns as required in step 4 b. 9. Check power down relief pressure using instructions in Section L10. 10. Check hydraulic tank oil level.

General Safety and Operating Instructions

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TOWING

Special Wiring Harness

Before towing a truck, many factors must be carefully considered. Serious personal injury and/or significant property damage may result if important safety practices, procedures and preparation for moving heavy equipment are not observed. A disabled machine may be towed after the following precautions have been taken. • Do not tow the truck any faster than 8 kph (5 mph). • Tow with a solid tow bar. DO NOT tow with a cable. Use a towing device with ample strength for the weight of this truck. • Never tow a truck on a slope.

Before towing, a special wiring harness must be made in order to release the parking brake. The harness will require approximately 9 meters (30 ft) of #14 wire, and one ON/OFF switch (capable of carrying 2 amps of current) and two ring terminals. Refer to Figure 3-23. Using a ring terminal, one end of the wire must connect to a 24VDC bus bar (1) in the auxiliary control cabinet to supply 24V to the solenoid. Switch (2) must be positioned in the harness so the operator can operate the switch while seated in the operators seat. The harness must be fitted with a connector (4) to allow it to be plugged into parking brake solenoid (3) inside the brake cabinet. Wire (5) leading from this connector is to be connected to the ground block using a ring terminal. Refer to Figure 3-11 for an overview of the special wiring harness when installed on the truck.

• Inspect towing components, such as tow bars and couplings, for any signs of damage. Never use damaged or worn components to tow a disabled vehicle.

The parts required to connect to the solenoid are: 1 housing (PB8538), 2 sockets (0819105430) and 1 wedge (PB8540).

• Keep a safe distance from the trucks and towing apparatus while towing a vehicle.

Towing Procedure

• After connecting a truck that is to be towed, do not allow anyone to go between the tow vehicle and the disabled vehicle. • 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. • An operator is to remain in the cab of the towed vehicle at all times during the towing procedure.

1. Shut the engine off. 2. Block the wheels on the disabled truck to prevent movement while preparing the truck for towing and while attaching the tow bar. 3. Ensure the towing vehicle has adequate capacity to both move and stop the towed truck under all conditions. 4. Ensure that the tow bar has adequate strength (approximately 1.5 times the empty vehicle weight of truck being towed). Install tow bar between the two vehicles. 5. Block the wheels on the tow vehicle to prevent movement while preparing the disabled truck for towing. 6. If necessary, install quick disconnect fittings to the bleeddown manifold to allow the hydraulic system to be operational. Install hydraulic connections for steering/braking between the tow vehicle the and disabled vehicle. An auxiliary power unit can also be used.

FIGURE 3-23. PARKING BRAKE HARNESS 1. 24VDC Connection 2. Switch (ON/OFF) 3. Park Brake Solenoid

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4. Connector 5. Ground Wire

7. After the hydraulic connections are made, check the disabled vehicle braking and steering systems for normal operation. Install 24 100 kPa (3,500 psi) pressure gauges on both the BF test port and the BR test port on the brake manifold in the brake cabinet. Ensure proper pressure is displayed on the gauge when depressing the brake pedal.

General Safety and Operating Instructions

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FIGURE 3-24. PARKING BRAKE WIRING FOR TOWING 1. Switch 2. Ground Wire

3. Harness

8. If the truck is loaded, dump the entire load. Never pull or tow a loaded truck. Refer to “Disabled Truck Dumping Procedure”. 9. The parking brakes must be released before towing. To release the parking brake, follow the steps below to install a special wiring harness to release the parking brakes. a. Ensure switch (1, Figure 3-24) is in the OFF position. b. Connect one lead of the special wiring harness to the 24VDC bus bar terminal on the side wall in the auxiliary control cabinet for the 24V supply. c. Disconnect the truck wiring harness from parking brake solenoid (2, Figure 3-25). Connect special wiring harness (3, Figure Figure 3-24) to the parking brake solenoid. Attach the short lead (2) to ground. d. WIth the window lowered, place the end of the special wiring harness inside the cab so the operator can control the parking brake with switch (1).

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FIGURE 3-25. BRAKE CABINET 1. Brake Manifold

General Safety and Operating Instructions

2. Park Brake Solenoid

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10. Ensure the operator in the towing vehicle has 2way radio communications with the driver in the disabled truck. 11. When ready to tow the disabled truck, remove blocking from the wheels. 12. The operator in the disabled truck should now move switch (1, Figure 3-24) to the ON position. This will release the parking brakes. 13. Tow the disabled truck. Sudden movement may cause tow bar failure. Smooth, gradual truck movement is preferred. Do not tow the truck any faster than 8 kph (5 mph).

15. When the desired location has been reached, the operator in the towed vehicle is to apply the service brakes, then turn switch (1) to the OFF position. This will apply the parking brakes. 16. Block the wheels on the towing vehicle and the disabled truck to prevent roll-away. 17. Shut down the engine in the towing vehicle. Disconnect the hydraulic hoses. 18. Disconnect special wiring harness (3) from the truck. Connect the truck wiring harness back to the parking brake solenoid. 19. Disconnect the tow bar.

14. Minimize the tow angle at all times. Never exceed 30 degrees. The towed truck must be steered in the direction of the tow bar.

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General Safety and Operating Instructions

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RESERVE ENGINE OIL SYSTEM (Optional) The reserve oil tank for the engine is designed to add more oil capacity to the engine and to make less frequent servicing of the engine oil. The circulation of oil between the engine sump and reserve tank increases the total volume of working oil. This dilutes the effects of contamination and loss of additives and maintains the oil quality over longer periods. Operation Engine oil is circulated between the engine sump and the reserve tank by two electrically driven pumps within a single pumping unit (11, Figure 3-26). The pump unit is mounted on the side of the reserve tank, and is equipped with an LED monitor light on one side. Pump 1 (in the pump unit) draws oil from the engine sump at a preset control point determined by the height of the suction tube. Oil above this point is withdrawn and transferred to reserve tank (9). This lowers the level in the engine sump until air is drawn.

NOTE: DO NOT use the oil in the reserve tank to fill the engine sump. Both must be at proper level before starting the engine. 4. The engine oil level must be checked with the engine dipstick at every shift change. If the oil level in the engine is incorrect, check for proper operation of the reserve engine oil system. 5. The oil level in the reserve tank must also be checked at every shift change. Use dipstick on fill cap (8) to check oil level. If necessary, add oil to the reserve tank by using the quick fill system utilizing tank fill valve (3). For filling instructions, refer to Section 40, Lubrication and Service in the Operation and Maintenance Manual. NOTE: Oil must always be visible in lower sight gauge (12). If the tank is equipped with three sight gauges, the oil must always be visible in the middle sight gauge.

Air reaching the pumping unit activates pump 2 (in the pump unit) which returns oil from the reserve tank and raises the engine sump level until air is no longer drawn by pump 1. Pump 2 then turns off. The running level is continuously adjusted at the control point by alternation between withdrawal and return of oil at the sump. LED Monitor Light • Steady - Pump 1 is withdrawing oil from the engine sump and bringing down the oil level. • Regular Pulsing - Pump 2 is returning oil to the engine sump and raising the oil level. • Irregular Pulsing - Oil is on the correct operating level. Changing Oil 1. Drain both the engine sump and the reserve tank. Refill both the engine and reserve tank with new oil to proper levels. 2. Change engine filters as required. 3. Start the engine and check for proper operation.

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FIGURE 3-26. RESERVE ENGINE OIL SYSTEM 1. Oil Suction 2. Oil Tank Fill 3. Fill Valve 4. Engine Fill Line 5. Oil Level Sensor 6. Air Valve 7. Tank Fill Line

General Safety and Operating Instructions

8. Fill Cap 9. Reserve Oil Tank 10. Engine Fill Line 11. Pump Unit 12. Sight Gauge 13. Tank Return Line

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NOTES:

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General Safety and Operating Instructions

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WARNINGS AND CAUTIONS The following pages give an explanation of the warning, caution, and service instruction plates and decals attached to the truck. The plates and decals listed here are typical of this Komatsu model, but because of customer options, individual trucks may have plates and decals that are different from those shown here. The plates and decals must be kept clean and legible. If any decal or plate becomes illegible or damaged, it must be replaced with a new one. A warning decal is located below the key switch on the instrument panel. The warning stresses the importance of reading the operator's manual before operation.

A grade/speed retard chart is located on the left front post of the operator's cab and provides the recommended MAXIMUM speeds to be used when descending various grades with a loaded truck. Always refer to the decal in operator's cab. This decal may change with optional truck equipment such as: wheel motor drive train ratios, retarder grids, tire sizes, etc.

A plate attached to the right rear corner of the cab states the Rollover Protective Structure (ROPS) and Falling Object Protective Structure (FOPS) meets various SAE performance requirements. ! WARNING! Do not make modifications to this structure, or attempt to repair damage without written approval from Komatsu. Unauthorized repairs will void certification.

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Warnings and Cautions

A4-1

Attached to the exterior of both battery compartments is a danger plate. This plate stresses the need to keep from making any sparks near the battery. When another battery or 24VDC power source is used for auxiliary power, all switches must be OFF prior to making any connections. When connecting auxiliary power cables, positively maintain correct polarity. Connect the positive (+) posts together and then connect the negative (-) lead of the auxiliary power cable to a good frame ground. Do not connect to the negative posts of the truck battery or a ground near the battery box. This hookup completes the circuit but minimizes danger of sparks near the batteries. Sulfuric acid is corrosive and toxic. Use proper safety gear, goggles, rubber gloves and rubber apron when handling and servicing batteries. Get proper medical help immediately, if required.

This plate is placed on both battery boxes and near the battery disconnect switches to indicate that the battery system (24VDC) is a negative (-) ground system.

This decal is located on the battery box cover. It details the correct procedure for disconnecting the battery cables from the batteries. Before disconnecting the battery cables, turn the key switch to the OFF position and wait for the engine to stop. After the engine has stopped, wait two minutes, and if no warning lights illuminate, then turn the battery disconnect switches to the OFF position.

Wireless signals from the truck’s KOMTRAX Plus system can interfere with other wireless signals in the area. This interference can cause a malfunction in a blast zone resulting in an unintended detonation. Know the locations of blast zones in the area and keep a safe distance to avoid unintentional blasts. Operating frequency of KOMTRAX Plus is 148 MHz to 150 MHz.

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Warnings and Cautions

3/11 A04066

This decal is placed on the cover for the ground level engine shutdown switch to indicate where the emergency shutdown control is located. The shutdown switch is mounted above the isolation box.

This decal is located below the engine shutdown switch. It is used for emergency shutdown only. Push the button in to stop the engine.

This decal is located on the isolation box. The isolation box contains the disconnect switches that can be used to isolate the starter, battery and propulsion system circuits.

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Warnings and Cautions

A4-3

These plates are located above the battery disconnect switches on the isolation box to indicate the OFF and ON positions of the switches. The master switch will disconnect the batteries from the entire electrical system. The starter switch will disconnect the power supply to the two starters. This will prevent the truck from starting, but will allow for diagnostic testing of the electrical system if the master switch is still ON. Stop the engine and turn the key switch to the OFF position. After the engine has stopped, wait two minutes, and if no warning lights illuminate, then turn the battery disconnect switches to the OFF position. After the key switch is turned OFF, the interface module remains on, monitoring the park brake function and the accumulator bleeddown function. If a failure in either system is detected, an alarm will sound to notify the operator of a failure in that system. If the battery disconnect switches are turned OFF without waiting two minutes, a potential failure could be masked. Always use the battery disconnect switches before: • Storing the machine for more than one month • Replacing electrical system components • Performing welding maintenance • Handling batteries, or starting with booster cables • Replacing fuses or fusible links

This plate is located above the propel lockout lever on the isolation box to indicate the OFF and ON positions of the lever. When this lever is placed in the OFF position, the truck’s AC electric drive system is locked out and the truck will not propel. When the lever is placed in the ON position, the truck’s AC electric drive system will function and the truck can be driven.

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Warnings and Cautions

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A warning plate is mounted on top of the radiator surge tank cover near the radiator cap. The engine cooling system is pressurized. Always turn the key switch OFF and allow the engine to cool before removing the radiator cap. Unless the pressure is first released, removing the radiator cap after the engine has been operating for a time will result in the hot coolant being expelled from the radiator. Serious scalding and burning may result.

Warning plates are mounted on the frame in front of, and to the rear, of both front tires. All personnel are warned that the clearances change when the truck is steered and could cause serious injury.

Warning plates are attached to both the hydraulic tank and fuel tank to alert technicians not to work on the truck with the body in the raised position unless the body-up retention device (cable/sling) is in position.

This decal is located by the emergency ladder on both sides of the truck.

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Warnings and Cautions

A4-5

These danger plates are mounted on the outside of each frame rail to alert technicians to read the warning labels attached to the side of each of the accumulators (see below) prior to releasing internal nitrogen pressure or disconnecting any hydraulic lines or hardware. There are similar decals mounted on top of each of the accumulators (both steering and brake) with the same danger message.

This danger plate is attached to all four suspensions. The plate contains instructions for releasing internal pressure before disconnecting any hardware. Serious injury can occur if these directions are not followed.

A plate on the side of the hydraulic tank furnishes instructions for filling the hydraulic tank. Keep the system open to the atmosphere only as long as absolutely necessary to lessen the chances of system contamination. Service the tank with clean Type C-4 hydraulic oil. All oil being put into the hydraulic tank must be filtered using filters rated at three microns.

A caution decal is attached below the hydraulic tank oil level sight gauge. Check level with body down, engine stopped, and key switch OFF. Add oil per filling instructions, if oil level is below top of sight glass.

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Warnings and Cautions

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A warning plate is attached to the hydraulic tank to inform technicians that high pressure hydraulic oil is present during operation. When it is necessary to open the hydraulic system, Ensure the engine is stopped and key switch is OFF to bleed down hydraulic pressure. There is always a chance of residual pressure being present. Open fittings slowly to allow all pressure to bleed off before removing any connections.

Any operating fluid, such as hydraulic oil, escaping under pressure can have sufficient force to enter a person's body by penetrating the skin. Serious injury and possibly death may result if proper medical treatment by a physician familiar with this injury is not received immediately.

A wheel motor oil level decal is attached to the gear cover on both electric wheel motors. This decal stresses the fact that the truck must be on a level surface and parked for 20 minutes prior to checking the oil level. This is necessary in order to get an accurate reading.

A decal plate located on the frame near the left hoist cylinder provides the operator or technician with the hook-up procedure for dumping a loaded, disabled truck. The use of a functional truck for hydraulic power is required. Refer to the Section L for additional instructions for using this procedure.

Warning decals are applied to both brake accumulators located inside the brake system cabinet behind the operator cab. These decals remind servicing technicians to close the accumulator drain valves after they have been opened to bleed brake pressure. It further warns not to over-tighten the drain valves to prevent damage to the valve seat(s).

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Warnings and Cautions

A4-7

A warning plate alerts the technician to stop the engine, turn the key switch OFF, and open the drain valves on all three accumulators to bleed the hydraulic system pressure before disconnecting a brake line.

A decal plate is located on the frame near the left hoist cylinder. It provides the operator or technician with the hydraulic hook-up procedure before towing a disabled truck, by using a functional truck for hydraulic power.

This decal is located on the automatic lubrication reservoir informing the technician that the cover must never be removed for filling purposes as there is potential for dirt or debris entering the system. Always fill the grease reservoir through the coupling provided where the grease passes through a filter before entering the reservoir.

This STORED ENERGY HAZARD warning decal is located below the battery disconnect switches to warn personnel not to disconnect the batteries during the first 90 seconds after turning the key switch off. Turn the key switch to the OFF position and wait for the engine to stop. After the engine has stopped, wait two minutes, and if no warning lights illuminate, then turn the battery disconnect switches to the OFF position. The first 90 seconds after the key switch is turned off is the bleeddown process. Turning the battery disconnect switches off within 90 seconds could interrupt the bleeddown process and leave stored energy in the accumulator. Wait two minutes after the engine has stopped, then observe for bleeddown malfunction warning light in overhead panel. If warning is being displayed, notify maintenance immediately. Turning the battery disconnect switches to the OFF position sooner than two minutes could mask a problem that was detected during the bleeddown process.

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Warnings and Cautions

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This caution decal is placed near the battery disconnect switches on the right side of the front bumper to alert servicing technicians that before doing any welding on the truck, always disconnect the battery charging alternator lead wire and isolate electronic control components before making welding repairs. In addition, always disconnect the positive and negative battery cables of the vehicle. Failure to do so may seriously damage the battery and electrical equipment. Always fasten the welding machine ground (-) lead to the piece being welded; grounding clamp must be attached as near as possible to the weld area. Never allow welding current to pass through ball bearings, roller bearings, suspensions, or hydraulic cylinders. Always avoid laying welding cables over or near the vehicle electrical harnesses. Welding voltage could be induced into the electrical harness and possibly cause damage to components.

A high voltage danger plate is attached to the door of the rear hatch cover. High voltage may be present! Only authorized personnel can access this rear housing.

These warning plates are mounted on all of the AC drive control housings and cabinets. High voltage may be present, with or without, the engine running! Only authorized personnel can access these cabinets.

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Warnings and Cautions

A4-9

This caution decal is placed on the back of the control cabinet to alert service technicians that this area contains capacitors and must not be disturbed in any manner.

This information decal is placed on the outside of the door panel on the control cabinet wall that faces the right side of the operator cab.

This decal is placed near three different indicator lights: •

In the operator cab, on the rear of the center console.

•

On the front of the control box which is mounted on the right side of the main control cabinet.

•

On the outside of the left control cabinet wall that faces the right side of the operator cab. (See also Information decal above.)

When any of these indicator lights are on, high voltage is present throughout the propulsion and retarding system. Extreme care should be exercised!

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Warnings and Cautions

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This page illustrates a variety of decals which are mounted on deck mounted cabinets, housings, and structures which must be lifted in a specific manner, and from specific points, in order to safely move or lift any of these structures. If any of these decals are damaged or defaced, so that it is no longer legible, it must be replaced immediately. Maintenance personnel must follow these lifting instructions.

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Warnings and Cautions

A4-11

A product identification plate is located on the frame in front of the right side front wheel and shows the truck model number, maximum GVW and Product Identification Number (PIN). NOTE: This product identification plate may vary depending on engine options.

The PIN consists of 19 total characters. The first and last characters are tamper preventative symbols (*). The remaining 17 alpha/numeric characters are used to identify 5 characteristics of the machine. The 5 characteristics are detailed below.

WMC - Character positions 1, 2 and 3 identify the Worldwide Manufacturer Code (WMC). The WMC designates the manufacturer of the product. Komatsu brand products are identified with the letters KMT.

MDS - Character positions 4, 5, 6, 7 and 8 identify the Machine Descriptor Section (MDS). The MDS code identifies general information regarding machine specifications. The MDS is a code for the machine type and model.

CL - Character position 9 identify the Check Letter (CL). The CL is used to verify the accuracy of the individual PIN.

FC - Character positions 10 and 11 identify the Factory Code (FC). The FC identifies the Komatsu factory in charge of claims for the product. The FC for electric drive trucks is 61. SN - Character positions 12, 13, 14, 15, 16, and 17 identify the Serial Number (SN). The SN is a unique sequential number.

A4-12

Warnings and Cautions

3/11 A04066

A caution decal is also attached to the door of the rear hatch cover to alert personnel that hot exhaust air is present and may cause injury. This caution decal is also placed around the retarding grid cabinet.

This decal is placed on both front wheel hubs to warn about hot oil inside the wheel hubs. Remove the oil level plug carefully to avoid injury.

The lubrication chart is mounted on the right hand side of the radiator grille structure. Refer to Section P, Lubrication and Service, in this manual for more complete lubrication instructions.

A04066 3/11

Warnings and Cautions

A4-13

NOTES:

A4-14

Warnings and Cautions

3/11 A04066

TORQUE TABLES AND CONVERSION CHARTS

This manual provides dual dimensioning for many specifications. Metric units are specified first, with U.S. standard units in parentheses. When torque values are not specified in the assembly instructions contained in this manual, use the standard torque value for the hardware being used. Standard value torque tables are contained in this chapter for metric and SAE hardware.

References throughout the manual to standard torques or other standard values will be to one of the following tables. Do not use standard values to replace specific torque values in assembly instructions.

NOTE: This truck is assembled with both metric and SAE (U.S.) hardware. Reference the correct table when determining the proper torque value.

For values not shown in any of the charts or tables, standard conversion factors for most commonly used measurements are provided in the following tables.

INDEX OF TABLES TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

TABLE 1

Standard Tightening Torque For Metric Cap screws and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

TABLE 2

Standard Tightening Torque For SAE Grade 5 & 8 Cap Screws and Nuts . . . . . . . . . . . . . . . . 12-3

TABLE 3

Standard Tightening Torque 12-Pt, Grade 9, Cap Screws (SAE) . . . . . . . . . . . . . . . . . . . . . . . 12-4

TABLE 4

Tightening Torque for T-Bolt Type Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5

TABLE 5

Standard Tightening Torque For Split Flange Clamp Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5

TABLE 6

Tightening Torque For Flared Tube And Hose Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5

TABLE 7

JIC 37° Swivel Nuts Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

TABLE 8

Pipe Thread Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

TABLE 9

O-Ring Boss Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7

TABLE 10

O-Ring Face Seal Torque Chart (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7

TABLE 11

Common Conversions Multipliers - Metric -to- English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8

TABLE 12

Common Conversions Multipliers - English -to- Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9

TABLE 13

Temperature Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10

A05001 1/13

Torque Tables and Conversion Charts

A5-1

EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values

STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts

The Komatsu engineering department does not 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.

The following specifications apply to required assembly torques for all metric class 10.9 finished hexagon head cap screws and class 10 nuts.

If special friction-reducing lubricants are used with the standard torque values listed in this chapter, excessive stress and possible breakage of the fasteners may result. Where the torque tables specify “Lubricated Threads” for the standard torque values listed, these standard torque values are to be used with simple lithium base chassis grease (multi-purpose EP NLGI) or a rust-preventive grease (see below) on the threads and seats unless specified otherwise. NOTE: Ensure the threads of fasteners and tapped holes are free of burrs and other imperfections before assembling.

• Cap screw threads and seats shall not be lubricated when assembled. These specifications are based on all cap screws, nuts, and hardened washers being phosphate and oil coated. If zinc-plated hardware is used, each piece must be lubricated with simple lithium base chassis grease (multi-purpose EP NLGI) or a rust preventive grease (see list, this page) to achieve the same clamping forces provided below. • Torques are calculated to give a clamping force of approximately 75% of proof load. • The maximum torque tolerance shall be within ±10% of the torque value shown. • In the following table under “Cap Screw Size”, the first number represents the shank diameter (mm). The second number represents threads per millimeter. Example: M20 x 2.25

Suggested* Sources for Rust Preventive Grease:

M20 = shank diameter (20 mm)

• American Anti-Rust Grease #3-X from Standard Oil Company (also American Oil Co.)

2.25 = thread pitch in millimeter

• Gulf NoRust #3 from Gulf Oil Company. • Mobilarma 355, Product No. 66705 from Mobil Oil Corporation. • Rust Ban 326 from Humble Oil Company. • Rustolene B Grease from Sinclair Oil Co. • Rust Preventive Grease - Code 312 from the Southwest Grease and Oil Company. NOTE: This list represents the current engineering approved sources for use in Komatsu manufacture. It is not exclusive. Other products may meet the same specifications of this list.

A5-2

TABLE 1. Standard Tightening Torque for Metric Class 10.9 Cap screws & Class 10 Nuts Cap Screw Size

Torque N•m

Torque ft lb

Torque kg•m

M6 x1

12

9

1.22

M8 x 1.25

30

22

3.06

M10 x 1.5

55

40

5.61

M12 x 1.75

95

70

9.69

M14 x 2

155

114

15.81

M16 x 2

240

177

24.48

M20 x 2.5

465

343

47.43

M24 x 3

800

590

81.6

M30 x 3.5

1600

1180

163.2

M36 x 4

2750

2028

280.5

Torque Tables and Conversion Charts

1/13 A05001

STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws The following specifications apply to required assembly torques for all grade 5 and grade 8 cap screws.

• The maximum torque tolerance shall be ±10% of the torque value shown.

• Cap screw threads and seats shall be lubri-

• In the following table under Cap Screw Size, the first number represents the shank diameter (in.). The second number represents threads per inch.

cated when assembled. Unless instructions specifically recommend otherwise, these standard torque values are to be used with simple lithium base chassis grease (multi-purpose EP NLGI) or a rust- preventive grease (see list, previous page) on the threads.

Example: 7/16 - 20 7/16 = shank diameter (7/16 inch (0.438 inch)) 20 = threads per inch

• Torques are calculated to give a clamping force of approximately 75% of proof load.

TABLE 2. Standard Tightening Torque for SAE Hex Head Cap Screw And Nut Assembly Cap Screw Size

Torque Grade 5 N·m

Torque Grade 8

ft lb

kg·m

N·m

ft lb

Torque Grade 5

Torque Grade 8

kg·m

Cap Screw Size

N·m

ft lb

kg·m

N·m

ft lb

kg·m

1/4-20

9.5

7

0.97

13.6

10

1.38

3/4-16

319

235

32.5

454

335

46.3

1/4-28

10.8

8

1.11

14.9

11

1.52

7/8-9

475

350

48.4

678

500

69.2

5/16-18

20.3

15

2.07

28

21

2.90

7/8-14

508

375

51.9

719

530

73.3

5/16-24

22

16

2.21

30

22

3.04

1.0-8

712

525

72.6

1017

750

103.7

3/8-16

34

25

3.46

47

35

4.84

1.0-12

759

560

77.4

1071

790

109.3

3/8-24

41

30

4.15

54

40

5.5

1.0-14

773

570

78.8

1085

800

110.6

7/16-14

54

40

5.5

79

58

8.0

1 1/8-7

881

650

89.9

1424

1050

145

7/16-20

61

45

6.2

84

62

8.57

1 1/8-12

949

700

96.8

1546

1140

158

1/2-13

88

65

9

122

90

12.4

1 1/4-7

1234

910

125.9

2007

1480

205

1/2-20

95

70

9.7

129

95

13.1

1 1/4-12

1322

975

134.8

2142

1580

219

9/16-12

122

90

12.4

169

125

17.3

1 3/8-6

1627

1200

166

2630

1940

268

9/16-18

129

95

13.1

183

135

18.7

1 3/8-12

1776

1310

181

2874

2120

293

5/8-11

169

125

17.3

237

175

24.2

1 1/2-6

2142

1580

219

3471

2560

354

5/8-18

183

135

18.7

258

190

26.2

1 1/2-12

2305

1700

235

3756

2770

383

3/4-10

298

220

30.4

420

310

42.8

1 ft. lb. = 0.138 kg·m = 1.356 N.m

A05001 1/13

Torque Tables and Conversion Charts

A5-3

STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws The following specifications apply to required assembly torques for all 12-point, grade 9 (170,000 psi minimum tensile), cap screws.

• Cap screw threads and seats shall be lubricated when assembled. Unless instructions specifically recommend otherwise, these standard torque values are to be used with simple lithium base chassis grease (multipurpose EP NLGI) or a rust- preventive grease (see list, this page) on the threads.

• Torques are calculated to give a clamping force of approximately 75% of proof load.

• The maximum torque tolerance shall be ±10% of the torque value shown.

TABLE 3. Standard Tightening Torque for 12-Point, Grade 9 Cap Screws Cap Screw Size*

Torque N·m

Torque ft lb

Torque kg·m

0.250 - 20

16

12

1.7

0.312 - 18

33

24

3.3

0.375 - 16

57

42

5.8

0.438 -14

95

70

9.7

0.500 -13

142

105

14.5

0.562 - 12

203

150

20.7

0.625 - 11

278

205

28.3

0.750 - 10

488

360

49.7

0.875 - 9

780

575

79.4

1.000 - 8

1166

860

119

1.000 - 12

1240

915

126

1.125 - 7

1670

1230

170

1.125 - 12

1800

1330

184

1.250 - 7

2325

1715

237

1.250 - 12

2495

1840

254

1.375 - 6

3080

2270

313

1.375 - 12

3355

2475

342

1.500 - 6

4040

2980

411

1.500 - 12

4375

3225

445

* Shank Diameter (in.) - Threads per inch

A5-4

Torque Tables and Conversion Charts

1/13 A05001

TABLE 4. Tightening Torque For T-Bolt Type Hose Clamp (SAE J1508 Type TB) Thread Size

Band Width

Newton meters (N·m)

Inch Pounds (in. lb)

0.25-28 UNF

19.05 mm (0.75 in.)

8.5 ± 0.6 N·m

75 ± 5 in lb

Cap Screw Thread Diameter (mm) 10 12 16

Thread Diameter of Nut (mm) 14 18 22 24 30 33 36 42

A05001 1/13

Width Across Flat (mm) 14 17 22

TABLE 5. Tightening Torque For Split Flange Clamp Bolts Newton meters (N·m) Tolerances ±10% 66 112 279

Foot Pounds (ft lb) Tolerances ±10% 48 83 206

Kilogram meters (kg·m) Tolerances ±10% 6.7 11.5 28.5

Width Across Flat (mm) 19 24 27 32 36 41 46 55

TABLE 6. Tightening Torque For Flared Tube And Hose Fittings Newton meters (N·m) Tolerances ±10% 25 50 80 140 175 195 245 295

Foot Pounds (ft lb) Tolerances ±10% 18 36 58 101 130 145 180 215

Kilogram meters (kg·m) Tolerances ±10% 2.5 5 8 14 18 20 25 30

Torque Tables and Conversion Charts

A5-5

TABLE 7. Torque Chart For JIC 37° Swivel NutS With Or Without O-ring Seals Size Code

Tube Size (OD)

Threads UNF-2B

Newton meters (N·m)

Foot Pounds (ft lb)

–2

0.125

0.312 – 24

5±1

4±1

–3

0.188

0.375 – 24

11 ± 4

8±3

–4

0.250

0.438 – 20

16 ± 4

12 ± 3

–5

0.312

0.500 – 20

20 ± 4

15 ± 3

–6

0.375

0.562 – 18

24 ± 7

18 ± 5

–8

0.500

0.750 – 16

40 ± 7

30 ± 5

– 10

0.625

0.875 – 14

54 ± 7

40 ± 5

– 12

0.750

1.062 – 12

75 ± 7

55 ± 5

– 14

0.875

1.188 – 12

88 ± 7

65 ± 5

– 16

1.000

1.312 – 12

108 ± 7

80 ± 5

– 20

1.250

1.625 – 12

136 ± 14

100 ± 10

– 24

1.500

1.875 – 12

163 ± 14

120 ± 10

– 32

2.000

2.500 – 12

312 ± 27

230 ± 20

TABLE 8. Torque Chart For Pipe Thread Fittings

A5-6

Size Code

Pipe Thread Size

With Sealant N·m

With Sealant ft lb

Without Sealant N·m

Without Sealant ft lb

–2

0.125 – 27

20 ± 4

15 ±3

27 ± 7

20 ± 5

–4

0.250 – 18

27 ± 7

20 ±5

34 ± 7

25 ± 5

–6

0.375 – 18

34 ± 7

25 ±5

48 ± 7

35 ± 5

–8

0.500 – 14

48 ± 7

35 ±5

61 ± 7

45 ± 5

– 12

0.750 – 14

61 ± 7

45 ±5

75 ± 7

55 ± 5

– 16

1.000 – 11.50

75 ± 7

55 ±5

88 ± 7

65 ± 5

– 20

1.250 – 11.50

95 ± 7

70 ±5

108 ± 7

80 ± 5

– 24

1.500 – 11.50

108 ± 7

80 ±5

129 ± 14

95 ± 10

– 32

2.000 – 11.50

129 ± 14

95 ±10

163 ± 14

120 ± 10

Torque Tables and Conversion Charts

1/13 A05001

TABLE 9. Torque Chart For O-ring Boss Fittings Size Code

Tube Size (OD) Threads UNF-2B

Newton meters (N·m)

Foot Pounds (ft lb)

–2

0.125

0.312 – 24

4±3

4±2

–3

0.188

0.375 – 24

7±3

5±2

–4

0.250

0.438 – 20

11 ± 4

8±3

–5

0.312

0.500 – 20

14 ± 4

10 ± 3

–6

0.375

0.562 – 18

18 ± 4

13 ± 3

–8

0.500

0.750 – 16

33 ± 7

24 ± 5

– 10

0.625

0.875 – 14

43 ± 7

32 ± 5

– 12

0.750

1.062 – 12

65 ± 7

48 ± 5

– 14

0.875

1.188 – 12

73 ± 7

54 ± 5

– 16

1.000

1.312 – 12

98 ± 7

72 ± 5

– 20

1.250

1.625 – 12

109 ± 7

80 ± 5

– 24

1.500

1.875 – 12

109 ± 7

80 ± 5

– 32

2.000

2.500 – 12

130 ± 14

96 ± 10

TABLE 10. Torque Chart For O-ring Face Seal Fittings

A05001 1/13

Size CodeE

Tube Size (O.D.)

Threads UNF-2B

Newton meters (N·m)

Foot Pounds (ft lb)

–4

0.250

0.438 – 20

15 ± 1

11 ± 1

–6

0.375

0.562 – 18

24 ± 3

18 ± 2

–8

0.500

0.750 – 16

48 ± 5

35 ± 4

– 10

0.625

0.875 – 14

69 ± 7

51 ± 5

– 12

0.750

1.062 – 12

96 ± 10

71 ± 7

– 16

1.000

1.312 – 12

133 ± 8

98 ± 6

– 20

1.250

1.625 – 12

179 ± 10

132 ± 7

– 24

1.500

1.875 – 12

224 ± 20

165 ± 15

Torque Tables and Conversion Charts

A5-7

TABLE11. Common Conversion Multipliers Metric To English To Convert From millimeter (mm)

inch (in.)

0.0394

centimeter (cm)

inch (in.)

0.3937

meter (m)

foot (ft)

3.2808

meter (m)

yard (yd)

1.0936

kilometer (km)

mile (mi)

0.6210

square centimeters (cm )

square inch (in. )

0.1550

square centimeters (cm2)

square feet (ft2)

0.001

cubic centimeters (cm3)

cubic inch (in.3)

0.061

liters (l)

cubic inch (in.3)

61.02

cubic meters (m3)

cubic feet (ft3)

35.314

liters (l)

cubic feet (ft3)

0.0353

2

2

grams (g)

ounce (oz)

0.0353

milliliter (ml)

fluid ounce (fl oz)

0.0338

kilogram (kg)

pound (mass)

2.2046

Newton (N)

pounds (lb)

0.2248

Newton meters (N·m)

kilogram meters (kg·m)

0.102

Newton meters (N·m)

foot pounds (ft lb)

0.7376

kilogram meters (kg·m)

foot pounds (ft lb)

7.2329

kilogram meters (kg·m)

Newton meters (N·m)

9.807

kilopascals (kPa)

pounds/square inch (psi)

0.1450

megapascals (MPa)

pounds/square inch (psi)

145.038

kilograms/cm2 (kg/cm2)

pounds/square inch (psi)

14.2231

kilopascals (kPa)

98.068

kilograms/cm2

A5-8

Multiply By

To

(kg/cm2)

kilogram (kg)

short ton (tn)

0.0011

metric ton

short ton (tn)

1.1023

liters (l)

quart (qt)

1.0567

liters (l)

gallon (gal)

0.2642

Watts (W)

horsepower (hp)

0.00134

kilowatts (kW)

horsepower (hp)

1.3410

Torque Tables and Conversion Charts

1/13 A05001

TABLE 12. Common Conversion Multipliers English to Metric To

Multiply By

inch (in.)

millimeter (mm)

25.40

inch (in.)

centimeter (cm)

2.54

To Convert From

foot (ft)

meter (m)

0.3048

yard (yd)

meter (m)

0.914

mile (mi)

kilometer (km)

1.61

square centimeters (cm )

6.45

square feet (ft2)

square centimeters (cm2)

929

cubic inches (in.3)

cubic centimeters (cm3)

16.39

cubic inches (in.3)

liters (l)

0.016

cubic feet (ft3)

cubic meters (m3)

0.028

cubic feet (ft.3)

liters (l)

28.3

ounce (oz)

kilogram (kg)

0.028

fluid ounce (fl oz)

milliliter (ml)

29.573

pound (lb)

kilogram (kg)

0.454

pound (lb)

Newton (N)

4.448

inch pounds (in. lb)

Newton meters (N·m)

0.113

foot pounds (ft lb)

Newton meters (N·m)

1.356

foot pounds (ft lb)

kilogram meters (kg·m)

0.138

kilogram meters (kg·m)

Newton meters (N·m)

9.807

pounds/square inch (psi)

kilopascals (kPa)

6.895

square inch

(in.2

2

)

pounds/square inch (psi)

megapascals (MPa)

0.007

pounds/square inch (psi)

kilograms/square centimeter

0.0704

(kg/cm2)

A05001 1/13

short ton (tn)

kilogram (kg)

907.2

short ton (tn)

metric ton (t)

0.0907

quart (qt)

liters (l)

0.946

gallon (gal)

liters (l)

3.785

horsepower (hp)

Watts (w)

745.7

horsepower (hp)

kilowatts (kw)

0.745

Torque Tables and Conversion Charts

A5-9

Celsius C° 121 118 116 113 110 107 104 102 99 96 93 91 88 85 82 79 77 74 71 68 66

250 245 240 235 230 225 220 215 210 205 200 195 190 185 180 175 170 165 160 155 150

TABLE 13. Temperature Conversions Formula: F° - 32  1.8 = C° or C° x 1.8 + 32 = F° Fahrenheit Celsius Fahrenheit Celsius F° C° F° C° 482 63 145 293 4 473 60 140 284 2 464 57 135 275 –1 455 54 130 266 –4 446 52 125 257 –7 437 49 120 248 –9 428 46 115 239 – 12 419 43 110 230 – 15 410 41 105 221 – 18 401 38 100 212 – 21 392 35 95 293 – 23 383 32 90 194 – 26 374 29 85 185 – 29 365 27 80 176 – 32 356 24 75 167 – 34 347 21 70 158 – 37 338 18 65 149 – 40 329 15 60 140 – 43 320 13 55 131 – 46 311 10 50 122 – 48 302 7 45 113 – 51

40 35 30 25 20 15 10 5 0 –5 – 10 – 15 – 20 – 25 – 30 – 35 – 40 – 45 – 50 – 55 – 60

Fahrenheit F° 104 95 86 77 68 59 50 41 32 23 14 5 –4 – 13 – 22 – 31 – 40 – 49 – 58 – 67 – 76

NOTE: The numbers in the unmarked columns refer to temperature in either degrees Celsius (C°) or Fahrenheit (F°). Select a number in this unmarked column and read to the left to convert to degrees Celsius (C°) or read to the right to convert to degrees Fahrenheit (F°). If starting with a known temperature (either C° or F°), find that temperature in the marked column and read the converted temperature in the center, unmarked column.

A5-10

Torque Tables and Conversion Charts

1/13 A05001

SECTION A7 STORAGE PROCEDURES INDEX STORAGE AND IDLE MACHINE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-3 SHORT TERM IDLE PERIODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-3 PREPARATION FOR STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-4 REMOVAL FROM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-5 RECONDITIONING AN IDLE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-7 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-9 AFTER ENGINE HAS STARTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-10 ENGINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-11 Engine Storage-(Short Term) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-11 Engine Storage- (Long Term) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12 ELECTRIC DRIVE TRUCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-13 TRANSMISSION PRESERVATION AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-17 Restoring Transmission to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-17

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NOTES

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STORAGE AND IDLE MACHINE PREPARATION There may be periods when it is necessary for a machine to be idle for an extended period of time. Properly prepared, a stored machine may promptly and safely be put back into operational service. Improper preparation, or complete lack of preparation, can make the job of getting the vehicle back to operating status difficult.

1. Keep the vehicle fully serviced.

The following information outlines the essential proper steps for preparing a unit for extended storage, and the necessary steps to bring it back to operational status. Additional information is given to help restore those machines which were not put into storage, merely shut down and left idle for a long period of time.

3. Operate all hydraulic functions through complete range to insure that cylinder rams and all seals are fully lubricated.

2. On a weekly schedule, perform a visual check of the vehicle, start and run the engine until both the engine and transmission are up to operating temperature. Move the vehicle around the yard for a few minutes to insure that all internal gears and bearings are freshly lubricated.

Much of this material is of a general nature since the environment, where the machine has been standing idle, will play a big part in its overall condition. Hot, humid climate will affect vehicle components much differently than the dry desert atmosphere or a cold arctic environment. These climatic aspects must be considered, and appropriate actions taken when restoring a long term idle vehicle. These instructions are not intended to be all inclusive, but are furnished to provide the minimum guide lines. The final aim should always be to provide the operator with a safe, fully productive vehicle, that he can rely on.

4. Check and operate all systems. 5. Once a month, perform the 10 hour service items shown in the Operation and Maintenance Manuals. Keep batteries properly serviced.

SHORT TERM IDLE PERIODS There will be periods when a vehicle may be idle from 30-60 days, but must be ready for use at all times. The most effective handling of this type situation is to follow the procedure given below to prevent any deterioration from beginning.

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PREPARATION FOR STORAGE For long term idle periods, proper preparation will pay large dividends in time and money when future operation of the vehicle is scheduled.

Refer to Section P, Lubrication and Service, for the proper anti-freeze and conditioner concentrations. After refilling the system, always operate the engine until the thermostats open to circulate the solution through the cooling system.

1. Engine should be prepared for storage according to instructions found in the engine manufacturers manual. 2. The transmission should be prepared for storage. Refer to the instructions in this chapter. 3. The vehicle should be in top operating condition with all discrepancies corrected. Paint should be in good condition with no rust or corrosion. All exposed, machined or unpainted surfaces should be coated with a good rust preventative grease.

Never store a vehicle with a dry cooling system. 8. New hydraulic filters should be installed and the hydraulic tank fully serviced with type C-4 oil as specified in Section P, Lubrication and Service.

4. After the vehicle has been parked in its storage location, all hydraulic cylinders, including Hydrair suspensions, should be retracted as much as possible (steering cylinders centered). Wipe the exposed portion of all cylinder rams clean and, coat (including seals on ends of barrel) with good preservative grease.

Any operating fluid, such as hydraulic oil, escaping under pressure can have sufficient force to enter a person's body by pentrating the skin. Serious injury and possible death may result if proper medical treatment by a physician familiar with this injury is not received, immediately.

5. If long term storage is anticipated, the vehicle should be blocked up with the tires clear of the ground or floor to remove vehicle weight from the tires. Lower air pressure in the tires to 15-25 psi (103-172 kPa). Completely cover the tires with tarpolins to minimize rubber oxidation and deterioration.

9. Disconnect batteries, If possible, batteries should be removed and stored in a battery shop or a cool dry location on wooden blocks. Do not store batteries on a concrete floor. Clean battery compartment, remove all corrosion and paint compartment with acid proof paint.

6. Clean the radiator. Refer to Section C, Cooling System, for proper cleaning instructions. 7. The cooling system should be completely drained, chemically flushed, and refilled with a conditioned water/antifreeze solution suitable for the lowest temperature anticipated.

10. Wheel axle housings and final drives should be fully serviced with prescribed lubricants. Seal all vents. 11. Exhaust openings and air cleaners should be covered tightly with moisture barrier paper and sealing tape. 12. All lubrication points (grease fittings) should be serviced with the prescribed lubricants.

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13. Relieve tension from all drive belts. The engine manufacturer recommends insertion of heavy kraft paper between belts and pulleys to prevent sticking. 14. All vandalism covers and locks should be in place and secured. 15. Cab windows should be closed, locked and sealed and the cab door locked to prevent vandalism and weather effects. 16. The vehicle fuel tanks should be completely drained of fuel, fogged with preservative lubricant, ("NOX-RUST" MOTOR STOR., SAE10) and closed tightly. All fuel filters should be replaced. 17. If at all possible, to aid those who will eventually place the unit back in operation, all available service publications (vehicle, engine and transmission) and a current parts catalog should be packaged in a moisture proof package and placed in the vehicle cab. 18. Be certain water drain holes in the body are open.

4. The cooling system should be completely drained, chemically flushed, and refilled with a conditioned water/antifreeze solution suitable for the lowest temperature anticipated. Refer to Fluid Specifications in Section P, Lubrication and Service, for the proper anti-freeze and conditioner concentrations. After refilling the system, always operate the engine until the thermostats open to circulate the solution through the cooling system. 5. Refer to instructions for returning the transmission to operation at the end of this chapter. 6. Thoroughly inspect all drive belts, hydraulic, air and oil lines for evidence of damage, wear or deterioration. Replace any suspected lines. Don't take chances on ruptures or blow-outs. 7. New hydraulic filters should be installed and the hydraulic tank (reservoir) checked and serviced with type C-4 oil as specified in Section P, Lubrication and Service. 8. Drain on fuel tank should be opened to remove any build up of moisture or sediment that may have accumulated while in storage. Close the drain then fill the fuel tank with approved diesel fuel.

REMOVAL FROM STORAGE If the foregoing preparations were conscientiously followed in placing the vehicle into storage, getting it back to operational status is a simple matter of reversing these steps. NOTE: Before starting the job or restoring a vehicle to operation, obtain copies of the Operation and Maintenance Manual, Engine and Transmission Manuals and/or the Parts Book and follow all special instructions regarding servicing the vehicle and its components. In addition to removing the storage materials, the following actions should be performed.

Never blend gasoline, gasohol and/or alcohol with diesel fuel. This practice creates an extreme fire hazard and under certain conditions may cause an explosion. 9. Make certain that all hydraulic controls, steering linkage, and throttle linkage points are lubricated and operate freely before engine start-up. 10. All electrical connections must be clean and tight. Check secureness of all ground straps and cables.

1. Inspect the entire vehicle carefully for rust and corrosion, correct as necessary. 2. Service the engine according to the Engine Manufacturer's Operation and Maintenance Manual. 3. Clean the radiator. Refer to Section C, Cooling System.

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11. Install fully charged batteries in unit. Clean connectors and connect battery cables. Compartment must be free of corrosion. Secure batteries with hold downs.

12. Check all electrical cables for weathering, cracks and/or damage. Replace any defective cables.

Air pressure must be released from any tires with bad cuts or wear that extends into the plies, before removing from the vehicle. Also, do not allow personnel to stand in removal path of tires. 13. Check all tires, carefully for serviceability and inflate to proper pressure. 14. If disconnected, reconnect the parking brake linkage. 15. Completely service the vehicle as recommended in Section P, Lubrication and Service, for both 10 and 100 hour inspections.

18. Use the Operation and Maintenance Manual for guidance on engine start and vehicle checkout. Make a thorough check of all hose and line connections for leakage when the engine is running.

19. Before moving the vehicle, cycle all hydraulic controls and steering to verify proper operation. Verify proper operation of service brakes, emergency braking system and parking brake. Check all system instruments to insure that all systems are operational. 20. When all systems are operational and all discrepancies are corrected, road test the vehicle in a smooth, level, unobstructed area (with qualified, experienced operator only) to check steering response, transmission shifting, service brake efficiency, and hydraulic functions. Only when it is assured that the vehicle is in safe operational condition should it be turned over to an operator. 21. Fire protection equipment on a machine which has been in storage should be recharged before the machine is returned to service.

16. Adjust all drive belts to the specified tension. 17. Make certain that all hydraulic controls, steering linkage and throttle linkage points are free and properly lubricated before engine start up.

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RECONDITIONING AN IDLE VEHICLE

Never attempt operation of a vehicle which has been standing idle for a long period until all systems which affect steering, brakes, engine, transmission and running gear have been completely reconditioned. An unsafe vehicle can cause serious injuries and/or major property damage DON'T TAKE CHANCES! At times a vehicle is subjected to long idle periods without being properly serviced for storage - merely shut down and left to the elements for an extended period. Reconditioning of this vehicle can and does present a major expenditure of time and money when it is to be put into operating condition. 1. Remove all trash and thoroughly clean the vehicle before starting any inspection or maintenance. 2. Remove vehicle batteries and move to battery shop for service and charging or replacement as necessary.

3. Inspect tires thoroughly for tread and side wall condition, weathering, cuts and cracks. a. Any tire suspected of being unserviceable should be dismounted and thoroughly inspected inside and out before being inflated.

Do not mix rim parts of different rim manufacturers. Rim parts may resemble those of a different manufacturer, but the required tolerances may be wrong. Use of mismatched rim parts is hazardous. b. If tires are dismounted, all wheel components must be cleaned, inspected, all rust and corrosion removed and parts repainted as applicable before remounting the tires. Follow the safety rules when mounting and inflating tires. c. Mount and inflate tires as shown in the service manual. 4. Inspect vehicle service brakes, carefully.

Before disabling the brake circuit, block all wheels to prevent possible movement of the vehicle. The use of vapor degreasing or steam cleaning is not recommended, either for brake assemblies or the component parts. Corrosion and rusting may occur. a. All brake lines and connections must be clean, serviced and free of rust and corrosion. b. Treadle valves must operate smoothly and show no internal or external damage or contamination. Leakage limitations are shown in Section J, Brake System. Do not disassemble an inflated tire. Remove valve core slowly, and allow pressure to bleed off before attempting to remove the lockring. Also, eye protection should be worn during tire deflation to protect against any foreign object being projected into the eyes.

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c. The parking brake actuator must cycle smoothly when actuated by the parking brake valve.

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5. The vehicle engine should be inspected and serviced according to the Engine Manufacturer's Operation And Maintenance Manuals. a. Insure that exhaust is clear and clean with no foreign materials. If water entry is suspected, disconnect air tubes at the turbochargers to check for water damage before attempting startup. b. Replace fuel filters. Fill filter cans with fresh fuel for engine priming.

Have a new safety filter (secondary) filter element on hand before removing old one. Do not keep intake system open to atmosphere any longer than absolutely necessary. c. Remove and replace both the primary and safety filter (secondary) elements in the air cleaners. Check all intake lines between air cleaners and engine. All clamps must be tight. d. The tubes in the precleaner section of the air cleaner assembly should be inspected; all tubes should be clear and clean. Use a light to inspect the tubes. The light should be visible. If clogging is evident, the precleaner must be cleaned. Clean the precleaner according to instructions in Section C. e. Drain and flush the engine cooling system. Fill with coolant and inhibitors after checking all lines, hoses and connections. Refer to Section P, Lubrication and Service, for antifreeze recommendations. Radiator cores must be clear of dirt and trash.

To prevent injuries, always release spring tension before replacing the fan belt. f. Check and tighten engine fan drive belts, and install a new belt set if necessary. g. Check and tighten the engine mounts. 6. Inspect and service the transmission according to the Transmission service manual. NOTE: If a hydraulic pump or the engine is inoperative, the dump body should be raised with a crane so body holding devices can be installed.

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a. Check all transmission electrical connections for corrosion, cleanliness and tightness. Check electrical cables for weathering, damage and proper clamping. b. Check drive lines for worn U-joints and proper hardware torque. c. Check the condition of the transmission mounts. 7. If fuel was left in the tank, it must be removed. Do not attempt to use old diesel fuel. a. With the tank empty, remove inspection plates and thoroughly check the interior of the tank; clean if necessary to remove sediment and contamination. If the fuel was contaminated, the lines should be disconnected and blown clear. b. Check all fuel lines for deterioration or damage. Replace lines as necessary. c. Replace inspection covers, and install new gaskets. d. Fill the tank with specified diesel fuel. e. Replace fuel filters.

Any operating fluid, such as hydraulic oil or brake fluid escaping under pressure, can have sufficient force to enter a person's body by penetrating the skin. Serious injury and possible death may result if proper medical treatment by a physician familiar with this injury is not received, immediately. 8. The hydraulic tank should be drained. If oil is not contaminated and is stored in clean containers, it may be reused if filtered through 3-micron filter elements when being pumped back into the tank. Do not attempt to use contaminated hydraulic oil, especially if water entry into the system is suspected. NOTE: If filling is required, use clean hydraulic oil only. Refer to the Lubrication chart in Section P, Lubrication and Service, for proper oil specifications. a. Replace hydraulic filter elements and clean suction strainer elements. While suction strainers are removed, inspect and clean the interior of the tank thoroughly to remove all sediment and foreign material. b. Inspect all hydraulic lines for deterioration or damage. Replace suspect lines - don't risk hose ruptures or blow outs.

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c. Check all hydraulic components - pumps, valves and cylinders for damage and corrosion. Secure all mountings and connections. Control valves in the cab must be free moving with no binding.

ENGINE OPERATION

d. Check exposed portions of all hydraulic cylinder rams for rust, pitting and corrosion. If plating is deteriorated, the cylinder should be removed and overhauled or replaced; pitted or scored plating will cause leakage at the cylinder seals.

Insure that all tools and loose equipment have been removed prior to engine start-up. Sound horn prior to engine start. Make sure emergency shut down is reset. Cables must be free moving in their housings.

9. Check the front wheel hub, final drive and wheel axle lubricant. If contamination is suspected, oil should be drained completely and the component serviced with clean prescribed lubricant. If major contamination is present, disassembly and overhaul will be in order.

When all reconditioning operations have been completed, a static check of engine operation along with operation of systems as well as verification of braking and steering must be done before the vehicle is moved.

10. Check the parking brake. Since it is springapplied, the brake pads may be stuck tightly to the disc, it may be necessary to remove and overhaul the parking brake assembly. 11. Lubricate all grease fittings with prescribed lubricants which are not part of the automatic lubrication system. All pivot points must be free of any binding. 12. Check the alternator for corrosion or deterioration. The alternator rotor must be free, with no binding or roughness. Inspect, install and properly tension the alternator drive belts. 13. Check secureness of steering cylinder ball joints, link, and hydraulic connections. 14. Examine Hydrair suspensions for signs of damage. a. Discharge nitrogen from suspensions as outlined in Section H. Check the condition of the suspension oil and cylinder wipers. If wipers are cracked or hardened, the suspension must be rebuilt. Recharge the suspension with new oil if old oil is deteriorated. b. Check exposed chrome portions of the cylinder for rust, pitting and corrosion. If plating is deteriorated the suspension should be removed and overhauled or replaced; pitted or scored plating will rapidly cause leakage at the seals. c. Recharge suspensions as outlined in the service manual. 15. If not previously done, install fully charged batteries and completely charge air tank (if equipped) with shop air.

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1. Insure all personnel are clear of equipment before starting engine. Always sound the horn as a warning before actuating any operational controls.

Before starting engine, clear the immediate area of personnel and obstructions. Never start the engine in a building unless the doors and windows are open and ventilation is adequate. 2. Turn key switch ON. Warning lights for low brake, and steering pressure should illuminate and the horn should sound. If the horn does not sound, check all components in the circuit and correct the discrepancy before continuing. 3. Start the engine, and watch the engine oil pressure gauge; if pressure does not show on the gauge within 10 - 15 seconds, shut down the engine and locate the problem.

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4. While the engine is warming up, check the engine and related components for any leaks. Check the hydraulic pump for leakage as well as all hydraulic lines. 5. Listen for any abnormal engine noises. 6. Check the transmission and piping for leakage. If leakage is evident, shut down the engine and correct before continuing the checkout. Listen for unusual sounds, which may indicate problems in components. 7. When the engine is up to operating temperature, check operation of the throttle circuit acceleration should be smooth. Watch the gauges closely for any abnormal activity. Proper temperatures and pressures are shown in the Engine Operation and Maintenance Manual.

AFTER ENGINE HAS STARTED Any machine which is unsafe and/or not in top operating condition should not be assigned to an operator for production use. 1. Become thoroughly familiar with steering and emergency controls. Test the steering in extreme right and left directions. If the steering system is not operating properly, shut the engine down, immediately. Determine the steering system problem and have repairs made before resuming operation. 2. Operate each of the brake circuits at least twice prior to operating and moving the machine. These circuits include individual activation of the service brake and parking brake from the operator's cab. a. Activate each circuit individually with the engine running and with the hydraulic circuit fully charged. b. If any application or release of any brake circuit does not appear proper or if sluggishness is apparent on application or release, shut the engine down and notify maintenance personnel. Do not operate the machine until the brake circuit in question is fully operational.

3. Check gauges, warning lights and instruments before moving the machine to insure proper system operation and proper gauge functioning. Give special attention to braking and steering circuit warning lights. If warning lights come on, shut down the engine immediately and determine the cause. 4. Cycle hoist controls and steering several times to remove trapped air. Complete steering cycles in both directions to verify steering response, smoothness and reliability. Check seals and lines for leaks. 5. When satisfied that all discrepancies have been corrected, the vehicle is ready for a road test. This test should be done only by a capable and experienced operator and should be accomplished in a large open area where plenty of maneuvering room is available. Some of the road test items which should be covered will include: a. Repeated test of braking efficiency at progressively higher speeds. Start at slow speeds. Don't take chances with higher speeds until the machine has been determined to be completely safe. b. Progressive upshifting and downshifting through all speed ranges to insure proper transmission shifting and synchronization. 6. When all tests and checks have been made and the vehicle is ready for work, it should be visually rechecked and fully serviced according to Section P, Lubrication and Service.

Some of the conditions (others may be found) which might be encountered after a machine has been exposed to the elements for a long period would include: • Increased corrosion and fungus growth on electrical components in humid/tropical areas. • Accelerated rust formation in humid climates. • Increased sand and dust infiltration in windy, dry dusty areas. (These conditions can approach sand blasting effects.) • Deterioration of rubber products in extreme cold areas. Cables, hoses, O- rings, seals and tires may become weather checked and brittle. • Animal or bird's nests in unsealed openings.

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ENGINE STORAGE Engine Storage-(Short Term) 1 Month to 6 Months

11. Disconnect the electrical wiring from the fuel pump solenoid.

This procedure describes the proper method for the short term storage of an engine.

12. Turn the fuel pump manual shutoff valve counterclockwise until it stops.

Prepare the Engine for Short Term Storage

13. Crank the engine slowly. Spray lubricating oil into the intake manifold and the inlet of the air compressor.

1. Operate the engine at high idle until the coolant temperature is 160° F (70° C).

14. Cover all of the openings with tape to prevent dirt and moisture from entering the engine.

2. Turn the engine off.

15. Drain the coolant.

3. Disconnect the fuel lines to the engine fuel filter and the injector return line. 4. Use a preservative oil. Use Dauber T Chemical NoxRust No. 518, or equivalent. The oil must meet Military Specification MIL-L-644, Type P9. 5. Fill two containers, one with diesel fuel, and the second with preservative oil. Put both fuel lines in the container of diesel fuel.

NOTE: It is not necessary to drain the coolant if it is a permanent type antifreeze with a rust inhibitor. 16. Store the engine in an area that is dry and has a uniform temperature. 17. Bar turn the Crankshaft two or three revolutions every 3 to 4 weeks.

6. Start the engine. 7. After the engine is operating smoothly, transfer the fuel supply line to the container of preservative oil. Operate the engine until the preservative oil flows out of the injector return line. 8. Turn the engine off. Connect the fuel lines to the fuel filter and the injector return line. 9. Drain the oil pan sump, oil filters, and fuel filters. 10. Install the drain plugs in the oil sump. The sump can remain empty until the engine is ready to be returned to service.

Remove the Engine from Short Term Storage 1. Prime the lubricating system. Refer to Cummins Engine Shop Manual, (Section 14-01, Engine Run-in-Period). 2. Fill the coolant system if necessary. 3. Adjust the injector and the valve clearance. Refer to Cummins Engine Shop Manual, (Section 00-02, Engine Assembly). 4. Tighten the intake manifold mounting cap screws to specified torques, refer to the Cummins Service Manual for specifications.

Put a warning tag on the engine. The tag must indicate:

5. Fill the oil pan sump, oil filters, and fuel filters with recommended lubricants and fuels.

• The engine does not contain oil. • Do not operate the engine.

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Engine Storage- (Long Term) 6 Months to 24 Months This procedure describes the proper method for the long term storage of an engine.

Prepare the Engine for Long Term Storage 1. Operate the engine at high idle until the coolant temperature is 160° F (70° C). 2. Turn engine off. 3. 3. Drain the oil. Install the drain plugs. Use Shell 66202 or equivalent, preservative oil. The oil must meet Military Specification MIL-L-21260, Type P-10, Grade 2, SAE 30. Fill the engine to the "HIGH" mark. 4. Disconnect the fuel lines to the engine fuel filter and the injector return line. 5. Use Daubert Chemical NoxRust No. 518, or an equivalent preservative oil. The oil must meet Military Specification MIL- L- 644 Type P9. 6. Fill two (2) containers: one with diesel fuel, the second with preservative oil. Put both fuel lines in the container of diesel fuel. 7. Start the engine. 8. After the engine is operating smoothly, transfer the fuel supply line to the container of preservative oil. Operate the engine until the preservative oil flows out of the injector return line. 9. Turn the engine off. Connect the fuel lines to the fuel filter and the injector return. 10. Drain the preservative oil from the engine oil pan sump, the air compressor and the oil filters. 11. Remove the intake and exhaust manifolds. Spray preservative oil into the intake and exhaust ports in the cylinder heads and in the manifolds. 12. Spray preservative oil in the intake port on the air compressor. 13. Use a rust preventative compound that meets Military Specification MIL-C-16173C, Type P-2, Grade 1 or 2. Brush or spray the compound on all of the exposed surfaces that are not painted.

Put a WARNING tag on the engine. The tag must indicate: • The engine has been treated with preservatives. • Do not bar turn the crankshaft. • The coolant has been removed. • The date of treatment. • Do not operate the engine. 16. Store the engine in an area that is dry and has a uniform temperature.

Remove the Engine from Long Term Storage 1. Use clean diesel fuel. Flush the fuel system until all of the preservative oil is removed. 2. Remove the plug from the main oil rifle passage. Use a hot, lightweight mineral oil. To flush all of the preservative oil from the engine: Bar the engine crankshaft three to four revolutions during the flushing procedure. 3. Fill the oil pan sump, oil filters, and fuel filters. 4. Drain the rust preventative compound from the cooling system. Fill the cooling system with coolant. 5. Prime the lubricating system. Refer to Cummins Engine Shop Manual, (Section 14-01, Engine Run-in-Period). 6. Adjust the injector and the valve clearance. Refer to Cummins Engine Shop Manual, (Section 00-02, Engine Assembly). 7. Tighten the intake manifold mounting cap screws.

14. Remove the rocker lever covers. Spray the rocker levers, the valve stems, the springs, the valve guides, the crossheads, and the push rods with preservative oil. Install the covers. 15. Cover all the openings with heavy paper and tape to prevent dirt and moisture from entering the engine.

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ELECTRIC DRIVE TRUCKS Storage Instructions and Procedures

Placing Equipment Into Storage

This instruction provides the recommended procedures for protecting equipment from damage during both short-term and long-term storage periods and for maintaining adequate protection while in storage. Also included are instructions for placing this equipment into service after having been stored.

Perform the following instructions when preparing General Electric equipment for storage. There are three main equipment categories to consider:

For the purposes of this instruction, a short-term storage period is considered to be less than three months; a long-term storage period is considered to be three months or longer. General Electric recommends a maximum storage period of three years, with these storage procedures being repeated after each year. After a storage period of three years or more, the Motorized Wheels should be removed and sent to an overhaul facility for teardown and inspection of seals and bearings. These should be replaced if necessary. Periodic (every three months) inspections should be made to determine the lasting qualities of long-term storage protection measures. Such inspections will indicate the need for renewing protective measures when necessary to prevent equipment deterioration. Proper storage of this equipment is vital to equipment life. Bearings, gears, and insulation may deteriorate unless adequate protective measures are taken to protect against the elements. For example, bearings and gears in the Motorized Wheel gear case are susceptible to the formation of rust; insulation in rotating electrical equipment can accumulate moisture; and bearings may become pitted.

NEVER APPLY ANY SPRAY, COATING OR OTHER PROTECTIVE MATERIALS TO AREAS NOT SPECIFICALLY RECOMMENDED. It is also important to note that these instructions cannot possibly anticipate every type of storage condition and, therefore, cannot prevent all equipment deterioration problems caused by inadequate storage. However, these instructions should be considered as a minimum procedure to achieve the best possible equipment life and the lowest operating cost when the equipment is returned to service. NOTE: Local conditions and/or experience may require ADDITIONAL procedures and/or additional storage precautions.

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1. When storing a truck that is operational. 2. When storing a truck that is not operational. 3. When storing major components (Motorized Wheel, alternator, etc.). These three major categories are the basis for determining required protective measures. NOTE: In addition to these instructions, refer to truck storage instructions. When Storing A Truck That Is Operational When a fully operational truck is being placed into storage for less than three months, the best protective measure which can be taken is to drive the truck once a week for at least 30 minutes. Prior to driving the truck, the rotating equipment should be Meggered and: 1. If greater than 2 megohms, run normally. 2. If less than 2 megohms, isolate condition and correct before running. Driving the truck circulates oil in the gear case to keep gears and bearings lubricated and free from rust. It also prevents deterioration of the brushes, commutators and slip rings. When a fully operational truck is being placed into storage for three months or longer, and the truck cannot be operated weekly throughout the storage period as indicated above, perform the following instructions: 1. Drain oil from the gear case and install rust preventive 4161 (product of Van Straaten Chemical Co.)or equivalent. Fill per General Electric Motorized Wheel Service Manual. 2. Megger the wheels as indicated in the instructions above. Operate the truck for at least 30 minutes to insure that the rust preventive compound has been thoroughly circulated throughout the gear case. Stop the truck and drain the rust preventive compound. NOTE: Do not run a LOADED truck with rust preventive compound in Motorized Wheel gear cases.

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When Storing A Truck That Is Not Operational

Do not operate trucks without oil in the Motorized Wheel gear cases. 3. Perform a megohmmeter test. Refer to the truck's Vehicle Test instructions for the correct procedure. Record the Megger readings for future reference. They will be helpful in determining if deterioration is being experienced when additional Megger tests are made as part of the periodic inspection. 4. Lift all brushes in the Motorized Wheels, blowers and the alternator. They must be removed from the brush holder. Disconnecting brush pigtails is not required. 5. Cover any open ductwork with screening material to prevent rodents from entering. Then tape over the screen to prevent the entry of water and dirt (allow breathing). 6. Examine all exposed machined surfaces for rust or other dirt accumulation. Remove all dirt as necessary. Remove rust by using a fine abrasive paper. Old flushing compound can be removed with mineral spirits (GE-D5B8). Methanol should be used to remove all residue. When clean, coat with Tarp B rust preventive. Refer to General Electric Motorized Wheel Service Manual for specifications.

When a truck which is not fully operational is being stored for a period of any length, perform the following: 1. Drain the oil from the gear case and install rust preventive compound 4161 (or equivalent). Fill per General Electric Motorized Wheel Service Manual. 2. Jack each side of the truck (one side at a time) enough to rotate the tires. 3. Connect a D-C welder as described in the Vehicle Test Instructions (Wheel Motor inst. 400A, arm & field in stress 900- 1000 rpm arm). 4. Rotate each Motorized Wheel (one at a time) for at least 30 minutes to insure that the rust preventive compound has been thoroughly circulated throughout the gear case. Disconnect the welder. Remove the jacks. Drain the gear case. 5. If the truck is partially dismantled, pay careful attention to ductwork, blower shrouds, etc., which may be exposed to weather conditions as a consequence. These areas will require the same sealing measures as in Step 5 above which deals with protecting ductwork. Cover exposed blower housings to prevent entry of water and dirt. 6. Perform Steps 3 through 11 under When Storing a Truck that is Operational.

7. Loosen exciter drive belts (where applicable). 8. Open all switches in the control compartment.

When Storing A Major Component

9. Install a 500 watt heat source inside all control groups which house electronic control equipment. These heat sources are to be energized below 32° F (0° C) and de-energized above 41° F (5° C).

When storing a Motorized Wheel, alternator, blower or control group for a period of any length, always store it inside a warm, climate-controlled environment. Do not attempt to store individual components where they would be exposed to inclement weather, climatic changes, high humidity and/or temperature extremes.

10. Install a 500 watt heat source inside the commutator chamber of both Motorized Wheels and inside the alternator slip ring chamber. This will minimize the accumulation of moisture. A hole in the bottom of the hubcap will accommodate the electrical cord for the heat source in the Motorized Wheels. These heat sources are to be energized continuously. 11. Seal compartment doors with a weatherproof tape to prevent entry of rain, snow and dirt (allow breathing).

A7-14

Storage Procedures

A07006

Periodic Inspections It is important that periodic inspections (every three months) of stored equipment be performed to insure the continued serviceability of all protective measures initially taken when the storage period began. Items which should be checked at each inspection interval are listed as follows: 1. Remove the weatherproof tape from the compartment doors and preform a Megger test as described in the Vehicle Test Instructions. Record the test results and compare them with the recorded Megger readings taken when storage first began, and those taken throughout the storage period. Remove all test equipment and close up the compartment. Reseal the compartment doors with new weatherproof tape. If Megger readings indicate a deterioration of insulation quality, to below 2.0 megohms then consideration should be given to providing more protection. 2. Check all other weatherproofing tape. Replace any that has become loose or is missing completely. 3. Check all heat sources. Replace or repair any units which have become inoperative. 4. Check all machine surfaces which were coated with flushing compound when storage began. If compound appears to be deteriorating, it must be cleaned off and renewed. Placing Equipment Into Service After Storage When taking equipment out of storage, perform the following procedures:

amount oil to be used. This oil should be drained and new oil should be added after 500 hours of operation. 5. Clean all Motorized Wheel grease fittings in the axle box. Insure that all grease lines are completely full of grease. Then add the recommended amount of grease to all fittings. 6. Install brushes in the Motorized Wheels, blowers and the alternator. Make sure that brushes move freely in their carbonways and that they have enough length to serve until the truck's next inspection period. Install new brushes if necessary. Insure that all brush pigtail screws are tight. 7. Perform a megohmmeter test. Refer to the truck's Vehicle Test Instructions for the correct procedure. If Megger readings are less than 2.0 megohms, the problem could be an accumulation of moisture in motor or alternator. If this is the case, the faulty component will have to be isolated and dried out using procedures recommended in the G.E.Service Manual. 8. Perform a thorough inspection of the Motorized Wheels, alternator, blowers and control compartments. Look for: a. Rust or dirt accumulation on machine surfaces b. Damaged insulation c. An accumulation of moisture or debris d. Loose wiring and cables e. Any rust on electrical connectors in the control compartment

When A Truck Is Operational

f. Any loose cards in the card panels

If a truck has been operated weekly throughout the storage period, perform a complete visual inspection of the Motorized Wheels, blowers, alternator and control compartments. Repair any defects found, then place the truck directly into service.

g. Any accumulation of moisture or debris in ductwork.

When A Truck Is Not Operational If the truck was not operated weekly throughout the storage period, perform the following procedures: 1. Remove all weatherproofing tape from control compartment doors and ductworks. 2. Remove all screening material from ductwork. 3. Remove all heat sources from Motorized Wheels, control compartments and the alternator.

Clean and make repairs as necessary. 9. Check retarding grids and insulators for loose connections and dirt accumulation. Clean and make corrections as necessary. 10. Where applicable, check exciter drive belts for cracks, and deterioration. If acceptable, set belt tension to specification. 11. Before starting engine, turn on control power. Check that contactors and relays pick up and drop out normally.

4. Fill with recommended oil. Refer to the Motorized Wheel Service Manual for the type and

A07006

Storage Procedures

A7-15

12. Perform a start-up procedure on the complete system to insure maximum performance during service. Refer to the truck's Vehicle Test Instructions for the complete test procedure.

For The First Hour After all storage protection has been removed, the truck has been cleaned and inspected and repairs made as necessary, the Motorized Wheel gear case has been filled with new oil, the dirt seals have been completely purged with new grease and the system completely checked, the truck can be placed into service. It is recommended, however, that the truck be driven unloaded at a low speed (10 mph) for the first hour of operation.

A7-16

Storage Procedures

A07006

TRANSMISSION PRESERVATION AND STORAGE

5. Continue running the engine at 1500 rpm with the transmission in neutral until normal operating temperature is reached.

Storage, New Transmission (Prior to installation). New transmissions are tested with preservative oil and drained prior to shipment. The residual oil remaining in the transmission provides adequate protection to safely store the transmission for up to one year (stored inside the conditions of normal climate and with all shipping plugs installed) without further treatment. Preservation Methods. When the transmission is to be stored or remain inactive for an extended period (one or more years), specific preservation methods are recommended to prevent damage due to rust, corrosion, and organic growth in the oil. Preservation methods are presented for storage with and without transmission fluid.

If the unit does not have a converter-out temperature gage, do not stall the converter. 6. If normal operating temperature is less than 225° F (107° C), shift the transmission to the highest forward range and stall the converter.When the converter-out temperature reaches 225° F (107° C), stop the engine. Do not exceed 225° F (107° C). 7. As soon as the transmission is cool enough to touch, seal all openings and the breather with moisture-proof tape. 8. Coat all exposed, unpainted surfaces with preservative grease such as petrolatum (MIL-C11796, Class 2).

Storage, One Year -- Without Oil 1. Drain the oil. 2. Spray two ounces (60 milliliters) of VCI #10 through the fill tube. 3. Seal all openings and the breather with moisture-proof tape. 4. Coat all exposed, unpainted surfaces with preservative grease such as petroleum (MIL-C11796, Class 2). 5. If additional storage time is required, repeat steps (2), (3) and (4) at yearly intervals.

9. If additional storage time is required, repeat steps (2) through (8) at yearly intervals; except, it is not necessary to drain the transmission each year. Just add Motorstor and Biobor Jf (or equivalents).

Restoring Transmission to Service 1. Remove all tape from openings and the breather. 2. Wash off all external grease with mineral spirits.

Storage, One Year With Oil (normally in a vehicle chassis) 1. Drain the oil and replace the oil filter element(s). 2. Fill the transmission to operating level with a mixture of one part VCI #10 (or equivalent) to 30 parts C-3 transmission fluid. Add 1/4 teaspoon of Biobor JF (or equivalent) for each 3 gallons (11 liters) of fluid in the system. NOTE: When calculating the amount of Biobor JF required, use the total volume of the system, not just the quantity required to fill the transmission. Include external lines, filters, and the cooler.

3. If the transmission is new, drain the residual preservative oil. Refill the transmission to the proper level with C-4 transmission fluid. 4. If the transmission was prepared for storage without oil, drain the residual oil and replace the oil filter elements. Refill the transmission to the proper level with C-4 transmission fluid. 5. If the transmission was prepared for storage with oil, it is not necessary to drain and refill the transmission with new transmission fluid. Check for proper fluid level. Add or drain transmission fluid as required to obtain to proper level.

3. Run the engine for approximately five minutes at 1500 rpm with the transmission in neutral. 4. Drive the vehicle. Make sure the transmission shifts through all ranges. Make sure the lockup clutch is working.

A07006

Storage Procedures

A7-17

NOTES

A7-18

Storage Procedures

A07006

SECTION B STRUCTURES INDEX STRUCTURAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-1

DUMP BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1

B01022

Index

B1-1

NOTES:

B1-2

Index

B01022

SECTION B2 STRUCTURAL COMPONENTS INDEX 1 STRUCTURAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3 LADDERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4 RIGHT DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6 LEFT DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-7 CENTER DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-7

B02031 8/08

Structural Components

B2-1

NOTES:

B2-2

Structural Components

8/08 B02031

STRUCTURAL COMPONENTS The 830E deck components are removable in sections as shown in Figure 2-1. The following removal and installation instructions detail the steps to be taken before the decks and hood can be removed. Additional steps may be required before the deck or another major structure is removed, depending on optional equipment installed on the truck at the factory or after delivery.

The anti-slip material on the decks must be inspected and maintained for the safety of all personnel.

Prior to removal or repair procedures, it may be necessary to remove the body to provide clearance for lifting equipment to be used. If body removal is not required, the body must be raised and the safety cables installed at the rear of the truck.

• Before performing any welding on the truck, always turn the battery disconnect switches to the OFF position and disconnect the alternator positive cable. Failure to do so may seriously damage the battery and electrical equipment. It is not necessary to disconnect or remove any control circuit cards on electric drive dump trucks or any of the Alarm Indicating Device (AID) circuit control cards. Always fasten the welding machine ground (-) lead to the piece being welded; the grounding clamp must be attached as near as possible to the weld area. Never allow welding current to pass through ball bearings, roller bearings, suspensions, or hydraulic cylinders. Always avoid laying welding cables over or near the vehicle electrical harnesses. Welding voltage could be induced into the electrical harness and cause damage to components.

Read and observe the following instructions before attempting any repairs!

• DO NOT attempt to work in deck area until body safety cables have been installed. • DO NOT step on or use any power cable as a handhold when the engine is running. • DO NOT open any electrical cabinet covers or touch the retarding grid elements until all shutdown procedures have been followed. • All removal, repairs and installation of propulsion system electrical components, cables etc. must be performed by an electrical maintenance technician properly trained to service the system. • In the event of a propulsion system malfunction, a qualified technician must inspect the truck and verify the propulsion system does not have dangerous voltage levels present before repairs are started.

After the truck is parked in position for the repairs, the truck must be shut down properly to ensure the safety of those working in the areas of the deck, electrical cabinet and retarding grids. The following procedures will ensure the electrical system is properly discharged before repairs are started.

B02031 8/08

•

All hoses and mating fittings must be capped as they are removed to prevent possible system contamination.

•

It is important to tag and visually verify all cables, harnesses, hoses etc. have been removed before the structure is lifted off the truck.

•

For cab removal instructions, refer to Section N, Truck Cab, in this manual.

Preparation 1. Reduce the engine speed to idle. Place the selector switch in PARK. Ensure the parking brake applied indicator lamp in the overhead panel is illuminated. 2. Place the drive system in the rest mode by turning the rest switch on the instrument panel ON. Ensure the rest warning lamp is illuminated. 3. Shut down the engine using the key switch. If, for some reason the engine does not shut down, use the shutdown switch on the center console.

Structural Components

B2-3

4. Verify the link voltage lights are off. If they remain on longer than 5 minutes after shutdown, notify the electrical department.

5. Disconnect ladder light wiring and any other wiring harnesses, hoses, etc. that may be attached.

5. Verify the steering accumulators have bled down by attempting to steer.

6. Remove mounting hardware and lift ladder off truck.

6. Bleed down the brake accumulators using the manual bleed valves on the brake manifold. Installation

7. Open the battery disconnect switches.

LADDERS A diagonally mounted ladder (7, Figure 2-1) provides an easy and safe path for the operator to mount and dismount the truck. In addition, vertical ladders (6) are available as additional exits from the cab if necessary. Anti-skid material is placed at various places on the decks and ladder platform area. Ensure this material is in good condition and replace when worn.

Perform the removal proceduress in reverse order for installation of components. Tighten all attaching hardware to standard torque values listed in Section A. Reinstall all wiring and hoses removed and be certain all clamps are installed and secure.

RIGHT DECK The diagonal ladder must be removed from the truck if it becomes necessary to remove the radiator or the complete power module for major repairs. When removing the ladder(s), check to ensure all wiring and hoses which may be attached to the structure have been removed. NOTE: Some trucks may be equipped with different boarding equipment than shown in Figure 2-1. Refer to Options Section for additional information.

The procedure below describes the sequence to follow for complete removal of all the right hand deck components. If complete disassembly is not required, select the appropriate steps for removal of the desired component. Additional removal of equipment, wiring, hoses etc. may be required depending on optional factory installed and field installed equipment. Refer to Figure 2-1 for location and nomenclature of parts described.

Removal Before performing deck removal or repairs, ensure the battery disconnect switch is open and all hydraulic pressure has been released prior to removing any hoses, electrical harness connectors, etc.

1. Shut down engine following all the procedures listed on page B2-3 in this section of the manual.

Removal

3. Remove clamps and electrical cables.

2. Open battery disconnect switch located in the isolation at the battery box on the front bumper.

1. Remove handrails (8, Figure 2-1) attached to diagonal ladder handrail and the platform.

a. Remove power cables routed to retarding grids (3, Figure 2-2).

2. Attach a lifting device to ladder structure (7). 3. Remove all attaching hardware and lift diagonal ladder from mounts.

b. Remove all 24 volt wiring (clearance lights, ground straps, etc.) that will interfere with deck and ladder removal.

4. If vertical ladder removal is necessary, attach a lifting device to ladder structure (6).

c. Remove hoses or wiring routed to optional equipment; fire suppression system etc.

B2-4

Structural Components

8/08 B02031

FIGURE 2-1. ACCESS LADDERS AND DECKS 1. Right Deck 2. Center Deck 3. Left Deck Components

B02031 8/08

4. Deck Handrail 5. Platform 6. Vertical Ladder

Structural Components

7. Diagonal Ladder 8. Ladder Handrail 9. Grille Structure

B2-5

• Ensure all electrical connections and harness clamps are reinstalled and secure. • Replace plugs covering deck mounting hardware to prevent dirt accumulation.

All propulsion system power cables must be properly secured in their wood or other non-ferrous cable cleats. If clamps are cracked and broken, oil soaked or otherwise damaged, replace them with new parts. Inspect cable insulation and replace cable if insulation is damaged.

LEFT DECK

FIGURE 2-2. RH DECK MOUNTING 1. Right Deck Structure 2. Mounting Hardware 3. Retard Grid Package

4. Diagonal Ladder Structure

4. Attach overhead hoist to lifting eyes on grid package (3). 5. Remove hardware attaching grid package to the deck, lift assembly off deck and move to storage or work area. NOTE: If grid assembly or cooling blower repairs are required refer to applicable G.E. publication for service and maintenance procedures. 6. Install lifting device at eyes at each corner of the deck and take up slack. DO NOT attach lifting device to the hand rail structure.

Removal NOTE: The left deck mounting arrangement is nearly identical to the right deck. Refer to Section N, Truck Cab, for cab removal and installation instructions. Refer to Figure 2-1 for the location of individual sections. 1. Shut down engine following all the procedures listed on page B2-3 of this Section of the manual. 2. Ensure the brake system accumulators have been bled down to release pressure. 3. Tag and disconnect all hydraulic lines and electrical cables which will interfere with deck removal. Cap all lines to prevent entrance of foreign material.

7. Remove plugs covering deck mounting hardware (see Figure 2-2). 8. Verify all wiring harnesses, cables or hoses have been removed. Carefully raise deck and remove from deck supports. Installation Perform the removal procedures in reverse order for installation of the deck and components. Tighten all attaching hardware to standard torque specifications as listed in Section A, Standard Torque Chart and Tables. • Clean all mount installation.

mating

surfaces

before

• Clean mounting area before installing ground cables.

B2-6

If equipped with air conditioning and air conditioning system components are to be removed, refer to Section N, Operator Comfort, for special instructions on discharging the air conditioning system prior to disconnecting any air conditioning lines. 4. Install lifting device to lift eyes at each corner of the deck and take up slack. DO NOT attach lifting device to the hand rail structure. 5. Remove deck mounting hardware at frame support and front upright.

Structural Components

8/08 B02031

6. Verify all wiring harnesses, cables or hoses have been removed. Carefully raise deck and remove from deck supports.

CENTER DECK Center deck removal only requires removal of any attached hoses cables etc. before removing the mounting hardware and lifting the deck structure off. Follow proper shutdown described on page B2-3.

Installation

procedures

as

Perform the removal procedures in reverse order for installation of the deck and components. Tighten all attaching hardware to standard torque specifications as listed in Section A, Standard Torque Chart and Tables. • Clean all mount installation.

mating

surfaces

before

• Clean mounting area before installing ground cables. • Ensure all electrical connections and harness clamps are reinstalled and secure. • If the air conditioning system has been discharged, refer to Section N, Operator Comfort, for the correct procedure for system service. 1. Start engine and allow systems to charge. Observe for any air or oil leaks. Ensure all shields, covers and clamps are in place. 2. Service the hydraulic reservoir if required. Check for proper operation of the steering and brake systems, including dynamic retarding.

B02031 8/08

Structural Components

B2-7

NOTES:

B2-8

Structural Components

8/08 B02031

SECTION B3 DUMP BODY INDEX

DUMP BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4 BODY PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6 BODY GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7 BODY-UP RETENTION CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-8 BODY POSITION INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-8 HOIST LIMIT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-8 BODY UP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-8 ROCK EJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-9 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-9

B03027 7/11

Dump Body

B3-1

NOTE:

B3-2

Dump Body

7/11 B03027

DUMP BODY 1. Park truck on a hard, level surface and block all the wheels. Connect cables and lifting device to the dump body and take up the slack as shown in Figure 3-1.

Removal

2. Remove mud flaps and rock ejectors from both sides of the body. Remove electrical cables, lubrication hoses, etc, attached to the body.

Inspect all lifting devices. Slings, chains, and/or cables used for lifting components must be inspected daily for serviceable condition. Refer to the manufacturer's manual for correct capacities and safety procedures when lifting components. Replace any questionable items. Slings, chains, and/or cables used for lifting components must be rated to supply a safety factor of approximately 2X the weight being lifted. When in doubt as to the weight of components or any assembly procedure, contact the Komatsu area representative for further information. Lifting eyes and hooks should be fabricated from the proper materials and rated to lift the load being placed on them. 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, be sure there is adequate clearance between the body and overhead structures or electric power lines. Be sure that the lifting device is rated for at least a 45 ton capacity.

3. Attach chains around upper end of hoist cylinders to support them after the mounting pins are removed. 4. At each of the upper hoist cylinder mounting eyes, remove shoulder bolt (4, Figure 3-2), flat washer (5) and nut (6). With adequate means of supporting the hoist cylinders in place, remove both pins (2).

FIGURE 3-2. HOIST CYLINDER MOUNTING (UPPER)

FIGURE 3-1. DUMP BODY REMOVAL 1. Lifting Cables

B03027 7/11

2. Guide Rope

1. Dump Body 2. Pin 3. Hoist Cylinder

Dump Body

4. Shoulder Bolt 5. Flat Washer 6. Locknut

B3-3

5. Remove shoulder bolts (1, Figure 3-3), flat washer (10) and nuts (2) from each body pivot pin. 6. Remove pivot pins (3) far enough to allow shims (6) to drop out. Complete removal is not necessary unless a new pin is to be installed. 7. Lift dump body clear of the chassis and move to storage or work area. Block the body to prevent damage to the body guide etc. 8. Inspect bushings (5, 8, and 9) for excessive wear or damage. Replace as required.

FIGURE 3-3. DUMP BODY PIVOT PIN 1. Shoulder Bolt 2. Locknut 3. Pivot Pin 4. Body Ear 5. Bushing

Installation

Inspect all lifting devices. Slings, chains, and/or cables used for lifting components must be inspected daily for serviceable condition. Refer to the manufacturer's manual for correct capacities and safety procedures when lifting components. Replace any questionable items. Slings, chains, and/or cables used for lifting components must be rated to supply a safety factor of approximately 2X the weight being lifted. When in doubt as to the weight of components or any assembly procedure, contact the Komatsu area representative for further information. Lifting eyes and hooks should be fabricated from the proper materials and rated to lift the load being placed on them. 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, be sure there is adequate clearance between the body and overhead structures or electric power lines. Be sure that the lifting device is rated for at least a 45 ton capacity.

6. Shim 7. Frame Pivot 8. Body Pivot Bushing 9. Bushing 10. Flat Washer

1. Park truck on a hard, level surface and block all the wheels. 2. Attach cables and a lifting device to the dump body and take up the slack as shown in Figure 3-1. Lower the body over the truck frame and align the body pivots with the frame pivot holes. 3. Install shims (6, Figure 3-3) in both body pivots, as required, to fill the outside gaps and center the body on the frame pivot. Do not install shims at the inside. NOTE: A minimum of 1 shim is required at the outside end of both frame pivots.

B3-4

Dump Body

7/11 B03027

4. Align the hole in pivot pin (3) with bolt hole in body pivot flange. Push the pivot pin through the shims (6), frame pivot (7), and into the pivot bushing (9). 5. Install shoulder bolt (1) through each pin. Ensure locknuts (2) are in good condition. Install flat washers (10) and locknuts (2). Fully install locknut so it is tight against the flat washer, and the flat washer is tight against the shoulder on the shoulder bolt. Ensure that the shoulder bolt has some end play.

BODY PADS It is not necessary to remove the dump body to replace the body pads. The body pads should be inspected during scheduled maintenance inspections and replaced if worn excessively. If the body pads are worn unevenly, adjustment of the body pad shims will be required. Removal 1. Raise the body to a height sufficient to allow access to all pads.

NOTE: If Locknut (2) is not a self-locking nut, tighten the nut to 340 N·m (250 ft lb). 6. Align hoist cylinder upper bushings with the hole through the body. With pin retaining bolt hole and the retaining hole in dump body aligned, install pin (2, Figure 3-2).

Place blocks between the body and frame. Secure blocks in place. Never work under a raised body unless safety device(s) are in position to prevent dump body from lowering. 2. Remove hardware attaching pads to the dump body. (Refer to Figure 3-4.)

7. Install shoulder bolt (4) through each pin. 8. Ensure locknuts (6) are in good condition. Install flat washers (5) and locknuts (6). Fully install locknut so it is tight against the flat washer, and the flat washer is tight against the shoulder on the shoulder bolt. Ensure that the shoulder bolt has some end play. NOTE: If nut (6) is not a self-locking nut, tighten the nut to 340 N·m (250 ft lb).

3. Remove body pad(s) and shim(s). Note number of shims installed at each pad location. (The rear pad on each side should have one less shim than the other pads.) Installation

9. Install mud flaps, rock ejectors, electrical cables and lubrication hoses.

1. Install new pads with the same number of shims as removed in Step 3. 2. Install the mounting hardware and tighten to 88 N·m (65 ft lb) torque. 3. Remove blocks from frame and lower body onto the frame.

FIGURE 3-4. BODY PAD MOUNTING 1. Nut 2. Lock Washer 3. Shim(s)

B03027 7/11

Dump Body

4. Body Pad 5. Flat Washer 6. Cap Screw

B3-5

NOTE: The frame rail and the body bolster do not have to be parallel.

Adjustment

4. Subtract the body pad thickness of 39.7 mm (1.56 in.) from measurement “A” at each pad mounting location. The difference will be measurement “B”. There will be a total of eight “B” measurements per side.

Proper body pad to frame contact is required to assure maximum pad life. 1. Without any body pads installed, bolt two spacer blocks (2, Figure 3-5) using the body pad mounting holes closest to the front of the dump body. After the spacer blocks are installed, lower the body completely. NOTE: The spacer blocks can be made locally. Refer to the Special Tools section for detailed information on how to make the spacer blocks. 2. After lowering the dump body with the spacer bocks installed, check the dump body’s position and fit on the truck. If there is any interference when the body is resting on the spacer blocks, contact your local Komatsu distributor to resolve the issue.

5. Divide measurement “B” by the shim thickness of 1.5 mm (0.06 in.) to determine the number of shims required for each position. 6. Assemble a shim pack for each body pad location as determined in the previous step. On the rear most body pad mounting location (4, Figure 3-7), remove one shim from the calculation. NOTE: Using half shims is allowed if necessary. Half shims must be installed at the top of the stack. 7. Install the body pads and shims at each location using mounting hardware shown in (Figure 3-4). Tighten nuts (6) to 88 N·m (65 ft lb) torque.

3. With the body lowered, measure and record the distance from the frame rail to the dump body’s pad mounting hole locations as shown in Figure 3-7. This will be measurement “A”. Refer to Figure 3-6. There will be a total of eight “A” measurements per side, one at each mounting hole location (front and back) for each pad.

FIGURE 3-6. MEASUREMENT DETAILS 1. Shim

2. Body Pad

FIGURE 3-5. SPACER BLOCK INSTALLED 1. Body 2. Spacer Block (XC2293)

B3-6

3. Truck Frame

Dump Body

7/11 B03027

FIGURE 3-7. BODY PAD LOCATIONS 1. Body Pad Position 1 2. Body Pad Position 2

3. Body Pad Position 3 4. Body Pad Position 4

BODY GUIDE 1. Body guide wear points should be inspected each time a body pad inspection is performed. (Refer to Figure 3-8.) The body guide should be centered between the wear plates (3), with a maximum gap of 4.8 mm (0.19 in.) at each side when new. 2. If gap becomes excessive, install new parts.

FIGURE 3-8. BODY GUIDE 1. Dump Body 2. Body Guide

B03027 7/11

Dump Body

3. Body Guide Wear Plates

B3-7

BODY-UP RETENTION CABLE

BODY POSITION INDICATOR

To avoid serious personal injury or death, the body up retention cable must be installed anytime personnel are required to perform maintenance on the vehicle with 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 it's maximum height. 2. Install two shackles (2, Figure 3-9) and body retention sling (3) between rear body ear (1) and the axle housing.

The Body Position Indicator is a device mounted on the canopy of the dump body. When the body is lowered, the indicator is visible to the operator. This device should be inspected daily and repairs made if required.

HOIST LIMIT SWITCH Refer to Section D, Electrical System (24VDC) for adjustment procedure of the hoist limit switch.

BODY UP SWITCH Refer to Section D, Electrical System (24VDC) for adjustment procedure of the body up switch.

3. Secure the shackle pins with cotter pins. 4. Move the hoist lever to the FLOAT position to slowly lower the body until the cable is supporting the full weight of the body. Then move the hoist lever to the HOLD position. 5. After maintenance work is completed, return the sling to stored position.

FIGURE 3-9. BODY-UP CABLE INSTALLATION 1. Rear Body Ear 3. Body Retention 2. Shackle And Pin Sling

B3-8

Dump Body

7/11 B03027

ROCK EJECTORS

3. If the rock ejector becomes bent, it must be removed and straightened.

Rock ejectors are placed between the rear dual wheels to keep rocks or other material from lodging between the tires. Failure to maintain the rock ejectors could allow debris to build up between the dual wheels and cause damage to the tires.

4. The wear plates (2) must be replaced if severely worn. 5. Inspect the mounting brackets (4, Figure 3-11), pins (2) and stops (3) for wear and/or damage and repair as necessary.

Inspection

6. With rock ejector hanging vertical as shown, there must be NO GAP between stop block (3). and the rock ejector. Adjust stop block as necessary to obtain NO GAP.

1. The rock ejectors (1, Figure 3-10) must be positioned on the center line between the rear tires within 6.35 mm (0.25 in.). 2. With the truck parked on a level surface, the rock ejector should be approximately 88 mm (3.50 in.) from the wheel spacer ring (3) when hanging vertical.

FIGURE 3-11. ROCK EJECTOR MOUNTING BRACKET (Detail View) 1. Rock Ejector Arm 2. Pin

3. Stop Block 4. Mounting Bracket

FIGURE 3-10. ROCK EJECTOR 1. Rock Ejector 2. Wear Plate

B03027 7/11

3. Rear Wheel Spacer Ring

Dump Body

B3-9

NOTES:

B3-10

Dump Body

7/11 B03027

SECTION B4 FUEL TANK INDEX

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-2 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4 FUEL TANK BREATHER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4 FUEL GAUGE SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6 Specifications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6 QUICK FILL FUEL RECEIVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-7

B04034

Fuel Tank

B4-1

FUEL TANK Installation

Removal 1. Raise the truck body and install the body retention sling. 2. Drain sediment from the fuel tank and dispose of properly. 3. Loosen filler cap (5, Figure 4-1) and open the drain cock on the bottom of fuel tank (1) to drain the fuel from the tank into clean containers. Tighten the filler cap when the fuel is completely drained.

The weight of the empty fuel tank is approximately 1 711 kg (3,772 lb). Use lifting devices with adequate capacity to remove the fuel tank.

4. Disconnect the wire harness from hoist circuit filter assemblies (11) and steering circuit filter assembly (12). Remove ground wire (13). 5. If equipped, close the in-line shutoff valves. Remove fuel return hose (6), fuel supply hose (7) and quick fill hose (10). Cap the hoses and tank fittings to prevent contamination. 6. Remove hoist circuit filter assemblies (11) and steering circuit filter assembly (12) from the fuel tank. Support the filter assemblies by placing a chain over the frame rail. It is not necessary to remove the hydraulic hoses.

1. Thoroughly clean the frame mounting brackets and the mounting hardware holes. Re-tap the threads if damaged. 2. Attach a lifting device to the lifting eyes on each side of the tank. Lift the fuel tank into position over the frame trunnion mounts and lower it into position. 3. Install mounting caps (4, Figure 4-1), flat washers (3) and cap screws (2). Do not tighten the cap screws at this time. 4. Install rubber mounts (18), large washers (17), flat washers (16), lockwashers (15) and capscrews (14). Tighten the lower mounting cap screws to 800 ± 80 N·m (590 ± 59 ft lb). 5. Tighten upper mounting cap screws (2) to 712 ± 72 N·m (525 ± 53 ft lb). 6. Attach ground wire (17), and connect wire harness (13). Install wire harness clamps.

The weight of the empty fuel tank is approximately 1 711 kg (3,772 lb). Use lifting devices with adequate capacity to remove the fuel tank. 7. Attach a lifting device to the lifting eyes on each side of the tank. 8. Remove cap screws (14), lock washers (15), flat washers (16), large washers (17) and rubber mounts (18). Remove cap screws (2), flat washers (3) and mounting caps (4).

7. Attach fuel supply hose (7), return hose (6) and quick fill hose (10). If equipped, open the in line shutoff valves. 8. Attach hoist circuit filter assemblies (11) and steering circuit filter assembly (12) to the fuel tank. 9. Refill the fuel tank with clean fuel.

9. Lift the fuel tank from the brackets and move it to a work area. 10. Inspect rubber mounts (18) and replace if necessary.

B4-2

Fuel Tank

B04034

FIGURE 4-1. FUEL TANK 1. Fuel Tank 2. Cap Screw 3. Flat Washer 4. Mounting Cap 5. Filler Cap 6. Fuel Return Hose

B04034

7. Fuel Supply Hose 8. Vent Assembly 9. Overflow Tube 10. Quick Fill Hose 11. Hoist Circuit Filter Assemblies 12. Steering Circuit Filter Assembly

Fuel Tank

13. Ground Wire 14. Cap Screw 15. Lock Washer 16. Flat Washer 17. Large Washer 18. Rubber Mount

B4-3

Assembly

Repair If a fuel tank has been damaged and requires structural repair, perform such repairs before final cleaning.

1. Clean and inspect all parts. If any parts are damaged, replace the entire assembly. 2. Place valve spring (3) into position in body (2). 3. Insert stem (6) into end fitting (5). 4. Screw end fitting (5) into body (2). Ensure the components are properly aligned and seated. 5. Install fitting (1).

If a tank is to be weld repaired, special precautions are necessary to prevent fire or explosion. Consult local authorities for safety regulations before proceeding.

Cleaning

6. Insert the balls into ball cage (8) with solid ball (9) on top. 7. Insert the ball cage onto the stem. A minimum of two cage coils must be seated in the groove on the stem. Ensure the solid ball is able to seat properly on the stem. If not, adjust the cage accordingly.

The fuel tank is provided with a drain cock and a cleaning port in the side that allows steam or solvent to be utilized in cleaning tanks that have accumulated foreign material. It is not necessary to remove the tank from the truck for cleaning of sediment. However, rust and scale on the walls and baffles may require complete tank removal. This allows cleaning solutions to be in contact with all interior surfaces by rotating the tank in various positions. Prior to a cleaning procedure of this type, the vent assembly, fuel gauge sender and hose connections must be removed and temporarily sealed. After all scale, rust, and foreign material has been removed, the 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.

FUEL TANK BREATHER VALVE NOTE: The relief pressure of the fuel tank breather valve is 70 - 89 kPa (10 - 13 psi). Disassembly 1. Remove fitting (1, Figure 4-2).

FIGURE 4-2. BREATHER VALVE

2. Remove ball cage (8), solid ball (9) and float balls (10). 3. Unscrew end fitting (5) from body (2). 4. Remove stem (6) and valve spring (3).

B4-4

Fuel Tank

1. Fitting 2. Body 3. Valve Spring 4. O-Ring 5. End Fitting

6. Stem 7. O-Ring 8. Ball Cage 9. Solid Ball 10. Float Ball

B04034

FUEL GAUGE SENDER

Installation

Fuel gauge sender (1, Figure 4-3) is mounted on the top of the fuel tank and provides an electrical signal to operate the fuel level gauge on the instrument panel. Removal

Never work under a raised body unless safety device(s) are in position to prevent the dump body from lowering.

1. Raise the dump body all the way. Secure the dump body in the fully raised position using the body sling.

Never work under a raised body unless safety device(s) are in position to prevent the dump body from lowering. 2. Remove the fuel gauge cover from the top of the fuel tank. 3. Disconnect wiring harness (4, Figure 4-3) from connector (3) on the fuel gauge sender. 4. Remove fuel gauge sender mounting hardware (2). Carefully remove sender (1) and the gasket.

1. Clean the fuel gauge sending mating surface on the fuel tank. If reinstalling the same fuel gauge sender, clean the mating surface on the sender and install a new gasket (2, Figure 4-4). (New fuel gauge senders are supplied with a new gasket.) 2. Install fuel gauge sender (1, Figure 4-3) into the tank. Ensure the guide on the bottom of the fuel sender is seated in the cup in the bottom of the fuel tank. If it is not seated in the cup, the mounting flange on the sender will not be level with the mounting surface on the fuel tank. 3. Install sender mounting hardware (2) and tighten the cap screws to the standard torque. 4. Connect wiring harness (4) to connector (3) attached to the sender. 5. Install the cover on the top of the sender. 6. Remove the body up sling and completely lower the dump body.

FIGURE 4-3. FUEL GAUGE SENDER 1. Fuel Gauge Sender 2. Mounting Cap Screws

B04034

Fuel Tank

3. Wire Connector 4. Wire Harness

B4-5

Operation Float (4, Figure 4-4) moves up and down as the fuel level changes. The resistance value in the fuel gauge sender changes with the level of fuel in the tank. The fuel gauge sender is equipped with one 30 ohm resistor (2, Figure 4-5) which is always connected to the sender circuit. There are also 16 bi-stable reed switches (3) evenly spaced inside the fuel sender tube. Each reed switch is wired to a 13 ohm resistor (1). As the float moves up with the fuel level, the float will open the individual reed switches, and 13 ohms of resistance is added to the circuit. When the float is at the very top, all of the reed switches will be latched open.

As the fuel level goes down, the float will move downward past the reed switches again. This will switch them to the closed position and it will reduce the resistance value by 13 ohms as each switch is closed. Specifications: Minimum Resistance: 30 ohms (float at bottom) Maximum Resistance: 238 ohms (float at top)

FIGURE 4-5. FUEL GAUGE SENDER SCHEMATIC 1. Resistors (13 Ohm) 3. Reed Switch (NC) 2. Resistor (30 Ohm)

FIGURE 4-4. FUEL GAUGE SENDER 1. Connector 4. Float 2. Gasket 5. Guide 3. Tube

B4-6

Fuel Tank

B04034

QUICK FILL FUEL RECEIVERS Fuel receiver assembly (4, Figure 4-6) is mounted on the RH face of the fuel tank. If equipped, fuel receiver assembly (6) is mounted to the bottom of the hydraulic tank. It is connected to the rear of the fuel tank by hose (2). The quick fill fuel system is a pressurized system that is rated at a maximum of 568 l/m (150 gpm). When filling the tank, vent assembly (1) allows air to escape to prevent the tank from over-pressurizing. When the fuel level reaches the float balls in the vent, the balls rise with the fuel. When the fuel level reaches its maximum level, the float balls block air flow out of the vent, causing pressure to rise in the fuel tank. When pressure reaches 55 - 70 kPa (8 - 10 psi), the fuel nozzle should turn off.

If the nozzle fails to turn off and fuel continues to fill the tank, a relief valve in the vent will open at 79 kPa (11.5 psi) to prevent over-pressurization of the tank. If filling persists and the fuel reaches the top of the tank, fuel will flow out of the vent until the nozzle is turned off. If fuel spills from the vent, or if the tank does not completely fill, check the vent to see whether the float balls are in place and overflow tube is clean. If the vent is operating properly, the problem will most likely be in the fuel supply system. NOTE: Keep the cap on each fuel receiver to prevent dirt buildup in valve area and nozzle grooves.

FIGURE 4-6. FUEL GAUGE SENDER & QUICK FILL FUEL 1. Vent Assembly 2. Quick Fill Hose

B04034

3. Fuel Receiver Cap 4. RH Fuel Receiver Assembly

Fuel Tank

5. Adapter Plate 6. LH Fuel Receiver Assembly

B4-7

NOTES:

B4-8

Fuel Tank

B04034

SECTION C ENGINE INDEX

POWER MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-1

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-1

POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-1

AIR CLEANERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-1

FAN CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-1

C01029

Index

C1-1

NOTES

C1-2

Index

C01029

SECTION C2 POWER MODULE INDEX

POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-3 PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2-8

C02027 11/11

Power Module

C2-1

NOTES:

C2-2

Power Module

11/11 C02027

POWER MODULE The radiator, engine and alternator/blower assemblies are mounted on a roller equipped subframe which is contained within the truck's main frame and is referred to as a “Power Module”. This arrangement permits removal and installation of these components with a minimum amount of disconnect being made and by utilizing the unique “Roll In/Roll Out” feature. Although the instructions in this section are primarily based upon the “Rollout” method for major component removal, the radiator and fan may be removed as separate items. Instructions for radiator and fan removal are contained later in this section.

4. It is not necessary to remove the grille or radiator prior to the removal of the power module. If radiator removal is desired or if only radiator repair is necessary, refer to Cooling System in this section.

Removal 1. Disconnect batteries using the following procedure in this order: a. Open battery disconnect switch located on battery switch box on top of front bumper. b. Inside the battery box, identify the battery ground cables that connect the negative terminals of two batteries to the ground bus bar in the bottom of the battery box. Disconnect these ground cables from the negative terminal of each battery.

PREPARATION

c. Disconnect the ground cables from below the battery box.

The complete power module weighs approximately 16 760 kg (36,950 lbs.). Make sure lifting device to be used is of an adequate capacity.

d. Disconnect the three positive battery cables from the bus bar outside the battery box. Also disconnect three wiring harness from the battery box.

1. Position the truck in a work area with a flat, level surface and adequate overhead clearance to permit raising the dump body. 2. Apply parking brake and block wheels to prevent truck movement. Raise body and install safety lock pin and body cable.

e. Remove mounting cap screws and remove battery box from front bumper. 2. Follow the steps below to remove main alternator inlet duct (2, Figure 2-1):

Do not work under raised body without first making sure the body lock pin and body cable is installed. 3. Tag or mark all oil lines, fuel lines and electrical connections to ensure correct hookup at time of power module installation. Plug all ports and cover all hose fittings or connections when disconnected to prevent dirt or foreign material from entering.

C02027 11/11

Power Module

a. Remove cover and disconnect cables (routed to main alternator) from front side of transition structure (4). Disconnect air sensor from left side of inlet duct. b. Remove clamps and disconnect air hose (6) at electrical cabinet and transition structure (3). c. Remove mounting hardware and remove transition structure (3).

C2-3

d. Attach hoist to lifting eyes on blower inlet duct assembly. Remove hardware attaching duct to main alternator inlet. Remove hardware attaching upper duct mounts to electrical cabinet. Remove hardware attaching duct to deck at right and left sides.

4. Disconnect all (already marked) electric, oil and fuel lines that would interfere with power module removal. Cover or plug all lines and their connections to prevent entrance of dirt or foreign material. To simplify this procedure, most connections utilize quick disconnects.

e. Recheck for any other cables or hoses and lift duct assembly from the truck. Cover all openings to prevent entrance of foreign material.

5. Disconnect the air cleaner restriction gauge hoses. Disconnect electrical wiring and hoses etc. that would interfere with front center deck removal.

f. Remove mounting hardware and remove transition duct (4) from alternator.

6. Remove air inlet duct support rods on underside of center deck.

3. Remove clamp and remove the outlet hose to rear axle on the blower assembly.

7. Attach hoist to the front center deck. Remove all cap screws, flat washers, lockwashers and nuts securing the deck. Check for any remaining wiring, hoses or other items on underside of deck. Lift deck and remove from truck. 8. Close both cab heater shutoff water valves disconnect water lines and drain water from the heater core. Secure water lines away from engine compartment so as not to interfere with power module removal. 10. Remove cap screws (2, Figure 2-2) and nuts securing left (1) and right (3) exhaust ducts to turbocharger outlets. Remove “V” band clamps (5) and support clamps (4). Remove exhaust ducts and move clear of engine. Cover turbocharger exhaust openings to prevent entrance of foreign material.

FIGURE 2-1. MAIN ALTERNATOR BLOWER DUCT 1. Electrical Cabinet 2. Inlet Duct 3. Transition Structure

C2-4

4. Transition Duct 5. Air Hose

Power Module

11/11 C02027

14. Remove cap screws and washers securing cover (10, Figure 2-4) to grille at center of front bumper and remove. Remove cap screws and lockwashers (9) securing front subframe support to main frame.

Install safety chain around the front engine subframe cross member and main frame to prevent the power module from rolling forward when the subframe rollers are installed.

15. Remove cap screws (4, Figure 2-4) and caps (3) securing subframe mounting bushings to the subframe support bracket (6) at rear of subframe. 16. Check engine and alternator to make sure all cables, wires, hoses, tubing and linkages have been disconnected.

FIGURE 2-2. EXHAUST DUCTS (Heated Body Exhaust Shown) 1. LH Exhaust Duct 2. Cap Screws 3. RH Exhaust Duct

17. Remove the mounting hardware at the diagonal ladder mounting pads. Lift the diagonal ladder from the truck and move it to a storage area.

4. Support Clamp 5. “V” Band Clamp 6. Frame Rails

11. Remove clamps (6, Figure 2-3) securing the air intake ducts (3) to turbochargers (4). Remove clamps at hump hoses (1). and remove air intake ducts. Cover inlets on turbochargers and ducts to air cleaners to prevent contamination. 12. Remove upper radiator support struts (12, Figure 2-4). 13. Disconnect grounding strap located near the front subframe mount.

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. 18. Refer to Section N, Operator Comfort, for the procedures required to properly remove the refrigerant from the air conditioning system. After the system has been discharged, disconnect the refrigerant hoses to the cab at the compressor and receiver/drier. NOTE: System contains HFC-134A refrigerant.

C02027 11/11

Power Module

C2-5

19. Disconnect hydraulic pump drive shaft (1, Figure 2-4) at the drive shaft U-joint companion flange.

Only lift power module at the lifting points on subframe and engine/alternator cradle structure. (Refer to Figure 2-6.)

20. Attach hoist to lift points (2, Figure 2-4) at engine/alternator cradle structure. Raise the rear portion of engine subframe and install subframe rollers (Refer to Figure 2-5). Lower the rear portion of the subframe carefully until the rollers rest on the main frame guide rail. NOTE: Subframe rollers are supplied in the truck tool group and can be installed in the storage position after use, as shown in Figure 2-5.

Note: Illustration shows engine equipped with two-stage turbochargers. Single stage turbocharger equipped engine ducts and supports are similar.

1. Hump Hose 2. Support Rods 3. Air Intake Ducts

C2-6

FIGURE 2-3. AIR INTAKE DUCTS 4. Turbocharger 7. T-Bolt Clamp 5. Center Deck Structure 8. Air Cleaner Assembly 6. Clamp

Power Module

11/11 C02027

21. Reposition hoist to front subframe lifting points (8, Figure 2-4). Raise the engine subframe until the engine is on a level plane. Remove the safety chain.

22. Roll the power module forward sufficiently so that adequate clearance is provided for the lifting device to be attached to the engine/alternator cradle structure and front subframe lifting points. Place stands or block under front of subframe and lower hoist until front of subframe is supported. Install safety chain to prevent subframe from rolling.

The engine, alternator, radiator and subframe weigh approximately 16 760 kg (36,950 lbs.). Make sure the lifting device used is of an adequate capacity.

FIGURE 2-4. ENGINE MODULE INSTALLATION 1. Pump Driveshaft 2. Rear Module Lift Eye 3. Cap 4. cap screws 5. Bushing

C02027 11/11

6. Rear Subframe Mount Bracket 11. Grille Structure 12. Upper Radiator Support Rod 7. Module Subframe 13. Engine 8. Front Module Lift Eye 9. Front Mount cap screws 10. Cover

Power Module

C2-7

24. Raise the power module slightly to determine if module is on an even plane. Move the power module straight out of truck to a clean work area for disassembly. For further disassembly of the engine, alternator, and radiator, refer to the appropriate section of this manual.

Installation 1. Inspect the main frame guide rails. Remove any debris which would interfere with power module installation. 2. Clean the main frame rear support brackets. Apply a light film of soap solution to each rubber bushing (5, Figure 2-4) located at the rear of the subframe.

FIGURE 2-5. SUBFRAME ROLLERS 1. Roller Assembly 2. Subframe

3. cap screws

3. Check the subframe rollers making sure they roll freely and are in the “roll-out” position. (Figure 2-5).

23. Attach lifting device to hoist and attach to engine/alternator cradle structure and front subframe lifting points as shown in Figure 2-6. Remove safety chain.

4. Attach a lifting device to engine/alternator cradle structure and front subframe lifting points. (Figure 2-6)

The complete power module weighs approximately 16 760 kg (36,950 lbs.). Make sure lifting device to be used is of an adequate capacity. 5. Raise the power module and align the subframe rollers within the main frame guide rails. 6. Lower the power module to the subframe guide rails, relax the hoist slightly and roll the power module into truck frame until lifting chains contact frame cross member. FIGURE 2-6. POWER MODULE LIFT POINTS 1. Module Lifting Tool 2. Main Alternator 3. Module Lift Points

C2-8

4. Engine 5. Power Module Subframe

Power Module

11/11 C02027

7. Place stands or blocking under front of subframe to support assembly while repositioning hoist. 8. Install a safety chain around the truck frame and the front subframe cross member. The safety chain will prevent the power unit from rolling forward.

17. Install the rear subframe mounting caps (3) and secure caps in place with lubricated cap screws (4). Tighten cap screws to 551 ±21 N·m (407 ±15 ft lbs) torque. 18. Install radiator support struts (12).

9. Place a small block behind each rear subframe roller to prevent rolling.

19. Install exhaust ducts (1 & 3, Figure 2-2) Install cap screws (2) washers and nuts to secure ducts to turbochargers. Install “V” band clamps (5) and support clamps (4).

10. Lower hoist to allow subframe to rest on stands and rollers. Remove lifting device.

20. Connect the cab heater inlet and outlet hoses and open both valves.

11. Attach hoist to front lifting eyes on subframe.

21. Connect the hydraulic pump drive shaft (1, Figure 2-4) to the companion flange on the alternator. Tighten cap screws to standard torque.

12. Remove the small blocks behind the subframe rollers, remove safety chain, and slowly roll the power module into position over the main frame mounts. Lower hoist until front subframe mount is aligned and seated on the front, main frame mount. Reinstall safety chain. 13. Relocate hoist to the rear portion of the engine/ alternator cradle structure and raise just enough to permit removing the subframe rollers.

22. Connect wheel motor cooling blower air outlet hose. Tighten all clamps securely to insure a positive air seal. 23. Install diagonal ladder on front of truck. 24. Install transition duct (4, Figure 2-1) to alternator.

14. Lower the rear portion of the subframe until the subframe rubber bushings are seated in the rear mounting brackets located on the main frame of the truck.

25. Install transition structure (3) to alternator.

15. After subframe is seated in frame mounts, the safety chain may be removed from the front subframe member.

27. Install control cabinet air hose (5), electrical cables and any other hoses and wiring removed during power module removal.

16. Install cap screws (9, Figure 2-4) and lockwashers in the front mount and tighten cap screws to 298 ±30 N·m (220 ±22 ft lbs) torque. Install ground strap between frame and subframe. Reinstall air dam. Install cover (10) if grille is installed.

28. Connect all remaining electric, oil, and fuel lines.

26. Lift main alternator blower intake duct (2) into position and install all mounting hardware at mounts.

29. Attach hoist to the front center deck and lift into position. Align the rear center deck mounting holes with the support structure in front of the electrical cabinet. Install cap screws and flat washers. Do not tighten at this time. 30. Align the front center deck, front mounting holes with both left and right fender supports. Install cap screws and flat washers. Tighten all deck mounting cap screws to standard torque values.

C02027 11/11

Power Module

C2-9

31. Install battery box on front bumper with mounting hardware. Connect the batteries as follows: a. Connect the three positive battery cables to the bus bar outside the battery box. Also connect the three wiring harness to the battery box. b. Connect the ground cables below the battery box. c. Ensure the battery disconnect switches are in the OFF position. Inside the battery box, connect both battery negative ground cables to the battery posts. d. Close battery disconnect switch. 32. Install air intake duct supports (2, Figure 2-3). Install engine air intake ducts (3). Position adjusters of adjacent T-bolt clamps 180° apart. Clamp the ducts securely to ensure a positive seal is made. Refer to Figure 2-7 for an example of correct installation and alignment.

33. Connect the air filter restriction gauge hoses. 34. Install the exhaust system piping and hangers. Tighten all hardware to standard torque. 35. Install exhaust blankets (6, 7, 8, 9 & 11, Figure 2-8). Then install blankets (5) and (10). Blankets should have 50 mm (2 in.) overlap on the ends. 36. Install the remaining exhaust blankets. 37. Refill the radiator with coolant and service the engine with the appropriate fluids. Refer to Section P, Lubrication and Service, for capacity and fluid specifications. 38. Refer to Section N, Operator Comfort, for the procedures to properly recharge the air conditioning system. 39. NOTE: System contains HFC-134A refrigerant.

FIGURE 2-7. AIR INLET PIPING CONNECTIONS

C2-10

Power Module

11/11 C02027

FIGURE 2-8. EXHAUST BLANKETS 1. Exhaust Blanket 2. Exhaust Blanket 3. Exhaust Blanket 4. Exhaust Blanket 5. Exhaust Blanket 6. Exhaust Blanket

C02027 11/11

7. Exhaust Blanket 8. Exhaust Blanket 9. Exhaust Blanket 10. Exhaust Blanket 11. Exhaust Blanket 12. Exhaust Blanket

Power Module

13. Exhaust Blanket 14. Exhaust Blanket 15. Exhaust Blanket 16. Exhaust Blanket

C2-11

NOTES:

C2-12

Power Module

11/11 C02027

SECTION C3 COOLING SYSTEM INDEX

COOLING SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-3 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-7 Radiator Filling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-8 REPAIRING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-9 Internal Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-9 External Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-9 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-9 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-10 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-10 Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-12 COOLANT SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-12

C03035

Cooling System

C3-1

NOTES:

C3-2

Cooling System

C03035

COOLING SYSTEM DESCRIPTION The standard 830E engine is a Komatsu model SDA16V160 single stage turbocharged engine equipped with aftercoolers. The engine cooling radiator assembly contains two cores; A “low temperature” core (2, Figure 3-1) is connected to the four aftercoolers (7). There are two aftercoolers located on each cylinder bank. This coolant is circulated by the engine’s LTA (Low Temperature Aftercooler) water pump (6). The LTA thermostats (4) begin to open at 46° C (115° F) and are fully open at 57° C (135° F).

A second, “high temperature” core (3), located at the rear of the radiator assembly is used for the engine coolant circuit. In this circuit, the engine water pump (10) circulates coolant through the engine block (9) (heads, liners, internal oil coolers etc.). The engine coolant thermostats (5) begin to open at 82° C (180° F) and are fully open at 94° C (202° F). In addition, a fuel cooler, located on the lower right corner of the radiator assembly reduces fuel temperature after fuel leaves the engine, before it is returned to the tank. The air conditioning system refrigerant condenser is mounted on the lower left corner of the radiator assembly.

FIGURE 3-1. COOLING SYSTEM DIAGRAM 1. Surge/Fill Tank 2. Low Temperature Core (LTA) 3. High Temperature Core 4. Low Temperature Thermostats

C03035

5. Engine (Hi Temp) Thermostats 6. LTA Circuit Water Pump 7. Aftercooler 8. Engine Oil Coolers

Cooling System

9. Engine Block (Heads, Liners) 10. Engine Circuit Water Pump

C3-3

RADIATOR Removal 1. Place battery disconnect switch in the OFF position.

4. Disconnect surge tank vent hoses and electrical cable attached to coolant level probe (6). Remove clamps (5) securing hoses and electrical cables to fan shroud, tubes and support rods.

2. Release pressure from cooling system. Drain the coolant into clean containers for possible reuse after engine installation. Refer to Section P, Lubrication and Service, for the cooling system capacity. 3. Remove cover (7, Figure 3-2) protecting surge tank (1).

FIGURE 3-3. RADIATOR PIPING AND MOUNTS (Viewed from Below) 1. Radiator Assembly 2. Mount Hardware 3. Low Temp Core Tubes

4. High Temp Core T

5. Loosen clamps and remove coolant piping at upper and lower radiator tanks. Refer to Figure 3-2 and 3-4). 6. Grille structure (2, Figure 3-2) removal: a. Remove lower left grille section for access to air conditioning condenser hoses.

FIGURE 3-2. GRILLE INSTALLATION 1. Surge Tank 2. Grille Structure 3. Coolant Drain Cock 4. Water Pump Inlet

C3-4

5. Clamp 6. Coolant Level Probe 7. Surge Tank Cover

Cooling System

C03035

NOTE: The system is charged with HFC-134A refrigerant.

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.

8. After system is evacuated, remove hoses from condenser and cap all openings to prevent contamination. Unclamp hoses and remove from radiator area to prevent interference when radiator is removed.

7. Refer to Section N, Operator Comfort, for the procedures required to properly remove the refrigerant from the air conditioning system.

FIGURE 3-4. RADIATOR AND SHROUD (Rear View) 1. Shroud 2. Fan Guard Str. 3. Support Rod 4. Clamp

C03035

5. Hose 6. Lift Points 7. Upper Tubes 8. Vent Hoses

Cooling System

9. Level Sensor 10. Receiver/Drier 11. Pressure Switch

C3-5

9. Remove fan guard (2, Figure 3-4) from shroud: a. Guard can be completely removed from the truck by separating the halves and removing. b. If complete removal is not necessary, remove hardware attaching guard to shroud and slide assembly toward the engine and allow it to hang on the fan clutch. 10. Disconnect batteries using the following procedure in this order:

14. Remove hardware attaching grille structure to radiator assembly, attach overhead crane, and lift slightly. Move grille structure forward to clear radiator assembly. Lift grille structure off truck and set aside. 15. Install lift eyes (included in truck tool group) in tapped blocks (6, Figure 3-4) at upper corners of radiator assembly and attach overhead crane.

a. Open battery disconnect switch located on battery switch box on top of front bumper. b. Inside the battery box, identify the battery ground cables that connect the negative terminals of two batteries to the ground bus bar in the bottom of the battery box. Disconnect these ground cables from the negative terminal of each battery. c. Disconnect the ground cables from below the battery box. d. Disconnect the three positive battery cables from the bus bar outside the battery box. Also disconnect three wiring harness from the battery box. e. Remove mounting cap screws and remove battery box from front bumper. 11. Disconnect hoses and pressure switch at receiver/drier located on fan shroud.

The radiator assembly weighs approximately 1907 kg (4,200 lbs) Ensure lifting device is capable of lifting the load. 16. Remove radiator support struts (3), upper support rods, and hardware (2, Figure 3-3) attaching radiator assembly to power module subframe. 17. Lift radiator enough to separate from mounts on subframe and move forward until shroud clears the engine fan. Do not allow shroud to contact fan blades. 18. Move assembly to a work area. Remove air conditioner condenser and fuel cooler.

12. Remove lower right grille section and disconnect hoses from fuel cooler. Cap openings to prevent contamination. 13. Disconnect headlight wire harness at each light. Remove cable clamps and remove harness to allow radiator removal.

C3-6

Cooling System

C03035

Installation 1. Reinstall shroud (1, Figure 3-4), air conditioner condenser, and fuel cooler. Install air conditioner receiver/drier (10) if removed.

9. Position fan guard against shroud and tighten mounting hardware to 55 N·m (40 ft lbs) torque. (If halves of guard were disassembled, tighten cap screws clamping halves together to 34 N·m (25 ft lbs) torque. 10. Attach hoses to fuel cooler.

The radiator assembly weighs approximately 1907 kg (4,200 lbs) Ensure lifting device is capable of lifting the load. 2. Attach lifting eyes in tapped blocks at upper corners of radiator assembly (6, Figure 3-4). Attach hoist and lift into place on power module subframe. 3. Position radiator assembly to equalize gap between tip of fan blades and shroud at right and left sides. Install mounting hardware (2, Figure 3-3) through lower mounts and tighten to 298 N·m (220 ft lbs) torque. 4. Install radiator support rods (3, Figure 3-4). If necessary, adjust to position radiator perpendicular to the subframe. Tighten the support strut locknuts. Install upper support rods to brackets on front upright supports. 5. Adjust fan shroud ring vertically to equalize gap between tip of fan blades and ring. 6. Lift grille structure (2, Figure 3-2) into position and install mounting hardware. 7. Route headlight wire harness to lights. Attach connectors to lights and clamp harness at weld studs.

11. Route A/C condenser hoses to condenser and attach. Install lower grille sections. Install receiver/drier (10) hoses. Connect pressure switch (11). 12. Install surge tank hoses and electrical wiring to the coolant level probe (9, Figure 3-4). Clamp hoses and electrical cables to the shroud. Install surge tank cover. 13. Make sure all coolant drains are closed, hoses are installed, and all wiring reconnected. Close drain valve on main air tank. 14. If the truck is equipped with air conditioning, the system must be evacuated and recharged. Refer to “Heater/Air Conditioning System” in Section M for detailed instructions for recharging with refrigerant. 15. Service the cooling system per the instructions below. 16. Check for static leakage and correct any leaks. After servicing is complete, start the engine and run until normal operating temperature is reached. Repeat check for leaks and correct as required.

8. Install upper and lower radiator piping. Seat hoses and clamps securely.

C03035

Cooling System

C3-7

Radiator Filling Procedure

Cooling System is pressurized due to thermal expansion of coolant. DO NOT remove radiator cap while engine and coolant are hot. Severe burns may result. 1. With engine and coolant at ambient temperature, remove radiator cap. Note: If coolant is added using the Wiggins quick fill system, the radiator cap MUST be removed prior to adding coolant. 2. Fill radiator with proper coolant mixture (as specified by the engine manufacturer) until coolant is visible in the sight gauge. 3. Install radiator cap. 4. Run engine for 5 minutes, check coolant level. 5. If coolant is not visible in the sight gauge, repeat steps 1 through 4. Any excess coolant will be discharged through the vent hose after the engine reaches normal operating temperature. Engine coolant must always be visible in the sight gauge before truck operation.

C3-8

Cooling System

C03035

REPAIRING THE RADIATOR Radiator service is a specialized function usually not accomplished by most maintenance shops. The large size and weight of the off-road truck radiators requires that a radiator repair shop equipped with special tools and handling equipment be used for service and repair. 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 can indicate overall radiator condition, as well as coolant and additive breakdown. To perform this inspection, remove four random tubes from the air inlet side of the radiator. Remove tubes from both the top and bottom cores, and near each end of the radiator. Refer to Disassembly and Assembly in this section for the proper instructions for removing and installing tubes. 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 cleaning, ensure that the cleaning solutions are not harmful to solder. Otherwise, damage to the radiator will result. Completely rinse the cleaned tube or core in clean water after removing it from the boil-out tank. As an alternative to boil-out tanks, radiators can be cleaned externally with a high pressure washer and soap. In most cases, it may be best to blow out any dry dirt with a high pressure air gun prior to washing the core with the high pressure washer.

C03035

Pressure washers should not exceed 8275 kPa (1200 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. Disassembly

To aid in removal of the tubes, clean the radiator prior to disassembly. Heating the seals with hot water helps to loosen the grip on the tubes. Cleaning the radiator prior to disassembly also reduces the risk of internal contamination. After cleaning, spray lubricating oil at the top end of the tubes.

FIGURE 3-5. BREAKER TOOL (XA2307)

1. Start at the top row of tubes. Use the breaker tool (XA2307) to loosen the tube to be removed. When using the breaker tool, position it at the top or bottom of the tube. Never position it in the middle of the tube or damage may result. Use the breaker tool to lightly twist the tube back and forth within the seals to loosen the grip. Refer to Figure 3-5.

Cooling System

C3-9

Cleaning and Inspection 1. Use a drill with a 19 mm (3/4 in.) wire brush to remove any foreign material from the tube holes, then wipe the holes clean. 2. Clean the inside of the tanks and tubes. In most cases, just flushing the inside with soap and a high pressure hot water washer will be sufficient. If not, contact an L&M manufacturing facility for further instructions or visit the L&M website at www.mesabi.com.

FIGURE 3-6. INSTALLATION TOOL (VJ6567) 2. After the tube is loose, position the installation tool (VJ6567) at the bottom of the tube to be removed. Refer to Figure 3-6. The upper jaw of the installation tool should be positioned just below the rectangular section of the tube. The bottom jaw should rest on the seal. Squeeze the installation tool just enough to allow the bottom of the tube to be removed from the bottom seal. NOTE: To ease in the removal of tubes, use the breaker tool and installation tool simultaneously.

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. Assembly NOTE: For easier installation, soak the seals in hot water before installing. 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.

FIGURE 3-7. ANGLING TUBE DURING REMOVAL 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 3-7. Removing the tube at an excessive angle may cause damage to the tube.

The seal holes must be dry during installation. Use a rubber mallet and a flat metal plate to lightly tap the seals into place. Using excessive force will drive the seals in too far. When installed properly, the seals should be slightly convex. Improperly installed seals are concave with a smaller diameter hole. Refer to Figure 38.

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.

C3-10

Cooling System

C03035

5. 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 3-8. PROPER SEAL INSTALLATION

2. Use a 13 mm (1/2 in.) diameter brush to lubricate the seals with lube/release agent (XA2308).

6. Center the bottom end of the tube in the bottom seal. Push the tube downward until the formed bead on the tube is seated inside the lock ring groove in the seal. If necessary, use the installation tool (VJ6567) to pull the tube downward into the seal. The tool has a hooking device on the end of one of the handles for aiding in installation. Refer to Figure 3-9.

3. Use a spray bottle to lubricate the tube ends with the lube/release agent. 4. When installing tubes, start at one end and work toward the center. After you reach the center, move to the opposite end, and again work toward the center. If any of the tubes are difficult to install, do not force the tube. Remove the tube and determine the problem. Possible causes may be: •adequate seal/tube lubrication •improperly installed seal •damaged seal or tube end •tube angle excessive during installation and/or tube not centered in seal. Inspect the seals and tube ends for damage before trying to reinstall a tube. Replace as necessary.

C03035

FIGURE 3-9. USING INSTALLATION TOOL TO INSTALL TUBE 7. Ensure that all tube beads are seated in their respective bottom seals. Align and straighten all tubes during the installation of each row to allow maximum air flow through the radiator. 8. Install tube stay ends. Install the felt air baffles behind the front and back rows while completing tube installation.

Cooling System

C3-11

Pressure Testing The radiator should be pressure tested at 103 kPa (15 psi) for 30 minutes. Various methods of pressure testing include the following: • Pressurize the radiator and submerge into a test tank. Watch for leaks.

COOLANT SYSTEM TROUBLESHOOTING If abnormal coolant temperatures are experienced, perform the following visual inspections and tests: 1. Check the coolant level and thoroughly inspect the system 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 source and monitor the pressure gauge. • Pressurize the radiator with air, and spray sealed joints with soapy water.

a. Check for proper coolant/antifreeze mixture. b. Follow the recommendations of the engine manufacturer regarding use of cooling system additives. 2. Inspect the radiator fins for restrictions. Ensure the air flow through the radiator is not restricted by debris or bent radiator fins. 3. Inspect the fan blades for damage. 4. Check the radiator cap sealing surfaces.

Additional service information can be found on the L&M Radiator website at www.mesabi.com.

5. If equipped with a fan clutch, refer to Section N, Operator Comfort, for complete instructions for testing and repairs, if required. 6. Refer to the engine manufacturer's Service Manual for information about testing and replacing the cooling system thermostats.

C3-12

Cooling System

C03035

SECTION C4 POWER TRAIN INDEX

ALTERNATOR REMOVAL PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-3 Removal (Komatsu SSDA16V160 or SDA16V160 Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-3 ENGINE/ALTERNATOR MATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-5 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-5 Measuring Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-5 Joining Alternator and Komatsu SSDA16V160 or SDA16V160 Engine . . . . . . . . . . . . . . . . . C4-7 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-8 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4-9

C04034 11/11

Power Train

C4-1

NOTES:

C4-2

Power Train

11/11 C04034

ALTERNATOR REMOVAL PROCEDURE Removal (Komatsu SSDA16V160 or SDA16V160 Engine) The following instructions cover the removal of the main alternator from the engine after the power module has been removed from the truck. (Refer to Figure 4-2.)

When lifting alternator, attach hoist to lift eyes only. The alternator weighs approximately 4037 kg (8,900 lbs). Use a lifting device that can handle the load safely. 1. Attach hoist with two lifting chains to the alternator lifting eyes (7, Figure 4-2). 2. Block under rear of engine a. Loosen cradle adjustments setscrews (3, Figure 4-1).

FIGURE 4-1. CRADLE STRUCTURE 1. Cradle Structure 2. Jam Nut 3. Adjustment Setscrew

4. Subframe 5. Gap

b. Loosen engine/cradle cap screws (3, Figure 4-2).

FIGURE 4-2. ENGINE AND ALTERNATOR 1. Cap Screws and Lockwashers 2. Cradle Structure 3. Cap Screws

C04034 11/11

4. Flywheel Housing 5. Subframe 6. Engine

Power Train

7. Alternator Lift Eyes 8. Alternator/Blower

C4-3

3. Remove access covers at front, right side of the engine flywheel housing. Install engine barring tool as shown in Figure 4-3.

FIGURE 4-3. ACCESS TO ALTERNATOR/ ENGINE DRIVE RING CAP SCREWS 1. Engine Barring Tool 2. Access Hole

3. Flywheel Housing

4. Reach through the access opening and remove 12 cap screws (6, Figure 4-4) joining the engine drive ring (7) to the alternator rotor (8). (Rotate crankshaft with barring tool to align each cap screw with access hole.)

FIGURE 4-4. ALTERNATOR TO ENGINE MOUNTING 1. Alternator 2. Flywheel Housing Adapter 3. Cap Screw (16 each) 4. Flywheel Housing

Ensure all cap screws have been removed! 5. Remove 16 cap screws (3) securing flywheel housing adapter (2) to the alternator housing (1). NOTE: The clearance between the head of the cap screw (3) and the flywheel housing (4) will not permit complete removal of the cap screws at all locations. Be sure all the cap screw threads are completely disengaged from the alternator housing (1).

C4-4

Power Train

5. Cap Screw 6. Cap Screw (12 each) 7. Engine Drive Ring 8. Alternator Rotor

6. Take up slack in hoist and remove cap screws and lockwashers (1, Figure 4-2) securing the alternator to the cradle structures. 7. Keep alternator as level as possible and move away from engine. 8. Note shim location and quantity. Retain shims for possible use during reinstallation. 9. For further disassembly instructions for the alternator refer to the General Electric Service Manual.

11/11 C04034

ENGINE/ALTERNATOR MATING Measuring Procedure Komatsu SSDA16V160 or SDA16V160 Engine

1. Thoroughly clean the alternator housing mounting surface, rotor drive adapter mounting surface and flywheel housing adapter mounting surfaces.

The following instructions must be followed to ensure proper alignment and engine crankshaft endplay. Failure to follow these instructions can result in serious damage to the engine and/or alternator. General Instructions

2. With magnetic base mounted on the front of the engine and the dial indicator on the front of the crankshaft, measure total crankshaft end-play: • Verify end play is within 0.13 - 0.38 mm (0.005 0.015 in.). Record Total Crankshaft End-play: ____________ 3. Refer to Figure 4-5. Move the engine crankshaft to the rear of its end travel. a. Carefully measure Dimension “C” at four locations, 90° apart:

• Never pry on the engine crankshaft damper! • Loosen or remove fan belt prior to measuring crankshaft end-play to insure that the crankshaft moves easily and completely.

1st measurement:_________________________ 2nd measurement: ________________________

• When taking measurements, always take four equally spaced readings and average them.

3rd measurement: ________________________

• Always measure from mating surface to mating surface.

Dimension “Cavg”: _________________ Average

4th measurement:_________________________

• References to crankshaft rotation; clockwise (CW), or counterclockwise (CCW), is the direction of rotation when looking at the front (damper end) of engine.

b. Add 1/2 (one-half) of Total Crankshaft Endplay from Step 2 to Dimension “Cavg”. c. Record (Step 3a + Step 3b) as Measurement “C”:___________________

• Crankshaft end-play for Komatsu SSDA16V160 or SDA16V160 Engine: 0.13 - 0.38 mm (0.005 - 0.015 in.).

SERVICE DATA - Eccentricity & Runout Limits Description

T.I.R.

Max. Flywheel Housing Bore Eccentricity

0.66 mm (0.026 in.)

Max. Face Runout, Flywheel Housing

0.25 mm (0.010 in.)

Max. Eccentricity of Flywheel (Coupling Assembly)

0.18 mm (0.007 in.)

Max. Axial Runout of Flywheel Face (Coupling Assembly)

0.25 mm (0.010 in.)

C04034 11/11

FIGURE 4-5. SHIM LOCATION 1. Alternator Housing 2. Alternator Rotor 3. Flywheel Housing Adapter 4. Flywheel Housing 5. Engine Drive Ring

Power Train

“A”: Dimension “A” “B”: Dimension “B” “C”: Dimension “C” “D”: Dimension “D”

C4-5

4. Refer to Figure 4-6. Alternator End-play: a. Using flat steel bar (3, Figure 4-6) bolted rigidly to the alternator rotor (2), install a 5/8" 11 cap screw (4) at each end into the alternator housing (1). Leave cap screws fingertight. b. Move alternator rotor (2) axially towards the rear (slip-ring end) by alternately tightening the cap screws (4) one-half-turn-at-a-time. Do NOT exceed 16.3 N·m (12 ft lbs) torque on each cap screw. This establishes the maximum permissible rear travel for the alternator rotor. c. Alternately loosen cap screws (4) one-turnat-a-time, until all torque is released. Carefully remove steel bar (3). Note: The object is to leave the rotor in its most rearward position. Refer to Figure 4-5. d. Carefully measure Dimension “A” (Do not move alternator rotor) at four locations, 90° apart, and average the measurements. 1st measurement: _________________________ 2nd measurement: ________________________ 3rd measurement: ________________________ 4th measurement:_________________________

FIGURE 4-6. ALTERNATOR END-PLAY 1. Alternator Housing 2. Alternator Rotor

3. Steel Bar 4. Cap Screw

Dimension “Aavg”: _________________ Average e. Add 0.25 mm (0.010 in.) “Aavg”.

to Dimension

f. Record (Step 4d + 4e) as Measurement “A” 5. To determine the correct shims to use, compare Measurement “C” (Step 3c) with Measurement “A” (Step 4f). a. If C is greater than A, subtract: (C - A) = B B = _____________ Shim pack thickness to be installed at location “B”, Figure 4-5.

b. If A is greater than C, subtract: (A - C) = D D = ___________ Shim pack thickness to be installed at location “D”, Figure 4-5.

Alternator-to-Flywheel Housing Adapter, Location “D” Shim Part Number

Rotor-to-Drive Ring, Location “B” Shim Part Number

C4-6

Shim Thickness

TM3466

0.10 mm (0.004 in.)

TM3468

0.78 mm (0.007 in.)

Shim Thickness

TM3467

0.10 mm (0.004 in.)

TM3469

0.18 mm (0.007 in.)

Power Train

11/11 C04034

8. Compare the step 7 value to the measurement taken before alternator was installed on engine.

Joining Alternator and Komatsu SSDA16V160 or SDA16V160 Engine

When lifting alternator, attach hoist to lift eyes only. The alternator weighs approximately 4037 kg (8,900 lbs). Use a lifting device that can handle the load safely.

1. Use the two top lift brackets provided on the alternator for lifting. The top front lifting bracket should be equipped with some method of adjusting the alternator to keep it horizontal. 2. Carefully move alternator into place and engage the engine drive ring (6, Figure 4-7) into the alternator rotor drive (7) using shims “B”, if required (refer to step 5.a. “Determining Shims”). 3. Install flywheel housing adapter cap screws (2) into alternator housing (1). Tighten to 237 N·m (175 ft lbs) torque. 4. Install cap screws (5) through engine drive ring (6) into the alternator rotor adapter (7). Rotate crankshaft to access and align holes. Tighten cap screws (5) to 237 N·m (175 ft lbs) torque. 5. Install alternator-to-cradle structure mounting cap screws and washers (1, Figure 4-2) and tighten to 1017 N·m (750 ft lbs) torque. 6. Tighten engine-to-cradle structure mounting cap screws (3, Figure 4-2) to 465 N·m (345 ft lbs) torque.

Never pry on the engine crankshaft damper! 7. With magnetic base mounted on the front of the engine and the dial indicator on the front of the crankshaft, measure total crankshaft end-play:

FIGURE 4-7. ALTERNATOR TO ENGINE MOUNTING 1. Alternator Housing 2. Cap Screw 3. Flywheel Housing Adapter 4. Engine Flywheel Housing

5. Cap Screw 6. Engine Drive Ring 7. Alternator Rotor “B” Drive Shims “D” Housing Shims

The total Engine Crankshaft End-play (step 7) must equal the original measurement or 0.51 mm (0.020 in.) (alternator end-play), whichever is smaller. If the end-play after the alternator and engine are assembled is less than 0.51 mm (0.020 in.), and less than the starting engine crankshaft end-play, RESHIMMING IS REQUIRED.

Record Total Crankshaft End-play: ____________

C04034 11/11

Power Train

C4-7

9. Rotate the crankshaft one full revolution and listen for any unusual noise caused by moving components contacting stationary parts. 10. Install engine sidecover, if removed. Install lockwire on all alternator mounting cap screws. 11. Remove barring tool and install access covers on flywheel housing.

ENGINE Removal Refer to instructions in previous sections for removal instructions for the Power Module, alternator, and radiator assembly.

12. Reinstall fan belt. Refer to engine manufacturer’s Operation and maintenance Manual. The engine weighs approximately 9616 kg (21,200 lbs) wet. Ensure lifting devices are capable of handling the load safely. 1. Disconnect any remaining wiring or hoses between the engine and subframe. 2. Remove cap screws and lockwashers (5, Figure 4-7) securing front engine mount to subframe. 3. Attach spreader bar with lifting straps at front lift hooks and rear lift hooks (6) on engine. Remove cap screws and lockwashers (2) at rear engine mount securing engine to cradle structure (1). Always use a spreader bar to ensure lift straps are vertical at each lift hook. 4. Lift engine from subframe and move to clean work area for further disassembly.

C4-8

Power Train

11/11 C04034

2. Install alternator on engine following instructions for “Engine/Alternator Mating”.

Service Complete instructions covering the disassembly, assembly and maintenance of the engine and its components can be found in the engine manufacturer's service manual. Installation 1. Align engine to subframe and install front mounting cap screws and lockwashers (5, Figure 4-7). Align and install rear engine mounting cap screws and lockwashers (2) through cradle structure, but do not tighten at this time. Tighten front mount cap screws to 465 N·m (345 ft lbs) torque.

3. Tighten rear engine mounting cap screws (2) to 465 N·m (345 ft lbs) torque after alternator is installed. 4. Adjust setscrew (3, Figure 4-1) to equalize gap (5) between cradle structure (1) and subframe (4) at left and right side. Lock setscrew with jam nut (2).

FIGURE 4-8. ENGINE MOUNTING 1. Cradle Structure 2. Cap Screws and Lockwashers

C04034 11/11

3. Engine Module Subframe 4. Engine

Power Train

5. Cap Screws and Lockwashers 6. Engine Lift Points

C4-9

NOTES:

C4-10

Power Train

11/11 C04034

SECTION C5 AIR CLEANERS INDEX

AIR CLEANERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3 SERVICING THE AIR CLEANERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-3 Replacing The Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-4 AIR CLEANER ASSEMBLY CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-5 Primary Element Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-5 Precleaner Section Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-7 AIR INTAKE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-8

C05020 9/10

Air Filtration System

C5-1

NOTES

C5-2

Air Filtration System

9/10 C05020

AIR CLEANERS OPERATION

SERVICING THE AIR CLEANERS

Air required by the diesel engine passes through the air cleaner assemblies mounted on each side of the radiator. These air cleaners discharge heavy particles of dust and dirt by centrifugal action and then remove finer particles by passing air through filter cartridges. The engine demand for air creates a vacuum in the air cleaners and causes outside air to be drawn in through air inlets on the air cleaners. Dirty air entering here is drawn through a series of tubes that are designed to produce a cyclonic action. As the air passes through the outer portion of the tubes, a circular motion is set up causing dust and dirt particles to be thrown from the air stream into dust collectors (1, Figure 5-1). At the same time, the air stream turns and is directed up through the center of the tubes into the filter chamber. Here the air passes through the main filter element and safety filter element and out the clean air outlet to the engine's air intake system. The function of the safety filter is to increase overall reliability and engine protection.

The engine must be turned off before servicing the air cleaner assemblies or opening the engine air intake system. Never start the engine with the filter elements removed. Serious engine damage can result. • Inspect and empty the dust cups at regular intervals. Daily inspection is recommended. Never allow the dust level to build up to the tube (precleaner) chamber. • During operation or after the engine has been turned off, observe the air filter restriction gauges mounted on the overhead panel in the cab. When a gauge shows maximum restriction, filter service is required. • Check all engine air inlet tubes, hoses and clamps. All connections must be air tight to prevent dirt from entering. • Air cleaner housing fasteners and mountings must be tight. • After the filters have been serviced, reset the air filter restriction gauges by pressing the reset button on the face of the gauge.

FIGURE 5-1. AIR CLEANERS 1. Dust Collectors 2. Precleaner Section

C05020 9/10

3. Air Intake Cover 4. Element Covers

Air Filtration System

C5-3

Replacing The Elements NOTE: The function of the safety element is to increase overall reliability and engine protection. If the safety element indicator shows red, the element has become clogged and should be replaced with a new one. 1. Turn off the engine. Clean any dirt and dust from the area around the element cover.

2. Loosen the clips on element cover (1, Figure 52) and remove the element cover. Pull primary element (2) from air cleaner assembly (4). 3. Inspect the primary element carefully for damage, holes or breaks which might affect reuse of the element. If the element appears serviceable, proceed with the cleaning procedure. If defects are found in the element, replace the element.

FIGURE 5-2. AIR CLEANER ASSEMBLY 1. Element Cover 2. Primary Element 3. Safety Element 4. Air Cleaner Assembly

C5-4

5. Gasket (long strips) 6. Gasket (short strips) 7. Precleaner Section 8. Clamp

Air Filtration System

9. O-Ring 10. Dust Cup 11. Dust Cup Valve 12. Air Intake Cover

9/10 C05020

AIR CLEANER ASSEMBLY CLEANING Primary Element Cleaning

Have a new safety (secondary) filter element on hand before removing the used filter element. Do not keep the intake system open to the atmosphere any longer than necessary. 4. If the safety element must be replaced, remove and discard the safety element. Do not clean the damaged or dirty safety element. 5. Install the new safety element. 6. Install primary element (2) into the air cleaner. If the original element is being reused, ensure the sealing gasket is not damaged. The gasket must seal completely. 7. If open, close and latch dust cup valves (11) on the bottom of dust cups (10).

Only the primary elements may be cleaned, and then only if they are structurally intact. Do not reuse an element that is damaged. Do not clean and reuse the safety elements. Replace them with new parts if necessary. After inspection, determine the condition of the primary element. Choose either the washing method or compressed air method for cleaning the element. If the element is clogged with carbon, soot, oil and/or dust, the complete washing procedure will produce the best results.

Wash elements with water and detergent as follows: 1. Soak the element in a solution of detergent and water for at least 15 minutes. Rotate the element back and forth in the solution to loosen dirt deposits. Do not soak elements for more than 24 hours. 2. Rinse the element with a stream of fresh water in the opposite direction of normal air flow until rinse water runs clear. Maximum permissible water pressure is 276 kPa (40 psi). A complete and thorough rinse is essential. 3. Dry the element thoroughly. If drying is done with heated air, the maximum temperature must not exceed 60°C (140°F) and must be circulated continually. Do not use a light bulb to dry elements.

C05020 9/10

Air Filtration System

C5-5

4. After cleaning, inspect the element thoroughly for the slightest ruptures and damaged gaskets. A good method for detecting paper ruptures is to place a light inside the filter element, as shown in Figure 5-3, and inspect the outer surface of the filter element. If holes or ruptures are found, do not reuse the element. Discard and replace with a new element. .

Clean dust loaded elements with dry filtered compressed air as follows: 1. Maximum nozzle pressure must not exceed 207 kPa (30 psi). The distance from the nozzle to the surface of the filter element must be at least 25 mm (1 in.) to prevent damage to the filter material. 2. As shown in Figure 5-4, direct the stream of air from the nozzle against the inside of the filter element. This is the clean air side of the element and air flow should be opposite of normal air flow. 3. Move the air flow up and down vertically with the pleats in the filter material while slowly rotating the filter element. 4. When cleaning is complete, inspect the filter element as shown in Figure 5-3. If holes or ruptures are noted, discard the element and replace with a new element.

FIGURE 5-3. INSPECTING THE FILTER ELEMENT

FIGURE 5-4. CLEANING THE FILTER ELEMENT WITH COMPRESSED AIR

C5-6

Air Filtration System

9/10 C05020

Precleaner Section Cleaning The tubes in precleaner section (7, Figure 5-2) should be cleaned at least once per year and at each engine overhaul. More frequent cleaning may be necessary depending upon operating conditions and and the local environment. To inspect the tubes in the precleaner section, remove the primary element. Do not remove the safety element. Loosen clamps (8) and remove dust cups (10) and O-rings (9). Use a light to inspect the tubes. All tubes should be clear and the light should be visible. NOTE: Both the primary and safety elements must be installed in the air cleaner while Steps 1 and 2 are being accomplished to prevent any possibility of dirt being forced into the engine intake area. Dust can be removed with a stiff fiber brush (see Figure 5-5). Do not use a wire brush. Dust may also be removed effectively using compressed air. Heavy plugging of the tubes may require soaking and washing the entire precleaner section. Refer to the following procedure.

NOTE: The precleaner section may be separated from the air cleaner assembly without removing the entire air cleaner from the truck. 1. Remove air intake cover (12, Figure 5-2). Remove the mounting hardware that secures precleaner section (7) to air cleaner assembly (4). Remove the precleaner section. The safety element must remain in place to protect the engine intake. 2. Loosen clamps (8) and remove dust cups (10) and O-rings (9) from the precleaner section. Wash the dust cups with a water and liquid soap solution. 3. Submerge the precleaner section in a solution of Donaldson D-1400 and warm water (see Figure 5-6). Mix the solution according to the directions on the package. The tube section must be down. Soak for 30 minutes, then remove the precleaner section from the solution. Rinse thoroughly with fresh water and blow dry. Severe plugging may require the use of an Oakite 202 and water solution instead. The solution should be 50% Oakite 202 and 50% fresh water. 4. Check precleaner gaskets carefully for any evidence of air leaks. Replace if necessary. 5. Install precleaner section (7) and gaskets (5) and (6) on air cleaner assembly (4). Install all mounting hardware that was removed. 6. Install dust cups (10) and O-rings (9) on the precleaner section. Secure the dust cups with clamps (8).

FIGURE 5-5. REMOVING DUST FROM THE TUBES

FIGURE 5-6. WASHING AND SOAKING THE PRECLEANER SECTION

C05020 9/10

Air Filtration System

C5-7

AIR INTAKE TROUBLESHOOTING To ensure maximum engine protection, ensure that all connections between the air cleaners and engine intake are tight and positively sealed. If air leaks are suspected, check the following: 1. All intake lines, tubes and hump hoses for breaks, cracks, holes, etc, which could allow an intake air leak. 2. Check all air cleaner gaskets for positive sealing. 3. Check the primary and safety elements for ruptures, holes or cracks. 4. Check air cleaner assembly for structural damage, cracks, breaks or other defects which could allow air leakage. Check all mounting hardware for tightness.

C5-8

Air Filtration System

9/10 C05020

SECTION C7 FAN CLUTCH INDEX

REMOVAL & INSTALLATION TOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-6 CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-16 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-20 TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-34

C07001

Fan Clutch

C7-1

NOTES

C7-2

Fan Clutch

C07001

FAN CLUTCH REMOVAL & INSTALLATION TOOLING

TOOL

TOOL

C07001

A

B

-

-

FRONT

SLEEVE

BEARING

REAR

SLEEVE

BEARING

Fan Clutch

C7-3

TOOL C - FRONT AND REAR SLEEVE BEARING REMOVER

TOOL D - WEAR SLEEVE AND RETAINER/SEAL ASSEMBLY INSTALLER; BEARING REMOVER; ASSEMBLY PUSHER TOOL

C7-4

Fan Clutch

C07001

TOOL E - BEARING INSTALLER

TOOL

C07001

F

-

BEARING

Fan Clutch

INSTALLER

C7-5

DISASSEMBLY

FIGURE 7-1. FAN CLUTCH EXPLODED VIEW 1. Orifice Fitting 2. Dowel Pin (Rear) 3. Pitot Tube 4. Wear Sleeve 5. Retainer/Seal Assembly 6. Shaft Assembly 7. Name Plate Kit 8. Washer 9. Bolt 10. Oil Seal 11. Bearing Retainer (Rear) 12. Bearing Spacer (External Snap Ring) 13. O-Ring Seal 14. Main Bearing (Rear) 15. Internal Snap Ring

C7-6

16. External Snap Ring (Spacer) 17. Seal Ring (Hook-Type) 18. Bolt 19. Washer 20. Pulley 21. Pulley Adapter 22. Seal Ring (Large) 23. Piston 24. Seal Ring (Small) 25. Spring Washer 26. Shim 27. External Snap Ring 28. External Snap Ring 29. Clutch Hub 30. Facing Plate 31. Steel Clutch Plate

Fan Clutch

32. Internal Snap Ring 33. Main Bearing (Front) 34. O-Ring Seal 35. Bearing Retainer (Front) 36. Oil Seal 37. Washer 38. Bolt 39. Wear Sleeve 40. Retainer/Seal Assembly 41. Sleeve Bearing (Rear, Short) 42. Fan Mounting Hub 43. Dowel Pin (Front) 44. Sleeve Bearing (Front, Long) 45. End Cap

C07001

3. Pitot Tube 4. Wear Sleeve 5. Retainer/Seal Assembly 6. Shaft Assembly 8. Washer 9. Bolt 10. Oil Seal 11. Bearing Retainer 13. O-Ring Seal

C07001

FIGURE 7-1. FAN CLUTCH CUTAWAY (Typical) 27. External Snap Ring 14. Main Bearing 28. External Snap Ring 15. Internal Snap Ring 29. Clutch Hub 16. External Snap Ring 17. Seal Ring (Hook-Type) 30. Facing Plate 31. Steel Clutch Plate 20. Pulley 32. Internal Snap Ring 22. Seal Ring (Large) 33. Main Bearing 23. Piston 34. O-Ring Seal 24. Seal Ring (Small) 35. Bearing Retainer 25. Spring Washer 36. Oil Seal 26. Shim

Fan Clutch

37. Washer 38. Bolt 39. Wear Sleeve 40. Retainer/Seal Assembly 41. Sleeve Bearing (Rear, Short) 42. Fan Mounting Hub 44. Sleeve Bearing (Front, Long) 45. End Cap

C7-7

FIGURE 7-4.

FIGURE 7-2. 1. Support the fan clutch on a bench with fan mounting hub (42) facing upward. Support the assembly beneath the pulley. Remove bolts (38) and washers (37).

FIGURE 7-5.

FIGURE 7-3. 2. Install lifting eyes, and attach a hoist and chains to front bearing retainer (35). Use a small screwdriver to separate the front bearing retainer from pulley adapter (21), and set it aside on a bench.

C7-8

3. Remove O-ring seal (34).

Fan Clutch

4. Position the bearing retainer and hub assembly on the bench with clutch hub (29) up. Remove external snap ring (28).

C07001

FIGURE 7-8. FIGURE 7-6.

7. Remove front oil seal (36).

5. Remove clutch hub (29).

FIGURE 7-9. FIGURE 7-7. 8. Remove internal snap ring (32). 6. Position the sub-assembly beneath the ram of a press. Support the assembly beneath the bearing retainer as close as possible to fan mounting hub (42). Press the fan mounting hub out of the front bearing using tooling (B).

C07001

Fan Clutch

C7-9

FIGURE 7-10. FIGURE 7-12.

9. Turn bearing retainer (35) over on the press bed. Press front bearing (33) out of the bearing retainer using tooling (D).

11. Remove front retainer/seal assembly (40). Wedge a large chisel or other appropriate tool behind the retainer to force it off fan mounting hub (42).

FIGURE 7-13. Use a chisel to make three indentations in wear sleeve (39) in order to loosen the sleeve. The indentations should be approximately 120 degrees apart from one another. Remove the wear sleeve.

FIGURE 7-11. 10. Support beneath the fan mounting hub with end cap (45) down, but approximately 50 mm (2 in.) above the press bed. Using a solid steel bar or equivalent, press the end cap from the fan mounting hub.

C7-10

NOTE: Use caution when using the chisel. Do not cut through the sleeve. Damage to the shaft can cause future leaks.

Fan Clutch

C07001

FIGURE 7-14. 12. Inspect sleeve bearing (44) and sleeve bearing (41). Compare the color of each bearing to the chart above. The lighter the appearance of the bearing, the more worn it is. If either bearing needs replacing, proceed to the next step. If the bearings are in good condition, skip the next step.

FIGURE 7-16. 14. Remove the stack of facing plates (30) and steel clutch plates (31) from inside the pulley.

FIGURE 7-17.

15. Remove external snap ring (27), shim (26), and spring washer (25).

FIGURE 7-15. 13. Position tooling (C) against sleeve bearing (41). Press the front sleeve bearing downward to press it out of the fan mounting hub. Rear sleeve bearing (44) will be pressed out simultaneously.

C07001

Fan Clutch

C7-11

FIGURE 7-20. FIGURE 7-18. 16. Attach wire lifting hooks to piston (23). Use the lifting hooks to pull the piston from pulley adapter (21).

18. Support beneath the pulley to prevent it from dropping to the bench. Remove bolts (9) and lockwashers (8).

FIGURE 7-19. FIGURE 7-21. 17. Remove seal rings (22) and (24) from the piston.

19. Install lifting eyebolts to the shaft and bearing retainer assembly. Use a suitable lifting device to lift the assembly from the pulley. Remove Oring seal (13). NOTE: It may be necessary to use a soft rubber mallet to separate the shaft and bearing retainer from the pulley.

C7-12

Fan Clutch

C07001

FIGURE 7-22. 20. Position the shaft as shown. Insert a phillipshead screwdriver into pitot tubes (3) to loosen and remove them from the shaft. Rotate the pitot tube until the sealant holding it tight is broken loose. Then grip the pitot tube with a pair of pliers and gently tap on the pliers to remove the pitot tubes from the hole in the shaft.

FIGURE 7-24.

22. Remove external snap ring (16).

FIGURE 7-25. FIGURE 7-23.

21. Remove both seal rings (17).

C07001

23. Remove internal snap ring (15).

Fan Clutch

C7-13

FIGURE 7-28.

26. Use tooling (E) to press rear bearing (14) out of rear bearing retainer (11).

FIGURE 7-26.

24. Support the bearing retainer as close as possible to the bearing bore. Be careful not to damage the retainer/seal assembly. Press the shaft out of bearing (14) using tooling (E).

FIGURE 7-29. 27. Use a chisel to make three indentations in wear sleeve (4). The indentations should be approximately 120 degrees apart from one another. Remove the wear sleeve.

FIGURE 7-27.

25. Remove oil seal (10) from bearing retainer (11).

C7-14

NOTE: Use caution when using the chisel. Do not cut through the sleeve. Damage to the shaft can cause future leaks.

Fan Clutch

C07001

FIGURE 7-30.

28. Remove rear retainer/seal assembly (5). Drive the assembly off the shaft or wedge a large chisel or other appropriate tool behind the retainer to force it off.

C07001

Fan Clutch

C7-15

CLEANING AND INSPECTION Thoroughly clean all components before inspection. Check each of the following components, and follow the guidelines for reuse: • Ball bearings - Replace at time of rebuild. • Internal snap rings - Must not be damaged or worn. Must be flat and have square edges at outer diameter. • External snap rings - Must not be damaged or worn. Must be flat and have square edges at inner diameter. • Seal rings - Replace during rebuild. • Oil seals - Replace during rebuild. • Bolts and washers - Reuse unless damaged or worn. • Retainer/Seal assemblies - Replace if damaged or worn. • Wear sleeves - Replace during rebuild. • Sleeve bearings - Inspect color of surface. Refer to Figure 7-14.

FIGURE 7-31. SHAFT ASSEMBLY WEAR DIMENSIONS 1. Check the shaft assembly for wear or damage. Refer to Figure 7-31 for dimensions. NOTE: Some shafts were manufactured as two-piece assemblies. Do not attempt to separate the shaft assembly. 2. Inspect and clean the pitot tube holes in the shaft. Use a standard reamer (straight flute, 0.3770 in. diameter). Remove pipe plugs in the shaft for cleaning and reinstall using Loctite® Primer N and #242.

C7-16

Fan Clutch

C07001

FIGURE 7-32.

3. Check pulley and adapter dimensions.

FIGURE 7-34.

5. Check piston (23) dimensions.

FIGURE 7-33.

4. Check rear bearing retainer (11) dimensions.

C07001

Fan Clutch

C7-17

FIGURE 7-35. PISTON REWORK (For earlier pistons with the drilled orifice.)

6. Check the piston for a drilled orifice at the inside face. If the piston contains the orifice, modify the piston as shown in Figure 7-35. 7. Inspect clutch hub (29) for wear. Wear marks that may be present on the teeth must not restrict plate movement. If they have smooth entry and exit ramps, the notches will not restrict plate movement and the clutch hub may be reused. 8. Check steel plates (31) for wear. The plates must be smooth and free of grooves or heat related damage. The plates are 3.07 mm (0.121 in.) minimum thickness when new and must be flat within 0.13 mm (0.005 in.). 9. Inspect facing plates (30). Minimum thickness for new facing plates is 2.77 mm (0.109 in.). Grooves are 0.15 mm (0.006 in.) deep. The plates must be flat within 0.13 mm (0.005 in.). Check the teeth for excessive wear. When new, the space between the teeth is approximately 7.11 mm (0.280 in.). FIGURE 7-36.

10. Inspect fan mounting hub (42).

C7-18

Fan Clutch

C07001

FIGURE 7-37.

11. Inspect front bearing retainer (35). 12. Inspect end cap (45) for any wear or raised nicks.

C07001

Fan Clutch

C7-19

ASSEMBLY NOTE: The fan clutch is reassembled using Loctite ® (or equivalent) sealants. Follow manufacturer's recommendations regarding minimum cure time to prevent oil from washing the sealant from the sealing surfaces. 1. Place end cap (45) in a freezer or on dry ice to prepare for installation in the following steps.

2. If removed, install dowel pin (43) into fan mounting hub assembly (42). Refer to Figure 738. Press the pin into the hub, leaving 2.3 mm (0.090 in.) exposed. If the shaft did not originally come with pinned bearings, install the dowel per instructions in Figures 7-38 and 7-39.

FIGURE 7-39.

FIGURE 7-38.

C7-20

Fan Clutch

C07001

FIGURE 7-40.

FIGURE 7-42. 4. Turn the hub over on the bed of the press. Using tooling (B), press rear sleeve bearing (41) into the fan mounting hub until the tool contacts the shoulder of the hub.

FIGURE 7-41.

3. Using tooling (A), press front (long) sleeve bearing (44) into the fan mounting hub until the tool contacts the shoulder of the hub. Ensure the correct bearing is installed. There are two sleeve bearings, and each one must be installed in the proper area of the hub to ensure the lube passage is not restricted. Refer to Figure 7-40.

C07001

Fan Clutch

C7-21

FIGURE 7-44.

FIGURE 7-43. 5. Press front retainer/seal assembly (40) onto the fan mounting hub (42) using tooling (D). The inner race of the retainer should be recessed 1.0 mm (0.040 in.) below the shoulder. Check carefully to ensure that the retainer/seal assembly is installed straight and is not bent or damaged in any way which will cause interference between it and the bearing retainer after assembly.

• Front wear sleeve (39) is NOT interchangeable with rear (notched) wear sleeve (4). The inside diameter of the front wear sleeve is color coded red. • Note the direction of the lead pattern on the sleeve. The wear sleeve must be installed with the pattern leading in the correct direction in order to prevent leakage from occurring. • Use extreme care when handling the wear sleeve. The slightest nicks or scratches may cause leakage.

FIGURE 7-45.

6. Coat the inside diameter of front wear sleeve (39) and the wear sleeve diameter of the shaft with Loctite Primer N and #242 (or equivalent). Using tooling (D), press the wear sleeve onto the shaft until it is flush with the shoulder.

NOTE: Some fan hubs may have a small hole on the wear sleeve mounting journal. This hole is not used and will be covered by the wear sleeve.

C7-22

Fan Clutch

C07001

FIGURE 7-46.

FIGURE 7-48.

7. Coat the bore of the fan mounting hub (42) with a thin coating of Loctite Primer N and #242.

9. Install internal snap ring (32).

Remove frozen end cap (45) from the freezer. Do not apply Loctite to the end cap. Press the end cap into the hub until the cap bottoms out.

FIGURE 7-47. FIGURE 7-49. 8. Apply Loctite Primer N and #609 to the mating surfaces of front bearing (33) and front bearing retainer (35). Place the bearing into position on the retainer with the notch for the bearing pin facing downward.

10. Turn the retainer over on the press bed. Coat the outside diameter of front oil seal (36) and the mating surface on the bearing retainer with Loctite Primer N and #242 (or equivalent).

Press the front bearing into the bearing retainer using tooling (E) or equivalent. Press ONLY on the outer race of the bearing until it seats at the bottom of the bore.

Use tooling (E) to press the oil seal into the front bearing retainer until it is flush with the front face. Ensure that the lip of the seal is dry. Wipe any excess Loctite from the seal area and remove any rubber strings from the seal.

C07001

Fan Clutch

C7-23

FIGURE 7-50. 11. Coat the inside diameter of the bearing and the fan mounting hub bearing journal with Loctite Primer N and #609 (or equivalent). Place the front bearing retainer sub-assembly into position on the fan mounting hub. Ensure the notch in the bearing is aligned with the bearing dowel pin. Do not allow the seal lip to come in contact with the Loctite. Press the bearing onto the hub using tooling (D) until it contacts the wear sleeve.

FIGURE 7-51.

12. Install clutch hub (29) on the fan mounting hub assembly (42) with the open end down. (No special timing is necessary.)

Wipe any lubricant or sealer from the seal lip. The seal lip is teflon and must remain dry for proper sealing to occur. Spin the bearing retainer at least 25 revolutions to ensure proper rotation of the bearing and to burnish the seal.

FIGURE 7-52. 13. Install external snap ring (28) to hold the clutch hub in place.

C7-24

Fan Clutch

C07001

FIGURE 7-53.

FIGURE 7-55.

15. Use tooling (D) to press rear retainer/seal assembly (5) onto shaft (6). The inner race of the retainer should be recessed 1.0 mm (0.040 in.) below the shoulder. Check carefully to ensure that the retainer/seal assembly is installed straight and not bent or damaged in any way which will cause interference between it and the bearing retainer after assembly.

FIGURE 7-54.

14. If removed, install rear dowel pin (2) in shaft assembly (6). Press the pin until 2.0 mm (0.080 in.) is left exposed above the surface. If the shaft did not originally come with pinned bearings, install the dowel per instructions in Figures 7-53 &7-54.

C07001

Fan Clutch

C7-25

FIGURE 7-57. FIGURE 7-56.

17. Coat the outside diameter of rear bearing (14) and the mating surface of bearing retainer (11) with Loctite Primer N and #609 or equivalent. The end of the bearing with the notch is installed first. Using tooling (F) or equivalent, press the bearing into the bearing retainer. Press ONLY on the outer race of the bearing until the bearing bottoms out in the bore.

• Rear (notched) wear sleeve (4) is NOT interchangeable with front wear sleeve (39). The inside diameter of the rear wear sleeve is color coded blue. • Note the direction of the lead pattern on the sleeve. The wear sleeve must be installed with the pattern leading in the correct direction in order to prevent leakage from occurring. • Use extreme care when handling the wear sleeve. The slightest nicks or scratches may cause leakage. 16. Coat the inside diameter of rear (notched) wear sleeve (4) and the wear sleeve diameter of the fan mounting hub with Loctite Primer N and #242 (or equivalent). Locate the sleeve so the notch in the sleeve will be aligned with the small lube hole in the shoulder. Using tooling (D), press the wear sleeve onto the fan mounting hub until it is flush with the shoulder.

C7-26

FIGURE 7-58.

18. Install internal snap ring (15).

Fan Clutch

C07001

FIGURE 7-59. 19. Some fan clutches were assembled with an external snap ring that is used as a spacer between the bearing and the oil seal. Newer models were assembled using a notched spacer. If an external snap ring was used, place snap ring (12) on top of the bearing (oil seal side). If a notched spacer was used, the spacer will be installed in a later step. Proceed to the next step.

FIGURE 7-60. FIGURE 7-61. 20. Coat the outside diameter of rear oil seal (10) with Loctite Primer N and #242 (or equivalent). Use tooling (E) or an equivalent to install the oil seal in the rear bearing retainer until it is flush with the rear face.

21. If a bearing spacer is used instead of a snap ring (as explained in Step 19), place the spacer into position in the groove on shaft assembly (6). Note the location of the spacer in Figure 761.

Do not lubricate the seal. The seal is made of teflon and must be installed dry.

C07001

Fan Clutch

C7-27

FIGURE 7-62. FIGURE 7-63.

22. Place the shaft sub-assembly on the press bed. Coat the inside diameter of the bearing and the bearing journal on the shaft with Loctite Primer N and #609 (or equivalent).

23. Install external snap ring (16). Ensure that the snap ring is fully seated in the groove. It may be necessary to tap on the snap ring with a screwdriver to fully seat it.

Carefully, lower the rear bearing retainer subassembly in place on the shaft. Do not allow the seal lip to come in contact with the Loctite. Ensure the notch in the bearing and the dowel pin are aligned. If external snap ring (16) was installed in the bearing retainer, ensure the opening is aligned with the dowel pin. Press the bearing onto the shaft until it reaches the shoulder of the wear sleeve. Wipe any excess Loctite from the assembly. Ensure the seal lip is dry. The seal must remain dry for proper sealing. Spin the bearing retainer approximately 25 times to burnish the teflon seal on the wear sleeve. Check for abnormal sounds or other indications of contact between the retainer/seal assembly and the bearing retainer. If interference is found, remove the bearing retainer and eliminate the point of interference.

C7-28

FIGURE 7-64. 24. Ensure that the pitot tube holes in the shaft are clean and free of burrs and staking material to allow the pitot tubes to fit into the holes and seat completely to the bottom. Apply a thin coating of Loctite Primer N and #609 (or equivalent) on the straight end of one pitot tube (3). Coat the tube to approximately 20 mm (0.75 in.) from the end.

Fan Clutch

C07001

Push the pitot tubes to the bottom of the hole. The outer end of the tube should be located well within the pulley-locating shoulder of the bearing retainer. Rotate the tube so the open, bent end faces in a counterclockwise direction and is exactly parallel to the surface of the bearing retainer. (A large phillips-head screwdriver inserted in the end of the tube can be used as an alignment gage). Install the second pitot tube in the same manner as the first. Stake each pitot tube in three places (at the 9, 12, and 3 o'clock positions) to prevent the tubes from rotating in operation.

FIGURE 7-66.

26. Lubricate the seal ring grooves of piston (23) with an oil-soluble lubricant such as engine assembly grease. Install small seal ring (24) in the inside groove and large seal ring (22) in the outside groove. Refer to Figure 7-66 for proper orientation.

FIGURE 7-65.

25. Install both hook-type seal rings (17) in the grooves in the shaft. Rotate the rings so the slits in the rings are 180 degrees apart from one another.

FIGURE 7-67.

27. Lubricate the external surfaces of seal rings (22) and (24) with an oil-soluble lubricant such as engine assembly grease. Also lubricate the seal mating surfaces in the pulley adapter.

C07001

Fan Clutch

C7-29

Do not push the piston in place. Forcing the piston will usually cause the seal rings to be cut. 28. Carefully place the piston in the pulley. Without pressing down on the piston, rotate it slowly back and forth until it falls into place.

FIGURE 7-69. 30. Install spring washer (25), shim (26), and spirolock ring (27). It will be necessary to press downward to compress the spring washer while forcing the spirolock to properly seat in the groove. The shim must then be centered on the spring washer to prevent it from interfering with the movement of the piston.

FIGURE 7-68.

29. Align the tangs of the piston for final assembly of the fan clutch. Lift the front bearing retainer sub-assembly in place on the pulley. While doing so, the slots of the front bearing retainer will engage the tangs of the piston, and the retainer will rest against the pulley. Then, rotate the bearing retainer (and piston) until the bolt holes align in the bearing retainer and pulley. Carefully remove the bearing retainer sub-assembly.

FIGURE 7-70. 31. Place the front bearing retainer sub-assembly on the bench with the clutch hub up. Install one steel clutch plate (31) in place in the bearing retainer. Dip one facing plate (30) in new engine oil. Allow the excess oil to drain off, then place the facing plate on top of the steel plate. Repeat this step until all 16 plates have been installed.

C7-30

Fan Clutch

C07001

32. Turn the pulley adapter assembly over and install two lifting eyes 180 degrees apart. Install a guide bolt in one bolt hole of the pulley. Refer to Figure 7-71. Coat front O-ring seal (34) with petroleum jelly or an oil-soluble grease. Place the seal in the groove in the pulley. The grease should secure the seal in the groove during installation. Carefully lower the pulley. Ensure that the guide bolt is aligned with a bolt hole in the bearing retainer assembly and the O-ring seal is still securely in place. Lower the pulley until it rests on the front bearing retainer.

FIGURE 7-71.

FIGURE 7-73. 33. Install at least four bolts (38) with lockwashers (37) 90 degrees apart. Snug them down.

FIGURE 7-72.

C07001

Fan Clutch

C7-31

FIGURE 7-76. FIGURE 7-74.

36. Install bolts (9) with lockwashers (8). Tighten each bolt to 49 - 58 N•m (36 - 43 ft lbs).

34. Lubricate O-ring seal (13) with petroleum jelly or an oil-soluble grease and install it in the pulley groove.

FIGURE 7-77. FIGURE 7-75. 35. Lubricate hook-type seal rings (17) on the shaft assembly. Carefully lower the shaft subassembly into the pulley bore and onto the pulley until the retainer rests on the pulley.

37. If removed, install orifice fitting (1) in the “oil in” port of the bracket.

Use caution when lowering. Damage to the sleeve bearings may result if the shaft is cocked during installation.

C7-32

Fan Clutch

C07001

FIGURE 7-78.

38. Turn the assembly over on the bench. Install remaining bolts (38) and lockwashers (37). Tighten each bolt to 49 - 58 N•m (36 - 43 ft lbs).

C07001

Fan Clutch

C7-33

TEST PROCEDURE

1. The fan clutch should be fully locked up with 275 kPa (40 psi) oil pressure supplied at the control pressure port. 2. Operate the fan clutch with 82° C (180° F) oil supplied to the “oil in” port for 2 hours. Manually engage and disengage the clutch during the test to operate seals in both modes. Restrict the fan mounting hub rotation while the clutch is disengaged, but ensure that the fan mounting hub is allowed to rotate freely while the clutch is engaged.

The fan clutch rotation causes the pitot tubes to pump lubricating oil from inside the fan clutch, maintaining low internal oil pressure. If lubricating oil is supplied to the fan clutch before it is rotating in the proper direction, internal pressures will become excessive, causing the oil seals to leak.

C7-34

Fan Clutch

C07001

SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEX 24VDC ELECTRIC SUPPLY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-1 24VDC ELECTRICAL SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-1 KOMTRAX Plus SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-1 INTERFACE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-1 KOMTRAX Plus AND INTERFACE MODULE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . D13-1 KOMTRAX Plus FORMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D14-1

NOTE: Electrical system wiring hookup and electrical schematics are located in Section R of this manual.

DANGEROUS VOLTAGE LEVELS ARE PRESENT WHEN THE TRUCK IS RUNNING AND CONTINUE TO EXIST AFTER SHUTDOWN IF THE REQUIRED SHUTDOWN PROCEDURES ARE NOT FOLLOWED. Before attempting repairs or working near propulsion system components, the following precautions and truck shutdown procedure must be followed:

•DO NOT step on or use any power cable as a handhold. •Never open any electrical cabinet covers or touch the retarding grid elements. Additional procedures are required before it is safe to do so. Refer to Section E for additional propulsion system safety checks to be performed by a technician trained to service the system.

•ALL removal, repairs and installation of propulsion system electrical components, cables etc. must be performed by an electrical maintenance technician properly trained to service the system.

•In the event of a propulsion system malfunction, a qualified technician should inspect the truck and verify the propulsion system does not have dangerous voltage levels present before repairs are started.

•Prior to welding on the truck, maintenance personnel should attempt to notify the Komatsu Factory Representative. The welding ground electrode should be attached as close as possible to the area to be welded. Never weld on the rear of the electrical control cabinet or the retard grid exhaust air louvers. After the truck is parked in position for the repairs, the truck must be shut down properly to ensure the safety of anyone working in the areas of the deck, electrical cabinet, traction motors, and retarding grids. The following procedure will ensure that the electrical system is properly discharged before repairs are begun.

D01047

Index

D1-1

TRUCK SHUTDOWN PROCEDURE 1. Reduce the engine speed to idle. Place the directional control lever in PARK. Ensure that the parking brake applied indicator light in the overhead panel is illuminated. 2. Place the drive system in the rest mode by turning the rest switch on the instrument panel ON. Ensure that the rest mode indicator light is illuminated. 3. Shut down the engine using the key switch. If the engine does not shut down, use the emergency shutdown switch on the center console. 4. After approximately 90 seconds, verify that the steering accumulators have bled down by attempting to turn the steering wheel. 5. Verify that the link voltage lights on the electrical cabinet and the DID panel in the cab are OFF. If they remain on longer than five minutes after shutdown, the propulsion system must be inspected by a technician who is trained to investigate the cause. 6. Place the GF cutout switch, located in the information display panel at the left side of the electrical control cabinet, in the CUTOUT position.

D1-2

Index

D01047

SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM INDEX

24VDC ELECTRIC SUPPLY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3 ELECTRICAL SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3 BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3 Maintenance and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-3 BATTERY SUPPLY SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-5 24VDC Battery Charging Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-5 Battery Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-5 Battery Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6 24VDC Auxiliary Battery Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6 Engine Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6 ISOLATION BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6 Engine Shutdown Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6 Access Ladder Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6 Battery Disconnect Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-6 Propel Lockout Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-7 LED Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-7 AUXILIARY CONTROL CABINET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-8 24VDC to 12VDC Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-8 24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE). . . . . . . . . . . . . . . . . . . . D2-9 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-9 Engine Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-9 Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-9

D02044

24VDC Electric Supply System

D2-1

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-9 Prelube System Operation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-9 Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-9 TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-10 24VDC ELECTRIC START SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-12 CRANKING MOTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-12 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-12 CRANKING MOTOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-13 Preliminary Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-13 No-Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-13 Interpreting Results of Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-14 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-14 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-15 Armature Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-17 Field Coil Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-17 Field Coil Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-17 SOLENOID CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-18 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-18 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-19 Bearing Replacement: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-19 Motor Assembly: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-19 Pinion Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-20 MAGNETIC SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-20 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-20 Coil Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-21

D2-2

24VDC Electric Supply System

D02044

24VDC ELECTRIC SUPPLY SYSTEM ELECTRICAL SYSTEM DESCRIPTION The truck uses a 24VDC electrical system which supplies power for engine starting circuits and most nonpropulsion electrical components. The 24VDC engine starting circuit is supplied by four heavy duty, Type 8D, 12-volt storage batteries. Several components require 12VDC electrical power and are supplied by a 60 amp 24VDC to 12VDC converter. The batteries are of the lead-acid type, each containing six 2-volt cells. With the engine off, power is supplied by the batteries. During engine cranking, power is supplied by the four engine cranking batteries only. When the engine is running, power is supplied by a high capacity alternator that is driven by the engine.

DO NOT SMOKE or allow flame around a dead battery or during the recharging process. The expelled gas from a dead cell is extremely explosive. Excessive consumption of water indicates leakage or overcharging. Normal water usage for a unit operating eight hours per day is about 30 to 60 cm3 (1 to 2 oz.) per cell per month. For heavy duty operation (24 hours per day), normal consumption will be approximately 30 to 60 cm3 (1 to 2 oz.) per cell per week. Any appreciable increase over these figures are considered a danger signal. Troubleshooting

Lead-acid storage batteries contain sulfuric acid which, if handled improperly, may cause serious burns on skin or other serious injuries to personnel. Wear protective gloves, aprons and eye protection when handling and servicing lead-acid storage batteries. See the precautions in Section A of this manual to ensure proper handling of batteries and accidents involving sulfuric acid. During operation, the storage 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.

Two most common problems that occur in the charging system are undercharging and overcharging of the truck's batteries. An undercharged battery is incapable of providing sufficient power to the truck's electrical system. Some possible causes for an undercharged battery are: • Sulfated battery plates • Loose or corroded battery connections • Defective wire in electrical system • Loose alternator drive belt • Defective alternator

BATTERIES Maintenance and Service The electrolyte level of each cell must be checked at the interval specified in Section P, Lubrication and Service. Add water if necessary. The proper level to maintain is 10 to 13 mm (3/8 to 1/2 in.) above the plates. To ensure maximum battery life, use only distilled water or other types of water recommended by the battery manufacturer. After adding water in freezing weather, operate the engine for at least 30 minutes to thoroughly mix the electrolyte.

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Overcharging, which causes overheating, is first indicated by excessive use of water. If allowed to continue, the cell covers will push up at the positive ends and, in extreme cases, the battery container will become distorted and cracked. Leakage can be detected by continual wetness of the battery or excessive corrosion of the terminals, battery carrier and surrounding area. (A slight amount of corrosion is normal in lead-acid batteries). Inspect the case, covers and sealing compound for holes, cracks and other signs of leakage. Check the battery hold down connections to ensure that the tension is not great enough to crack the battery or loose enough to allow vibration to open the seams. A leaking battery must be replaced.

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To remove corrosion, clean the battery with a solution of ordinary baking soda and a stiff, non-wire brush and flush with clean water. Ensure that none of the soda solution is allowed to enter the battery cells. Ensure that the terminals are clean and tight. Clean terminals are very important in a voltage regulated system. Corrosion creates resistance in the charging circuit, which causes undercharging and gradual starvation of the battery. NOTE: When washing batteries, ensure that the cell caps are tight to prevent cleaning solution from entering the cells. Addition of acid will be necessary if considerable electrolyte has been lost through spillage. Before adding acid, ensure that the battery is fully charged by putting the battery on charge and taking hourly specific gravity readings on each cell. When all the cells are gassing freely and three successive hourly readings show no rise in specific gravity, the battery is considered charged. Additional acid may now be added. Continue charging for another hour and check specific gravity again. Repeat the above procedure until all cells indicate a specific gravity of 1.260 - 1.265 corrected to 27°C (80°F). Use 1.400 strength sulfuric acid when making specific gravity adjustments. Acid of higher strength will attack the plates and separators before it has a chance to diffuse into the solution. If the temperature of the electrolyte is not reasonably close to 27°C (80°F) when the specific gravity is taken, temperature must be corrected to 27°C (80°F) as follows: • For every 5°C (10°F) below 27°C (80°F), 0.004 must be SUBTRACTED from the specific gravity reading.

The rate of self-discharge of a battery kept at 38°C (100°F) is about six times that of a battery kept at 10°C (50°F), and self-discharge of a battery kept at 27°C (80°F) is about four times that one at 10°C (50°F). Over a 30 day period, the average self-discharge runs about 0.002 specific gravity per day at 27°C (80°F). To offset the results of self-discharge, idle batteries must receive a booster charge (not a quick charge) at least once every 30 days. Batteries allowed to stand for long periods in a discharged condition are attacked by a crystallization of the lead sulfate on the plates. Such batteries are called “sulfated” and are, in the majority of cases, irreparably damaged. In less severe cases, the sulfated battery may be restored to limited service by prolonged charging at a low rate (approximately 1/2 normal rate). An undercharged battery is extremely susceptible to freezing when allowed to stand in cold weather. The electrolyte of a battery in various stages of charge will start to freeze at temperatures indicated in the table below. The temperatures in the table below indicate the points at which the first ice crystals appear. Lower temperatures must be reached for a solid freeze. Solid freezing of the electrolyte may crack the battery case and damage the positive plates. As will be noted, a charged battery is in no danger of freezing. Therefore, a battery must be kept charged, especially during winter weather.

SPECIFIC GRAVITY Corrected to 27°C (80°F)

FREEZING TEMPERATURE

1.280

-70°C (-94°F)

1.250

-54°C (-65°F)

1.200

-27°C (-16°F)

1.150

-15°C (+5°F)

1.100

-7°C (+19°F)

• For every 5°C (10°F) above 27°C (80°F), 0.004 must be ADDED to the reading. Idle batteries must not be allowed to stand unattended. If equipment is to stand unused for more than two weeks, the batteries must be removed and placed in a cool, dry place where they may be checked periodically and charged when necessary. Remember, all lead-acid batteries discharge slowly when not in use. This self-discharge takes place even though the battery is not connected in a circuit, and it is more pronounced in warm weather than in cold weather.

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24VDC Electric Supply System

D02044

BATTERY SUPPLY SYSTEM 24VDC Battery Charging Alternator The battery charging alternator is a 26-Volt (250 Amp) alternator. Battery Box Four type 8D batteries (2, Figure 2-1) for the 24VDC engine cranking circuit are located in the battery box (1) in the center of the front platform. For access to the batteries, remove the hardware from the front of the battery box and open the hinged cover. When maintenance or repairs are performed, the batteries can be quickly disconnected from the cranking motor or control circuits by using the disconnect switches located on the isolation station. An external battery charger may also be connected to auxiliary battery receptacles (7) located on battery control box (3).

Removal This truck is equipped with a master disconnect switch (3, Figure 2-2) on the battery ground circuit.

1. Battery Box 2. Batteries 3. Battery Control Box

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When removing or installing a battery, positively identify the positive (+) terminal and negative (-) terminal and use precautions not to cause a short circuit between the terminals.

1. When disconnecting battery cables, always move the battery master disconnect switch to the OFF position. 2. At the battery terminals, disconnect the two positive (+) battery cables that connect the batteries to the bus bar inside the battery control box. 3. At the battery terminals, disconnect the two negative (-) battery cables that connect the batteries to the bus bar inside the battery control box. NOTE: The negative battery cables are to be disconnected last. If the master disconnect switch is OFF, and a wrench on the negative (-) terminal touches the battery box frame, a spark will occur if any electrical component on the truck was left in the ON position.

FIGURE 2-1. BATTERY BOX & BATTERY CONTROL BOX 4. 24VDC Bus Bar 7. Auxiliary Battery Receptacles 5. Engine Start Relays 8. Battery Pallet 6. Negative Bus Bar 9. Mounting Hardware

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4. Remove mounting hardware (9, Figure 2-1).

Engine Start Relay

5. To remove all four batteries by using a forklift and picking up the battery pallet (8).

Engine start relays (5) receives the signal to begin cranking from the pre-lube pressure switch.

Installation 1. Before connecting battery cables, always move the battery master disconnect switch (3, Figure 2-2) to the OFF position.

When the pre-lube pressure switch closes, it provides current to the two engine start relays. The engine start relays then give current to the cranking motor solenoids. The Cranking motor solenoids engage the cranking motors to begin cranking the engine.

2. Using a forklift, install battery pallet (8, Figure 21) into position on the truck. Tighten mounting hardware (9). 3. Ensure all battery cable clamps and battery posts are clean.

ISOLATION BOX ASSEMBLY

4. Connect the two negative (-) cables to the batteries. Then connect the two positive cables (+) last. Tighten battery terminals securely. Loose terminals can generate sparks and could lead to an explosion.

Isolation box (6, Figure 2-2) is located on top of the front bumper, on the left hand side. This box contains battery disconnect switches (3 & 4) and other components listed below. Access ladder light switch (2) is mounted on the isolation box. Propel lockout lever (5) is located on the front panel.

5. Tighten all battery caps securely. 6. Lower the battery box cover and secure with mounting hardware.

Battery Control Box Battery control box (3, Figure 2-1) is located to the left of the battery box. This box contains the components listed below. 24VDC Auxiliary Battery Receptacles Two pairs of receptacles (7), located on the battery control box, are provided to attach battery charger leads for charging the batteries. These receptacles can also be used for connecting external batteries to aid engine starting during cold weather. When external batteries are used, they must be of the same type (8D) as the batteries installed on the truck. Two pairs of batteries must be used. Each pair must be connected in series to provide 24VDC, with one pair connected to the front receptacle and the other pair connected to the rear receptacle on the truck.

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Engine Shutdown Switch Engine shutdown switch (1, Figure 2-2) is a push-pull type switch and is located on top of isolation box (6). This switch provides a ground level means to shut the engine off in an emergency. Push the button in to stop the engine. Access Ladder Light Switch Access ladder light switch (2, Figure 2-2) provides a ground level means to operate the light for the access ladder. Battery Disconnect Switches Battery disconnect switches (3 & 4, Figure 2-2) provide a convenient method of disconnecting the truck batteries from the truck electrical circuits without having to remove any battery cables. Starter disconnect switch (4) opens the cranking motor battery circuit only, preventing engine startup while still allowing battery power to the 24VDC control system circuits, if desired. Master disconnect switch (3) disconnects the 24VDC system circuit. When the battery disconnect switches are in the OFF positions, the 24VDC electrical system and start system are disabled. When the battery disconnect switches are ON, the 24VDC electrical system is active and the engine can be operated.

24VDC Electric Supply System

D02044

Propel Lockout Lever

LED Lights

Propel lockout lever (5, Figure 2-2) provides a convenient method of disconnecting the AC electric drive system while the engine is in operation. This ensures the truck will remain stationary without the need to check the GF cutout switch. When the propel lockout lever is in the OFF position, the drive system is locked out and the truck will not propel. When the propel lockout lever is in the ON position, the drive system is active and the truck can be driven.

LED lights (7, Figure 2-2) provide a positive, visual indicator when a selected switch is in the ON position. LED lights (8) provide a positive, visual indicator when a selected switch is in the OFF position.

FIGURE 2-2. ISOLATION BOX ASSEMBLY (COVERS REMOVED) 1. Engine Shutdown Switch 2. Access Ladder Light Switch 3. Master Disconnect Switch

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4. Starter Disconnect Switch 5. Propel Lockout Lever 6. Isolation Box

24VDC Electric Supply System

7. LED Lights (on) 8. LED Lights (off)

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AUXILIARY CONTROL CABINET 24VDC to 12VDC Converter 24VDC to 12VDC converter (3, Figure 2-3) is used to convert the 24 volt battery system voltage to 12 volts for various truck components such as the AM/FM Radio / CD Player and the auxiliary power receptacles in the cab. The converter is powered by the control power relay, and is protected by CB60, a 50 amp circuit breaker (4).

Observe and verify polarity, connection points, and correct circuit numbers if relay replacement is necessary. Incorrect hookup will damage the solid state relay.

FIGURE 2-3. AUXILIARY CONTROL CABINET (LEFT WALL) 1. Interface Module 2. Payload Meter 3. 24VDC to 12VDC Converter 4. 50 Amp Circuit Breaker 5. Timer

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24VDC Electric Supply System

D02044

24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE) The Komatsu SDA16V160 engine includes an engine pre-lubrication system designed to reduce wear due to dry starts. The prelube system automatically, safely and quickly fills filters and all oil passages prior to cranking at each engine startup. In addition, the system prevents startup if no oil is present in the engine. The prelube system includes:

Check Valve The oil pressure supply hose will have a check valve installed between the prelube pump and the engine. The check valve prevents the passage of oil from the engine back through the prelube pump to the pan after the engine is started. Check valve leakage back to the prelube pump will cause extensive damage to the pump.

MAINTENANCE

• Remote mounted 24VDC powered pump • Pre-Lube Magnetic Switch • Oil pressure switch

Prelube system maintenance must be performed annually or at 5000 hour intervals as described below.

• Oil suction line • Oil outlet line

Prelube System Operation Checks

• Check valve

Verify system operates according to the two phases of operation as listed in “Troubleshooting Prelube Cranking Motor Circuit” on the following page. If a problem exists, refer to the list of problems and possible causes for troubleshooting system components.

• Electrical harness. • Pre-Lube Relay

If system is operating properly, continue with the inspection of component parts below:

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 the prelube cranking motor solenoid. When this pre-lube solenoid is activated, current flows through fusible link to the prelube motor, driving the prelube pump, but does not allow the cranking motor motors to engage the cranking motor pinion gears at this time. The prelube pump supplies oil from the engine oil pan to fill the engine oil filters and oil passages prior to cranking. When the pressure in the engine cam oil rifle reaches 31 kPa (4.5 psi), the current is supplied to the cranking motor solenoids (8); 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.

Check Valve Verify no internal leakage exists in the check valve when the engine is running. Check valve leakage back to the prelube pump will cause extensive damage to the pump. If check valve replacement is required, ensure the valve is installed with the arrow pointed toward the engine, and NOT toward the pump.

Engine Oil Pressure Switch The pressure switch is a 31 kPa (4.5 psi), normally closed (N.C.) switch, located so that it can sense oil pressure after the engine oil has passed through the filters. (Normally, this location is the cam cover at the rear of the engine block.)

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24VDC Electric Supply System

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TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT Two distinct phases are involved in a complete prelubrication cycle. The two phases are: 1. Prelubrication Phase- Begins when the key switch is held in the START position. A circuit is provided to ground through the normally closed pressure switch. The circuit is interrupted upon opening of the pressure switch when the prelube pressure reaches 17.2 kPa (2.5 psi). 2. Delay and Crank Phase- Begins when the pressure switch opens. A three second delay precedes the crank mode.

Problem

Probable Cause

• Cranking motor prelubricates only. Does not delay or crank.

Indicates oil pressure is not sufficient to open the pressure switch. a. No oil or low oil in engine. The pump can not build sufficient pressure to open switch. b. Pump failure. c. Pressure switch has failed (closed) and is grounding circuit. d. Oil pressure switch wire chafed and shorting to block.

• Cranking motor prelubricates regardless of key switch position.

continuously

Indicates Prelube relay contacts have welded. a. Low voltage can cause relay failure. b. Jump starting of the vehicle with a voltage that is higher than was designed for the system, can cause solenoid contacts to weld.

• Cranking motor delays prelubrication mode.

and

cranks.

• Starting circuit is irregular when in crank mode.

No

If an operator indicates the ignition is totally dead, ensure the key is being held in the crank position for 3 to 4 seconds. If the engine cranks after a short delay, this indicates that a ground connection to the pressure switch has been broken. Without a ground path, the prelubrication unit will proceed to delay and crank. a. Check the wire to the pressure switch. If the wire is removed or cut, replace it. b. Check the ground strap to engine block. If the ground strap is missing the block is not grounded. c. Check the pressure switch for an open circuit. Remove the wire, then check for an open circuit between the switch terminal and the switch base. If open, replace pressure switch. a. Check for low or dead batteries. b. Check alternator output. c. Check ground connection at “G” terminal of cranking motor bendix solenoid. d. Check for defective cranking motor safety relays. e. If everything checks OK, replace batteries. NOTE: Maximum allowable voltage drop is - 2 volts for cranking motor control circuit.

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24VDC Electric Supply System

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Problem

Probable Cause

• Cranking motor has very long prelubrication cycle.

Except for severe cold weather starts, the prelube cycle must not exceed 45 seconds. a. Low oil pressure. b. Ensure oil of the proper viscosity is being used in respect to outside temperature. (Refer to engine manufacturer's specifications). c. Check for suction side air leaks, loose connections, cracked fittings, pump casting, or hose kinks and blockage. d. Check the oil pressure switch for the correct location. Be certain that it has not been moved into a metered oil flow, as in a bypass filter or governor assembly.

• Cranking motor has no prelubrication, no delay and no crank.

If the cranking motor is totally inoperative and no prelubrication, no delay and crank, this indicates a possible failure of the prelubrication timer solenoid. Remove the wire from the pressure switch (ground wire) and activate the key switch for several seconds. a. If the cranking motor delays - then cranks, the Prelube Timer Solenoid is bad. Replace the timer solenoid assembly. b. If the cranking motor is still inoperative, check the truck cranking motor switch circuit. Ensure proper voltage is available to the Prelube Timer Solenoid when the key is activated.

• Cranking motor prelubricates, delays, then does not crank.

Indication is either a timer failure, or a cranking motor problem. a. Place a jumper wire to the cranking motor solenoid “S” post. If the engine starts to crank, replace the Prelube Timer Solenoid. b. If the engine fails to crank when the "S" post is energized with voltage, check out cranking motor bendix solenoid and cranking motor pinion drive.

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24VDC Electric Supply System

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24VDC ELECTRIC START SYSTEM CRANKING MOTORS Operation Heavy duty batteries supply 24VDC to each of the two cranking motors through magnetic switches activated by the key switch on the instrument panel. Note: When a Komatsu SDA16V160 engine with a prelube system is installed, there is a delay between the time the key switch is moved to the START position, and the cranking motors actuate. When the key switch is placed in the Start position, the magnetic switches close, connecting the motor solenoid “S” terminals to the batteries. When the solenoid windings are energized, the plunger (56, Figure 2-6) is pulled in, moving the cranking motor drive (71) assembly forward in the nose housing to engage the engine flywheel ring gear. Also, when the solenoid plunger is pulled in, the main solenoid contacts close to provide current to the motor armature and cranking takes place. When the engine starts, an overrunning clutch in the drive assembly protects the armature from excessive speed until the key switch is released. When the key switch is released, a return spring causes the drive pinion to disengage. After the engine is running, a normally closed pressure switch senses engine oil pressure and opens the electrical circuit to prevent actuation of the motor(s) after the engine has started. Removal

FIGURE 2-4. CRANKING MOTORS 1. Cap Screws 3. Solenoid 2. Cranking Motor

Installation

1. Disconnect battery power: a. Open the battery disconnect switch to remove power from the system. b. Disconnect the negative (-) battery cables first. c. Disconnect the battery positive (+) battery cables last. 2. Mark wires and cables and remove from cranking motor (2, Figure 2-4) and solenoid (3) terminals. 3. Remove cranking motor mounting cap screws (1).

1. Align cranking motor (2, Figure 2-6) housing with the flywheel housing adaptor mounting holes and slide into position. 2. Insert cranking motor cap screws (1). 3. Connect marked wires and cables to cranking motor and solenoid terminals. 4. Install in the following sequence: a. Connect the battery positive (+) cables first. b. Connect the battery negative (-) cables. 5. Close the battery disconnect switch.

4. Remove cranking motor assembly from flywheel housing.

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24VDC Electric Supply System

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CRANKING MOTOR TROUBLESHOOTING If the cranking system is not functioning properly, check the following to determine which part of the system is at fault:  Batteries -- Verify the condition of the batteries, cables, connections and charging circuit.  Wiring -- Inspect all wiring for damage or loose connections at the key switch, magnetic switches, solenoids and cranking motor(s). Clean, repair or tighten as required. If the above inspection indicates the cranking motor to be the cause of the problem, remove the motor and perform the following tests prior to disassembly to determine the condition of the motor and solenoid and repairs required.

FIGURE 2-5. NO-LOAD TEST CIRCUIT

Preliminary Inspection 1. Check the cranking motor to be certain the armature turns freely. a. Insert a flat blade screwdriver through the opening in the nose housing. b. Pry the pinion gear to be certain the armature can be rotated.

DO NOT apply voltages in excess of 20 volts. Excessive voltage may cause the armature to throw windings.

2. If the armature does not turn freely, the cranking motor must be disassembled immediately.

d. Connect the motor and an ammeter in series with two fully charged 12 volt batteries.

3. If the armature can be rotated, perform the NoLoad Test before disassembly. No-Load Test Refer to Figure 2-5 for the following test setup.

e. Connect a switch in the open position from the solenoid battery terminal to the solenoid switch terminal. 2. Close the switch and compare the RPM, current, and voltage reading to the following specifications:  RPM: 5500 Minimum to 7500 Maximum  AMPS: 95 Minimum to 120 Maximum

Be certain switch is open before connections or disconnections are made during the following procedures.

 VOLTS: 20VDC

1. Setup the motor for test as follows: a. Connect a voltmeter from the motor terminal to the motor frame. b. Use an RPM indicator to measure armature speed. c. Connect a carbon pile across one battery to limit battery voltage to 20VDC.

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24VDC Electric Supply System

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Disassembly

Interpreting Results of Tests 1. Rated current draw and no-load speed indicates normal condition of the cranking motor.

The cranking motor must be disassembled only as far as necessary to repair or replace defective parts.

2. Low free speed and high current draw indicates:

1. Note the relative position of the solenoid (53, Figure 2-6), lever housing (78), nose housing (69), and C.E. frame (1) so the motor can be reassembled in the same manner.

a. Too much friction; tight, dirty, or worn bearings, bent armature shaft or loose pole shoes allowing armature to drag. b. Shorted armature. This can be further checked on a growler after disassembly. c. Grounded armature or fields. Check Further after disassembly. 3. Failure to operate with high current draw indicates: a. A direct ground in the terminal or fields.

2. Disconnect field coil connector (42) from solenoid motor terminal, and lead from solenoid ground terminal. 3. Remove the brush inspection plug (52), and brush lead screws (15). 4. Remove the attaching bolts (34) and separate the commutator end frame (1) from the field frame (35).

b. “Frozen” bearings (are determined by turning the armature by hand).

5. Separate the nose housing (69) and field frame (35) from lever housing (78) by removing attaching bolts (70).

4. Failure to operate with no current draw indicates:

6. Remove armature (45) and drive assembly (71) from lever housing (78).

a. Open field circuit. This can be checked after disassembly by inspecting internal connections and tracing circuit with a test lamp.

7. Separate solenoid (53) from lever housing by pulling apart.

b. Open armature coils. Inspect the commutator for badly burned bars after disassembly. c. Broken brush springs, worn brushes, high insulation between the commutator bars or other causes which would prevent good contact between the brushes and commutator. 5. Low no-load speed and low current draw indicates: a. High internal resistance due to poor connections, defective leads, dirty commutator and causes listed under Number 4. 6. High free speed and high current draw indicates shorted fields. If shorted fields are suspected, replace the field coil assembly and check for improved performance.

D2-14

24VDC Electric Supply System

D02044

Cleaning and Inspection 1. Drive (71), armature (45) and fields (46) must not be cleaned in any degreasing tank, or with grease dissolving solvents, since these will dissolve the lubricant in the drive and damage the insulation in the armature and field coils. 2. All parts except the drive must be cleaned with mineral spirits and a clean cloth. 3. If the commutator is dirty, it may be cleaned with No. 00 sandpaper. NOTE: DO NOT use emery cloth to clean the commutator. 4. Inspect brushes (13, Figure 2-6) for wear. a. If worn excessively when compared with a new brush, they must be replaced. b. Ensure the brush holders (10) are clean and the brushes are not binding in the holders. c. The full brush surface must ride on the commutator. Check by hand to insure that brush springs (16) are giving firm contact between brushes (13) and commutator. d. If springs (16) are distorted or discolored, they must be replaced.

D02044

FIGURE 2-6 CRANKING MOTOR ASSEMBLY 1. C.E. Frame 2. Washers 3. O-Rings 4. Insulator 5. Support Plate 6. Brush Plate Insulator 7. Washers 8. Plate & Stud 9. Plate 10. Brush Holder 11. Lockwasher 12. Screw 13. Brush (12 required) 14. Lockwasher 15. Screw 16. Brush Spring 17. Screw 18. Screw 19. Screw 20. Lockwashers 21. Plate 22. Brush Holder Insulator 23. Screw 24. Lockwasher 25. Washer 26. O-Ring 27. Bushing 28. Insulator 29. Washer 30. Lockwasher 31. Nut 32. Nut 33. Lockwasher 34. Screw 35. Field Frame 36. Stud Terminal 37. Bushing 38. Gasket 39. Washers 40. Washers

24VDC Electric Supply System

41. Nut 42. Connector 43. Lockwasher 44. Nut 45. Armature 46. Field Coil 47. Shoe 48. Insulator 49. Screw 50. Washer 51. O-ring 52. Inspection Plug 53. Solenoid Housing 54. Lockwasher 55. Screw 56. Plunger 57. Washer 58. Boot 59. Washer 60. Spring 61. Retainer 62. Snap Ring 63. Shift Lever 64. Nut 65. O-Ring 66. O-Ring 67. Snap Ring 68. Lever Shaft 69. Drive Housing 70. Screw 71. Drive Assembly 72. Gasket 73. Plug 74. Gasket 75. Brake Washer 76. Screw 77. Lockwasher 78. Lever Housing 79. Washer 80. O-Ring

D2-15

FIGURE 2-6. CRANKING MOTOR ASSEMBLY

D2-16

24VDC Electric Supply System

D02044

Armature Servicing If the armature commutator is worn, dirty, out of round, or has high insulation, the armature (45, Figure 2-6) must be put on a lathe and the commutator turned down. The insulation must then be undercut 0.79 mm (0.031 in.) wide and 0.79 mm (0.031 in.) deep, and the slots cleaned out to remove any trace of dirt or copper dust. As a final step in this procedure, the commutator must be sanded lightly with No. 00 sandpaper to remove any burrs left as a result of the undercutting procedure. Check the armature for opens, short circuits and grounds as follows: 1. Opens are usually caused by excessively long cranking periods. The most likely place for an open to occur is at the commutator riser bars. Inspect the points where the conductors are joined to the commutator bars for loose connections. Poor connections cause arcing and burning of the commutator as the cranking motor is used. If the bars are not too badly burned, repair can often be effected by resoldering or welding the leads in the riser bars (using rosin flux), and turning down the commutator in a lathe to remove the burned material. The insulation must then be undercut. 2. Short circuits in the armature are located by use of a growler. When the armature is revolved in the growler with a steel strip such as a hacksaw blade held above it, the blade will vibrate above the area of the armature core in which the short circuit is located. Shorts between bars are sometimes produced by brush dust or copper between the bars. These shorts can be eliminated by cleaning out the slots.

D02044

3. Grounds in the armature can be detected by the use of a 110-volt test lamp and test points. If the lamp lights when one test point is placed on the commutator with the other point on the core or shaft, the armature is grounded. Grounds occur as a result of insulation failure which is often brought about by overheating of the cranking motor produced by excessively long cranking periods or by accumulation of brush dust between the commutator bars and the steel commutator ring.

Field Coil Checks Field coils (46, Figure 2-6) can be checked for grounds and opens by using a test lamp. 1. Grounds - The ground connections must be disconnected during this check. Connect one lead of the 110 volt test lamp to field frame (35) and the other lead to field connector (42). If the lamp lights, at least one field coil is grounded and must be repaired or replaced. 2. Opens - Connect test lamp leads to ends of field coils (46). If lamp does not light, the field coils are open.

Field Coil Removal Field coils can be removed from the field frame assembly by using a pole shoe screwdriver. A pole shoe spreader must also be used to prevent distortion of the field frame. Careful installation of the field coils is necessary to prevent shorting or grounding of the field coils as the pole shoes are tightened into place. Where the pole shoe has a long lip on one side and a short lip on the other, the long lip must be assembled in the direction of armature rotation so it becomes the trailing (not leading) edge of the pole shoe.

24VDC Electric Supply System

D2-17

5. To check for grounds, move battery lead from “G” (Figure 2-8) and from “MTR” (Figure 2-9) to the solenoid case. Ammeter must read zero. If not, the winding is grounded.

FIGURE 2-7. SIMPLIFIED SOLENOID CIRCUIT

SOLENOID CHECKS A basic solenoid circuit is shown in Figure 2-7. Solenoids can be checked electrically using the following procedure. Test 1. With all leads disconnected from the solenoid, make test connections as shown to the solenoid, switch terminal and to the second switch terminal “G”, to check the hold-in winding (Figure 2-8).

FIGURE 2-8. SOLENOID HOLD-IN WINDING TEST

2. Use the carbon pile to decrease the battery voltage to 20 volts. Close the switch and read current.  The ammeter must read 6.8 amps maximum. 3. To check the pull-in winding, connect from the solenoid switch terminal “S” to the solenoid motor “M” or “MTR” terminal (Figure 2-9).

To prevent overheating, DO NOT leave the pull-in winding energized more than 15 seconds. The current draw will decrease as the winding temperature increases. 4. Use the carbon pile to decrease the battery voltage to 5 volts. Close the switch and read current.  The ammeter must read 9.0 to 11.5 amps. NOTE: High readings indicate a shorted winding. Low readings indicate excessive resistance.

D2-18

FIGURE 2-9. SOLENOID PULL-IN WINDING TEST

24VDC Electric Supply System

D02044

Assembly Lubricate all bearings, wicks and oil reservoirs with SAE No. 20 oil during assembly. Bearing Replacement: 1. If any of the bronze bearings are to be replaced, dip each bearing in SAE No. 20 oil before pressing into place. 2. Install wick, soaked in oil, prior to installing bearings. 3. DO NOT attempt to drill or ream sintered bearings. These bearings are supplied to size. If drilled or reamed, the I.D. will be too large and the bearing pores will seal over. 4. DO NOT cross-drill bearings. Because the bearing is so highly porous, oil from the wick touching the outside bearing surface will bleed through and provide adequate lubrication. 5. The middle bearing is a support bearing used to prevent armature deflection during cranking. The clearance between this bearing and the armature shaft is large compared to the end frame bearings. Motor Assembly: 1. Install the end frame (with brushes) onto the field frame as follows: a. Insert armature (45, Figure 2-6) into field frame (35). Pull the armature out of the field frame just far enough to permit the brushes to be placed over the commutator. b. Place end frame (1) on the armature shaft. Slide end frame and armature into place against the field frame. c. Insert screws (34) and washers (33) and tighten securely. 2. Assemble lever (63) into lever housing (78) If removed. 3. Place washer (79) on armature shaft and install new O-Ring (80). Position drive assembly (71) in lever (63) in lever housing. Apply a light coat of lubricant (Delco Remy Part No. 1960954) on washer (75) and install over armature shaft. Align lever housing with field frame and slide assembly over armature shaft. Secure with screws (76) and washers (77).

FIGURE 2-10. PINION CLEARANCE CHECK CIRCUIT

5. Using a new gasket (72), install drive housing (69) and secure with screws (70). 6. Assemble field coil connector (42) to solenoid. 7. Adjust pinion clearance per instructions on the following page. 8. After pinion clearance has been adjusted, install gasket (74) and plug (73).

4. Assemble and install solenoid assembly through lever housing and attach to field frame. Install nut (64) but do not tighten at this time. Install brush inspection plugs (52).

D02044

24VDC Electric Supply System

D2-19

MAGNETIC SWITCH The magnetic switch is a sealed unit and not repairable.

FIGURE 2-11. CHECKING PINION CLEARANCE FIGURE 2-12. MAGNETIC SWITCH ASSEMBLY

Removal

Pinion Clearance To adjust pinion clearance, follow the steps listed below.

1. Remove battery power as described in Cranking Motor Removal.

1. Make connections as shown in Figure 2-10.

2. Disconnect cables from the switch terminals and wires from coil terminals (Figure 2-12).

2. Momentarily flash a jumper lead from terminal “G” to terminal “MTR”. The drive will now shift into cranking position and remain so until the batteries are disconnected. 3. Push the pinion or drive back towards the commutator end to eliminate slack movement. 4. The distance between the drive pinion and housing must be between 8.3 mm to 9.9 mm (0.330 to 0.390 in.) as shown in Figure 2-11. 5. Adjust clearance by turning shaft nut (64, Figure 2-6).

NOTE: If the magnetic switch being removed has a diode across the coil terminals, mark the leads prior to removal to ensure correct polarity during installation. 3. Remove mounting cap screws and washers. Remove switch from mounting bracket. 4. The switch coil circuit can be tested as described below. Installation 1. Attach magnetic switch to the mounting bracket using the cap screws and lockwashers removed previously. 2. Inspect cables and switch terminals. Clean as required and install cables. 3. Install the diode across the coil terminals. Ensure diode polarity is correct. Attach wires from the truck harness to coil terminals (See Figure 2-5). 4. Connect battery power as described in Cranking Motor “Installation”.

D2-20

24VDC Electric Supply System

D02044

Coil Test 1. Using an ohmmeter, measure the coil resistance across the coil terminals. a. The coil must read approximately 28 at 22.2°C (72°F). b. If the ohmmeter reads , the coil is open and the switch must be replaced. c. If the ohmmeter reads 0 , the coil is shorted and the switch must be replaced.

3. The ohmmeter must display when the probes are placed across the switch terminals. NOTE: The switch terminals will show continuity when 24VDC is applied to the coil terminals, however high resistance across the internal switch contacts due to arcing etc. could prevent the switch from delivering adequate current to the cranking motor. If the coil tests are satisfactory but the switch is still suspect, it must be replaced with a new part.

2. Place one of the ohmmeter probes on a coil terminal and another on the switch mounting bracket. If the meter displays any resistance reading, the coil is grounded and the switch must be replaced.

D02044

24VDC Electric Supply System

D2-21

NOTES:

D2-22

24VDC Electric Supply System

D02044

SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX

24 VDC ELECTRICAL SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3 TRUCK SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3 BRAKE WARNING BUZZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3 AUXILIARY CONTROL CABINET COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-3 Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-4 Payload Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-4 24VDC to 12VDC Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-4 Circuit Breaker (CB60) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-4 Inclinometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-4 Vehicle Electrical Center (VEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-5 Pump Module Service Light Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-5 Power Distribution Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-5 Ground Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-5 Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-6 Engine Service Light Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-6 RTMR1 - VEC Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-7 VEC-89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-8 VEC-90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-10 VEC-91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-12 MAGNETIC SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-14 Body position switches (With proximity switch and magnet) . . . . . . . . . . . . . . . . . . . . . . . . . . D3-14 Proximity switch operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-14 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-14

D03051

24VDC Electrical System Components

D3-1

BODY-UP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15 Adjust the body up switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-15 HOIST LIMIT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-16 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-16 Adjust the hoist limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-17

D3-2

24VDC Electrical System Components

D03051

24 VDC ELECTRICAL SYSTEM COMPONENTS AUXILIARY CONTROL CABINET COMPONENTS

Do not attempt repairs until the truck is properly shut down. Dangerous voltage levels are present in the propulsion system while the engine is running and for a period of time after shutdown. Refer to the Index in Section D for additional warnings.

TRUCK SHUTDOWN PROCEDURE 1. Reduce the engine speed to idle. Move the directional control lever in PARK. Make sure that the parking brake applied indicator light in the overhead panel is illuminated. 2. Place the drive system in the rest mode by turning the rest switch on the instrument panel ON. Ensure that the rest mode indicator light is illuminated.

The following 24VDC electrical system components are located in the auxiliary control cabinet, which is mounted on the left side of the main control cabinet behind the cab. The auxiliary control cabinet houses various components for the 24VDC circuits, engine related devices, and terminal strips that connect truck wiring harnesses with the main control cabinet and cab. The following information describes the components in the auxiliary control cabinet and their operation. Additional detailed information for operation and troubleshooting procedures not included below can be found in Section E, Electrical Propulsion System, the engine manufacturer's service publications, and the appropriate GE publications. The electrical schematics in Section R should be used when troubleshooting problems with the following 24VDC electrical system components.

3. Stop the engine using the key switch. The engine could continure to operator for up to three minutes to cool down. If, for some reason the engine does not stop after three minutes, use the stop switch on the center console. 4. Verify the link voltage lights on the electrical cabinet and next to the DID panel in the cab are OFF. If they remain on longer than 5 minutes after shutdown, the propulsion system must be inspected by a technician trained to investigate the cause. 5. Place the GF cutout switch in the CUTOUT position throughout test and troubleshooting procedures. 6. Verify that the steering accumulators have bled down by attempting to turn the steering wheel.

BRAKE WARNING BUZZER The brake warning buzzer provides an audible alarm for the operator if a malfunction occurs in the hydraulic service brake system. This buzzer is located inside the radio module in the overhead panel. Refer to Section J for additional details.

D03051

24VDC Electrical System Components

D3-3

Interface Module The interface module (IM) (1, Figure 3-1) collects data from various sensors and sends this information to the KOMTRAX Plus controller through the main wiring harness. Refer to Interface Module later in this Section.

Payload Meter The Payload Meter (PLM) (2) collects data from various sensors and sends this information to the KOMTRAX Plus controller through the main wiring harness. Refer to Payload Meter later in this Section.

24VDC to 12VDC Converter A 24VDC to 12VDC converter (3) is used to convert the 24 volt battery system voltage to 12 volts for various truck components. The converter is powered by the control power relay.

Circuit Breaker (CB60) Circuit breaker(4) CB60 is a 50 amp circuit breaker that protects the 24VDC to 12VDC converter.

Inclinometer The inclinometer (5) measures the tilt of the truck and sends the information to the payload meter system.

D3-4

FIGURE 3-1. AUXILIARY CONTROL CABINET LEFT WALL 1. Interface Module 2. Payload Meter 3. 24V to 12V DC Converter 4. Circuit Breaker CB60 5. Inclinometer 6. Diagnostic Ports (Komtrax Plus, IM, PLMIII)

24VDC Electrical System Components

D03051

Vehicle Electrical Center (VEC) There are three VEC’s located inside the auxiliary control cabinet (1, 2 & 4, Figure 3-2). Each VEC contains relays and fuses for various circuits. For details on the relays, refer to Figure 3-3.

Pump Module Service Light Timer This timer (3) will turn off the hydraulic pump service lights after two hours of operation.

Power Distribution Terminals 24VDC terminal (5) is mounted on the right wall of the cabinet. These terminals distribute 24VDC battery voltage. The 24VDC terminal is a convenient test point for measuring battery voltage during troubleshooting procedures. Ground Terminal Ground terminals (6) are mounted on the right wall of the cabinet. These terminals create a good ground location for many circuits. The ground terminals are a convenient test point during troubleshooting procedures.

RTMR VEC Block This VEC (7) contains two relays. There are empty spaces to add diodes, fuses and relays to add additional circuits. For the location of the relays, refer to Figure 3-4. Mounting holes are provided to add an additional RTMR-VEC block above the existing RTMR-VEC block.

D03051

FIGURE 3-2. AUXILIARY CONTROL CABINET RIGHT WALL 1. VEC Block 90 2. VEC Block 89 3. Pump Module Light Timer 4. VEC Block 91

24VDC Electrical System Components

5. 24VDC Terminal 6. Ground Terminal 7. RTMR VEC Block

D3-5

Relays Relays (2-8, Figure 3-3) control various items on the truck. These relays are rated at 24V and 50 amps or 200 amps and are used to switch heavy loads. Key switch power relay (3) is switched on/off by the key switch. This relay powers most 24VDC systems. Control power relay (4) is energized when the control power switch, located in the main control cabinet, is turned ON. This relay isolates the GE control power from the truck circuits and provides power to nonpropulsion system 24VDC components. 12VDC Power Relay (5) switches the 12VDC power on/off that is provided to VEC-91. Low mounted low beam light relay (6) switches the power on/off to these lights. High mounted low beam light relay (7) switches the power on/off to these lights. Backup light relay (8) switches the power on/off to these lights. Relay (9) is a 200 amp relay that switches the power on/off to the ladder and deck mounted lights. Relay (10) is a 200 amp relay that switches the power on/off to the high beam headlights.

Engine Service Light Timer This timer (11) will turn off the engine service lights after two hours of operation.

D3-6

FIGURE 3-3. AUXILIARY CONTROL CABINET RIGHT WALL DETAIL 1. Plug (AHT) 2. Horn Relay 3. Key Switch Power Relay 4. Control Power Relay 5. 12V Power Relay 6. Low Mtd Headlight Relay 7. High Mtd Headlight Relay 8. Back Up Light Relay 9. 200 A Ladder/Deck Light Relay 10. 200 A Headlight Hi-Beam Relay 11. Engine Service Light Timer

24VDC Electrical System Components

D03051

RTMR1 - VEC Block

FIGURE 3-4. RTMR - VEC BLOCK 1. RTMR-VEC Block 2. Relay R1 (A/C Shutter Control) 3. Relay R2 (930E Park Brake Protection)

D03051

24VDC Electrical System Components

D3-7

VEC-89 VEC-89 contains replaceable relays, diodes and fuses that are mounted on a plug-in connector for easy replacement. All diodes are used to control the flow of current in a circuit as required.

The relays switch on/off circuits that require control logic on the truck. The relays in the VEC are replaceable. The following briefly describes each component and its function. Refer to Section R, Schematics, for the circuit components described below.

The fuses protect various circuits on the truck. Always replace a blown fuse with a new one of the same rating. Spare fuses are provided in the VEC’s.

84052

FIGURE 3-5. VEC-89

Table 1: VEC-89 LOCATION

AMPS

F2

25

Back-Up Lamps

F3

15

Back-Up Horn

F4

15

Left Low Beam Headlights

D3-8

DEVICES(S) PROTECTED

F5

15

Right Low Beam Headlights

F6

10

Hi-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

Auto Lube

F43

1

Direction Selector Switch

F44

5

Display Mode Switch, Camera Switch and Switch LED Lights

F45

15

GE Drive Control & Feedback

24VDC Electrical System Components

D03051

F53

20

Heated Mirror

F56

10

Operator Seat

F57

10

Pre-Shift Brake Test

F61

1

Left Rear Wheel Speed

F62

15

Fog Lamp

F63

15

Customer Seat Belt Alarm

F64

5

Headlight Switch

SP1

1

Spare

SP2

1

Spare

SP3

1

Spare

SP4

5

Spare

SP5

10

Spare

SP6

15

Spare

SP7

20

Spare

SP8

25

Spare

D14

Back-Up Diode 1

D15

Back-Up Diode 2

R3

Back-Up Horn Micro Relay

R8

Marker & Tail Light Micro Relay

R9

Brake Light Micro Relay

R11

Left Turn Micro Relay

R12

Right Turn Micro Relay

R13

Turn Signal Hazard Flasher Relay

R14

Steering Bleed Down Micro Relay

R15

Retard Lamps Micro Relay

R29

Auto Lube Micro Relay

R39

Heated Mirror Micro Relay

R40

Fog Lamp Micro Relay

R41

Seat Belt Alarm Micro Relay

D03051

24VDC Electrical System Components

D3-9

VEC-90

84053

FIGURE 3-6. VEC-90

Table 2: VEC-90 LOCATION

D3-10

AMPS

DEVICES(S) PROTECTED

F14

25

Payload Lamps

F15

15

Park Brake Status

F17

15

Payload Meter

F18

15

Ground Level Shutdown Switch

F19

10

Park Brake Control

F46

15

Payload Meter Key Switch Power

F47

10

VHMS Key Switch Power

F48

20

Modular Mining Conn Key Switch Power

SP1

5

Spare

SP2

5

Spare

SP3

10

Spare

SP4

10

Spare

SP5

10

Spare

SP6

15

Spare

SP7

15

Spare

SP8

15

Spare

D1

Key Switch Run Diode

D2

Shift Selector Reverse Diode

D3

Shift Selector Neutral Diode

D4

Shift Selector Forward Diode

D5

Park Brake Diode

24VDC Electrical System Components

D03051

D6

Truck Moving Diode

D7

Brake Lock Diode

D8

Park Brake Latch Diode

D9

GE True Forward Signal Diode

D10

GE True Reverse Signal Diode

D11

GE Propel System At Rest Diode

D12

GE Propel System Not Ready Diode

D13

Forward, Neutral, Reverse Signal Diode

D14

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

D03051

24VDC Electrical System Components

D3-11

VEC-91

84054

FIGURE 3-7. VEC-91

Table 3: VEC-91 LOCATION

AMPS

F21

10

D3-12

DEVICES(S) PROTECTED Ether Start

F22

20

Op-Cab Communication Radio 12V

F23

10

Entertainment Radio 12V

F24

10

A/C Compressor

F25

10

Shutter Control

F26

15

Electronic Gauge Display Un-Switch

F27

10

IM Un-switched # 1

F28

10

IM Un-switched # 2

F29

10

VHMS & Orbcomm

F30

20

Modular Mining Un-switch

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

F39

20

Engine Un-switched Power Fuse #4

F40

20

Op-Cab Communication Radio 24V

24VDC Electrical System Components

D03051

F41

5

Op-Cab Fire Suppression

F49

15

Operator Cab HVAC Key Switch

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

1

Right Front Wheel Speed

F59

1

Left Front Wheel Speed

F60

1

Left Rear Wheel Speed

F62

20

Electric Window - Right

F63

20

Auxiliary Power Port 12V

SP1

5

Spare

SP2

5

Spare

SP3

10

Spare

SP4

10

Spare

SP5

10

Spare

SP6

15

Spare

SP7

15

Spare

SP8

15

Spare

D13

Turn Signal Switch Diode

D14

Key Switch Power Or Diode

D15

GE Control Power Or 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

D03051

24VDC Electrical System Components

D3-13

MAGNETIC SWITCHES Body position switches (With proximity switch and magnet)

Proximity switch operation The body position switches on these trucks are magnetic field change switches. The switches sense a ferrous material target, as well as a specific pole (south pole) magnet field. When a switch is activated by ferrous material, the maximum sensing distance is approximately 13 mm (0.5 in.). When a magnet is used instead of ferrous material, maximum sensing distance is approximately 95 mm (3.75 in.). Therefore, use of a magnet target allows the switch to activate at greater sensing distances.

Inside the body limit switch, there are two magnets of slightly varying strengths in line with one another. The magnets are located on separate ends of a rocker lever assembly which contains the functional switch contacts. In the non-actuated or rest state, in which there is no disturbance in the internal switch natural magnetic fields, the stronger magnet dominates the rocker into the “normal” position. Refer to Figure 3-8. When the field of the dominate magnet becomes distracted by a target, (a ferrous plate, or an opposite polarity magnet field (south pole), the weaker magnet in the switch will then become more dominate and move the rocker lever. The switch is then considered to be actuated or in the “sensed” position.

FIGURE 3-8. SWITCH CONTACTS - NORMAL AND SENSED POSITIONS

Service Keep the sensing area clean and free of metallic dust and other debris that may damage or inhibit operation of the switches. If a switch is damaged or not functioning, the switch must be replaced.

D3-14

24VDC Electrical System Components

D03051

BODY-UP SWITCH

Adjust the body up switch.

Operation

Figure 3-9 shows the body-up switch (2) and the magnet (1) used to activate the switch. If switch adjustment is necessary, follow the procedure below:

A magnetically activated proximity switch senses the position of the truck dump body. Body-up switch (2, Figure 3-9) is located inside the right frame rail, forward of the body pivot. This switch provides a "body seated" signal when the body is resting on the frame. When the body is raised above the frame rail, the magnetic field is removed from the switch sensing area. The switch sends a "body float" signal and a warning lamp in the dash illuminates to inform the operator. NOTE: The body float lamp will also illuminate if the hoist control is not in the FLOAT position or if there is an open circuit between the switch controller.

1. With the body resting completely on the frame, loosen switch mounting bracket cap screws and the magnet adjustment cap screws. 2. Position the upper edge of the magnet (1) 131.5 mm (5.18 in.) (Dimension A) from the bottom of mounting bracket. Tighten cap screws. 3. Adjust the proximity switch (2) so the passing distance between the two targets is 45 mm (1.77 in) (Dimension B). Tighten the cap screws.

The body-up switch is designed to prevent propulsion in REVERSE when the dump body is not resting on the frame rails. The switch also prevents forward propulsion with the body up unless the override button is depressed and held. The switch must be properly adjusted at all times. Improper adjustment or loose mounting bolts may cause false signals or damage to the switch assembly. FIGURE 3-9. BODY-UP SWITCH ADJU 1. Magnet

D03051

24VDC Electrical System Components

2. Body-Up Switch

D3-15

HOIST LIMIT SWITCH Operation Hoist limit proximity switch (1, Figure 3-11) is located on the right frame rail just behind the pivot. When the hoist cylinders approach maximum stroke and the body pivots on the pins, magnet (2) moves close enough to the proximity switch to close the electrical contacts. The proximity switch sends a signal to the hoist limit solenoid in the hydraulic cabinet. The solenoid activates and blocks oil flow from the hoist pilot valve to the hoist valve. The “power up” oil supply is blocked to prevent full hoist cylinder extension, and possible damage to the hoist cylinders. Proper switch adjustment ensures the hoist cylinder travel stops approximately 152 mm (6 in.) before full extension. The switch must be properly adjusted at all times. If the hoist limit switch does not function as described above, adjust the switch according to the procedure below. Improper adjustment or loose mounting bolts may cause false signals or damage to the switch assembly.

NOTE: Since a magnetic target is used to activate the switch, a larger initial distance in setting the switch is required. This is due to the fact that magnetic fields are not crisp 90 degree boxed fields but are instead curved about the shape of the magnet. Refer to Figure 3-10. The sensing field boundary limit takes on the same curved sensing area shape of the magnet field. The curved sensing area results in the actuation of the switch approximately 30 mm (1.18 in.) prior to reaching the edge of the magnet. Therefore, it is crucial that the 30 mm (1.18 in.) is observed when setting the hoist limit switch.

D3-16

FIGURE 3-10. HOIST LIMIT SWITCH OPTIMUM SETTING ADJUSTMENT

24VDC Electrical System Components

D03051

Adjust the hoist limit switch 1. Prior to adjustment, the dump body must be raised to 152 mm (6 in.) of the maximum hoist cylinder extension and supported in that location. Ensure there is adequate overhead clearance to fully raise the dump body. 2. Loosen proximity switch adjustment cap screws (4, Figure 3-11). Slide switch (1) up or down to position the top of the switch 30 mm (1.18 in.) (Dimension B) away from the lower edge of magnet (2). Tighten cap screws when in position.

4. Tighten the cap screws when adjusted properly. If necessary, additional cap screws could also be loosened to move the magnet to obtain the correct gap. 5. Lower the body onto the frame. 6. Check the operation of the proximity switch to verify that the hoist cylinders stop before reaching maximum cylinder stroke. If the cylinders extend to full stroke, adjust the proximity switch as necessary to prevent full cylinder extension.

3. Loosen cap screws (2, Figure 3-12). Slide the switch to the left or right until the passing distance between the two targets is 45 mm (1.77 in.) (Dimension A).

FIGURE 3-11. HOIST LIMIT SWITCH (SIDE VIEW) 1. Proximity Switch 2. Magnet

D03051

3. Cap Screws 4. Cap Screws

24VDC Electrical System Components

5. Dump Body

D3-17

FIGURE 3-12. HOIST LIMIT SWITCH (REAR VIEW) 1. Magnet 2. Cap Screws

D3-18

3. Proximity Switch

24VDC Electrical System Components

D03051

SECTION D11 KOMTRAX Plus SYSTEM INDEX

KOMTRAX Plus COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-3 KOMTRAX Plus BASIC FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-3 KOMTRAX Plus BASIC FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-3 Gather Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-3 Convert and Record Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-3 Communicate Data to Off-Board Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-4 USING THE KOMTRAX Plus SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-5 Turning the KOMTRAX Plus System ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-5 Normal KOMTRAX Plus Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-5 Turning the KOMTRAX Plus System OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-6 Downloading from the KOMTRAX Plus Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-6 KOMTRAX Plus DATA ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-7 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-7 Machine History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-7 KOMTRAX Plus History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-7 Snapshots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-8 Manual Snapshots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-8 Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-10 Histogram (Load Map) Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-10 Haul Cycle Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D11-11 Alarm and Snapshot Triggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-12 Satellite Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-12 KOMTRAX Plus DIAGNOSTIC FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-14 Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-14 KOMTRAX Plus LED Digits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-14 KOMTRAX Plus CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-15 KOMTRAX Plus SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-17 NECESSARY SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-17 NECESSARY TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-17 KOMTRAX Plus SYSTEM SET UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-18 KOMTRAX Plus Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-18 KOMTRAX Plus CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-18

D11013

KOMTRAX Plus COMPONENTS

D11-1

KOMTRAX Plus TOOL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-18 KOMTRAX Plus SETTING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-18 KOMTRAX Plus INITIALIZATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-19 1. KOMTRAX Plus CONTROLLER SETUP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-19 KOMTRAX Plus Setting Tool software program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-19 Select Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-19 KOMTRAX Plus Setting Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-20 Machine Information Setting(1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-20 Machine Information Setting(2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-20 Date & Time Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-20 GCC Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-21 Setting Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-21 2. KOMTRAX Plus SNAPSHOT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-22 3. KOMTRAX Plus DOWNLOAD PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-23 4. LOCATION OF DOWNLOAD FILES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-23 5. KOMTRAX Plus FTP UPLOAD PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-24 6. KOMTRAX Plus INITIALIZATION FORMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-25 WHEN REPLACING A KOMTRAX Plus CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-26 To Set: Date & Time; Satellite; Payload Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-28 Review Setting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-30 KOMTRAX Plus CONTROLLER CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-31 KOMTRAX Plus Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-31 Necessary Equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-31 Preliminary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-32 KOMTRAX Plus Controller Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-33 ORBCOMM CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-35 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-35 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11-35

D11-2

KOMTRAX Plus COMPONENTS

D11013

KOMTRAX Plus COMPONENTS KOMTRAX Plus BASIC FEATURES

Convert and Record Data

The center of the KOMTRAX Plus (previously called VHMS) system is the controller which gathers data about the operation of the truck from sensors and other controllers installed on the truck. Refer to Figure 11-1 for an overview of the KOMTRAX Plus system components.

KOMTRAX Plus controller (2, Figure 11-1) processes data received from external controllers and stores the following data in internal memory:

For instructions on how to use KOMTRAX Plus software programs, refer to KOMTRAX Plus Software elsewhere in this section. For error codes and troubleshooting procedures, refer to KOMTRAX Plus & Interface Module Error Codes and Troubleshooting elsewhere in this section.

• Fault codes from the engine, Interface Module, and PLM III • Snapshots of data when specific fault codes occur • Trends of parameters

specific

engine

and

chassis

• Load map and other measures of engine and chassis usage • Haul cycle summary information, including payload, distance traveled, and travel times In addition to data gathered from external controllers, KOMTRAX Plus records information about the vehicle and KOMTRAX usage, including:

Gather Data The KOMTRAX Plus controller gathers data from four sources. Real-time and alarm data from each controller is gathered continually. In addition, haul cycle summary data from the PLM III is requested by the KOMTRAX Plus controller one time per day.

• Key ON and engine ON record • KOMTRAX Plus configuration changes

The KOMTRAX Plus system performs three primary functions: 1. Gathers data from on-board sources: a. PLM III Controller b. Interface Module (IM) c. Engine Controllers d. Drive System Controller 2. Converts data into usable formats and record into permanent memory. 3. Communicates data to off-board systems: a. Satellite (ORBCOMM) b. Laptop Personal Computer (PC) Download

1

2

84050

FIGURE 11-1. KOMTRAX Plus SYSTEM COMPONENTS 1. ORBCOMM Controller 2. KOMTRAX Plus Controller

NOTE: The ORBCOMM controller may not be approved for use in certain countries of the world. Local regulation may prohibit the use of the ORBCOMM controller/satellite communicator. If equipped, the controller and antenna may be disconnected and/or removed from the truck..

D11013

KOMTRAX Plus COMPONENTS

D11-3

FIGURE 11-2. KOMTRAX Plus SYSTEM

Communicate Data to Off-Board Systems The KOMTRAX Plus has two methods to communicate data to off-board systems: • Via satellite to the WebCARE database • Download to a laptop PC running the VHMS Technical Analysis Toolbox software Communication to the satellite (using ORBCOMM) occurs automatically, but only sends critical data items. ORBCOMM controller (1, Figure 11-1) is located inside the auxiliary cabinet. ORBCOMM antenna (1, Figure 11-3) is mounted on the front left corner of the cab by magnetic mount (2). NOTE: The ORBCOMM controller installed at the factory on all new trucks may not be approved for use in certain countries of the world. Local regulation may prohibit the use of the ORBCOMM controller/ satellite communicator. The controller and antenna may be disconnected and/or removed.

D11-4

Communication to a laptop PC occurs whenever a user connects a laptop PC to the KOMTRAX Plus controller and requests a data download. All KOMTRAX Plus data is available for download to a laptop PC. Once downloaded to a laptop PC, the information is then sent to Komatsu via FTP. This data is then compiled at the Komatsu computer server. Based on this information, the local Komatsu distributor will suggest improvements and provide information aimed at reducing machine repair costs and downtime.

In order to collect all the necessary machine data, a preventative maintenance (P.M.) snapshot needs to be recorded every 500 hours of operation. The snapshot and other data is then downloaded into a laptop PC. This data is to be sent to Komatsu via the FTP program which is a part of the VHMS Technical Analysis Tool Box program. Refer to the check-out procedure for more detailed information regarding a P.M. snapshot.

KOMTRAX Plus COMPONENTS

D11013

Turning the KOMTRAX Plus System ON The KOMTRAX Plus controller is turned on by the truck key switch (circuit 712). Immediately after receiving input from the key switch signal, the KOMTRAX Plus controller begins its power-up initialization sequence. This sequence takes about three seconds, during which time the red LED digits on the top of the KOMTRAX Plus controller unit will display a circular sequence of flashing LED segments. The controller will not support a connection from a laptop PC or a manual snapshot during this initialization time. The KOMTRAX Plus controller is connected directly to the battery circuit which provides a constant 24 volt signal from the truck batteries. However, the controller has the ability to turn itself off, and will do so automatically within three minutes after the key switch is turned off.

FIGURE 11-3. ORBCOMM ANTENNA 1. Orbcomm Antenna

2. Magnetic Mount

USING THE KOMTRAX Plus SYSTEM The primary tool for configuring, downloading, and viewing KOMTRAX Plus data is the VHMS Technical Analysis Toolbox software. Use of this software requires: • A laptop PC running Windows 95/98/2000/ME/ XP operating system • A serial cable to connect the laptop PC to the KOMTRAX Plus controller Refer to the VHMS Technical Analysis Tool Box instruction manual for additional information about using this software. NOTE: It is recommended that the engine be OFF when downloading or configuring the KOMTRAX Plus controller.

The battery disconnect switch, located at the truck battery box, will remove 24 volt power from the KOMTRAX Plus controller and cause the controller to LOSE ALL DATA gathered since the key switch was last turned ON. DO NOT disconnect the batteries until the controller has completed its shutdown operations and has turned off its LED digits. Normal KOMTRAX Plus Operation The red LED digits on the top of the controller indicate the current condition of the KOMTRAX Plus system. The possible conditions are shown in Table 1.

Table 1: KOMTRAX Plus STATUS LED DISPLAY

DESCRIPTION

Flashing LED segments in circular sequence

Power-on initialization

Numeric display, counting 00 - 99 at rate of 10 numbers per second

Normal Operation

Flashing Fault Codes Normal operation, but a fault code is active NOTE: Only a limited number of fault codes are displayed on the LED display. Most fault conditions are recorded internally in the KOMTRAX Plus controller, but are NOT indicated on the LED digits.

D11013

KOMTRAX Plus COMPONENTS

D11-5

Turning the KOMTRAX Plus System OFF

Downloading from the KOMTRAX Plus Controller

The KOMTRAX Plus controller is connected directly to the truck batteries, but will remain in normal operation only if the truck key switch input (circuit 712) is on. When the controller senses that the truck key switch has been turned off, it finishes its internal processing and then saves recent data into permanent memory. This process can take up to three minutes.

Downloading data requires a laptop PC running Windows 95/98/2000/ME/XP operating system, the VHMS Technical Analysis Toolbox software, and a serial cable to connect the laptop PC to the KOMTRAX Plus controller. Refer to the VHMS Technical Analysis Tool Box instruction manual for additional information about using this software.

If 24 volt power is removed from the KOMTRAX Plus controller before it has time to save data to permanent memory, data loss or corruption may occur.

When a download to a laptop PC is performed, certain files are generated to store data. A listing of the file types and data is shown in Table 2.

The controller will turn off the red LED digits when it is off.

KOMTRAX Plus diagnostic port (2, Figure 11-4), located on the D.I.D. panel at the rear of the operator cab, is used to download data from the controller.

Do not remove 24 volt power from the KOMTRAX Plus controller unless the red LED digits on the controller are off!

FIGURE 11-4. DIAGNOSTIC PORTS 1. IM Diagnostic Port 2. KOMTRAX Plus Diagnostic Port

Table 2: File Types of Download Data File Name

Data Type

Description

cyc_int0

Cycle Interval

csvdata_3f.csv

Temporary Brake Load Map

Fault0.csv

Fault History

Records all faults

index00.csv

Index

Lists all common data files

loadm1.csv

Temporary Load Map

mcn_his0.csv

Machine History

Key On, Key Off

m_area0.csv

Running Area Map

Records engine operation distribution

m_drct0.csv

Running Direction Map

Records engine performance movement

snap00.csv

Snapshot

Records snapshot data over time period

vhmshis0.csv

KOMTRAX Plus History

Records changes to KOMTRAX Plus

*.k

Zipped File

Contains all data files

D11-6

Changes in engine speed

KOMTRAX Plus COMPONENTS

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KOMTRAX Plus DATA ITEMS Fault Codes The KOMTRAX Plus controller maintains a history of the most recent 600 fault codes. For each fault code, the controller records the following information:

Serious fault conditions will be sent to WebCARE via the ORBCOMM satellite network, as well as being recorded in permanent memory. Some fault codes are configured to generate a snapshot when they occur. Refer to Table 6 for detailed information showing which fault codes will send data to WebCARE and which ones trigger a snapshot.

• Fault Code Number • SMR (service meter reading) when the fault occurred • Time/Date when the fault occurred • SMR (service meter reading) when the fault cleared

Machine History The KOMTRAX Plus controller maintains a history of the most recent 400 Key ON and Engine ON conditions.

• Time/Date when the fault cleared KOMTRAX Plus History If a fault occurs more than once within 30 minutes, the KOMTRAX Plus controller will only maintain a single fault entry, but will count the number of times the fault occurred and cleared. This feature prevents an intermittent fault that occurs repeatedly from filling up the fault memory.

The KOMTRAX Plus controller maintains a history of the most recent 400 KOMTRAX Plus configuration changes. The controller will record a history entry each time one of the following configuration changes occurs: • Changing the date or time of the KOMTRAX Plus controller • Changing the ORBCOMM satellite settings • Performing a KOMTRAX Plus memory clear operation

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KOMTRAX Plus COMPONENTS

D11-7

Snapshots

Manual Snapshots

A snapshot is a time history of real-time data that is recorded before and after the instant that a fault code occurs. The KOMTRAX Plus controller is continually recording real-time data for various engine data items. This allows the KOMTRAX Plus controller to record data for the time period before and after a fault code occurred.

A manual snapshot is taken by pressing the data store button (1, Figure 11-5), located at the rear of the center console. When the 7.5 minute snapshot is being recorded by the KOMTRAX Plus controller, KOMTRAX Plus snapshot in progress light (located on the status indicator light panel) will be illuminated. During the first five minutes, the LED will be on continuously. During the next two minutes, the LED will flash slowly. During the last 30 seconds, the LED will flash rapidly.

Only certain fault codes generate snapshots. When a snapshot enabled fault code occurs, the KOMTRAX Plus controller will record data for 330 seconds (5.5 minutes) before the fault to 120 seconds (2 minutes) after the fault. In order to conserve storage memory, the KOMTRAX Plus controller records snapshot data at two different sample rates. Each data item is recorded at a rate of one sample every 10 seconds up until 30 seconds prior to the fault occurrence. Each data item is then recorded at a rate of one sample per second from 30 seconds prior to 120 seconds after the fault occurrence.

Manual snapshots are used to record current machine data, and can then be downloaded and stored in a laptop PC. These snapshots can be used to observe current conditions on a machine. Over time, these snapshots can be compared and trends can be monitored. During the snapshot recording period, the machine must be driven over a variety of conditions so useful data can be collected.

If a snapshot enabled fault condition occurs more than one time, the KOMTRAX Plus controller will record the snapshot for the first (earliest) fault occurrence. The only exception is the manual snapshot button, in which case the controller will record the latest (most recent) snapshot. Refer to Table 3 for all the items that are recorded in each snapshot.

FIGURE 11-5. REAR OF CENTER CONSOLE 1. Data Store Button

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KOMTRAX Plus COMPONENTS

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Table 3: Snapshot Data Data Item

Data Source

Model Note

Engine Coolant Temperature

Engine QUANTUM Controller

Engine Oil Pressure

Engine QUANTUM Controller

Accelerator Position%

Engine QUANTUM Controller

Engine Speed

Engine QUANTUM Controller

Exhaust Gas Temperature (Left Front)

Engine CENSE Controller

Exhaust Gas Temperature (Left Rear)

Engine CENSE Controller

Exhaust Gas Temperature (Right Front)

Engine CENSE Controller

Exhaust Gas Temperature (Right Rear)

Engine CENSE Controller

Engine Oil Temperature

Engine CENSE Controller

Fuel Rate

Engine QUANTUM Controller

Boost Pressure

Engine QUANTUM Controller

Blow-by Pressure

Engine QUANTUM Controller

Vehicle Speed

PLM III

Sprung Weight

PLM III

haul cycle State

PLM III

Brake Pressure

Interface Module

Hoist Pressure 1

Interface Module

Hoist Pressure 2

Interface Module

Steering Pressure

Interface Module

Front Left Brake Oil Temperature

Interface Module

930E Only

Front Right Brake Oil Temperature

Interface Module

930E Only

Rear Left Brake Oil Temperature

Interface Module

930E Only

Rear Right Brake Oil Temperature

Interface Module

930E Only

Ambient Temperature

Interface Module

Hydraulic Oil (Tank) Temperature

Interface Module

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KOMTRAX Plus COMPONENTS

830E Only

D11-9

Trends The KOMTRAX Plus controller develops trends by monitoring real-time data, and reducing the data into 20 hour statistical values. For each trended data item, the controller can determine the maximum value, minimum value, and average value during the preceding 20 hour period. Table 4 shows the type of statistical data recorded for each item. NOTE: Trend data is only collected when the engine is running. Histogram (Load Map) Data The KOMTRAX Plus controller develops histograms by sampling data every 100ms while the engine is running. The data is presented as a two dimensional histogram showing time-at-level for various combinations of the two input data items.

The KOMTRAX Plus controller maintains an engine speed vs. fuel rate histogram called the Engine Load Map, and a brake pressure vs. speed histogram. The Engine Load Map histogram shows time-at-level for specific engine speed and fuel rate combinations. The Brake Pressure vs. Speed histogram shows time-at-level for specific brake pressure and vehicle speed combinations. Two engine load maps are maintained in the KOMTRAX Plus controller. The Permanent Load Map contains load map data for the life of the engine. The Temporary Load Map contains load map data since the most recent memory clear action. Although the engine data is sampled every 100ms internally, the histograms are only updated every two hours.

Table 4: Trend Data Data Item

Data Source

MAX

AVG

MIN

Model Notes

Engine Coolant Temperature

QUANTUM Controller

X

X

Engine Oil Pressure

QUANTUM Controller

X

X

Engine Speed

QUANTUM Controller

X

Atmospheric Pressure

QUANTUM Controller

Exhaust Gas Temperature

CENSE Controller

X

Engine Oil Temperature

CENSE Controller

X

Fuel Rate

QUANTUM Controller

Boost Pressure

QUANTUM Controller

X

Blow-by Pressure

QUANTUM Controller

X

Brake Pressure

Interface Module

X

Hoist Pressure 1

Interface Module

X

Hoist Pressure 2

Interface Module

X

Steering Pressure

Interface Module

X

Front Left Brake Oil Temperature

Interface Module

X

X

930E Only

Front Right Brake Oil Temperature

Interface Module

X

X

930E Only

Rear Left Brake Oil Temperature

Interface Module

X

X

930E Only

Rear Right Brake Oil Temperature

Interface Module

X

X

930E Only

Ambient Temperature

Interface Module

X

X

Hydraulic Oil (Tank) Temperature

Interface Module

X

X

D11-10

X

X

KOMTRAX Plus COMPONENTS

X

X 830E Only

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Haul Cycle Data The KOMTRAX Plus controller downloads haul cycle data from Payload Meter III one time every 24 hours, at a time specified by the VHMS Setting Tool software. The data consists of a summary report of all haul cycles completed in the past 24 hours. The summary data items are listed in Table 5. After receiving the haul cycle summary data from Payload Meter III, the KOMTRAX Plus controller immediately attempts to send the data to WebCARE via the ORBCOMM satellite. The haul cycle summary data is also stored in controller internal memory.

The KOMTRAX Plus controller maintains a record of the payload summary data from the past 100 daily transmissions to ORBCOMM. NOTE: The haul cycle summary statistics exclude haul cycles that the Payload Meter III controller has marked as 'not trusted'. The total number of haul cycles that occurred during the summary period, but were excluded from the summary, are indicated in the 'Total Excluded Cycles' field. See the Payload Meter III coverage in Section M, Options, for more information on excluded cycles.

Table 5: Haul Cycle Data Summary Data Item

Description

Summary Start Time

Start time of first haul cycle in summary

Summary End Time

Start time of last haul cycle in summary

Total Cycles

Total haul cycles included in this summary

Total Excluded Cycles

Total haul cycles occurring during summary period, but excluded from the statistics

Average Carried Load

Average Gross Payload

Standard Deviation of Carried Load

Standard Deviation of Gross Payload

Number of Loads Over Rated

Number of haul cycles with carried load > rated payload for this truck.

Number of Loads Over 110%

Number of haul cycles with carried load > 110% of rated payload for this truck.

Number of Loads over 120%

Number of haul cycles with carried load > 120% of rated payload for this truck.

Maximum Carried Load

Maximum carried load during this summary

Maximum Speed EMPTY

Maximum truck speed while truck was empty

Average Speed EMPTY

Average truck speed while truck was empty

Maximum Speed LOADED

Maximum truck speed while truck was loaded

Average Speed LOADED

Average truck speed while truck was loaded

Maximum Sprung Load

Maximum instantaneous sprung weight recorded during this summary

Average Maximum Sprung Load

Average of all 'Maximum Sprung Load' values recorded in each haul cycle

Maximum Frame Torque

Maximum instantaneous frame torque recorded during this summary

Average Maximum Frame Torque

Average of all 'Maximum Frame Torque' values recorded in each haul cycle.

Right Front Tire TKPH

Total tire ton kilometer per hour recorded for the right front tire.

Left Front Tire TKPH

Total tire ton kilometer per hour recorded for the left front tire

Rear Tires TKPH

Total tire ton kilometer per hour recorded for the rear tires

Relative Application Severity

Total frame damage recorded during this summary

Reserved_1

Future Use

Reserved_2

Future Use

Reserved_3

Future Use

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KOMTRAX Plus COMPONENTS

D11-11

Alarm and Snapshot Triggers

Satellite Features

Serious fault conditions will be sent to WebCARE via the ORBCOMM satellite network, as well as being recorded in permanent memory. Some fault codes are configured to generate a snapshot when they occur.

The KOMTRAX Plus controller sends data to WebCARE via the ORBCOMM satellite network in the following conditions:

Table 6 shows which fault codes trigger a snapshot and which fault codes will be sent to WebCARE via satellite.

• A periodic event occurs, such as reception of daily PLM III summary data or a 20 hour trend.

• A fault code occurs that has been configured for transmission via ORBCOMM.

• A remote request for data is received via the satellite network.

Table 6: Alarm and Snapshot Triggers VHMS Fault Code

KOMTRAX Fault Description

Source

Sent via ORBCOMM

Snapshot Trigger

Model Notes

#A018

RR Flat Cylinder Warning

PLM III

X

830E-AC

#A019

LR Flat Cylinder Warning

PLM III

X

830E-AC

#A101

Pump Filter Switches

IM

X

830E-AC

#A107

Propel System Caution

IM

X

830E-AC

#A108

Propel System Temp Caution

IM

X

830E-AC

#A109

Propel System Reduced Level

IM

X

830E-AC

#A115

Low Steering Precharge

IM

X

830E-AC

#A124

No Propel / Retard

IM

X

830E-AC

#A125

No Propel

IM

X

830E-AC

#A126

Hydraulic Tank Level

IM

X

830E-AC

#A127

IM Sensor +5V Low

IM

X

830E-AC

#A128

IM Sensor +5V High

IM

X

830E-AC

#A190

Auto Lube Switch

IM

X

830E-AC

#A193

High Hydraulic Tank Oil Temp

IM

X

X

830E-AC

MFA0

Manual Trigger

Manual

X

X

All

C00115

Speed Signal Lost

Engine

X

X

All

C00135

Oil Pressure Circuit Failed High

Engine

X

X

All

Continued

D11-12

KOMTRAX Plus COMPONENTS

D11013

Table 6: Alarm and Snapshot Triggers (Continued) KOMTRAX KOMTRAX Plus Fault Description Fault Code

Source

Sent via ORBCOMM

Snapshot Trigger

Model Notes

C00143

Low Oil Pressure

Engine

X

X

All

C00151

High Coolant Temperature

Engine

X

X

All

C00155

High IMT LBF

Engine

X

X

All

C00158

High IMT LBR

Engine

X

X

All

C00162

High IMT RBF

Engine

X

X

All

C00165

High IMT RBR

Engine

X

X

All

C00214

High Oil Temperature

Engine

X

X

All

C00219

Remote Oil Level Low

Engine

X

X

All

C00233

Low Coolant Pressure

Engine

X

X

All

C00234

Engine Overspeed

Engine

X

X

All

C00235

Low Coolant Level

Engine

X

X

All

C00261

High Fuel Temperature

Engine

X

X

All

C00292

OEM Temp out of Range

Engine

X

X

All

C00293

OEM Temp Failed High

Engine

X

All

C00294

OEM Temp Failed Low

Engine

X

All

C00296

OEM Pressure Out of Range

Engine

X

X

All

C00297

OEM Pressure Failed High

Engine

X

All

C00298

OEM Pressure Failed Low

Engine

X

All

C00473

Remote Oil Level Signal Invalid

Engine

X

X

All

C00555

High Blow-by Pressure

Engine

X

X

All

X

C00639

Intake Air Leak LBR

Engine

X

All

C00641

High Exh Temp #1 LB

Engine

X

All

C00642

High Exh Temp #2 LB

Engine

X

All

C00643

High Exh Temp #3 LB

Engine

X

All

C00644

High Exh Temp #4 LB

Engine

X

All

C00645

High Exh Temp #5 LB

Engine

X

All

C00646

High Exh Temp #6 LB

Engine

X

All

C00647

High Exh Temp #7 LB

Engine

X

All

C00648

High Exh Temp #8 LB

Engine

X

All

C00651

High Exh Temp #1 RB

Engine

X

All

C00652

High Exh Temp #2 RB

Engine

X

All

C00653

High Exh Temp #3 RB

Engine

X

All

C00654

High Exh Temp #4 RB

Engine

X

All

C00655

High Exh Temp #5 RB

Engine

X

All

C00656

High Exh Temp #6 RB

Engine

X

All

C00657

High Exh Temp #7 RB

Engine

X

All

C00658

High Exh Temp #8 RB

Engine

X

All

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KOMTRAX Plus COMPONENTS

D11-13

KOMTRAX Plus DIAGNOSTIC FEATURES

KOMTRAX Plus CONTROLLER

The KOMTRAX Plus system provides several basic data items that are useful for troubleshooting failures in the KOMTRAX Plus system itself.

The KOMTRAX Plus controller collects and stores signals from sensors and data from other controllers. It also gives commands for transmitting the accumulated data through the communications system. The controller operates on 20VDC - 30VDC.

Fault History The Fault History recorded in the KOMTRAX Plus controller can help identify failures within the system and in the communications network to the engine controllers, interface module, or PLM III. For a complete listing of all the error codes, refer to the KOMTRAX Plus Troubleshooting and Checkout Procedures in this section.

KOMTRAX Plus LED Digits The KOMTRAX Plus controller indicates some system errors or communication errors on two red LED digits (2, Figure 11-6) on the controller. Error codes are flashed as a two-part sequence. If no errors are occurring, the controller LED's count from 00 - 99 continuously at a rate of 10 numbers per second. For a complete listing of all the error codes, refer to the KOMTRAX Plus Troubleshooting and Checkout Procedures in this section. The KOMTRAX Plus controller also has two red LED lights (10 and 11, Figure 11-6). Light (10) PLM III communication • OFF - no communication with the PLM III controller • ON - is communication with the PLM III controller

FIGURE 11-6. KOMTRAX Plus CONTROLLER

Light (11) ORBCOMM • OFF - no communication with ORBCOMM controller • ON - communication with ORBCOMM controller • FLASHING - satellite in view

D11-14

1. KOMTRAX Plus Controller 2. LED Digit Display 3. Connector CN3B 4. Connector CN3A 5. Connector CN4B 6. Connector CN4A

KOMTRAX Plus COMPONENTS

7. Connector CN1 8. Connector CN2A 9. Connector CN2B 10. PLM III Light 11. ORBCOMM Light

D11013

Installation

Removal If the KOMTRAX Plus controller has to be replaced, the following steps must be performed in order to maintain accurate information after the controller has been replaced. If the new KOMTRAX Plus controller is not set up correctly (like the one being removed), the data in the controller and at WebCARE may not be usable. Some steps will require using a laptop PC and the VHMS Setting Tool software or the VHMS Technical Analysis Tool Box software. For more detailed instructions on performing these steps with a laptop PC and software, refer to KOMTRAX Plus Software elsewhere in this section. During the controller replacement process, two data downloads will have to be taken (one before, one after) and sent to WebCARE. Also, a KOMTRAX Plus Initialization form will have to be filled out and sent to Komatsu North America as shown on the form.

1. With the key switch OFF, connect a laptop PC to the KOMTRAX Plus controller using the serial cable. 2. Using a laptop PC and the VHMS Technical Analysis Tool Box software, perform a complete data download from the KOMTRAX Plus controller. 3. Save this data so it can be sent to WebCARE at a later time when a connection to the internet is available. 4. Using the VHMS Setting Tool software, enter the Service ID and choose the “Save/Load” function. 5. From the File menu, select “Save”. 6. Capture a screen shot (“Alt” and “Print Screen” keys at the same time) of the Save Confirmation window, paste it into a Microsoft Word document and save it.

1. Install the new KOMTRAX Plus controller and connect the wiring harnesses to it. Connect the laptop PC to the KOMTRAX Plus controller with the serial cable. 2. Connect battery power. Turn the key switch ON, but do not start the engine. 3. With the VHMS Setting Tool software, enter the Service ID and choose the “Save/Load” function. 4. From the file menu, select “Load”. 5. Capture a screen shot (“Alt” and “Print Screen” keys at the same time) of the Save Confirmation window, paste it into a Microsoft Word document and save it. 6. Click the [OK] button to load the settings. 7. Click the [Apply] button to reset the controller, then click the [OK] and [Yes] buttons to confirm. Then select the [Close] button. 8. Fill out a “KOMTRAX Plus Initialization” form and send it to Komatsu as instructed on the form. 9. Exit the VHMS Setting Tool program. 10. Turn the key switch OFF and wait three minutes. 11. Turn the key switch ON. Wait three minutes and watch for any error messages on the KOMTRAX Plus controller LED lights that might indicate a problem in the system. 12. If there are no error messages, continue to Step 13. If there are error messages, refer to the KOMTRAX Plus Checkout procedures or KOMTRAX Plus Error Codes elsewhere in this section. 13. Using a laptop PC and the VHMS Technical Analysis Tool Box software, perform a complete data download from the KOMTRAX Plus controller.

7. Click the “OK” button to save the settings. 8. Exit the VHMS Setting Tool program. 9. Turn the key switch OFF. 10. Wait three minutes, then disconnect battery power. 11. After the two LED lights are off, disconnect the wiring harnesses and remove the KOMTRAX Plus controller.

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KOMTRAX Plus COMPONENTS

D11-15

14. Confirm the download data is good by using the VHMS Technical Analysis Tool Box software. Ensure the settings are correctly applied by looking at the date, time, SMR, etc. 15. Turn the key switch OFF. Disconnect the laptop PC from the KOMTRAX Plus controller.

16. Use internet access available to the laptop PC to send the download data set that was taken before the KOMTRAX Plus controller was removed from the truck to WebCARE. Use the FTP feature built into the VHMS Technical Analysis Tool Box program to send the files. 17. Use the FTP program to send the download data set that was taken after the new KOMTRAX Plus controller was installed to WebCARE.

D11-16

KOMTRAX Plus COMPONENTS

D11013

KOMTRAX Plus SOFTWARE To work with the KOMTRAX Plus system, several special tools and software programs are required. Refer to Table 7 and Table 8 for detailed information on KOMTRAX Plus software and tools.

The data files, application code and flashburn software are only required if the interface module is being replaced. Replacement interface modules from Komatsu do not have any software installed in them.

Refer to the following pages for detailed information on how to perform certain procedures using KOMTRAX Plus specific software.

NOTE: Be aware that the software and data files are updated periodically. Check with the local Komatsu distributor for the latest software versions.

NECESSARY SOFTWARE

Table 7: KOMTRAX Plus Software Part Number

Name

Description

Source

Version 3.04.03.01 VHMS Technical Analysis Tool Box

To maintain KOMTRAX Plus system

Komatsu Distributor

Version 3.06.00.00 VHMS Setting Tool

To initialize KOMTRAX Plus system

Komatsu Distributor

1.4.7.39

PDM

Payload Meter III Data Manager

Komatsu Distributor

EJ0575-5

PLM III

PLM III Controller Software to work with KOM- Komatsu Distributor TRAX Plus

NECESSARY TOOLS

Table 8: KOMTRAX Plus Tools Part Number

D11013

Name

Description

Source

Laptop PC

200 MHz or higher 64 MB RAM or more Serial or USB Port CD/DVD -Rom drive Floppy Drive Windows 95/98/2000/ME/XP

Purchased Locally

Serial cable

(RS232) Purchase locally Male DB9 connector at one end Female DB9 connector at other end

Purchased Locally

Adaptor

USB port to RS232 (serial) port adapter (If laptop PC does not have an RS232 port, this adaptor is required)

Purchased Locally

KOMTRAX Plus COMPONENTS

D11-17

KOMTRAX Plus SYSTEM SET UP

KOMTRAX Plus SETTING TOOL

The following topics are covered in detail.

Installation

• KOMTRAX Plus Setting Tool

1. Insert the CD. If the VHMS Technical Analysis Tool Box software begins installing automatically, select the [Cancel] button to stop the installation process.

• KOMTRAX Plus Initialization Procedure

2. Open My Computer.

KOMTRAX Plus Controller • KOMTRAX Plus Tool Box

• KOMTRAX Plus Snapshot Procedure • KOMTRAX Plus Download Procedure • Location of Download Files • KOMTRAX Plus FTP Upload Procedure

3. Right-click on the CD drive and select Open. 4. Open the Setting Tool folder. 5. Double-click on the Setup.exe file. 6. Accept the recommended defaults and finish installing VHMS Setting Tool.

• KOMTRAX Plus Initialization Forms • When Replacing a KOMTRAX Plus Controller

KOMTRAX Plus CONTROLLER KOMTRAX Plus TOOL BOX Installation 1. Insert the CD. The VHMS Technical Analysis Tool Box software will begin installing automatically. 2. Accept the recommended defaults and finish installing VHMS Technical Analysis Tool Box. 3. Double-click on the new icon on the desktop, VHMS Technical Analysis Tool Box. 4. Initialize the software by inserting the Set Up Disk. 5. Enter the User Name. The User Name is user. 6. Enter the Password. The Password you entered the first time will be your Password from then forward, unless you change it. 7. VHMS Technical Analysis Tool Box is installed.

D11-18

KOMTRAX Plus COMPONENTS

D11013

KOMTRAX Plus INITIALIZATION PROCEDURE

1. KOMTRAX Plus CONTROLLER SETUP PROCEDURE

When a new KOMTRAX Plus equipped machine is being assembled, there are several procedures to perform in order to initialize the KOMTRAX Plus system. Following the procedures will ensure a smooth initialization process which will not take longer than an hour to complete. To ensure the initialization process has been completed properly, check off each item on the list below as it is done. It is important to complete the entire procedure at one time. Submitting a data download with a date and SMR that does not match the KOMTRAX Plus Initialization form will not allow the system to be initialized.

KOMTRAX Plus Setting Tool software program

NOTE: The interface module must be fully operational before initializing the KOMTRAX Plus controller.

1. Start the VHMS Setting Tool software program. There will be three choices to choose from. • Use the [VHMS Setting] function to initialize a machine or change a machine's settings. • Use the [When KOMTRAX Plus needs to be replaced] function when replacing a machine's KOMTRAX Plus controller. • Use the [Review setting information] function when only needing to view a machine's settings.

Select Operation 2. Select VHMS Setting, then click [Next].

The initialization procedure consists of the following:  1. KOMTRAX Plus Controller Setup Procedure  2. KOMTRAX Plus Snapshot Procedure  3. KOMTRAX Plus Download

Procedure  4. Location Of Download Files  5. KOMTRAX Plus FTP Upload

Procedure  6. KOMTRAX Plus Initialization Forms

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KOMTRAX Plus COMPONENTS

D11-19

Machine Information Setting(2)

KOMTRAX Plus Setting Function 3. Select Set up & All clear if initializing a machine, then click [Next].

5. Verify that the Machine Information Settings are correct. If not, enter the correct settings. Then click [Next].

Machine Information Setting(1) 4. Verify that the Machine Information Settings are correct. If not, enter the correct settings. Then click [Next]. NOTE: Serial number must be included, and is case sensitive. Use all upper case letters.

Date & Time Setting 6. Enter the correct Time Zone, Date and Time. Check [DST (Summer Time)] if the machine's location uses Daylight Savings Time. Then click [Next]. NOTE: The KOMTRAX Plus time clock is the master time keeper. The PLM III time clock is synchronized with the KOMTRAX Plus time clock. Do not set the time in the PLM III controller if the KOMTRAX Plus controller is operational.

D11-20

KOMTRAX Plus COMPONENTS

D11013

9. Click [YES].

GCC Setting 7. Choose the correct GCC code. The GCC code tells machines equipped with ORBCOMM which satellite ground station to use. Then click [Next].

10. Click [OK].

11. Click [OK]. The VHMS Setting Tool program will close.

Setting Summary 8. Verify that all the setting information is correct and click [Apply].

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KOMTRAX Plus COMPONENTS

D11-21

2. KOMTRAX Plus SNAPSHOT PROCEDURE

c. Lower the dump body to the frame, then hold it in the power down position momentarily.

A snapshot through the KOMTRAX Plus system records important data about different systems on the machine. Take snapshots on a periodic schedule and store them as part of the machine history. These snapshots can then be compared and trends can be analyzed to predict future repairs.

d. Turn the steering wheel to full left, then full right against the stops momentarily.

A single snapshot records machine data for 7.5 minutes.

g. On an 830E-AC truck, perform a horsepower check using a laptop PC connected to the GE drive system.

NOTE: On a 830E-AC drive truck, a laptop PC must also be connected to the GE drive system to allow for maximum horsepower check of the engine during the snapshot recording process.

1. Allow the machine to run until it is at normal operating temperatures. 2. Press and hold the GE data store switch for three seconds, then release. The white data store in progress LED will illuminate. 3. While the manual snapshot is being taken, operate the machine.

e. Travel forward to maximum speed and apply the brakes hard. f. Travel in reverse.

4. The white LED will begin flashing slowly after five minutes has elapsed, then flash rapidly during the last 30 seconds. 5. Wait until the LED has finished flashing. After one more minute, turn the key switch OFF to stop the engine. Verify the KOMTRAX Plus controller red LED display is off. 6. Use VHMS Technical Analysis Tool Box program to download the snapshot data into a laptop PC. Use the FTP feature to send the download data to WebCARE.

a. Operate the engine at high and low idle. b. Raise the dump body to the full dump position.

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KOMTRAX Plus COMPONENTS

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3. KOMTRAX Plus DOWNLOAD PROCEDURE

16. Select the [Machine History] option from the list on the left side of the screen.

NOTE: Always verify a full download has been taken before disconnecting the laptop PC from the machine.

17. Verify that the key ON/OFF and engine ON/OFF records are recorded correctly.

1. Turn the key switch to the OFF position to stop the engine.

19. Verify a full download has been taken. Refer to Location of Downloaded Files on Computer for more detailed instructions.

2. Turn the key switch to the ON position, but DO NOT start the engine. 3. Allow the KOMTRAX Plus controller to start up. This will take about one minute. Verify the red LED display starts counting up.

18. Exit any open windows on the laptop PC.

20. Disconnect the KOMTRAX Plus cable from the laptop PC and from the machine. 21. Turn the key switch to OFF.

4. Attach the KOMTRAX Plus serial cable to the machine's KOMTRAX Plus port, and the other end to the laptop PC’s serial port. 5. Double-click on the VHMS Technical Analysis Tool Box icon on the laptop PC's desktop. 6. Enter the appropriate User Name and Password and click the [OK] button. 7. Double-click on the [Download] icon. 8. Select the COM port in the Port No. drop-down box and click the [Connection] button. 9. Verify that the date and time is correct for current local date and time. Also verify that the displayed service meter hours are equal to the value entered previously. 10. If this is the first time this laptop PC has connected to the machine, you will need to download its definition file by clicking the [OK] button. 11. Verify that a manual snapshot (MFAO) has been recorded. The display will show an item named “Snapshot” with the code MFAO and text “Manual Trigger”. 12. On the Download screen, click the [Select All] button. All items will become checked. 13. Click the [Download] button. The download may take one to ten minutes. Generally, if there are several snapshots in the download items, the download will take longer. 14. Click the [OK] button to complete the download. 15. Verify that the “Download Completed” message is displayed. Click on [Exit].

4. LOCATION OF DOWNLOAD FILES When a download using VHMS Technical Analysis Tool Box is performed, several files are downloaded onto the computer. They are organized in a specific way so that they can be used by VHMS Technical Analysis Tool Box at a later time. This structure is created automatically when the computer is used to perform the download from the KOMTRAX Plus controller. The situation may arise where the files need to be sent to someone, or someone gives these files to you. 1. Open Windows Explorer by right-clicking on the Start button and choosing Explore. 2. In the left frame, the computer's file structure will be displayed. The right frame will show the details for the folder that is highlighted in the left frame. 3. In the left frame, navigate to the download files.

The basic path is as follows: - Desktop - My Computer - Local Disk (C:) - VHMS_Data - Model - Serial Number - Date - Check Number NOTE: The Date folder is named in the format YYYYMMDD.

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KOMTRAX Plus COMPONENTS

D11-23

5. KOMTRAX Plus FTP UPLOAD PROCEDURE After downloading, the KOMTRAX Plus data resides on the laptop PC that performed the download. At this point, it can be reviewed and analyzed using VHMS Technical Analysis Tool Box on this laptop PC only. In order to make this data available to others, it must be sent to an online database named WebCARE. Once the data has been uploaded (ftp'd) to WebCARE, it is accessible to anyone with an internet connection and an ID and password. VHMS Technical Analysis Tool Box is used to perform the ftp upload. Perform an ftp upload as soon as the person who performed the download can obtain an internet connection. All downloads must be uploaded to WebCARE.

The screenshot shows the location of where the KOMTRAX Plus download files reside on a computer. The Check Number folder is named in the format CHK000#. Each time a download is taken, it is placed in one of these folders. The first download will be in the CHK0001 folder. If a second download is taken on the same day, will be in the CHK0002 folder, etc.

1. Double-click on the VHMS Technical Analysis Tool Box icon on the laptop PC's desktop. 2. Enter the appropriate user name and password and click the [OK] button. 3. Double click the [FTP] icon.

Once the appropriate folder is selected, the contents will be shown in the right frame. These files can then be e-mailed or copied to a disk. If someone provides KOMTRAX Plus download files through e-mail or on a disk, the same folder organization must be created in order to view them in VHMS Technical Analysis Tool Box.

4. At the ftp Client Login window, enter the ftp User ID and Password. User ID = komatsu Password = vhms 5. The target directory must be set to the laptop PC's hard drive (usually drive C:\). a. Double-click the VHMS_Data folder to drop down the model folders. b. Double-click the appropriate model folder to drop down the serial number folders. c. Double-click the appropriate serial number folder to drop down the date folders.

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KOMTRAX Plus COMPONENTS

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d. Double-click the appropriate date folder to drop down the check number folders. e. Double-click the appropriate check number folder to display its contents in the files window.

6. Some models will automatically create a sending file during the download process. Others need to have the sending file created at this time. A sending file is just a compressed version of all the other downloaded files. If there is already a sending file in the Send File window, you do not need to perform this step. If there is not a sending file in the Send File window, click the [Make Sending File] button.

9. If the sending file was uploaded successfully, the file will appear in the OK window. If the sending file was not uploaded successfully, the file will appear in the NG (No Good) window. Ensure the laptop PC has an internet connection.

10. Click the [OK] button, then the [Exit] button. Close all other open windows.

6. KOMTRAX Plus INITIALIZATION FORMS NOTE: The compressed sending file will look similar to this file name, and will always end with a “.K”. P_830E_-_A30761_1105208857.K

Complete the initialization check list and initialization forms found in this section. Send the initialization form to Komatsu. Initialization is now complete.

7. After selecting the correct file to send, click the [Send (FTP)] button. 8. Click the [Yes] button to verify that you want to upload the data to WebCARE.

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KOMTRAX Plus COMPONENTS

D11-25

WHEN REPLACING A KOMTRAX Plus CONTROLLER

3. Click the [Save] button.

Refer to KOMTRAX Plus Components, KOMTRAX Plus controller removal and installation instructions (elsewhere in this section) for replacing a KOMTRAX Plus controller. Follow the steps below when using the VHMS Setting Tool software to save the data and settings so they can be transferred from the old controller to the new controller.

1. Select the [When VHMS Replaced] function.

Needs

To Be

4. Click the [OK] button.

2. Select the [Save current setting before replacement of VHMS controller] function.

D11-26

5. Replace the KOMTRAX Plus controller as described elsewhere in this section. After the new KOMTRAX Plus controller is installed, proceed to Step 6.

KOMTRAX Plus COMPONENTS

D11013

6. Select the [Use previous setting after replacement of VHMS controller] function.

8. If the correct data is not showing, click the [Select File] button and choose the correct data. Then click the [Next] button.

7. Verify that the data showing is the data to be loaded and then click the [Next] button.

9. Enter the correct Time Zone, Date and Time information. Check [DST (Summer Time)] if the machine's location uses Daylight Savings Time. Click the [Apply] button.

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KOMTRAX Plus COMPONENTS

D11-27

10. Click the [OK] button.

To Set: Date & Time; Satellite; Payload Meter • Date & Time • Satellite • Payload Meter 1. Select the [VHMS Setting] function, then click the [Next] button.

11. Click the [OK] button. The Setting Tool Program will close.

2. Select the [Set up only] function, then click the [Next] button.

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KOMTRAX Plus COMPONENTS

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3. After selecting one of the following choices, click the [Next] button. • [Date & Time]

5. Satellite: Select the correct country location from the drop-down menu, then click the [Apply] button to change the setting.

• [Satellite] • Payload Meter

4. Date & Time: May be set to current date and time. If not correct, set the correct Time Zone, Date and Time to current time zone, date and time. Be sure to select [DST Summer Time)] if it applies. Click the [Apply] button.

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6. Payload Meter: Set Start Time to “0”, and Interval to 1. Then click the [Apply] button to save the setting.

KOMTRAX Plus COMPONENTS

D11-29

Review Setting Information 1. Select the [Review setting information] function and then click the [Next] button.

3. Click the [Yes] button to close the Setting Tool Program.

2. Review the settings for accuracy. If something is not correct, click the [Back] button, select the appropriate category and reset the information to the correct settings. If everything is correct, click the [Exit] button.

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KOMTRAX Plus COMPONENTS

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KOMTRAX Plus CONTROLLER CHECKOUT KOMTRAX Plus Controller The KOMTRAX Plus controller (1, Figure 11-7) collects and stores signals from sensors and data from other controllers. It also gives commands for transmitting the accumulated data through the communications system. The controller operates on 20VDC 30VDC.

Necessary Equipment: • Checkout procedure • System schematic • Laptop personal computer (PC) • VHMS Technical Analysis Toolbox software • VHMS Setting Tool software • Tera Term Pro software • Serial cable (RS232) (male DB9 connector on one end, female connector on the other end)

FIGURE 11-7. KOMTRAX Plus CONTROLLER 1. KOMTRAX Plus Controller 2. LED Display 3. Connector CN3B 4. Connector CN3A 5. Connector CN4B 6. Connector CN4A

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KOMTRAX Plus COMPONENTS

7. Connector CN1 8. Connector CN2A 9. Connector CN2B 10. PLM III Light 11. OrbComm Light

D11-31

The interface module must be fully functional before performing the this checkout procedure. The KOMTRAX Plus controller must be initialized and fully functional before performing this checkout procedure.

9. Select the [Review setting information] function and then click the [Next] button.

Preliminary 1. Turn the key switch to the OFF position to stop the engine. With the key switch OFF, verify the seven segment LED display on the KOMTRAX Plus controller is off. 2. Turn the key switch to the ON position, but DO NOT start the engine. 3. Allow the KOMTRAX Plus controller to boot up. Watch the red, two digit LED display on the KOMTRAX Plus controller to show a circular sequence of seven flashing segments on each digit. After a short time the two digit display will start counting up from 00 - 99 at a rate of ten numbers per second. 4. Attach the KOMTRAX Plus serial cable to the machine's KOMTRAX Plus diagnostic port (2, Figure 11-4), and the other end to the laptop PC’s serial port. 5. Double-click on the VHMS Technical Analysis Tool Box icon on the computer's desktop. 6. Enter the appropriate User Name and Password and click the [OK] button.

10. Review the settings for accuracy. •If everything is correct, click the [Exit] button. The checkout procedure is complete. •If a setting is not correct, click the [Back] button, select the appropriate category and reset the information to the correct settings. Then proceed to the next step.

7. Check for any active fault codes. If any are found, these circuits must be analyzed to determine the cause of the fault and they must be repaired before continuing. 8. Start the VHMS Setting Tool program by clicking on the icon on the laptop PC screen.

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KOMTRAX Plus COMPONENTS

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KOMTRAX Plus Controller Checkout Procedure 1. Connect the serial cable from the PC to the serial port of the VHMS controller. 2. Start the serial communications software (Tera Term). 3. Setup the serial communications software by selecting the appropriate serial COM port, and baud rate equal to 19200. 4. After completing the setup, wait for five seconds then while holding the CTRL key, type VHMS (Notice that nothing will display on the screen while typing). 5. After VHMS has been typed, some text followed by a prompt, >, will be displayed. This confirms that proper communication between the pc and controller has been established. 11. If any one of the following settings were changed, a new KOMTRAX Plus Initialization Form must be filled out and submitted to Komatsu America Service Systems Support Team. •KOMTRAX Plus controller replaced

6. At the prompt, >, type "ver". Something similar to the following will be displayed: >ver VHMS OS Ver 1.6.5.1 Mar 01 2004 16:37:25

•Engine or alternator replaced

>

•Adjusted time or time zone

NOTE: Newer versions may be available than what is shown above.

12. Select [Apply] and exit the VHMS Setting Tool program. Click [YES] when prompted to reset the controller. 13. E-mail or fax the completed KOMTRAX Plus Initialization form to Komatsu America Service Systems Support Team.

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KOMTRAX Plus COMPONENTS

D11-33

7. At the prompt type "dispvhmsinf". Information similar to the following will be displayed:

8. The KOMTRAX Plus controller also has two red LED lights (10 and 11, Figure 11-7). Verify the connection status and repair any problems. Light (10) PLM III communication

>dispvhmsinf

• OFF - no communication with the PLM III controller. Troubleshoot and repair the connection.

---- MACHINE INFORMATION --------

• ON - communication with the PLM III controller is good.

PRODUCT GROUP: Dumptruck MACHINE_MODEL: 830AC-

Light (11) ORBCOMM

MACHINE_SERIAL:

• OFF - no communication with ORBCOMM controller. Troubleshoot and repair the connection.

ENG_MODEL: QSK60 ENG_SERIAL_NO1:

• ON - communication with ORBCOMM controller is good.

ENG_SERIAL_NO2: PRG_NO1: 12000100100

• FLASHING - satellite in established, which is good.

PRG_NO2: 782613R290

view

and

signal

---- DEVICES -----------------------PLC NO CONNECTION PLM23 Disabled PLM3 CONNECTED ---- Condition -------------------SMR: 90.0 H DATE 04-10-25 TIME14:44:24 TIMEZONE: 0.0 H SUMMERTIME 0 ----Controller Info ------------------PartNumber: 0000000000 Serial No.: 000000 Compo Name: KDE1010 SilkyID: VA011740744 >

NOTE: Use the results of step 6 and 7 to confirm that the correct software is installed in the KOMTRAX Plus controller.

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KOMTRAX Plus COMPONENTS

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ORBCOMM CONTROLLER

Installation

The ORBCOMM controller (1, Figure 11-8) receives data from the KOMTRAX Plus controller and sends this data through the antenna to the Komatsu computer center.

NOTE: The ORBCOMM controller may not be approved for use in certain countries of the world. Local regulation may prohibit the use of the ORBCOMM controller/satellite communicator. If equipped, the controller and antenna may be disconnected and/or removed from the truck.. Removal 1. Turn the key switch OFF. Disconnect battery power by using the battery disconnect switches. 2. Disconnect the wire harnesses from the ORBCOMM controller. 3. Remove the ORBCOMM controller.

1. Install the ORBCOMM controller. Connect the wire harnesses to the controller. 2. Turn the key switch ON, but do not start engine. Wait three minutes and watch for any error messages on the KOMTRAX Plus controller LED lights that might indicate a problem with the ORBCOMM controller or communications to the controller. 3. If there are no error messages, turn the key switch OFF. If there are error messages, refer to the KOMTRAX Plus Troubleshooting and Checkout Procedures elsewhere in this section. 4. Fill out the “KOMTRAX Plus Initialization” form and send it to Komatsu as instructed on the form. Failure to submit the form to Komatsu will prevent machine data from being sent to the Komatsu computer center. NOTE: The new controller comes with a special ORBCOMM Terminal Activation form that includes space to list the failed controller serial number and new controller serial number. Komatsu must have this information to maintain accurate data. 5. It may take up to two weeks for Komatsu to activate the new ORBCOMM controller. During this time, a manual download of data must be taken one time each week using a laptop PC. This data must then be sent to WebCARE using the FTP feature in VHMS Technical Analysis Tool Box program. Keep downloading data and sending it to WebCARE one time each week until the new ORBCOMM controller has been activated. Komatsu will notify the person who performed the controller replacement by e-mail when the new controller has been activated and no more manual downloads will have to be performed.

FIGURE 11-8. ORBCOMM CONTROLLER 1. ORBCOMM Controller 2. Connector CN1A

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3. Connector CN1B 4. Antenna Connector

KOMTRAX Plus COMPONENTS

D11-35

NOTES:

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KOMTRAX Plus COMPONENTS

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SECTION D12 INTERFACE MODULE INDEX

INTERFACE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-3 SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-4 Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-4 Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-4 INTERFACE MODULE SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-5 NECESSARY SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-5 NECESSARY TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-5 FLASHBURN PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-6 INTERFACE MODULE APPLICATION CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-6 INTERFACE MODULE REALTIME DATA MONITOR SOFTWARE PROGRAM . . . . . . . . . . . D12-6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-6 Using The Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-6 INTERFACE MODULE CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-7 Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-7 Necessary Equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-7 Preliminary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-8 Checking Inputs And Outputs From The Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . D12-8 Check Analog Inputs To The Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-12 Check CAN RPC & J1939 Interfaces To The IM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-12 Check Outputs From The Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12-12

D12006 12/12

INTERFACE MODULE

D12-1

NOTES:

D12-2

INTERFACE MODULE

12/12 D12006

INTERFACE MODULE The interface module (IM) (1, Figure 12-1) collects data from various sensors and sends this information to the KOMTRAX Plus controller through the main wiring harness. If a new interface module is purchased, the operating system (software) has to be installed into the new interface module. To install the operating system, a laptop PC must be connected to the IM diagnostic port (1, Figure 12-5). Two software programs are required to install the software: the operating system and the program to perform the installation of the software (flashburn).

6. Turn the key switch OFF and wait one minute. 7. Turn the key switch ON, but do not start the engine. Wait three minutes and watch for any error messages on the KOMTRAX Plus controller LED lights that might indicate a problem in the system. 8. If there are no error messages, turn the key switch OFF. If there are error messages, refer to the KOMTRAX Plus & Interface Module Troubleshooting and Error Codes elsewhere in this section.

Removal 1. Turn the key switch OFF. Wait three minutes to allow the KOMTRAX Plus controller to process and store data. 2. Disconnect the battery using the battery disconnect switch. 3. Disconnect the wiring harnesses from the interface module. 4. Remove the mounting hardware and remove the interface module.

Installation 1. Install the interface module. Attach all wire harnesses to the interface module. 2. Refer to the KOMTRAX Plus Software instructions to install the flashburn program on a laptop PC. 3. Connect the laptop PC to IM diagnostic port (1, Figure 12-5). 4. Turn the key switch ON, but do not start the engine. 5. Run the flashburn program to install the application code into the interface module. Make sure the correct application code is installed for the model and serial number range (if any) of truck that is being serviced. After the application code has been installed, proceed with to Step 6.

D12006 12/12

FIGURE 12-1. INTERFACE MODULE 1. Interface Module 2. Connector IM1

INTERFACE MODULE

3. Connector IM2 4. Connector IM3

D12-3

SENSORS

Pressure Sensors

Temperature Sensors

Four pressure sensors (Figure 12-3) have been added to the truck to monitor various hydraulic circuits. The four circuits are:

Temperature sensors (Figure 12-2) monitor the ambient air temperature and the hydraulic oil temperature. An ambient air temperature sensor is located on the left side of the air blower inlet duct for the traction alternator. The hydraulic oil temperature sensors are located at each wheel to measure the oil temperature as it leaves each brake assembly.

• both inlets to the hoist valve • steering supply circuit • front brake apply circuit

The hoist pressure sensors are both located right at the inlet of the hoist valve. The front brake apply pressure sensor is located in the brake circuit junction block in the hydraulic cabinet behind the cab. The steering pressure sensor is located on the bleeddown manifold in the port labeled “TP2”.

FIGURE 12-2. TEMPERATURE SENSOR

FIGURE 12-3. PRESSURE SENSOR 1. Pin 1, Input (Brown) 2. Pin 2, Signal (Red)

D12-4

INTERFACE MODULE

3. Sensor

12/12 D12006

INTERFACE MODULE SOFTWARE To work with the interface module system, several special tools and software programs are required. Refer to Tables 1 and 2 for detailed information on software and tools. Refer to the following pages for detailed information on how to perform certain procedures using specific software.

The data files, application code and flashburn software are only required if the interface module is being replaced. Replacement interface modules from Komatsu do not have any software installed in them. NOTE: Be aware that the software and data files are updated periodically. Check with the local Komatsu distributor for the latest software versions.

NECESSARY SOFTWARE

Table 1: Interface Module Software Part Number

Name

Description

Source

1.1.0.0 Install.exe (or higher)

Use to watch inputs and outputs in the interInterface Module Realtime Data Moni- face module tor Software Version 1.1.0.0 Install.exe

Komatsu Distributor

EJ3055-2.exe

Flashburn Software

To install application code in interface module

Komatsu Distributor

A30001 - A30108 A30109 - A30209

830E-AC Application Code

Application code for interface module

Komatsu Distributor

A30210 - A30850

XB0253-0

Komatsu Distributor

IM830_T1_EDP_11 _21_12

A40851 & Up

Trucks with Tier 1 engines

Komatsu Distributor

IM830_T2_EDP_10 Trucks with Tier 2 engines _26_12

Komatsu Distributor

NOTE: There are four different versions of interface module software for the 830E-AC trucks. This software is specific for each serial number range of trucks, and they are not interchangeable. Ensure the correct interface module software is installed on each truck. NECESSARY TOOLS

Table 2: Interface Module Tools Part Number

D12006 12/12

Name

Description

Source

Laptop PC

200 MHz or higher 64 MB RAM or more Serial or USB Port CD/DVD -Rom drive Floppy Drive Windows 95/98/2000/ME/XP

Purchased Locally

Serial cable

(RS232) Purchase locally Male DB9 connector at one end Female DB9 connector at other end

Purchased Locally

Adaptor

USB port to RS232 (serial) port adapter (If laptop PC does not have an RS232 port, this adaptor is required)

Purchased Locally

INTERFACE MODULE

D12-5

FLASHBURN PROGRAM Installation The Flashburn program is used to install the application code into the interface module controller. 1. Save the file EJ3055-2.exe to local drive on a laptop PC. 2. Double click on the “EJ3055-2.exe” file to extract the files to a directory (such as C:\temp). 3. Inside that directory, double click on “Setup.exe” to install the Flashburn program. 4. Follow the on screen prompts to install the program.

6. Be sure the power is off to the interface module. Then click [Next]. 7. Select the correct COM port. Then click [Next]. 8. Select the correct “.KMS” file. Then click [Next]. Flashburn will now install the application code into the interface module.

INTERFACE MODULE APPLICATION CODE Installation The application code is truck specific software that is installed into the interface module. Application code is installed using the Flashburn program. 1. Using a laptop PC, save the application code files to a folder on a local hard drive (such as C:\temp). NOTE: There are two different versions of interface module software for the 830E-AC trucks. This software is specific for each serial number range of trucks, and they are not interchangeable. Ensure the correct interface module software is installed on each truck. 2. Double click on the correct application code file so it will extract the file. Chose a folder on a local hard drive to save the file into (such as C:\temp). 3. Using a serial cable, connect the laptop PC to the IM-Diag connector located near the interface module. 4. Start the Flashburn program. 5. Select [Download Application to Product].

INTERFACE MODULE REALTIME DATA MONITOR SOFTWARE PROGRAM The Interface Module Realtime Data Monitor Software is used to display the data going into and out of the interface module. The program is installed onto a laptop PC. Installation 1. Copy the file onto the laptop PC hard drive. 2. Double click on the file and follow the screen prompts to install the software.

Using The Program 1. Start the Interface Module Realtime Monitor program. 2. Click on the [Select Serial Port] menu item. Select the correct communication port. It will usually be Com1. 3. Click on the [Start/Stop] menu item and choose [Start]. 4. Click on the [Units] menu to select the desired units to display the information.

D12-6

INTERFACE MODULE

12/12 D12006

INTERFACE MODULE CHECKOUT Interface Module The interface module (1, Figure 12-4) collects data from various sensors and sends this information to the KOMTRAX Plus controller through the main wiring harness. It also controls some truck functions.

If a new truck with KOMTRAX Plus is being assembled, or a new KOMTRAX Plus system has just been installed, refer to the KOMTRAX Plus System for instructions regarding the KOMTRAX Plus Initialization Procedure. The initialization procedure and form must be completed before the truck can be put into service.

Necessary Equipment: • System schematic • Laptop personal computer (PC) • Interface Module Real Time Data Monitor software • Serial cable (RS232) (male DB9 connector on one end, female connector on the other end)

FIGURE 12-4. INTERFACE MODULE 1. Interface Module 2. Connector IM1

3. Connector IM2 4. Connector IM3

• Jumper wire 77 mm (3 in.) or longer • Volt Meter • 300 to 332 ohm resistor • 3/8 in. nut driver

The interface module should already have the application code installed. If not, refer to the Interface Module Application Code for installation instructions.

D12006 12/12

INTERFACE MODULE

D12-7

Preliminary 1. Turn the key switch to the OFF position to stop the engine. 2. Turn the key switch to the ON position, but DO NOT start the engine. 3. Allow the KOMTRAX Plus controller to start up. This should take about one minute. Verify the red LED display starts counting up. 4. Attach the KOMTRAX Plus serial cable to the machine's KOMTRAX Plus diagnostic port (2, Figure 12-5), and the other end to the laptop PC’s serial port.

7. Check for fault codes associated with the interface module. a. Perform a KOMTRAX Plus download with the VHMS Technical Analysis Toolbox program. Refer to KOMTRAX Plus Download for detailed instructions on performing a download. b. In the download data, view the fault history and confirm that there are no fault codes associated with the interface module. If any are found, these circuits should be analyzed to determine the cause of the fault and repaired. c. Confirm that there are no fault codes associated with the communications between PLM III, engine controller, interface module, drive system controller or the Orbcomm controller. If any are found, these circuits should be analyzed to determine the cause of the fault and repaired.

Checking Inputs And Outputs From The Interface Module 1. Attach the KOMTRAX Plus serial cable to the machine's IM diagnostic port (1, Figure 12-5), and the other end to the laptop PC’s serial port. FIGURE 12-5. DIAGNOSTIC PORTS 1. IM Diagnostic Port

2. KOMTRAX Plus Diagnostic Port

2. Start the Interface Module Real Time Data Monitor program by double-clicking on the shortcut. The program begins with a blank window. On the menu bar, there are five items: Select Serial Port, Start/Stop, Logging, Screenshot, and Units.

5. Double-click on the VHMS Technical Analysis Tool Box icon on the computer's desktop.

3. Click on [Select Serial Port] in the menu bar. Select the correct communication port. It will usually be Com1.

6. Enter the appropriate User Name and Password and click the [OK] button.

4. Click on [Start/Stop] in the menu bar and select Start. 5. The program should display data as shown in Figures 12-6 and 12-7. NOTE: If any fault codes associated with the interface module are found, these circuits should be analyzed to determine the cause of the fault, and they should be repaired.

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INTERFACE MODULE

12/12 D12006

Check Digital Inputs To The Interface Module 1. Hydraulic Tank Level (IM2-K) - short wire 34LL to ground at TB35-N momentarily and confirm state change (one to zero). 2. No Propel / Retard - (IM2-N) short wire 75-6P to ground at TB26-C momentarily and confirm state change (one to zero). 3. Reduced Retard - (IM2-R) short wire 76LR to ground at TB28-D momentarily and confirm state change (one to zero).

4. Propel System Temp Caution - (IM3-A) short wire 34TW to ground at TB26-B momentarily and confirm state change (one to zero). 5. Lamp Test (IM2-R) - actuate lamp test switch and confirm state change (zero to one). 6. Low Steering Precharge (IM2-W) - short wire 33KL to ground at TB44-P momentarily and confirm state change (one to zero).

FIGURE 12-6. INTERFACE MODULE REAL TIME DATA MONITOR

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INTERFACE MODULE

D12-9

7. Pump Filter Switches (IM2-Y) - short wire 39L to ground at TB44-N momentarily and confirm state change (one to zero).

10. Reduced Propel System (IM3-B) - short wire 72LP to ground at TB25-W momentarily and confirm state change (one to zero).

8. No Propel (IM2-p) - short wire 75NP to ground at TB25-P momentarily and confirm state change (one to zero).

11. Park Brake Set (IM2-M) - disconnect park brake pressure switch in brake cabinet at CN240 momentarily and confirm state change toggles continually (zero to one).

9. Propel System Caution (IM2-t) - short wire 79W to ground at TB26-D momentarily and confirm state change (one to zero).

FIGURE 12-7. INTERFACE MODULE REAL TIME DATA MONITOR

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INTERFACE MODULE

12/12 D12006

12. Park Brake Request (IM3-V) - Short the engine oil pressure switch wire circuit 36 on TB26-L to ground. Move shift lever from neutral to park position and confirm state change (one to zero). Remove the ground from TB26-L.

20. Steering Bleed Pressure Sw (IM2-Z) - Disconnect the steering bleed down pressure switch and confirm state change (zero to one). Reconnect the switch.

13. Auto Lube Switch (IM3-Y) - short wire 68LLP1 to ground at TB24-T momentarily and confirm state change (one to zero).

21. Brake Lock Switch Power Supply (IM3-L) - Use GE DID to simulate a vehicle speed of 2 kph. Confirm state change (zero to one). Leave vehicle speed at 2 kph until completion of step 24.

14. GE Batt + (IM3-M) -- confirm this is a one. 15. Starter Motor 1 Energized (IM3-R) - Disconnect wire 11SM1 from cranking motor to TB29-K at TB29-K. Momentarily short TB29-K to 24V and confirm state change (zero to one). Reconnect disconnected wire. 16. Starter Motor 2 Energized (IM3-S) - Disconnect wire 11SM2 from cranking motor to TB29-G at TB29-G. Momentarily short TB29-G to 24V and confirm state change (zero to one). Reconnect disconnected wire. 17. Crank Sense (IM3-U) -Open the start battery disconnect switch so that there is no battery voltage to the starters. Momentarily short TB32M to 24V and confirm state change (zero to one). After removing 24V short from TB32-M, close the start battery disconnect switch. 18. Selector Switch (Park) (IM3-T) - Place shifter into park position and confirm 1 state then shift into neutral and confirm 0 state. Return shifter to park position.

22. Brake Lock (IM2-i) -Actuate brake lock switch and confirm state change (zero to one). Turn off brake lock switch. (The Brake Lock Switch Power Supply test, item 23, must be completed before this test can be successfully completed.) Reset vehicle speed to zero. 23. Service Brake Set sw (IM3-C) - Short wire 44R at TB26-X to 24 volts momentarily and confirm state change (zero to one). 24. Engine Shutdown (IM3-F) - Disconnect wire 21ISL from the Cummins ECM at TB36-W leaving wire 21ISL to IM connected at TB36-W. Momentarily short TB36-W to 24V and confirm state change (zero to one). Reconnect disconnected wire. 25. Secondary Engine Shutdown Switch (IM3-E) Actuate the Secondary Engine Shutdown switch and confirm state change (zero to one).

19. Selector Switch (FNR) (IM2-N) - Place shifter into park position and confirm 0 state then shift into neutral and confirm 1 state. Return shifter to park position.

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INTERFACE MODULE

D12-11

Check Analog Inputs To The Interface Module NOTE: Instead of using a resister in place of a sensor for verifying pressure readings, a calibrated pressure gauge can be installed in the hydraulic circuit to compare system pressures with the pressures displayed in the Interface Module Real Time Data Monitor program.

Check CAN RPC & J1939 Interfaces To The IM

1. CAN/J1939 - (IM1-q,r,s): confirm fault A184, J1939 Not Connected, is not active. 2. CAN/RPC (IM1-I,j,k) - confirm fault A257, Payload CAN/RPC Not Connected, is not active.

Verify that the used analog inputs are in the range of the values listed below. 1. Truck Speed [kph] (IM1-gh): Use GE DID to simulate vehicle speed and confirm reported speed matches vehicle speed set using GE DID +/- 2 kph. 2. Steering Pressure [kPa] (IM3-d): Disconnect steering pressure sensor and confirm fault A204, Steering Pressure Sensor Low, is active. Reconnect sensor. 3. Ambient Air Temp [C] (IM3-e): confirm reported temperature matches ambient temperature within 3 C. 4. Fuel Level [%] (IM3-g): confirm reported % level matches actual fuel level in tank +/- 5%. 5. Battery Voltage A [V] (IM3-h): confirm reported voltage is +/- 1 volt of actual measured 12 volt battery voltage. 6. Brake Pressure [kPa] (IM3-p): Disconnect service brake pressure sensor located in brake cabinet (reference circuit 33SP) and confirm fault A205, Brake Pressure Sensor Low, is active. Reconnect sensor. 7. Hydraulic Tank Temp [C] (IM3-m): Disconnect tank temp sensor and confirm fault A103, Hydraulic Oil Temp - Tank Sensor Low, is active. Reconnect sensor. 8. Hoist Pressure 2 [kPa] (IM3-q): Short wire 33HP2 to ground at TB41-J momentarily and confirm fault A203, Hoist Pressure 2 Sensor Low, is active. 9. Hoist Pressure 1 [kPa] (IM3-s): Short wire 33HP1 to ground at TB41-A momentarily and confirm fault A202, Hoist Pressure 1 Sensor Low, is active.

Check Outputs From The Interface Module Note: Before performing these next steps, the key switch must be turned off for at least 7 minutes to allow the IM to completely shutdown. Confirm that the IM has shutdown by verifying that the green LED on the IM controller has stopped flashing. While performing the following IM output checks, ensure that no output short circuit fault codes are reported by the IM Realtime Data Monitor software. 1. Short the engine oil pressure switch wire circuit 36 to ground on TB26-L. Key on and shift into neutral. Confirm that park brake solenoid is energized by verifying that coil is magnetized. Use the GE DID panel to set the truck speed to a speed above 1 kph. Shift into park. Confirm that the park brake solenoid remains energized. Reduce the truck speed to 0 kph. Confirm that the park brake solenoid de-energizes. Remove the ground from TB26-L. 2. Connect circuit 528 at TB35-L to 24 volts and confirm that the Battery Charger Failure lamp energizes. 3. With circuit 528 at TB35-L still shorted to 24 volts, confirm that the IM Warning lamp energizes. 4. With circuit 528 at TB35-L still shorted to 24 volts, confirm that the Engine Start Fail lamp energizes. 5. With circuit 528 at TB35-L still shorted to 24 volts, confirm that the Low Fuel lamp energizes.

10. Battery Voltage 24V [V] (IMint): confirm reported voltage is +/- 1 volt of actual measured battery voltage.

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INTERFACE MODULE

12/12 D12006

6. Disconnect park brake pressure switch. With circuit 528 at TB35-L still shorted to 24 volts, confirm that the Park Brake lamp energizes. Reconnect pressure switch. 7. With circuit 52B at TB35-L still shorted to 24 volts, confirm that the Hydraulic Filter lamp energizes. 8. With circuit 528 at TB35-L still shorted to 24 volts, confirm that the Brake Oil Temp lamp energizes. Remove 24 volts from TB35-L. 9. Check the Brake Oil Temperature gauge by placing a 316 ohm resistor (a range of 300 to 332 ohms should work) between circuit 5VIM on TB42-L and 34BT3 on TB24-G. Verify that the gauge needle pointer moves clockwise. Remove the resistor between circuits 5VIM and 34BT3.

11. Crank Enable Output. Disconnect circuit 21A from pre-lube timer prior to performing this step. Place shifter in park and confirm that circuit 21A on TB25-D is 24 volts while cranking. Place shifter in neutral and confirm that circuit 21A on TB25-D is 0 volts while cranking. Reconnect circuit 21A to pre-lube timer. 12. Steering Bleeddown Solenoid. Confirm steering bleeddown solenoid is de-energized. Turn key switch off and confirm that steering bleeddown solenoid is energized by verifying that coil is magnetized.

10. Smart Timer Latch (IM1-H). Ensure that the park brake is applied. Disconnect wire 21ISL from the Cummins ECM at TB36-W leaving wire 21ISL at TB36-W connected to the IM. Momentarily short TB36-W to 24V. Momentarily short the engine oil pressure switch wire circuit 36 to ground on TB26-L. Turn the key switch OFF. Verify that the Engine Shutdown indicator illuminates. Remove 24V short and reconnect disconnected wire 21ISL to TB36-W. Remove short to ground from engine oil pressure switch circuit 36 at TB26-L. Turn the key switch ON.

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INTERFACE MODULE

D12-13

NOTES:

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INTERFACE MODULE

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SECTION D13 KOMTRAX Plus & INTERFACE MODULE TROUBLESHOOTING AND ERROR CODES INDEX

KOMTRAX Plus AND INTERFACE MODULE ERROR CODES AND TROUBLESHOOTING . . . . . D13-3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-3 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-3 Structure and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-4 Communications Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-4 Coaxial Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-4 FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-5 Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-5 KOMTRAX Plus LED Display Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-6 Chassis Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-7 Engine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-11 FAULT TREE ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13-17 Unable to connect to KOMTRAX Plus from laptop PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flashing Error Code N4-23 (PLM III Communications Fault) . . . . . . . . . . . . . . . . . . . . . . . Flashing Error Code N4-22 (Engine Communications Fault) . . . . . . . . . . . . . . . . . . . . . . . No Data Received By WebCARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coaxial Cable Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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KOMTRAX Plus CHECK-OUT & TROUBLESHOOTING

D13-17 D13-18 D13-19 D13-20 D13-21

D13-1

NOTES

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KOMTRAX Plus CHECK-OUT & TROUBLESHOOTING

9/10 D13007

KOMTRAX Plus AND INTERFACE MODULE ERROR CODES AND TROUBLESHOOTING TROUBLESHOOTING

Structure and Purpose

GENERAL The center of the KOMTRAX Plus system is the controller which gathers data about the operation of the truck from sensors and other controllers installed on the truck. Refer to Figure 13-1 for an overview of the KOMTRAX Plus system components. For instructions on how to use KOMTRAX Plus software programs, refer to KOMTRAX PLUS System elsewhere in this section.

The checkout procedure is in two parts. The first part verifies that the interface module is in good working condition. Refer to the Interface Module Section for specific checkout instructions. The second part verifies the KOMTRAX Plus controller operation and also reviews the settings for accuracy. Refer to the KOMTRAX Plus System Section for specific check out instructions.

The following areas are covered in this section. • Troubleshooting • Fault Code Tables • Fault Tree Analysis

FIGURE 13-1. KOMTRAX Plus SYSTEM

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KOMTRAX Plus CHECK-OUT & TROUBLESHOOTING

D13-3

TROUBLESHOOTING The KOMTRAX Plus system basically consists of five communications networks connected to the KOMTRAX Plus and ORBCOMM modem controllers. Figure 13-1 shows the KOMTRAX Plus system block diagram.

Communications Networks Each RS232 network uses three wires: transmit, receive, and ground. Both transmit and receive are voltage signals, referenced individually to the ground wire. The shield for the cable is grounded at one end only. Each CAN network uses two wires: CAN_High & CAN_Low. The communications signal is a voltage differential measured between CAN_High and CAN_Low. The cable shields are connected at each module through a high pass filter and grounded at one point only on the truck. Both ends of each network have termination resistors.

Effective troubleshooting of RF communications systems can be complex and cannot always be reduced to a simple check of electrical resistance. However, a few basic troubleshooting procedures may be helpful in identifying common problems. The following steps can help identify a failed coaxial cable. Repair or replace the cable if any of the following is true: 1. The center conductor is broken. There are more than two ohms of resistance when measuring from one end of the coaxial cable to the other. 2. The outer shield is broken. 3. There is an electrical connection between the center conductor and the outer shield. There are less than two megohms of resistance when measuring from the center conductor to the outer shield.

Coaxial Cable The coaxial cable carries the Radio Frequency (RF) communications signal between the ORBCOMM modem and the antenna. The coaxial cable consists of an inner conductor and an outer shield (connected to the connector shell) that are separated by a nonconductive dielectric material. In an RF application such as KOMTRAX Plus, the communications signal sent over coaxial cable is very susceptible to changes in the cable. Physical damage, as well as contaminants such as water, may affect the ability of the cable to properly transmit the RF signal. Bending the coaxial cable into a small loop may also damage the inner conductor.

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KOMTRAX Plus CHECK-OUT & TROUBLESHOOTING

9/10 D13007

FAULT CODES Fault History The fault history recorded in the KOMTRAX Plus controller can help identify a failure within KOMTRAX and in the communications network to the engine, interface module and PLMIII. The KOMTRAX Plus system provides the following fault codes.

Table 1: Fault History Fault Code

D13007 9/10

Description

DBB0KK

Source Voltage Error

DBB3KK

Abnormality in VBAT Voltage (VHMS VBAT 22 ma

4

Right front pressure low

Input current < 2 ma

5

Left rear pressure high

Input current > 22 ma

6

Left rear pressure low

Input current < 2 ma

7

Right rear pressure high

Input current > 22 ma

8

Right rear pressure low

Input current < 2 ma

9

Inclinometer high

Input voltage < 0.565 VDC

10

Inclinometer low

Input voltage > 5.08 VDC

11

Speed input failure

Not Used

12

Brake lock input failure

Not Used

13

Body-up input failure

Payload meter detected dumping activity without receiving a body up signal

16

Memory write failure

Indicates possible memory problem at power start up. Cycle power and recheck.

17

Memory read failure

Indicates possible memory problem at power start up. Cycle power and recheck.

18

Rear right suspension flat

Payload meter detected an undercharged suspension condition on the rear right suspension.

19

Rear left suspension flat

Payload meter detected an undercharged suspension condition on the rear left suspension.

20

Time change

Payload meter time was changed by more than 10 minutes. The Alarm Set time indicates original time. The Alarm Clear time indicates the new time.

21

Tare value reset

The user manually forced the payload meter to reset the haul cycle empty (tare) sprung weight. This forced the meter into the tare_zone state and lost all data for the previous haul cycle.

22

Excessive carryback

The payload meter detected an empty carryback load in excess of the user-defined carryback threshold on two consecutive haul cycles.

26

User switch fault - SELECT

Select switch on for more than 2 minutes, may indicate short to ground

27

User switch fault - SET

Set switch on for more than 2 minutes, may indicate short to ground

M20-18

Payload Meter III

12/12 M20008

PC SOFTWARE OVERVIEW

Installing the PLMIII Software

The PC software has several basic functions:

The CD ROM containing the Payload Data Management (PDM) Software will automatically begin installation when it is inserted into the drive on the PC. If this does not happen, the software can be installed by running the Setup.exe program on the CD ROM.

• Configure the PLMIII system on the truck. • Troubleshoot and check the PLMIII system. • Download data from the PLMIII system. • Analyze data from the payload systems.

Configuration, troubleshooting and downloading require a serial connection to the payload meter on the truck. Analysis can be done at any time without a connection to the payload meter. Payload data is downloaded from several trucks into one database on the PC. The database can be queried to look at the entire fleet, one truck or truck model. The data can be graphed, reported, imported or exported. The export feature can take payload data and save it in a format that spreadsheet programs like Excel or word processing programs can easily import.

The minimum PC requirements for running the software is a Pentium 133Mhz with 64 MB of ram and at least 300 MB of free hard drive space available. For improved performance, the recommended PC would be a Celeron, AMD K6-2 or better processor with 128 MB of ram running at 400 Mhz. The PDM Software uses a powerful database to manipulate the large amounts of data gathered from the PLMIII system. Using a more powerful computer and added memory to run the software can result in a significant improvement in performance. The software is written to use a minimum 800 x 600 screen resolution.

System Configuration PLMIII needs to be configured for operation when it is first installed on the truck. This process requires several steps and uses the laptop computer to make the necessary settings. The setup procedure can be broken down into several steps:

• Connecting the laptop to the PLMIII system. • Starting communications • Setting the time & date • Setting the truck type • Setting the truck ID • Setting the speedometer/display gauge units

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Payload Meter III

M20-19

DOWNLOADING DATA PLMIII records many types of data. The PLMIII PC software is designed to download the data from a whole truck fleet. Instead of creating one data file for each truck, the PC software combines all the data from many trucks into one database on the hard drive of the computer. The software then allows users to query the database to create custom reports and graphs. Data for individual trucks or groups of trucks can be easily analyzed. This same data can be exported for use in other software applications like word processors and spreadsheet applications. As the database grows, performance of the PC software for analysis will slow down. It may be helpful to periodically export data. For example, query the database to show the oldest quarter, month, or half year and print out a summary report. Then export the data to a compressed format and save the file in a secure location. Once the data is exported, delete the entire query results from the database. If necessary, the data can easily be imported back into the main database for analysis at a future date. Removing this older data will improve performance.

To download the payload meter: 1. Connect to the payload meter and start the PC software. 2. From the main menu, select "Connect to Payload Meter". The PC will request the latest status information from the payload meter. The number of haul cycles and alarms will be displayed. 3. Select the "Begin Download" button. The PC will request the payload and alarm data from the payload meter and save it into the database. This may take several minutes. A progress bar at the bottom will show the approximate time left.

The PC software downloads the data from the payload meter into a single Paradox database. The data from all the trucks is added to the same database. Downloading the payload meter can take several minutes. The data is added to the database on the laptop used to download. To move the data to another computer, a query must be run to isolate the particular data for export. Do not press the operator switch on the dashboard while downloading

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Payload Meter III

12/12 M20008

PLM III SYSTEM CONFIGURATION

Short Tons: Payload is displayed in short tons, distances and speeds will be displayed in Miles

Starting Communications The PDM software allows users to download and configure the system.

Metric Tons: Payload is displayed in metric tons, distances and speeds are displayed in Kilometers Long Tons: Payload is displayed in long tons, distances and speeds are displayed in Miles Time Units Minutes and Seconds Example: Five minutes and thirty-two seconds = 5:32 Decimal Minutes Example: Five minutes and thirty-two seconds = 5.53 Connection Menu

Before connecting to the payload meter, select "Change Program Options" and confirm that the program has selected the correct laptop serial port. Most laptop computers use Comm 1 for serial communications. The units displayed for reports and graphs by the PC software can be set on this form. Click “Done” to return to the main menu.

The connection screen displays basic system information to the user.

From the main menu, click the "Connect to Payload Meter" button. The PC will try to connect to the payload meter and request basic information from the system. In the event of communications trouble, the PC will try 3 times to connect before "timing-out". This may take several seconds. Displayed Payload Units Three options are available for the display of units in the PC software, reports, and graphs:

• Frame S/N should agree with the truck serial number from the serial plate located on the truck frame. • Truck Number is an ID number assigned to the truck by the mine. • The Payload Meter Date / Time values come from the payload meter at the moment of connection. • Number of Haul Cycle Records is the number of haul cycles records stored in memory and available for download. • Number of Active Alarms shows how many alarms are currently active in the system at the time of connection. If there are active alarms, the "Display Active Alarms" button is available. • Number of Inactive Alarms shows how many alarms have been recorded in memory and are available for download. • PLM Software Version displays the current version of software in the payload meter. The information on the connection menu comes from the configuration of the payload system on the truck.

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Payload Meter III

M20-21

There are also many configuration and download options available from this screen. The Connection Menu is updated only when the connection is first made. It does not update automatically. To view changes made while connected, the user must close the window and reconnect to the payload meter. The connection menu is displayed after a serial connection has been established and the PC software has connected to the payload meter.

Setting the Date and Time

The time shown on the form is the time transmitted from the payload when the connection was first established.

Connecting to the Payload Meter Communications to the PLMIII requires a laptop computer running the PDM software. The software connects to the payload meter through the meter's serial port #1. This is the same port used by the speedometer/display gauge. When the laptop is using the serial port, the lower display on the operator gauge on the dashboard will be blank. This does not affect the operation of the speedometer. • Connect the laptop to the system using the EF9160 or PC2525 communications harness. The download connector is typically located on the housing mounted in the cab to the back wall. The PLMIII system uses the same connection as the Payload Meter II system. Configure the Payload Meter Configuration of the payload meter requires a serial connection to the PLMIII system. Clicking the "Configure Payload Meter" button will bring up the Truck Configuration screen and menu. This screen displays the latest configuration information stored on the payload meter. When changes are made to the configuration, the "Save Changes" button must be pressed to save the changes into the payload meter. To confirm the changes, exit to the main menu and re-connect to the payload meter.

The date and time are maintained by a special chip on the PLMIII circuit board. The memory for this chip is maintained by a large capacitor when the power is removed from the payload meter. This will maintain the date and time settings for approximately 30 days. After this time, it is possible for the payload meter to lose the date and time setting. It is recommended that the system be powered every 20 days to maintain the date and time. If the date and time is lost, reset the information using this procedure. It takes approximately 90 minutes to recharge the capacitor. Changing the date and time will affect the haul cycle in progress and may produce unexpected results in the statistical information for that one haul cycle. NOTE: If the truck is equipped with KOMTRAX Plus, do not set the time or date in the PLM III controller. The PLM III clock is synchronized by the KOMTRAX Plus clock. To change the time: 1. Click on the digit that needs to be changed. 2. Use the up/down arrows to change or type in the correct value. 3. Press the "Save Changes" button to save the new time in the payload meter. To change the date: 1. Click on the digit that needs to be changed. 2. Type in the correct value or use the pull-down calendar to select a date. 3. Press the "Save Changes" button to save the new time in the payload meter.

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Payload Meter III

12/12 M20008

Setting the Truck Number

Setting the Truck Type

1. From the Truck Configuration screen, use the pull-down menu to select the truck type that the payload meter is installed on. 2. Press the "Save Changes" button to program the change into the meter.

Most mining operations assign a number to each piece of equipment for quick identification. This number or name can be entered in the Truck Number field. It is very important to enter a unique truck number for each truck using the PLMIII system. This number is one of the key fields used within the haul cycle database. The field will hold 20 alpha-numeric characters.

1. On the Truck Configuration screen, enter the truck number in the appropriate field.

Setting the Gauge Display Units The payload meter speedometer / display gauge displays the speed on the upper display. The units for the speed display are selected using a jumper on the rear of the case. The payload units on the lower display can be changed from metric to short tons or long tons using the Truck Configuration screen. This selection also switches between metric (kg/cm2) and psi (lbs/in2) for the live display of pressure on the gauge. 1. From the Truck Configuration screen, select the payload units to be used on the lower display of the speedometer/display gauge. 2. Press the "Save Changes" button to program the change into the payload meter. Setting the Frame Serial Number

2. Press the "Save Changes" button to program the change into the payload meter.

Setting the Komatsu Distributor This field in the haul cycle record can hold the name of the Komatsu distributor that helped install the system. Komatsu also assigns a distributor number to each distributor. This number is used on all warranty claims. This Komatsu distributor number can also be put into this field. The field will hold 20 alpha-numeric characters.

1. On the Truck Configuration screen, enter the distributor name or number in the appropriate field. 2. Press the "Save Changes" button to program the change into the payload meter.

Setting the Komatsu Customer

The frame serial number is located on the plate mounted to the truck frame. The plate is outboard on the lower right rail facing the right front tire. It is very important to enter the correct frame serial number. This number is one of the key fields used within the haul cycle database. The field will hold 20 alphanumeric characters. 1. On the Truck Configuration screen, enter the truck frame serial number in the appropriate field. 2. Press the "Save Changes" button to program the change into the payload meter.

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This field in the haul cycle record can hold the name of the mine or operation where the truck is in service. Komatsu also assigns a customer number to each customer. This number is used on all warranty claims. This Komatsu customer number can also be put into this field. The field will hold 20 alpha-numeric characters.

1. On the Truck Configuration screen, enter the customer name or number in the appropriate field. 2. Press the "Save Changes" button to program the change into the payload meter.

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5. Once the calibration is complete, confirm that the PLM module states “Empty” in the Haul Cycle State parameter. If the calibration is not complete or has failed, the Haul Cycle State parameter will state “Tare Zone”.

Clean Truck Tare Calibration

Inclinometer Calibration

The payload meter uses the clean truck tare value to calculate carry-back load for each haul cycle. The carry-back stored in the haul cycle record is the new empty tare minus the clean truck tare. This procedure should be performed after service to the suspensions or when significant changes are made to the sprung weight of the truck. Before performing this procedure, make sure that the suspensions are properly filled with oil and charged. It is critical to payload measurement that the proper oil height and gas pressure be used. Once the clean tare process is started, the payload meter will begin to calculate the clean empty sprung weight of the truck. This calculation continues while the truck drives to the next loading site. Once the procedure is started, there is no reason to continue to monitor the process with the PC. The truck does not need to be moving to start this procedure. 1. Clean all debris from the truck and dump body. 2. Ensure that there are no faults recorded in the system and all sensors are reading correctly. 3. Use the PDM software to connect to the payload meter. From the Truck Configuration screen, select "Clean Truck Tare". 4. Follow the on-screen instructions. NOTE: The truck must be driven continuously for ten minutes above 5 kph (3 mph). The PLM module does not calibrate while the machine is stopped. NOTE: Drive on actual haul roads and do not use the wheel brake lock during calibration. Otherwise, inaccurate payload readings may result.

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The inclinometer calibration procedure is designed to compensate for variations in the mounting attitude of the inclinometer. The inclinometer input is critical to the payload calculation. This procedure should be performed on relatively flat ground. The maintenance area is often an ideal location for this procedure. 1. Clean all debris from the truck and dump body. 2. Ensure that there are no faults recorded in the system and all sensors are reading correctly. 3. Use the PDM software to connect to the payload meter. From the Truck Configuration screen, select "Inclinometer". 4. With the truck stopped and the brake lock on, click on “Start”. This instructs the payload meter to sample the inclinometer once. 5. Turn the truck around. Drive the truck around and park in the exact same spot as before, facing the other direction. 6. With the truck stopped and the brake lock on, click on “Start”. This instructs the payload meter to sample the inclinometer again. The payload meter will average the two samples to determine the average offset. 7. Follow the on-screen instructions.

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DATA ANALYSIS PAYLOAD SUMMARY FORM

The data analysis tools allow the user to monitor the performance of the payload systems across the fleet. Analysis begins when the "View Payload Data" button is pressed. This starts an "all trucks, all dates, all times" query of the database and displays the results in the Payload Summary Form. The user can change the query by changing the dates, times, or trucks to include in the query for display. Haul cycles in the data grid box at the bottom can be double-clicked to display the detailed results of that haul.

Sorting on Truck Unit Number The truck unit number is the truck unit number entered into the payload meter when it was configured at installation. The query can be set to look for all trucks or one particular truck number. When the program begins, it searches through the database for all the unique truck numbers and creates a list to select from. Choosing one particular truck number will limit the data in the displays, summaries and reports to the one selected truck. To create reports for truck number 374, select 374 from the pull-down menu and hit the "Query Database and Display" button.

Creating a Query The program defaults to show all trucks, all types, all dates and all times for the initial query. The display can be narrowed by selecting which trucks or types to view and for what dates and times. The query items are added in the "AND" condition. If the user selects a truck # and date range, the query will sort the data for that truck number AND the date range.

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Sorting on Truck Type The truck type is the size of the truck from the family of Komatsu trucks. This allows the user to quickly view results from different types of trucks on the property. For example, a separate report can be generated for 830E and 930E trucks.

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Sorting on Date Range The default query starts in 1995 and runs through the current date on the PC. To narrow the range to a specific date, change the “From” and “To” dates. For example, to view the haul cycle reports from truck 374 for the month of July, 2000: 1. Select truck 374 from the Truck Unit pull-down menu. 3. Change the “To” date to January 8, 2000. 4. Change the “From” time to 06:00. 5. Change the “To” time to 18:00.

6. Press the "Query Database and Display" to view the results. 2. Change the “From” date to July 1, 2000. This query will display haul cycles from January 5 to January 8, from 6:00 AM to 6:00 PM. Date Time

Jan 5, 2000

Jan 6, 2000

Jan 7, 2000

Jan 8, 2000

Jan 9, 2000

0:00

6:00

3. Change the “To” date to July 31, 2000. 4. Press the "Query Database and Display" to view the results.

12:00

Sorting on Time Range The time range sorts the times of the day for valid dates. Changing the time range to 6:00AM to 6:00PM will limit the payloads displayed to the loads that occurred between those times for each day of the date range. Times are entered in 24:00 format. To view the haul cycle reports from the first shift for truck 374 from January 5, 2000 to January 8, 2000:

1. Select truck 374 from the Truck Unit pull-down menu.

18:00

24:00 Query : Date: 1/5/00 to 1/8/00 Daily Shift Time: 6:00 to 18:00

Haul Cycles Included in the Query

The shift times selected can extend the query past the original date. If the dates set for the query are January 5 to January 8 and the times were changed to query the 6:00 PM (18:00) to 6:00 AM (06:00) shift, the results would extend into the morning of the 9th. This can been seen in the following example:

2. Change the “From” date to January 5, 2000.

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Creating Reports Date Time

Jan 5, 2000

Jan 6, 2000

Jan 7, 2000

Jan 8, 2000

Jan 9, 2000

0:00

6:00

Reports can be generated and viewed on the screen or printed. These reports are generated from the query displayed on the Payload Summary Screen. From the example in "Sorting on Time Range", the report printed would only contain data from truck 374 during the month of July 2000, from 8:00 AM to 5:00 PM.

12:00

It is important to carefully select the query data and press the "Query Database & Display" button before printing a report. 18:00

24:00 Query : Date: 1/5/00 to 1/8/00 Daily Shift Time: 18:00 to 6:00

Haul Cycles Included in the Query

Payload Detail Screen The Payload Detail screen gives the details for any individual haul cycle. From the “Payload Summary” screen, double-click on any haul cycle to display the detail.

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NOTE: Some haul cycles may contain the Sensor Input warning flag. This indicates that one of the four pressure sensors or inclinometer was not functioning properly during the haul cycle. Haul cycles with this warning are displayed in red on the Payload Summary window and are not included in the summary statistics for reports or display. Summary - one page report A summary of the queried data can be printed onto 1 page. The cycle data is summarized onto one sheet. Displayed is the speeds, cycle times, load statistics, frame and tire data.

Detailed - multi-page report The detail report starts with the summary report and follows with pages of data for each haul cycle. The detailed report prints date, time, payload, cycle times, and cycle distances, speeds and the number of swing loads.

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Exporting Data

Creating Graphs The PLMIII software can generate graphs that quickly summarize payload data. These graphs can be customized for printing. Just like the reports, the graphs are generated from the query displayed on the “Payload Summary” screen. From the "Sorting on Time Range" example, the graph that is printed would only contain data from truck 374 during the month of July 2000, from 8:00 AM to 5:00 PM. It is important to carefully select the query data and press the "Query Database & Display" button before creating a graph. 1. From the Payload Summary Screen select the “Graph” button at the bottom. The Histogram Setup screen will display

The data from the database can be exported for use with other software applications. The data is selected from the currently displayed query. The exported data can be put into a ".cvs" file or a compressed ".zip" file.

• The “.cvs” format allows data to be easily imported into spreadsheet applications and word processing applications. • The “.zip” format allows data to be transferred from one computer to the PDM Software database on another computer. This offers a compact way to transfer data from one computer to another.

CSV Export

2. Enter the "Lowest Value". This will be the lowest payload on the graph. Any payloads less than this value will be summed in the first bar. 3. Enter the "Highest Value". This will be the highest value on the graph. Payloads over this value will be summed in the last bar. 4. Enter the "Incremental Change". This will determine the number of bars and the distance between them. The program limits the number of bars to 20. This allows graphs to fit on the screen and print onto 1 page. 5. Press the “Create Graph” button. The graph will be displayed based on the query settings from the Payload Summary screen. The graph can be customized and printed.

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CSV stands for Comma Separated Value. This is an ASCII text file format that allows spreadsheet applications like Excel and Lotus 123 to import data easily. To export the data into a ".csv" file, press the "Export" button at the bottom of the payload summary screen and select "To CSV". The program will request a filename and location for the file.

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• •

Reserved 1-5, 7-10: These values are internal calculations used in the continued development of PLMIII and should be ignored. Reserved 6: This value is the payload estimate at the shovel just before the truck begins to move.

Two sets of data are exported. At the top of the file will be the haul cycle data. The columns, left to right are: • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Truck number Haul cycle start date Haul cycle start time Payload Swingloads Operator ID Warning Flags Carry Back Total Haul Cycle time Empty Running Time Empty stop time Loading time Loaded running time Loaded stopped time Dumping time Loading start time Dumping start time Loaded haul distance Empty haul distance Loaded maximum speed Time when loaded maximum speed occurred Empty maximum speed Time when loaded maximum speed occurred Maximum + frame torque Time when the maximum + frame torque occurred Maximum - frame torque Time when the maximum - frame torque occurred Maximum sprung weight calculation Time when the maximum sprung weight calculation occurred Left Front Tire-kilometer-hour Right Front Tire-kilometer-hour Average Rear Tire-kilometer-hour Frame serial number

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The second series of data below the haul cycle data is the alarms. The alarm columns, left to right are: • • • • • •

The alarm type The date the alarm was set The time the alarm was set Alarm description The date the alarm was cleared The time the alarm was cleared

Compressed

This export function allows the data from one laptop to be transferred to another computer. This can be useful when a service laptop is used to download multiple machines and transfer the data to a central computer for analysis. This can also be used to copy haul data from a particular truck onto a diskette for analysis. The file format is a compressed binary form of the displayed query. The file can only be imported by another computer running the PDM Software.

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Deleting Haul Cycle Records

To export data in ZIP format: 1. Confirm that the data displayed is the query data that needs to be exported. 2. From the payload summary screen, press the "EXPORT" button and select "To ZIP". 3. The program will ask for a filename and location. Importing Data This import function allows the data from one laptop to be transferred to another computer. This can be useful when a service laptop is used to download multiple machines and transfer the data to a central computer for analysis. This can also be used to copy haul data from a particular truck from a diskette into a database for analysis. To import data, press the "IMPORT" button at the bottom of the “Payload Summary” screen. The program will ask for a ".zip" file to import, locate the file and press "Open". The program will only import ".zip" files created by another computer running the PDM Software.

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To delete haul cycle records from the main database, press the "Delete" button at the bottom of the “Payload Summary” screen. The program will display a summary of the records from the displayed query. To delete a record, select one at a time and press the "Delete" button. It is recommended that records be exported to a .zip file for archival purposes before deletion. Multiple records may be selected by holding down the Shift key. Pressing the "Delete All" button will select all the records from the current query and delete them.

NOTE: There is no recovery for records that have been deleted from the main database. It is highly recommended that all records be exported and archived in a compressed file format for future reference before being deleted.

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Viewing Alarms From the Payload Summary screen, click the “Alarms” button to display the alarm screen. The alarms are sorted by the query settings from the Payload Summary screen. Alarms can be displayed as Active or Inactive.

Deleting Alarm Records To delete alarm records from the main database, press the "Delete" button at the bottom of the “Alarm Display” screen. The program will display a summary of the alarms from the query. To delete an alarm, select one at a time and press the "Delete" button. It is recommended that the query data be exported to a “.zip” file for archival purposes before deletion. Multiple records may be selected by holding down the Shift key. Pressing the "Delete All" button will select all the alarms from the current query and delete them.

NOTE: There is no recovery for alarms that have been deleted from the main database. It is highly recommended that all records be exported and archived in a compressed file format for future reference before being deleted.

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TROUBLESHOOTING SECTION TROUBLESHOOTING

Real-Time Data Display

Troubleshooting the PLMIII system is done through the PC software you can: • • • • •

View active alarms. View the sensor inputs using the Real-Time Data Display. Test the payload lights. Create log files of sensor inputs for further analysis. These activities require a connection to the PLMIII system.

Viewing Active Alarms Active alarms are alarms that have been set, but not yet cleared. Each alarm is set when the conditions for activation are held for 5 seconds. Each alarm is cleared when the condition has been returned to normal range for 5 seconds. For example, 5 seconds after the left-rear pressure sensor is disconnected, the LR-Pressure Lo alarm will be activated. This can be viewed using to the "Connect to Payload Meter" screen. 5 seconds after the pressure sensor is reconnected, the alarm will clear and be recorded in memory. Active alarms are recorded in memory as "cleared" when the key switch is turned off. When power is restored to the payload meter, the alarms will be reactivated if the conditions still exist for 5 seconds. To view active alarms: 1. Connect to the payload meter and start the PC software. 2. From the main menu, select "Connect to Payload Meter". The PC will request the latest status information from the payload meter. 3. If there are active alarms, the "Display Active Alarms" button in the lower left corner will be available. If the button is not available, there are no active alarms at the time of connection. The screen does not automatically refresh. If a condition changes to cause an alarm, the user must exit and re-enter the "Connect to Payload Meter" screen.

The PC software can be used to view the 'live' input readings from the payload meter. The numbers displayed are 1-second averages. 1. Connect to the payload meter and start the PC software. 2. From the main menu, select "Connect to Payload Meter". The PC will request the latest status information from the payload meter. 3. Select the "Real Time Data" button. The data screen will pop up. The PC will request the payload meter to begin transmitting data. 4. To exit, press the “Close” button. The units for each measurement are determined by the setting in the Program Options for the PC software. The four suspension pressures and inclinometer are shown. The status of the Body-Up and BrakeLock inputs is also shown. The haul cycle state and speed is displayed. The current sprung weight is displayed. This differs from pure payload. The sprung weight is a measurement of the weight of the truck above the suspension. It does not include the tires, spindles, wheel motors, drive case, or anything below the suspensions. Testing the Payload Lights The real time data display also allows the user to individually power the payload lights. This can be useful for testing the lights. To turn on a particular color payload light: 1. Click the check box beside the color light to power. 2. Press the "Set Lights" button to turn on the light. 3. Uncheck the box and press "Set Lights" to turn off the light. The lights will return to their normal state when the real time data display is closed.

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Creating Log Files of Inputs

Daily Inspections

The PC software can create a text file of the live data stream from the payload meter. This can be very useful for diagnostic purposes. The data is written into a text data file in comma separated value format. The data is recorded in metric units at 50 samples per second. The data file can grow large very quickly. Each sample writes one line into the ASCII file in comma separated format.

An important part of maintaining the Payload Meter III (PLMIII) system is monitoring the basic inputs to the system. It is recommended that the truck operator walk around the truck and visually inspect the following: • Charging condition of the suspensions - not flat, not overcharged. • Pressures in the suspensions - check suspensions by using the operator gauge and the operator switch.

The order for each line of data in is: • Date • Time • Sprung Weight • LF Pressure • RF Pressure • LR Pressure • RR Pressure • Incline • Speed • Body Up State (1=up) • Brake Lock State (1=on) • Payload State • Status Flags • Spare

Periodic Maintenance It is recommended that the following items be checked every 500 hours: • Confirm the suspension pressures using external gauges. • Confirm proper suspension height. • Confirm suspensions do not collapse and make metal-to-metal contact when the truck is loaded. • Confirm that inclinometer indicates positive (+) values for truck nose up, and negative (-) values for truck nose down.

To create a log file: 1. Connect to the payload meter and start the PC software. 2. From the main menu, select "Connect to Payload Meter". The PC will request the latest status information from the payload meter. 3. Select the "Real Time Data" button. The real time data screen will pop up. The PC will request the payload meter to begin transmitting data.

In addition, it may be useful to confirm proper operation of the suspensions by riding the truck during a complete haul cycle. Record the suspension pressures using the CSV log file tool in the Payload Data Manager software for the PC. The suspension pressures in this log file can be graphed to inspect for flat or overcharged suspensions.

4. Click the "Set File Name” button and enter a name and location for the text file. The default extension is ".txt". This data can be easily imported into spreadsheets as a comma separated value (.csv) format. 5. Once the filename has been entered, the Start Log and Stop Log buttons will be active. 6. Press the “Start Log” button to start taking data and recording into the file. Once a file is started, it cannot be stopped and started again. 7. Press the “Stop Log” button to stop recording data. Attempting to start the log file again will overwrite the previous file and erase the previous data. To gather more data, close the real time data window, start it again and create a new log file.

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Abnormal Displays at Power-Up The payload meter performs several internal memory system checks every time it powers-up. In case of error, the operator gauge may display an error code when power is applied to the PLMIII system. Er:01 - Bad Truck Configuration error indicates that the meter encountered an error while reading the current truck configuration record from memory. Er:02 - Bad Calibration Record error indicates that the meter encountered an error while passing messages between the microprocessors on the circuit board. Er:03 - Interprocessor Communications error indicates that the meter encountered an error while passing messages between the microprocessors on the circuit board. To resolve these errors:

• If these errors persist after reprogramming, the primary and secondary processors then the payload meter must be replaced.

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No Payload Display When Key Switch is Turned ON • Confirm battery voltage in PLMIII junction box between TB45-A (positive) and TB45-X (ground). • Check the 5A circuit breaker (CB A) in PLMIII junction box. • Check all connectors and terminal connectors in the power circuits to the payload meter. • If two digit display on payload meter displays 00 then 88 on power up, continue to “No Display on Operator Display”. This two digit display normally alternates 0 on each display. In the case of active alarms, this display will show the code for each active alarm. The alarm codes are in the operation section.

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No Display on Speedometer No Display on Operator Display

• If the speedometer works but the operator displays remain blank, confirm payload connections at “No Payload Display When Key Switch is Turned ON”.

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No Communications With PC In a case where the laptop PC will not properly connect to the PLMIII system: • Confirm power to the payload meter. • Confirm laptop serial port setting using the PC software. From the mail menu select "Change Program Options". Confirm that the selected serial port is correct and that it is available. • Confirm that a Personal Digital Assistants (PDA) synchronization software is not using the serial port. Often, PDA software like Palm Pilot’s HotSync software will take control of the serial port and not let other applications use the serial connection. Close the synchronization software and retry the Payload Data Manager software. • Confirm Operator Switch use. If this switch works properly, it confirms that the communications wiring between the payload meter and the junction box is functional. • Before the beginning of troubleshooting, turn key switch OFF. Wait 1 minute and turn key switch ON.

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Load Lights Don’t Light During Loading • Confirm that the truck operator uses the brake lock switch (NEUTRAL) during loading. Without this input, the payload meter will not properly recognize swingloads. • Confirm bulbs in payload lights by using lamp check mode. • Confirm 15A breaker CB-B in payload junction box. • To continue troubleshooting, turn on all the payload lights using the lamp check mode of the Payload Data Manager software.

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Load Lights Remain ON Load Lights Remain ON During Dumping Display Doesn't Clear When The Load Is Dumped • Confirm the body up switch signal. When the body up signal is not properly received during dumping, the payload meter may maintain the lights after the body is lowered. • Confirm the payload light wiring using the procedures in "Load Lights Don't Light During Loading".

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Calibration Problems • Confirm that the truck is empty and clean. • Confirm that the payload meter is in the proper haul state. The payload meter must be in the empty, or tare zone states to begin calibration. This can be checked by using the real-time monitor mode of the Payload Data Manager software. • The payload meter can be reset to acknowledge the beginning of a new haul cycle by raising the body when the truck is empty. This may be necessary after servicing the suspensions.

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Alarm 1 - Left Front Pressure High Alarm 2 - Left Front Pressure Low Troubleshoot Wiring to Left Front Suspension These alarms indicate that the current being read by the payload meter is higher than 22ma or lower than 2ma. The pressure sensor is designed to output 4-20ma over a pressure range of 27 579 kPa (4000 psi). • Confirm 18V sensor supply at TB46-L in payload junction box. • Confirm proper connection of signal circuit 39FD from left suspension connection box, TB42-B to payload junction box TB46-F to payload meter connector R264, pin 39.

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Alarm 3 - Right Front Pressure High Alarm 4 - Right Front Pressure Low Troubleshoot Wiring to Right Front Suspension These alarms indicate that the current being read by the payload meter is higher than 22ma or lower than 2ma. The pressure sensor is designed to output 4-20ma over a pressure range of 27 579 kPa (4000 psi). • Confirm 18V sensor supply at TB46-L in payload junction box. • Confirm proper connection of signal circuit 39FC from right suspension connection box, TB41-B to payload junction box TB46-G to payload meter connector R264, pin 20.

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Alarm 5 -Left Rear Pressure High Alarm 6 - Left Rear Pressure Low Troubleshoot Wiring to Left Rear Suspension These alarms indicate that the current being read by the payload meter is higher than 22ma or lower than 2ma. The pressure sensor is designed to output 4-20ma over a pressure range of 27 579 kPa (4000 psi). • Confirm 18V sensor supply at TB46-L in payload junction box. • Confirm proper connection of signal circuit 39FC from right suspension connection box, TB41-B to payload junction box TB46-G to payload meter connector R264, pin 20.

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Alarm 7 - Right Rear Pressure High Alarm 8 - Right Rear Pressure Low Troubleshoot Wiring to Right Rear Suspension These alarms indicate that the current being read by the payload meter is higher than 22ma or lower than 2ma. The pressure sensor is designed to output 4-20ma over a pressure range of 27 579 kPa (4000 psi). • Confirm 18V sensor supply at TB46-L in payload junction box. • Confirm proper connection of signal circuit 39FC from right suspension connection box, TB41-B to payload junction box TB46-G to payload meter connector R264, pin 20.

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Alarm 9 - Inclinometer High Alarm 10 - Inclinometer Low Troubleshoot Inclinometer Wiring These alarms indicate that the voltage to the payload meter from the inclinometer is out of range. The voltage on signal 39FE should be greater than 0.5V and less than 5.0V as measured in the junction box between TB46-.

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Alarm 13 - Body Up Input Failure

The payload meter senses when the load is dumped without receiving a body-up signal. When the load quickly drops below 50% without the body up signal, Alarm 13 is set. The alarm will be cleared when a normal dump cycle is detected. A normal dump cycle will be detected when the body up signal is received, the load drops quickly and the body down signal is received.

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Alarm 16 - Memory Write Failure Alarm 17 - Memory Read Failure These alarms indicate that the payload meter has encountered a problem internally with its memory. It is recommended that power to the payload meter be removed for 1 minute. First turn the key switch OFF. Wait 30 seconds, then turn the battery disconnect OFF. Wait 1 minute before restoring power. In cases where re-powering the payload meter does not restore normal operation, it may necessary to reprogram the payload meter. All current data in memory will be lost. This will effectively restart the payload meter. • See “Troubleshooting Abnormal Displays at Power-Up” for more information.

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Alarm 18 Payload meter detected an undercharged suspension condition on the rear right suspension. The suspension may be in need of servicing. Refer to Section H in the shop manual for information on charging the suspensions.

Alarm 19 Payload meter detected an undercharged suspension condition on the rear left suspension. The suspension may be in need of servicing. Refer to Section H in the shop manual for information on charging the suspensions.

Alarm 22 The payload meter detected an empty carryback load in excess of the user-defined carryback threshold on two consecutive haul cycles. Stop the truck and clean any stuck material from the truck body.

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Operator Switch Doesn't Work Alarm 26 - User Switch Fault - SELECT Alarm 27 - User Switch Fault - SET • Confirm power to the payload meter speedometer and display gauge. • Confirm that a laptop is not connected to the PLMIII system. • Turn key switch OFF. Wait 1 minute and turn key switch ON. Confirm problem still exists.

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Connector Map This diagram shows the general location of connectors, terminal boards and miscellaneous connections.

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Connectors

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PLMIII CHECK OUT PROCEDURE 8. Return to the cab and check the speedometer/ display gauge. The gauge will display the current payload. With the EJ3057 harnesses attached at the sensor locations, the payload should be 0.

General Description The process consists of attaching dummy loads in place of the suspension pressure sensors and checking the pressures indicated by the payload meter. In addition, connecting to the payload meter using a laptop PC in order to confirm the latest software version and the rest of the inputs and outputs of the system. Tools Required • Payload Data Manager software • EF9160 or PC2525 - Download Harness

NOTE: The display can be used to quickly show the current readings from the four suspension pressure sensors and the inclinometer. This can be used during regularly scheduled service periods to check the state of the suspensions. These displays are live and will update as the values change. The display is changed by pressing the “SELECT” button on the dashboard. The sequence of displays is:

• EJ3057 - Harness Str, PLMIII test (4 needed). Checkout Procedure 1. Attach one EJ3057 harness to the left-front suspension connection box. The red alligator clip attaches to the 39F circuit at TB42-A. The white alligator clip attaches to the 39FD circuit at TB42-B. The EJ3057 acts as a dummy load to simulate a suspension pressure sensor for the payload system. 2. Attach one EJ3057 harness to the right-front suspension connection box. The red alligator clip attaches to the 39F circuit at TB41-A. The white alligator clip attaches to the 39FC circuit at TB41-B. 3. Attach one EJ3057 harness to the left-rear suspension connection in the rear suspension connection box. The red alligator clip attaches to the 39F circuit at TB61-A. The white alligator clip attaches to the 39FB circuit at TB61-C. 4. Attach one EJ3057 harness to the right-rear suspension connection in the rear suspension connection box. The red alligator clip attaches to the 39F circuit at TB61-A. The white alligator clip attaches to the 39FA circuit at TB61-B. 5. In the PLMIII junction box, check the input voltage on circuit 39G between TB45-B and TB45X. This voltage should be 24VDC from the batteries. 6. Turn the key switch ON. The speedometer/display gauge on the dashboard will scroll the truck type across the lower display. The payload meter defaults to 930E. 7. In the PLMIII junction box, check the sensor supply voltage on circuit 39F between TB46-L and TB45-X. This voltage should be 18VDC ±1VDC.

M20008 12/12

• • • • • • • • •

PL= Payload Id= Operator ID tL= Total Shift Tons LC= Shift Load Counter LF= Left Front Suspension Pressure rF= Right Front Suspension Pressure Lr= Left Rear Suspension Pressure rr= Right Rear Suspension Pressure In= Inclinometer

NOTE: The live displays cannot be cleared and the SET button will have no effect. NOTE: The units for the display are controlled by the configuration of the payload meter. The payload meter defaults to display metric units, the pressures will be displayed in tenths of kg/cm2. For example, if the display shows 202 the actual value is 20.2 kg/ cm2. If the payload meter is set to display short tons, the pressures will be displayed in psi (lbs/in2). To convert from kg/cm2 to psi, multiply by 14.2233. 14.2233 psi (lbs/in2) = 1 kg/cm2. NOTE: The inclinometer displays whole degrees of incline. Positive incline is when front of truck is pointing up. NOTE: The gauge will quickly display the type of information being displayed every 1 minute. For example, if the left-front pressure is being displayed, LF= will quickly display every minute. Only the payload display, PL= does not display this information.

Payload Meter III

M20-53

9. Press and hold the “SELECT” button on the dashboard. Id= will be displayed. Release the button and the Operator ID will be displayed. This value should be 0. 10. Press and hold the “SELECT” button on the dashboard. tL= will be displayed. Release the button and the total tons will be displayed. This value should be 0.

15. Press and hold the “SELECT” button on the dashboard. rr= will be displayed. Release the button and the right-rear pressure will be displayed. This value should be displayed in metric units. Refer to Section H4, Suspension Oiling and Charging Procedures, for the nominal charging pressure. The acceptable pressure range varies according to truck model. 16. Press and hold the “SELECT” button on the dashboard. In= will be displayed. Release the button and the inclinometer value will be displayed. This value is in degrees. The incline will depend on how the truck is set during assembly. Values between ±3° are acceptable. It is not necessary to zero this reading by adjusting the attitude of the inclinometer in the buddy seat.

11. Press and hold the “SELECT” button on the dashboard. Lc= will be displayed. Release the button and the number of loads will be displayed. This value should be 0. 12. Press and hold the “SELECT” button on the dashboard. Lf= will be displayed. Release the button and the left-front pressure will be displayed. This value should be displayed in metric units. Refer to Section H4, Suspension Oiling and Charging Procedures, for the nominal charging pressure. The acceptable pressure range varies according to truck model. 13. Press and hold the “SELECT” button on the dashboard. rf= will be displayed. Release the button and the right-front pressure will be displayed. This value should be displayed in metric units. Refer to Section H4, Suspension Oiling and Charging Procedures, for the nominal charging pressure. The acceptable pressure range varies according to truck model.

17. Press and hold the “SELECT” button on the dashboard. PL= will be displayed. Release the button and the current payload will be displayed. 18. Connect a laptop to the PLMIII system. Typically an EF9160 or PC2525 download cable is used. Refer to Section D11 for the location of the payload meter connector. The laptop must have the Payload Data Manager software installed. 19. Run the PC software. 20. From the main menu, select "Connect to Payload Meter".

14. Press and hold the “SELECT” button on the dashboard. Lr= will be displayed. Release the button and the left-rear pressure will be displayed. This value should be displayed in metric units. Refer to Section H4, Suspension Oiling and Charging Procedures, for the nominal charging pressure. The acceptable pressure range varies according to truck model.

M20-54

Payload Meter III

12/12 M20008

21. The Connection Menu will be displayed. Select "Configure Payload Meter".

22. Confirm that the PLMIII software version matches the latest available version. As of 26June-06 the EJ0575-5 software version will display as "EJ0575-5". The latest version can be found at the Komatsu Extranet web site. If the version does not match the latest indicated on the internet, download the latest and update the PLMIII software using the Flashburn software. See Checkout Procedure Confirmation for more information. 23. Using the Truck Configuration menu, set the following:

24. Setting the Frame Serial Number.

NOTE: The frame serial number is located on a plate mounted to the truck frame. The plate is outboard on the lower right rail facing the right front tire. It is very important to enter the correct frame serial number. This number is one of the key fields used within the haul cycle database. The field will hold 20 alphanumeric characters. • On the Truck Configuration screen, enter the frame serial number in the appropriate field. • Press the "Save Changes" button to program the change into the payload meter. 25. Setting the Customer Unit Number. NOTE: Most mining operations assign a number to each piece of equipment for quick identification. This number or name can be entered in the Customer Unit Number field. It is very important to enter customer unit number. This number is one of the key fields used within the haul cycle database. The field will hold 20 alpha-numeric characters. If no truck number has been specified, enter the frame serial number. • On the Truck Configuration screen, enter the truck number in the appropriate field. • Press the "Save Changes" button to program the change into the payload meter. 26. Setting the Komatsu Distributor.

• • •

• •

Set the time. Set the Date to today’s date. Set the Gauge display units to Metric, Short Tons or Long Tons according to the final destination of the vehicle. If nothing has been specified, set to Metric Tons. Set the truck type to the proper truck model. Press the “Save Changes” button to program the change into the payload meter.

M20008 12/12

NOTE: This field in the haul cycle record can hold the name of the Komatsu distributor that helped install the system. Komatsu also assigns a distributor number to each distributor. This number is used on all warranty claims. This Komatsu distributor number can also be put into this field. This number is one of the key fields used within the haul cycle database. The field will hold 20 alpha-numeric characters. If the distributor is not known, enter "UNKNOWN". • On the Truck Configuration screen, enter the distributor name or number in the appropriate field. • Press the "Save Changes" button to program the change into the payload meter.

Payload Meter III

M20-55

27. Setting the Komatsu Customer. NOTE: This field in the haul cycle record can hold the name of the mine or operation where the truck is in service. Komatsu also assigns a customer number to each customer. This number is used on all warranty claims. This Komatsu customer number can also be put into this field. This number is one of the key fields used within the haul cycle database. The field will hold 20 alpha-numeric characters. If the customer is not known, enter "UNKNOWN" • On the Truck Configuration screen, enter the customer name or number in the appropriate field. • Press the "Save Changes" button to program the change into the payload meter. 28. Press "Save Changes" and close the Truck Configuration screen and the Connection Menu. 29. From the main menu select "Connect to Payload Meter". 30. From the Connection Menu select "Configure Payload Meter". Confirm that all previous changes have been saved and close the Truck Configuration form. 31. From the Connection Menu select "Real Time Data".

32. Confirm that the suspension pressures are within range. The nominal value should be 23.4 kg/cm2 (332 psi). Values between 17.6 and 29.2 kg/cm2 (250 and 416 psi) are acceptable. Record the values displayed. 33. Confirm that the inclinometer is within range and record the value. 34. Confirm that the body up input is working correctly. Place a steel washer on the body up switch. The real time data screen should indicate "No". Remove the washer and the real time data screen should indicate "Yes". The Haul Cycle State should change to "Dumping". 35. Confirm that the brake lock input is working correctly. Turn the brake lock on using the switch on the dashboard. The real time data screen should indicate ON. Turn the brake lock off. The real time data screen should indicate OFF. 36. Turn on the green payload lights by checking "Green Light" and pressing the "Set Lights" button. Check to be sure that only the green payload lights on the truck are illuminated. 37. Uncheck the green light and turn on the amber payload lights by checking "Amber Light" and pressing the "Set Lights" button. Check to be sure that only the amber payload lights are illuminated. 38. Uncheck the amber light and turn on the red payload lights by checking "Red Light" and pressing the "Set Lights" button. Check to be sure that only the red payload lights are illuminated. 39. Uncheck all the payload lights and press the "Set Lights" button. Confirm that all the lights are off.

NOTE: The weight shown on the real time data screen is the sprung weight and includes the weight of the truck. Given the suspension pressure dummy loads, the nominal value shown should be 101 metric tons (112 short tons).

M20-56

40. Use the procedure for speedometer calibration for the particular truck type to simulate a 40.2 km/h (25 mph) speed signal. Confirm that this value is displayed by the speedometer on the dashboard and the real time data screen. The value can be ±2 km/h (±1 mph). The brake lock must be off for the PLMIII to recognize speed input. 41. On the PC, close the Real Time Screen and the Connection Menu and return to the Main Menu.

Payload Meter III

12/12 M20008

42. Remove the EJ3057 harness from the left front suspension junction box, TB42-A and TB42-B.

PLMIII CHECKOUT PROCEDURE CONFIRMATION

43. Wait at least 1 minute, then remove the EJ3057 harness from the left rear connections in the rear junction box, TB61-B and TB61-C.

Flashburn Programming

44. Wait at least 1 minute, then remove the EJ3057 harness from the right-rear connections in the rear junction box, TB61-A and TB61-C. 45. Wait at least 1 minute, then remove the EJ3057 harness from the right front connections in the right-front junction box, TB61-B and TB61-C. 46. Wait at least 1 minute. 47. From the main menu of the PC software, press the "Connect to Payload Meter" button. 48. From the Connection Menu select "Display Active Alarms". Confirm that the four alarms displayed occurred in the proper order: Left-front suspension low

Before beginning, make sure that you have the .kms file required to program the product and you know where to find it on your computer. Programming will reset all the truck configuration information. NOTE: Before starting this procedure, record the Payload Meter configuration information. This information can be found using the Payload Data Manager software. After programming, it will be necessary to restore this information in the payload meter configuration.

1. Turn off power to the payload meter by turning the key switch OFF. 2. Start the Flashburn software installed on the laptop.

Left-rear suspension low Right-rear suspension low Right-front suspension low

Flashburn

49. Close all screens and disconnect the laptop from the PLMIII system.

1. Power OFF

Before programming, power must be turned off to the target device. Be sure the power is turned off before continuing.

2. Select Port 3. Select File 4. Power ON

< Back

Next >

Cancel

3. Confirm that the payload meter power is OFF and press “NEXT".

M20008 12/12

Payload Meter III

M20-57

4. Confirm the proper communications port for the programming laptop. This is usually COM 1. Press “NEXT”.

Flashburn

1. Power OFF

Flashburn

1. Power OFF 2. Select Port

2. Select Port

Select the serial communications port to use between the computer and the target device. For most computers this will be COM 1.

3. Select File

COM 1

4. Power ON

3. Select File

Turn on power to the target device. This will start the programming process. Comm Port:

COM 1

Filename:

071000A.KMS Status

Steps Connection:

Complete

Preparation:

Complete

Programming:

Complete

Verification:

4. Power ON

Complete 61 %

< Back

< Back

Next >

Cancel

Cancel

7. After successful programming, turn the key witch OFF. 5. Press “BROWSE” and select the ".kms" file to program into the payload meter. Press “NEXT”. Flashburn

1. Power OFF

Select the file that will be used to program the target device. This file will end with the ".KMS" extension.

2. Select Port

Comm Port: COM 1 Filename:

*.KMS

8. Wait 20 seconds and turn the key switch ON. 9. The payload meter will need to be configured as instructed in the manual using the Payload Data Manager software on the laptop computer.

Browse

3. Select File 4. Power ON

< Back

Next >

Cancel

6. When instructed, turn the key switch ON in order to power-up the payload meter. The PC will begin to reprogram the payload meter. This process takes approximately 5 minutes.

M20-58

Payload Meter III

12/12 M20008

Confirmation Checklist Use the Real Time Data Screen in order to verify the checklist items in the table below. Checklist Item

Value

Initials

PLMIII Software Version User switch and display works properly Left - Front Pressure Right - Front Pressure Left - Rear Pressure Right - Rear Pressure Inclinometer Green light works properly Amber light works properly Red light works properly Brake Lock input works properly Body Up input works properly Speed input works properly

Date Truck Signature

M20008 12/12

Payload Meter III

M20-59

NOTES

PORTIONS OF THIS PRODUCT RELATING TO PAYLOAD MEASURING SYSTEMS ARE MANUFACTURED UNDER LICENSE FROM L.G. HAGENBUCH, holder of U.S. Patent Numbers 5,416,706; 5,528,499; 5,631,832; 5,631,835; 5,644,489; 5,650,928; 5,650,930; 5,742,914

M20-60

Payload Meter III

12/12 M20008

SECTION M31 RESERVE ENGINE OIL SYSTEM INDEX

RESERVE ENGINE OIL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-4 LED Monitor Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-4 Tank Fill Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-5 Filling Procedure (Remote fill feature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-5 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-6 Every 10 Hours, or once each shift: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-6 Every 500 Hours: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-6 Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-6 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-7 Circuit Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-7 SYSTEM ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M31-8

M31004 10/07

Reserve Engine Oil System

M31-1

NOTES

M31-2

Reserve Engine Oil System

10/07 M31004

RESERVE ENGINE OIL SYSTEM The reserve engine oil system is designed to add more oil capacity to the engine sump and to reduce frequent servicing of the engine oil. The constant circulation of oil between the engine sump and reserve tank (9, Figure 31-1) increases the total volume of working oil. This dilutes the effects of contamination and loss of additives and maintains the oil quality over longer periods. The system adds or removes oil from the engine as required to maintain a constant level which prevents over fills or under fills.

The normal reserve system capacity of oil carried in the tank can be one half or nearly the same (depending on tank size) volume inside the engine. In the process of continuous adjustment of the engine oil level, there is a constant circulation of oil between the engine and the reserve tank. The volume of oil in the tank becomes part of the working oil for the engine. Oil change intervals may usually be extended in proportion to the increased working oil volume. Extension beyond a proportional increase is often possible, but should be undertaken only as determined by oil sampling and analysis. Local conditions such as engine application, climate, and fuel quality should be taken into consideration before determining permissible oil life.

M31004 10/07

FIGURE 31-1. OIL RESERVE TANK 1. Suction Line 2. Remote Fill Line 3. Fill Valve 4. Engine Add Line 5. Fill Switch 6. Air Relief Valve 7. Tank Fill Line

Reserve Engine Oil System

8. Tank Fill Cap 9. Reserve Tank 10. Engine Add Line 11. Pumping Unit 12. Sight Gauge 13. Tank Add Line

M31-3

LED Monitor Light

Operation Engine oil is circulated between engine oil pan (1, Figure 31-2) and reserve tank (2) by two electrically driven pumps (pump 1 and pump 2) within a single pumping unit (4). The pumping unit is mounted on the side of the reserve tank. The pump unit is equipped with an LED monitor light on one side.

• Steady - Pump 1 is withdrawing oil from the engine sump and bringing down the oil level. • Regular pulsing - Pump 2 is returning oil to the engine sump and raising the oil level. Irregular pulsing - Oil is at the correct running level.

Pump 1 draws oil from the engine oil pan (1) at a preset control point determined by the height of the suction tube (3). Oil above this point is withdrawn and transferred to the reserve tank. This lowers the level in the engine oil pan until air is drawn. Air reaching the pumping unit activates pump 2, which returns oil from reserve tank (2) and raises the engine oil level until air is no longer drawn by pump 1. Pump 2 then turns off. The running level is continuously adjusted at the control point by alternating between withdrawal and return of oil at the engine oil pan. The oil returning to the engine oil pan is below the normal operating level to prevent aeration of the oil.

FIGURE 31-2. RESERVE SYSTEM SCHEMATIC 1. Engine Oil Pan (Sump) 2. Oil Tank 3. Suction Tube

M31-4

4. Pumping Unit (1 & 2) 5. Air Relief Valve

Reserve Engine Oil System

A. Oil Suction Line B. Oil Return Line C. Engine Oil Level

10/07 M31004

Tank Fill Control (Optional) With the reserve oil system the engine oil level is held constant, with only the reserve tank needing routine filling. The fill system automatically controls the filling of remote tank from a convenient ground level position. Filling of the tank to the proper “full” level is fast and accurate and accomplished in 2 to 3 minutes. The reserve oil tank for the engine is designed to add more oil capacity to the engine to reduce the frequent servicing of the engine oil. The engine oil level must still be checked every shift using the dipstick. The oil level in the reserve tank should also be checked using the filler cap dipstick. If the engine oil has been drained from the engine oil pan, the new oil must be added through the engine fill tube. After an oil change, both engine and reserve tank must be at the full level of oil before starting the engine. NOTE: DO NOT use the oil in the reserve tank to fill the engine oil pan. System switch (2, Figure 31-3) is an illuminated push-pull POWER-ON switch that powers the fill system. Start switch (3) is a momentary push button switch that opens the fill valve mounted on the reserve tank to begin the automatic filling of the reserve tank. Supply oil under pressure flows through the fill valve and into the tank. Filling Procedure (Remote Fill Feature) NOTE: This procedure adds oil to the reserve tank. 1. Connect the pressure supply hose from the new oil supply to the quick coupler on the truck. Open valve on supply hose to apply pressure.

FIGURE 31-3. RESERVE OIL TANK REMOTE FILL 1. Remote Control Box 2. System Switch 3. Start Switch

4. FULL Light 5. VALVE OPEN Light

2. Pull out on system switch (2, Figure 31-3) to turn the fill system on. 3. Push start switch (3). VALVE OPEN light (5) should illuminate and the filling process will begin. 4. When the tank is full, the VALVE OPEN light will turn off and FULL light (4) will illuminate. 5. Close the oil supply valve in the fill hose. 6. Press and hold start switch (3) for a couple of seconds to relieve oil pressure in the line. 7. Disconnect the new oil supply hose. 8. Push switch (2) in to turn fill system power off.

M31004 10/07

Reserve Engine Oil System

M31-5

SERVICE

Every 500 Hours

Between oil drains, the only normal servicing required is routine replenishment of oil at the reserve supply tank. Maintenance of running levels should be checked routinely; manually before starting the engine and with the LED system monitor on the reserve tank pumping unit (11, Figure 31-1) when the engine is running. There is also an in-line filter (screen) installed at the inlet of the fill valve (3, Figure 31-1). This filter requires no periodic maintenance, but it can be cleaned by removing it from the system and back flushing through the filter.

1. Change all engine filters, if applicable. 2. More system failures result from bad electrical connections than all other causes combined. Check electrical system connections for tightness, corrosion and physical damage. Check battery, alternator, oil pressure switch, junction boxes, remote control fill box and circuit breakers. 3. Examine electrical cables over their length for possible damage. 4. Small hose leaks can cause system malfunction. Examine all hoses, including those on the reserve tank and the ones leading to and from the engine for leaks, cracks or damage. Check all fittings for tightness, leakage or damage. Changing Oil

Always check the engine oil level before starting engine. Use the engine dipstick. Every 10 Hours, or once each shift:

1. Drain both the engine sump and the reserve tank. Refill both engine and reserve tank with new oil to proper levels. 2. Change engine oil filters as required.

1. Before starting engine, check oil level using the engine dipstick. Oil level should be in normal operating range. If not, check the reserve system for proper operation. 2. The engine oil quality will be best if the reserve tank is kept reasonably full. Check the oil level in the reserve tank. As a minimum guideline, if the oil is below the half-full level, fill the tank manually according to the filler cap dipstick or by using the automatic fill control method.

3. Start engine and check for proper operation. NOTE: Do not use the oil in the reserve tank to fill the engine sump. Both must be at proper level before starting engine. The engine oil level should be checked with the engine dipstick at every shift change. The oil level in the reserve tank must also be checked at every shift change using the fill cap dipstick.

3. After starting and warm-up, check engine oil level signal (LED) to verify that the engine is being maintained at the preset running oil level. The signal should alternate between periods of ‘steady on’ and ‘flashing’.

NOTE: Oil should always be visible in the lower sight gauge. If the tank is equipped with three sight gauges, oil should always be visible in the middle sight gauge.

M31-6

Reserve Engine Oil System

10/07 M31004

TROUBLESHOOTING It is important to understand the LED signal for the pumping unit. It is used primarily to verify that the system is maintaining the oil level at the level of the open end of the withdrawal tube in the engine oil pan. The signal is also a valuable tool in troubleshooting the system. When the signal is STEADY (not flashing), pump 1 is running and oil is being withdrawn from the engine and being transferred to the reserve tank. When the signal is FLASHING, pump 1 is drawing air from the suction tube which triggers operation of the pump 2 to operate and transfer oil back to the engine from the tank (the flashing is actually the pulses of pump 2). When the oil is at the correct level in the engine, air and oil are alternatively entering the suction tube, with pump 1 commanding operation of pump 2 with each portion of air that comes through the line. This is a complete test for proper operation of the pumping unit. This operation can be accomplished without running the engine by jumping the oil pressure switch that activates the system. 1. If the signal light is STEADY, pump 1 should be pumping oil. Verify by loosening the hose at pump 1 outlet to verify that oil is coming through (pump 1 is marked by a groove on its outlet). 2. Loosen the hose at the inlet of pump 1 to admit air. Pump 2 should then run and the signal should be flashing. Verify proper pumping of pump 2 by loosening the hose at its outlet to see that oil is coming through. 3. Re-tighten the inlet hose on pump 1. The pump should again receive oil and the flashing should stop.

M31004 10/07

NOTE: There is a condition that would show a level higher than the controlled point. If both the engine and reserve tank are overfilled, there is no room in the tank to draw the oil level down in the engine. In this case, the LED signal would never start FLASHING because pump 1 is never receiving air. It will continue to pump oil from the engine to the tank, but because the tank is full, the oil will be routed back to the engine via the air relief valve on top of the tank.

There are two explanations for an overfilled tank and engine: • When the tank is filled to “FULL” and the engine is overfilled. • When oil is added directly to the engine between oil changes. The system transfers the oil to the reserve tank until it can not receive any more and the engine remains overfilled. It is, therefore, important that oil should be added only to the reserve tank between oil changes (except if the engine oil level is extremely low).

Circuit Fuse The reserve system fill control unit is protected by a 15 amp fuse (Fuse Block 2, position 10) located in the auxiliary control cabinet. The pump unit is protected by a 15 amp fuse (Fuse Block 2, position 9) located in the auxiliary control cabinet. For circuit information, refer to the system schematic in the back of the shop manual.

Reserve Engine Oil System

M31-7

SYSTEM ELECTRICAL SCHEMATICS

FIGURE 31-4. FILL SYSTEM SCHEMATIC 1. Fill Valve 2. Oil Level Sensor (top of reserve oil tank) 3. 15 Amp Fuse

M31-8

4. Auxiliary Control Box 5. Ground Wire 6. Remote Fill Control Box

Reserve Engine Oil System

10/07 M31004

SECTION M32 RETRACTABLE LADDER SYSTEM INDEX

RETRACTABLE LADDER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-6 GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-6 LADDER SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-6 LADDER SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-6 Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-6 Emergency Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-8 Limit Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-8 IN-CAB CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-8 IN-CAB CONTROL PANEL FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-10 Digital Display Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-10 Command Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-10 IN-CAB CONTROL PANEL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-12 Timing Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-12 Ladder System Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-12 Fault Code Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-12 Ladder System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-13 In-Cab Control Panel Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-13 Automatic Raising. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-13 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-13 USING THE IN-CAB CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-14 Raising the Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-14 Lowering the Ladder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-15 USING THE GROUND LEVEL CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-16 Raising the Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-16 Lowering the Ladder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32-16

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Retractable Ladder System

M32-1

POWER PACK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-17 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-21 Safety During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-21 Unplanned Ladder Movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-21 Automatic Ladder Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-21 Automatic Accumulator Recharging (Ladder in UP position) . . . . . . . . . . . . . . . . . . . . . . . .M32-22 PREVENTIVE MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-23 Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-23 250 Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-23 5000 Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-23 SERVICING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-24 Check Reservoir Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-24 Changing RLS Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-24 Cleaning the RLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-25 RLS DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-25 Description of Diagnostics Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-25 Continuous System Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-26 Historic System Data Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-27 Comms Integrity Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-27 Log and Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-27 System Event Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-28 SECURITY ACCESS LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-29 Access Level 1 – NONE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-29 Access Level 2 – RESTRICTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-29 Access Level 3 – COMPLETE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-29 User Access Privileges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-30 USER ID – PASSWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-31 Sequential Field Value Selection Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-31 Password Character Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-31 USER ID – NEW USER SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-32

M32-2

Retractable Ladder System

M32002

SYSTEM FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-32 Fault Type 1: Communications error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-33 Fault Type 2: 10A/15A fuse blown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-33 Fault Types 3, 4, 5, 6, 7: Up/Down/In/Out pump coil short or disconnected . . . . . . . . . . . . .M32-34 Fault Type 8: Power pack recharge too long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-34 Fault Type 9: Inhibit relay fail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-35 Fault Types 10, 11: Light/Siren relay failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-35 Fault Type 12: Ladder came off upper limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-36 Fault Type 13: Ladder did not reach limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-36 Fault Type 14: Ladder stayed on limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-37 Fault Type 15: Low oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-37 Fault Type 16: System voltage over 18V during movement . . . . . . . . . . . . . . . . . . . . . . . . .M32-38 Fault Type 17: System voltage under 18V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-38 Fault Type 18: System voltage over 31V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-39 Fault Types 19, 20: Remote UP and/or DOWN toggle held too long (when equipped). . . . .M32-39 Fault Type 21: Accumulator recharge > than once/hour . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-40 Fault Type 22: System raised by park brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-40 Fault Types 23, 24: Levels 1 and 2 service overdue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-41 Fault Type 25: Levels 1 and 2 service complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-41 DATA MANAGEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-42 Log Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-42 Generating Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-43 MENU DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-49 Controller Config . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-49 Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-49 Show Recent Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-49 System Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-49 Upload Logs to USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-49 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32-49

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Retractable Ladder System

M32-3

NOTES:

M32-4

Retractable Ladder System

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FIGURE 32-1. RETRACTABLE LADDER SYSTEM (LOWERED) (830E-1AC INSTALLATION SHOWN)

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Retractable Ladder System

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RETRACTABLE LADDER SYSTEM GENERAL SAFETY

LADDER SYSTEM DESCRIPTION

The following safety procedures, at a minimum, must be followed to ensure safe operation and use of the Retractable Ladder System (RLS).

The RLS is an electro-hydraulic ladder powered by the truck’s 24VDC electrical system. The RLS provides a safe means to mount and dismount the truck under normal and emergency conditions. The RLS consists of two main control components (Refer to Figure 32-2):

1. DO NOT run or jump on the ladder. 2. DO NOT overload the ladder. Use the ladder one person at a time.

1. The in-cab control panel is a microprocessor that controls, monitors, stores and reports ladder system operational data.

3. Hold onto the handrail when using the ladder. 4. Always face the ladder when ascending or descending.

2. The electro-hydraulic power pack is in a ground level stainless steel cabinet. It houses the main control hydraulics and electrical components that lower and raise the ladder.

5. DO NOT attempt to ride on the ladder while it is being raised or lowered or while the truck is in motion. 6. Always visually check the ladder before use to ensure the unit has not been damaged. 7. Ensure the ladder is in the fully down position before boarding. 8. Keep hands and fingers away from pinch points while the ladder is in motion. 9. Always check to ensure no personnel are on or in the immediate vicinity of the ladder while it is in motion. 10. The ladder must be kept clean and free of moisture, grease and oil 11. When in the truck’s cab, always use the in-cab control panel to raise the ladder. 12. Report defects immediately.

to

maintenance

personnel

The RLS also contains wiring harnesses and Deutsch-style plug connectors, hydraulic hoses and an emergency down valve.

LADDER SYSTEM OPERATION Normal Operation During normal operation, a person can lower or raise the RLS by using the: • In-cab control panel • Ground level control box located next to the battery isolation box • Control switches in the power pack. NOTE: The master disconnect switch located in the isolation box and the isolation switch in the power pack must both be in the ON position for the RLS to operate. As an added safety measure, the RLS uses a parking brake interlock that requires the parking brake to be set before the ladder can be operated under normal conditions. The RLS will automatically raise the ladder if the operator releases the parking brake and fails to press the [UP] button on the in-cab control panel before attempting to drive the truck.

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M32002

FIGURE 32-2. POWER PACK AND IN-CAB CONTROL PANEL

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Retractable Ladder System

M32-7

Emergency Operation

Limit Switch Operation

In an emergency, the RLS ladder can be lowered by using the emergency down valve (1, Figure 32-3) mounted on the frame above the left hand side headlight assembly. The emergency down valve relieves ladder system hydraulic pressure and allows the ladder to smoothly lower to the ground.

The RLS uses an upper limit switch to monitor ladder position and to ensure the ladder stays in the UP position while the truck is moving. When the truck is in motion, the in-cab control panel display screen will indicate ladder position with text and graphic to the operator. If the ladder breaks contact with the limit switch for more than three seconds, the power pack will attempt to reposition the ladder. This can occur a maximum of three times per hour, but no less than eight minutes apart. These limits protect the power pack from unnecessary operation and inevitable burnout of the 24VDC electric motor. The fault alarm will be activated and the message “LADDER has come off limit switch” will be displayed on the in-cab control panel. The alarm must be acknowledged by pressing the [EXIT] or [ENTER] buttons on the in-cab control panel. If the ladder does not contact the limit switch within a preset time period of three seconds, the alarm will reactivate. NOTE: Depending on the reason for the ladder not contacting the upper limit switch (defective limit switch, physical damage to the ladder, etc.), even with a fault alarm, the ladder can still be raised enough for the vehicle to be driven without the risk of damaging the RLS. This enables maintenance or repairs to be done at a more convenient time. However, it is the sole responsibility of the operator to investigate the ladder’s condition before continuing to operate the truck. The RLS fault alarm is a reminder to the operator that a problem exists and requires attention at the earliest convenience.

FIGURE 32-3. EMERGENCY DOWN VALVE 1. Emergency Down Valve

IN-CAB CONTROL PANEL

2. Grille

To lower the ladder, rotate the handle on the emergency down valve clockwise. The ladder will lower smoothly until it reaches the ground.

In-cab control panel (1, Figure 32-4) is located on the left side of the dash and contains a microprocessor that controls, displays, monitors, stores and reports ladder system operational data. The in-cab control panel provides real time position of the ladder to the operator.

To reset the ladder, rotate the handle counterclockwise to its original position and, with power restored to the power pack, press the [UP] button to raise the ladder. NOTE: The handle on the emergency down valve must be in the original position before re-activating the ladder.

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M32002

FIGURE 32-4. CAB CONTROLS (OPERATOR VIEW) 1. In-cab Control Panel

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M32-9

IN-CAB CONTROL PANEL FEATURES The in-cab control panel features a digital display screen, command buttons ([UP], [DOWN], [ENTER], [EXIT], [LEFT], [RIGHT]) for operating the ladder and navigating through the various menu display screens, a USB key port and RS 232 port for downloading ladder system operational data to a laptop computer for troubleshooting. The control panel is connected to an electrical harness with a 15-pin harness plug. Refer to Figure 32-5.

Digital Display Screen In-cab control panel display screen (1, Figure 32-5) provides the user with system status, error/fault messages and a visual indicator of the ladder’s position (lowered, raised, in motion).

[DOWN] button (3, Figure 32-5) is a dual function control that is used to lower the ladder during normal operation and scroll through the menu displays. Pressing this button and holding it briefly will cause the ladder to lower. Pressing and releasing this button one time will scroll down one line of menu display, and holding it will result in continuous menu scrolling.

[ENTER] button (6, Figure 32-5) is a multi-function button used for ladder system alarm acknowledgement and menu access when in Display Mode. This button is also used to confirm or accept changes shown on the display screen. Press this button to confirm or accept changes listed on the display screen.

Command Buttons [UP] button (2, Figure 32-5) is a dual function control that is used to raise the ladder during normal operation and scroll through the menu displays. Pressing this button and holding it briefly will cause the ladder to raise. Pressing and releasing this button one time will scroll up one line of menu display, and holding it will result in continuous menu scrolling.

M32-10

[EXIT] button (7, Figure 32-5) is a multi-function button used for ladder system alarm acknowledgement and menu access when in Display Mode. This button is also used to exit from the menu screens. Press this button to exit from menu screens.

Retractable Ladder System

M32002

FIGURE 32-5. IN-CAB CONTROL PANEL (FRONT VIEW) 1. Display Screen 2. [UP] Button 3. [DOWN] Button

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4. [LEFT] Button 5. [RIGHT] Button 6. [ENTER] Button

Retractable Ladder System

7. [EXIT] Button 8. USB Port 9. 15-Pin Harness Plug

M32-11

[LEFT] button (4, Figure 32-5) is for scrolling left when entering a password.

Ladder System Status The in-cab control panel shows the ladder system status/position on the display screen. While the ladder is in motion, an animated ladder image indicates that the ladder is being lowered or raised.

[RIGHT] button (5, Figure 32-5) is for scrolling right when entering a password.

USB Port (8, Figure 32-5) is located on the side of the control panel and allows the user to access and download ladder operational data onto a USB key or flash drive for analysis.

The control panel is connected to the electrical system with 15-pin harness plug (9, Figure 32-5).

IN-CAB CONTROL PANEL FUNCTIONS

Fault Code Identification

The normal functions of the in-cab control panel are as follows:

The in-cab control panel displays system fault codes and messages and produces an audible alert signal when an error or problem has occurred. The system is programmed to diagnose 25 different types of fault codes and messages. System faults must be corrected to ensure uninterrupted ladder operation. Refer to the Diagnostics section later in this chapter for additional information.

Timing Control The in-cab control panel automatically controls the timing of the ladder raise and lower operations.

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Ladder System Configuration

Automatic Raising

The in-cab control panel allows only authorized persons to alter electro-hydraulic timing, boarding light time-out, screen display time-out, and date/time settings. Access is password protected to prevent unauthorized or accidental system changes.

The in-cab control panel automatically raises the ladder if the operator releases the parking brake and does not press the [UP] button on the control panel before driving the truck. This is a safety feature to avoid ladder system damage. Raising the ladder in this manner will cause a fault to be stored in system memory.

Diagnostics The in-cab control panel allows the viewing of the last 50 events on the display screen. In addition, a 3,000point data log capacity is built into the panel’s nonvolatile memory. Full ladder system diagnostics can be retrieved via data log download by using a USB key for analysis in Microsoft® Excel.

In-Cab Control Panel Lockout To control the ladder operation from the ground level control only, the in-cab control panel can be locked out. This action is password protected to prevent unauthorized in-cab control panel lockout.

Maintenance The in-cab control panel monitors the ladder system oil level and counts the number of ladder system operation cycles. When maintenance is required, an audible warning will sound and an on-screen message will automatically be displayed on the control panel. Refer to the Servicing section later in this chapter for additional information.

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Retractable Ladder System

M32-13

USING THE IN-CAB CONTROL PANEL

Raising the Ladder

While the ladder is in motion, the direction (up or down) can be changed by pressing the opposite direction ([UP] or [DOWN]) button on the control panel.

The ladder will typically be in the lowered position on a stationary truck. The in-cab control panel will indicate that the access is DOWN, as shown here:

If the IN CAB LOCKOUT message is displayed on the control panel screen, then the RLS can only be operated from the ground level control box mounted next to the battery isolation box. All other control panel functionality is still available including fault indication and audible alarms.

When in the operator’s cab, always use the [UP] button on the control panel to raise the ladder instead of releasing the parking brake. The automatic operation of the ladder when the parking brake is released is an emergency feature only. DO NOT release the parking brake to raise the ladder as part of normal operation.

To raise the ladder, press and hold (temporarily) the [UP] button located on the in-cab control panel. The illustrated ladder on the screen will animate and begin to rise to the UP position and the UP arrow (on the control panel button) will flash. When the ladder is completely raised, the [UP] button will remain lit continuously. When the ladder has reached its raised travel position and strikes the limit switch, the control panel will indicate that the access is UP, as shown here:

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Retractable Ladder System

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The RLS power pack will continue to operate for three more seconds to charge hydraulic accumulator (15, Figure 32-9). During this time, the UP arrow will continue to flash until the cycle is complete. The RLS uses a limit switch to monitor ladder travel to the UP position. If the ladder fails to strike the limit switch or the limit switch fails to close, a fault alarm will activate after a short delay and the in-cab control panel will display this message, as shown here:

Lowering the Ladder NOTE: The parking brake must be applied before the ladder can be lowered. To lower the ladder, press and hold (temporarily) the [DOWN] button located on the in-cab control panel. The illustrated ladder on the screen will animate and begin to lower to the DOWN position and the [DOWN] button will flash. When the ladder has reached its lowered travel position, the control panel will indicate that the access is DOWN, as shown here:

NOTE: The fault alarm must be acknowledged by pressing the [EXIT] or [ENTER] buttons on the control panel. Once the alarm has been acknowledged, the fault message will be replaced by a FAULT IN SYSTEM message. A defective limit switch will prevent normal RLS operation and must be corrected immediately.

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When the ladder is completely lowered, the [DOWN] button will remain lit continuously.

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USING THE GROUND LEVEL CONTROL BOX Ground level control box (1, Figure 32-6) is located next to the battery isolation box and contains toggle switch (2) that lowers and raises the ladder. NOTE: The parking brake must be applied before the ladder can be lowered. If toggle switch (2) is held in either position for more than ten seconds, a fault will be activated and will need to be acknowledged by pressing either the [EXIT] or [ENTER] buttons located on the in-cab control panel.

Raising the Ladder To raise the ladder, push toggle switch (2, Figure 326) to the LADDER UP position and release. Ladder operation via this switch is the same as using the incab control panel. Any ladder movement will be shown on the in-cab control panel. Lowering the Ladder To lower the ladder, push toggle switch (2, Figure 326) to the LADDER DOWN position and release. Ladder operation via this switch is the same as using the in-cab control panel. Any ladder movement will be shown on the in-cab control panel.

FIGURE 32-6. GROUND LEVEL CONTROL BOX 1. Ground Level Control Box

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2. Toggle Switch

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POWER PACK OPERATION The power pack is a ground level stainless steel cabinet that houses the main control hydraulics and electrical components. It uses 24VDC from the truck’s electrical system to lower and raise the ladder. Refer to Figure 32-8 and Figure 32-9. When the ladder is raised, 24VDC motor (14, Figure 32-9) operates and directional control valve (5) moves to the UP position. RLS hydraulic pressure is controlled by pressure relief valves (13). Maximum system operating pressure is set at 17 000 kPa (2,466 psi), but the system’s actual working pressure may be lower. RLS hydraulic fluid flows through directional control valve (5) and flow control valve (6) [metering out] to the UP side of the actuator and past a cavity plug. During this time, hydraulic fluid will charge accumulator (15) and a pressure switch as the ladder moves to the UP position.

When the ladder is lowered, directional control valve (5, Figure 32-9) will change to the DOWN position and 24VDC motor (14) begins to lower the ladder. The power pack will cut-off at a predetermined length of time and the ladder will continue to lower under its own mass controlled by flow control valve (6) [metering out]. An added feature of the power pack is a thermostatically-controlled heater installed on fluid reservoir (11) to heat RLS fluid in cold weather operation. Refer to Figure 32-7.

FIGURE 32-7. OIL HEATER

Hydraulic accumulator (15, Figure 32-9) keeps the ladder in the raised position and is automatically recharged if the accumulator pressure falls below 4 000 kPa (580 psi). If the hydraulic pressure in the accumulator falls below 4 000 kPa (580 psi), a pressure switch will start the hydraulic pump and recharge the system. This should only occur three times per hour and not more than once every eight minutes. If the ladder breaks contact with the limit switch, a fault alarm will activate and the in-cab control panel will display an error message that will have to be acknowledged. NOTE: The fault alarm must be acknowledged by pressing the [EXIT] or [ENTER] buttons on the control panel. Once the alarm has been acknowledged, the fault message will be replaced by a FAULT IN SYSTEM message.

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FIGURE 32-8. POWER PACK (EXPLODED VIEW)

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FIGURE 32-8. POWER PACK (EXPLODED VIEW) 1. Cover 2. Stauf 3. Electrical Cover Plate 4. Flat Washer 5. Nut 6. Mount Plate 7. Control Unit 8. Cap Screw 9. Rubber Mount 10. Solenoid 11. Washer 12. Screw 13. Bolt 14. Lifting Lug 15. Nut 16. Motor 17. Spline Coupling 18. Motor Mount 19. Bolt 20. Spring Washer 21. O-Ring 22. Shaft Seal 23. Pump Assembly

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24. Suction Cover 25. Flat Washer 26. Spring Washer 27. Cap Screw 28. Cap Screw 29. Hose Clamp 30. Suction Filter 31. Suction Pipe 32. Breather 33. Swivel 34. Set Screw 35. Flat Washer 36. P-Clamp 37. Flat Washer 38. Nut 39. Breather Hose 40. Swivel 41. Breather Flow 42. Bolt 43. Spring Washer 44. Cap Screw 45. Cap Screw 46. Manifold Assembly

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47. Pipe Kit 48. Return Pipe 49. O-Ring 50. Oil Heater 51. Sight Glass 52. Plug 53. Elbow 54. Hydraulic Tank

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FIGURE 32-9. POWER PACK (ASSEMBLED VIEW) 1. Power Pack 2. 24VDC Motor Solenoid 3. Hydraulic Node w/ Isolation Switch 4. Harness Cover Plate 5. Directional Control Valve 6. Pilot Stage Relief

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7. Test Points 8. Sight Glass 9. Mount Plate 10. Oil Heater 11. OIl Reservoir 12. Hydraulic Manifold 13. Adjustable Flow Regulator

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14. 24VDC Motor 15. Hydraulic Accumulator 16. Cabinet Door 17. Tank Breather 18. Accumulator Bleed Valve

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MAINTENANCE

4. Prevent dirt or debris from entering the system by plugging or capping disconnected lines.

Safety During Maintenance Before attempting to service or perform maintenance on the ladder system, all personnel must be familiar with the hazards and precautionary steps required. Servicing or maintaining the ladder must only be performed by qualified and authorized personnel.

5. DO NOT use the electrical harness or hydraulic lines as a step. 6. DO NOT activate the ladder system unless the relief valve is in place. 7. DO NOT use your hand to check for hydraulic leaks. Serious injury will result. If a high-pressure injection injury is suspected, seek medical treatment immediately. 8. Always wear proper eye protection while servicing or performing maintenance on this equipment.

Follow all applicable worksite isolation and tagout procedures before attempting to service or perform maintenance on this equipment. Failure to properly isolate the ladder’s energy sources, electricity and hydraulics may lead to personal injury or death. At a minimum, the following steps are to be followed while servicing or maintaining this equipment: 1. Always isolate the electrical power from the ladder system, unless it is required for testing or adjusting purposes, before attempting any electrical or mechanical work on the ladder. Failure to properly isolate the ladder’s electrical power can lead to serious injury. 2. DO NOT attempt to repair, loosen or open any part of the hydraulic system unless both the electrical power and hydraulic supply have been isolated and the hydraulic lines have been depressurized. Ensure the system is depressurized by checking a gauge connected to the immediate line or equipment by opening a test valve, or by noting that a line is already disconnected. DO NOT bleed a pressurized line by loosening a fitting. 3. Check the ladder’s electrical harness, wiring and hydraulic lines for damage or wear on a regular basis. Ensure replacement hydraulic lines are the same quality and length as the original.

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Unplanned Ladder Movements During maintenance, the RLS can automatically raise the ladder if the truck’s parking brake is released. This is normal operation for the ladder system. However, unplanned ladder movements pose potential risk of injury to maintenance personnel. NOTE: These circumstances would not apply to an RLS with its hydraulic system powered from the truck’s hydraulic system unless the truck’s system is pressurized.

Automatic Ladder Raising Inadvertent raising of the ladder will occur if the parking brake is released and: • Power has not been isolated from the RLS power pack, or • Power is restored to the RLS power pack after previously being isolated. To prevent this unplanned ladder movement, do the following: • Isolate electrical power from the RLS before releasing the parking brake. • Reset the parking brake electrical power to the RLS.

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before

restoring

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Automatic Accumulator Recharging (Ladder in UP position) Hydraulic accumulator (1, Figure 32-10) ensures the ladder is held in the fully raised position. However, pressure loss can occur mainly due to external leaks in hydraulic lines and fittings. The RLS will automatically activate the power pack and recharge the accumulator. Refer to Figure 32-10.

While the RLS hydraulic pressure is low, the ladder may move a short distance from its upper limit. The RLS will sense this movement and reposition the ladder while the accumulator is being charged. Ladder movement is sudden and forceful. Accumulator recharging occurs normally when the truck is being operated. When the truck is stopped and the parking brake is applied, no recharging will occur. During maintenance, if the ladder must be in the UP position with power on and the ladder moves from its upper limit, the RLS will sense this movement and reposition the ladder if the parking brake is inadvertently released. NOTE: This unplanned ladder movement can be eliminated by ensuring that power has been isolated from the RLS before attempting maintenance on other parts of the truck.

FIGURE 32-10. HYDRAULIC ACCUMULATOR 1. Hydraulic Accumulator

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PREVENTIVE MAINTENANCE PROCEDURES Use the following maintenance procedures to ensure proper retractable ladder system operation. Daily Inspection 1. Visually inspect the ladder for mechanical damage. If movement is impaired in any way, the assembly must be removed for repair. 2. Visually inspect for cleanliness. Ensure the ladder is dry and free of grease and oil. 3. Ensure the correct oil level is maintained in the reservoir, approximately center of the sight glass. 4. Raise and lower the ladder. Check for loose parts or any adverse noise conditions.

6. Ensure the control box is properly sealed and free of moisture. 7. Check the truck electrical supply. With the engine on, the alternator supply voltage to the ladder system controls must not exceed 30VDC. With the engine off, the battery supply voltage must not fall below 21VDC. NOTE: If the battery voltage drops below 21VDC or exceeds 30VDC, damage to the system’s electronic components may result. 24 to 28VDC is required for proper ladder system operation. 8. Check all electrical connections in the RLS circuit for security.

5. Ensure the movement alarm and both up and down LEDs operate properly. 6. Check for any change in equipment appearance, especially that which will effect the stability of the ladder system.

Ensure the area is clear of equipment and personnel prior to this check.

250 Hour Inspection 1. Check for loose or missing hardware, especially those securing the ladder to the truck. 2. Operate the ladder through its complete cycle two times and check for: a. Adverse noise conditions. b. Bent or misaligned structures, such as steps and sides, that may restrict the movement of the ladder. Inspect the operation of the ladder in a vertical plane (viewed from the front). The ladder must move up and down relative to the actuator box. 3. Inspect the actuator box and the ladder for deposits of foreign materials, such as dirt, mud, or debris, that could effect the proper operation of the ladder. 4. Check the range of functions of the ladder system, including remote switches and parking brake interlock. Ensure the LED on the remote switch, as well as the audible alarm, indicate correctly during each cycle. 5. Check the condition of all wiring and electrical harnesses, inside and outside of the stainless steel control box, for physical damage.

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9. Check the parking brake function by releasing the parking brake with the ladder in the DOWN position. The ladder must raise.

10. Visually inspect all hydraulic lines and fittings for leaks. Repair any leaks.

Ensure covers are used when maintenance is performed on the hydraulics system to prevent dirt and debris from entering the system. 11. Ensure the correct oil level is maintained in the reservoir. Refer to Check Reservoir Oil Level for more information. 5000 Hour Inspection 1. Complete the 250 Hour Inspection. 2. Drain, flush and re-fill the hydraulic oil reservoir. Refer to Changing RLS Fluid.

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SERVICING

Changing RLS Fluid

Check Reservoir Oil Level

Hydraulic oil becomes contaminated over time and this may impact RLS operation. Therefore, it is recommended that the oil in the RLS be changed at least once a year. During oil replacement, it is recommended that the reservoir be flushed to remove any debris that may have accumulated in order to avoid contaminating the new oil.

Ensure that all necessary safety guidelines have been observed before attempting to check the oil level in oil reservoir (4, Figure 32-11). In addition, ensure the ladder is in the fully lowered position. Visually check all hydraulic oil lines and fittings for leaks. DO NOT top-off the ladder’s oil reservoir if leaks are found. Replace defective parts and repair any leaks that are found. After all leaks have been repaired, service the reservoir’s oil level. NOTE: It is recommended that any hydraulic oil to be used for filling or adding to the hydraulic system should be routed through a 3-micron filter device prior to use.

To change the RLS hydraulic oil: 1. Remove the plug from fill port (2, Figure 32-11). 2. Remove oil heater (3) from reservoir (4) and allow the oil to drain into an acceptable container. DO NOT damage the heating end of the oil heater. 3. Flush the interior of the reservoir with a cleaning solvent and allow used solvent to drain into an acceptable container. 4. Re-install oil heater (3). DO NOT overtighten. 5. Re-fill the reservoir through fill port (2) with the correct quantity and type of clean, filtered hydraulic oil. 6. Re-install plug in the fill port. 7. Operate the ladder through two complete up and down cycles. 8. Re-check the oil level through sight glass (1). Top-off as needed. DO NOT overfill. NOTE: After changing the oil, the RLS should be operated through its full range of motion at least two times. This is to expel any air that may be present, which would otherwise destroy the seals in the hydraulic system.

FIGURE 32-11. POWER PACK RESERVOIR 1. Sight Glass 2. Fill Port

3. Oil Heater 4. Reservoir

To service the power pack reservoir: 1. Remove cap from fill port (2, Figure 32-11). 2. Use the MAX indicator mark on the sight glass to determine the correct oil level approximately center of the sight glass. 3. If necessary, add the correct quantity and type of hydraulic oil. DO NOT overfill. 4. Re-install plug.

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Cleaning the RLS Depending on the operating environment, the RLS should be cleaned frequently to extend the life of the equipment and to lessen the risk of personal injury during use.

Diagnostic information is accessible to the user in four ways: 1. Continuous System Monitoring Real time RLS status is available via the in-cab control panel display. Current ladder position (UP, DOWN, GOING UP or GOING DOWN) and system faults and/or errors are clearly displayed with visual and audible in-cab control panel indications. No user ID password is required for this function.

DO NOT aim high-pressure spray equipment at or near the RLS power pack, actuator box, bearings or electrical harnesses. Moisture introduced in the electrical harnesses may result in uncontrolled ladder movement. To clean the RLS: 1. Use an approved degreaser to remove or loosen unwanted debris from the ladder step surfaces. Use a nylon bristle brush to remove debris from the ladder steps if necessary. 2. Use high-pressure spray equipment to remove the degreaser and debris. DO NOT aim highpressure spray equipment at or near the RLS power pack, actuator box, bearings or electrical harnesses. Moisture introduced into the electrical harnesses may result in uncontrolled ladder movement.

RLS DIAGNOSTICS

2. Historic System Data Review The last 50 logged RLS events can be viewed directly from the in-cab control panel display. Each entry is time and date stamped for easy identification. No user ID password is required for this function.

Description of Diagnostics Features As mentioned earlier in this chapter, the in-cab control panel monitors, stores and reports RLS operational data. The in-cab control panel is designed to provide the user with RLS maintenance scheduling, system fault identification and the development of an information database for individual RLS reporting.

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3. Comms Integrity Monitoring The ‘Diagnostics’ menu option is accessed from the Controller Menu area of the In-Cab Display. A comprehensive list of system events can be viewed directly on the display providing additional fault finding capabilities. All events are listed as either active or inactive for ease of identification. This function also monitors system communications integrity between the InCab Control Panel and the Main Control Board in the Power Pack. The results are displayed as a percent value for various time periods up to 24 hours. For a healthy system, the percentages should be no lower than 80%. No User ID password is required.

4. System Event Logs A continuous data log of system events is stored in non-volatile memory for download to a USB key for transfer to a PC or laptop computer. The file can then be translated into a usable Microsoft Excel file using the Microsoft Excel interface provided on the USB key supplied with the RLS. The log is capable of storing up to 3,000 time and date stamped events. Set up in a rolling log format, the earliest data is overwritten when the log is full, providing a continuous bank of data available for review at any time. No User ID password is required for this function.

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Continuous System Monitoring Real time identification of the current ladder position is available via the animated ladder graphic and accompanying text on the in-cab control panel display. The following illustrations indicate a ladder in motion going up (raising) and going down (lowering). While the ladder is in motion, the applicable [UP] or [DOWN] button on the control panel will flash.

When the ladder has reached the raised or lowered positions, the animated graphic will stop moving and the text “UP” or “DOWN” will appear on the display screen. Once the ladder has completed its motion cycle and is either in the up or down position, the applicable [UP] or [DOWN] button on the control panel will remain lit continuously.

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Historic System Data Review

Comms Integrity Monitoring

To view up to 50 of the last logged events:

The Comms Integrity interface provides a simple health check for the communications between the incab control panel and the main controller in the power pack. To access this screen:

1. Press the [ENTER] or [EXIT] buttons on the incab control panel. 2. From the CONTROLLER MENU screen, use the [DOWN] button to scroll to “Show Recent Logs” and press the [ENTER] button. 3. To view each entry, use the [DOWN] button to scroll.

1. From the CONTROLLER MENU screen, use the [DOWN] button on the in-cab control panel to scroll down to Diagnostics and press the [ENTER] button. 2. Use the [DOWN] button to scroll to DIAGNOSTICS and press the [ENTER] button. A comprehensive list of system events are tagged as either ‘active’ or ‘inactive’ for quick identification of system faults that are currently active and need immediate attention. Comms Integrity is listed as a percent value. These percent values indicate communications integrity for the last 30 seconds, 15 minutes, 4 hours and 24 hours.

NOTE: The events are listed from the last time and date stamped event (1/50) through to the first in the series (50/50). Pressing and holding the DOWN or UP button will continuously scroll through the list until the button is released. NOTE: The In-Cab Control Node contains a rechargeable battery to maintain the clock. If the Date and Time set screens appear on start up the internal battery will require charging. Charge times are as follows: Standby Time (Fully Charged) – 3 Weeks Time to fully Charge – 5 Hours Minimum Charge Time – 1.5 Hours NOTE: This battery status only affects Time and Date settings. IT DOES NOT AFFECT NORMAL LADDER, STAIRWAY OR STEP OPERATION.

If intermittent, unreliable operation of the ladder, stairway or step access system is experienced, a check of the Comms Integrity entries is recommended. For a healthy system, the percentages should be no lower than 80%. If the percentages fall below this prescribed value, the possible symptoms will be: • Intermittent communications errors shown on the controller • Unreliable/unpredictable ladder operation • No ladder operation The possible causes are: • Poor/degraded wiring • Substantial electrical interference • An internal fault with the controller hardware

Log and Service Information

ues.

The DIAGNOSTICS screen provides additional information following the Comms Integrity displayed val-

These listings are:

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• When the logs were last cleared.

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• The percentage of the logging space currently being used. A total of 3,000 logging entries are available.

3. The message “Please insert a USB key” will then be displayed.

• The system software code version. • The number of operations remaining until the next level 1 or level 2 service is required. System Event Logs The data retrieval feature of the in-cab control panel allows the simple download of RLS operational data pertaining to the day-to-day operation of the RLS. All events, including raising and lowering of the ladder and fault indications, are time and date stamped to provide a sequential record of all RLS operations. To access the data log from the main display screen: 1. Press the [ENTER] or [EXIT] buttons on the incab control panel.

4. Insert a USB key in the slot on the right hand side of the in-cab control panel.

2. From the CONTROLLER MENU screen, use the [DOWN] button to scroll to “Upload Logs to USB” and press the [ENTER] button.

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5. The logged data will begin to download automatically once the USB key is inserted. Download progress is displayed as an incremental percentage value.

SECURITY ACCESS LEVELS The software program driving the In-Cab and Hydraulic Control Nodes is factory configured for proper RLS operation. If it becomes necessary to adjust any timing parameters through the In-Cab Control Panel access will be required to the Controller Config menu option. To avoid the possibility of accidental or detrimental changes to timing parameters, graded levels of security access can be initiated by the user. There are three levels of access available NONE, RESTRICTED and COMPLETE. The three access levels and their privileges are as follows: Access Level 1 – NONE No User ID is required for this level. Privileges:

6. When the download is complete, press the [ENTER] or [EXIT] buttons to confirm the data transfer and remove the USB key. Data can now be transferred to a PC or laptop computer for review.

• View ladder, stairway or step setup (System Settings) • Upload logs to USB • View recent log entries • Read Diagnostics • Clear Level 1 service prompt Access Level 2 – RESTRICTED A valid User ID is required for access. (012345 – Default password) See User ID-Access Privileges Table for access privileges. Access Level 3 – COMPLETE A Master User ID is required for access. See User ID-Access Privileges Table for access privileges.

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User Access Privileges PARAMETER

DESCRIPTION

ACCESS LEVEL

Vehicle ID

15 character vehicle identifier

RESTRICTED

Ladder type

SINGLE action or DOUBLE action ladder (Double – Swing Ladder only)

RESTRICTED

UP movement time for Ladder UP

Maximum length of time for Ladder UP movement (1-300 sec) Default – 18 secs

RESTRICTED

IN movement time for Ladder UP (Swing Ladder only)

Length of time for Ladder IN movement (1-300 sec) Default – 6 secs

RESTRICTED

DOWN movement time for Length of time for Ladder DOWN movement into cradle Ladder UP (1-300 sec) Default – 3 secs (Swing Ladder only)

RESTRICTED

UP movement time for Ladder DOWN (Swing Ladder only)

Length of time for Ladder UP movement out of cradle (1-300 sec) Default – 3 secs

RESTRICTED

OUT movement time for Ladder DOWN (Swing Ladder only)

Length of time for Ladder OUT movement (1-300 secs) Default – 6 secs

RESTRICTED

DOWN movement time for Ladder DOWN (Swing Ladder only)

Length of time for Ladder DOWN movement driven by power pack (1-300 sec) Default – 10 secs

RESTRICTED

DOWN movement time for Ladder DOWN

Length of time for Ladder DOWN movement driven by power pack (1-300 sec) Default – 2.5 secs

RESTRICTED

DOWN run-on time for Ladder DOWN

Length of time for Ladder DOWN movement without power pack (1-300 sec) Default – 4 secs

RESTRICTED

Wiring Set Up

Configure the switching status for the Park Brake – NO/NC E Stop – NO/NC Inhibit connected – Yes/No

RESTRICTED

Boarding Light

Length of time for boarding light to switch on after ladder movement initiated. Default – 30 secs

RESTRICTED

Menu timeout

Period of time without human input after which the display reverts to the main screen. Default – 300 secs

RESTRICTED

Screen timeout

Period of time without human input after which the display switches off and user information is cleared. Default – 600 secs

RESTRICTED

Buzzer time

Frequency of buzzer beeps for fault reminder. Default – 60 secs

RESTRICTED

Cabin Lockout

If set to ON, user can only initiate a ladder movement from a remote control switch panel. If OFF, user may initiate a ladder movement from the cabin controller.

RESTRICTED

Date and Time

Used for synchronizing data log

RESTRICTED

Power Pack Timings

Power Pack on-time for accumulator recharge (1-300 sec) Default – 3 secs

COMPLETE

Power Pack Timings

Power Pack on-time for accumulator recharge after ladder UP (1-300 sec) Default – 3 secs

COMPLETE

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PARAMETER

DESCRIPTION

ACCESS LEVEL

User Setup

In addition to the built-in Master User who has COMPLETE access, three additional users may be configured.

COMPLETE

Phone Number

15 character contact details

COMPLETE

Clear Logs

Clear the current log of system event data

COMPLETE

Set Defaults

Reset the current System configuration to default settings

COMPLETE

Level 1 Service Interval

Number of Access System operations before Level 1 service prompt is displayed on screen

COMPLETE

Level 2 Service Interval

Number of Access System operations before Level 2 service prompt is displayed on screen

COMPLETE

Overdue Interval

Number of operations after Level 1 and Level 2 service prompts appear before a Service Overdue fault is logged

COMPLETE

USER ID – PASSWORD Allowance has been made for up to four, separate User ID accounts to be configured and managed in the RLS In-Cab Control Panel. A Master User ID is pre-configured to allow one user Complete Level 3 Access and a second User (User 1) Restricted Level 2 Access. As with all User ID access a valid password must be input before access is granted. To access this screen: 1. From the In-Cab Control Display Mode press either the [ENTER] or [EXIT] buttons to move to the CONTROLLER MENU as shown below.

2. Use the [DOWN] button to scroll to CONTROLLER CONFIG and press [ENTER]. A valid User ID can now be entered. A valid User ID should consist of up to 6 letters, numbers and/or characters from the options shown in the Password Character table. Use the [UP] and [DOWN] buttons to scroll through the list. After selecting the correct value for a password field, use the [RIGHT] button to scroll to the next field until complete. Use the [LEFT] button to scroll back through the fields. When the password fields are set, press [ENTER] to accept.

Sequential Field Value Selection Options Letters Alphabetical A to Z (Capitals) Numbers

Numerical 0 to 9

Characters

:;?@

Password Character Table From Initial Field Marker: >_

<

Pressing UP

_0123456789 : ; < = > ? @ ABCDEFGHIJKLMNOPQRSTUVWXYZ

Pressing DOWN

_ZYXWVUTSRQPONMLKJIHGFEDCBA @ ? > = < ; : 9876543210

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USER ID – NEW USER SETUP

SYSTEM FAULTS

Once access to the CONTROLLER CONFIG options is complete a series of menu options will be available. To view currently set User ID’s (including the Master User) or add a new User ID:

The in-cab control panel is programmed to display, record, store and diagnose 25 different types of faults. Faults must be acknowledged and corrected to ensure uninterrupted ladder operation.

1. Use [DOWN] button to scroll to USER SET UP and press [ENTER]. To add a new User ID, use [DOWN] button to scroll to the next unassigned User ID (from new this will be User 2) and assign the password using the same method as that used to enter the password to access the CONTROLLER CONFIG interface.

In addition, every normal ladder request is logged. A maximum of 3,000 log entries may be stored before data is overwritten. Every detectable fault type is classified as either high or low priority.

2. After entering the new User ID password press [ENTER].

• A low priority fault will result in a buzzer sounding at regular intervals.

Another window will open with a prompt to either [SAVE] the changes or [EXIT] without saving. NOTE: The Master User password is fixed and can’t be changed. For added security the User 1 default password should be changed as the default is listed in this manual. Copies of any assigned passwords should be stored in a secure place to avoid loss as the result of personnel moving to new positions or mine sites.

• A high priority fault will result in a continuous alarm on the in-cab control panel.

All system faults (excluding high or low voltage detected with the ladder at rest) require user acknowledgement. A message will be displayed on the control panel display screen listing all faults in order of priority. All alarm conditions must be acknowledged by pressing the [EXIT] or [ENTER] buttons on the in-cab control panel. If a fault condition exists after being acknowledged (for example, the pump coil remains disconnected), a FAULT IN SYSTEM message will be displayed on the display screen and the buzzer will continue to sound. Refer to the next series of tables for the 25 faults that must be acknowledged to ensure uninterrupted ladder operation. NOTE: When an alarm indicates that a fault exists, it is the sole responsibility of the operator to investigate the condition of the ladder before placing the truck into service.

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Fault Type 1: Communications error Fault Type 1 Priority

High

Description

A communications error occurs when the communications link between the in-cab control panel and the power pack have had no positive transmissions for a period of two seconds or more.

Possible Cause(s)

May be caused by deteriorated or incorrect wiring, large amounts of electrical noise interference, or an electrical failure in the control system.

Operator Alerting System Response

The in-cab control panel will display a fault message and list all of the faults in order of priority. The in-cab control panel will sound a continuous alarm.

Resulting Problem(s) Any current ladder movement will be completed, new ladder movements cannot be initiated. Operator Acknowledgment Required?

Yes.

Fault Type 2: 10A/15A fuse blown Fault Type 2 Priority

High

Description Possible Cause(s)

Faulty wiring or a damaged coil can cause this also.

Operator Alerting System Response

The in-cab control panel will display a fault message and list all of the faults in order of priority. The in-cab control panel will sound a continuous alarm.

Resulting Problem(s) If the 10A fuse is blown the ladder, stairway or step cannot operate. If the 15A fuse is blown the light/siren will not operate. Operator Acknowledgment Required?

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Yes.

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Fault Types 3, 4, 5, 6, 7: Up/Down/In/Out pump coil short or disconnected (In/Out only relevant to Swing Ladder) Fault Types

3, 4, 5, 6, 7

Priority

High

Description

This fault occurs when an open or shorted circuit is detected on the corresponding output.

Possible Cause(s)

May be caused by a failure of the détente solenoid coil driver or pump solenoid, or poor wiring.

Operator Alerting System Response

The in-cab control panel will display a fault message and list all of the faults in order of priority. The in-cab control panel will sound a continuous alarm.

Resulting Problem(s) Any current ladder movement will be stopped, new ladder movements cannot be initiated. 10A fuse in power pack may blow. Operator Acknowledgment Required?

Yes.

Fault Type 8: Power pack recharge too long Fault Type 8 Priority

High

Description

This fault occurs when the pump continues to run three seconds after the pump driver output has been deactivated.

Possible Cause(s)

May be caused by frozen contacts in the pump driver coil, or poor wiring.

Operator Alerting System Response

The in-cab control panel will display a fault message and list all of the faults in order of priority. The in-cab control panel sound provide a continuous alarm.

Resulting Problem(s) None. Operator Acknowledgment Required?

M32-34

Yes.

Retractable Ladder System

M32002

Fault Type 9: Inhibit relay fail Fault Type 9 Priority

High

Description Possible Cause(s)

May be caused by defective relay coil connected to the inhibit output or internal damage to the controller.

Operator Alerting System Response

The in-cab control panel will display a fault message and list all of the faults in order of priority. The in-cab control panel will sound a continuous alarm.

Resulting Problem(s) None. Operator Acknowledgment Required?

Yes.

Fault Types 10, 11: Light/Siren relay failure Fault Types 10, 11 Priority

High

Description

This fault occurs when an open or shorted circuit is detected on the Light or Ladder Moving (a.k.a. Siren) output.

Possible Cause(s)

May be caused by a failure of the light/ladder moving apparatus, or poor wiring.

Operator Alerting System Response

The in-cab control panel will display a fault message and list all of the faults in order of priority. The in-cab control panel will sound a continuous alarm.

Resulting Problem(s) Boarding Light or Ladder Moving Contact will not be operated. 15A fuse may blow. Operator Acknowledgment Required?

M32002

Yes.

Retractable Ladder System

M32-35

Fault Type 12: Ladder came off upper limit Fault Type 12 Priority

High

Description

This fault occurs when the UP limit switch opens and the ladder is supposed to be in the fully raised position.

Possible Cause(s)

May be caused by a mechanical failure of the system, low pressure or a fault with the limit switch or poor wiring.

Operator Alerting System Response

The in-cab control panel will display a fault message and list all of the faults in order of priority. The in-cab control panel sound provide a continuous alarm.

Resulting Problem(s) The power pack will attempt to re-position the ladder to the fully raised position for the length of time defined by the “Power Pack Recharge” setting. Operator Acknowledgment Required?

Yes.

Fault Type 13: Ladder did not reach limit Fault Type 13 Priority

High

Description

This fault occurs when the UP movement of the RLS is completed due to a time-out rather than the system detecting a closure of the UP limit switch.

Possible Cause(s)

May be caused by the ladder having a mechanical obstruction that prevents it from closing within the allowed time, or a fault with the limit switch or poor wiring.

Operator Alerting System Response

The in-cab control panel will display a fault message and list all of the faults in order of priority. The in-cab control panel will sound a continuous alarm.

Resulting Problem(s) None. Operator Acknowledgment Required?

M32-36

Yes.

Retractable Ladder System

M32002

Fault Type 14: Ladder stayed on limit Fault Type 14 Priority

High

Description

If the UP limit switch is detected to have remained closed at the completion of a DOWN ladder, stairway or step operation will continue and be controlled by preset timing parameters.

Possible Cause(s)

A fault with the limit switch or wiring to the limit switch.

Operator Alerting System Response

The in-cab control panel will display a fault message and list all of the faults in order of priority. The in-cab control panel will sound a continuous alarm.

Resulting Problem(s) Ladder, stairway or step operation continues but the UP limit switch is disregarded; all ladder movement is controlled with timers. Operator Acknowledgment Required?

Yes.

Fault Type 15: Low oil level Fault Type 15 Priority

High

Description

If the oil level input determines that the oil level is too low this error is flagged. The Park Brake must be set to ensure an accurate reading. When the park brake is released the system disregards the oil level input.

Possible Cause(s)

Reservoir oil level not maintained or an oil leak in the hydraulic system.

Operator Alerting System Response

The in-cab control panel will display a fault message and list all of the faults in order of priority. The in-cab control panel will sound a continuous alarm.

Resulting Problem(s) None (until oil level is too low for operation). Operator Acknowledgment Required?

M32002

Yes.

Retractable Ladder System

M32-37

Fault Type 16: System voltage over 18V during movement Fault Type 16 Priority

Low

Description

This fault occurs when the RLS voltage is measured to be under 18VDC during a ladder movement.

Possible Cause(s)

Often caused when the truck is under an electrical load (for example, cranking for ignition) while the ladder is moving.

Operator Alerting System Response

The in-cab control panel will display a fault message and list all of the faults in order of priority. The in-cab control panel will sound a buzzer at regular intervals.

Resulting Problem(s) As a continued fault, this may shorten the operational life of the RLS hydraulic pump or damage the RLS hydraulic pump. Operator Acknowledgment Required?

Yes.

Fault Type 17: System voltage under 18V Fault Type 17 Priority

Low

Description

This fault occurs when the RLS voltage is measured to be under 18VDC. The RLS should not be operated under these conditions, but the ladder is not locked-out to prevent use.

Possible Cause(s)

Often caused when the truck is under an electrical load (for example, cranking for ignition).

Operator Alerting System Response

The in-cab control panel will display a fault message and list all of the faults in order of priority. The in-cab control panel will sound a buzzer at regular intervals.

Resulting Problem(s) None. Operator Acknowledgment Required?

M32-38

No.

Retractable Ladder System

M32002

Fault Type 18: System voltage over 31V Fault Type 18 Priority

Low

Description

This fault occurs when the RLS voltage is measured to be over 31VDC. The RLS should not be operated under these conditions, but the ladder is not locked-out to prevent use.

Possible Cause(s)

May indicate the truck’s alternator is not functioning correctly.

Operator Alerting System Response

The in-cab control panel will display a fault message and list all of the faults in order of priority. The in-cab control panel will sound a buzzer at regular intervals.

Resulting Problem(s) None. Operator Acknowledgment Required?

No.

Fault Types 19, 20: Remote UP and/or DOWN toggle held too long (when equipped) Fault Types 19, 20 Priority

Low

Description

This fault occurs when the upper remote access terminal’s toggle switch is held in either the UP or DOWN position for more than 10 seconds. The logged event and displayed error message will distinguish the actual location of the fault.

Possible Cause(s)

May be caused by a user holding the toggle switch for too long, an accumulation of dust/mud in the contact or mechanical damage to the unit.

Operator Alerting System Response

The in-cab control panel will display a fault message and list all of the faults in order of priority. The in-cab control panel will sound a buzzer at regular intervals.

Resulting Problem(s) Current ladder movement will be completed normally. The toggle switch may not be used to initiate ladder movement until the fault has been cleared. Operator Acknowledgment Required?

M32002

Yes.

Retractable Ladder System

M32-39

Fault Type 21: Accumulator recharge > than once/hour Fault Type 21 Priority

Low

Description

This fault occurs when the accumulator requires recharging due to low pressure more than once per hour.

Possible Cause(s)

Often caused by a fault with the RLS hydraulic components.

Operator Alerting System Response

The in-cab control panel will display a fault message and list all of the faults in order of priority. The in-cab control panel will sound a buzzer at regular intervals.

Resulting Problem(s) None. Operator Acknowledgment Required?

Yes.

Fault Type 22: System raised by park brake Fault Type 22 Priority

Low

Description

When the system is in the DOWN position and the park brake is released the ladder, stairway or step will automatically be raised. This is not the correct operation of the system so it is logged as a fault.

Possible Cause(s)

Use of the park brake instead of the in-cab Control Panel to raise the ladder, stairway or step.

Operator Alerting System Response

The in-cab control panel will display a fault message and list all of the faults in order of priority. The in-cab control panel will sound a buzzer spaced at regular intervals.

Resulting Problem(s) None. Operator Acknowledgment Required?

M32-40

Yes.

Retractable Ladder System

M32002

Fault Types 23, 24: Levels 1 and 2 service overdue Fault Types 23, 24 Priority

Low

Description

When the first, second and overdue service intervals have been exceeded by the operations count an error is logged and a user acknowledgement is requested.

Possible Cause(s)

Ladder, stairway or step has not been serviced within the acceptable number of operations. If the service has been completed then the service request has not been cleared from the system.

Operator Alerting System Response

The in-cab control panel will display a fault message and list all of the faults in order of priority. The in-cab control panel will sound a buzzer spaced at regular intervals.

Resulting Problem(s) None. Operator Acknowledgment Required?

Yes.

Fault Type 25: Levels 1 and 2 service complete Fault Type 25 Priority

Low

Description

Once the ladder, stairway or step has been serviced a user with the Master User ID must clear the service request. When the service request is cleared a Level 1 and/or 2 Service Complete entry will be logged.

Possible Cause(s) Operator Alerting System Response

The in-cab control panel will display a fault message and list all of the faults in order of priority. The in-cab control panel will sound a buzzer spaced at regular intervals.

Resulting Problem(s) None. Operator Acknowledgment Required?

M32002

Yes.

Retractable Ladder System

M32-41

DATA MANAGEMENT To review the downloaded log data from the in-cab control panel, there is a Microsoft Excel interface loaded on the USB key supplied with the RLS unit. The data is presented in summary view and as the complete log. The interface allows additional sorting of the complete log for custom report development. Log Files Even though the log files can be stored on the USB key supplied with the RLS unit, it is recommended that the log files be transferred to a laptop computer or PC for long-term file management. The standard file created on the USB key during data download has the following filename and format:

For example, a typical filename could be 08072302.RLS, which is the 2nd .RLS file created on July 23, 2008. It is important that the correct date and time are set on the in-cab control panel for the following reasons: • The year, month and day information used in the filename is taken from the on-board clock. • The logs are time and date stamped to provide an accurate real time record of ladder system events. To be of value in troubleshooting faults, the logs must correlate with the actual events.

YYMMDDIN.RLS, where • YY is the last two digits of the current year • MM is the current month • DD is the current day • IN is the file index. If multiple files are created on the same USB key, each subsequent file will be incrementally indexed. If the log is cleared via the in-cab control panel, the file index will begin again at 00 for the next download. • .RLS is the default RLS file format from the raw hexidecimal-encoded data used in the RLS operating system.

M32-42

Retractable Ladder System

M32002

Generating Reports Once the .RLS files have been retrieved, they need to be translated into a usable format. The Microsoft Excel file Komatsu_RLS_1V40.xls is loaded on the USB key supplied with the RLS unit. This interface will generate reports from the .RLS files.

1. Open the Komatsu_RLS_1V40.xls file directly from the USB key or from a stored location on a laptop computer or PC. NOTE: The file Komatsu_RLS_1V40.xls contains a macro which will generate a Windows Security Warning when opened. The Enable Macros option (Office 2003) or Enable this content option (Office 2007) will have to be chosen in order to continue.

The following sequence describes the generation of a report from a raw file to an Excel spreadsheet:

M32002

Retractable Ladder System

M32-43

2. The Microsoft Excel Home Page interface (in Office 2007) will then be displayed as shown below.

3. To load a file to view the logged data, click the [Load File] button in the Action box as shown below.

M32-44

Retractable Ladder System

M32002

4. After clicking the [Load File] button, the “Clear Data First?” message will appear. Click [Yes] to clear previously-loaded data from the spreadsheet.

5. From the File Open window, browse to the .RLS file location, choose the required file and double-click or click the [Open] button to open the file in the Komatsu_RLS_1V40.xls interface.

M32002

Retractable Ladder System

M32-45

6. The file should open at the Summary Report Page as shown in the figure below. This report presents a summary of the current RLS timing Settings, General system timings, RLS Error Counters (all events as indicated at the in-cab control panel) and time and date stamped Log Information.

M32-46

The tabs located at the bottom of the currently opened worksheet provide access to the three available worksheet data selections in the Komatsu_RLS_1V40.xls interface. These are the Home page, Report page and Log Data page as shown in the figure below.

Retractable Ladder System

M32002

7. To view the Log Data, click on the Log Data tab at the bottom of the worksheet as shown in the figure above. The page should appear as shown in the figure below.

M32002

Retractable Ladder System

M32-47

8. To preview specific events easily, use the Highlight Events drop-down list to choose an event type. Then select a color highlight and the [Highlight Events] button to highlight all the same events throughout the log in the same color. The [Clear Highlighting] button will remove the colored highlighting from all the entries and allow a further selection if required. The [Remove Events] button will remove all highlighted events from the log.

Use the [Remove Events] button with extreme caution as it completely removes events from the file. To retain the log file in its original state, use the “Save As” option after removing the events to ensure the original file remains intact.

M32-48

Retractable Ladder System

M32002

9. Events can also be sorted by selecting one of the four options in the Sort Log dialogue box. The logged events will then be re-arranged according the Sort Log selection chosen. By default, it is set to Log Type.

MENU DIAGRAMS The following pages contain diagrams to assist the user in navigating through the various menus of the in-cab control panel functions. Controller Config Figure 32-12 provides information for changing or updating RLS parameters such as ladder and power pack timing. Contact Information Figure 32-13 provides information for contacting Komatsu with technical-related issues regarding the RLS. Show Recent Logs Figure 32-14 provides information on viewing RLS operational data on the in-cab control panel. System Settings Figure 32-15 provides information on viewing current RLS system settings. Upload Logs to USB Figure 32-16 provides information on transferring RLS operational data to a USB key. The data can then be downloaded to a computer or database for analysis. Diagnostics Figure 32-17 provides a comprehensive list of system events and the Comms Integrity of the system displayed as a percentage.

M32002

Retractable Ladder System

M32-49

MAIN ACCESS DISPLAY Displays current ladder status

To access the CONTROLLER MENU press the [ENTER] or [EXIT] buttons

CONTROLLER MENU Displays Main Root Menu Options

System Settings Displays Currently Programmed System Settings

Use the [DOWN] button to scroll to Controller Config then press [ENTER]

Controller Config Password access to change the System Settings

To return to MAIN ACCESS DISPLAY press the [EXIT] button.

Show Recent Logs Displays the 50 latest events time & date stamped

ENTER USER ID Enter password for access. Use the arrow keys to select. To change a Controller Configuration Option, use the [UP] and [DOWN] buttons to set an alpha numeric code or make a selection (the [LEFT] and [RIGHT] buttons will move the cursor across the fields). When complete, press [ENTER] to accept. CONTROLLER CONFIG OPTIONS Vehicle ID (SET VEHICLE ID) Ladder Type (SET LADDER TYPE - double action Swing Ladder only) Ladder Timing (Adjust LADDER TIMING UP drive time in 0.1 sec increments)

Upload Logs to USB Allows the download of the data log via USB Key

Wiring Setup (Set INHIBIT, E STOP, PARK BRAKE Relays) Inhibit (Yes/No), E Stop (NO/NC), Park Brake (NO/NC) Power Pack Timing (Adjust POWER PACK TIMING for Accumulator Recharge in 0.1 sec increments)

Diagnostics Displays a summary of Events and Comms Integrity

Ph: +555-555-1212 Displays Komatsu Contact Details

Boarding Light (Adjust BOARDING LIGHT ON TIMING in 1 sec increments) Display Options Set Menu Timeout (Adjust Menu Display Timeout in 10 sec increments) Set Screen Timeout (Adjust Screen Display Timeout in 10 sec increments) Set Beep Pause Time (Adjust Menu Display Timeout in 1 sec increments) In Cab Lock (Set IN CAB Lockout to ON or OFF) User Set Up (View Password Access for the Master User and Restricted User 1 plus set Password Access for additional Users 2 and 3) Set Date/Time (Set Date and Time for Data Log Synchronization) Set Phone Number (Change Phone Number for Komatsu Service) Clear Logs (Clear current data log - Press [ENTER] to clear or [EXIT] to escape) Set Defaults (Return all Settings to their Default Values) Servicing Setup (Set Service Interval Indicators) Set Level 1 Service Interval (0 to 30,000 operations) Set Level 2 Service Interval (0 to 30,000 operations) Set Service Overdue Interval (20 to 5,000 operations)

FIGURE 32-12. Control Panel Menu Structure - Controller Config

M32-50

Retractable Ladder System

M32002

MAIN ACCESS DISPLAY Displays current ladder status

To access the CONTROLLER MENU press the [ENTER] or [EXIT] buttons

CONTROLLER MENU Displays Main Root Menu Options

To view the Recent Logs, use the [UP] and [DOWN] buttons to scroll through the logged data for the last 50 entries. SHOW RECENT LOGS OPTION

System Settings Displays Currently Programmed System Settings

Controller Config Password access to change the System Settings

Show Recent Logs Displays the 50 latest events time & date stamped

Upload Logs to USB Allows the download of the data log via USB Key

Diagnostics Displays a summary of Events and Comms Integrity

CONTACT DETAILS For Technical assistance, call: +555-555-1212 Or visit www.abc123.com for contact details

The Contact Detail information is displayed as shown in the text box to the left. Should you require technical assistance you can call Komatsu using the displayed number.

Use the [DOWN] button to scroll to Ph Number then press [ENTER]

Ph: +555-555-1212 Displays Komatsu Contact Details

To return to MAIN ACCESS DISPLAY press the [EXIT] button.

NOTE: The Technical Assistance contact phone number can be changed through Controller Config. Password access will be required to enter the Controller Config sub menu options. If Komatsu approved Technical Assistance is available locally, input that contact number.

FIGURE 32-13. Control Panel Menu Structure - Contact Information

M32002

Retractable Ladder System

M32-51

MAIN ACCESS DISPLAY Displays current ladder status

To access the CONTROLLER MENU press the [ENTER] or [EXIT] buttons

CONTROLLER MENU Displays Main Root Menu Options

System Settings Displays Currently Programmed System Settings

To view the current Recent Logs press the [UP] or [DOWN] buttons to scroll through the logged data for the last 50 entries

SHOW RECENT LOGS OPTIONS

Controller Config Password access to change the System Settings Use the [DOWN] button to scroll to Upload Logs then press [ENTER]

Show Recent Logs Displays the 50 latest events time & date stamped

50 LATEST EVENTS 1/50, 19/06/2008 14:31:34 Access Sys Raised by Command 2/50, 19/06/2008 16:55:23 Access Sys Lowered by Command

The Recent Log information is displayed as shown in the text box to the left with two time and date stamped vents being displayed simultaneously. Scrolling down will drop the top event and display the next two events.

To return to MAIN ACCESS DISPLAY press the [EXIT] button.

Upload Logs to USB Allows the download of the data log via USB Key

Diagnostics Displays a summary of Events and Comms Integrity

Ph: +555-555-1212 Displays Komatsu Contact Details

NOTE: The log is a rolling log. When full, it overwrites the earliest logged data. The actual data log capacity is 3,000 data points and is stored in a non-volatile memory providing a continuous bank of time and date stamped data available for download to a USB Key.

FIGURE 32-14. Control Panel Menu Structure - Show Recent Logs

M32-52

Retractable Ladder System

M32002

MAIN ACCESS DISPLAY Displays current ladder status

To access the CONTROLLER MENU press the [ENTER] or [EXIT] buttons

CONTROLLER MENU Displays Main Root Menu Options

To view the current System Settings press the [UP] or [DOWN] buttons to scroll through the options

SYSTEM SETTINGS OPTIONS Use the [DOWN] button to scroll to Upload Logs then press [ENTER] ID (displays vehicle number if set) Single or Double Action System (double action Swing Ladder only) System Settings Displays Currently Programmed System Settings

To return to MAIN ACCESS DISPLAY press the [EXIT] button.

Controller Config Password access to change the System Settings

Show Recent Logs Displays the 50 latest events time & date stamped

Upload Logs to USB Allows the download of the data log via USB Key

System IS - (Displays current ladder position – Up or Down) In Cab Lock - On or Off (default set to OFF) Solenoid ON Times System UP UP (default set at 18 seconds) IN (default set at 3 seconds) (Swing Ladder Only) DOWN (default set at 3 seconds) (Swing Ladder Only) System DOWN UP (default set at 3 seconds) (Swing Ladder Only) OUT (default set at 3 seconds) (Swing Ladder Only) DOWN (default set at 4 seconds) RUN ON (default set at 10 seconds) Power Pack ON Times Acc Recharge (default set at 3 seconds) System UP (default set at 3 seconds) Boarding Light (default set at 30 seconds) Menu Timeout (default set at 300 seconds) Screen Timeout (default set at 600 seconds)

Diagnostics Displays a summary of Events and Comms Integrity

Buzzer Pause (default set at 60 seconds) NOTE: All System Settings are User adjustable - see Controller Config

Ph: +555-555-1212 Displays Komatsu Contact Details

FIGURE 32-15. Control Panel Menu Structure - System Settings

M32002

Retractable Ladder System

M32-53

MAIN ACCESS DISPLAY Displays current ladder status

To access the CONTROLLER MENU press the [ENTER] or [EXIT] buttons

CONTROLLER MENU Displays Main Root Menu Options

System Settings Displays Currently Programmed System Settings

Controller Config Password access to change the System Settings

Show Recent Logs Displays the 50 latest events time & date stamped

To Upload Logs to USB, a USB Key will be required and is placed in the port on the lower right hand side of the In Cap Control Panel. Only insert the USB Key once the on screen prompt indicates to do so.

UPLOAD LOGS TO USB OPTION

Transferring data to USB key: X% complete

USB Processing Complete Enter/Exit to confirm

USB Device found, Initializing transfer

After inserting the USB Key the data transfer is automatic through the following three screen displays. On completion, press the [ENTER] or [EXIT] buttons to confirm the download.

Please Insert a USB Key

USB data transfer Failed, General Error Error Code: 12 Enter/Exit to Confirm

After pressing the [ENTER] button the display above should appear. Insert the USB Key into the USB port.

If there is no response to this screen prompt, the option will time out and the error message above will appear.

Use the [DOWN] button to scroll to Upload Logs then press [ENTER]

Upload Logs to USB Allows the download of the data log via USB Key

To return to MAIN ACCESS DISPLAY press the [EXIT] button.

Ph: +555-555-1212 Displays Komatsu Contact Details

NOTE: Once the above sequence is complete simply remove the USB Key from the Port.

FIGURE 32-16. Control Panel Menu Structure - Upload Logs to USB

M32-54

Retractable Ladder System

M32002

MAIN ACCESS DISPLAY Displays current ladder/stairway status

To access the CONTROLLER MENU press the [ENTER] or [EXIT] buttons

CONTROLLER MENU Displays Main Root Menu Options

System Settings Displays Currently Programmed System Settings

To view the current System Settings press the [UP] or [DOWN] buttons to scroll through the options

DIAGNOSTICS RECORDS OPTIONS Controller Config Password access to change the System Settings

Show Recent Logs Displays the 50 latest events time & date stamped

Upload Logs to USB Allows the download of the data log via USB Key

Active Events (A comprehensive list of system events indicated whether currently active or inactive). Comms Failed, 10A Fuse Blown, 15A Fuse Blown, Up Coil Failed, Down Coil Failed, In Coil Failed [Swing Ladder only], Out Coil Failed [Swing Ladder only], Pump Coil Failed, Power Pack Failed, Inhibit Relay Failed, Ladder Off Limit, Did Not Reach Limit, Stay on Limit, Low Oil Level [Future Inclusion], Under Voltage at Command, Under Volts, Over Volts, Top Remote UP Held, Top Remote DOWN Held, Low Remote UP Held, Low Remote DOWN Held, Pressure Recharge > 1 Hour, Raised by Park Brake, L1 Service Overdue, L2 Service Overdue. Comms Integrity (Monitors system communications integrity between the InCab Control Panel and the Main Control Board in the Power Pack. The results are displayed as a percent value for various time periods up to 24 hours. For a healthy system, the percentages should be no lower than 80%). Time intervals displayed are 30 seconds, 15 minutes, 4 hours and 24 hours. Log Last Cleared (Displays the date when the log was last cleared)

Use the [DOWN] button to scroll to Diagnostics then press [ENTER].

Diagnostics Displays a summary of Events and Comms Integrity

Total Log Space (Displays the log storage space remaining as a percent) Code Versions (Displays the current software code versions for the In-Cab and Hydraulic Control Nodes) Operations Until L1 Service Due (Displays the remaining access system operations before Service Level 1 Indicator is activated) Operations Until L2 Service Due (Displays the remaining access system operations before Service Level 2 Indicator is activated)

To return to MAIN ACCESS DISPLAY press the [EXIT] button.

Ph: +555-555-1212 Displays Komatsu Contact Details

FIGURE 32-17. Control Panel Menu Structure - Diagnostics

M32002

Retractable Ladder System

M32-55

NOTES:

M32-56

Retractable Ladder System

M32002

SECTION M33 CAMERA SYSTEM INDEX CAMERA SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M33-2 CAMERA SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M33-2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M33-2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M33-2 Camera Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M33-3 CAMERA MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M33-4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M33-4 CAMERA CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M33-5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M33-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M33-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M33-5 Camera Controller Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M33-5 CAMERA SWITCHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M33-6 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M33-6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M33-6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M33-6 CAMERA SYSTEM SETUP AND CHECKOUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . M33-7 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M33-7 STEP 1 - Switch Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M33-7 STEP 2 - Monitor Settings System Settings to DEFAULT: . . . . . . . . . . . . . . . . . . . . . . . . . . . M33-7 STEP 4 - Monitor Settings - System Settings Unique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M33-9 STEP 4 - Monitor Settings - System Settings Unique - Cameras . . . . . . . . . . . . . . . . . . . . M33-11 STEP 5 - Monitor Settings - System Settings Unique - On Screen Delay . . . . . . . . . . . . . . M33-13 STEP 6 - Monitor Settings - System Settings Unique - Standby Mode . . . . . . . . . . . . . . . . M33-14 STEP 7 - Integrated Functions Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M33-15

M33001

Camera System

M33-1

CAMERA SYSTEM CAMERA SYSTEM

Operation

General

With the key switch ON, the camera switch ON, the truck stopped and the directional control lever in PARK, the camera system will power up and immediately display the view from front center camera (1, Figure 33-1). The number 1 will be shown in the upper left corner of the camera monitor.

The camera system consists of four cameras mounted around the truck. There are three cameras on the front of the truck: at the right front corner (2, Figure 33-1), center (1) and left front corner (3). The fourth camera (4) is mounted on the rear axle housing looking behind the truck. A camera monitor (2, Figure 33-2) is located inside the cab to display camera images to the operator.

When the right hand turn signal is activated, the view on the camera monitor will display the view from right front camera (2). The number 2 will be shown in the upper left corner of the camera monitor.

FIGURE 33-1. CAMERA SYSTEM 1. Front Center Camera 3. Left Front Camera 2. Right Front Camera 4. Rear Camera

M33-2

Camera System

M33001

When the left hand turn signal is activated, the view on the camera monitor will display the view from left front camera (3). The number 3 will be shown in the upper left corner of the camera monitor. When the directional control lever is moved into the REVERSE position, the view on the camera monitor will display the view from rear mounted camera (4). The number 4 will be shown in the upper left corner of the camera monitor.

If the truck has been moving faster than 16 kph (10 mph), and then slows below that speed or stops, the camera monitor will still remain dark for at least 10 seconds. Within one minute, the camera monitor will display the view from the front center camera. When REVERSE is selected, the monitor displays the rear view from camera (4) regardless of truck speed or turn signal activation.

When the directional control lever is moved back to the PARK position (or FORWARD), the view will switch and the camera monitor will display the view from front center camera (1). When the truck is moving forward at a speed greater than 16 kph (10 mph) for about 30 seconds, the camera monitor screen will go dark. The camera monitor screen will stay dark until the truck speed decreases below 16 kph (10 mph) and stays below that speed for at least 10 seconds.

FIGURE 33-2. CAMERA MONITOR LOCATION 1. Overhead Panel 2. Camera Monitor Camera Switch Camera switch (Figure 33-3) is located on the lower right hand dash panel. It is a three-position rocker switch, but the third position (top) is only momentary. Pressing the top of the rocker switch to place the switch in the middle position turns the camera system on. Pressing the bottom of the switch turns the camera system off. To display the view from the rear camera, momentarily press the top of the rocker switch. Regardless of truck speed, the view from the rear camera will be displayed in the camera monitor for approximately 30 seconds.

M33001

Camera System

FIGURE 33-3. CAMERA SWITCH

M33-3

CAMERA MONITOR General The camera monitor has eight buttons to adjust various settings. Refer to Figure 33-5. Camera Selection Press button (1, Figure 33-5) once. The camera LED will blink, indicating that the manual camera override is active. Use the “plus” and “minus” buttons to select the desired camera. Press button (1) again to stop the manual override. The manual camera selection has priority over the scan function and the switching wires. Auto Backlight Control/Day/Night settings Push button (2) to switch between the Auto Backlight Control (ABC) modes, the LCD backlight day and the LCD backlight night settings. The ABC mode controls the backlight settings between minimum settings and 100%, depending on the amount of available ambient light. The day and night brightness settings can be manually adjusted by pushing the “plus” or “minus” button (settings will be saved).

Brightness Adjustment Press button (4) once to enter brightness adjustment mode. Use the “plus” and “minus” buttons to select the image brightness. Saturation Adjustment Press buttons (3) and (4) at the same time to enter saturation adjustment mode. Use the “plus” and “minus” buttons to select the image saturation. Single Scan / Return When pushed, button (5) generates a single sequence scan (not continuous) of the attached cameras. During setup, it also returns the monitor to the previous menu. Minus Press button (6) to go to the next menu option. Plus Press button (7) to go to the previous menu option. Enter Press button (8) to select or activate the selected option.

Contrast Adjustment Press button (3) once to enter contrast adjustment mode. Use the “plus” and “minus” buttons to select the image contrast.

FIGURE 33-5. CAMERA MONITOR AND BUTTONS 1. Camera Selection 2. Backlight Selection 3. Contrast

M33-4

4. Brightness 5. Single Scan / Return 6. Minus

Camera System

7. Plus 8. Enter

M33001

CAMERA CONTROLLER

Installation

General Camera controller (1, Figure 33-6) is located inside the cab in the overhead compartment. camera controller (1) determines which camera is displayed on the camera monitor based on inputs from the turn signal, truck speed and the position of the directional control lever. The camera controller is pre-programed with software that contains the proper logic. If the device fails, it must be replaced with a new unit. There is no software to install or update for the camera controller.

Removal 1. Remove mounting hardware and allow the overhead console (3) to swing down. 2. Disconnect wire connector (4) from camera controller (1). 3. Remove mounting hardware (2) and remove the camera controller.

1. Place new camera controller (1, Figure 33-6) into position and securely fasten it with mounting hardware (2). 2. Connect harness connector (4) to camera controller. 3. Close the overhead console and fasten it to the cab with hardware that was removed earlier. Camera Controller Connector Pins 1. Ground 2. Front Camera Command (Output) 3. Right Side Camera Command (Output) 4. Left Side Camera Command (Output) 5. Rear Camera Command (Output) 6. Reverse Operator Manual Switch (Input) 7. Reverse Directional Selector (Input) 8. Right Turn Signal (Input) 9. Left Turn Signal (Input) 10. Vehicle Speed Positive (Input) 11. Vehicle Speed Negative (Input) 12. 12VDC Supply Power

FIGURE 33-6. CAMERA CONTROLLER 1. Camera Controller 3. Overhead Console 2. Hardware 4. Connector

M33001

Camera System

M33-5

CAMERA SWITCHER General Camera switcher (1, Figure 33-7) is located in the front compartment of the cab, below the windshield. The camera switcher electronically switches the camera monitor between the four different cameras on the truck. The signal to switch between different cameras comes from the camera controller. Removal 1. Remove the mounting hardware and the front cover from the front of the cab. 2. Disconnect the four camera cables from camera switcher (1, Figure 33-7). 3. Remove mounting hardware (2) and remove the camera switcher. FIGURE 33-7. CAMERA SWITCHER INSTALLATION

Installation 1. Place camera switcher (1, Figure 33-7) into position and fasten it with mounting hardware (2). 2. Connect the four camera cables to the camera switcher. The camera switcher has four connections and they are marked as follows: MON - Monitor cable C1 - Front Center Camera C2 - Front Right Camera C3 - Front Left Camera

M33-6

1. Camera Switcher 2. Hardware 3. Camera Monitor Cable

Camera System

4. Camera Cable (C1) 5. Camera Cable (C2) 6. Camera Cable (C3)

M33001

SETUP AND CHECKOUT PROCEDURE

STEP 2 - Monitor System Settings to Default

General This procedure will set up the camera monitor so it will work properly. During the checkout procedure, the truck must be outside in a safe area where it can be driven forward and in reverse.

STEP 1 - Switch Function 1. Turn the key switch to the RUN position. 2. Press the camera switch (Figure 33-8) to the bottom position. Verify dash that the switch is lighted green on the bottom.

The purpose of this step is to place the monitor into a known default state for all settings. There are many settings which may be adjusted within the monitor. This step will ensure that the settings that are configurable are placed to a default value. However, this does not completely set everything as required for the operation of the camera installation on the truck. Additional steps are required to complete the setup.

1. Place the camera monitor into Service Menu Mode by pressing buttons (1, 6 and 7, Figure 33-10) at the same time. The monitor will now show a screen similar to Figure 33-11.

FIGURE 33-10. MONITOR BUTTONS 1. Camera Selection 2. Backlight Selection 3. Contrast 4. Brightness

FIGURE 33-8. CAMERA SWITCH

5. Single Scan / Return 6. Minus 7. Plus 8. Enter

3. Press the camera switch to the middle (power ON) position. Verify that the switch is lighted amber on top.

M33001

Camera System

M33-7

4. Navigate the highlighted bar downward to the row named "Default settings" using the minus button. If on the last row, pressing the minus again will place the highlight to the top row. Note that there are more rows below that are indicated by the triangle symbol at the bottom. Similarly, when more lines are above the first row, a triangle symbol will also be shown at the top. Press the enter button to obtain the menu "Default Settings" as shown in Figure 33-13.

FIGURE 33-11.

2. Navigate the highlighted bar to the row named "System settings" by using minus button, (6, Figure 33-10). If on the last row, pressing the minus again will place the highlight to the top row. 3. Press enter button (8) to go to the system settings menu. Now the menu should be similar to Figure 33-12.

FIGURE 33-13.

5. Verify that “select defaults” shows a value of "1". If it does not, then press the enter button which will then highlight the entry area in green color. Press the plus or minus button to change the entry number. When the number "1" is shown, then press the enter button to select the option number 1 for the system. This only selects which default version will be enacted if a restore is activated, but does not change any settings.

FIGURE 33-12.

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Camera System

M33001

6. Navigate the highlight bar to the row named "Restore defaults" and press the enter button. This will activate the default set number 1 which was selected. The screen menu will then return to the System settings screen shown in Figure 33-14.

STEP 4 - Monitor Settings - System Settings Unique The purpose of this step is to configure unique settings that are required for the camera monitor.

1. Place the camera monitor into Service Menu Mode by pressing buttons (1, 6 and 7, Figure 33-10) at the same time. The monitor will now show a screen similar to Figure 33-15.

FIGURE 33-14.

7. Press the enter button twice to move out of the service mode menus. Now the system is at default settings level and ready for the next step of this procedure.

FIGURE 33-15. 2. Navigate the highlighted bar to the row named "System settings" by using the minus button. 3. Press the enter button to go to the “System Settings” menu. The monitor will display a screen as shown in Figure 33-16.

FIGURE 33-16.

M33001

Camera System

M33-9

4. Navigate the highlighted bar downward to the row named "Camera Switch" (Figure 33-17) using the minus button. Press the enter button to cause the setting for this row to become highlighted in green color. Use the plus button or the minus button as needed to cycle to option "4C" in the available settings. When "4C" is shown, select this option by pressing the enter button. Now the complete row should be highlighted in yellow and the text "4C" is shown as the selected option. NOTE: The other options are also shown in Figure 33-17, and they are QUA, 2C, 3C AND OFF.

FIGURE 33-17. 5. Now Navigate the highlighted bar downward to the row named "Frontcam", then press the enter button. This will have a default setting screen similar to Figure 33-18. Set “Enable Frontcam” to OFF.

FIGURE 33-18.

M33-10

Camera System

M33001

6. Navigate the highlighted bar to the "AUX wire function" line and press the enter button. This will highlight the setting with green color. Use the plus button or the minus button as needed to cycle to the “OFF” option in the available settings. When "OFF" is shown, select the option by pressing the enter button. Now the complete row should be highlighted in yellow and "OFF" is shown as the selected option.

STEP 4 - Monitor Settings - System Settings Unique - Cameras The purpose of this step is to configure unique settings to the camera monitor required for the truck.

1. Place the camera monitor into Service Menu Mode by pressing buttons (1, 6 and 7, Figure 33-10) at the same time. The monitor will now appear as shown in Figure 33-19.

NOTE: Both must show "OFF" for setting: Enable Frontcam = OFF Aux wire function = OFF 7. Press the return button several times to exit the service mode of the monitor.

FIGURE 33-19. 2. Navigate the highlighted bar to the row named "Camera Settings" by using the minus button and then pressing the enter button. The monitor screen will then be similar to Figure 33-20.

FIGURE 33-20.

M33001

Camera System

M33-11

There are markers showing the status for each option of the camera. Enabled is a check mark symbol located on a square box. Non-enabled is a simply a blank square box.

NOTE: The default setting done in Step 1 of this procedure puts camera 1 (forward camera), into a mirror mode function, but it must be placed into normal mode. 3. Using the plus or minus buttons, navigate the highlight bar to the "C1" column as shown in Figure 33-20. Press the enter button. This will cause the highlight bar to move down a line in the column to the desired setting place for the mirror.

9. When completed, press the return button to return to the previous menu state as shown in Figure 33-20. The setting should remain as set. 10. Using the plus or minus buttons, navigate the highlight bar to the "C3" column. Press the enter button. This will cause the highlight bar to move down a line in the column to the desired setting place for the mirror. 11. Navigate to the setting "switch delay" for C3. Press the enter button to select the function as disabled, which should be a blank box symbol. C3 needs to be set as switch delay disabled. 12. When completed, press the return button to return to the previous menu state as shown in Figure 33-20. The setting should remain in the disabled state.

NOTE: Now the plus or minus buttons will navigate the highlight upward and downward within the settings of the column for this camera.

13. Using the plus or minus buttons, navigate the highlight bar to the "C4" column. Press the enter button. This will cause the highlight bar to move down a line in the column to the desired setting place for the mirror.

4. Navigate to the setting "Mirror" for C1. Press the enter button to select the mirror function as disabled, which should be a blank box symbol. C1 needs to be set as mirror disabled.

14. Navigate to the setting "Mirror" for C4. Press the enter button to select the mirror function as enabled, which should be a check mark symbol. C4 needs to be set as mirror enabled.

5. Navigate to the setting "switch delay" for C1. Press the enter button to select the function as disabled, which should be a blank box symbol. C1 needs to be set as switch delay disabled.

15. Navigate to the setting "switch delay" for C4. Press the enter button to select the function as disabled, which should be an empty square box symbol. C4 needs to be set as switch delay disabled.

6. When completed, press the return button to return to the previous menu state as shown in Figure 33-20. The setting should remain in the disabled state. 7. Using the plus or minus buttons, navigate the highlight bar to the "C2" column as shown in Figure 33-20. Press the enter button. This will cause the highlight bar to move down a line in the column to the desired setting place for the mirror. 8. Navigate to the setting "switch delay" for C2. Press the enter button to select the function as disabled, which should be a blank box symbol. C2 needs to be set as switch delay disabled.

M33-12

16. When completed, press the return button to return to the previous menu state as shown in Figure 33-20. The settings should remain as set.

TABLE 1: CAMERA SETTINGS Setting C1 C2 C3 C4 Mirror







Switch Delay







Camera System



M33001

3. Navigate the highlighted bar downward to the row named "On Screen display" using the minus button. Press the enter button to go to the screen shown in Figure 33-23.

STEP 5 - Monitor Settings - System Settings Unique - On Screen Delay

1. Place the camera monitor into Service Menu Mode by pressing buttons (1, 6 and 7, Figure 33-10) at the same time. The monitor will now appear as shown in Figure 33-21.

FIGURE 33-23.

4. Navigate the highlighted bar to "OSD timeout" using the minus button. 5. Press the enter button which will highlight the setting in green.

FIGURE 33-21.

2. Navigate the highlighted bar to the row named "System settings" by using the minus button and then press the enter button. The monitor screen will then be similar to Figure 33-22.

6. Obtain the setting of "ON" by using the minus or plus buttons. 7. Press the enter button which will then cause the highlight of green to return to yellow, entering the setting into the monitor. This setting causes the display to have text constantly shown to indicate which camera is being used. 8. Press the return button three times to exit the setup program.

FIGURE 33-22.

M33001

Camera System

M33-13

STEP 6 - Monitor Settings - System Settings Unique - Standby Mode

1. Place the camera monitor into Service Menu Mode by pressing buttons (1, 6 and 7, Figure 33-10) at the same time. The monitor will now appear as shown in Figure 33-24.

FIGURE 33-25. 3. Navigate the highlighted bar downward to the row named "Power Settings" using the minus button. Press the enter button to go to a screen similar to Figure 33-26. 4. Navigate the highlighted bar to "Standby mode" using the minus button. 5. Press the enter button which will highlight the setting in green.

FIGURE 33-24.

6. Obtain the setting of "IMM" by using the minus or the plus buttons.

2. Navigate the highlighted bar to the row named "System settings" by using the minus button and then press the enter button. The monitor screen will then be similar to Figure 33-25.

7. Press the enter button which will cause the highlight of green to return to yellow, entering the setting into the monitor. This setting causes the display to immediately go into the automatic standby mode when initially powered on. 8. Press the return button three times to exit the setup program.

FIGURE 33-26.

M33-14

Camera System

M33001

STEP 7 - Integrated Functions Check This step is a verification of the automated functions of the system. This requires the truck to be mobile for the last few item checks. Ensure there is enough room available to safely drive the truck forward and in reverse.

1. With the key switch ON, truck stopped and the directional control lever in PARK, the camera system should power up and immediately show the front center camera. The number "1" should be shown on the upper left of the monitor. 2. Activate the right hand turn signal by moving the turn signal level upward. The view of the monitor should now show the view as seen from the right front camera. The number “2” should be shown in the upper left of the monitor. 3. Activate the left hand turn signal by moving the turn signal level downward. The view of the monitor should now show the view as seen from the left front camera. The number “3” should be shown in the upper left of the monitor.

6. Operate the truck forward to a speed of 16 kph (10 mph) for 60 seconds. The monitor should revert to a darkened screen upon being over 16 kph (10 mph) at about 30 seconds. Once darkened, activate the turn signals both ways to verify that the monitor remains darkened (no view). 7. While still moving faster than 16 kph (10 mph), press the camera switch to the top position and hold for one second. The switch should return to the middle position. The monitor should show the rear camera view and remain for about 30 seconds, then return to a darkened blank screen. 8. Stop the truck. Verify that the monitor remains darkened for more than 10 seconds but less than one minute while stopped. The monitor should then show the front camera view. 9. Place the directional control lever into REVERSE and drive at a speed over 16 kph (10 mph) for 30 seconds. The monitor should continuously show the rear camera view.

4. Firmly press down on the brake pedal. Place the directional control lever into REVERSE. The monitor should now show the rear camera view with the number "4" in the upper left of the monitor. 5. Return the directional control lever to PARK. The monitor view should switch back to the forward camera view.

Movement of the truck is required for the next few steps. Take all necessary precautions required for movement of the machine in a safe manner.

M33001

Camera System

M33-15

NOTES:

M33-16

Camera System

M33001

SECTION N OPERATOR CAB INDEX

TRUCK CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-1

CAB COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-1

OPERATOR COMFORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-1

OPERATOR CAB CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-1

N01020

Index

N1-1

NOTES

N1-2

Index

N01020

SECTION N2 TRUCK CAB AND COMPONENTS INDEX TRUCK CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-5 CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-6 Door Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-6 Door Jamb Bolt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-7 Door Handle Plunger Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-8 Replace Door Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-9 Replace Door Window Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-13 Replacing the Door Handle or Latch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-14 Replacing the Door and Door Hinge Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-14 Removing the Door Opening Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-15 GLASS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-16 Adhesive-bonded Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-16 Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-16 WINDSHIELD & REAR GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N2-18

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NOTES:

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TRUCK CAB AND COMPONENTS TRUCK CAB Description The truck cab is a fully insulated design incorporating an integral ROPS structure for maximum operator comfort and safety. All gauges, switches, and controls have been designed to simplify operation and are placed within easy reach of the operator. Servicing of cab and associated electrical systems is simplified by use of heavy-duty connectors on the various wiring harnesses. Hydraulic components are located outside of the interior and are accessed through covers (2, Figure 2-1) on the front of the cab.

DO NOT attempt to modify or repair damage to the ROPS structure without written approval from the manufacturer. Unauthorized repairs to the ROPS structure will void certification. If modification or repairs are required, contact the servicing Komatsu Distributor.

FIGURE 2-1. CAB ASSEMBLY 1. Mounting Pad 2. Access Covers 3. Filter Cover 4. Windshield Wiper Arms 5. Stop Light (Service Brakes Applied)

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6. Retard Light (Retarder Applied) 7. Lifting Eye 8. Rear, Side Glass 9. Front, Side Glass

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7. Close heater shutoff valves located at the water pump inlet housing on the right side of the engine and at the water manifold. Disconnect heater hoses at each valve and drain coolant into a container.

Prior to cab removal or repair procedures, it may be necessary to remove the body to provide clearance for lifting equipment to be used. If body removal is not required, the body should be raised and the safety cables installed at the rear of the truck.

8. Remove clamps and heater hoses from fittings underside of deck, below heater.

Do not attempt to work in deck area until body safety cables have been installed.

Removal NOTE: The following procedure describes removal of the cab as a complete module with the hydraulic brake cabinet attached. All hoses and wire harnesses should be marked prior to removal for identification to ensure correct reinstallation:

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. 9. Evacuate the air conditioning system as follows: a. Attach a recycle/recovery station at the air conditioning compressor service valves. (Refer to "Heater/Air Conditioning System" in this section for detailed instructions.)

1. Turn the key switch to the OFF position and allow at least 90 seconds to bleed the steering accumulator. Turn the steering wheel to be sure no pressure remains.

b. Evacuate air conditioning system refrigerant.

2. Block truck securely, and open the brake accumulator bleed down valves on the accumulators located in the cabinet mounted on the rear of the cab. Allow sufficient time for accumulators to bleed down completely.

c. Remove the air conditioner system hoses routed to the cab from the receiver/drier and compressor. Cap all hoses and fittings to prevent contamination. 10. Attach a lifting device to the lifting eyes provided on top of the cab.

3. Disconnect the batteries by activating the battery disconnect switches located at one end on the battery box. 4. Disconnect hydraulic hoses routed to frame from fittings at rear of cab under brake cabinet (3, Figure 2-2). (It is not necessary to disconnect hoses (4) attached to, and routed under the cab.) Cap all fittings and plug hoses to prevent contamination.

The cab assembly weighs approximately 2270 kg (5000 lbs). Be sure lifting device is capable of lifting the load. 11. Remove the cap screws and washers from each mounting pad (1, Figure 2-1) at the corners of the cab.

5. Disconnect the wire harnesses at connectors (5) located under hydraulic cabinet. 6. Remove cable and hose clamps as needed for cab removal

NOTE: The tool group shipped with the truck contains the following tools which may be used to remove the inner cap screws, as clearance is limited: • TZ3535 - 1-1/2" offset wrench • TZ2733 - Tubular Handle • TZ2734 - 3/4" torque wrench Adaptor

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FIGURE 2-2. CAB HYDRAULIC AND ELECTRICAL CONNECTIONS 1. Cab 2. Steering Control Valve 3. Hydraulic Components Cabinet

4. Hoist Valve Hoses 5. Electrical Harness Connectors

12. Check for any other hoses or wiring which may interfere with cab removal. 13. Lift the cab assembly off the truck and move to an area for further service. 14. Place blocking under each corner of the cab to prevent damage to floor pan and hoses before cab is lowered to the floor.

2. After cab is positioned, measure the gap between each cab mounting pad and the frame. Insert 1 mm (0.040 in.) shims as required so gap at each pad is less than 1 mm (0.040 in.). 3. Insert the remaining cap screws and hardened washers. (32 total). Tighten the cap screws to 1017 N·m (750 ft lb) torque.

1. Lift the cab assembly and align the mounting pad holes with tapped pads. Insert at least one cap screw and hardened washer at each of the four pads prior to lowering cab onto the truck.

4. Route the wire harnesses to the electrical connectors on the rear corner of the cab (5, Figure 2-2). Align cable connector plug key with receptacle key and push plug onto receptacle. Carefully thread retainer onto receptacle and tighten securely. Install clamps if removed during cab removal.

NOTE: The tool group shipped with the truck contains the following tools which may be used to install the inner cap screws, as clearance is limited:

5. Remove the caps from the hydraulic hoses and tubes and reinstall the hoses and tubes. Reinstall any hose clamps as required.

Installation

• PB8326 - 1-1/2" offset wrench • TZ2733 - Tubular Handle • TZ2734 - 3/4" torque wrench Adaptor

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5. Insert a lifting sling through the door and attach it to a hoist. Remove the capscrews (a swivel socket works best) that secure the door hinge to the cab. Lift the door from the cab.

6. Install the heater hoses and clamps on the fittings on the underside of the cab. Connect the other end of each hose to the fittings at the shutoff valves on the engine. Open the heater shutoff valves. Connect the air cleaner restriction indicator hoses.

6. Place the door on blocks or on a work bench to protect the window glass and allow access to internal components for repair.

7. Remove the caps and reinstall the air conditioning system hoses to the compressor and receiver/drier. Refer to “Heater/Air Conditioning System” for detailed instructions about evacuation and recharging with refrigerant. 8. Close the brake accumulator bleed down valves.

Installation 1. Attach a lifting sling and hoist to the door assembly. Lift the door up to the deck and position the door hinges on the cab.

9. Deactivate the battery disconnect switches. 10. Service the hydraulic tank and engine coolant as required.

2. Align the door hinges with the cab and install the capscrews that secure the door to the cab.

11. Start the engine and verify proper operation of all controls.

3. Attach the travel limiting strap with the bolt and clip that were removed previously. Some straps may have extra loops at the end to allow adjustment of how wide the door swings open.

12. Ensure that the air conditioning system is properly recharged.

4. Connect the door harness to the receptacle mounted in the cab floor. Ensure the harness is routed through the bottom loop of the door strap.

CAB DOOR

5. Verify proper operation of the power window and door latch adjustment.

The cab door assemblies are similar except for the hinge side. Each is hinged on the rear edge with a heavy duty hinge. For repairs on the door latches or window controls it is usually better, but not necessary, to remove the door from the cab and lower it to the floor for service.

6. Install the door panel. 7. If an adjustment is necessary to ensure tight closure of the door, refer to "Door Jamb Bolt Adjustment". 8. A rubber sealer strip is mounted with adhesive around the perimeter of the door assembly to keep out dirt and drafts. This sealer strip should be replaced if it becomes damaged.

Removal 1. If overhead space is available, raise the body to allow access to the door with an overhead hoist. Secure the body in the raised position with safety cables. 2. Lower the door glass far enough to allow insertion of a lifting sling when the door is removed. 3. Remove the door panel for access to the power window motor harness connector. Disconnect the door harness from the floor. 4. Remove the retainer clip and bolt clip from the travel limiting strap.

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Door Adjustment If adjustment is necessary to insure tight closure of door, loosen striker bolt in the door jamb, adjust, and retighten. A rubber sealer strip is mounted with adhesive around the perimeter of the door assembly to exclude dirt and drafts. This sealer strip should be kept in good condition and replaced if it becomes torn or otherwise damaged.

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4. The door seal should firmly grip the paper all along the top, front, and bottom edge of the door. If the paper is loose all around, REPEAT STEP 2. If the paper is firmly gripped, but can be removed without tearing it, open door and tighten the jamb bolt completely without affecting the adjustment.

Door Jamb Bolt Adjustment Over a period of time, the door latch mechanism and door seals may wear and allow dirt and moisture to enter the cab. To insure proper sealing of the door seals, the door jamb bolt may need to be adjusted periodically.

5. If the paper slips out from the door seal easily along the top and not at the bottom, the door itself will have to be "adjusted". Or if the paper slips out easier at the bottom than at the top, the door will have to be "adjusted". • If seals are tight at bottom of 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 seal tension again using the paper method. Seal compression should be equal all the way around the door. If seal is still loose at the top, repeat procedure again until seal compression is the same all the way around.

FIGURE 2-3. DOOR JAMB BOLT ADJUSTMENT 1. Washer 2. Striker Bolt

• If seal compression is greater at the top than at the bottom of the door, place a 4 x 4 block of wood at the top corner of the cab door. Then press firmly inward on the lower corner of the door. Press in one or two times, then remove the wood block and check seal compression again. Seal compression should be equal all the way around the door. If seal is still loose at the bottom, repeat procedure again until seal compression is uniform all the way around.

3. Frame 4. Seal

Step A. If the door closes, but not tightly enough to give a good seal between the seal on the door and the cab skin: 1. Mark the washer location (1, Figure 2-3) portion of the door jamb bolt with a marker, pen, or pencil by circumscribing the outside edge of the washer onto the jamb. 2. Loosen the door jamb bolt (2) and move straight inwards 1/16" and retighten.

Step B. If the door springs back when trying to close it, the striker bolt (2, Figure 2-4) has probably loosened and slipped down from where the catch can engage with the bolt.

3. Hold a piece of paper such as a dollar bill between where the door seal (4) will hit the skin of the cab and firmly close the door ensuring that it latches on the second catch. (The door latch mechanism has a double catch mechanism.)

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1. Open the door and close both claws (3 & 5, Figure 2-4) on the catch until they are both fully closed.

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2. Transfer the center of this opening onto the skin of the cab nearest where the door jamb bolt is located. Use a T-square or other measuring equipment and mark on the cab with a pencil. NOTE: Release the door catch before trying to close the door.

Door Handle Plunger Adjustment If the door handle becomes inoperative, it can either be adjusted or replaced. The following is a procedure for adjusting the exterior door handle plunger. 1. Determine the amount of free play in the door release plunger by pushing in on the plunger until it just contacts the door release mechanism. Measure the distance that the plunger travels (Figure 2-5) from this position to where the plunger is fully released.

FIGURE 2-5. MEASURING TRAVEL DISTANCE OF PLUNGER

2. Remove the door panel as follows: a. Remove hair pin clip (1, Figure 2-6) and bolt (2) from the door check strap closest to the door.

FIGURE 2-4. DOOR JAMB BOLT ADJUSTMENT 1. Washer 2. Striker Bolt

3. Frame 4. Seal

3. Loosen and vertically align (center) the door jamb bolt with this mark and tighten it firmly enough to hold it in place but still allow some slippage. 4. Carefully try to close door (4) and determine whether this adjustment has helped the “springing” problem. If the door latches but not firmly enough, follow the procedure in Step 1. If the door latch does not catch, move the bolt outward and try again. When corrected, follow the adjustment procedures in Step 1 to ensure a good seal.

b. Remove two cap screws (3), which hold the door strap bracket to the door. c. Disconnect wiring harness (4) to the window regulator. d. Open the door as far as possible in and remove the internal door panel. e. Before removing all door panel mounting screws, support the panel to prevent the assembly from dropping. Remove 15 mounting screws (5).

By design, if both seals are in good condition, proper adjustment of the outside seal will ensure good contact on the inside seal to prevent dust and moisture from entering the cab.

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NOTE: Remove panel screws across the top last.

Replace Door Glass 1. Remove hair pin clip (1, Figure 2-6) and bolt (2) from the door check strap closes to the door.

NOTE: Door glass and internal door panel will drop when door panel screws are removed.

f. Carefully lower the door panel a few inches. Hold glass at top to prevent it from dropping. Slide the door panel toward the cab to disengage the window regulator roller (Figure 2-7) from the track on the bottom of the glass. Slide the panel away from the cab to disengage the other top roller and lower roller from its tracks. Place the panel out of the way after removal. g. Lift door glass and support at the top of the frame. h. Remove 2 screws (Figure 2-8) holding the roller track to the bottom of the door glass. 3. Remove the cap screw and nut from inside release lever (1, Figure 2-14).

FIGURE 2-6.

4. Remove the four mounting screws that holds the latch mechanism in the door (2).

1. Hair Pin Clip 2. Door Strap Bolt 3. Strap Bracket

5. Remove door latch mechanism (4). Check to see if door latch mechanism works properly by performing the following test. a. Close latch mechanism pawls

4. Wiring Harness 5. Panel Screws 6. Window Regulator Mounting Screw

2. Remove 2 M8X12 cap screws (3), which hold the door strap bracket to the door.

b. Operate inside door release lever to see if pawls open. If pawls do not open, replace assembly.

3. Disconnect wiring harness (4) to the window regulator. 4. Open the door as far as possible in order to remove the internal door panel.

c. Close pawls again. d. Press the outside door button to see if pawls open. e. If mechanism operates properly go on to STEP 6. If mechanism does not work properly, replace with a new door latch assembly then continue with STEP 6. 6. Remove mounting screws (3) from the outside door handle. With the door handle removed, adjust the plunger counter clock wise to increase the height of the door handle release button. Lock the plunger cap screw with locking nut. Apply lock tight to prevent screw from working loose.

Door glass and internal door panel will drop when door panel screws are removed.

7. Reassemble the door assembly by reversing the previous steps.

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5. Before removing all door panel mounting screws, support the panel to prevent the assembly from dropping. Remove 15 mounting screws (5).

7. Remove two screws (Figure 2-8) holding the roller track to the bottom of the door glass.

NOTE: Remove panel screws across the top last. 6. Carefully lower the door panel a few inches. Hold the glass at the top to prevent it from dropping. Slide the door panel toward the cab to disengage the window regulator roller (Figure 2-7) from the track on the bottom of the glass. Slide the panel away from the cab to disengage the other top roller and lower roller from its tracks. Place the panel out of the way after removal.

FIGURE 2-8.

8. Support the glass in the door frame with support block (1, Figure 2-9) as shown. Remove screws (2) that hold the adapter for the window regulator track.

FIGURE 2-7.

FIGURE 2-9. 1. Support Block

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2. Screws

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11. Lift door glass up in window frame (1, Figure 212) so that it is near the top. While holding the glass in place, tilt frame out at the top. Lift the frame and glass straight up and out of door.

Bracket (2, Figure 2-12) at bottom of glass must clear the door frame, if still on glass.

FIGURE 2-10. 1. Screws

2. Rubber Felt Insert

9. Remove the screw at the lower end of the window channels. It is necessary to pull the rubber felt insert (2, Figure 2-10) out of the channel in order to be able to remove the screws. 10. Remove the trim material covering the screws holding the window frame to the door. Remove screws (1, Figure 2-11) holding window frame to the door. NOTE: The screws along the bottom of the window frame may be shorter than the screws along the top and sides. FIGURE 2-12. 1. Window Frame

2. Window Bracket

12. Move the window glass and frame to a work area where the glass can be removed. Slide the glass down and out of the window channels. 13. Before installing new window glass, inspect the window frame. In each corner there is an “L” shaped bracket (1, Figure 2-13) with two screws in it to hold the corners of the frame together. Check the screws to ensure that they are tight. Also ensure that rubber felt insert (2, Figure 210) in the window channels is in good condition. Replace it if necessary. FIGURE 2-11. 1. Screws

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17. Install screws (1, Figure 2-10) that secure the window frame to the door frame.

14. Slide the new window glass into the window frame glass channels. Move the glass to the top of the frame. 15. While holding the glass at the top of the frame, lift the window frame and lower the assembly into the door.

The screws along the outer bottom of the window frame may be shorter than the ones along the sides and top. These screws must be used in this area to prevent the window glass from being scratched or cracked. See Figure 2-11. 18. Install the trim material over the top of screws that hold the window frame to the door. Use a flat blade screwdriver to assist with installing the trim material. See Figure 2-15. NOTE: Be careful not to cut the retainer lip on the trim material.

FIGURE 2-13. 1. “L” Shaped Brackets

Ensure the one channel (5, Figure 2-14) which is next to the door latch passes to the inside of the latch assembly (4). 16. Lower the glass in the frame and support it with a support block as shown in Figure 2-9. FIGURE 2-14. 1. Cap Screw & Nut 3. Mounting Screw - Out2. Mounting Screws side Door Handle Latch 4. Latch Assembly 5. Window Frame

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23. Lift up the door panel, regulator and glass to align the screw holes in the panel with the holes in the door frame. Install the screws that secure the panel to the door frame.

19. Install the two screws that were removed in Step 8. Ensure that the rubber felt insert is back in place after the screws are installed. 20. Install the window regulator track bracket as shown in Figure 2-7. Ensure that the nylon bushings and gaskets are installed properly to prevent damage to the glass.

24. Hook up the electrical connector for the window regulator. Install the two capscrews that hold the door strap bracket to the door frame. 25. Align the door check strap opening with the holes in the bracket and install the bolt. Install the hair pin clip. See Figure 2-6.

21. Lift the window glass in the frame and install the window regulator roller track onto the bracket installed in Step 20. See Figure 2-8. 22. While holding the window glass as shown in Figure 2-9 (a few inches from the top), install the lower and upper regulator rollers in their tracks. Start by moving the door panel (with the window regulator) away from the cab just far enough to allow the rollers to enter their tracks. Then, with the rollers in the tracks, slide the panel toward the cab. Move the panel just far enough to allow the upper regulator roller to go into the track on the bottom of the glass.

Replace Door Window Regulator 1. Perform Steps 1 through 6 in the procedure “Replacing the Door Glass”. 2. Move the inner panel assembly to a work area. 3. Remove four mounting screws (6, Figure 2-6). 4. If replacing the motor assembly of the window regulator, ensure that the worm gear on the motor is engaged properly into the regulator gear. Also, the regulator should be in the UP position before replacing the motor assembly. Ensure that the motor mounting screws are tight. 5. If replacing the window regulator assembly, the new regulator should be in the UP position before being mounted. 6. Mount the window regulator to the inner panel with the four mounting screws that were removed in Step 3. Ensure that the screws are tight. 7. Perform Steps 22 through 25 in the procedure “Replacing the Door Glass”.

FIGURE 2-15.

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Replacing the Door and Door Hinge Seal

Replacing the Door Handle or Latch Assembly The cab doors are equipped with serviceable latch handle assemblies (inner and outer). If they become inoperative, they should be replaced. The outer latch handle assembly on each door has a key-operated lock. 1. Perform Steps 1 through 6 in the procedure “Replacing the Door Glass”. 2. Remove cap screw and nut (1, Figure 2-14) from the inside door handle. 3. Remove four mounting screws (2) for the latch. Remove the latch assembly. 4. If replacing the latch assembly, proceed to Step 5. If replacing the outside door handle, remove three screws (3) that secure the handle to the door panel.

1. The door assembly seal has only three members to it (sides and top) and is glued on the door. This seal can be replaced by peeling the seal away from the door frame. Then use a suitable cleaner to remove the remaining seal and glue material. 2. The area where the door seal mounts should be free of dirt and oil. Spread or spray a glue which is quick drying and waterproof onto the area where the seal is to installed. 3. Install the seal so that the corners of the seal fit up into the corners of door frame (3, Figure 216). 4. Door hinge seal (2, Figure 2-17) is glued to the hinge. Use the same procedure as above for this seal.

Note: Only one screw is shown. The other two are behind the latch assembly. 5. Install a new latch assembly and align the mounting holes. Install four mounting screws (2, Figure 2-14). Ensure that they are tight. 6. Align the inside door handle and install capscrew and nut (3). 7. Perform Steps 22 through 25 in the procedure “Replacing the Door Glass”.

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Removing the Door Opening Seal 1. Starting at the lower center of the door opening, pull up on one end of the seal. The seal should pull loose from the cab opening lip. Pull the seal loose all the way around opening (1, Figures 216 and 2-17). 2. Inspect the cab opening lip for damage, dirt, and oil. Repair or clean the cab opening as necessary. Remove all dirt and old sealant Ensure that the perimeter of the opening is clean and free of burrs.

Installation 1. Install the seal material around the door opening in the cab. Start at the bottom center of the cab opening and work the seal lip over the edge of the opening. Go all the way around the opening. Ensure that the seal fits tightly in the corners. A soft face tool may be used to work the seal up into the corners.

FIGURE 2-16. 1. Door Opening Seal

3. Door Assembly Seal

2. Continue going all the way around the opening. When the ends of the seal meet at the bottom center of the cab opening, it may be necessary to trim off some of the seal. NOTE: The ends of the seal material need to be square-cut to assure a proper fit. 3. Fit both ends so that they meet squarely. Then while holding the ends together, push them firmly into the center of the opening.

FIGURE 2-17. 1. Door Opening Seal

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2. Door Hinge Seal

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GLASS REPLACEMENT

Replacement Procedure

Adhesive-bonded Windows

Recommended Tools/Supplies • Cold knife, pneumatic knife, or a piano wire cutting device, long knife. Cutout tools are available at an auto glass supply store.

The first concern with all glass replacement is SAFETY! Wear heavy protective gloves and safety eyeglass goggles when working with glass.

• Heavy protective gloves

1. Use a cut-out tool to slice into the existing urethane adhesive and remove the window.

• Safety eyeglass goggles

2. Carefully clean and remove all broken glass chips from any remaining window adhesive. The surface should be smooth and even. Use only clean water.

• Windshield adhesives, proper cleaners, primers & application gun • SM2897 glass installation bumpers (6 - 7 per window)

NOTE: Removal of all old adhesive is not required; just enough to provide an even bedding base.

• Window glass (Refer to Parts Catalog) Recommended adhesives • SikaTack Ultrafast or Ultrafast II (both heated). 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).

3. Use a long knife to cut the remaining urethane from the opening, leaving a bed 2 - 4 mm (0.08 0.15 in.) thick. If the existing urethane is loose, completely remove it. Leave the installation bumpers in place, if possible.

• Sikaflex 255FC or Drive (unheated). Vehicle can be put into service in 8 hours under optimum conditions.

4. 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.

Sika Corporation 30800 Stephenson Hwy. Madison Heights, MI 48071 Toll Free Number: 1-800-688-7452 Fax number: 248-616-7452 http://www.sika.com or http://www.sikasolutions.com

5. Using only the new side window(s) which are to be bonded in place, center the new glass over the opening in the cab. Use a permanent marker to mark on the cab skin along all the edges of the new glass that is to be installed. All edges must be marked on the cab in order to apply the adhesive in the proper location. 6. Use Sika Primer 206G+P to touch up any bright metal scratches on the metal frame of the truck. Do not prime the existing urethane bed. Allow it to dry for ten minutes.

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, be certain to follow that manufacturer's instructions for use, including the use of any primers, and double the allowances for proper curing time.

N2-16

Truck Cab

7. Use a clean, lint free cloth to apply Sika Aktivator to the black ceramic Frit surrounding the new window. Use a clean, dry cloth and wipe off the Sika Aktivator. Allow it to dry for ten minutes.

4/10 N02019

8. For the side windows, use six or seven glass installation bumpers (SM2897). Space them equally around the previously marked glass perimeter, approximately 19 mm (0.75 in.) inboard from where the edge of the glass will be when it is installed.

NOTE: Do not allow the truck to move until double the cure time for the adhesive has passed. Otherwise, vibration or movement from a moving truck will weaken the adhesive bond and the glass may fall off the cab.

NOTE: Be careful not to place the adhesive too far inboard, as it will make any future glass replacement more difficult. 9. Apply a continuous, even bead of adhesive (approximately 10 mm (0.38 in.) in diameter) to the cab skin at a distance of 13 - 16 mm (0.50 0.63 in.) inboard from the previously marked final location of the glass edges from Step 4. 10. Immediately install the glass. Carefully locate the glass in place with the black masking side toward the adhesive. Press firmly, but not abruptly, into place to ensure that the glass is properly seated. Do not pound the glass into place.

Be certain to follow all the adhesive manufacturer's instructions for use, including full allowances for proper curing time. The curing time may be as long as 48 hours (24 hours for some adhesives, then double it) before a truck can be driven. 12. Remove tape or prop from glass after the cure time has expired.

11. Use a wooden prop and duct tape to hold the glass in place for at least two hours or double the adhesive manufacturer’s curing time, whichever time is longer.

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Truck Cab

N2-17

WINDSHIELD & REAR GLASS

Installation

NOTE: Two people are required to remove and install the windshield or rear glass. One person inside the cab, and the other person on the outside.

1. If the weatherstrip that was previously removed is broken, weathered, or damaged in any way, install a new rubber weatherstrip.

Special tools are available from local tool suppliers that are helpful in removing and installing automotive glass.

NOTE: Using a non-oily rubber lubricant on the weatherstrip material and cab opening will make the following installation easier: a. Install weatherstrip (3, Figure 2-18 or 2-19) around the window opening. Start with one end of the weatherstrip at the center, lower part of the window opening and press the weatherstrip over the edge of the opening.

Removal 1. If the windshield is to be replaced, lift the windshield wiper arms out of the way.

b. Continue installing the weatherstrip all around the opening. When the ends of the weatherstrip meet at the lower, center part of the window opening, there must be 12.7 mm (0.5 in.) of overlapping material.

2. Starting at the lower center of the glass, pull out weatherstrip locking lip (2, Figure 2-18 or 2-19). Use a non-oily rubber lubricant and a screwdriver to release the locking lip. 3. Remove glass (1) from weatherstrip (3) by pushing it out from inside the cab. 4. Clean all dirt and old sealant from the weatherstrip grooves. Ensure that the perimeter of the window opening is clean and free of burrs.

NOTE: The ends of the weatherstrip material need to be square-cut to assure a proper fit. c. Lift both ends so that they meet squarely. Then, while holding the ends together, force them back over the lip of the opening. 2. Lubricate the groove of the weatherstrip where the glass is to be seated. 3. Lower the glass into the groove along the bottom of the window opening. 4. Two people should be used for glass installation. Have one person on the outside of the cab pushing in on the glass against the opening, while one person on the inside uses a soft flat tool (such as a plastic knife) to work the weatherstrip over the edge of the glass all the way around.

FIGURE 2-18. Front Windshield 1. Glass 2. Locking Lip

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3. Weatherstrip Material 4. Sheet Metal

Truck Cab

4/10 N02019

5. After the glass is in place, go around the weatherstrip and push in on the locking lip (2, Figure 2-18 or 2-19) to secure the glass in the weatherstrip. 6. If windshield was being replaced, lower windshield wiper arms/blades back to the glass.

FIGURE 2-19. Rear Window 1. Glass 2. Locking Lip

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3. Weatherstrip Material 4. Sheet Metal

Truck Cab

N2-19

NOTES:

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Truck Cab

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SECTION N3 CAB COMPONENTS INDEX CAB COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3 WINDSHIELD WIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3 WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3 WIPER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-4 WIPER LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-4 WINDSHIELD WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-5 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-5 OPERATOR SEAT (STANDARD SEAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-6 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-6 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-7 Replacing the Seat Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-8 PASSENGER SEAT (STANDARD SEAT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-13 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-13 SEAT BELT REPLACEMENT (STANDARD SEATS - PC3230) . . . . . . . . . . . . . . . . . . . . . . . . . . N3-14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-14 SEAT BELT REPLACEMENT (STANDARD SEATS - 58E-57-00500) . . . . . . . . . . . . . . . . . . . . . N3-16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-16 OPERATOR SEAT (OPTIONAL SEAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-18 Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-18 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-18 PASSENGER SEAT (OPTIONAL SEAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-19 Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-19 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-19

N03032 1/13

Heater/Air Conditioner

N3-1

SEAT BELT REPLACEMENT (OPTIONAL SEATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-20 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N3-20

N3-2

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1/13 N03032

CAB COMPONENTS WINDSHIELD WIPERS The windshield wipers are operated by a 24 volt electric motor. The wipers can be adjusted for a variable intermittent delay or a constant low or high speed by the switch mounted on the turn signal lever.

WIPER MOTOR

3. While holding the linkage stationary, remove nut (10, Figure 3-1) and disconnect the linkage from the motor. 4. Remove three cap screws (6) with washers attaching the wiper motor to plate (5). Remove the motor assembly. Installation

Removal 1. Remove the large access panel from the front of the cab. 2. Disconnect the wiper motor harness connector.

1. Place wiper motor (1, Figure 3-1) into position on plate (5). 2. Install three cap screws (6) with flat washers (7) and lock washers (8). Tighten the cap screws to 8 - 9 N·m (71 - 79 in. lb). 3. Align the motor output shaft with the wiper linkage. Install nut (10) and while holding the linkage stationary, tighten the nut to 22 - 24 N·m (16 - 18 ft lb). 4. Reconnect the wiper motor harness connector. 5. Verify the wipers operate properly and park in the proper position. Refer to Figure 3-3.

WIPER ARM Removal 1. Note the parked position of wiper arm (1, Figure 3-2). 2. Lift the wiper arm cover and remove nut (2) and washer (3). 3. Disconnect the washer hose, and remove wiper arm (1).

FIGURE 3-1. WINDSHIELD WIPER INSTALLATION 1. Wiper Motor 2. Cap Screw 3. Flat Washer 4. Lock Washer 5. Plate

N03032 1/13

6. Cap Screw 7. Flat Washer 8. Lock Washer 9. Linkage 10. Nut

FIGURE 3-2. WIPER ARM DETAIL 1. Wiper Arm 2. Nut 3. Spring Washer

Heater/Air Conditioner

4. Cap 5. Washer 6. Nut

N3-3

WIPER LINKAGE

Installation 1. Place wiper arm (1, Figure 3-2) into the position noted during removal. Install washer (3) and nut (2). Tighten the nut to 16 - 20 N·m (142 - 177 in. lb). Close the cover. 2. Connect the washer hose to the wiper arm. 3. Ensure the wipers arms operate properly and park in the proper position after installation is complete. Refer to Figure 3-3.

Removal 1. Remove the wiper arms. Refer to Wiper Arm Removal in this section. 2. Remove wiper retainer (8, Figure 3-3) and disconnect the wiper linkage from the wiper motor drive arm. 3. Remove nut (6, Figure 3-2) and washer (5) from each wiper shaft. 4. Remove cap screws (3, Figure 3-3) with washers. 5. Remove wiper assembly from cab.

Installation 1. Place the wiper assembly into position in the wiper compartment. 2. Install cap screws (3, Figure 3-3) with lock washers (4) and flat washers (5) and tighten cap screws. 3. Install washer (5, Figure 3-2) and nut (6) on each wiper shaft and tighten finger-tight. Tighten the nuts to 18 - 20 N·m (160 - 177 in. lb). DO NOT overtighten. The threads on the shafts are easily stripped when improperly tightened. Install cap (4) over nut (6). 4. Align the linkage and attach to the wiper motor drive arm using retainer (8, Figure 3-3). NOTE: When the motor is parked, the drive arm will be in the 3 o’clock position as shown in Figure 3-3. FIGURE 3-3. PARK POSITION A. Park Position (7°) 1. Wiper Motor 2. Wiper Blade 3. Cap Screw 4. Lock Washer

N3-4

5. Flat Washer 6. Wiper Arm 7. Nozzle 8. Retainer 9. Hose

5. Install the wiper arms. Refer to Wiper Arm Installation. Ensure the wipers arms operate properly and park in the proper position after installation is complete.

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1/13 N03032

WINDSHIELD WASHER Operation The windshield washer, mounted on the right side of the hydraulic components cabinet behind the cab, has a 3.8 liter (1 gal) plastic reservoir (1, Figure 3-4) with a 24 volt electric pump (2). The washer is controlled by the windshield wiper switch mounted on the turn signal lever. When the switch is activated, washing solution is pumped through outlet hose (3) and fed to a jet located in each of the windshield wiper arms. Service If windshield washer maintenance is required, check the strainer opening for obstructions and inspect the hoses for damage. Check the voltage to the pump from the control switch. If the pump is inoperable, replace it with a new pump assembly. Note: The pump is only available as an assembly and cannot be repaired.

FIGURE 3-4. WINDSHIELD WASHER FLUID RESERVOIR AND PUMP 1. Reservoir 2. Pump

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Heater/Air Conditioner

3. Outlet Hose 4. Filler Cap

N3-5

OPERATOR SEAT (STANDARD SEAT) The operator's seat provides a fully adjustable cushioned ride for driver comfort and easy operation. Adjustment The following adjustments must be made while sitting in the seat. Refer to Figure 3-5. 1. Headrest - Move headrest (1) up, down, fore, or aft to the desired position. 2. Seat Height - Push and hold switch (2) to adjust the height of the seat. Release the switch when the desired height is reached. Optimum ride height is obtained when the suspension is at the middle of its stroke. To properly adjust, raise the seat to its highest level. Then, lower the seat approximately 51 mm (2 in.) to the middle of the suspension stroke.

9. Seat Cushion Tilt - Lift and hold lever (9) and tilt the seat cushion to a comfortable position. Release the lever to lock the position adjustment. 10. Fore/Aft Location of Seat - Lift and hold lever (10) and move the seat to a comfortable height. Release the lever to lock the height adjustment. NOTE: The seat compressor must be allowed to cool down for ten minutes for every one minute of continuous operation. The compressor must not be operated continuously for more than three minutes.

3. Lumbar Support - Move dial (3) to adjust the lumbar support to the desired position. 4. Armrest Tilt - Rotate adjusting knob (4) until the armrest is in desired position. 5. Seat Belt - The operator must always have seat belt (5) buckled and properly adjusted whenever the truck is being operated. 6. Backrest Recline - Lift handle (6) to select the desired backrest recline. Release the handle to set the position. 7. Fore/Aft Location of Seat Cushion - Lift and hold lever (7) and move the seat cushion to a comfortable position. Release the lever to lock the position adjustment. 8. Suspension Dampener - Adjust suspension dampener (8) to obtain the desired stiffness of the adjustable shock absorber. Move the lever upward to stiffen the absorbency of the shock. Move the lever downward to soften the ride. Five detented settings are available. NOTE: This seat contains a fixed rate shock absorber in addition to the adjustable shock absorber that is controlled by the suspension dampener.

N3-6

FIGURE 3-5. OPERATOR’S SEAT ADJUSTMENT CONTROLS 1. Headrest 2. Seat Height 3. Lumbar Support 4. Armrest Tilt 5. Seat Belt 6. Backrest Recline

Heater/Air Conditioner

7. Seat Cushion Fore and Aft 8. Suspension Dampener 9. Seat Tilt 10. Fore and Aft

1/13 N03032

Inspection 1. Inspect the seat for wear or damage. Replace worn or damaged parts on the seat. 2. Inspect the seat belts and buckles for proper operation. Also check for worn or frayed fabric. Replace all worn or damaged parts. 3. Inspect the date of manufacture on the seat belt. If the seat belt is over five years old, replace the seat belt. Or, if the seat belt has been in service for more than three years, replace the seat belt.

2. Install cap screws (2), flat washers (3) and lock washers (4) that secure the riser to the floor. Tighten the cap screws to the standard torque. 3. Connect seat harness (7). 4. Fasten seat belt tethers (6) to eye bolts in the cab floor. Install cotter pins (5). 5. If the door was removed, install the door. Refer to the index in this chapter for door installation instructions.

4. Inspect the seat tethers. If worn or damaged, replace the tethers.

Do not remove the handrail from the deck to allow room to remove the operator seat from the cab. Remove the cab door to gain clearance for seat removal. There is a risk to personnel of falling if the handrail is removed. Removal 1. Disconnect the door stop strap so the door can swing open wider. If necessary, remove the door from the cab to allow room to remove the seat. Refer to the index in this chapter for door removal instructions. 2. Remove cotter pins (5, Figure 3-6) so that seat belt tethers (6) can be disconnected from the eye bolts in the cab floor. 3. Disconnect seat harness (7) at the cab floor. 4. Remove cap screws (2), flat washers (3) and lock washers (4) that secure the riser to the floor. 5. The seat weighs approximately 58 kg (128 lb). Remove the seat from the cab. Then use a suitable lifting device to lift the seat from the deck down to the ground. Do not lift the seat by using the arm rests, as they could be damaged. Installation

FIGURE 3-6. SEAT INSTALLATION

1. The seat weighs approximately 58 kg (128 lb). Use a suitable lifting device to lift the seat from the ground up to the deck. Place seat assembly in position in the cab.

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1. Seat Assembly 2. Cap Screw 3. Flat Washer 4. Lock Washer

Heater/Air Conditioner

5. Cotter Pin 6. Seat Belt Tether 7. Seat Harness

N3-7

Replacing the Seat Compressor NOTE: The following procedure assumes the operator seat has been removed from the cab.

1 72638

1

1

2

FIGURE 3-9.

2

1. Nut

72636

FIGURE 3-7. 1. Cap Screw

3. Remove front bearing shaft nut (1, Figure 3-9).

2. Nut

1. Remove four nuts (2, Figure 3-7) and two cap screws (1) from rear of seat assembly. Release the fore and aft lever from the front of the seat. Slide the top portion of the seat forward off the suspension assembly and set it aside.

2 1

72639

FIGURE 3-10. 1. Block

1

1

2

72637

FIGURE 3-8. 1. Plastic Clip

2. Boot

2. Dampener Switch

4. Raise the suspension, then use a block or propping device (1, Figure 3-10) to hold the suspension at the top of its stroke. Release the air pressure from the suspension using suspension dampener switch (2) located at the front of the suspension assembly.

2. Remove 28 plastic clips (1, Figure 3-8) from suspension boot (2), then remove the boot from the seat suspension.

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Heater/Air Conditioner

1/13 N03032

1

1 72640

72642

FIGURE 3-11.

FIGURE 3-13.

1. Front Bearing Shaft

1. Rear Bearing Shaft

5. Remove front bearing shaft (1, Figure 3-11) from the suspension assembly.

7. Remove rear bearing shaft (1, Figure 3-13) from the suspension assembly.

1 2 1

72641

72643

FIGURE 3-12.

FIGURE 3-14.

1. Nut

1. Shock Cable

2. Upper Housing

6. Remove rear bearing shaft nut (1, Figure 3-12). 8. Remove upper housing (2, Figure 3-14), invert it and set it next to the suspension. Leave shock cable (1) connected.

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Heater/Air Conditioner

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1

72644

1

72646

FIGURE 3-15.

FIGURE 3-17.

1. Harness Connector

1. Cap Screw

9. Disconnect wire harness connector (1, Figure 3-15) from the compressor.

11. Remove two compressor mounting cap screws (1, Figure 3-17).

1

2

1

72645

1

FIGURE 3-16. 1. Air Hose

1. Compressor

10. Disconnect two air hoses (1, Figure 3-16) from the compressor fitting by pushing in on the fitting collet and pulling out on the air line.

N3-10

72647

FIGURE 3-18. 2. Clamp

12. Remove compressor (1, Figure 3-18) and clamp (2) from the seat suspension assembly.

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1/13 N03032

2

1

2

1

72648

FIGURE 3-19. 1. Compressor

72650

FIGURE 3-21.

2. Clamp

1. To Air Bladder

13. Assemble new clamp (2, Figure 3-19) over new compressor (1) as shown.

2. To Supply

15. Place the new compressor in position inside the suspension assembly, then connect the air hoses to the compressor fittings as shown in Figure 3-21.

2

1

1

72649

FIGURE 3-20. 1. Cable Tie

2. Harness Jumper

14. Attach wire harness jumper (2, Figure 3-20) to the compressor. Ensure the orange wire is connected to the compressor terminal on the valve side of the compressor. Secure wire harness jumper (2) to the clamp using cable tie (1) as shown.

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72651

FIGURE 3-22. 1. Cap Screw

16. Install mounting cap screws (1, Figure 3-22) and tighten to 3 N·m (30 in. lb). NOTE: Ensure the air line does not become pinched between the compressor clamp and the suspension assembly.

Heater/Air Conditioner

N3-11

17. Connect compressor harness (1, Figure 3-23) to the main harness and secure it with cable ties (2) as shown in Figure 17. 18. Reassemble the suspension assembly in the reverse order of disassembly. Connect to power supply and actuate the seat compressor prior to installing suspension assembly in the cab. 19. Test the air hose connections by spraying them with soapy water to check for leaks. If no leaks are present, continue with the assembly process.

1

2

72652

FIGURE 3-23. 1. Harness Connector

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2. Cable Tie

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1/13 N03032

PASSENGER SEAT (STANDARD SEAT)

3. Fasten seat belt tethers (2) to eye bolts in the cab floor. Install cotter pins (3).

Inspection

4. Install the door stop strap. The strap has three holes on each end for adjustment of how wide the door can swing open. Install the pin in the door stop strap where desired.

1. Inspect the seat for wear or damage. Replace worn or damaged parts on the seat. 2. Inspect the seat belts and buckles for proper operation. Also check for worn or frayed fabric. Replace all worn or damaged parts. 3. Inspect the date of manufacture on the seat belt. If the seat belt is over five years old, replace the seat belt. Or, if the seat belt has been in service for more than three years, replace the seat belt.

5. If disconnected, route power window wires through the loop in the bottom of the door stop strap.

4. Inspect the seat tethers. If worn or damaged, replace the tethers. Removal 1. Disconnect the door stop strap so the door can swing open wider. 2. Remove cotter pins (3, Figure 3-24) so that seat belt tethers (2) can be disconnected from the eye bolts in the cab floor. 3. Remove cap screws (4), flat washers (6) and lock washers (5) that secure the riser to the floor. 4. The seat weighs approximately 55 kg (121 lb). Remove the seat from the cab. Then use a suitable lifting device to lift the seat from the deck down to the ground.

Installation 1. The seat weighs approximately 55 kg (121 lb). Use a suitable lifting device to lift the seat from the ground up to the deck. Place seat assembly in position in the cab. 2. Install cap screws (4), flat washers (6) and lock washers (5) that secure the riser to the floor. Tighten the cap screws to the standard torque.

N03032 1/13

FIGURE 3-24. PASSENGER SEAT INSTALLATION 1. Seat Assembly 2. Seat Belt Tether 3. Cotter Pin

Heater/Air Conditioner

4. Cap Screw 5. Lock Washer 6. Flat Washer

N3-13

SEAT BELT REPLACEMENT (STANDARD SEATS - PC3230)

Installation

Inspect the date of manufacture on the seat belt. If the seat belt is over five years old, replace the seat belt. Or, if the seat belt has been in service for more than three years, replace the seat belt. Removal 1. Remove cap screw, flat washer and nut (4, Figure 3-25). Then remove shoulder belt retractor (1). 2. Recline back of seat forward. Remove screws (5, Figure 3-26). Then remove pad (4).

1. Install tether and seat belt buckle (11, Figure 326) to seat with cap screw (12). Tether belt is to be positioned at 45 degree angle. Tighten cap screw (12) to 68 N·m (50 ft lb). 2. If required, install bracket (3, Figure 3-25) with cap screws (2) and nuts. Tighten cap screws to 47 N·m (35 ft lb). 3. Install seat belt retractor (10, Figure 3-26) and tether (9) using flat washer (7) and cap screw (8). Tether belt is to be positioned at 45 degree angle. Tighten cap screw (8) to 68 N·m (50 ft lb).

3. Remove nut (6), cap screw (2) and then spacer (3). Place loose shoulder belt on seat cushion. 4. Remove cap screw (8), seat belt retractor (10), flat washer (7) and tether (9) and from seat. It may be necessary to also remove cap screws (2, Figure 3-25) and nuts and bracket (3). Remove seat belt and shoulder belt from seat. 5. Remove cap screw (12, Figure 3-26) and remove seat belt buckle (11) and the other tether.

FIGURE 3-25. SHOULDER BELT 1. Shoulder Belt Retractor 2. Cap Screw

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FIGURE 3-26. SEAT BELTS

3. Bracket 4. Cap Screw, Nut, Flat Washer

1. Seat 2. Cap Screw 3. Spacer 4. Pad 5. Screws 6. Nut

Heater/Air Conditioner

7. Flat Washer 8. Cap Screw 9. Tether 10. Seat Belt Retractor 11. Seat Belt Buckle 12. Cap Screw

1/13 N03032

4. While installing the top shoulder belt bracket, ensure that the seat belt is not twisted. Install the top shoulder belt bracket to upright support with cap screw (2) and nut (6), with spacer (3) inside the support. Tighten nut to 68 N·m (50 ft lb). 5. Install top pad (4) to support bar with screws (5).

N03032 1/13

6. Ensure the shoulder belt is not twisted. Slowly extend the shoulder belt and install shoulder belt retractor (1, Figure 3-25) to bracket (3). Install cap screw, nut and flat washer (4). Tighten nut to 68 N·m (50 ft lb). 7. Test the seat belt function by buckling and unbuckling the seat belt, and fully extending it. Also, rapidly pull on the shoulder belt to check the locking function. Remove the cardboard warning tag from the belt.

Heater/Air Conditioner

N3-15

SEAT BELT REPLACEMENT (STANDARD SEATS - 58E-57-00500) Inspect the date of manufacture on the seat belt. If the seat belt is over five years old, replace the seat belt. Or, if the seat belt has been in service for more than three years, replace the seat belt.

Installation 1. Install tether (3, Figure 3-27) and seat belt buckle (1) to seat with cap screw and flange nut (2). Tether belt is to be positioned at 45 degree angle. Tighten flange nut to 68 N·m (50 ft lb). 2. Connect the harness and secure with clip (4), if equipped.

Removal 1. Remove carriage bolt, flat washer and locknut (8, Figure 3-28). Then remove shoulder belt retractor (9). 2. Recline back of seat forward. Remove two nuts (1). Then remove adjuster (2) from mount. Place loose shoulder belt on seat cushion. 3. Remove cap screw (5), seat belt retractor (4), flat washer and tether (6) and from seat. It may be necessary to also remove cap screw, flat washer and locknut (10) and bracket (7). Remove seat belt and shoulder belt (3) from seat. 4. Disconnect the harness and remove from clip (4), if equipped. 5. Remove cap screw and flange nut (2, Figure 327). Then remove seat belt buckle (1) and tether (3).

FIGURE 3-28. SHOULDER BELT

FIGURE 3-27. SEAT BELT BUCKLE 1. Seat Belt Buckle 2. Cap Screw and Flange Nut

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3. Tether 4. Clip

1. Nut 2. Adjuster 3. Shoulder Belt 4. Seat Belt Retractor 5. Cap Screw 6. Tether

Heater/Air Conditioner

7. Bracket 8. Carriage Bolt, Washer, Locknut 9. Shoulder Belt Retractor 10. Capscrew, Washer, Locknut

1/13 N03032

3. If required, install bracket (7, Figure 3-28) with cap screw, flat washer and locknut (10) and bracket (7). Tighten locknut to 47 N·m (35 ft lb). 4. Install seat belt retractor (4) and tether (6) using flat washer and cap screw (5). Tether belt is to be positioned at 45 degree angle. Tighten cap screw (5) to 68 N·m (50 ft lb). 5. While installing adjuster (2), ensure that shoulder belt (3) is not twisted. Install adjuster (2) onto mount with two nuts (1). Tighten nuts to 68 N·m (50 ft lb).

N03032 1/13

6. Ensure the shoulder belt is not twisted. Slowly extend the shoulder belt and install shoulder belt retractor (9) to bracket (7). Install carriage bolt, flat washer and locknut (8). Tighten locknut to 68 N·m (50 ft lb). 7. Test the seat belt function by buckling and unbuckling the seat belt, and fully extending it. Also, rapidly pull on the shoulder belt to check the locking function. Remove the cardboard warning tag from the belt.

Heater/Air Conditioner

N3-17

OPERATOR SEAT (OPTIONAL SEAT) The operator's seat provides a fully adjustable cushioned ride for driver comfort and easy operation. Seat Belts • On both driver and passenger seats, check the seat belt fabric, buckle, all belt retractors and hardware for damage or wear. Replace any worn or damaged parts immediately.

comfortable position. Release the lever to lock the position adjustment. 9. Seat Tilt: Lift seat slope lever (9) and hold to adjust the slope of the seat. Release the lever to lock the adjustment. Armrests: Rotate adjusting knob (10) until the armrest is in the desired position.

• Even if there are no signs of damage, replace both driver and passenger seat belts 5 years after seat belt manufacture, or every 3 years after start of use, whichever comes first. The passenger seat 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. Adjustment The following adjustments must be made while sitting in the seat. 1. Headrest: (1, Figure 3-29) will move up, down, fore, or aft by moving headrest to desired position. 2. Backrest Angle: Lift backrest adjustment handle (2) to release and select the backrest angle. Release the control handle to set. 3. Seat Belt: The operator must have seat belt (3) buckled in place and properly adjusted whenever vehicle is in motion. 4. Air Lumbar Support: Each rocker switch (4) controls an air pillow. One switch controls the lower air pillow and the other switch controls the upper air pillow. To inflate, press on top of the rocker switch and hold for desired support, then release. To deflate, press on the bottom of the rocker switch and hold for desired support, then release. Adjust each pillow for desired support. 5. Suspension Dampener: Press rocker switch (5) on top to increase ride firmness. Press on lower part of rocker switch to decrease ride firmness. 6. Fore/Aft Location of Seat: Lift fore and aft lever (6) and hold. Bend knees to move seat to a comfortable position. Release the control lever to lock the adjustment. 7. Seat Height: Press rocker switch (7) on top to increase ride height. Press on lower part of rocker switch to decrease ride height.

FIGURE 3-29. OPERATOR’S SEAT CONTROLS 1. Headrest 2. Backrest Angle 3. Seat Belt 4. Lumbar Support 5. Suspension Dampener

6. Fore and Aft 7. Seat Height 8. Seat Cushion Fore and Aft 9. Seat Tilt 10. Armrest Tilt

8. Fore/Aft Location of Seat Cushion - Lift and hold lever (8) and move the seat cushion to a

N3-18

Heater/Air Conditioner

1/13 N03032

PASSENGER SEAT (OPTIONAL SEAT) The passenger seat provides a fully adjustable cushioned ride for passenger comfort and easy operation. Seat Belts • On both driver and passenger seats, check the seat belt fabric, buckle, all belt retractors and hardware for damage or wear. Replace any worn or damaged parts immediately.

8. Seat Belt: The operator must have seat belt (3) buckled in place and properly adjusted whenever vehicle is in motion. 9. Backrest Angle: Lift backrest adjustment handle (2) to release and select the backrest angle. Release the control handle to set.

• Even if there are no signs of damage, replace both driver and passenger seat belts 5 years after seat belt manufacture, or every 3 years after start of use, whichever comes first. The passenger seat 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. Adjustment The following adjustments must be made while sitting in the seat. 1. Headrest: (1, Figure 3-30) will move up, down, fore, or aft by moving headrest to desired position. 2. Seat Height: Press rocker switch (7) on top to increase ride height. Press on lower part of rocker switch to decrease ride height. 3. Fore/Aft Location of Seat Cushion - Lift and hold lever (8) and move the seat cushion to a comfortable position. Release the lever to lock the position adjustment. 4. Seat Tilt: Lift seat slope lever (9) and hold to adjust the slope of the seat. Release the lever to lock the adjustment. 5. Fore/Aft Location of Seat: Lift fore and aft lever (6) and hold. Bend knees to move seat to a comfortable position. Release the control lever to lock the adjustment. 6. Suspension Dampener: Press rocker switch (5) on top to increase ride firmness. Press on lower part of rocker switch to decrease ride firmness. 7. Air Lumbar Support: Each rocker switch controls an air pillow. One switch controls the lower air pillow and the other switch controls the upper air pillow. To inflate, press on top of the rocker switch and hold for desired support, then release. To deflate, press on the bottom of the rocker switch and hold for desired support, then release. Adjust each pillow for desired support.

N03032 1/13

FIGURE 3-30. PASSENGER’S SEAT CONTROLS 1. Headrest 2. Seat Height 3. Seat Cushion Fore and Aft 4. Seat Tilt 5. Fore and Aft

Heater/Air Conditioner

6. Suspension Dampener 7. Lumbar Support 8. Seat Belt 9. Backrest Angle

N3-19

SEAT BELT REPLACEMENT (OPTIONAL SEATS)

2. Remove seat belt buckle bolt (1, Figure 3-32) and discard bolt and buckle.

General Inspect the date of manufacture on the seat belt. If the seat belt is over five years old, replace the seat belt. Or, if the seat belt has been in service for more than three years, replace the seat belt.

Follow the instructions to install the new seat belts. The instructions are the same for operator or passenger seats except where noted. Required Tools: • Rubber mallet • Rivet press • box end wrench - 17 mm • Torx - T40

FIGURE 3-32.

• Torx - T45

1. Bolt

• Allen Head - 6 mm • Allen Head - 5mm • Torque wrench

3. Remove two screws (2, Figure 3-33) from upper seat belt cover (1).

Removal 1. Lift up tilt handle (2, Figure 3-31). Remove lower seat belt bolt (1) and discard.

FIGURE 3-33. 1. Cover

2. Screws

FIGURE 3-31. 1. Bolt

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2. Tilt Handle

Heater/Air Conditioner

1/13 N03032

4. Remove upper seat belt bolt (1, Figure 3-34) or (2) while holding the nut on the backside with a wrench.

6. Remove seat belt retractor bolt (2, Figure 3-36). Discard bolt and seat belt (1).

NOTE: Both operator and passenger seats are shown in Figure 3-34.

FIGURE 3-36. 1. Seat Belt

2. Bolt

FIGURE 3-34. 1. Bolt

2. Bolt

5. Remove rear cover (1, Figure 3-35) by pushing out the center of the four plastic rivets.

7. Separate the plastic cover from the tongue of the seat belt by unlatching two inside tabs (1, Figure 3-37). The plastic cover will then slide off.

FIGURE 3-35. 1. Cover

FIGURE 3-37. 1. Tabs

N03032 1/13

Heater/Air Conditioner

N3-21

8. Align new seat belt retractor (2, Figure 3-38) with the upper seat belt mount (1). Install seat belt retractor with a 16 mm long bolt (3) and tighten to 35 ± 5 N·m (26 ± 4 ft lb).

10. Select new seat belt buckle (1 or 2, Figure 340), spacer (5), washer (4) and bolt (3). Align the bolt, washer, spacer and buckle in the correct order as shown. Add grease to bolt below its head.

FIGURE 3-38. 1. Belt 2. Seat Belt Retractor

FIGURE 3-40. 3. Bolt

9. Push the seat belt through the upper mount. Reinstall upper seat belt bolt (1, Figure 3-39) and tighten to 35 ± 5 N·m (26 ± 4 ft lb) while holding the nut on the back side with a wrench. Reinstall the upper seat belt cover and tighten screws to 4 N·m (3 ft lb). Reattach the plastic bezel to the tongue.

1. Seat Belt Buckle 2. Seat Belt Buckle 3. Bolt

4. Washer 5. Spacer

11. Secure tether and seat belt (1, Figure 3-41) with new bolt and tighten to 70 N·m (52 ft lb). Note that the washer must be aligned with lip (2) on the buckle.

FIGURE 3-39. 1. Bolt

2. Cover FIGURE 3-41. 1. Seat Belt

N3-22

Heater/Air Conditioner

2. Lip

1/13 N03032

12. Using a 22 mm long bolt (1, Figure 3-42), attach seat belt to opposite side with the tether (2) underneath the belt anchor. Tighten the bolt to 35 N·m (26 ft lb).

14. Remove cardboard note (1, Figure 3-44) from the seat belt. Install rear cover (2) to the seat frame using the four plastic rivets previously removed.

FIGURE 3-44. 1. Cardboard Cover

FIGURE 3-42. 1. Bolt

2. Cover

2. Tether

13. If installing a driver buckle, push seat belt minder cord (1, Figure 3-43) between the seat cushions and the side frame to the back of the seat. Wire tie the cord to the hoses in the back. Connect the minder cord to the wire harness in the cab, if equipped.

FIGURE 3-43. 1. Seat Belt Minder Cord

N03032 1/13

Heater/Air Conditioner

N3-23

NOTES

N3-24

Heater/Air Conditioner

1/13 N03032

SECTION N4 OPERATOR COMFORT INDEX OPERATOR COMFORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-3 HEATER / AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-3 Fan Speed Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Flow Directional Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater/Air Conditioner Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

N4-3 N4-3 N4-3 N4-4

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-4 Fuse and Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Motor And Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

N4-4 N4-4 N4-4 N4-5 N4-5 N4-5

ENVIRONMENTAL IMPACT OF AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-8 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-8 PRINCIPLES OF REFRIGERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-8 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-8 Refrigeration - The Act Of Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-9 The Refrigeration Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-9 AIR CONDITIONER SYSTEM COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-10 Compressor (Refrigerant Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Receiver-Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expansion Block Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

N4-10 N4-10 N4-10 N4-10 N4-11 N4-11 N4-11

ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-12 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-12 Compressor Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-12 Trinary™ Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-13 SYSTEM SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-14 SERVICE TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-15 Recovery/Recycle Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leak Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Manifold Gauge Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purging Air From Service Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

N04041

Operator Comfort

N4-15 N4-15 N4-16 N4-16 N4-17 N4-18 N4-18

N4-1

SYSTEM PERFORMANCE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-19 SYSTEM OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-20 Handling and Reusing PAG Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-20 Oil Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-20 Checking System Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-21 REFRIGERANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-22 Recycled Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-22 Reclaimed Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-22 Refrigerant Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-22 R-134a Refrigerant Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-22 SYSTEM LEAK TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-23 Electronic Leak Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-23 Tracer Dyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-23 Soap and Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-23 RECOVERING AND RECYCLING THE REFRIGERANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-23 Draining Oil from the Previous Recovery Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-23 Performing the Recovery Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-24 Performing the Recycling Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-24 Evacuating and Charging the A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-24 SYSTEM REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-24 System Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-25 COMPONENT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-26 Hoses and Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-26 Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-26 Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-26 Receiver-Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-26 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-26 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-27 Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-27 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-27 EVACUATING THE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-28 EVACUATING THE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-28 CHARGING THE A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-30 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-31 Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-31 Diagnosis Of Gauge Readings And System Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-31 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-32 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . N4-36

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OPERATOR COMFORT HEATER / AIR CONDITIONER The heater/air conditioner compartment contains heater/air conditioner controls and some of the heater/air conditioner components, such as the blower motor assembly and the heater coil. Optimum cab air climate can be selected by using the following controls in various combinations. Fan Speed Control Knob Fan speed control knob (1, Figure 4-1) is provided to control the cab air fan motor. The fan motor is a 3speed motor (low, medium and high). Speeds are selected by rotating the control knob clockwise to the desired position. OFF is in the full counter-clockwise position. The control knob must be switched ON for the air conditioner to function. Temperature Control Knob Temperature control knob (2, Figure 4-1) allows the operator to select a comfortable air temperature. The control knob determines the operation of the air conditioning and heater modes. Rotating the control knob counter-clockwise (blue zone (3)) will cause the A/C compressor to operate and result in cooler air temperatures. Full counterclockwise position is the coldest air setting. Rotating the control knob clockwise (red zone (4)) will affect coolant flow through the heater core and result in warmer air temperatures. The full clockwise position is the warmest heater setting. Air Flow Directional Knob Air flow directional knob (5, Figure 4-1) controls the direction of airflow as follows: Provides airflow to floor vents, only.

FIGURE 4-1. A/C & HEATER CONTROLS

Provides airflow to upper vents and floor vents. Provides airflow to upper vents, only. Defrost - Provides dehumidified air to the windshield.

1. Fan Speed Control Knob 2. Temperature Control Knob 3. Blue Zone

4. Red Zone 5. Air Flow Directional Knob 6. Vents

Defrost - Provides dehumidified air to the windshield as well as to floor vents.

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Heater/Air Conditioner Vents

Relays

Heater/air conditioner vents (6, Figure 4-1) may be rotated 360°. There are three vents in the heater/air conditioner compartment, four vents across the top of the instrument panel, and one vent each in the RH and LH instrument panels. There are also an additional four vents under the instrument panel. Air flow through the vents is controlled by manually opening, closing or turning the louvers.

Three relays (8, Figure 4-2) control the damper doors, A/C compressor clutch, temperature control switch, water (heater) valve and the actuator motors.

COMPONENTS Figure 4-2 and Figure 4-4 illustrate both the heater system and air conditioning system parts contained in the cab mounted enclosure. Refer to the air conditioning system topics later in this section for additional information regarding air conditioning system components, maintenance and repair.

Heater Core Heater core (2, Figure 4-4) receives engine coolant through water valve (33) when heat is selected. If temperature control knob (2, Figure 4-1) is placed in between the red and blue area, or turned counterclockwise to the blue area, coolant flow should be blocked. If temperature control knob (2) and water valve (33, Figure 4-4) appear to be working properly, yet no heat is apparent in heater core (2), the core may be restricted. Remove and clean or replace the core.

Fuse and Circuit Breaker Before attempting to troubleshoot the electrical circuit in the heater enclosure, turn the key switch ON and verify that the fuse is not burned out. Refer to the electrical schematic for more detailed information.

FIGURE 4-2. CAB HEATER/AIR CONDITIONER COMPONENTS 1. Enclosure 2. Water (Heater) Valve 3. A/C Refrigerant Hoses 4. Water Outlet (To Engine) 5. Water Inlet (From Engine Water Pump 6. Evaporator Core 7. Heater Core 8. Relays

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Fan Motor And Speed Control

Cab Air Filter

Fan speed is controlled by the position of the fan speed control knob (1, Figure 4-1).

Recirculation air filter (5, Figure 4-4) and fresh air filter (2, Figure 4-3) in the front access panel of the cab need periodic cleaning to prevent restrictions in air circulation. Restricted filters will decrease the performance of the heater and air conditioner. The recommended interval for cleaning and inspection is 250 hours, but in extremely dusty conditions the filters may need daily service and inspection, especially the outer panel filter on the cab shell. The filter elements should be cleaned with water and dried in a dust free environment before reinstallation. Replace the filter element every 2000 hours, or sooner if inspection indicates a clogged or damaged filter.

If blower assembly (3, Figure 4-4) does not operate at any of the speed selections, verify that battery voltage is available at the switches and relay. Refer to the electrical schematic in Section R. If voltage is present, the blower assembly is probably defective and should be removed and replaced.

Actuators Two rotary actuator motors (9, Figure 4-4) are installed inside the heater housing and are used to actuate the damper doors for the following: •

Defroster outlet

•

Bi-level or floor outlets

A failure to switch one of the above modes of operation may be caused by a faulty actuator. Visually inspect damper doors (35, 36) and the linkage for the function being diagnosed. Ensure that the damper door is not binding or obstructed, preventing movement from one mode to the other. Verify that 24 VDC is present at the actuator when air flow directional knob (5, Figure 4-1) is moved through its various positions of operation. If the correct voltages are present during operation of the switch, disconnect the actuator from the damper door and verify that actuator force is comparable to a known (new) actuator. If it is not, install a new actuator. FIGURE 4-3. CAB FILTER LOCATION 1. Access Cover

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2. Cab Filter

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FIGURE 4-4. HEATER/AIR CONDITIONER ASSEMBLY 1. Evaporator Core 2. Heater Core 3. Blower Assembly 4. Outer Recirculation Grille 5. Recirculation Filter 6. Inner Recirculation Grille 7. Expansion Block Valve 8. Relay 9. Actuator

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10. Louver 11. Thermostat 12. LH Seal 13. Front Seal 14. Top Seal 15. Screw 16. Screw 17. Cover 18. Knob 19. Seal 20. Foam

21. Foam 22. Bracket 23. Case 24. Bracket 25. Control Panel Harness 26. Main Unit Harness 27. Seal 28. Screw 29. Screw 30. Bulb 31. Pivot Bushing

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32. Punched Strip 33. Water Valve 34. Drive Adapter 35. Damper Door (Up) 36. Damper Door (Side) 37. Punched Strip 38. Punched Strip 39. Blower Retainer 40. Control Panel 41. Grommet 42. Duct Adapter

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FIGURE 4-5. BASIC AIR CONDITIONING SYSTEM 1. Blower Switch 2. Thermostatic Switch 3. Battery Supply 4. Circuit Breaker 5. Blower 6. Temperature Sensor

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7. Evaporator 8. Expansion Valve 9. Suction Line 10. Test Gauges & Manifold 11. Compressor 12. Refrigerant Container

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13. Magnetic Clutch 14. Compressor Drive Pulley 15. Receiver-Drier 16. Discharge Line 17. Condenser 18. Accumulator

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ENVIRONMENTAL IMPACT OF AIR CONDITIONING Environmental studies have indicated a weakening of the earth’s protective Ozone (O3) layer in the outer stratosphere. Chloro-flouro-carbon compounds (CFC’s), such as R-12 refrigerant (Freon), commonly used in mobile equipment air conditioning systems, have been identified as a possible contributing factor of the Ozone depletion. Consequently, legislative bodies in more than 130 countries have mandated that the production and distribution of R-12 refrigerant be discontinued after 1995. Therefore, a more environmentally-friendly hydro-flouro-carbon. (HFC) refrigerant, commonly identified as HFC-134a or R-134a, is being used in most current mobile air conditioning systems. Additionally, the practice of releasing either refrigerant to the atmosphere during the charging/recharging procedure is prohibited. These restrictions require the use of equipment and procedures which are significantly different from those traditionally used in air conditioning service techniques. The use of new equipment and techniques allows for complete recovery of refrigerants, which will not only help to protect the environment, but through the recycling of the refrigerant will preserve the physical supply, and help to reduce the cost of the refrigerant.

The general cleanliness of the system and components is important. Dust or dirt collected in the condenser, evaporator, or air filters decreases the system's cooling capacity. The compressor, condenser, evaporator units, hoses and fittings must be installed clean and tight and be capable of withstanding the strain and abuse they are subjected to on off-highway vehicles. Equipment downtime costs are high enough to encourage service areas to perform preventative maintenance at regular intervals on vehicle Air Conditioning (A/C) systems. (Cleaning, checking belt tightness, and operation of electrical components).

PRINCIPLES OF REFRIGERATION A brief review of the principles of air conditioning is necessary to relate the function of the components, the technique of troubleshooting and the corrective action necessary to put the A/C unit into top operating efficiency. Too frequently, the operator and the serviceman overlook the primary fact that no A/C system will function properly unless it is operated within a completely controlled cab environment. The circulation of air must be a directed flow. The cab must be sealed against seepage of ambient air. The cab interior must be kept free of dust and dirt which, if picked up in the air system, will clog the intake side of the evaporator coil.

AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES Mining and construction vehicles have unique characteristics of vibration, shock-loading, operator changes, and climate conditions that present different design and installation problems for air conditioning systems. Off-highway equipment, in general, is unique enough that normal automotive or highway truck engineering is not sufficient to provide the reliability to endure the various work cycles encountered. The cab tightness, insulation, and isolation from heat sources is very important to the efficiency of the system. It is advisable to close all vents, even the intakes of pressurization systems, when there are high humidity conditions.

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Air Conditioning Air conditioning is a form of environmental control. As applied to the cab, it refers to the control of temperature, humidity, cleanliness, and circulation of air. In the broad sense, a heating unit is as much an air conditioner as is a cooling unit. The term “air conditioner” is commonly used to identify an air cooling unit. To be consistent with common usage, the term “air conditioner” will refer to the cooling unit utilizing the principles of refrigeration; sometimes referred to as the evaporator unit.

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Refrigeration - The Act Of Cooling • There is no process for producing cold; there is only heat removal. • Heat always travels toward cooler temperatures. This principle is the basis for the operation of a cooling unit. As long as one object has a temperature lower than another, this heat transfer will occur. •

Temperature is the measurement of the intensity of heat in degrees. The most common measuring device is the thermometer.

• All liquids have a point at which they will turn to vapor. Water boiling is the most common example of heating until vapor is formed. Boiling is a rapid form of evaporation. Steam is a great deal hotter than boiling water. The water will not increase in temperature once brought to a boil. The heat energy is used in the vaporization process. The boiling point of a liquid is directly affected by pressure. By changing pressure, we can control the boiling point and temperature at which a vapor will condense. When a liquid is heated and vaporizes, the gas will absorb heat without changing pressure. • Reversing the process, when heat is removed from water vapor, it will return to the liquid state. Heat from air moves to a cooler object. Usually the moisture in the cooled air will condense on the cooler object. • Refrigerant - Only R-134a should be used in the new mobile systems which are designed for this refrigerant.

Ambient air, passing through the condenser removes heat from the circulating refrigerant resulting in the conversion of the refrigerant from gas to liquid. The liquid refrigerant moves on to the receiver drier where impurities are filtered out, and moisture removed. This component also serves as the temporary storage unit for some liquid refrigerant. The liquid refrigerant, still under high pressure, then flows to the expansion valve. This valve meters the amount of refrigerant entering the evaporator. As the refrigerant passes through the valve, it becomes a low temperature, low pressure liquid and saturated vapor. This causes the refrigerant to become cold. The remaining low pressure liquid immediately starts to boil and vaporize as it approaches the evaporator, adding to the cooling. The hot, humid air of the cab is pulled through the evaporator by the evaporator blower. Since the refrigerant is colder than the air, it absorbs the heat from the air producing cool air which is pushed back into the cab. The moisture in the air condenses upon movement into the evaporator and drops into the drain pan from which it drains out of the cab. Refrigerant leaving the evaporator enters the accumulator. The accumulator functions as a sump for liquid refrigerant in the system. Because of its design, the accumulator only allows vaporized refrigerant to return to the compressor, preventing compressor slugging from occurring. Desiccant is located at the bottom of the accumulators to remove moisture that is trapped in the system. The cycle is completed when the heated low pressure gas is again drawn into the compressor through the suction side.

The Refrigeration Cycle In an air conditioning system, the refrigerant is circulated under pressure through the five major components in a closed circuit. At these points in the system, the refrigerant undergoes predetermined pressure and temperature changes.

This simplified explanation of the principles of refrigeration does not call attention to the fine points of refrigeration technology. Some of these will be covered in the following discussions of the components, controls, and techniques involved in preparing the unit for efficient operation.

The compressor (refrigerant pump) takes in low pressure heat laden refrigerant gas through the suction valve (low side), and as its name indicates, pressurizes the heat laden refrigerant and forces it through the discharge valve (high side) on to the condenser.

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AIR CONDITIONER SYSTEM COMPONENTS Compressor (Refrigerant Pump) The compressor is where the low pressure side of the system changes to high pressure. It concentrates the refrigerant returning from the evaporator (low side) creating high pressure and a temperature much higher than the outside air temperature. The high temperature differential between the refrigerant and the outside air is necessary to aid rapid heat flow in the condenser from the hot refrigerant gas to much cooler outside air. To create high pressure concentration, the compressor draws in refrigerant from the evaporator through the suction valve and during compression strokes, forces it out through the discharge valve to the condenser. The pressure from the compressor action moves the refrigerant through the condenser, receiver-drier and connecting hoses to the expansion valve. The compressor is driven by the engine through a vbelt driving an electrically operated clutch mounted on the compressor drive shaft.

Service Valves Quick-connect hose end fittings with integral service valves attach to system service ports for servicing the unit. A manifold gauge set is connected into the system at the service valve ports and all procedures, such as discharging, evacuating and charging the system, are performed through the service valves.

Condenser The condenser receives the high pressure, high-temperature refrigerant vapor from the compressor and condenses it to high pressure, hot liquid. It is designed to allow heat movement from the hot refrigerant vapor to the cooler outside air. The cooling of the refrigerant changes the vapor to liquid. Heat exchange is accomplished using cooler air flowing through the condenser. Condenser cooling is achieved by air flowing from the radiator fan along with ram air provided by vehicle movement. The radiator fan moves more than 50% of condenser air flow unless travel speed is at least 25 mph.

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Ram air condensers depend upon the vehicle movement to force a large volume of air past the fins and tubes of the condenser. The condenser is usually located in front of the radiator or on the roof of the truck. Condensing of the refrigerant is the change of state of the refrigerant from a vapor to a liquid. The action is affected by the pressure of the refrigerant in the coil and air flow through the condenser. Condensing pressure in an A/C system is the controlled pressure of the refrigerant which affects the temperature at which it condenses to liquid, giving off large quantities of heat in the process. The condensing point is sufficiently high to create a wide temperature differential between the hot refrigerant vapor and the air passing over the condenser fins and tubes. This difference permits rapid heat transfer from the refrigerant to ambient air.

Receiver-Drier The receiver-drier is an important part of the air conditioning system. The drier receives the liquid refrigerant from the condenser and removes any moisture and foreign matter present which may have entered the system. The receiver section of the tank is designed to store extra refrigerant until it is needed by the evaporator. The storage of this refrigerant is temporary and is dependent on the demand of the expansion valve. A desiccant is a solid substance capable of removing moisture from gas, liquid or solid. It is held in place within the receiver between two screens, which also act as strainers. The receiver-drier is also equipped with a sight glass and a moisture indicator. The sight glass can give a good indication of the charge of the system. If the sight glass is not clear, the system is low on refrigerant. The moisture indicator is a device to notify service personnel that the drier is full of moisture and must be replaced. The indicator is blue when the component is free from moisture. When the indicator turns beige or tan, the drier must be replaced.

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Expansion Block Valve The expansion block valve controls the amount of refrigerant entering the evaporator coil. Both internally and externally equalized valves are used. The expansion valve is located near the inlet of the evaporator and provides the functions of throttling, modulating, and controlling the liquid refrigerant to the evaporator coil. The refrigerant flows through a restriction creating a pressure drop across the valve. Since the expansion valve also separates the high side of the system from the low side, the state of the refrigerant entering the valve is warm to hot high pressure liquid; exiting it is low pressure liquid and gas. The change to low pressure allows the flowing refrigerant to immediately begin changing to gas as it moves toward the evaporator. This produces the desired cooling effect. The amount of refrigerant metered into the evaporator varies with different heat loads. The valve modulates from wide open to the nearly closed position, seeking a point between for proper metering of the refrigerant. As the load increases, the valve responds by opening wider to allow more refrigerant to pass into the evaporator. As the load decreases, the valve reacts and allows less refrigerant into the evaporator. It is this controlling action that provides the proper pressure and temperature control in the evaporator. This system uses an internally equalized, block type expansion valve. With this type valve, the refrigerant leaving the evaporator coil is also directed back through the valve so the temperature of the refrigerant is monitored internally rather than by a remote sensing bulb. The expansion valve is controlled by both the temperature of the power element bulb and the pressure of the liquid in the evaporator. NOTE: It is important that the sensing bulb, if present, is tight against the output line and protected from ambient temperatures with insulation tape.

Accumulator As the accumulator receives vaporized refrigerant from the evaporator, moisture and/or any residual liquid refrigerant is collected at the bottom of the component. The moisture is absorbed by the desiccant where it is safely isolated from the rest of the system.

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The storage of the liquid refrigerant is temporary. When the liquid vaporizes into a gas it will be pulled from the bottom of the accumulator into the compressor. This process not only allows the accumulator to act as a storage device, but also protects the compressor from liquid slugging. The low side service port is also located on the accumulator.

Evaporator The evaporator cools and dehumidifies the air before it enters the cab. Cooling a large area requires that large volumes of air be passed through the evaporator coil for heat exchange. Therefore, a blower becomes a vital part of the evaporator assembly. It not only draws heat laden air into the evaporator, but also forces this air over the evaporator fins and coils where the heat is surrendered to the refrigerant. The blower forces the cooled air out of the evaporator into the cab. Heat exchange, as explained under condenser operation, depends upon a temperature differential of the air and the refrigerant. The greater the temperature differential, the greater will be the amount of heat exchanged between the air and the refrigerant. A high heat load condition, as is generally encountered when the air conditioning system is turned on, will allow rapid heat transfer between the air and the cooler refrigerant. The change of state of the refrigerant in and going through the evaporator coil is as important as that of the air flow over the coil. All or most of the liquid that did not change to vapor in the expansion valve or connecting tubes boils (expands) and vaporizes immediately in the evaporator, becoming very cold. As the process of heat loss from the air to the evaporator coil surface is taking place, any moisture (humidity) in the air condenses on the cool outside surface of the evaporator coil and is drained off as water. At atmospheric pressure, refrigerant boils at a point lower than water freezes. Therefore, the temperature in the evaporator must be controlled so that the water collecting on the coil surface does not freeze on and between the fins and restrict air flow. The evaporator temperature is controlled through pressure inside the evaporator, and temperature and pressure at the outlet of the evaporator.

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ELECTRICAL CIRCUIT

Compressor Clutch

The air conditioner's electrical circuit is fed from an accessory circuit and is fused with a 30-ampere circuit breaker.

An electromagnetic clutch is used in conjunction with the thermostat to disengage the compressor when it is not needed, such as when a defrost cycle is indicated in the evaporator, or when the system or blower is turned off.

The blower control is a switch which provides a range of blower speeds from fast to slow. When the blower switch is turned on, current is available at the compressor clutch. Once the blower is turned on, fan speeds may be changed without affecting the thermostat sensing level. The thermostat reacts to changing temperatures which cause electrical contacts to open and close. The thermostat has a capillary tube extended into the evaporator coil to sense temperature. When the contacts are closed, current flows to the clutch field and energizes the clutch, causing the swash plate inside the compressor to turn which starts the refrigeration cycle. When the temperature of the evaporator coil drops to a predetermined point, the contacts open and the clutch disengages. When the clutch is disengaged, the blower remains at the set speed. After the evaporator temperature rises about twelve degrees above the cutout point, the contacts in the thermostat close and the refrigeration cycle resumes.

Thermostat An electromagnetic clutch is used on the compressor to provide a means of constant temperature control of the cab. The clutch is controlled by a thermostat in the evaporator which is set initially by the driver to a predetermined point. Evaporator temperature is then maintained by the cycling action of the clutch.

The stationary field clutch is the most desirable type since it has fewer parts to wear. The field is mounted to the compressor by mechanical means depending on the type field and compressor. The rotor is held on the armature by a bearing and snap rings. The armature is mounted on the compressor body. When no current is fed to the field, there is no magnetic force applied to the clutch and the rotor is free to rotate on the armature, which remains stationary on the crankshaft. When the thermostat or switch is closed, current is fed to the field. This sets up a magnetic force between the field and armature, pulling it into the rotor. When the armature becomes engaged with the rotor, the complete unit rotates while the field remains stationary. This causes the compressor crankshaft to turn, starting the refrigeration cycle. When the switch or thermostat is opened, current is cut off. The armature snaps back out and stops while the rotor continues to turn. Pumping action of the compressor is stopped until current is again applied to the field. In addition, safety switches in the compressor clutch electrical circuit control clutch operation, disengaging the clutch if system pressures are abnormal.

The thermostat is simply a thermal device which controls an electrical switch. When warm, the switch is closed; when cold, it is open. Most thermostats have a positive OFF position as a means to turn the clutch off regardless of temperature. The bellows type thermostat has a capillary tube connected to it which is filled with refrigerant. The capillary tube is attached to the bellows inside of the thermostat. Expansion of the gases inside the capillary tube exerts pressure on the bellows, which in turn closes the contacts at a predetermined temperature.

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Trinary™ Switch This switch is mounted on the receiver-drier and has three functions, as implied by the name: 1. Disengage the compressor clutch when system pressure is too high. 2. Disengage the compressor clutch when system pressure is too low. 3. Engage and disengage the radiator fan drive clutch during normal variation of system pressure. The Trinary™ switch performs three distinct functions to monitor and control refrigerant pressure in the system. This switch is installed on the receiverdrier. The switch functions are: Terminals 1 & 2 are connected internally through two, normally closed pressure switches in series, the low pressure switch and the high pressure switch.

• Fan Clutch - The mid-range function actuates the engine fan clutch, if installed. • High Pressure - This switch opens and disengages the compressor clutch if system pressure rises above the 2068-2413 kPa (300350 psi) range. After system pressure drops to 1448-1724 kPa (210-250 psi), the switch contacts will close and the clutch will engage. The switch functions will automatically reset when system pressure returns to normal. OPENS

CLOSES

Low Pressure

103-207 kPa (15-30 psi) descending pressure

276 kPa (40 psi) rising pressure

High Pressure

2068-2413 kPa (300-350 psi)

1448-1724 kPa (210-250 psi)

241-414 kPa (35-60 psi) below closing pressure

1379-1586 kPa (200-230 psi) rising pressure

Fan Clutch

The pressures listed above are typical of pressures at the receiver-drier. Due to normal system flow losses and the distance between the service port and the receiver-drier, it is expected that actual system pressure displayed on the gauge will normally be approximately 20 psi higher. This factor should be observed when checking for proper operation of the switch. Terminals 3 & 4 are connected internally through a normally open switch that is used to control the clutch that drives the radiator fan. This switch closes and causes the cooling fan clutch to engage when system pressure rises to 1379-1586 kPa (200-230 psi). When pressure falls to 965-1344 kPa (140-195 psi), the switch contacts open, and the cooling fan clutch disengages. • Low Pressure - This switch opens and disengages the compressor clutch if system pressure drops into the 103-207 kPa (15-30 psi) range. When pressure rises above 276 kPa (40 psi), the switch contacts close, and the clutch engages the compressor. Since temperature has a direct effect on pressure, if the ambient temperature is too cold, system pressure will drop below the low range, and the pressure switch will disengage the clutch.

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NOTE: One other pressure controlling device is installed within the compressor. A mechanical relief valve is located on the back of the compressor. The relief valve will open at 3447-3792 kPa (500 - 550 psi). The purpose of this valve is to protect the compressor in the event that pressure should be allowed to rise to that level. Damage to the compressor will occur if pressure exceeds 550 psi.

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SYSTEM SERVICING 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 R-134a refrigerant quality and quantity in an air conditioning system. Because the refrigerant in an air conditioning system must remain pressurized and sealed within the unit to function properly, safety is a major consideration when anything causes this pressurized, sealed condition to change. The following warnings are provided here to alert service personnel to their importance before learning the correct procedures. Read, remember, and observe each warning before beginning actual system servicing. NOTE: If the mine operates a fleet with some trucks using R-12 and others using R-134a refrigerant, it is essential that servicing tools that come into contact with the refrigerant (gauge sets, charging equipment, recycle/recovery equipment etc.) be dedicated to one type refrigerant only, to prevent cross contamination.

Ensure sufficient ventilation whenever refrigerant is being discharged from a system, keeping in mind refrigerant is heavier than air and will fall to low-lying areas. When exposed to flames or sparks, the 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 direct a steam cleaning hose or torch in direct contact with components in the air conditioning system. Localized heat can raise the pressure to a dangerous level. Do not heat or store refrigerant containers above 49° C (120° F). Do not flush or pressure test the system using shop air or another compressed air source. Certain mixtures of air and R-134a refrigerant are combustible when slightly pressurized. Shop air supplies also contain moisture and other contaminants that could damage system components.

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Federal regulations prohibit venting R-12 and R-134a refrigerant into the atmosphere. An SAE and UL approved recovery/recycle station must be used to remove refrigerant from the A/C system. Refrigerant is stored in a container on the unit for recycling, reclaiming, or transporting. In addition, technicians servicing A/C systems must be certified they have been properly trained to service the system.

Trucks operating in cold weather climates must continue to keep the A/C system charged during cold weather months. Keeping the system charged helps prevent moisture intrusion into system oil and desiccants.

Although accidental release of refrigerant is a remote possibility when proper procedures are followed, the following warnings must be observed when servicing A/C systems: Provide appropriate protection for your eyes (goggles or face shield) when working around refrigerant. A drop of the liquid refrigerant on your skin will produce frostbite. Wear gloves and exercise extreme care when handling refrigerant. If even the slightest trace of refrigerant enters in your eye, flood the eye immediately with cool water and seek medical attention as soon as possible.

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SERVICE TOOLS AND EQUIPMENT Recovery/Recycle Station Whenever refrigerant must be removed from the system, a dual purpose station as shown in Figure 4-6, performs both recovery and recycle procedures which follows the new guidelines for handling used refrigerant. The recovered refrigerant is recycled to reduce contaminants, and can then be reused in the same machine or fleet.

Mixing different types of refrigerant will damage equipment. Dedicate one recovery/recycle station to each type of refrigerant processing to avoid equipment damage. DISPOSAL of the gas removed requires laboratory or manufacturing facilities.

To accomplish this, the recovery/recycle station separates the oil from the refrigerant and filters the refrigerant multiple times to reduce moisture, acidity, and particulate matter found in a used refrigerant.

Test equipment is available to confirm the refrigerant in the system is actually the type intended for the system and has not been contaminated by a mixture of refrigerant types.

NOTE: To be re-sold, the gas must be “reclaimed” which leaves it as pure as new, but requires equipment normally too expensive for all but the largest refrigeration shops.

Recycling equipment must meet certain standards as published by the Society of Automotive Engineers (SAE) and carry a UL approved label. The basic principals of operation remain the same for all machines, even if the details of operation differ somewhat.

Equipment is also available to just remove or extract the refrigerant. Extraction equipment does not clean the refrigerant - it is used to recover the refrigerant from an A/C system prior to servicing.

Leak Detector The electronic detector (Figure 4-7) 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 the leak detector being used applies to the refrigerant in the system.

FIGURE 4-6. RECOVERY/RECYCLE STATION

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FIGURE 4-7. TYPICAL ELECTRONIC LEAK DETECTOR

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FIGURE 4-9. VACUUM PUMP

FIGURE 4-8. R-134a SERVICE VALVE 1. System Service Port Fitting 2. Quick Connect

3. Service Hose nection

Co Vacuum Pump

Service Valves Because an air conditioning system is a sealed system, two service valves are provided on the compressor to enable diagnostic tests, system charging or evacuation. Connecting the applicable hoses from the manifold gauge set to the compressor service valves enables each of these to be readily performed.

The vacuum pump (Figure 4-9) is used to completely evacuate all of the refrigerant, air, and moisture from the system by deliberately lowering the pressure within the system to the point where water turns to a vapor (boils) and together with all air and refrigerant is withdrawn (pumped) from the system.

New and unique service hose fittings (Figure 4-8) 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.

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Manifold Gauge Set A typical manifold gauge set (Figure 4-10) 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 12 inches 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 12 inches of the hose end. These special hoses and fittings are 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 R134a.”

Functions of the manifold gauge set are included in many of the commercially available recovery or recovery/recycle stations.

FIGURE 4-10. MANIFOLD GAUGE SET

Low Side Gauge The low side 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 150 psi.

Never open the hand valve to the high side at anytime when the air conditioning system is operating. High side pressure, if allowed, may rupture charging containers and potentially cause personal injury. High Side Gauge The high side gauge is used to measure pressure only on the discharge side of the compressor. The scale is calibrated from 0 to 500 psi.

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Installing Manifold Gauge Set Before attempting to service the air conditioning system, a visual inspection of both the engine and A/C 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 the condenser and the radiator for any obstructions or potential contamination. Minimize all the possibilities for error or malfunction of components in the air conditioning system.

Shut off engine. DO NOT attempt to connect service equipment when the engine is running.

4. Connect the two service hoses from the manifold to the correct service valves on the compressor and accumulator, as shown in Figure 411. (High side to compressor discharge valve and low side to accumulator.) Do not open the service valves at this time.

This gauge hook-up process will be the same, regardless of the gauge set being installed. Whether it is a recovery station or individual gauges, the connections are the same. The procedures performed next will vary depending what type of equipment is being used. If a recovery/recycling station is being used, complete servicing can be accomplished. Using only a set of gauges will limit the servicing to only adding refrigerant or observing pressures.

1. Be sure all valves on the manifold are closed all the way (turn them clockwise). 2. Check the hose connections on the manifold for tightness. 3. Locate the low and high side system service fittings and remove their protective caps.

Purging Air From Service Hoses The purpose of this procedure is to remove all the air trapped in the hoses prior to actual system testing. Environmental regulations require that all service hoses have a shutoff valve within 12 inches of the service end. These valves are required to ensure only a minimal amount of refrigerant is lost to the atmosphere. R-134a gauge sets have a combination quick disconnect and shutoff valve on the high and low 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.

FIGURE 4-11. SERVICE HOSE HOOK-UP

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SYSTEM PERFORMANCE TEST This test is performed to establish the condition of all components in the system. Observe these conditions during testing: 1. Place a fan in front of the condenser to simulate normal ram air flow and allow the system to stabilize.

8. Feel the hoses and components on the low side. They should be cool to the touch. Check connections near the expansion valve; the inlet side should be warm and the outlet side cold. 9. After a minimum of 10 minutes has elapsed and the system has stabilized, observe the gauge readings. Compare the readings to the specifications in Table 1.

2. Install a thermometer into the air conditioning vent closest to the evaporator. 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 temperature. 5. Set air conditioning system at maximum cooling and maximum blower speed operation. 6. Close all windows and doors to the cab. 7. Carefully feel the hoses and components on the high side. All should be warm-hot to the touch. Check the inlet and outlet of receiver-drier for even temperatures, if outlet is cooler than inlet, a restriction is indicated.

NOTE: Pressures may be slightly higher in very humid conditions and lower in very dry conditions. Pressures listed in Table 1 are during compressor clutch engagement.

10. Check the cab vents for cool air. Outlet air temperature should be approximately 16 - 22° C (30 - 40° F) below ambient air temperature. 11. If pressures and temperatures are not within the specified ranges, the system is not operating properly. Refer to Preliminary Checks near the end of this chapter 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 1. NOMINAL R-134a PRESSURE RANGES Ambient Air Temperature

High Side Pressure

Low Side Pressure

21° C (70° F)

820 - 1300 kPa (120 - 190 psi)

70 - 138 kPa (10 - 20 psi)

27° C (80° F)

950 - 1450 kPa (140 - 210 psi)

70 - 173 kPa (10 - 25 psi)

32° C (90° F)

1175 - 1650 kPa (170 - 240 psi)

105 - 210 kPa (15 - 30 psi)

38° C (100° F)

1300 - 1850 kPa (190 - 270 psi)

105 - 210 kPa (15 - 30 psi)

43° C (110° F)

1450 - 2075 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.

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SYSTEM OIL

Handling and Reusing PAG 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. Komatsu PAG oil is the only oil that is furnished in the system on Komatsu trucks. Two different compressors have been installed on the trucks at the factory. Compressor A is shown in Figure 4-12. Compressor B is shown in Figure 4-13. Ensure that the correct oil type and quantity is used depending on the compressor being serviced.

• Avoid skin contact and inhalation of PAG oil, as these are normal precautions with any chemical. • PAG oil removed from new or old components must not be retained for re-use. It must be stored 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 system must not be left exposed to the atmosphere any longer than necessary. PAG oil absorbs moisture very rapidly, and therefore, any absorbed moisture could cause damage to an air conditioning system.

Oil Quantity It is critical to keep the correct amount of lubricant in the air conditioning system at all times. Failure to do so could result in damage to the compressor. FIGURE 4-12. COMPRESSOR A 207 ML - (7 oz.) PC2212 PAG OIL

Damage to the compressor can be a result from not only a lack of oil, but from too much oil, also. A lack of oil will cause excess friction and wear on moving parts. Excessive oil can result in slugging the compressor. This condition occurs when the compressor attempts to compress liquid oil as opposed to vaporized refrigerant. Since liquid cannot be compressed, damage to internal parts results.

FIGURE 4-13. COMPRESSOR B 300 ml - (10.1 oz.) PC2279 PAG OIL

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Checking System Oil

The receiver-drier and accumulator must be replaced each time the system is opened. 1. Remove the compressor from the truck. With the compressor positioned horizontally, remove the drain plug, and capture the oil in a clear graduated container. Rock the compressor back and forth, and rotate the shaft to facilitate oil removal.

Under no circumstances should the A/C compressor be stood upright onto the clutch assembly. Damage to the compressor clutch will result, leading to premature compressor failures. 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 System Flushing. If no particles are found, proceed to the next step. 3. Add 207 ml (7oz.) of PAG oil to the compressor sump. Add the oil through the drain port, and install the drain plug. It is important to only add the specified amount to ensure optimal system performance. Too much oil will result in a reduction in cooling. Too little oil will result in compressor failure. 4. Determine the correct amount of additional oil to add to the system by using the Replacing Oil listed in Table 2. Add this extra oil to the inlet side of the receiver drier or accumulator. 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. 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.

When installing a new compressor, the compressor must be completely drained of its oil before installation. Add the correct amount of new PAG oil to the compressor to ensure proper system oil level. Failure to adjust the amount of oil in the compressor will lead to excessive system oil and poor A/C performance. Additionally, a new receiver-drier and accumulator must be installed and oil added to both of these components.

TABLE 2. REPLACING OIL Component

Oil to add

Condenser

60-90 ml (2-3 ounces)

Evaporator

30 ml (1 ounce)

Receiver-Drier

60 ml (2 ounces)

Accumulator

60 ml (2 ounces)

Compressor A (Figure 4-12)

207 ml (7 ounces) PC2212

Compressor B (Figure 4-13)

300 ml (10.1 ounces) PC2279

Block Valve (Expansion)

Adding oil is not necessary

Hoses

Drain and measure amount removed

5. Connect all hoses and components in the system. Lubricate O-Rings with clean mineral oil before assembly. NOTE: Do not use PAG oil to lubricate O-rings or fittings. PAG oil will attract moisture and will corrode 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 System.

NOTE: The proper quantity of oil may be injected into the system during charging as an alternate method of adding oil.

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REFRIGERANT Recycled 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 specifications stipulated by Society of Automotive Engineers, SAE J2099. The refrigerant that has passed through the filtering process has only been cleaned of contaminants that are associated with mobile systems. Therefore, recycled refrigerant from mobile systems is only acceptable for reuse in mobile systems. Reclaimed Refrigerant Reclaimed refrigerant has been filtered through a more thorough filtering process and has been processed to the same standards of purity as virgin refrigerant. Because of this, reclaimed refrigerant is 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.

If an incorrect charge is suspected, recover the refrigerant from the system, and charge the system with the correct operating weight 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.

An unclear sight glass on R-134a systems can indicate that the system may be low on refrigerant. However, the sight glass should not be used as a gauge for charging the system. Charging the system must be done with a scale to ensure the proper amount of refrigerant has been added.

R-134a Refrigerant Containers Two basic, readily available containers are used to store R-134a: the 14 or 28 kg (30 or 60 lb) bulk canisters (Figure 4-14). Always read the container label to verify the contents are correct for the system being serviced. Note the containers for R-134a are painted light blue.

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.

Refrigerant Quantity If not enough refrigerant is charged into the system, cooling ability will be diminished. If too much refrigerant is charged into the system, the system will operate at higher pressures, and in some cases, may damage system components. Exceeding the specified refrigerant charge will not provide better cooling. FIGURE 4-14. R-134a CONTAINERS 1. 14 kg (30 lb) Cylinder

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2. 28 kg (60 lb) Cylinder

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SYSTEM LEAK TESTING

Electronic Leak Detector

Refrigerant leaks are probably the most common cause of air conditioning problems, resulting from improper or no cooling, to major internal component damage. Leaks most commonly develop in two or three places. The first is around the compressor shaft seal, often accompanied by an indication of fresh refrigerant oil. If a system is not operated for a while (winter months), the shaft seal may dry out and leak slightly. The centrifugal force of the clutch pulley spinning can also cause the problem. When the system is operated and lubricant wets the seal, the leak may stop. Such leaks can often be located visually, or by feeling with your fingers around the shaft for traces of oil. (The R-134a itself is invisible, odorless, and leaves no trace when it leaks, but has a great affinity for refrigerant oil.)

(Refer to Figure 4-7). As the test probe is moved into an area where traces of refrigerant are present, a visual or audible announcement indicates a leak. Audible units usually change tone or speed as intensity changes.

A second common place for leaks is the nylon and rubber hoses where they are crimped or clamped to the fittings, or where routing allows abrasion. Other threaded joints or areas where gaskets are used should be visually and physically examined. Moving 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 evaporator. Any trace of fresh oil here is a clear indication of a leak.

Soap and water can be mixed together and applied to system components. Bubbles will appear to pinpoint the specific location of leaks.

Usually, a 50% charged system is enough to find most leaks. If the system is empty, connect the manifold gauge set to the system and charge at least 1.6 kg (3.5 lbs) of refrigerant into the system.

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. NOTE: The refrigerant is heavier than air and will move downward when it leaks. Apply pickup hose or test probe on the under-surface of all components to locate leaks.

Tracer Dyes Tracer dyes are available that can be added to the system as refrigerant is added. The system is then operated to thoroughly circulate the dye. As refrigerant escapes, it leaves a trace of the dye at the point of leakage, which is then detected using an ultraviolet light (black light), revealing a bright fluorescent glow. Soap and Water

After determining the location or source of leak(s), repair or replace leaking component(s). NOTE: The length of the hose will affect the refrigerant capacity. When replacing hoses, always use the same hose length, if possible.

Before system assembly, check the compressor oil level and fill to specifications.

RECOVERING AND RECYCLING THE REFRIGERANT Draining Oil from the Previous Recovery Cycle 1. Place the power switch and the controller on the recovery unit in the OFF position. 2. Plug in the recovery station to the correct power source. 3. Drain the recovered oil through the valve marked “oil drain” on the front of the machine. 4. Place the controller knob in the ON position. The low pressure gauge will show a rise. 5. Immediately switch to the OFF position and allow the pressure to stabilize. If the pressure does not rise to between 34-69 kPa (5-10 psi), switch the controller ON and OFF again.

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6. When the pressure reaches 34-69 kPa (5-10 psi), open the “oil drain” valve, collect the oil in an appropriate container, and dispose of container as indicated by local, state or federal regulation. The oil is not reusable due to contaminants absorbed during use. Performing the Recovery Cycle 1. Be sure the equipment being used is designed for the refrigerant you intend to recover. 2. Observe the sight glass oil level. Having drained it, it should be zero. 3. Check the cylinder refrigerant level before beginning recovery to make sure you have enough capacity.

Performing the Recycling Procedure The recovered refrigerant contained in the cylinder must undergo the recycle procedure before it can be reused. The recycle or clean mode is a continuous loop design and cleans the refrigerant rapidly. Follow the equipment manufacturer's instructions for this procedure. Evacuating and Charging the A/C System Evacuate the system once the air conditioner components are repaired or replacement parts are secured, and the A/C system is reassembled. Evacuation removes air and moisture from the system. Then, the A/C system is ready for the charging process, which adds new refrigerant to the system.

4. Confirm that all shut-off 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 as per the manufacturer's instructions. 7. Continue extraction until a vacuum exists in the A/C system. 8. If an abnormal amount of time elapses after the system reaches 0 psi and does not drop steadily into the vacuum range, close the manifold valves and check the system pressure. If it rises to 0 psi and stops, there is a major leak. 9. Check the system pressure after the recovery equipment stops. After five minutes, system pressure should not rise above “0” gauge pressure. If the pressure continues to rise, restart and begin the recovery sequence again. This cycle should continue until the system is void of refrigerant. 10. Check the sight glass oil level to determine the amount of oil that needs to be replaced. (The amount of oil that was lost during the recovery cycle must be replaced back into the system). 11. Mark the cylinder with a “RECOVERED” (red) magnetic label to reduce the chance of charging a system with contaminated refrigerant. Record the amount of refrigerant recovered.

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SYSTEM REPAIR The following service and repair procedures are not any different than typical vehicle service work. However, A/C system components are made of soft metals (copper, aluminum, brass, etc.). Comments and tips that follow will make the job easier and reduce unnecessary component replacement.

All of the service procedures described are only performed after the system has been discharged. Never use any lubricant or joint compound to lubricate or seal any A/C connections. NOTE: To help prevent air, moisture or debris from entering an open system, cap or plug open lines, fittings, components and lubricant containers. Keep all connections, caps, and plugs clean.

Never leave A/C components, hoses, oil, etc. exposed to the atmosphere. Always keep sealed or plugged until the components are to be installed and the system is ready for evacuation and charging. PAG oil and receiver-drier desiccants attract moisture. Leaving system components open to the atmosphere will allow moisture to invade the system, resulting in component and system failures.

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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 extremely susceptible to foreign particles and must be replaced. If contaminated, the evaporator and condenser must also be replaced. The evaporator and condenser are multi-pass units, and they can not be properly cleaned by flushing.

Only SAE and/or Mobile Air Conditioning Society (MACS) approved flushing methods with the appropriate refrigerants are to be performed when removing debris from the system. Other methods may be harmful to the environment, as well as air conditioning components.

2. Inspect all other components such as the condenser, evaporator, hoses and fittings. If any of these items are damaged or highly contaminated, replace the components. 3. Flush the remaining hoses with a flushing unit. Use only R-134a as a flushing agent. 4. After flushing, blow out the system with dry shop air for 5 to 10 minutes. 5. If the expansion valve has been removed of all foreign contamination, it may be re-installed back into the system. If contamination is still present, replace the valve. 6. Install a new compressor, receiver-drier, and accumulator. 7. Add oil to the system as outlined in Checking System Oil.

1. Remove the compressor, receiver-drier, expansion valve, and accumulator.

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COMPONENT REPLACEMENT

Receiver-Drier

Hoses and Fittings

The receiver-drier can not be serviced or repaired. It must be replaced whenever the system is opened for any service. The receiver-drier has a pressure switch to control the clutch, and should be removed and installed onto the new unit.

When replacing hoses, be sure to use the same type and ID hose you removed. When hoses or fittings are shielded or clamped to prevent vibration damage, be sure these are in position or secured. Lines Always use two wrenches when disconnecting or connecting A/C fittings attached to metal lines. Copper and aluminum tubing can kink or break very easily. When grommets or clamps are used to prevent line vibration, be certain these are in place and secure.

It is important to always tighten the fittings to the proper torque. Failure to do this may result in improper contact between mating parts and leakage may occur. Refer to the following torque chart for tightening specifications.

Fitting Size

Foot Pounds

Newton Meters

6

10 - 15 ft.lbs.

14 - 20 Nm

8

24 - 29 ft.lbs.

33 - 39 Nm

10

26 - 31 ft.lbs.

36 - 42 Nm

12

30 - 35 ft.lbs.

41 - 47 Nm

Installation torque for the single M10 or 3/8 in. cap screws securing the inlet and outlet fittings onto the compressor ports is 15-34 N·m (11-25 ft lbs).

Expansion Valve

NOTE: Do not use PAG oil to lubricate O-Rings or fittings. PAG oil will attract moisture and will corrode fittings when used externally. Use only clean mineral oil to lubricate fittings and O-Rings during assembly.

Thermostat A thermostat can be stuck open or closed due to contact point wear or fusion. The thermostat temperature sensing element (capillary tube) may be broken or kinked closed and therefore unable to sense evaporator temperature. When thermostat contact points are stuck open or the sensing element can not sense temperature in the evaporator, the clutch will not engage (no A/C system operation). Causes are a loss of charge in the capillary tube or a kink, burned thermostat contact or just no contact. When troubleshooting, bypass the thermostat by hot wiring the clutch coil with a fused lead. If the clutch engages, replace the thermostat. Thermostat contact points may be fused (burned) closed and the clutch will not disengage. Causes are a faulty switch that could be due to fatigue. The thermostat must be replaced. When the clutch will not disengage you may also note that condensate has frozen on the evaporator fins and blocked air flow. There will also be below normal pressure on the low side of the system. Side effects can be compressor damage caused by oil accumulation (refrigeration oil tends to accumulate at the coldest spot inside the system) and lower than normal suction pressure that can starve the compressor of oil.

When removing the expansion valve from the system, remove the insulation, clean the area and disconnect the line from the receiver-drier. Detach the capillary (bulb) and external equalizer tube (if present) from their mounting locations. Remove the expansion valve from the evaporator inlet. Expansion valve service is limited to cleaning or replacing the filter screen. If this is not the problem, replace the valve. Secure the capillary and equalizer, if used, to clean surfaces and replace or attach any insulating material.

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Compressor The compressor can fail due to shaft seal leaks (no refrigerant in the system), defective valve plates, bearings, or other internal parts or problems associated with high or low pressure, heat, or lack of lubrication. Be sure the compressor is securely mounted and the clutch pulley is properly aligned with the drive pulley. Use a mechanic's stethoscope to listen for noises inside the compressor.

When installing a new compressor, the compressor must be completely drained of its oil before installation. To ensure proper system oil level, refer to System Oil in this section to determine the correct type and amount of oil to use in the system. Failure to adjust the amount of oil in the compressor will lead to excessive system oil and poor A/C performance.

Under no circumstances should the A/C compressor be stood upright onto the clutch assembly. Damage to the compressor clutch will result, leading to premature compressor failures.

Accumulator The accumulator can not be serviced or repaired. It must be replaced whenever the system is opened for any service.

The fast way to check electrical failure in the lead wire or clutch coil is to hot wire the coil with a fused lead. This procedure enables you to bypass clutch circuit control devices. Clutch pulley bearing failure is indicated by bearing noise when the A/C system is off or the clutch is not engaged. Premature bearing failure may be caused by poor alignment of the clutch and clutch drive pulley. Sometimes it may be necessary to use shims or enlarge the slots in the compressor mounting bracket to achieve proper alignment.

NOTE: Some compressors may be discarded because it is suspected that internal components within the compressor have seized. Ensure that the compressor clutch is working properly before discarding a compressor for internal seizure. The normal compressor life span should be about twice as long as the normal life span of the compressor clutch. It is important to note that often times a weak clutch coil may be mistaken for a seized compressor. When a coil’s resistance has increased over time and the magnetic field weakens, the coil may not be able to pull the load of the compressor. Failure of the coil to allow the compressor shaft to be turned, may appear as though the compressor is locked up. Before a compressor is dismissed as being seized, a check for proper voltage to the coil should be performed. In addition, the coil should be ohm checked for proper electrical resistance. The coil should fall within the following range for compressor B (Figure 4-13): 17.6 ± 0.6 Ohms @ 20° C (68° F)

Clutch Clutch problems include electrical failure in the clutch coil or lead wire, clutch pulley bearing failure, worn or warped clutch plate or loss of clutch plate spring temper. Defective clutch assembly parts may be replaced or the whole assembly replaced. If the clutch shows obvious signs of excessive heat damage, replace the whole assembly.

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The temperatures specified above are roughly typical of a summer morning before first start-up.

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EVACUATING THE SYSTEM Evacuating the complete air conditioning system is required in all new system installations, and when repairs are made on systems requiring a component replacement (system opened), or a major loss of refrigerant has occurred. All these conditions will require that a vacuum be pulled using a vacuum pump that completely removes any moisture from the system. Once properly evacuated, the system can be recharged again.

2. Open the discharge valve on the vacuum pump or remove the dust cap from the discharge outlet. Turn the pump on 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. 3. Allow the vacuum pump to run for at least 45 minutes.

Using a pump to create a vacuum in the air conditioning system effectively vaporizes any moisture, allowing the water vapor to be easily drawn out by the pump. The pump does this by reducing the point at which water boils (100°C, 212°F at sea level with 14.7 psi). In a vacuum, water will boil at a lower temperature depending upon how much of a vacuum 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 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.

FIGURE 4-15. VACUUM PUMP HOOKUP Do not attempt to use the air conditioning compressor as a vacuum pump or the compressor will be damaged. NOTE: Refer to Table 3 for optimal vacuum specifications at various altitudes. 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 in Figure 4-15. Then open both hand valves to maximum.

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N04041

4. Close both valves on the manifold gauge set. Turn the vacuum pump off and observe the gauges. The system should hold the vacuum within 5 cm Hg (2.0 in. Hg) of the optimal vacuum for 5 minutes. If the vacuum does not hold, moisture may still be present in the system. Repeat the previous step. If the vacuum still does not hold, a leak may be present in the system. Find the source of the leak, repair, and evacuate the system, again.

NOTE: In some cases, 45 minutes of evacuation may not be sufficient to vaporize all of the moisture and draw it out of the system. If it has been verified that no system leaks exist and gauge readings increase after 45 minutes, extend the evacuation time to ensure total moisture removal.

TABLE 3. ALTITUDE VACUUM VARIATIONS Altitude

Optimal Vacuum

Meters (Feet) Above Sea Level

Cm Hg. (In. Hg.)

0

76.0 (29.92)

305 (1000)

73.5 (28.92)

610 (2000)

70.7 (27.82)

914 (3000)

68.1 (26.82)

1219 (4000)

65.6 (25.82)

1524 (5000)

63.3 (24.92)

1829 (6000)

60.8 (23.92)

2134 (7000)

58.5 (23.02)

2438 (8000)

56.4 (22.22)

2743 (9000)

54.2 (21.32)

NOTE: The chart indicates the expected gauge readings at altitude to obtain the optimal vacuum.

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Operator Comfort

N4-29

CHARGING THE A/C SYSTEM The proper method for charging refrigerant into a R134a system is to first, recover all of the refrigerant from the system. The charging refrigerant should then be weighed on a scale to ensure the proper amount is charged into the system. Most recovery units include a scale within the apparatus, thus making it very easy to charge the correct amount every time. If equipment such as this is not available, a common scale can be used to determine the weight of charge. Simply weigh the charging tank, subtract the weight of the proper charge, and charge the system until the difference is shown on the scale. On certain types of equipment, it is also possible to add any necessary lubricant when charging the system.

1. Charge the A/C system with 3.4 kg (7.4 lbs) of R-134a refrigerant. NOTE: Charging is to be performed with the engine and compressor 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. 2. Check the system for leaks. Refer to System Leak Testing. 3. If no leaks are found, verify the system’s cooling capacity meets requirements. Refer to System Performance Testing.

If a scale is not used when charging R-134a into a system, it is difficult to tell if the correct charge has been achieved. The sight glass can provide some indication, but it is not a reliable tool for determining proper charge.

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TROUBLESHOOTING Preliminary Checks If the system indicates insufficient cooling, or no cooling, the following points should be checked before proceeding with the system diagnosis procedures. NOTE: If the truck being serviced is a model 830EAC or a 930E, be certain the rest switch in the cab is ON. Place the GF cutout switch in the CUTOUT position. Some simple, but effective checks can be performed to help determine the cause of poor system performance. Check the following to ensure proper system operation. • Compressor belt - Must be tight, and aligned. • Compressor clutch - The clutch must engage. If it does not, check fuses, wiring, and switches. • Oil leaks - Inspect all connection or components for refrigeration oil leaks (especially in the area of the compressor shaft). A leak indicates a refrigerant leak. • Electrical check - Check all wires and connections for possible open circuits or shorts. Check all system fuses. • Cooling system - Check for correct cooling system operation. Inspect the radiator hoses, heater hoses, clamps, belts, water pump, thermostat and radiator for condition or proper operation. • Radiator shutters - Inspect for correct operation and controls, if equipped. • Fan and shroud - Check for proper operation of fan clutch. Check installation of fan and shroud.

• Cab filters - Ensure the outside air filter and inside recirculation filter are clean and free of restriction. • Condenser - Check the condenser for debris and clogging. Air must be able to flow freely through the condenser. • Evaporator - Check the evaporator for debris and clogging. Air must be able to flow freely through the condenser.

Diagnosis Of Gauge Readings And System Performance Successfully servicing an air conditioning system, beyond the basic procedures outlined in the previous section, requires additional knowledge of system testing and diagnosis. A good working knowledge of the manifold gauge set is required to correctly test and diagnose an air conditioning system. An accurate testing sequence is usually the quickest way to diagnose an internal problem. When correctly done, diagnosis becomes an accurate procedure rather than guesswork. The following Troubleshooting Chart lists typical malfunctions encountered in air conditioning systems. Indications and or problems may differ from one system to the next. Read all applicable situations, service procedures, and explanations to gain a full understanding of the system malfunction. Refer to information listed under “Suggested Corrective Action” for service procedures.

• Heater/water valve - Check for malfunction or leaking. With the heat switch set to COLD, the heater hoses should be cool. • System ducts and doors - Check the ducts and doors for proper function. • Refrigerant charge - Make sure system is properly charged with the correct amount of refrigerant.

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TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS

PROBLEM: Insufficient Cooling Indications: Low side pressure - LOW. High side pressure - LOW. Discharge air is only slightly cool. Possible Causes

Suggested Corrective Actions

- Low refrigerant charge, causing pressures to be slightly lower than normal.

Check for leaks by performing leak test. If No Leaks Are Found: Recover the refrigerant and use a scale to charge the proper amount into the system. Check system performance. If Leaks Are Found: After locating the source of the leak, recover the refrigerant, and repair the leak. Evacuate the system and recharge using a scale. Add oil as necessary. Check A/C operation and performance test the system.

PROBLEM: Little or No Cooling Indications: Low side pressure - VERY LOW High side pressure - VERY LOW Discharge air is warm. No bubbles observed in sight glass, may show oil streaks. Possible Causes

Suggested Corrective Actions

- Pressure sensing switch may have compressor clutch disengaged. - Refrigerant excessively low; leak in system.

N4-32

Add refrigerant (make sure system has at least 50% of its normal amount) and leak test system. It may be necessary to use a jumper wire to enable the compressor to operate, if the compressor has shut down due to faulty pressure sensing switch. Repair any leaks and evacuate the system if necessary, Replace the receiver-drier if the system was opened. Recharge the system using a scale and add oil as necessary. Check A/C operation and do system performance test.

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PROBLEM: Extremely Low Refrigerant Charge in the System Indications: Low side pressure - LOW. High side pressure - LOW. Discharge air is warm. The low pressure switch may have shut off the compressor clutch.

Possible Causes - Extremely low or no refrigerant in the system. Possible leak in the system.

Suggested Corrective Actions Check for leaks by performing leak test. No Leaks Found: Recover refrigerant from the system. Recharge using a scale to ensure correct charge. Check A/C operation and performance. Leaks Found: Add refrigerant (make sure system has at least 50% of its normal amount) and leak test system. It may be necessary to use a jumper wire to enable the compressor to operate, if the compressor has shut down due to faulty pressure sensing switch. Repair any leaks and evacuate the system if necessary, Replace the receiver-drier if the system was opened. Recharge the system using a scale and add oil as necessary. Check AC operation and do system performance test.

PROBLEM: Air and/or Moisture in the System Indications: Low side pressure - Normal High side pressure - Normal Discharge air is only slightly cool. (In a cycling type system with a thermostatic switch, the switch may not cycle the clutch on and off, so the low pressure gauge will not fluctuate.) Possible Causes Leaks in the system.

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Suggested Corrective Actions Test for leaks, especially around the compressor shaft seal area. When the leak is found, recover refrigerant from the system and repair the leak. Replace the receiver-drier or accumulator because the desiccant may be saturated with moisture. Check the compressor and replace any refrigerant oil lost due to leakage. Evacuate and recharge the system with refrigerant using a scale. Check A/C operation and performance.

Operator Comfort

N4-33

PROBLEM: Air and/or Moisture in the System Indications: Low side pressure - HIGH High side pressure - HIGH Discharge air is only slightly cool. Possible Causes

Suggested Corrective Actions

- Leaks in system.

Test for leaks, especially around the compressor shaft seal area. After leaks are found, recover refrigerant from the system and repair leaks. Replace the receiver-drier. Check the compressor and replace any oil lost due to leakage. Evacuate and recharge the system using a scale to ensure proper quantity. Check A/C operation and performance.

PROBLEM: Expansion Valve Stuck or Plugged Indications: Low side pressure - VERY LOW or in a Vacuum High side pressure - HIGH Discharge air only slightly cool. Expansion valve body is frosted or sweaty. Possible Causes

Suggested Corrective Actions

An expansion valve malfunction could mean the valve is stuck in the closed position, the filter screen is clogged (block expansion valves do not have filter screens), moisture in the system has frozen at the expansion valve orifice, or the sensing bulb is not operating. If the sensing bulb is accessible, perform the following test. If not, proceed to the Repair Procedure.

Test: Warm diaphragm and valve body with your hand, or very carefully with a heat gun. Activate the system and watch to see if the low pressure gauge rises. Next, carefully spray a little nitrogen, or any substance below 32° F, on the capillary coil (bulb) or valve diaphragm. The low side gauge needle should drop and read at a lower (suction) pressure on the gauge. This indicates the valve was partially open and that your action closed it. Repeat the test, but first warm the valve diaphragm or capillary with your hand. If the low side gauge drops again, the valve is not stuck. Repair Procedure: Inspect the expansion valve screen (except block type valves). To do this, remove all refrigerant from the system. Disconnect the inlet hose fitting from the expansion valve. Remove, clean, and replace the screen. Reconnect the hose and replace the receiver-drier. Evacuate and recharge the system with refrigerant using a scale. Check AC operation and performance. If the expansion valve tests did not cause the low pressure gauge needle to rise and drop, and if the other procedure described did not correct the problem, the expansion valve is defective. Replace the valve.

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PROBLEM: Expansion Valve Stuck Open Indications: Low side pressure - HIGH High side pressure - Normal Air from vents in the cab seems warm or only slightly cool. Possible Causes The expansion valve is stuck open and/or the capillary tube (bulb) is not making proper contact with the evaporator outlet tube. Liquid refrigerant may be flooding the evaporator making it impossible for the refrigerant to vaporize and absorb heat normally. In vehicles where the expansion valve sensing bulb is accessible, check the capillary tube for proper mounting and contact with the evaporator outlet tube. Then perform the following test if the valve is accessible. If it is not, proceed to the Repair Procedure.

Suggested Corrective Actions Test: Operate the A/C system on it's coldest setting for a few minutes. Carefully spray nitrogen or another cold substance on the capillary tube coil (bulb) or head of the valve. The low pressure (suction) side gauge needle should now drop on the gauge. This indicates the valve has closed and is not stuck open. Repeat the test, but first warm the valve diaphragm by warming with hands. If the low side gauge shows a drop again, the valve is not stuck. Clean the surfaces of the evaporator outlet and the capillary coil or bulb. Make sure the coil or bulb is securely fastened to the evaporator outlet and covered with insulation material. Operate the system and check performance. Repair Procedure: If the test did not result in proper operation of the expansion valve, the valve is defective and must be replaced. Recover all refrigerant from the system and replace the expansion valve and the receiver-drier. Evacuate and recharge the system with refrigerant using a scale. Check A/C operation and performance.

PROBLEM: High Pressure Side Restriction Indications: Low side pressure - LOW High side pressure - Normal to HIGH Discharge air is only slightly cool. Look for sweat or frost on high side hoses and tubing. The line will be cool to the touch near the restriction.

Suggested Corrective Actions

Possible Causes Kink in a line, collapsed hose liners, plugged receiver-drier or condenser, etc.

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Repair Procedure: After you locate the defective component containing the restriction, recover all of the refrigerant. Replace the defective component and the receiver-drier. Evacuate and recharge the system with refrigerant, then check A/C operation and performance.

Operator Comfort

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PROBLEM: Compressor Malfunction Indications: Low side pressure - HIGH High side pressure - LOW Compressor operates noisily. Possible Causes

Suggested Corrective Actions Repair Procedure: If the belt is worn or loose, replace or tighten it and recheck system performance and gauge readings. If inspection of the compressor is required, all of the refrigerant must be recovered and the compressor disassembled to the point that inspection can be performed. Replace defective components or replace the compressor. If particles of desiccant are found in the compressor, flushing of the system will be required. It will also be necessary to replace the receiver-drier. Always check the oil level in the compressor, even if a new unit has been installed. Rotary compressors have a limited oil reservoir. Extra oil must be added for all truck installations. Tighten all connections and evacuate the system. Recharge the system with refrigerant using a scale. Check system operation and performance.

- Defective reed valves or other internal components.

PROBLEM: Thermostatic Switch Malfunction Indications: Low side pressure - Normal High side pressure - Normal Low side pressure may cycle within a smaller range as the compressor clutch cycles more frequently than normal. This may indicate the thermostat is set too high.

Possible Causes - Thermostat malfunctioning possibly due to incorrect installation.

Suggested Corrective Actions Replace the thermostatic switch. When removing the old thermostat, replace it with one of the same type. Take care in removing and handling the thermostat and the capillary tube that is attached to it. Use care not to kink or break the tube. Position the new thermostat capillary tube at or close to the same location and seating depth between the evaporator coil fins as the old one. Connect the electrical leads

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PROBLEM: Condenser Malfunction or System Overcharge Indications: Low Side High High Side High Discharge air may be warm. High pressure hoses and lines are very hot.

Possible Causes

Suggested Corrective Actions

- Lack of air flow through the condenser fins

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Repair Procedure: Check the engine cooling system components, fan and drive belt, fan clutch operation, and the radiator shutter. Inspect condenser for dirt, bugs, or other debris, and clean if necessary. Be sure the condenser is securely mounted and there is adequate clearance (about 38 mm) between it and the radiator. Check the radiator pressure cap and cooling system, including the fan, fan clutch, drive belts and radiator shutter assembly. Replace any defective parts and then recheck A/C system operation, gauge readings, and performance. If the problem continues, the system may be overcharged. Recover the system refrigerant. Use a scale to recharge the system using the correct amount. Recheck A/C system operation, gauge readings and performance. If the gauge readings do not change, all of the refrigerant should be recovered and the system flushed. The condenser may be partially blocked -replace condenser. The receiver-drier must also be replaced. Evacuate the system, recharge, and check operation and performance.

Operator Comfort

N4-37

PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM Truck Serial Number_________________________

Last Maintenance Check:_____________________

Site Unit Number____________________________

Name of Service Technician________________

Date:____________Hour Meter:________________

Maintenance Interval COMPONENT

NOTE: Compressor should be run at least 5 minutes (40°F minimum ambient temperature) every month, in order to circulate oil and lubricate components.

(months) 3

6

12

Maintenance Interval Done

COMPONENT

1. Compressor Check noise level Check clutch pulley Check oil level Run system 5 minutes Check belt tension (80-100) lbs; V-belt

3 5. Expansion Valve

Check mounting bracket (tighten bolts)

Check solder joints on inlet/ outlet tubes (leakage)

Check clutch alignment w/ crankshaft pulley (within 0.06 in.)

Inspect condensation drain

2. Condenser Clean dirt, bugs, leaves, etc. from coils (w/compressed air) Verify engine fan clutch is engaging (if installed) Check inlet/outlet for obstructions or damage 3. Receiver-Drier

12

Done

X

6. Evaporator Clean dirt, bugs, leaves, etc. from fins (w/ compressed air)

Verify clutch is engaging

6

Inspect capillary tube (if used) for leakage, damage, looseness

Inspect shaft seal for leakage

Perform manifold gauge check

(months)

7. Other Components Check discharge lines (hot to touch) Check suction lines (cold to touch) Inspect fittings/clamps/hoses Check thermostatic switch for proper operation Outlets in cab: 40°F to 50° F Inspect all wiring connections Operate all manual controls through full functions

Check inlet line from condenser (should be hot to touch) Replace, if system is opened 4. Accumulator Check the inlet line from the evaporator. It should be cool to cold. Replace the accumulator each time the system is opened.

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SECTION N5 OPERATOR CAB CONTROLS INDEX

OPERATOR CAB AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-5 STEERING WHEEL AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-6 Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-6 Tilt / Telescope Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-6 Multi-Function Turn Signal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-6 STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-7 Steering Column Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-8 STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-8 PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-10 Service Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-10 Dynamic Retarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-10 Dynamic Retard Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-10 Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-10 GRADE/SPEED RETARD CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-11 OVERHEAD PANEL AND DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-12 CENTER CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-13 Directional Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-13 Override/Fault Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-14 Engine Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-14 L.H. Window Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-14 R.H. Window Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-14 Hoist Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-14 Raising The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-14 Lowering The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-15 Retard Speed Control (RSC) Adjust Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-15 Retard Speed Control (RSC) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-15

N05101

Operator Controls

N5-1

Data Store Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-16 12V Auxiliary Power Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-16 Fire Suppression Control Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-16 Communication Radio Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-16 DIAGNOSTIC PORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-16 KOMTRAX Plus Diagnostic Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-16 Interface Module (IM) Diagnostic Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-16 Payload Meter Diagnostic Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-16 Drive System Or Modular Mining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-16 Drive System Controller (DSC) Diagnostic Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-16 Engine Diagnostic Port (CENSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-16 Engine Diagnostic Port (QUANTUM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-16 HEATER / AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-17 Fan Speed Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-17 Temperature Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-17 Air Flow Directional Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-17 Heater/Air Conditioner Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-17 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-18 Control Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-18 Cab/Air Conditioner Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-20 Status Indicator Light Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-20 Hydraulic Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-20 Coolant Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-20 Speedometer/Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-20 Fuel Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-20 Drive System Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-20 Hazard Warning Light Switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-20

Pre-Shift Brake Test Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-21 Wheel Brake Lock Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-21 Rest Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-21 Engine Warm Up Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-22 Heated Mirror Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-22 Rotating Beacon Light Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-22 Camera System Switch (Optional)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-22

Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-22 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-22 Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-23 Digital Display Contrast Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-23

N5-2

Operator Controls

N05101

Turn Signal Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-23 Panel Light Dimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-23 Mode Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-23 Fog Light Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-23 Manual Backup Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-24 Headlight/Panel Illumination Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-24 STATUS INDICATOR LIGHT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-25 Status Indicator Light Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-25 DIGIT DISPLAY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-28 Toggling Through Main Level Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-28 Toggling Through Warning Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-29 Entering Payload Meter Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-30 KOMTRAX PLUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-31 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-31 Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-33 Basic Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-33 KOMATSU WIRELESS BRIDGE (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-34 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-34 Communication Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-34 Switching to the KWB_SETUP Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-34 Setting the Computer Subnet Mask and IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-35 Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-35 Setting Up the KWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-36 Adding Encryption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-36 Final Computer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-36 Data Downloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-37 Resetting the KWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-37 KWB Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N5-37

N05101

Operator Controls

N5-3

NOTES:

N5-4

Operator Controls

N05101

OPERATOR CAB AND CONTROLS

9

10

8

12

13

15

9

11

14

7

5

1

2

4

3

6

84047

FIGURE 5-1. CAB INTERIOR - OPERATOR VIEW 1. Steering Wheel 2. Service Brake Pedal 3. Retard Pedal 4. Throttle/Accelerator Pedal 5. Heater/Air Conditioner Controls

N05101

6. Recirculation Filter 7. Instrument Panel 8. Grade/Speed Retard Chart 9. Radio Speakers 10. Warning Alarm Buzzer

Operator Controls

11. Windshield Wipers 12. AM/FM Radio / CD Player 13. Air Cleaner Vacuum Gauges 14. Heater/Air Conditioner Vents 15. Camera Monitor (Optional)

N5-5

STEERING WHEEL AND CONTROLS

Multi-Function Turn Signal Switch

Steering wheel (1, Figure 5-2) can be telescoped "in" and "out" and the lilt angle can be adjusted to provide a comfortable steering wheel position for most operators.

Horn Button Horn (2, Figure 5-2) is actuated by pushing the button in the center of the steering wheel. Ensure that the horn operates before moving the truck. Observe all local safety rules regarding the use of the horn as a warning signal device before starting the engine and moving the vehicle.

Multi-function turn signal switch (4, Figure 5-2) is used to activate the turn signal lights, the windshield wipers, and to select either high or low beam headlights. Turn Signal Operation Move the lever upward to signal a right turn.

Tilt / Telescope Lever The steering column can be telescoped or the wheel tilted with lever (3, Figure 5-2). Adjust the tilt of the steering wheel by pulling the lever toward the steering wheel and moving the wheel to the desired angle. Releasing the lever will lock the wheel in the desired location. Adjust the telescope function by pushing the lever forward to unlock. After positioning as desired, release the lever to the lock position.

An indicator in the top, center of the instrument panel will illuminate to indicate turn direction selected. Refer to Instrument Panel and Indicator Lights in this section. Move the lever downward to signal a left turn. NOTE: The turn signal does not automatically cancel after the turn has been completed. High Beam Headlight Operation Pulling the lever inward (toward the rear of the cab) changes the headlights to high beam. When the high beams are selected, the indicator in the top center of the instrument panel will illuminate. Moving the switch back to the original position will return the headlights to low beam.

FIGURE 5-2. STEERING WHEEL & CONTROLS 1. Steering Wheel 2. Horn Button

N5-6

3. Tilt/Telescope Lever 4. Multi-Function Turn Signal Switch

Operator Controls

N05101

Windshield Wiper Operation Windshield Wipers OFF Intermittent - Long Delay Intermittent -Medium Delay Intermittent -Short Delay Low Speed High Speed Depressing the button at the end of the lever will activate the windshield washer.

STEERING COLUMN Removal 1. Shut the engine off by turning the key switch to OFF and allow at least 90 seconds for the steering accumulators to bleed down. Turn the steering wheel to ensure no pressure remains. 2. Open the battery disconnect switch. 3. Remove the access cover (15, Figure 5-3) from the front of the cab. If steering control unit is OK, DO NOT disconnect any hydraulic lines. 4. Loosen cap screws (10) on steering control unit (7) and move it out of the way. 5. Disconnect wire harness(es) from the steering column. 6. Remove screws retaining trim cover (14) where steering column enters the instrument panel and remove cover. 7. Remove four cap screws (4). Access to these screws is from the front of the cab through the access opening. Also remove cap screws (12). 8. Lift the steering column out of the instrument panel.

FIGURE 5-3. STEERING COLUMN INSTALLATION 9. Bracket R.H. 1. Steering Wheel 10. Cap Screw 2. Button Horn 11. Lock Washer 3. Steering Column 12. Cap Screw 4. Cap Screw 13. Nut 5. Flat Washer 14. Trim Cover 6. Lock Washer 7. Steering Control Unit 15. Access Cover 8. Bracket L.H. Steering Column Inspection Whenever the steering column or steering control unit is removed for service, the steering column shaft splines must be inspected for excessive wear. 1. With steering column assembly removed from truck, thoroughly clean splines on steering column shaft and inspect for damage or excessive wear. 2. Using an outside micrometer or dial caliper, measure the outside diameter of the male splines on the steering column shaft. • Minimum diameter: 24.13 mm (0.950 in.) 3. If splines are smaller than minimum diameter specification, replace steering column.

N05101

Operator Controls

N5-7

STEERING WHEEL

Installation 1. Insert cap screw (10, Figure 5-3) with lockwashers (11) and flatwashers (5) through brackets (8 & 9) and then through steering column flange. Add second flat washer (5) and nut (13) to each cap screw to hold parts together. Tighten nuts securely. 2. Slide the entire assembly down the tapered blocks until the brackets (8 & 9) contact the mounting surface in the cab. Install cap screws (4) and (12) with washers (5) and (6). Only tighten cap screws (4). 3. Inspect brackets (8 & 9) to see if they contact the mounting surface evenly, and are flat and inline with the surface. If so, then tighten cap screws (12). If brackets are not quite parallel, then install flat washers (as needed) between brackets and mounting surface to eliminate any gaps. Tighten cap screws (12) to standard torque. 4. After cap screws (4 & 12) are tightened to standard torque, remove nuts (13) and flatwashers (5) that were holding the steering column to the two brackets. DO NOT remove cap screws (10) from the brackets. 5. Lubricate the male splines on the end of the steering column shaft.

NOTE: There is no lower end bearing in this new steering column assembly, therefore the male end of the shaft will have to be guided into the mating female part of the steering control unit (7). 6. Without removing cap screws (10) from the holes, move the steering control unit (7) into place and start each of the cap screws.

Removal 1. Turn off the battery disconnect switch to remove battery power from the horn circuit. 2. Use a pocket screwdriver to pry horn button (4, Figure 5-4) from steering wheel (1). 3. Disconnect horn wire (3) and set the horn button aside. 4. Remove nut (2). 5. Pull the steering wheel from the column. If the steering wheel will not slide off the shaft it may be necessary to install a puller into the tapped holes (5/16" - 24NF) in the steering wheel.

Installation 1. A new, more relable horn contact is available. Some trucks may have the previous horn contact, which is a stick design (1, Figure 5-5). The new horn contact uses a roller (2). Install the new horn contact as shown in Figure 5-6. 2. Place steering wheel (1, Figure 5-4) into position on the steering column shaft while guiding horn wire (3) through the access hole in the steering wheel. Align the serrations and push the steering wheel onto the shaft. 3. Install nut (2). Tighten the nut to 81 ± 7 N·m (60 ± 5 ft lb). 4. Connect horn wire (3) to horn button (4). 5. Install the horn button onto the steering wheel. Turn on the battery disconnect switch and verify that the horn functions properly.

7. Tighten four cap screws (10). 8. Check for proper steering wheel rotation without binding. Ensure wheel returns to neutral after rotating 1/4 turn left and right. 9. If disconnected, re-connect the hoses to the steering control unit. 10. Connect the steering column wire harness(es) to the harness(es) in the cab. 11. Install access cover (15) and trim cover (14).

FIGURE 5-4. STEERING WHEEL RETAINER NUT 1. Steering Wheel 2. Nut

N5-8

Operator Controls

3. Horn Wire 4. Horn Button

N05101

FIGURE 5-5. HORN CONTACTS 1. Stick Contact

2. Roller Contact

FIGURE 5-6. INSTALLATION LOCATION

N05101

Operator Controls

N5-9

PEDALS

Dynamic Retard Pedal

Service Brake Pedal

Dynamic retard pedal (3, Figure 5-1) is a foot operated pedal which allows the operator to slow the truck and maintain a safe productive speed without the use of the service brakes. For normal truck operation, only dynamic retarding must be used to slow and control the speed of the truck. The Grade/Speed Retard Chart (8, Figure 5-1) must always be followed to determine MAXIMUM safe truck speeds for descending various grades with a loaded truck. Service brakes must be applied only when dynamic retarding requires additional braking force to slow the truck speed quickly or to bring the truck to a complete stop.

The service brake pedal (2, Figure 5-1) is a foot operated pedal which applies the service brakes. Service brakes must only be applied when dynamic retarding requires additional braking force to slow the truck speed quickly. They must also be used to bring the truck to a complete stop once the speed is less than 4.8 kph (3 mph). Dynamic Retarding Dynamic retarding is a braking torque (not a brake) produced through electrical generation by the wheelmotors when the truck motion (momentum) is the propelling force. For normal truck operation, dynamic retarding must be used to slow and control truck speed. Dynamic retarding is available in FORWARD/ REVERSE at all truck speeds above 0 kph/mph; however, as the truck speed slows below 4.8 kph (3 mph), the available retarding force may not be effective. Use the service brakes to bring the truck to a complete stop. Dynamic retarding will not hold a stationary truck on an incline.Use the parking brake or wheel brake lock for this purpose. Dynamic retarding is available in NEUTRAL only when truck speed is above 4.8 kph (3 mph). When dynamic retarding is in operation, engine rpm will automatically go to an advance retard speed setting. This rpm will vary depending on temperature of several electrical system components.

When dynamic retarding is in operation, the engine rpm will automatically go to an advance rpm retard speed setting (usually 1250 rpm). Dynamic retarding will be applied automatically, if the speed of the truck reaches the predetermined overspeed retard setting. Dynamic Retarding is available in FORWARD/ REVERSE at all truck speeds above 0 kph/mph, but is available in NEUTRAL only when truck speed is above 4.8 kph (3 mph). Accelerator Pedal Throttle/accelerator pedal (4, Figure 5-1), and shown below, is a foot-operated pedal which allows the operator to control engine rpm depending on pedal depression. It is used by the operator to request torque from the motors when in forward or reverse. In this mode, the propulsion system controller commands the correct engine speed for the power required. In NEUTRAL, this pedal controls engine speed directly.

Dynamic retarding will be applied automatically if the speed of the truck obtains the maximum speed setting programmed in the control system software. When dynamic retarding is activated, an indicator light in the overhead display will illuminate. The grade/speed retard chart must always be used to determine safe downhill speeds. Refer to Grade/ Speed Retard Chart in this section.

N5-10

Operator Controls

N05101

GRADE/SPEED RETARD CHART Grade/Speed Retard Chart (8, Figure 5-1), and shown below, provides the recommended MAXIMUM retarding limits at various truck speeds and grades with a fully loaded truck. This decal in the truck may differ from the decal below due to optional truck equipment such as: wheel motor drive train ratios, retarder grids, tire sizes, etc. Always refer to this decal in the operator's cab and follow these recommendations for truck operation. The operator must reference this chart before descending any grade with a loaded truck. Proper use of dynamic retarding will maintain a safe speed. Two speed lists are provided, one for continuous retarding, and the second for short term retarding. Both lists are matched to the truck at maximum Gross Vehicle Weight (GVW). The two ratings are guidelines for proper usage of the retard function on downhill grades.

The "short term" numbers listed on the chart indicate the combination of speeds and grades which the vehicle can safely negotiate for a short duration before system components reach the maximum allowable temperature during retarding. These speeds are faster than the "continuous" values, reflecting the thermal capacity of various system components. System components can accept heating at a higher-than-continuous rate for a short period of time. Beyond this short duration of time, the system would become overheated. If the vehicle is operated at "short term" grade and speed limits for a period of time, it is possible to exceed the thermal capacity of the drive system components. The Drive System Controller (DSC) will then gradually reduce the retarding effort from "short term" to "continuous". The "retard @ continuous" indicator light will flash for 15 seconds, then illuminate steadily alerting the operator of the reduction in retarding performance and the need for a reduction in speed. The operator must control the speed of the truck in accordance to the “continuous speeds” on the grade/ speed chart. The operator must use the service brakes to quickly slow the truck to the maximum "continuous" retarding limits (or less) based on the grade the truck is currently on.

DO NOT LIGHTLY apply the service brakes when attempting to slow the truck on a downhill grade. Overheating of the brakes will result. FULLY apply the brakes (within safe limits for road conditions) in order to quickly slow the truck to maximum "continuous" retarding limits or less. The "short term" rating will successfully accommodate most downhill loaded hauls. If actual time on the grade exceeds the allowable limits, the grade will need to be negotiated at the "continuous" speed. The "continuous" numbers on the chart indicate the combination of speeds and grades which the vehicle can safely negotiate for unlimited time or distance during retarding. DO NOT exceed these recommended MAXIMUM speeds when descending grades with a loaded truck.

N05101

Operator Controls

N5-11

OVERHEAD PANEL AND DISPLAYS

Air Cleaner Vacuum Gauges

The items listed below are located on the overhead panel. Refer to Figure 5-1 for the location of each item. A brief description of each component is documented below.

Air cleaner vacuum gauges (14, Figure 5-1) provide a continuous reading of the maximum air cleaner restriction reached during operation. The air cleaner(s) must be serviced when the gauge(s) shows the maximum recommended restriction of 635 mm (25 in.) of H2O vacuum.

Radio Speakers Radio speakers (9, Figure 5-1) for the AM/FM Radio / CD Player are located at the far left and right of the overhead panel.

NOTE: After service, push the reset button on face of gauge to allow the gauge to return to zero. Warning Alarm Buzzer Warning alarm buzzer (10, Figure 5-1) will sound when activated by any one of several truck functions. Refer to Instrument Panel and Indicator Lights in this section for a detailed description of functions and indicators that will activate this alarm.

Cab Radio This panel will normally contain AM/FM Radio / CD Player (12, Figure 5-1). Refer to Section 70 for a more complete description of the radio and its functions. Individual customers may use this area for other purposes, such as a two-way communications radio.

N5-12

Camer Monitor (Optional) The camer monitor (15, Figure 5-1) displays the images from one of four different cameras. Three cameras are mounted on the front of the truck (left corner, center, right corner) and one camera facing rearward. Once the truck speed reaches 16 km/h (10 mph), the camera monitor will go dark automatically. Once truck speed is reduced to less than 16 km/h 10 mph for more than 30 seconds, it will display camera images again.

Operator Controls

N05101

CENTER CONSOLE

Directional Control Lever Directional Control Lever (2, Figure 5-7) is mounted on a console to the right of the operator's seat. It is a four position lever that controls the park, reverse, neutral, and forward motion of the truck. Before moving the directional control lever, apply the service brakes to completely stop the truck. Depress the button on the side to release the detent lock, then move the control lever to the desired position. When the control lever is in the center N position, it is in NEUTRAL. When the control lever is in the P position, it is in PARK, and the parking brake will be applied. The parking brake is spring applied and hydraulically released. It is designed to hold the truck stationary when the engine is off and the key switch is turned OFF. The truck must be completely stopped before moving the control lever to PARK, or damage may occur to the park brake. When the key switch is ON, and the control lever is in PARK, the parking brake indicator light will be illuminated.

FIGURE 5-7. CENTER CONSOLE 1. Center Console 2. Directional Control Lever 3. Override/Fault Reset Switch 4. Engine Stop Switch 5. L.H. Window Control Switch 6. R.H. Window Control Switch 7. Hoist Control Lever 8. Retard Speed Control Dial 9. RSC Switch 10. Data Store Button 11. 12V Auxiliary Power Outlets 12. Fire Suppression Control Outlet 13. Communication Radio Outlet

The directional control lever must be in PARK to start the engine. NOTE: DO NOT move the directional control lever to the PARK position at the shovel or dump. The operator can select FORWARD drive by moving the control lever to the F position. The operator can select REVERSE drive by moving the control lever to the R position. DO NOT allow the control lever to travel too far and go into the PARK position when REVERSE is desired. NOTE: The truck must be completely stopped before the control lever is moved to a drive position or into PARK. A GE fault will be recorded if the control lever is placed into the PARK position while the truck is still moving. NOTE: The center console contains an access hole for a wiring harness resistor. This resistor is to reduce the current flow to the directional control lever contacts, increasing their service life.

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Operator Controls

N5-13

Override/Fault Reset Switch

R.H. Window Control Switch

Switch (3, Figure 57) is spring-loaded to the OFF position. When pushed in and held, this switch may be used for several functions.

Switch (6, Figure 5-7) is spring-loaded to the OFF position. • Pushing the front of the switch raises the right side cab window. • Pushing the rear of the switch lowers the window.

1. This switch permits the operator to override the body-up limit switch and move the truck forward when the directional control lever is in FORWARD, the dump body is raised, and the brakes are released.

Hoist Control Lever Hoist control (7, Figure 5-7) is a four position handoperated lever located between the operator seat and the center console (see Figure 5-8).

Use of the override switch for this purpose is intended for emergency situations only! 2. The push button deactivates the retard pedal function when the speed of the truck is below 4.8 kph (3 mph). 3. The override switch is also used to reset an electric system fault when indicated by a red warning light. Refer to Overhead Status/Warning Indicators in this section.

Engine Stop Switch Switch (4, Figure 5-7) is used to stop the engine. Pull the switch up to stop the engine. Push the switch back down to enable engine operation. Use this switch to stop the engine if the key switch fails to operate, or to stop the engine without turning off the 24 VDC electrical circuits. A ground level engine stop switch is also located at the right front corner of the truck.

FIGURE 5-8. HOIST LEVER POSITIONS 1. Raise 2. Hold

3. Float 4. Lower

Raising The Dump Body 1. Pull the lever to the rear to actuate hoist circuit. (Releasing the lever anywhere during "hoist up" will place the body in HOLD at that position.)

L.H. Window Control Switch

2. Raise engine rpm to increase hoist speed.

Switch (5, Figure 5-7) is spring-loaded to the OFF position.

3. Reduce engine rpm as the last stage of the hoist cylinders begin to extend and then let the engine go to low idle as the last stage reaches half-extension.

• Pushing the front of the switch raises the left side cab window. • Pushing the rear of the switch lowers the window.

4. Release hoist lever as the last stage reaches full extension. 5. After material being dumped clears the body, lower the body to frame. Refer to Operating Instructions - Dumping, for more complete details concerning this control

N5-14

Operator Controls

N05101

Dial (8, Figure 5-7) allows the operator to vary the downhill truck speed that the retard speed control system will maintain when descending a grade. This function can be overridden by either the accelerator or retard pedal.

With RSC switch on and dial adjusted, the system will function as follows: As truck speed increases to the "set" speed and throttle pedal released, dynamic retarding will apply. As truck speed tries to increase, the amount of retarding effort will automatically adjust to keep the selected speed. When truck speed decreases, the retarding effort is reduced to maintain the selected speed. If truck speed continues to decrease to approximately 4.8 kph (3 mph) below "set" speed, dynamic retarding will turn off automatically. If truck speed must be reduced further, the operator can turn the adjust dial to a new setting or depress the foot operated retard pedal.

When the dial is rotated counterclockwise toward this symbol, the truck will descend a grade at lower speeds.

If the operator depresses the foot operated retard pedal and the retard effort called for is greater than that from the automatic system, the foot pedal retard will override RSC.

Lowering The Dump Body Move hoist lever forward to DOWN position and release. Releasing the lever places hoist control valve in the FLOAT position allowing the body to return to frame. Retard Speed Control (RSC) Adjust Dial

When the dial is rotated clockwise toward this symbol, the truck speed will increase. Retard Speed Control (RSC) Switch Always refer to the Grade/Speed Retard Chart in the operator's cab and follow the recommendations for truck operation. DO NOT exceed these recommended MAXIMUM speeds when descending grades with a loaded truck.

Switch (9, Figure 5-7) turns the system on and off. Push the knob in for OFF and pull the knob out to turn the system ON.

Throttle pedal position will override RSC setting. If operator depresses throttle pedal to increase truck speed, dynamic retarding will not come on unless truck overspeed setting is reached or foot operated retard pedal is used. When throttle pedal is released and RSC switch is on, dynamic retarding will come on at, or above, the RSC dialed speed and will adjust truck speed to, and maintain, the dialed speed. To adjust RSC control, pull switch (9) ON and start with dial (8) rotated toward fastest speed while driving truck at desired maximum speed. Relax throttle pedal to let truck coast and turn RSC adjusting dial slowly counterclockwise until dynamic retarding is activated. Dynamic retarding will now be activated automatically anytime the "set" speed is reached, the RSC switch is on, and throttle pedal is released.

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Operator Controls

N5-15

Data Store Button Button (10, Figure 5-7) is for use by qualified maintenance personnel to record in memory a “snap-shot” of the AC drive system. It will also trigger the KOMTRAX Plus system to store a snap-shot of the truck operating system. Light (11, Figure 5-7) will stay illuminated while the KOMTRAX Plus system is recording the snap-shot.

Drive System Or Modular Mining Drive system controller (DSC) or Modular Mining diagnostic port (4) is used to access diagnostic information for the Drive System Controller (DSC) or for Modular Mining controller. Drive System Controller (DSC) Diagnostic Port

12V Auxiliary Power Outlets

Diagnostic port (5) is used to access diagnostic information for the Drive System Controller (DSC).

Outlets (11, Figure 5-7) can be used to provide 12VDC power for tools and accessories.

Engine Diagnostic Port (CENSE)

Fire Suppression Control Outlet

Diagnostic port (6) is a three pin connector used to access diagnostic information for the engine monitoring system.

Outlet (12, Figure 5-7) can be used to provide power for an optional fire suppression control system with the key switch ON. Communication Radio Outlet Outlet (13, Figure 5-7) can be used to provide power for any optional 2-way communication radio with the keyswitch ON.

Engine Diagnostic Port (QUANTUM) Diagnostic port (7) is a nine pin connector used to access diagnostic information for the engine control system.

7 DIAGNOSTIC PORTS

6

The diagnostic ports shown in Figure 5-9 are located on the back wall of the cab next to the D.I.D. Panel.

5

KOMTRAX Plus Diagnostic Port

4

Diagnostic port (1, Figure 5-9) is used to download truck operation data from the KOMTRAX Plus controller.

3

Interface Module (IM) Diagnostic Port

1

84049

FIGURE 5-9. DIAGNOSTIC PORTS

Diagnostic port (2) is used to connect the interface module to a computer for installing software. Payload Meter Diagnostic Port Diagnostic port (3) is used to download data from the payload meter system. Refer to Section 60, Payload Meter III, for a more complete description of the payload meter and its functions.

N5-16

2

1. KOMTRAX Plus Diagnostic Port 2. IM Diagnostic Port 3. Payload Meter Diagnostic Port 4. Drive System / MM Diagnostic Port

Operator Controls

5. DSC Diagnostic Port 6. Engine Diagnostic Port (CENSE) 7. Engine Diagnostic Port (QUANTUM)

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HEATER / AIR CONDITIONER

Heater/Air Conditioner Vents

The heater/air conditioner compartment contains heater/air conditioner controls and some of the heater/air conditioner components, such as the blower motor assembly and the heater coil. Optimum cab air climate can be selected by using the following controls in various combinations.

Heater/air conditioner vents (6, Figure 5-10) may be rotated 360°. There are three vents in the heater/air conditioner compartment, four vents across the top of the instrument panel, and one vent each in the RH and LH instrument panels. There are also an additional four vents under the instrument panel. Air flow through the vents is controlled by manually opening, closing or turning the louvers.

Fan Speed Control Knob Fan speed control knob (1, Figure 5-10) is provided to control the cab air fan motor. The fan motor is a 3speed motor (low, medium and high). Speeds are selected by rotating the control knob clockwise to the desired position. OFF is in the full counter-clockwise position. The control knob must be switched ON for the air conditioner to function. Temperature Control Knob Temperature control knob (2, Figure 5-10) allows the operator to select a comfortable air temperature. The control knob determines the operation of the air conditioning and heater modes. Rotating the control knob counter-clockwise (blue zone (3)) will cause the A/C compressor to operate and result in cooler air temperatures. Full counterclockwise position is the coldest air setting. Rotating the control knob clockwise (red zone (4)) will affect coolant flow through the heater core and result in warmer air temperatures. The full clockwise position is the warmest heater setting. Air Flow Directional Knob Air flow directional knob (5, Figure 5-10) controls the direction of airflow as follows: Provides airflow to floor vents, only. Provides airflow to upper vents and floor vents. (Blue Icon) Provides dehumidified air to the upper vents and the floor vents. Defrost - Provides dehumidified air to the upper vents only. Defrost - Provides dehumidified air to the upper vents and the floor vents.

FIGURE 5-10. A/C & HEATER CONTROLS 1. Fan Speed Control Knob 2. Temperature Control Knob 3. Blue Zone

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Operator Controls

4. Red Zone 5. Air Flow Directional Knob 6. Vents

N5-17

INSTRUMENT PANEL Control Symbols The operator must understand the function and operation of each instrument and control. Many control functions are identified with international symbols that the operator must learn to recognize immediately. This knowledge is essential for proper and safe operation. Items that are marked optional do not apply to every truck. The following symbols are general indicators and may appear in multiple locations and combinations on the instrument panel. Most switches have two LED lights inside them, one amber and one green in color. The amber is located in the top portion of the switch and indicates that function has been activated. The green LED is located in the lower portion of the switch and indicates that function has not been activated.

This symbol when it appears on an indicator or control identifies that this indicator or control is NOT used.

This symbol identifies a rotary control or switch. Rotate the knob clockwise or counterclockwise for functions.

This symbol identifies a switch used to test or check a function. Press the switch on the side near the symbol to perform the test.

• To activate a function, push on the top portion of the switch. At this time, the amber LED will be illuminated, and the green LED will be OFF. • To de-activate a function, push on the lower portion of the switch. At this time, the green LED will be illuminated, and the amber LED will be OFF. NOTE: The green LED light in the hazard light switch, head light switch and the ladder light switch will be illuminated when battery power is connected to the truck. The LED lights in the other switches will illuminate when the key switch is turned to the ON position.

N5-18

Operator Controls

N05101

1

2

3

4

5

6

7

8 !

9 10

26

25

24 23

22 21

20

19

18

17

16

15

14

13

12

11 84048

FIGURE 5-11. PANEL GAUGES, INDICATORS, AND CONTROLS 1. Heater/Air Conditioner Vents 2. Status Indicator Light Panel 3. Hydraulic Oil Temperature Gauge 4. Coolant Temperature Gauge 5. Speedometer / Digital Display 6. Fuel Level Gauge 7. Drive System Temperature Gauge 8. Hazard Lights Switch 9. Brake Test Switch 10. Wheel Brake Lock Switch 11. AC Drive System Rest 12. Engine Warm Up Switch (Optional) 13. Heated Mirrors (Optional)

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14. Rotating Beacon Switch (Optional) 15. Camera System Switch (Optional) 16. Key Switch 17. Warning Light 18. Digital Display Contrast Buttons 19. Turn Signal Indicators 20. Panel Lights Dimmer Switch 21. Mode Switch #1 22. Mode Switch #2 23. Fog Light Switch (Optional) 24. Backup Light Switch 25. Ladder Light Switch 26. Headlight/Panel Illumination Switch

Operator Controls

N5-19

Cab/Air Conditioner Vents

Speedometer/Digital Display

Vents (1, Figure 5-11) may be directed by the operator to provide the most comfortable cabin air flow.

Speedometer/digital display (5) displays the following information:

Status Indicator Light Panel

• The analog speedometer indicates the truck speed in miles per hour (mph) or in kilometers per hour (kph).

Status indicator light panel (2) contains an array of indicator lights to provide the operator with important status messages concerning selected truck functions. Refer to STATUS INDICATOR LIGHTS for a detailed description of these indicators.

Hydraulic Oil Temperature Gauge

Fuel level gauge (6, Figure 5-11) indicates how much diesel fuel is in the fuel tank.

Green indicates normal operation. As the needle approaches the red zone, minimum engine idle speed will increase to help cool the oil. Red indicates high oil temperature in the hydraulic tank. Continued operation could damage components in the hydraulic system. If this occurs, the operator should safely stop the truck, move directional control lever to PARK and operate the engine at 1200 - 1500 rpm to reduce system temperature.

If temperature gauge does not move into the green range after a few minutes, and the red overhead indicator light does not go out, stop the engine and notify maintenance personnel immediately.

Gauge (4, Figure 5-11) indicates the temperature of the coolant in the engine cooling system. The temperature range after engine warm-up and truck operating under normal conditions must be:

• The digital display also shows warning messages and fault codes indicating abnormal operating conditions and critical problems. See DIGITAL DISPLAY OPERATION for more information.

Fuel Level Gauge

Hydraulic oil temperature gauge (3, Figure 5-11) indicates oil temperature in the hydraulic tank. There are two colored bands: green and red.

Coolant Temperature Gauge

• The digital display shows payload meter information.

When there is only 10% of total fuel tank capacity remaining, the amber low fuel level indicator on the gauge will illuminate. The fuel tank capacity is 4542 liters (1,200 gallons).

Drive System Temperature Gauge

Drive system temperature gauge (7, Figure 5-11) indicates the status of the highest measured temperature range in the drive system.

Hazard Warning Light Switch

Switch (8, Figure 5-11) flashes all the turn signal lights. Pressing the top side of the rocker switch activates these lights. When these lights are on, a red LED light will be illuminated inside the switch. Pressing on the lower side of the rocker switch turns these lights off, and a green LED light will be illuminated.

85°-97°C (185°-207°F)

N5-20

Operator Controls

N05101

Pre-Shift Brake Test Switch

Rest Switch

Pre-shift brake test switch (9, Figure 5-11) is used to initiate a brake test. Press on the momentary switch to enter the brake test mode. If certain conditions are met, the operator can enter a brake test sequence.

Rest switch (11, Figure 5-11) is a rocker switch with a locking device. A safety tab on the switch must be pushed to unlock the switch before the top of the switch can be depressed to activate the rest mode.

The amber light in the top of the switch is used to indicate when the truck is in brake test mode, and is referred to as the brake check light. When illuminated, a brake test is ready. When flashing, the brake test is at the validation point, or the retard system test is finished.

When activated, an internal amber lamp will illuminate. The switch should be activated to deenergize the AC drive system whenever the engine is to be shutdown or parked for a length of time with the engine running.

Wheel Brake Lock Control

Switch (10, Figure 5-11) must be used when the engine is running during dumping and loading operations only. The brake lock switch actuates the hydraulic brake system which locks the rear wheel service brakes only. When pulling into shovel or dump area, stop the truck using the foot-operated service brake pedal. When truck is completely stopped and in loading position, move the directional control lever to NETURAL, then apply the brake lock by pressing the top of the rocker switch. To release the brake, press the bottom of the rocker switch. NOTE: The wheel brake lock will not function if the directional control lever is in the PARK position.

The directional control lever must be in PARK or NEUTRAL and the vehicle not moving to enable this function. This will allow the engine to continue running while the AC drive system is de-energized.

Activation of the rest switch alone DOES NOT completely ensure that the drive system is safe to work on. Refer to the Safety Chapter for more information on servicing an 830E truck. Check all "link-on", or "link energized", indicator lights to verify the AC drive system is de-engergized before performing any maintenance on the drive system. DO NOT activate the rest switch while the truck is moving! The truck may unintentionally enter the “rest” mode after stopping.

DO NOT use this switch to stop the truck unless the foot-operated treadle valve is inoperative. Use of this switch applies rear service brakes at a reduced, unmodulated pressure. DO NOT use the brake lock for parking. With the engine stopped, hydraulic pressure will bleed down, allowing the brakes to release. Use at shovel and dump only to hold the truck in position. NOTE: The wheel brake lock will not apply when the directional control lever is placed in the PARK position, or when the key switch is OFF, or when the engine is not running.

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Operator Controls

N5-21

Engine Warm (Optional)

Up

Switch

Camera (Optional)

Engine warm up switch (12, Figure 5-11) ) is a rocker switch. When in the ON position, this feature is used to keep the engine warm in cold conditions because it puts a small amount of load on the engine.

System

Switch

This feature can also be used in cold climates to warm up, or to maintain heat in the engine coolant while the truck is parked.

Switch (15, Figure 5-11) is a three position rocker switch, but the third position is only momentary. Pressing the top of the rocker switch to place the switch in the middle position turns the camera system on. Pressing the bottom of the switch turns the camera system off. To display the view from the rear camera, momentarily press the top of the rocker switch. Regardless of truck speed, the view from the rear camera will be displayed in the camera monitor for approximately 30 seconds.

Heated Mirror Switch (Optional)

Key Switch

This energy is created by passing a load through one bank of the grid resistors in the retarding grid.

Heated mirror switch (13, Figure 5-11) controls the operation of the heated mirrors.

Rotating Beacon Light Switch (Optional)

Rotating beacon switch (14, Figure 5-11) controls the operation of the rotating beacon. Starting

Key switch (16, Figure 5-11) is a four-position switch (ACC, OFF, RUN, START). The ACC position is not currently used. When the switch is rotated one position clockwise, it is in the RUN position and all electrical circuits except START are activated. 1. With the directional control lever in PARK, rotate key switch fully clockwise to the START position, and hold this position until the engine starts. The START position is spring-loaded to return to RUN when the key is released. If the engine is equipped with a prelube system, a noticeable delay will occur before engine cranking begins.

N5-22

Operator Controls

N05101

2. After engine has started, place rest switch (4, Figure 5-11) in the OFF position, which will deactivate the rest mode of operation. Refer to the discussion of rest switch later in this section.

NOTE: The electric cranking motors have a 30 second time limit. If the 30 second limit is reached, cranking will be prohibited for two minutes. After two minutes, cranking will be allowed. If the 30 second limit is reached seven consecutive times, the key switch must be turned to the OFF position. This will allow the interface module to power down and reset, which requires seven minutes to complete.

Panel Light Dimmer

Panel light dimmer (20, Figure 5-11) is a rheostat which allows the operator to vary the brightness of the instruments and panel lights.

• Rotating the knob to the full clockwise position turns the panel lights on to the brightest condition. • Rotating the knob counterclockwise continually dims the lights until OFF position is reached at full counterclockwise rotation.

Mode Switches

Warning Light

Mode switches (21) and (22) are two-way momentary rocker switches. The arrows are used to toggle through the different options and messages on the digital display.

Red warning light (17, Figure 5-11) will come on to indicate that a truck function requires immediate action by the operator. Safely stop the truck and notify maintenance personnel. A warning message will appear on the digital display.

Digital Display Contrast Buttons

Cold ambient operating temperatures may affect the contrast of the digital display. If necessary, use buttons (18, Figure 5-11) to increase or decrease the contrast of the digital display to make it easier to read.

The OK position is used to acknowledge and clear warnings and faults and set certain Payload Meter III settings. Refer to DIGITAL DISPLAY OPERATION for more information about using the digital display.

Turn Signal Indicators

Fog Light Switch (Optional)

Indicators (19, Figure 5-11) illuminate to indicate that the right or left turn signals are operating when the turn signal lever on the steering column is moved upward or downward. Moving the lever to its center position will turn the indicator off.

Pressing the top of fog light switch (23, Figure 5-11) turns the lights on. Pressing the bottom of the switch turns the lights off.

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Operator Controls

N5-23

Manual Backup Switch

Headlight/Panel Illumination Light Switch

Backup light switch (24, Figure 511) allows the backup lights to be turned on for added visibility and safety when the directional control lever is not in the REVERSE position.

The instrument panel lights, clearance lights, and the headlights are controlled by this three-position rocker type switch (26).

Ladder Light Switch

OFF is selected by pressing the bottom of the switch. Press the top of the switch until it reaches the first position to select the panel lights, clearance lights and tail lights only. Press the top of the switch again until it reaches the second position to select headlights, panel lights, clearance lights and tail lights.

Ladder light switch (25) turns the ladder lights and deck lights on or off after or before using ladder. Pressing the top of the rocker switch turns the lights on. Pressing the bottom of the switch turns the lights off. Another switch is mounted at the front left of truck near the base of ladder.

N5-24

Operator Controls

N05101

STATUS INDICATOR LIGHT PANEL

FIGURE 5-12. STATUS INDICATOR LIGHT PANEL 1. Body Up 7. Not Used This Application 13. Not Used This Application 2. Parking Brake 8. Wheel Brake Lock 14. Service Brake 3. Propulsion System Not Ready 9. Traction Control 15. Dynamic Retarding 4. No Propel 10. Repair Monitor 16. No DC Link Voltage 5. Engine Warm-Up 11. Snapshot In Progress 6. Engine Delay 12. Not Used This Application Parking Brake Status Indicator Light Panel

When illuminated, these amber (yellow) status lights alert the operator that the indicated truck function requires some precaution. Refer to the following descriptions for explanations of the symbols.

Body Up

The body up indicator (1, Figure 512) will illuminate when the body is not completely down on the frame. The truck must not be driven until body is down and the light is off.

N05101

The parking brake indicator (2) will illuminate when the parking brake is applied. The parking brake is applied by placing the directional control lever in the PARK position. If the directional control lever is in the PARK position and the interface module (IM) detects any parking brake abnormalities, this light will not illuminate. The red warning light on the dash will flash, the warning buzzer will sound intermittently and an error code will be displayed. If the red warning light and buzzer are active, the operator must not leave the cab. Notify maintenance personnel immediately.

Operator Controls

N5-25

Propel System Not Ready

Not Used

Propulsion system not ready indicator (3) will illuminate during start-up much like the hour glass icon on a computer screen.

This indicator light (7) is not used in this application.

This light indicates the computer is in the process of performing the self-diagnostics and set-up functions at start-up. Propulsion will not be available at this time.

Wheel Brake Lock

The wheel brake lock indicator (8) will illuminate when the wheel brake lock is on.

No Propel

The no propel indicator (4) will illuminate when the rest switch is placed in the ON position. It will also illuminate when a fault has occurred which has eliminated the propulsion capability. If this condition occurs, the operator must safely stop the truck, move directional control lever to PARK, shut down the engine, and notify maintenance personnel immediately.

Traction Control

The traction control feature is always ON. The traction control indicator (9) will only illuminate if the traction control feature has been disabled because a problem has been detected within the system.

Engine Warm Up

Repair Monitor

Engine warm up indicator (5) will illuminate when the engine warming switch is turned on.

The repair monitor indicator (10) will illuminate if a “repair” fault is detected, which must be corrected after the operator’s shift is done.

Engine Shutdown Delay Snapshot In Progress

When the key switch has been turned OFF, and certain conditions have been met, this indicator (6) light will illuminate to indicate that the shutdown timing sequence has started. The engine could operate for up to three minutes.

The indicator (11) will illuminate when the KOMTRAX Plus system is in the process of recording a “snapshot” of certain vehicle conditions.

• If the directional control lever is moved out of PARK, the engine will stop immediately. • If the key switch is turned back ON, the engine stop sequence will be terminated, and the engine will remain running.

N5-26

Operator Controls

N05101

Not Used

Dynamic Retarding

This indicator (12) light is not used in this application.

The dynamic retarding indicator (15) will illuminate whenever the retarder pedal is operated, or the automatic overspeed retarding circuit is energized. It indicates that the dynamic retarding function of the truck is being used.

Not Used

This indicator (13) light is not used in this application.

Service Brake

No DC Link Voltage

The no DC link voltage indicator (16) will illuminate when the rest switch in ON, or whenever the DC link in the control cabinet is not providing voltage to the propulsion system.

The service brake indicator (14) will illuminate when the service brake pedal is applied.

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Operator Controls

N5-27

DIGIT DISPLAY OPERATION Toggling Through Main Level Screens

N5-28

Operator Controls

N05101

Toggling Through Warning Screens

Warning Screens

OK

Note: If a switch having no defined function for the current mode is actuated, the message "INVALID ENTRY" will be displayed on the screen while the switch is being pressed.

< Switch 1

Switch 2

200 ST

MULTIPLE WARNINGS

BATT CHARGING FLT A155

PRESS OK

CLEARED - 0 ACTIVE

1000 rpm

1000 rpm SC 20 mph

200 ST

SC 20 mph

A warning becomes active.

HOT HYD OIL LR A196

Last active standard display with added warning reminder

ˆ 1000 rpm

MULTIPLE WARNINGS 200 ST

PRESS OK

PRESS OK

STOP: PARK: RUN ENG

<

HOT HYD OIL LR A196

A new lower severity fault with a lower priority operator action becomes active.

The highest priority fault becomes inactive.

1 of 1

STOP: PARK: RUN

MULTIPLE WARNINGS

MULTIPLE WARNINGS

A new higher severity warning with a higher priority action becomes active.

PRESS OK

CIRCUIT BREAKER FLT A100

SC 20 mph

OK

MULTIPLE WARNINGS

A new fault becomes active.

This newest fault becomes inactive before being displayed.

PRESS OK

STOP: PARK: RUN ENG

STOP: PARK: RUN ENG

PRESS OK

PRESS OK

GO TO SHOP NOW

STOP: PRK:

LOW STRG PRES A111

OK

OK

2 of 2

STOP: PARK

Notice that this one OK acknowledges both faults simultaneously

All warnings have now been OK'd.

STOP: PARK

OK LOW STRG PRES A111 2 of 2

STOP: PARK

CIRCUIT BREAKER FLT A100

This warning becomes inactive.

LOW STRG PRES A111 CLEARED - 1 ACTIVE

STOP: PARK: RUN ENG

1 OF 2 Continue to display inactive fault warning for 10 seconds or until OK'd. New operator action is shown.

Both faults clear.

CIRCUIT BREAKER FLT A100

ˆ HOT HYD OIL LR A196

HOT HYD OIL LR A196

1 of 2

STOP: PARK

CLEARED - 1 ACTIVE

1 of 1

GO TO SHOP NOW

STOP: PARK: RUN

2x

A new lower severity warning with a lower priority action becomes active.

 PRESS < FOR STANDARD DISPLAY

SNAPSHOT IN PROG A234

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CLEARED - 0 ACTIVE

HIGH FUEL TEMP C261

The last remaining fault becomes inactive.

MULTIPLE WARNINGS

HOT HYD OIL LR A196

PRESS OK

CLEARED - 0 ACTIVE

CLEARED - 0 ACTIVE

Load = 240 t

STOP: PARK: RUN ENG

<

Display each warning that went inactive without being displayed with the "FAULT CLEARED" message. They are displayed in the order in which they became inactive.

LC = 25

A new warning with a lower priority action becomes active.

3560.9 h

Operator Controls

TT = 6000 t

SC = 20 mph

83443

N5-29

Entering Payload Meter Data

Data Entry Detail (Sublevel 2) Note: If a switch having no defined function for the current mode is actuated, the message "INVALID ENTRY" will be displayed on the screen while the switch is being pressed.

OK < Switch 1

Switch 2

If the back switch is actuated before accepting a new driver ID, the old ID will remain in effect.

Payload Data OK to View

Screen 5

OK

ˆ DRIVER ID: 123

OK

0123456789

5x

0123456789

ˆ

PRESS OK TO CHANGE

OK

0123456789



5_

Screen5, subscreen 0

Screen5, subscreen max.

3x

3x

0123456789

OK

5_

0123456789

0123456789

ˆ

54_

OK

54_

0123456789

ˆ

547_

9x

0123456789

OK

547_

0123456789

548_

N5-30

0123456789

3x

0123456789



54_

OK

54_

Operator ID = 548

<

Press OK to enter ID

Operator Controls

Payload Data OK to View

OK

0123456789

ˆ

548_

83444

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KOMTRAX PLUS Operation

This system uses the KOMTRAX Plus system to gather data about the operation of the truck from sensors and other controllers installed on the truck. The data stored in KOMTRAX Plus controller (2, Figure 5-14) is collected by a laptop personal computer (PC) or transmitted directly by communications satellite (utilizing the ORBCOMM controller). This data is then compiled at the Komatsu computer server. Based on this information, the servicing Komatsu distributor will suggest improvements and provide information aimed at reducing machine repair costs and downtime. NOTE: A contract is necessary before KOMTRAX Plus can be used. Contact your Komatsu distributor for more information.

The KOMTRAX Plus system uses wireless components that transmit via radio waves. It is necessary to conform to local laws when using this system. Proper operation of the system is dependent on good reception. Operating in tunnels, mountain ranges and covered areas may prevent communication of the system. Contact your Komatsu distributor before selling or exporting a truck equipped with KOMTRAX Plus. It may be necessary to remove the system before transfer of ownership. Contact your Komatsu distributor before installing equipment that may interfere with the KOMTRAX Plus system.

DO NOT disassemble, repair, or modify the KOMTRAX Plus system without proper authorization. Changes to the system may cause machine failures and fire.

Komatsu is not responsible for any failures that result from neglecting KOMTRAX Plus system precautions and instructions.

DO NOT touch the KOMTRAX Plus system components during machine operation. DO NOT pull on KOMTRAX Plus system wiring harnesses, connectors, or sensors. This may cause short circuits or open circuits and lead to machine failure or fire. DO NOT allow water, dirt, or oil onto system components. The ORBCOMM satellite requires the installation of a pole and antenna, adding to the overall height of the machine. The height increase is 410 mm (16.2 in.). With the guard installed, the overall height increases another 260 mm (10.2 in.). Use caution when operating in areas with height restrictions.

Anyone with a pacemaker must remain a minimum of 22 cm (9 in.) from the communications antenna. Radio waves from the antenna can interfere with pacemaker operation.

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ORBCOMM is a two-way radio communication device. Wireless signals from the system can interfere with other wireless signals in the area. This interference can cause a malfunction in a blast zone resulting in an unintended detonation. Know the locations of blast zones in the area and keep a safe distance to avoid unintentional blasts. If the machine is operating within a distance of 12m (40 ft) of a blast zone, disconnect the ORBCOMM harness. Failure to do so could result in serious injury or death. This warning does not supersede requirements or regulations of the area or country where this machine is in operation. The following specifications are provided to ensure compliance with all of the applicable requirements or regulations: Transmit power: 5-10 Watts Operating Frequency Range: 148 - 150 MHz

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NOTE: The ORBCOMM modem installed from the factory on all new trucks may not be approved for use in certain countries of the world. Local regulation may prohibit the use of the ORBCOMM modem/ satellite communicator. Depending on local regulation, you may need to either remove the modem or disconnect it and remove the antenna. Check with KAC service for assistance and preferred action in your area. The following is a list of "at risk" countries: China, Russia, Serbia, Tanzania, Senegal, Zambia, Botswana and Namibia.

When the data-store button (1, Figure 5-13) is pressed on the back side of the center console, it will store a “snapshot” of the Statex III drive system. It will also trigger the KOMTRAX Plus system to store a “snapshot” of the truck operating system. A light on the status indicator light panel will stay illuminated while the KOMTRAX Plus system is recording the “snapshot”, which lasts for 7.5 minutes.

During normal truck operation, the red LED digits on the KOMTRAX Plus controller will count from 00-99 continuously. When the key switch is turned OFF, the KOMTRAX Plus controller will remain on while it finishes processing internal data and saves the recent data into permanent memory. When the data has been safely stored, the two digit LED display will turn OFF. This process could take up to three minutes to complete.

If 24V power is disconnected (using the battery disconnect switches) from the KOMTRAX Plus controller before it has completed it’s shut down procedure, the KOMTRAX Plus controller will lose all data gathered since the key switch was last turned ON. Do not disconnect battery power until the KOMTRAX Plus controller has completed the shut down procedure and has turned the LED digits off.

The KOMTRAX Plus system is turned on by the truck key switch. Immediately after receiving 24V power from the key switch, the KOMTRAX Plus controller (2, Figure 5-14) begins the power-up initialization sequence. This sequence takes about three seconds, during which time the red LED digits display a circular sequence of flashing LED segments.

1

2

84050

FIGURE 5-14. KOMTRAX PLUS COMPONENT LOCATION 1. ORBCOMM Controller 2. KOMTRAX Plus Controller

FIGURE 5-13. CENTER CONSOLE, REAR VIEW 1. Data Store Button

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The ORBCOMM controller (1, Figure 5-14) transmits data through antenna (1, Figure 5-15) mounted on top of the cab. The antenna coaxial cable is routed through the cab structure to protect it from damage. If the antenna or coaxial cable is damaged, replace the parts.

Basic Precautions

• When using this truck, there is no particular need to operate the KOMTRAX Plus system. • Never disassemble, repair, or modify the KOMTRAX Plus system. This may cause failure or fire on the machine or this system. • Do not touch the system when operating the machine. • Do not pull on the wiring harnesses, connectors. or sensors of this system. This may cause short circuits or disconnections that lead to failure or fire on the machine or this system. • Do not get water, dirt or oil on the system controllers. • If there is any abnormality with the KOMTRAX Plus system, please consult the servicing Komatsu distributor.

FIGURE 5-15. ORBCOMM ANTENNA 1. ORBCOMM Antenna 2. Magnetic Base Interface Module

The interface module (located in the Auxillary Control Box) receives data from the sensors installed on the truck and sends this information to the KOMTRAX Plus controller. There is a small green LED light on the face of the controller. With the key switch ON, the light must be blinking. If the light is continuously illuminated, there is a problem in the controller.

FIGURE 5-16. DIAGNOSTIC PORTS (D.I.D. PANEL AT REAR OF CAB) 1. IM Diagnostic Port 2. KOMTRAX Plus Diagnostic Port

When a new interface module controller is installed on the truck, new software has to be installed inside the controller. IM-Diag connector (1, Figure 5-16) is used to connect the interface module to a laptop PC for installing software.

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KOMATSU WIRELESS BRIDGE (Optional)

Switching to the KWB_SETUP Network

General Information

The Komatsu wireless bridge allows for the transfer of information from the KOMTRAX Plus controller to a laptop computer with wireless network capabilities. The information that is downloaded through the KWB (Komatsu wireless bridge) is the same information that is gathered during a manual download from the KOMTRAX Plus system. Downloads can be performed with the laptop computer located on or near a stationary truck, or the computer can be located close to a path of moving trucks. Total download time is approximately 10 seconds. If only a portion of the data is downloaded while the truck is passing by a laptop computer, the remaining information will be downloaded the next time a data download occurs.

The computer should be on the same network as the KWB. It will be necessary to "create a profile" for the new network. Check the wireless adaptor's manual for details. 3. Configure the new profile as follows: • Set the profile name to KWB_SETUP. • Set the SSID to KWB_SETUP. • Select the wireless network type as "ad hoc." • In the security settings, select "no encryption" or a similar setting. • Select channel 11 (most adaptors automatically select a channel).

Some wireless adaptor software allows the setting of a static IP address and subnet mask for each profile. If this option is available, complete the following steps:

The wireless bridge transmits data using an antenna.

a. Set the IP address to 192.168.0.xxx, where xxx is any number between 1 and 255. Number 123 is recommended if only one computer will be used to interact with the KWB. If multiple computers are used, each must be set to a different IP address.

Communication Setup

A computer running a Microsoft® operating system (with a wireless network adaptor) is required to download data from the KWB. The individual steps required are different depending upon the computer operating system and each computer’s specific wireless adaptor. Please refer to the computer and/or adaptor manuals for further details.

will

Set the subnet mask to 255.255.0.0. If asked for a default gate-way, this may be assigned the same IP address as the computer.

1. Ensure that the KWB: • shows power and function (LEDs illuminated) • has not been previously setup • is within range of the computer 2. Use the computer to scan for any available wireless networks. The computer should find a network with KWB_SETUP as its SSID (SSID = Service Set Identifier). If this SSID is present the KWB is transmitting correctly. Switch to the KWB_SETUP network. If the KWB_SETUP SSID is not detected, verify all connections to the KWB. If all connections are correct, the KWB will need to be reset. Reset the KWB by pushing the reset button (2, Figure 5-17) next to the connector plug. NOTE: A KWB_SETUP SSID could be transmitted by another laptop computer and not by the desired KWB. Power down any other wireless sources with an SSID of KWB_SETUP.

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Setting the Computer Subnet Mask and IP Address

If the adaptor software does not allow for setting an IP address, then this must be done manually. The Windows TCP/IP settings must be modified for the correct subnet mask and an adequate IP address. The steps to reach the point where the TCP/IP settings can be modified vary according to the operating system and are described below. The actual steps for making the changes to the settings are described for the following operating systems.

Windows Vista: 1. Click on the Windows menu, right click on "Network" then select "Properties." A window will open with the option "Manage network connections" as one of the options on the left side. Select that option. 2. A new window showing all available networks will open. Right click on the wireless network to be used to connect to the KWB and select "Properties." Vista will inquire if this was an intentional selection; select "Continue." Continue to the topic of “Properties”.

Windows 2000: 1. Click on the start menu, select settings and then "Network and Dial-up Connections." 2. Right click on the wireless network adaptor and select "properties." Skip instructions for other Operating Systems and continue to the topic of “Properties”. Windows XP: 1. Click on the start menu, right click on "My Networks" and select "Properties." A window with all available networks will be shown. 2. Right click on the wireless network and select "Properties." Skip instructions for Windows Vista and continue to the topic of “Properties”.

Properties

Once the window with the list of available protocols is shown, the TCP/IP should then be selected. Click on "Properties" and bring up a window for setting the IP address and the subnet mask (alternatively, double click on TCP/IP). Before making any changes, write down the current settings. These settings will be needed to restore the original computer settings if needed. 3. Select "Use the following IP address," then set the IP address to 192.168.0.xxx, where xxx represents any number between 1 and 255. Number 123 is generally used. However, no two computers should use the same IP address). The subnet mask should now be set to 255.255.0.0. If a gateway address is requested, this is set to the same as the IP address. This prepares the computer to communicate with the KWB and to interact with the automatic download software. NOTE: The previous steps are not necessary if the software that comes with the computer/adaptor allows an IP address and mask to be assigned to each profile. This is done automatically by selecting the profile. It may be necessary to repeat these steps to restore the computer settings when connecting to another network.

FIGURE 5-17. RESET LOCATION 1. Komatsu Wireless Bridge

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2. Reset Button Hole

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Setting Up the KWB

Adding Encryption

The KWB is preset from the factory. It is recommended that the SSID be changed at setup to establish a unique identity from other KWBs. No previously installed KWBs should show up as KWB_SETUP. Changing the network channel may be necessary. For example, if another network in the vicinity uses channel 11 for transmission, the KWB may interfere with this network. If the information downloaded from the KOMTRAX Plus controller is considered sensitive and private, then the KWB data should be encrypted.

It is recommend that encryption be added.

Once the computer has been setup correctly the KWB may be setup using a web browser as follows:

NOTE: If a more secure encryption method is desired, consult a network professional to setup WPA encryption.

1. On the KWB, label locate the IP address. 2. Type the KWB IP address into the address bar of a web browser (just the numbers and the periods). 3. When prompted to enter a User Name and Password, enter "dpac" for both. 4. The initial screen that is displayed will show the current status of the KWB. Select "Network" from the top right corner. 5. Change the SSID to any name. (for example, "KOMTRAX controller"). The SSID is used to separate networks. If one computer will be used to download data from excavators, one from haul trucks, and one from dozers, then the KWB that will be installed on these machines could have their SSID set to "KOMTRAX_dig," "KOMTRAX_haul," and "KOMTRAX_push" respectively. This would make excavators and haul trucks invisible to the computer setup to download data from dozers. All KWBs that are to be in the same network should be set to the same SSID. If the default channel (11) is used by another network in the vicinity, change the channel. It is preferable to assign channels that are at least three channels apart.

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1. On "Wireless Security Mode," select WEP128. In "WEP key 1", using only numbers and the letters from "A" to "F," input a 26 character long passkey, for example "0123456789ABCDEF0123456789" (a more complex combination should be used). All KWBs that are to be in the same network should have the same WEP key, SSID, and be on the same channel. 2. Keep a record of the key.

3. If the "DHCP Client Name" is blank, input the KWB IP address in this field before pressing the "Save" button at the bottom of the page. No further network settings are required. 4. Once the KWB is reset, all the settings will be applied. Reset the KWB when prompted or, if you prefer to review the settings, click on "Networks" and, when reviewing is complete, click on "Reset." Both of these options are in the blue bar under "KWB-1".

Final Computer Settings

Once the KWB SSID is changed, the KWB is no longer in the KWB_SETUP network. In order to establish communications with the KWB, the computer must be setup to have the same settings as the KWB. Follow steps 1 through 3 beginning in “Communication Setup”, but use the new settings to create a different network profile. Once all setting are complete, typing the KWB IP address in the browser's address bar should open the KWB settings page. This confirms that the KWB and the computer are on the same network. Once the steps described above have been performed, the computer will have two network profiles in the program that manages the network adaptor. The KWB_SETUP profile should remain in the list in order to setup other KWBs in the future. The other profile will be the one used to communicate with the existing KWB. For both networks, the computer IP address can remain the same. Therefore, Step 3 as described in “Switching to the KWB_SETUP Network” is not required. If the computer is also used to connect to the internet, select "obtain IP address automatically" when connecting to the internet.

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Data Downloading

Resetting the KWB

To obtain the software for data downloading from the KOMTRAX Plus controller, go to the Komatsu Extranet (https://www.komatsuamerica.net).

It may be necessary to reset the KWB. For example, if the WEP key was incorrectly typed when setting up the KWB, it will not be possible to connect to that KWB without the correct key.

1. Select KOMTRAX / VHMS / PLM. 2. Select VHMS / PLM, then select SOFTWARE. 3. Select KWB - Komatsu Wireless Bridge (Wireless Download Software). Load and install the software. The icon "VHMS Controller Auto Download Tool" will be created during the download process. Running the software for the first time will offer the opportunity to choose a login name and password; "user" should be used for "User Name" and "1" for "Password." This may change this the next time the software is run. Clicking "OK" will start the download tool. If any KWBs are within range and are connected to the VHMS controller, the tool will automatically download all the data from each VHMS controller. The auto-download software will not download from KOMTRAX Plus controllers that have not had the vehicle data setup (this is a consideration only when replacing a KOMTRAX Plus Controller or installing a KOMTRAX Plus Controller for the first time nor will any KWB that is not connected to a KOMTRAX Plus controller show up in the list of available download sources. Once the data from one vehicle has been downloaded, the tool will not perform another download for that vehicle until 20 hours have passed. It is possible to force a download by right clicking on a vehicle in "View." Vehicles in "View" are shown in the top list; vehicles that have been previously in "View" are shown in the lower list.

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1. Remove the power by turning OFF the key or by disconnecting the harness from the KWB. 2. Lightly insert, press and hold a paperclip into the hole on the connector face. To prevent damage to the internal switch do not use sharp objects. 3. Restore power to the KWB while keeping the reset switch depressed. The LEDs should begin to flash. The KWB is now reset. NOTE: After a reset, the KWB will revert to the KWB_SETUP SSID.

4. Switch to the KWB_SETUP SSID network. The IP address after a reset will be 192.168.1.0. 5. When setting the KWB, the IP address must be changed from the reset IP address. Use the address on the KWB label.

KWB Lights

Name

Table 1: KWB LIGHTS Description

CONN

Reserved for future use.

LINK

When ON, the KWB is operational. When OFF, the KWB may not be set for Ad-Hoc, or it may be damaged. An ON condition is not an indication that the antenna or antenna cable is in good condition or that the antenna is connected.

CFG

When ON, the KWB has an IP address. When OFF, the KWB may be configured for DHCP (DHCP should not be selected for ad-hoc mode).

POST

When ON, the KWB is receiving power and is operational. When OFF, the KWB may not be powered or it may be defective.

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NOTES:

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SECTION P LUBRICATION AND SERVICE INDEX

LUBRICATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-1

AUTOMATIC LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-1

P01024

Index

P1-1

NOTES

P1-2

Index

P01024

SECTION P2 LUBRICATION AND SERVICE INDEX LUBRICATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-3 830E SERVICE CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-3 HYDRAULIC TANK SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-3 Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-3 COOLANT LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-4 Radiator Filling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-4 Coolant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-4 Unacceptable Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-4 WHEEL MOTOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-4 RESERVE ENGINE OIL SYSTEM (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-5 Reserve Oil Tank Filling Procedure (Remote fill) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-5 Inline Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-5 QUICK FILL SERVICE CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-6 LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-7 10 HOUR (DAILY) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-8 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . .P2-11 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . P2-12 250 HOUR LUBRICATION AND MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . P2-13 500 HOUR LUBRICATION AND MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . P2-17 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . P2-19 2500 HOUR MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-20 5000 HOUR MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2-20

P02064 7/11

Lubrication and Service

P2-1

NOTES:

P2-2

Lubrication and Service

7/11 P02064

LUBRICATION AND SERVICE Recommended preventive maintenance will contribute to the long life and dependability of the truck and its components. The use of proper lubricants and the performance of checks and adjustments at the recommended intervals is most important. Lubrication requirements are referenced to the lube key found in the Lubrication Chart (page P2-5). For detailed service requirements for specific components, refer to the shop manual section for that component (i.e. Section H for suspensions, Section L for hydraulic system, etc.). Refer to the manufacturer's shop manual when servicing any components of the General Electric system.

Refer to the engine manufacturer's service manual when servicing the engine or any of its components. The service intervals presented here are in hours of operation. These intervals are recommended in lieu of an oil analysis program which may determine different intervals. However, if the truck is being operated under extreme conditions, some or all, of the intervals may need to be shortened and the service performed more frequently. The 830E truck is equipped with an automatic lubrication system. The initial setup for this system provides for nominal amounts of lubricant to be delivered to each serviced point. The lubrication injectors can be adjusted to vary the amount of lubricant delivered. In addition, the timer for lubrication intervals is normally adjustable. For adjustments to these devices, refer to Automatic Lubrication System later in this manual.

HYDRAULIC TANK SERVICE There are two sight gauges on the side of the hydraulic tank. With the engine stopped, key switch OFF, hydraulic system bled down and body down, oil should be visible in the top sight gauge. If hydraulic oil is not visible in the top sight gauge, follow Adding Oil instructions below. Adding Oil

Keep the system open to the atmosphere only as long as absolutely necessary to lessen the chances of system contamination. Service the tank with clean Type C-4 hydraulic oil only. All oil being put into the hydraulic tank must be filtered through filters rated at three microns. 1. Ensure that the engine is stopped, key switch is OFF, hydraulic accumulators depressurized, and body is down. 2. Remove fill cap (2, Figure 2-1) and add hydraulic oil until the oil level is visible in the center of the top sight gauge. 3. Install the fill cap. 4. Start the engine. Raise and lower the dump body three times. 5. Check the hydraulic oil level again with the engine stopped, key switch OFF, hydraulic accumulators depressurized, and body down. 6. Repeat Steps 1 - 5 until the oil level is maintained in the center of the top sight gauge.

830E SERVICE CAPACITIES Crankcase: (including 4 oil filters) Komatsu SDA16V160 or SSDA16V160 Engines

Liters

U.S. Gallons

280

74

Cooling System: Komatsu SDA16V160 or SSDA16V160 Engine

522

138

Hydraulic System: Refer to “Hydraulic Tank Service”

947

250

Wheel Motor: (each side)

38

10

Fuel Tank (Diesel Fuel Only)

4542

1200

Retractable Ladder System Hydraulic Oil Reservoir: (if equipped)

8

2

P02064 7/11

FIGURE 2-1. HYDRAULIC TANK SERVICE 1. Sight Gauges

Lubrication and Service

2. Fill Cap

P2-3

COOLANT LEVEL CHECK

Coolant Specifications

Inspect the coolant sight gauge. If coolant cannot be seen in the sight gauge, it is necessary to add coolant to the system before truck operation. Refer to the procedure below for the proper filling procedure. Radiator Filling Procedure

• For ambient temperatures of -32° C (-25° F) and above, use a standard 50/50 anti-freeze-to-water mixture. • For arctic climates with ambient temperatures between -32° C (-25° F) and -54° C (-65° F), use a 60/40 anti-freeze-to-water mixture. NOTE: Do not use propylene glycol coolant in arctic climates. Only use ethylene glycol coolants.

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. NOTE: If coolant is added using the Wiggins service center, the radiator cap must still be removed before adding coolant.

Engine coolant must always be visible in the sight gauge before truck operation. 1. With the engine and coolant at ambient temperature, remove the radiator cap (2, Figure 2-2). 2. Fill the radiator with the proper coolant mixture until coolant is visible in the sight gauge (1). 3. Install the radiator cap. 4. Run the engine for five minutes, then check the coolant level. 5. If coolant is not visible in the sight gauge, repeat Steps 1 - 4. Any excess coolant will be discharged through the vent hose after the engine reaches normal operating temperature.

Unacceptable Practices

• Use of high-silicate anti-freeze. • Under concentration or over concentration of Extended Service Additive (SCA). • Use of anti-freezes/coolants that are not fully formulated for extended service intervals. • Use of sealing additives (stop-leak) in the cooling system. • Use of soluble oils in the cooling system. • Use of poor-quality water. See the engine manufacturer’s specifications for water quality requirements. • Use of anti-freeze, Extended Service Additive (SCA) or coolant filter(s) that do not meet the engine manufacturer’s specifications. • Use of Treated Water coolant. • Use of coolants with less than 40 percent antifreeze.

WHEEL MOTOR SERVICE Due to differences in gear ratio and component evolution/design, wheel motor service intervals may be unit number and/or mine specific. Because of the wide variety of factors involved, it is necessary to consult your area Komatsu representative for all wheel motor service intervals and instructions. General intervals for oil service and sampling are listed in the interval charts.

FIGURE 2-2. COOLING SYSTEM SERVICE 1. Sight Gauge

P2-4

2. Radiator Cap

Lubrication and Service

7/11 P02064

RESERVE ENGINE OIL SYSTEM (Optional) The reserve oil tank for the engine is designed to add more oil capacity to the engine to reduce the frequent servicing of the engine oil. The engine oil level must still be checked every shift using the dipstick. If engine oil level is not correct, check for proper operation of the reserve oil system. Never add oil to the engine unless it has been drained. If the engine oil has been drained from the oil pan, the new oil must be added to the engine oil pan before starting. DO NOT use the oil in the reserve tank to fill an empty engine with oil. After an oil change, both the engine and reserve tank must be full of oil before starting the engine. With the engine running, check the operation of the red LED light on the pump. • Continuously on - Pump 1 is withdrawing oil from the engine sump and bringing down the oil level. • Regular pulsing - Pump 2 is returning oil to the engine sump and raising the oil level. • Irregular pulsing - Oil is at the correct running level.

Oil should always be visible in the bottom sight gauge. If not, add oil to the reserve oil tank until oil is visible in the top sight gauge. • Never add oil to the engine unless it has been completely drained. • If the engine oil has been drained from the oil pan, new oil must be added to the oil pan. Do not use the oil in the reserve oil tank to fill an empty engine oil pan. After an oil change, both the engine and reserve oil tank must be full of oil before starting the engine. Reserve Oil Tank Filling Procedure (Remote fill)

1. Connect the pressure supply hose from the new oil supply to the quick coupler on the truck. Open valve on supply hose to apply pressure. 2. Pull out on switch (2, Figure 2-3) to turn the system on. 3. Push start switch (3). The VALVE OPEN light (5) should illuminate and the filling process will begin. 4. When tank is full, the VALVE OPEN light will turn off and FULL light (4) will illuminate. 5. Close the oil supply valve in the fill hose. 6. Press and hold start switch (3) for a couple of seconds. 7. Disconnect the new oil supply hose. 8. Push switch (2) in to turn system power OFF.

Inline Screen

There is an inline screen located at the inlet of the fill valve. This screen does not require periodic maintenance, but it can be cleaned by removing the screen and back flushing.

FIGURE 2-3. CONTROL PANEL 1. Remote Control Box 4. “FULL” Light 2. System Switch 5. “VALVE OPEN” Light 3. Start Switch

P02064 7/11

Lubrication and Service

P2-5

QUICK FILL SERVICE CENTER The service center can be located on either side of the machine (Figure 40-4) and is used to fill system fluids. Table 1 on page 6 shows the maximum recomended fill pressures for the service center.

TABLE 1: MAXIMUM FIll PRESSURES Fill System

kPa

psi

Engine Crankcase

345

50

Reserve Tank

862

125

Hydraulic Tank

345

50

Coolant

345

50

Grease

10 342

1,500

103

15

Fuel

FIGURE 40-4. SERVICE CENTER 1. Hydraulic Oil 2. Radiator Coolant

P2-6

3. Engine Oil 4. Grease

Lubrication and Service

7/11 P02064

LUBRICATION CHART P02064 7/11

Lubrication and Service

P2-7

10 HOUR (DAILY) INSPECTION Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK

COMMENTS

CHECKED INITIALS

1. MACHINE - Inspect the entire machine for leaks, worn parts, and damage. Repair as necessary. 2. TURBOCHARGERS - Check for leaks, vibration or unusual noise. 3. RADIATOR - Check the coolant level and fill with the proper mixture as shown in the Cooling System Recommendation Chart in this chapter. Refer to the engine manual for proper coolant additives. 4. ENGINE a. Check the oil level. To obtain an accurate measurement, remove the dipstick and wipe it off. Then reinsert the dipstick and remove it again to check the oil level. Refer to the engine manual for oil recommendations. (Lube Key “A”). NOTE: If the truck is equipped with a reserve engine oil tank, check the oil level with the reserve tank dipstick. If necessary, add oil to the reserve tank. Also, with the engine running, check operation of the LED indicator light. See below for description of LED light signals. Refer to Figure 2-1.

LED Light Signals: • Steady - Pump 1 is withdrawing oil from the engine sump and bringing down the oil level. • Regular pulsing - Pump 2 is returning oil to the engine sump and raising the oil level. • Irregular pulsing - Oil is at the correct operating level. b. Inspect exhaust piping for integrity. c. Check for abnormal noises and fluid leaks. d. Eliminator Filter - Check operating indicator. 5. HYDRAULIC TANK - Check the oil level in the tank. Add oil if necessary. Refer to Hydraulic Tank Service Adding Oil. Oil should be visible in the top sight glass. - DO NOT overfill. Lube Key “B”. 6. WHEELS AND TIRES a. Inspect tires for proper inflation and wear. b. Check for embedded debris in tread and remove. c. Inspect for damaged, loose, or missing wheel mounting nuts and studs.

P2-8

Lubrication and Service

7/11 P02064

10 HOUR (DAILY) INSPECTION (Continued) Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK

COMMENTS

CHECKED INITIALS

7. COOLING AIR DUCTWORK - Inspect ductwork from the blower to the rear drive case. Ensure that ductwork is secure, free of damage, and unrestricted. 8. AIR CLEANERS - Check the air cleaner vacuum gauges in the operator cab, Figure 2-6. The air cleaner(s) must be serviced if the gauge(s) shows the following maximum restriction: Komatsu SDA16V160 or SSDA16V160 Engines: . . . . . . . . . . . . . . . 625 mm (25 in.) of water vacuum. Refer to Section C in the shop manual for servicing instructions for the air cleaner elements. NOTE: After air filter service, push the reset button on face of gauge to allow the gauge to return to zero.

9. WIPER & WASHER - Inspect the wiper blades for wear or damage. Replace if necessary. Check the windshield washer fluid level. If below 1/2 full, add windshield washer fluid.

FIGURE 2-5.

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Lubrication and Service

P2-9

10 HOUR (DAILY) INSPECTION (Continued) Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK

COMMENTS

CHECKED INITIALS

10. FUEL FILTERS (Fuel Separators) - Drain water from the bottom drain valve on each fuel separator. 11. AUTOMATIC LUBE SYSTEM • Check the grease reservoir; fill as required. Lube Key “D”. • When filling the reservoir, check the grease filter indicator. Clean or replace the grease filter if the indicator detects a problem. • Inspect the system and check for proper operation. Ensure the following important areas are receiving adequate amounts of grease. Lube Key “D”. Steering Linkage Final Drive Pivot Pin Rear Suspension Pin Joints - Upper & Lower Body Hinge Pins - Both Sides Hoist Cylinders Pins - Upper & Lower Anti-sway Bar - Both Ends 12. RETRACTABLE LADDER SYSTEM (If equipped) • Check the hydraulic oil reservoir; fill as required. • Operate the ladder. Check for loose parts and adverse noise conditions.

P2-10

Lubrication and Service

7/11 P02064

INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK

COMMENTS

CHECKED INITIALS

*1. FUEL FILTERS - Change the fuel filters, (fuel separators). Refer to engine manufacturer's maintenance manual for fuel filter replacement instructions. *2. HYDRAULIC SYSTEM FILTERS - Replace filter elements only, after the initial 50, 100, and 250 hours of operation; then at each 500 hours of operation thereafter. *3 FAN DRIVE ASSEMBLY - Check torque for the six fan mounting cap screws: 237 N·m (175 ft lb). See Figure 2-6. *These checks are required only after the initial 50 hours of operation (such as: the commissioning of a new truck, or after a new or rebuilt component installation).

FIGURE 2-6.

P02064 7/11

Lubrication and Service

P2-11

INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK

COMMENTS

CHECKED INITIALS

*1. HYDRAULIC SYSTEM FILTERS - Replace filter elements only, after the initial 100 and 250 hours of operation; then at each 500 hours of operation thereafter.

*These checks are required only after the initial 100 hours of operation (such as: the commissioning of a new truck, or after a new or rebuilt component installation).

P2-12

Lubrication and Service

7/11 P02064

250 HOUR LUBRICATION AND MAINTENANCE CHECKS The 10 hour lubrication and maintenance checks should also be performed at this time. NOTE: “Lube Key” references are to the lubrication chart. Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK

COMMENTS

CHECKED INITIALS

1. ENGINE - Refer to the engine manufacturer’s Operation & Maintenance manual for complete specifications regarding engine lube oil specifications. NOTE: If the engine is equipped with the *Centinel™ oil system and/or the Eliminator™ filter system, engine oil and filter change intervals are extended beyond 250 hours. Take an engine oil sample for analysis. Refer to engine Operation & Maintenance manual for specific oil and filter change intervals.

* The Centinel™ system is a duty-cycle-dependent lubrication management system whereby oil is blended with the fuel and burned and an extension of oil change intervals can occur. a. Change engine oil. Lube Key “A”. b. Replace engine oil filters. NOTE: When installing spin-on filter elements, follow the instructions as specified by the filter manufacturer. The tightening instructions are normally printed on the outside of the filter. Do not use a wrench or strap to tighten filter elements.

c. Check the torque on the cooling fan (1, Figure 2-6) mounting cap screws. Tighten cap screws (2) to 237 N·m (175 ft lb). (CONTINUED NEXT PAGE)

P02064 7/11

Lubrication and Service

P2-13

250 HOUR LUBRICATION AND MAINTENANCE (Continued) TASK

2.

COMMENTS

CHECKED INITIALS

COOLING SYSTEM a. COOLANT MIXTURE - Check for proper coolant mixture. Add coolant as required. b. COOLANT FILTERS - Change coolant filters. c. COOLING SYSTEM HOSES - Check cooling system hoses for damage and signs of deterioration. Refer to the engine maintenance manual for coolant filter replacement instructions and proper coolant mixture instructions.

3.

FUEL FILTERS - Change the fuel filters (fuel separators). Refer to engine Operation & Maintenance manual for specific filter replacement instructions.

4.

FUEL TANK - Drain water and sediment from the fuel tank. Refer to Shop Manual, Section B, Fuel Tank Cleaning.

5.

STEERING LINKAGE - Check the torque on pin retaining nuts (1, Figure 2-7) on the steering linkage 712 N·m (525 ft lb). Check the torque on tie rod retaining nuts (2) - 420 N·m (310 ft lb).

6.

CAB RECIRCULATION AIR FILTER - Under normal operating conditions, clean every 250 hours. In extremely dusty conditions, service as frequently as required. Clean the filter element with mild soap and water. Rinse completely clean and allow to air dry before use.

7.

CAB AIR FILTER - Under normal operating conditions, clean every 250 hours. In extremely dusty conditions, service as frequently as required. Clean the filter element with mild soap and water. Rinse completely clean and air dry with a maximum of 275 kPa (40 psi). Reinstall the filter. Refer to Figure 2-8.

FIGURE 2-7.

P2-14

FIGURE 2-8. 1. Filter Cover 2. Cab Filter

Lubrication and Service

7/11 P02064

250 HOUR LUBRICATION AND MAINTENANCE (Continued) TASK

COMMENTS

8.

HYDRAULIC PUMP DRIVESHAFT & U-JOINTS Add one or two applications of grease to each grease fitting. Use non - moly grease only. Check that each bearing of the cross & bearing assembly is receiving grease. Replace bearings if any wear is detected.

9.

MOTORIZED WHEEL GEAR CASE - Refer to the G.E. Planned Maintenance Manual and specific motorized wheel shop manual. Check for correct oil level. Lube key “C”.

CHECKED INITIALS

*10. HYDRAULIC SYSTEM FILTERS - Replace filter elements only after the initial 250 hours of operation; then at each 500 hours of operation thereafter. Check oil level. Add oil as necessary. Lube Key “B”. 11. BATTERIES - Check the electrolyte level and add water if necessary. 12. BODY-UP & HOIST LIMIT SWITCHES - Check operation of the switches. Clean the sensing areas of any dirt accumulation and inspect the wiring for any signs of damage. 13. DUMP BODY PADS - Check the pads, shims and mounting hardware for wear and proper tightening. 14. A/C DRIVE BELT - Check the belt for wear, cracks, glazing, tears or cuts. Refer to engine Operation & Maintenance manual for specific instructions. 15. BATTERY CHARGING ALTERNATOR DRIVE BELT Check the belt for wear, cracks, glazing, tears or cuts. Refer to engine Operation & Maintenance manual for specific instructions. 16. AUTOMATIC LUBE SYSTEM - Perform 250 hour checks as outlined in Automatic Lubrication System, Section P, in this manual. 17. FRONT WHEELS - Check the oil level. Position the fill plug at the 12 o’clock position. The floating ball in the sight gauge must be at its highest position. Add oil as necessary. Remove and inspect magnetic plug for contamination, if equipped. Use Lube key E. 18. G.E. PREFILTER BLOWER (If equipped) - Add one to two applications of grease to the grease fitting. Lube key “D”. 19. WHEEL MOTOR BLOWER (If equipped) - Grease motor blower shaft bearings. Lube key “D”.

P02064 7/11

Lubrication and Service

P2-15

250 HOUR LUBRICATION AND MAINTENANCE (Continued) TASK

COMMENTS

20.

AIR INTAKE PIPING - Check all mounting hardware, joints, and connections. Ensure no air leaks exist and all hardware is properly tightened. Figure 2-5.

21.

RETRACTABLE LADDER SYSTEM (If equipped) -

CHECKED INITIALS

Check the ladder system for: a. Loose or missing hardware. b. Bent or misaligned structures. c. Foreign materials such as dirt, mud, etc., that could effect proper operation of ladder. d. Damaged wiring and harnesses. e. Power pack box free of moisture and is properly sealed. f. System voltage of 21VDC (off) to 30VDC max (operating). Operate the ladder system through two complete cycles and check for: a. Adverse noise conditions. b. Proper movement in a vertical plane (viewed from front of ladder); the ladder must move up and down central to the actuator box. c. Range of functions, including switches and park-brake interlock.

remote

*This check is required only after the first 250 hours of operation (such as: the commissioning of a new truck, or after a new or rebuilt component installation).

FIGURE 2-9.

P2-16

Lubrication and Service

7/11 P02064

500 HOUR LUBRICATION AND MAINTENANCE CHECKS Maintenance requirements for every 10 & 250 hour Lubrication and Maintenance Checks should also be performed at this time. NOTE: “Lube Key” references are to the lubrication chart. Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK

COMMENTS

CHECKED INITIALS

1. FINAL DRIVE CASE BREATHERS - Remove the breather elements for the motorized wheels. Clean or replace the elements. 2. HYDRAULIC SYSTEM OIL FILTERS - Replace the high pressure filter elements. Check the hydraulic tank oil level. Add oil as necessary. Lube Key “B”. 3. HYDRAULIC TANK BREATHER - Replace the breather elements. 4. HYDRAIR® SUSPENSION - Check for the proper piston extension (front and rear). Refer to Section H4 in the shop manual for more information on proper suspension extension and maintenance procedures. 5. THROTTLE AND BRAKE PEDAL - Lubricate the treadle roller and hinge pins with lubricating oil. Lift the boot from the mounting plate and apply a few drops of lubricating oil between the mounting plate and the plunger. 6. HOIST ACTUATOR LINKAGE - Check operation. Clean, lubricate, and adjust as necessary. 7. PARKING BRAKE - Refer to Section J, Parking Brake Maintenance. Perform the recommended inspections. 8. RESERVE ENGINE OIL SYSTEM (OPTION) a. Check electrical system connections for tightness, corrosion and physical damage. Check the battery, oil pressure switch, junction boxes, remote control fill box and the circuit breakers. b. Examine all electrical cables over their entire length for possible damage. c. Examine all hoses, including those on the reserve tank and the ones leading to and from the engine. Check for leaks, cracks or other damage. Check all fittings for tightness, leakage or damage. 9. ACCUMULATOR PRECHARGE - Check all steering and brake system accumulator pre-charge pressures. Refer to Sections J and L for details.

P02064 7/11

Lubrication and Service

P2-17

500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)

Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK

COMMENTS

CHECKED INITIALS

10. WHEEL MOTOR OIL SAMPLING - Refer to shop manual Section G5, Wheel Motor, for oil sampling information. Refer to G.E. Motorized Wheel Service & Maintenance manual, Planned Maintenance section for additional required service tasks. (Initial 500 hours only) 11. WHEEL MOTOR OIL Change or filter wheel motor gear oil only after initial 500 hours of operation.

12. HVAC a. Ensure the air conditioner cab drains are clear of any obstructions. b. Also wash the air conditioner condensor with a low pressure hose. Check for any obstructions to airflow, clean as required. 13. FRONT BRAKE DISC - Measure the thickness of the disc. If 20 to 25% of the disc wear surface is worn below 28.7 (1.13 in.), the disc must be replaced. Refer to the shop manual, Parking Brake, Section J, for additional information. 14. FRONT WHEELS - Take an oil sample of the front wheel bearing oil. Refer to Section G in this shop manual for detailed instructions. 15. COOLING SYSTEM - Wash the radiator fins with a low pressure hose. Check for any obstructions to airflow, clean as required. 16. FUEL SYSTEM - Wash the fuel cooler, located on the front side of the radiator, with a low pressure hose. Check for any obstructions to airflow, clean as required. 17. FRAME AND AXLE BOX INSPECTION - Wash the truck, clean all of the weld joints, and visually inspect the entire frame and axle box for cracking or damage. 18. KOMTRAX Plus DATA DOWNLOAD - Using a laptop PC with the VHMS Technical Analysis Tool Box program, perform a data download from the KOMTRAX Plus controller. Send the data to WebCARE using the FTP feature. Refer to shop manual, Section D for more detailed instructions.

P2-18

Lubrication and Service

7/11 P02064

1000 HOURS LUBRICATION AND MAINTENANCE CHECKS Maintenance for every 10, 250, & 500 hour Lubrication and Maintenance Checks should also be performed at this time. NOTE: “Lube Key” references are to the lubrication chart. Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK

1.

COMMENTS

CHECKED INITIALS

HYDRAULIC TANK - Drain the hydraulic tank and clean the inlet strainer. Refill the tank with new oil; approximate capacity 901 l (238 gal). Use Lube Key “B”. NOTE: Oil change interval can be extended to 2,500 hours if oil is sampled at every 250 hour intervals and no abnormalities are detected.

2.

RADIATOR - Clean the cooling system with a quality cleaning compound. Flush with water. Refill the system with anti-freeze and water solution. Check the Coolant Specifications in this section for the correct mixture. Refer to the engine Operation and Maintenance Manual for the correct additive mixture.

3.

FUEL TANK - Remove the breather and clean in solvent. Dry with pressurized air and reinstall.

4.

OPERATOR'S SEAT - Apply grease to the slide rails. Lube Key “D”.

5.

AUTOMATIC BRAKE APPLICATION - Ensure the brakes are automatically applied when brake pressure decreases below the specified limit. Refer to the appropriate Shop Manual, Section J, Brake Checkout Procedure.

6.

FRONT ENGINE MOUNT TRUNION - Add one or two applications of grease at fitting. Lube key “D”.

7.

AUTOMATIC LUBE SYSTEM PUMP - Check pump housing oil level using dipstick on top of the pump unit. If necessary, add SAE 10W-30 motor oil.

8.

ELIMINATOR FILTER - Clean and check centrifuge. Refer to engine manufacture’s Operation & Maintenance Manual. (Service interval is dependent on duty cycle, oil quality, etc.).

P02064 7/11

Lubrication and Service

P2-19

2500 HOUR MAINTENANCE CHECKS Maintenance for every 10, 250, & 500 hour Lubrication and Maintenance Checks should also be performed at this time. NOTE: Lube Key references are to the lubrication chart. Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK

1.

COMMENTS

CHECKED INITIALS

FRONT WHEELS - Drain and refill with oil. Refer to the shop manual, Section G for detailed instructions on changing the oil. Lube key “E”. NOTE: Oil may need to be changed more frequently, depending on mine conditions and the results of the oil sample tests.

5000 HOUR MAINTENANCE CHECKS Maintenance for every 10, 250, 500 1,000 & 2,500 hour Lubrication and Maintenance Checks should also be performed at this time. NOTE: “Lube Key” references are to the lubrication chart. Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK

1.

COMMENTS

CHECKED INITIALS

AIR CLEANERS - Clean the Donaclone tubes in the pre-cleaner section of the air filter. Use low pressure cold water or low pressure air to clean the tubes. Refer to Section C, Air Cleaners. NOTE: Do not use a hot pressure washer or high pressure air to clean the tubes. Hot water/high pressure causes the pre-cleaner tubes to distort.

2.

FRONT WHEELS If oil sampling is done every 500 hours - And the contamination trends are not rising, do not replace the wheel bearings. Refer to Section G of the shop manual for more detailed instructions on oil sampling. If oil samples are not taken - Drain oil and completely disassemble the front wheel bearings and check all parts for wear or damage. Refer to Section G of the shop manual for disassembly and assembly procedures. Refill with oil. Check the oil level at the oil level plug on wheel hub. Lube key “E”.

3.

RETRACTABLE LADDER SYSTEM (If equipped) Drain, flush and re-fill the hydraulic oil reservoir.

P2-20

Lubrication and Service

7/11 P02064

SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX

AUTOMATIC LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-3 GENERAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-3 SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-5 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-5 Hydraulic Motor and Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-5 Grease Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-5 Pressure Reducing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-5 Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-5 Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-5 Vent Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-5 Over Pressure Cut Off Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-5 Grease Pressure Failure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-5 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-5 Interface Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-5 Relief Valve (unloader valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-5 SYSTEM OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-6 Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-6 Lubricant Required For System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-7 Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-7 LUBRICANT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-8 Pump Housing Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-8

P03037

Automatic Lubrication System

P3-1

INJECTORS (SL-1 Series “H”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-9 Injector Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-9 Injector Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-9 INJECTOR OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-10 PREVENTIVE MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-11 Daily Lubrication System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-11 250 Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-11 1000 Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-11 SYSTEM CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-12 Lubrication Cycle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-12 SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3-13

P3-2

Automatic Lubrication System

P03037

AUTOMATIC LUBRICATION SYSTEM GENERAL DESCRIPTION The automatic lubrication system is a pressurized lubricant delivery system which delivers a controlled amount of lubricant to designated lube points. The system is controlled by an electronic timer which signals a solenoid valve to operate a hydraulic motor powered grease pump. Hydraulic oil for pump operation is supplied by the truck steering circuit. Grease output is proportional to the hydraulic motor input flow. A pump control manifold, mounted on top of the hydraulic motor, controls input flow and pressure. A 24VDC solenoid mounted on the manifold turns the pump on and off. The pump is driven by the rotary motion of the hydraulic motor, which is then converted to reciprocating motion through an eccentric crank mechanism. The reciprocating action causes the pump cylinder to move up and down. The pump is a positive displacement, double-acting type as grease output occurs on both the up and the down stroke.

During the down stroke, the pump cylinder is extended into the grease. Through the combination of shovel action and vacuum generated in the pump cylinder chamber, the grease is forced into the pump cylinder. Simultaneously, grease is discharged through the outlet of the pump. The volume of grease during intake is twice the amount of grease output during one cycle. During the upstroke, the inlet check valve closes. One half of the grease taken in during the previous stroke is transferred through the outlet check and discharged to the outlet port.

Over-pressurizing the system, modifying parts, using incompatible chemicals and fluids, or using worn or damaged parts may result in equipment damage and/or serious personal injury.

• DO NOT exceed the stated maximum working pressure of the pump or the lowest rated component in the system.

• Do not alter or modify any part of this system unless approved by the factory.

• Do not attempt to repair or disassemble the equipment pressurized.

while

the

system

is

• Make sure that all fluid connections are securely tightened equipment.

before

using

this

• Always

read and follow the fluid manufacturer's recommendations regarding fluid compatibility and the use of protective clothing and equipment.

• Check all equipment regularly. Repair or

FIGURE 3-1. PUMP & RESERVOIR COMPONENTS 1. Hose From Filter 8. Pipe Plug 2. Filter 9. Dip Stick 3. Hydraulic Motor 10. Flow Control Valve 4. Pressure Reducing 11. Pressure Cutt OffValve Switch 5. Solenoid Valve 12. Grease Reservoir 6. Override Switch 13. Vent Hose 7. Vent Valve

P03037

replace worn or damaged parts immediately. This equipment generates very high grease pressure. Extreme caution must be used when operating this equipment as material leaks from loose or ruptured components can inject fluid through the skin and into the body causing serious bodily injury including possible need for amputation. Adequate protection is recommended to prevent splashing of material onto skin or into the eyes. If any fluid appears to penetrate the skin, get emergency medical care immediately! Do not treat as a simple cut. Tell attending physician exactly what fluid was injected.

Automatic Lubrication System

P3-3

FIGURE 3-2. AUTOMATIC LUBRICATION SYSTEM INSTALLATION 1. L.H. Suspension, Bottom Bearing 2. L.H. Hoist Cylinder, Top Bearing 3. L.H. Hoist Cylinder, Bottom Bearing 4. L.H. Anti-Sway Bar Bearing 5. L.H. Suspension, Top Bearing 6. L.H. Body Pivot Pin 7. R.H. Body Pivot Pin 8. Grease Supply From Pump 9. R.H. Suspension, Bottom Bearing 10. R.H. Hoist Cylinder, Top Bearing 11. R.H. Hoist Cylinder, Bottom Bearing 12. Rear Axle Pivot Pin

P3-4

13. R.H. Anti-Sway Bar Bearing 14. R.H. Suspension, Top Bearing 15. Grease Reservoir 16. Vent Hose 17. Pipe Plug (Oil Level) 18. Pressure Switch, N.O. - 20 684 kPa (3,000 psi) 19. Grease Pump 20. Vent Valve 21. Filter 22. Grease Supply to Injectors 23. Injectors 24. Pressure Switch, N.O. - 13 790 kPa (2,000 psi)

Automatic Lubrication System

P03037

SYSTEM COMPONENTS

Flow Control Valve

Filter

Flow control valve (10, Figure 3-1), mounted on the manifold, controls the amount of oil flow to the hydraulic motor. The flow control valve has been factory adjusted and the setting should not be disturbed.

Filter assembly (21, Figure 3-2), mounted on the grease reservoir, filters the grease prior to refilling the reservoir from the shop supply. A bypass indicator alerts service personnel when the filter requires replacement.

Solenoid Valve

Solenoid valve (5, Figure 3-1), when energized, allows oil to flow to the hydraulic motor.

Hydraulic Motor and Pump

Rotary hydraulic pump (3, Figure 3-1) is a fully hydraulically operated grease pump. An integrated pump control manifold is incorporated with the motor to control input flow and pressure. NOTE: The pump crankcase oil level must be maintained to the level marked on dipstick (9, Figure 3-1). If necessary, add 10W-30 motor oil.

Vent Valve

With vent valve (7, Figure 3-1) closed, the pump continues to operate until maximum grease pressure is achieved. As this occurs, the vent valve opens and allows the grease pressure to drop to zero, so the injectors can recharge for their next output cycle. Over Pressure Cut Off Switch

Hydraulic oil supply inlet pressure must not exceed 24 132 kPa (3500 psi). Exceeding the rated pressure may result in damage to the system components and personal injury.

Grease Reservoir

Grease reservoir (12, Figure 3-1) has an approximate capacity of 41 kg (90 lb) of grease. When the grease supply is replenished by filling the system at the service center, the grease is passed through the filter to remove contaminants before it flows into the reservoir. Pressure Reducing Valve

Pressure reducing valve (4, Figure 3-1), located on the manifold, reduces the hydraulic supply pressure (from the truck steering circuit) to a suitable operating pressure for the hydraulic motor used to drive the lubricant pump. The pressure control valve has been factory adjusted and the setting should not be disturbed unless grease output pressure is outside the recommendations. A pressure gauge can be installed where pipe plug (8, Figure 3-1) is located. The pressure gauge will indicate hydraulic oil pressure to the inlet of the hydraulic motor. Normal pressure is 2 241 - 2 413 kPa (325 - 350 psi).

P03037

Pressure switch (18, Figure 3-2) is a normally open switch set at 20 684 kPa (3,000 psi). This switch deenergizes the pump solenoid relay if the grease line pressure reaches the switch pressure setting, turning off the motor and pump. Grease Pressure Failure Switch

Pressure switch (24, Figure 3-2) is a normally open switch set at 13 789 kPa (2,000 psi). If the appropriate grease pressure is not achieved during the normal pump cycle, the warning system will be activated, illuminating the warning lamp in the overhead display to notify the operator a problem exists in the lube system. Injectors

Each injector (23, Figure 3-2) delivers a controlled amount of pressurized lubricant to a designated lube point. Refer to Figure 3-2 for locations. Interface Module

The interface module provides a 24 VDC timedinterval signal to energize the solenoid valve, providing oil flow to operate the grease pump motor. This interface module is mounted in the auxiliary control cabinet. Relief Valve (unloader valve)

Relief valve (14, Figure 3-3) protects the pump from high pressures. This relief valve is set at 27 580 kPa (4,000 psi).

Automatic Lubrication System

P3-5

SYSTEM OPERATION Normal Operation

1. During truck operation, the lubrication cycle timer will energize the system at a preset time interval. 2. The iterface module provides 24VDC to energize the pump solenoid valve (3, Figure 33), allowing hydraulic oil provided by the truck steering pump circuit to flow to the pump motor and initiate a pumping cycle. 3. The hydraulic oil from the steering circuit is directed through the pressure reducing valve (4) and flow control valve (6) before entering the motor. Pump pressure can be read on optional pressure gauge (5) mounted on the manifold. 4. With oil flowing into the hydraulic motor, the grease pump will operate, pumping grease from the reservoir to the injectors (13), through a check valve (10) and to the vent valve (11). 5. During this period, the injectors will meter the appropriate amount of grease to each lubrication point.

6. When grease pressure reaches pressure switch (18, Figure 3-2) setting, the switch contacts will close and energize the relay RB7-K5, removing power from the hydraulic motor/pump solenoid and the pump will stop. The relay will remain energized until grease pressure drops (pressure switch opens again) and the timer turns off. 7. After the pump solenoid valve is de-energized, hydraulic pressure in the manifold drops and vent valve (11, Figure 3-3) will open, releasing grease pressure in the lines to the injector banks. When this occurs, the injectors are then able to recharge for the next lubrication cycle. 8. The system will remain at rest until the lubrication cycle timer turns on and initiates a new grease cycle. 9. During the normal lubrication cycle, if grease pressure fails to reach 13 790 kPa (2,000 psi) within 120 seconds at the pressure switch located on the rear axle housing, an amber indicator light will illuminate on the overhead panel.

FIGURE 3-3. HYDRAULIC SCHEMATIC 1. Hydraulic Oil Return 2. Hydraulic Oil Supply 3. Pump Solenoid Valve 4. Pressure Reducing Valve 5. Motor Pressure Gauge

P3-6

6. Flow Control Valve 7. Hydraulic Motor 8. Grease Pump 9. Pressure Switch (N.O.) 10. Check Valve

Automatic Lubrication System

11. Vent Valve 12. Orifice 13. Injector Bank 14. Relief Valve

P03037

GENERAL INSTRUCTIONS Lubricant Required For System

Grease requirements will depend on ambient temperatures encountered during truck operation:

• Above 32°C (90°F) - Use NLGI No. 2 multipurpose grease (MPG).

• -32° to 32°C (-25° to 90°F) - Use NLGI No. 1 multipurpose grease (MPG).

• Below -32°C (-25°F) - Refer to local supplier for extreme lubricant requirements.

cold

weather

Filter Assembly

Filter element (5, Figure 3-4) must be replaced if bypass indicator (2) shows excessive element restriction.

FIGURE 3-4. FILTER ASSEMBLY 1. Housing 2. Bypass Indicator 3. O-Ring 4. Backup Ring 5. Element

P03037

Automatic Lubrication System

6. Spring 7. Bowl 8. O-Ring 9. Plug

P3-7

LUBRICANT PUMP Pump Housing Oil Level

The pump housing must be filled to the proper level with SAE 10W-30 motor oil. Check the oil level at at the 1000 hour maintenance interval. To add oil, remove dipstick (4, Figure 3-5) on top of the pump housing and fill the housing to the proper level marked on the dipstick. NOTE: If the pump is not equipped with dipstick (4), remove oil level plug (5) and fill the housing to the bottom of the plug hole. Pump Pressure Control

High pressure hydraulic fluid from the truck steering system is reduced by the pressure reducing valve located on the manifold on top of the pump motor. This pressure can be read if pipe plug (3) is removed, and a gauge is installed on the manifold.

FIGURE 3-5. AUTO LUBE PUMP CONTROLS 1. Pump Pressure Control 2. Override Switch 3. Pipe Plug (Gauge Port)

P3-8

Automatic Lubrication System

4. Dipstick 5. Oil Level Plug 6. Flow Control Valve

P03037

INJECTORS (SL-1 Series “H”) Injector Specifications

• Each lube injector services only one grease point. In case of pump malfunction, each injector is equipped with a covered grease fitting to allow the use of external lubricating equipment.

• Injector output volume: Maximum output = . . . . . 1.31 cc (0.08 in3). Minimum output = . . . . 0.13 cc (0.008 in3).

• Operating Pressure: Minimum - . . . . . . . 12 755 kPa (1,850 psi) Maximum - . . . . . . . 24 133 kPa (3,500 psi) Recommended - . . .17 238 kPa (2,500 psi)

• Maximum Vent Pressure - (Recharge) . . . . . . . . . . . . . . . . . . . 4 137 kPa (600 psi)

Injector Adjustment

The injectors may be adjusted to supply from 0.13 1.31 cc (0.008 - 0.08 in3) of lubricant per injection cycle. The injector piston travel distance determines the amount of lubricant supplied. This travel is in turn controlled by an adjusting screw in the top of the injector housing. Turn adjusting screw (1, Figure 3-6) counterclockwise to increase lubricant amount delivered and clockwise to decrease the lubricant amount. When the injector is not pressurized, maximum injector delivery volume is attained by turning the adjusting screw (1) fully counterclockwise until the indicating pin just touches the adjusting screw. At the maximum delivery point, about 9.7 mm (0.38 in.) adjusting screw threads should be showing. Decrease the delivered lubricant amount by turning the adjusting screw clockwise to limit injector piston travel. If only half the lubricant is needed, turn the adjusting screw to the point where about 4.8 mm (0.19 inch) threads are showing. The injector will be set at minimum delivery point with about 0.22 mm (0.009 in.) thread showing.

FIGURE 3-6. TYPE SL-1 INJECTOR 1. Adjusting Screw 2. Locknut 3. Piston Stop Plug 4. Gasket 5. Washer 6. Viton O-Ring 7. Injector Body Assy. 8. Piston Assembly 9. Fitting Assembly 10. Plunger Spring

11. Spring Seat 12. Plunger 13. Viton Packing 14. Inlet Disc 15. Viton Packing 16. Washer 17. Gasket 18. Adapter Bolt 19. Adapter 20. Viton Packing

NOTE: The piston assembly (8) has a visible indicator pin at the top of the assembly to verify injector operation.

NOTE: The above information concerns adjustment of injector delivery volume. The timer adjustment should also be changed, if overall lubricant delivery is too little or too much. Injector output should not be adjusted to less than 1/4 capacity.

P03037

Automatic Lubrication System

P3-9

INJECTOR OPERATION STAGE 1.

The injector piston (2) is in its normal or “rest” position. The discharge chamber (3) is filled with lubricant from the previous cycle. Under the pressure of incoming lubricant (6), the slide valve (5) is about to open the passage (4) leading to the measuring chamber (1) above the injector piston (2). STAGE 2.

When the slide valve (5) uncovers the passage (4), lubricant (6) is admitted to the measuring chamber (1) above the injector piston (2) which forces lubricant from the discharge chamber (3) through the outlet port (7) to the bearing.

STAGE 3.

As the injector piston (2) completes its stroke, it pushes the slide valve (5) past the passage (4), cutting off further admission of lubricant (6) to the passage (4) and measuring chamber (1). The injector piston (2) and slide valve (5) remain in this position until lubricant pressure in the supply line (6) is vented. STAGE 4.

After venting, the injector spring expands, causing the slide valve (5) to move, so that the passage (4) and discharge chamber (3) are connected by a valve port (8). Further expansion of the spring causes the piston to move upward, forcing the lubricant in the measuring chamber (1) through the passage (4) and valve port (8) to refill the discharge chamber (3). Injector is now ready for the next cycle.

P3-10

Automatic Lubrication System

P03037

PREVENTIVE MAINTENANCE PROCEDURES Use the following maintenance procedures to ensure proper system operation. Daily Lubrication System Inspection

1. Check the grease reservoir level after each shift of operation. Grease usage should be consistent from day-to-day operations. Lack of lubricant usage would indicate an inoperative system. Excessive usage would indicate a broken supply line. 2. Check the filter bypass indicator when filling the reservoir. Replace the element if bypassing. 3. Check all grease hoses from the SL-1 Injectors to the lubrication points. a. Repair or replace all damaged feed line hoses. b. Ensure that all air is purged and all new feed line hoses are filled with grease before returning the truck to service. 4. Inspect the key lubrication points for a bead of lubricant around the seal. If a lubrication point appears dry, troubleshoot and repair the problem. 250 Hour Inspection

1. Check all grease hoses from the SL-1 Injectors to the lubrication points (see Figure 3-2). a. Repair or replace all worn or broken hoses. b. Ensure that all air is purged and all new feed line hoses are filled with grease before returning the truck to service. 2. Check all grease supply line hoses from the pump to the SL-1 injectors. a. Repair or replace all worn or broken supply lines. b. Ensure that all air is purged and all new supply line hoses are filled with grease before returning the truck to service. 3. Check the grease reservoir level. a. Fill the reservoir if the grease level is low. Check the filter bypass indicator when filling the reservoir. Replace the element if bypassing. b. Check the reservoir for contaminants. Clean the reservoir, if required.

4. Inspect all bearing points for a bead of lubricant around the bearing seal. NOTE: It is good practice bearing point at the grease Injector. This will indicate frozen or plugged bearings, bearings of contaminants.

to manually lube each fitting provided on each whether there are any and it will help flush the

5. System Checkout a. Remove all SL-1 injector cover caps to allow visual inspection of the injector cycle indicator pins during system operation. b. Start the engine. c. Actuate lube system override switch (6, Figure 3-1). The hydraulic motor and grease pump should operate. d. With the grease under pressure, check each SL-1 injector assembly. The cycle indicator pin should be retracted inside the injector body. e. When the system is at 16 203 - 17 237 kPa (2,350 - 2,500 psi), the pump should shut off and the pressure in the system should drop to zero, venting back to the grease reservoir. f. After the system has vented, check the SL-1 injector indicator pins. All of the pins should be visible. Replace or repair any defective injectors. g. Install all injector cover caps. h. Check the lubrication timer operation. NOTE: Turning the key switch to the ON position will not initiate a lube cycle. To initiate a lube cycle while the truck is stationary, select manual lube using the dash display panel, or use the switch on the lubrication pump. The system should build 13 790 kPa (2,000 psi) at the rear axle during normal pump cycle.

• If the system is working properly, the machine is ready for operation. • If the system is malfunctioning, refer to the troubleshooting chart. 1000 Hour Inspection

1. Check the pump housing oil level using the dipstick on top of the pump unit. If necessary, add SAE 10W-30 motor oil.

c. Ensure that all filler plugs, covers and breather vents on the reservoir are intact and free of contaminants.

P03037

Automatic Lubrication System

P3-11

SYSTEM CHECKOUT To check system operation proceed as follows: 1. Remove the dust covers from the injectors. 2. Start the engine. 3. Actuate the manual override button at the pump assembly and observe pin movement at each injector. 4. Check for pump, hose or injector damage or leakage with the system under pressure. 5. After checking system, stop the engine. Observing normal precautions regarding high voltage present in the propulsion system before attempting to repair lube system. 6. Re-install the injector dust covers.

Main Level Screens Screen 1

Load = 240 t LC = 25

2100 rpm

ˆ Screen 2

OK

TT = 6000 t

<

SC = 20 mph

ˇ

Switch 1

Switch 2

Load = 240 t LC = 25

TT = 6000 t

10,000 m

ˆ

Screen 3

SC = 20 mph

ˇ

Load = 240 t LC = 25

TT = 6000 t

3560.9 h

ˆ

SC = 20 mph

ˇ

Screen 4

<

1 Active Warnings Press < to View

Lubrication Cycle Operation

The time between lube events is determined by the setting selected in the dash panel. Refer to Figure 37 for lubrication menu screens. With the key switch ON, scroll through the display menu screens and select either 8, 15, 24 or 30 minutes between lube cycles. The default setting is 15 minutes. NOTE: Turning the key switch to the ON position will not initiate a lube cycle. To initiate a lube cycle while the truck is stationary, select manual lube using the dash display panel, or use the switch on the lubrication pump. The truck must be moving before the lube system will initiate lube cycles based on the time interval selected.

Advance to screen 1 if moving and no realtime data.

ˇ

Advance to screen 4 .

ˆ Screen 5

Realtime Data OK to View (future development) Advance to screen 5 OR screen 4 OR screen 3. Screen 6

ˆ

ˇ

Advance to screen 1 if moving.

Payload Data OK to View

ˆ

Screen 7

ˇ

1 Repair Item OK to View

ˆ

Screen 8

ˇ

2 Maintenance Items OK to View

ˆ

Screen 9

ˇ

System Controls Press OK to View

Manual Lube

OK

ˆ

Press OK to Start Screen 9, subscreen 0

Screen 9, subscreen max. Screen 10

English Español Français OK Portuguese

ˆ

Screen 11

ˇ

Configure System Press OK to Edit

Lube Interval 8 15 24 30

OK

ˆ

Press OK to Edit

Screen 11, subscreen max.

Screen 11, subscreen 0

80414

FIGURE 3-7. LUBRICATION MENU

P3-12

Automatic Lubrication System

P03037

SYSTEM TROUBLESHOOTING CHART If the following procedures do not correct the problem, contact a factory authorized service center. TROUBLE

Pump Does Not Operate

Pump Will Not Prime

Pump Will Not Build Pressure

POSSIBLE CAUSES

SUGGESTED CORRECTIVE ACTION

Lube system is not grounded.

Correct grounding connections to pump assembly and truck chassis.

Electrical power loss.

Locate cause of power loss and repair. 24 VDC power required. Ensure key switch is ON.

Solenoid valve malfunction.

Replace the solenoid valve assembly.

Relay malfunction.

Replace relay.

Motor or pump malfunction.

Repair or replace motor and/or pump assembly. (Refer to shop manual for rebuild instructions.)

Low lubricant supply

Dirt in reservoir, pump inlet clogged, filter clogged.

Trapped air in lubricant supply line.

Prime system to remove trapped air.

Lubricant supply line is leaking.

Check lines and connections to repair leakage.

Vent valve is leaking.

Clean or replace vent valve.

Pump is worn or scored.

Repair or replace pump assembly. (Refer to shop manual for rebuild instructions.)

NOTE: Normally, during operation, the injector indicator stem will move into the body of the injector when pressure builds properly. When the system vents (pressure release) the indicator stem will again move out into the adjusting yoke. Injector Indicator Stem Does Not Operate

Pressure Gauge Does Not Register Pressure (pressure gauge not included with pump)

P03037

Malfunctioning injector - Usually indicated by the pump building pressure and then venting.

Replace individual injector assembly.

All injectors inoperative Pump build up not sufficient to cycle injectors.

Service and/or replace pump assembly. (Refer to shop manual for rebuild instructions.)

No system pressure to pump motor.

Check hydraulic hose from steering system.

No 24 VDC signal at pump solenoid.

Determine problem in 24 VDC electric system.

Pressure reducing valve setting is too low.

Refer to “Pressure Control Valve Adjustment”.

24V Relay may be defective.

Replace relay.

Automatic Lubrication System

P3-13

TROUBLE Pump Pressure Builds Very Slowly Or Not At All

POSSIBLE CAUSES

SUGGESTED CORRECTIVE ACTION

No signal at solenoid.

Check interface module.

No electric power to controller.

Turn on electric power to pump. “POWER” LED should light, “PUMP ON” LED should light when “MANUAL LUBE” is pressed.

Printed circuit board failure.

Remove and replace.

Load Connected To Terminals 3 & 4 Energized, But “PUMP ON” LED Does Not Light

Failure of the printed circuit board or keypad.

Remove and replace.

Bearing Points Excessively Lubricated

Injector output adjustment setting is too high.

Readjust to lower setting.

Timer/controller cycle time setting is too low.

Set to longer cycle time or reevaluate lube requirements.

Injector output adjustment setting is too low.

Readjust injector output setting.

Timer/controller cycle time setting does not deliver lubricant often enough.

Set to shorter cycle time or reevaluate lube requirements.

System is too large for pump output.

Calculate system requirements per planning manual.

Controller Does Not Operate

“PUMP ON” LED Lights, But Load Connected To Terminals 3 & 4 Will Not Energize

Bearing Points Are Not Sufficiently Lubricated

P3-14

Automatic Lubrication System

P03037

SECTION R SYSTEM SCHEMATICS INDEX

HYDRAULIC BRAKE SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HH360 HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EM7611 RETRACTABLE LADDER SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HH364 830E-1AC ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58E-06-02000

R01120

System Schematics

R1-1

NOTES

R1-2

System Schematics

R01120

TREADLE and PILOT ACTIVATED DUAL CONTROLLER PX T

P1

P2

0 - 10,894 kPa B1 (0 - 1580 psi)

B2 0 - 20,648 kPa (0 - 3000 psi)

FRONT BRAKE CALIPERS

Park Brake

BF

BR STOP LIGHT SW 517 ± 34 kPa (75 ± 5 psi)

LOW BRAKE LOCK APPLY SWITCH 6895 ± 172 kPa (1000 ± 25 psi)

Service Brake

REAR BRAKE CALIPERS

BRAKE LOCK PRESSURE 10,342 kPa (1500 psi)

9653 kPa (1400 psi) NITROGEN

BRAKE LOCK SOLENOID N.C.

ORF2 PR1

AR2

SV1

9653 kPa (1400 psi) NITROGEN PP3 BL

AF2 AF1

AR1

T1

LOW BRAKE PRESS SW Closes below 15,858 kPa LAP2 (2300 psi)

T3 PR2

HS1

PARK BRAKE PRESSURE REGULATOR 17,237 kPa (2500 psi)

LAP1

SP3

PK1

PARK BRAKE PK2 PRESSURE SWITCH Closes below 8618 kPa (1250 psi)

ORF1 BRAKE MANIFOLD CV1

LS1

CV2 PS1

NV1

AUTOMATIC APPLY 14,479 ± 517 kPa (2100 ± 75 psi)

NOTE: Solenoids and switches shown in their non-energized, non-pressurized positions.

CV3

NV2 AA STEERING PRESSURE SWITCH Closes below 15,858 kPa (2300 psi) STEERING BLEEDOWN MANIFOLD

SV2

PARK BRAKE SOLENOID

SP1 SUPPLY

22,063 to 24,132 kPa (3200 to 3500 psi)

HH360 JAN 06 Hydraulic Schematic

Brake System 830E-AC Effective with A30001 & UP

EM7611 AUG 10 HYDRAULIC SCHEMATIC 830E - 1AC A30561 & UP

DOWN

P

P

DOWN A

A B

A34

B

A34

72.3

72.2 85 MA1 DOWN G1/4 G1/4

85 UP G1/4

78 IN G1/4

MB1 G1/4

OUT G1/4

78

#8SAE 50 bar

75

67

1

62

S8-3 3

2

S4-2

62

200 bar

S4-2 68

74

Pc (P1) = 55 BAR V = 0.35 LTR

73 72.1

PS G1/4 ACC G1/4

P

60 bar

76

MA G1/4

77

S8-3

A

SZ6

71

A 2

1

a

b P

3 2 1

65

B

B T

66

69 SZ6

70

P

SZ6

T

63 S8-2

2

1

S8-2

NOTE: VALVE NORMALLY CLOSED 64 S10-2 2

1

61

79

G1/4 P

170 bar

G3/8 T

40 P

26 23

S 25 42

HH364 SEPT 08 HYDRAULIC SCHEMATIC RETRACTABLE LADDER SYSTEM SHEET 1 OF 1

HARNESS REFERENCE AUXILIARY CABINET CONNECTIONS FOR FRAME HARNESSES SEE SHEET 2

CN11

CN13

AR1

AH1

RIGHT FRONT FRAME RAIL CN505 ENGINE OIL RESERVE CONTROL MODULE

CN151

CN506 ENGINE OIL RESERVE PUMP

CN536

CN511

HH2 HH5 HH3

CN19

CN20

LEFT FRONT WHEEL SPEED SENSOR

LADDER LIGHT SW OPTION LOCATION

CN150

GROUND LEVEL SHUTDOWN SW OPTION LOCATION

CN534 RIGHT FRONT PAYLOAD SENSOR

FUEL TANK MARKER LIGHT (OPT)

CN536

LADDER LIGHT SW OPTION LOCATION

JJ5

STEERING FILTER PRESSURE SW

STARTER #2 RELAY

UPPER ENG SERVICE LIGHT

BATTERY BOX

RH ENGINE SERVICE LIGHT SW

CN540

RIGHT DECK LIGHT #1

GJ1

RIGHT HEATED MIRROR

CN520 SHUTTER CONTROL SOLENOID

LOW MOUNT RIGHT HIGH BEAM

RIGHT TURN/CLEARANCE LIGHT 2

RIGHT FOG LIGHT

RIGHT ROTATING BEACON

HIGH MOUNT RIGHT LOW BEAM

JL1

CN537

CN01

CC1

CN235

PROPEL LOCKOUT SW RELAY

CN236 CN237

GB10

RETARD LEVER (930 OPT)

CNP1

PROPEL LOCKOUT SW CLOSED LIGHT

CNP2 CN21

GROUND DASH LIGHT RHEOSTAT

CN18

HORN

CN20

ACTIA DASH PANEL 1

CC2

DID

GE DID PANEL

CAMERA SYSTEM (OPT)

GE TCI DIAGNOSTIC

CN31

DIAG4

CN651

DIAG5

GB12

GE TCI DIAGNOSTIC

GB10

ENGINE DIAGNOSTIC

DISPLAY MODE CONTROL SW 1

PAYLOAD METER 3

CN228

ESSW

DATA STORE SW CN212 DRIVER SEAT BELT SW DIRECTIONAL SHIFTER

CAN RPC

WIPER MOTOR WASHER DELAY TIMER WIPER RELAY HIGH

CN229

RSP

CN108

RETARD SPEED CONTROL SW

WIPER RELAY LOW

SECONDARY ENGINE SHUTDOWN SW

WIPER DELAY TIMER

RESET / BODY OVERRIDE CONTROL SW RETARD SPEED POT

FOG LIGHT SW MANUAL BACKUP LIGHT SW LADDER LIGHT SW

P209D

HEADLIGHT SW RETRACTIBLE LADDER RELAY (OPT) RETRACTIBLE LADDER (OPT)

MM2

P307B

CC1

J1939 CAN TEE #3

CN54

MM1

CN55

RIGHT STOP/TURN/CLEARANCE LIGHT 1

RIGHT STOP/TURN/CLEARANCE LIGHT 2

CN32

CN37

CN07

CN121

WADT

CN39

CN08

CN36

CN09

CN140

WIDT

CN59

CN22

CN58

CN23

CN071

CN24

CN072

CN25

CN601

CN263

CN602

CN262

OVERHEAD DASH

CC4

DIAG6

KOMTRAX PLUS DIAGNOSTIC

ROTATING BEACON SW (OPT) HEATED MIRROR SW (OPT)

GB12

GRID DRY SW DRIVE SYSTEM REST SW PRE-SHIFT BRAKE TEST SW

LEFT FRONT SPEAKER

TB10

LEFT REAR SPEAKER

ROTATING BEACON (OPT)

RIGHT FRONT SPEAKER

SERVICE BRAKE LIGHT

HORN BUTTON STEERING COLUMN COMBO CNTL LEVER

RIGHT REAR SPEAKER

DYNAMIC RETARD LIGHT

CN210

CAB DOME LIGHT

CN211

BRAKE LOCK SW

CNA

SONALERT

HAZARD LIGHT SW CAB HVAC CONNECTOR LEFT WINDOW MOTOR

KWB MODULE (OPT)

CN653

CN1 CN2A

RIGHT WINDOW MOTOR

CN3B

RIGHT WINDOW MOTOR SW

CN4A

LEFT WINDOW MOTOR SW

CC5

RADIO

ORBCOMM MODULE (OPT)

KOMTRAX PLUS MODULE

CN5

COMM RADIO CONNECTOR (OPT)

CN6 CN6A KOMTRAX PLUS HARNESS CODE

FIRE SUPPRESSION CONNECTOR (OPT)

CN2B JUMPER PLUG KOMTRAX PLUS (CC7)

12V POWER PLUG 1

P308B P310B P309D

BODY

RIGHT REAR PAYLOAD SENSOR

12V POWER PLUG 2

CC2

P207B

AUTO LUBE PRESSURE SW

KEY SW

CN120

MODULAR MINING RPC

AIR SEAT

CC3

CN35

TB10

GE - MODULAR

HID BACKUP LIGHT

CN04

CN34

INTERFACE MODULE

DIAG8

AIR SEAT

ENGINE CENSE TIER I

DIAG7

DISPLAY MODE CONTROL SW 2

RIGHT REAR BACKUP LIGHT

CAB LOWER DASH

CN33

DIAG3

ACTIA DASH PANEL 2

TO CAN TEE #3 SHEET 1 ZONE P-7

CN03

DIAG2

GB12 TB10

LEFT REAR BACKUP LIGHT

LEFT STOP/TURN/CLEARANCE LIGHT 2

LEFT DECK AHT MODE LIGHTS (OPT)

DIAG1

CAMERA SYSTEM SW (OPT)

TB10

PROPEL LOCKOUT SW OPEN LIGHT

ISOLATION STATION

ACCELERATOR PEDAL

RIGHT REAR RETARD LIGHT

LEFT REAR PAYLOAD SENSOR

LEFT STOP/TURN/CLEARANCE LIGHT 1

OP-CAB DIAGNOSTIC

RETARD PEDAL

STARTER LOCKOUT SW OPEN LIGHT GB12

CN02

LEFT REAR RETARD LIGHT

GRND-1

BODY

LEFT ROTATING BEACON

HIGH MOUNT LEFT HIGH BEAM

RIGHT REAR STOP/TAIL LIGHT

HOIST LIMIT SW

LEFT TURN/CLEARANCE LIGHT 2

HIGH MOUNT LEFT LOW BEAM

AJ1

RIGHT REAR FOG LIGHT

LEFT REAR STOP/TAIL LIGHT

LEFT BACKUP LEFT TURN/CLEARANCE LIGHT LIGHT 1

LOW MOUNT LEFT HIGH BEAM

GE CONTROL / ELECTRONIC DASH

STARTER LOCKOUT SW RELAY

PROPEL LOCKOUT SW

CN520 EITHER START SOLENOID

LEFT FOG LIGHT

NN1

RIGHT REAR BACKUP HORN

LEFT REAR FOG LIGHT

LEFT HEATED MIRROR

LOW MOUNT LEFT LOW BEAM

LEFT DECK AHT MODE LIGHTS (OPT)

MASTER LOCKOUT SW CLOSED LIGHT

STARTER LOCKOUT SW CLOSED LIGHT

LEFT PLM RED LIGHT

LEFT RADIATOR GRILL HARNESS

HIGH MOUNT RIGHT HIGH BEAM

STARTER LOCKOUT DISCONNECT SW

GG1

LEFT PLM GREEN LIGHT CN542

AHT MODE LIGHTS (OPT)

LEFT REAR BACKUP HORN

LEFT DECK HARNESS

RIGHT BACKUP LIGHT RIGHT TURN/CLEARANCE LIGHT 1

HYDRAULIC PUMP SERVICE LIGHT (OPT)

J1939 CAN TEE #4

TERM2 TERM RESISTOR

P208B

P209D

P210B TO HARN CC2 SHEET 1 ZONE N-6

RPC CAN TEE #4

P211B P213D P212D

RPC CAN TEE #5

TERM3 TERM RESISTOR

P2014D

HARNESS DESIGNATION KEY ___________________________________________ HARNESS TRUCK DESIGNATION LOCATION ___________________________________________ A AUXILIARY CABINET B BRAKE CABINET C OPERATOR CAB D REAR CASE E ENGINE F RIGHT DECK G LEFT DECK H RIGHT FRAME J LEFT FRAME K BATTERY BOX L RADIATOR GRILL M BODY N ISOLATION STATION P PANTOGRAPH R FRONT FRAME S PROPULSION ALTERNATOR T CONTROL CABINET U AHT ODS BOX

SYSTEM CIRCUIT LOCATOR ------------------------------------------------SHEET SYSTEM CIRCUIT ------------------------------------------------5 12VDC SUPPLY 15 AHT CONNECTION OPTION 2 AUXILIARY CABINET HARNESS LAYOUT 3 BATTERY BOX 10 BODY HOIST LIMIT 8 CAB SPARE WIRES 15 CAMERA SYSTEM OPTION 15 CAN J1939 NETWORK 15 CAN RPC NETWORK 5 CUSTOMER ACCESSORY POWER 7 DIRECTIONAL SHIFTER 8 ELECTRONIC GAUGE DISPLAY 7 ENGINE ETHER START OPTION 6 ENGINE INTERFACE 6 ENGINE OIL RESERVE SYSTEM OPTION 4 ENGINE SHUTDOWN 7 ENGINE SHUTTER OPTION 3 ENGINE START PRE-LUBE 3 ENGINE STARTERS 7 ENGINE TIER I OPTION 6 ENGINE TIER II OPTION 5 FRAME HARNESS GROUND RETURNS 11 FRONT VEHICLE HORN 15 GE ALTERNATOR 12 GE INTERFACE 10 GE INTERFACE 15 GE WHEEL MOTOR POWER CABLES 10 GE WHEEL MOTOR SPEED SENSORS 14 HEATED MIRRORS 15 HOT START OPTION 4 HYDRAULIC CABINET 15 HYDRAULIC LADDER OPTION 13 INTERFACE MODULE 4 INTERFACE MODULE 3 ISOLATION STATION 4 KEY SWITCH 12 KOMATRAX PLUS 12 KWB MODULE 14 LAMP ROTATING BEACON OPTION 5 LAMPS AUX BOX DOME 11 LAMPS BACKUP 9 LAMPS CLEARANCE 10 LAMPS ENGINE SERVICE 9 LAMPS FOG 9 LAMPS FRONT TURN 9 LAMPS HAZARDS 8 LAMPS HEADLIGHT 11 LAMPS HYDRAULIC CABINET 9 LAMPS DECK & LADDER 10 LAMPS PUMP MODULE SERVICE OPTION 11 LAMPS REAR AXLE SERVICE 11 LAMPS REAR TURN & TAIL 11 LAMPS STOP 10 OP-CAB WINDOW MOTORS 6 OPERATOR CAB HVAC 7 OPERATOR CAB SEAT 12 ORBCOMM MODULE 7 PARK BRAKE 14 PAYLOAD METER III 5 POWER DISTRIBUTION 20 REFERENCE CONNECTOR TABLE 18 REFERENCE DEVICE TABLE 19 REFERENCE DEVICE TABLE 1 REFERENCE FRAME & OP-CAB HARNESS LAYOUT 1 REFERENCE ISOLATION STATION HARNESS LAYOUT 2 REFERENCE ENGINE & HYD CABINET HARNESS LAYOUT 2 REFERENCE AUX BOX HARNESS LAYOUT 1 REFERENCE HARNESS INDEX TABLE 16 REFERENCE WIRE TABLE 17 REFERENCE WIRE TABLE 18 REFERENCE WIRE TABLE 5 VEC BLOCK POWER & GROUND 11 WINDSHIELD WIPER & WASHER

CC4

P311D

RPC CAN TEE #3

AHT RIGHT REAR BRAKE PRESSURE SENSOR (OPT)

REAR AXLE LIGHT

AHT MODE LIGHT CONNECTION RBML

LEFT PLM YELLOW LIGHT

LOW MOUNT RIGHT LOW BEAM

REAR AXLE LIGHT SW

DD1

LEFT DIAGONAL LADDER LIGHT CN503

DD3

HYDRAULIC PUMP SERVICE LIGHT SW (OPT)

REAR AXLE EXTERNAL HARNESS

LEFT DECK LIGHT (OPTIONAL)

RIGHT PLM RED LIGHT

BLOWER PRESSURE SW

JJ1

GND

LH ENGINE SERVICE LIGHT SW

RIGHT DECK HARNESS

DD4

CN703

CN704

LOWER ENG SERVICE LIGHT

RIGHT PLM GREEN LIGHT

MASTER GROUND DISCONNECT SW

DD2

UPPER ENG SERVICE LIGHT

RIGHT PLM YELLOW LIGHT

HL1

CN563

LEFT UPRIGHT FRAME RAIL

RIGHT DECK LIGHT #2

HYDRAULIC STEERING FILTER SW (AHT OPT)

HYDRAULIC PUMP SERVICE LIGHT (OPT)

RIGHT REAR COMPONENT JUNCTION BOX TB60, TB61

RIGHT UPRIGHT FRAME RAIL

RIGHT RADIATOR GRILL HARNESS

ATFS

STARTER # 1 RELAY

LOWER ENG SERVICE LIGHT

CN543

HYDRAULIC TANK TEMP SENSOR

REAR AHT MODE LIGHTS (OPT)

ACCUMULATOR PRE-CHARGE PRESS SW #2

FF1

HYDRAULIC TANK LEVEL SENDER

FUEL LEVEL SENDER

ACCUMULATOR PRE-CHARGE PRESS SW #1

CN502

STEERING ACCUMULATOR BLEEDDOWN PRESS SW CN732 HYDRAULIC TANK MARKER LIGHT (OPT)

HOIST FILTER PRESSURE SW 2

AUTOLUBE PUMP SOLENOID

FH1

STEERING ACCUMULATOR BLEEDDOWN SOLENOID

HOIST FILTER PRESSURE SW 1

CN721 LEFT WHEEL MOTOR SPEED SENSOR CN722 RIGHT WHEEL MOTOR SPEED SENSOR AHT LEFT REAR BRAKE PRESSURE SENSOR (OPT)

LOW STEERING PRESURE SW

HH4

GROUND LEVEL SHUTDOWN SW OPTION LOCATION

CENTER DECK LIGHT 2

STEERING PRESSURE SENSOR

FUEL TANK HARNESS

CN730

CENTER DECK LIGHT 1

AMBIENT AIR TEMP SENSOR

BODY UP SW

JJ2

REAR AXLE WHEEL MOTOR SPEED

JG1

CN565

HOIST PUMP PRESSURE SW 2

ENGINE OIL RESERVE TANK LEVEL

AD1

LEFT REAR FRAME RAIL

HOIST PUMP PRESSURE SW 1

ENGINE OIL RESERVE PUMP

RIGHT FRONT WHEEL SPEED SENSOR

AUTOLUBE TANK LEVEL SW

CN541

RIGHT REAR FRAME RAIL

CN18 ENGINE OIL RESERVE CONTROL MODULE

CN15

AJ2

AH2

FRONT LEFT FRAME RAIL

LEFT FRONT PAYLOAD SENSOR

CN507 ENGINE OIL RESERVE TANK LEVEL CN534

AJ1

FRONT PAYLOAD / WHL SPEED HARNESS

CN14

CN16

CN12

HARNESS HARNESS REFERENCE P/N DESCRIPTION __________________________________________________________ AA1 58E-06-00500 WIRING HARNESS, AUXB INTERN AA2 58E-06-00510 WIRING HARNESS, AUXB INTERN PWR AA3 58E-06-00520 WIRING HARNESS, GE INTERF AA4 58E-06-00530 WIRING HARNESS, PLM3 AA5 58E-06-00540 WIRING HARNESS, CAN RPC AA6 58E-06-00550 WIRING HARNESS, CAN J1939 AA7 XC2803 WIRING HARNESS, AHT PLUG1 AA8 58E-06-00570 WIRING HARNESS, AHT PLUG2 AA9 XB7690 WIRING HARNESS, CAN RPC AA10 XB7691 WIRING HARNESS, CAN J1939 AA11 58E-06-10730 WIRING HARNESS, CAN J1939 AA12 58E-06-10720 WIRING HARNESS, CAN RPC AB1 58E-06-00450 WIRING HARNESS, AUXB HYD AC1 58E-06-00440 WIRING HARNESS, AUXB CAB-GE AC2 58E-06-00460 WIRING HARNESS, AUXB CAB-DIAG AC3 58E-06-00470 WIRING HARNESS, AUXB CAB-DASH AC4 58E-06-00480 WIRING HARNESS, AUX CAB OH AD1 58E-06-00630 WIRING HARNESS, REAR WHEEL SPD AE1 58E-06-00490 WIRING HARNESS, QSK-60 T1-T2 AE2 58E-06-00580 WIRING HARNESS, ENG AUX BOX AF1 58E-06-01850 WIRING HARNESS, PLM AUXB LH AH1 58E-06-00640 WIRING HARNESS, RIGHT FRONT AH2 58E-06-00140 WIRING HARNESS, RIGHT REAR AJ1 58E-06-00650 WIRING HARNESS, LEFT FRONT AJ2 58E-06-00130 WIRING HARNESS, LEFT REAR AR1 58E-06-00910 WIRING HARNESS, FRONT WHEEL SPD BB1 58E-06-01300 WIRING HARNESS, IND BRAKE HYD CAB CC1 58E-06-00590 WIRING HARNESS, CAB GE CC2 58E-06-00600 WIRING HARNESS, CAB DIAG CC3 58E-06-00610 WIRING HARNESS, CAB DASH CC4 58E-06-00620 WIRING HARNESS, CAB OH CC5 EJ1556 HRN STR RADIO JUMPER CC6 XC0166 CAMERA SYSTEM (OPT) CC7 EJ6371 VHMS JUMPER PLUG (CN2B) CC8 EJ6372 VHMS HARNESS CODE JUMPER (CN1-6) CC9 XC0165 CAMERA DISPLAY Y CABLE (OPT) DD1 58E-06-01270 WIRING HARNESS, REAR AXLE HSG WRG DD2 XB0591 HRN STR AXLE BLWR PRESSS SW DD3 XB0592 HRN STR AXLE SERVICE LIGHT DD4 EL9925 HRN STR BLWR PRESS SW EE1 58E-06-01240 WIRING HARNESS, EXTERNAL QSK60 T2 EE2 58E-06-01780 HRN STR PRE-LUBE EE3 58E-06-01230 WIRING HARNESS, EXTERNAL QSK60 T1 EK1 XC2797 HRN STR STARTER RELAY / ALT SEN FF1 58E-06-00080 WIRING HARNESS, DECK RH FF2 XC0197 HRN STR JUMPER HEATED MIRROR (OPT) FG1 XB2041 HRN STR SCOREBOARD DECK LH / RH FH1 58E-06-00070 WIRING HARNESS, UPRIGHT RH GG1 58E-06-00090 WIRING HARNESS, DECK LH GG2 XC0197 HRN STR JUMPER HEATED MIRROR (OPT) GJ1 58E-06-00120 WIRING HARNESS, UPRIGHT LH HH2 EM7830 HRN STR LADDER SWITCH JUMPER RH HH3 EM5759 HRN STR AUTOLUBE HH4 58E-06-00030 WIRING HARNESS, FUEL TANK HH5 EM2231 HRN STR GNDLVL SHTDN SW JUMPER RH HL1 58E-06-01250 WIRING HARNESS, RH HEADLIGHT HL2 EM3430 HRN STR SHUTTER CONTROL JJ1 XB0924 HRN STR PUMP MOD LIGHT (OPT) JJ2 EM7830 HRN STR LADDER SWITCH JUMPER LH JJ5 EM2231 HRN STR GNDLVL SHTDN SW JUMPER LH JL1 58E-06-01260 WIRING HARNESS, LH HEADLIGHT JT1 XB0496 HRN STR CONTROL CABINET LIGHTS KK1 XB3625 HRN STR BATTERY BOX MM1 58E-06-01280 WIRING HARNESS, LEFT BODY LIGHTS MM2 58E-06-01290 WIRING HARNESS, RIGHT BODY LIGHTS NN1 58E-06-01310 WIRING HARNESS, ISO STATION IND _______________________________________________________ CABLE CABLE REFERENCE P/N DESCRIPTION _______________________________________________________ AJ3 58E-06-01820 CABLE STR 2/0 BLK AK1 58E-06-01860 CABLE STR 2/0 RED DT1 58E-06-10480 CABLE STR 7M1A1 DT2 58E-06-10470 CABLE STR 7M1A2 DT3 CH3677 CABLE STR 7M1B1 DT4 58E-06-10420 CABLE STR 7M1B2 DT5 58E-06-10460 CABLE STR 7M1C1 DT6 58E-06-10450 CABLE STR 7M1C2 DT7 CH3692 CABLE STR 7M2A1 DT8 CH3682 CABLE STR 7M2A2 DT9 58E-06-10430 CABLE STR 7M2B1 DT10 CH3684 CABLE STR 7M2B2 DT11 58E-06-10440 CABLE STR 7M2C1 DT12 58E-06-10410 CABLE STR 7M2C2 EE10 CH4526 CABLE STR 2/0 BLK EE4 CH4452 PRELUBE POWER CABLE 1/0 RED EE5 CH4320 PRELUBE GND CABLE 1/0 BLK EE9 CH4527 CABLE STR 2/0 BLK EJ1 CH4524 CABLE STR 2/0 BLK EK2 CH4625 CABLE STR 2/0 RED EN1 CH5812 CABLE STR 4/0 RED EN2 CH5813 CABLE STR 4/0 RED EN3 CH5739 CABLE STR 4/0 BLK EN4 CH5740 CABLE STR 4/0 BLK EN5/EN6 58E-06-01840 CABLE ASSY PRELUBE FUSE LINK JN1 CH4523 CABLE STR 2/0 BLK KK2 CH5811 CABLE STR 4/0 RED KK3 CH5810 CABLE STR 4/0 RED KK4 CH5737 CABLE STR 4/0 BLK KK5 CH5738 CABLE STR 4/0 BLK KK6 CH5736 CABLE STR 4/0 BLK KK7 CH5736 CABLE STR 4/0 BLK KN1 58E-06-01790 CABLE STR 4/0 RED KN2 58E-06-01810 CABLE STR 4/0 RED KN3 CH5742 CABLE STR 4/0 BATT BLK KN4 CH5741 CABLE STR 4/0 BATT BLK ST1 CH4914 CABLE STR ST1 ST2 CH4915 CABLE STR ST2

OPERATOR CAB SEE SHEET 2

58E-06-02000-00 NOV 11 ELECTRICAL SCHEMATIC 830E-1AC A40851 & UP Sheet 1 of 20

HARNESS REFERENCE TO HARN AE1 SHEET 2 ZONE G-12

P301B J1939 CAN TEE #1

AA6

P303B

P304B

J1939 CAN TEE #2

AA10

P315B

P302D

TERM2

PAYLOAD METER 3 MODULE

CN364

AA4

P206D IM CAN RPC

P206D IM CAN RPC

VHMS RS232 (PC TOOL CONNECTOR) INTERFACE MODULE (PC TOOL CONNECTOR)

CN

KEY SW POWER RELAY

IM2

GE CNTRL / KEY SW POWER RELAY

IM3

INTERFACE MODULE

DOME LIGHT SW

GE RPC CAN

AA11

TO HARN AC1 SHEET 2 ZONE H-15

CN

HIGH MOUNT HEADLIGHT RELAY

CN246

LOW MOUNT HEADLIGHT RELAY

24VDC GB31

BACKUP LIGHT RELAY

CN362

VEHICLE ELECT CENTER 89 (VEC-89) CONNECTORS P1,P2,P4,P9,P11,P12

HORN RELAY CN382

12V POWER RELAY

VEHICLE ELECT CENTER 90 (VEC-90) CONNECTORS P1,P2,P3,P4,P9,P11,P12

LADDER LIGHT RELAY

CN372

VEHICLE ELECT CENTER 91 (VEC-91) CONNECTORS P1,P2,P3,P4,P9,P10,P11,P12

ENGINE SERVICE LIGHT TIMER HYD PUMP SERVICE LIGHT TIMER

AA1

VEC-89 POWER & GROUND

ENGINE SERVICE LIGHT TIMER

VEC-90 POWER & GROUND

LADDER LIGHT RELAY

DOME LIGHT 1

GE CNTRL / KEY SW POWER RELAY

DOME LIGHT 2

HIGH MOUNT HEADLIGHT RELAY

GE

CONTROL CABINET INTERFACE CONNECTIONS (INVERTEX II) TERMINAL BLOCKS

AA3

CN301 CN302 CN303

DOME LIGHT 3

LOW MOUNT HEADLIGHT RELAY

CN304

DOME LIGHT 4

HI-BEAM HEADLIGHT RELAY

CN305

DOME LIGHT 5

BACKUP LIGHT RELAY

CN701

12V POWER SUPPLY

CN702

12V POWER RELAY

R57

DOME LIGHT 6

CB60

VEC-91 POWER & GROUND

AUXILIARY CABINET

GE USB

CN GE ETHERNET

TERMINAL BLOCKS

KEY SW POWER RELAY

GE J1939 CAN

CN

IM1

TERMINAL BLOCKS

HI-BEAM HEADLIGHT RELAY

PLM3 RS232 PORT

TO HARN AC2 SHEET 2 ZONE G-15

RPC CAN P216D TEE #6 P205B

AA9

P215B

AA12

P305B

P306D IM CAN J1939

RPC CAN P204B TEE #2

AA5

P203B

P202D PLM3 CAN RPC

PAYLOAD METER 3

PLM3 INCLINOMETER

RPC CAN TEE #1

P316B

P306D IM CAN J1939

PLM3 CAN J1939

TERM RESISTOR

J1939 CAN TEE #5

AA2

R58

AA2 AA1

AA1

AHT INTERFACE CONNECTOR #1

AHT OPTION INTERFACE

AHT INTERFACE CONNECTOR #1 AHT WHEEL SPD RESISTOR R57 AHT WHEEL SPD RESISTOR R58

AA1

AA1 TERMINAL BLOCKS

TO CAN TEE SHEET 2 ZONE B-3

TO CAN TEE SHEET 2 ZONE B-12

P301B

J1939 CAN

P305B

J1939 CAN

GB31 TO CAN TEE SHEET 2 ZONE C-12

P205B TERMINAL BLOCKS

CN11

CN13

CN12

CN14

CN16

FRAME RAIL HARNESS CONNECTIONS SEE SHEET 1

TERMINAL BLOCKS

TERMINAL BLOCKS

TERMINAL BLOCKS

AB1

BRAKE CABINET

AC1

GE CONTROL / ELECTRONIC DASH

AE1

AE2

CN01 CN240

BB1

LOW BRAKE PRESSURE SW

CN801

EE1

BRAKE LOCK SOLENOID PARK BRAKE SOLENOID HOIST LIMIT SOLENOID SERVICE BRAKE DEGRADE PRESSURE SW

GB71

QSK60 ECM TI CN804 CN805

CN808

START MOTOR 1 INPUT START MOTOR 2 INPUT COOLANT LEVEL SW ENGINE RUN OIL PRESSURE SW

CN806

OIL RESERVE PRESSURE SW

CN820

A/C RECEIVER DRIER PRESSURE SW CN815

CN803

ENGINE PRELUBE HARN

A/C COMPRESSOR CLUTCH

TIER I ENGINE HARN (OPT)

TERMINAL BLOCKS

GB71

QSK60 ECM T2

WINDSHIELD WASHER MOTOR

CN02

AF1

SCORE BOARD OPTION CN03

CN04

CNLIN

GND

LEFT PLM SCOREBOARD OPTION

CNLO

ENGINE RUN OIL PRESSURE SW

CN805

PARK BRAKE RELEASE PRESSURE SW

CN820

A/C RECEIVER DRIER PRESSURE SW

SERVICE LIGHT 1 FUEL FILTER CONN (TIER II OPT ONLY)

CN826

CN815

EE2

GRD72 CNRIN

PRELUBE PRESSURE SW

SERVICE LIGHT SWITCH TIER II FUEL FILTER (TIER II OPT ONLY)

FG1

COOLANT LEVEL SW

CN804

OIL RESERVE PRESSURE SW

HYD CABINET

AC4

OVERHEAD DASH

START MOTOR 2 INPUT

CN806

GB8

CAB LOWER DASH

SEE SHEET 1

START MOTOR 1 INPUT

LOW BRAKE PRESSURE SW

SERVICE LIGHT 2

AC3

AC2

OP-CAB DIAGNOSTIC

OPERATOR CAB HARNESS CONNECTIONS

CN808

PARK BRAKE APPLY PRESSURE SW

EE3

TERMINAL BLOCKS

TERMINAL BLOCKS

CN15

SERVICE BRAKE PRESSURE SENSOR

CN801

RPC CAN

PRELUBE MAG SW

LP

TIER II WATER IN WIF FUEL SEPERATOR (TIER II OPT ONLY)

CN803

EE6

PRELUBE RELAY

RIGHT PLM SCOREBOARD OPTION

A/C COMPRESSOR CLUTCH

TIER II ENGINE HARN (OPT)

58E-06-02000-00 NOV 11 ELECTRICAL SCHEMATIC 830E-1AC A40851 & UP Sheet 2 of 20

BATTERY ISOLATION STATION 71GG-000-NN1 (YEL 16ga )

BATTERY BOX / ISOLATION STATION

1

F1

B1

1

1

F2

B2

1

71GH-000-NN1 (ORG 16ga ) 71PS-000-NN1 (LBL 16ga )

1

2

72RQ-000-NN1 (GRY 16ga )

PC2834

J537

71PS-001-NN1 (LBL 16ga )

71PS-001-NN1 (LBL 16ga ) ENGINE JUMP START1 11-009-CH5510 (RED 2/0 ) CH5509 11-008-CH5509 (RED 2/0 )

1

-

+ 1

11-000-KK2 (RED 4/0 )

11-025-KK1 (RED 6ga )

1

BATT4

+ 1

1 1

1

1

1

1

BUSS BAR 24VDC BATT BOX XB3583

58E-06-10020

1

11-003-KN2 (RED 4/0 )

VZ0639

1

1

11-002-KN1 (RED 4/0 )

11-025-KK1 (RED 6ga ) 21PT-009-AJ1 (PNK 14ga )

1

1

1

BUSS BAR BAT(-)

85 -

RELAY ENG STARTER 2 (ESREL2) 1

1

86 +

85 -

1

1

11ST-002-EN1 (RED 4/0 )

BAT(-)-002-KN3 (BLK 4/0 )

PC1903

PC1903

BAT(-)-003-KN4 (BLK 4/0 )

1

1

1

DISC(-)-6 EC1725

BAT(-)-002-KN3 (BLK 4/0 ) BAT(-)-003-KN4 (BLK 4/0 )

1

0-004-EN3 (BLK 4/0 )

PLLO 8 7

SH4:A-2

2

2

71GH-001-AJ1 (ORG 16ga )

SH4:B-2

1

1

72RQ-001-AJ1 (GRY 16ga )

SH4:B-2

86

30 (C)

SWITCH MASTER GROUND DISCONNECT (DISC-)

MLREL

(NC)87A

1

3 2 1

RED

2

BLACK

58E-06-01990

1

RED

2

BLACK

58E-06-01990

LAMP LED STARTER LOCKOUT OPEN

SLLO

11ST-006-NN1 (RED 16ga ) 0-366-NN1 (BLK 16ga )

58E-06-10020 MLREL

0-026-NN1 (BLK 16ga ) 0-027-NN1 (BLK 16ga )

1

1

RED

2

BLACK

58E-06-01990

LAMP LED STARTER LOCKOUT CLOSED

85

(NO) 87

P537

6 5 4

SLON

1

RED

2

BLACK

58E-06-01990

LAMP LED MASTER DISCONNECT CLOSED

11-020-NN1 (RED 16ga )

1

0-000-JN1 (BLK 2/0 )

0-448-NN1 (BLK 16ga ) 0-033-NN1 (BLK 16ga ) 0-032-NN1 (BLK 16ga ) 0-030-NN1 (BLK 16ga ) 0-031-NN1 (BLK 16ga ) 0-034-NN1 (BLK 16ga ) 0-366-NN1 (BLK 16ga ) 0-027-NN1 (BLK 16ga )

0-034-NN1 (BLK 16ga ) RELAY MASTER DISCONNECT (+) (-)

1

0-003-EN4 (BLK 4/0 )

0-033-NN1 (BLK 16ga )

1S-000-NN1 (DGR 16ga )

1

88a 1

72RRQ-000-NN1 (DBL 16ga )

JB1

2

1 88

88a 1

(NC)87A

STARTER DISCONNECT (DISC+)

11-022-NN1 (RED 16ga ) 1 88

BAT(-)-000-KK5 (BLK 4/0 )

71GG-001-AJ1 (YEL 16ga )

LAMP LED PROPEL LOCKOUT LOCKED OUT

(NO) 87

11ST-005-NN1 (RED 16ga ) 11ST-006-NN1 (RED 16ga )

1

XB3617

1

86 +

1

11ST-001-EN2 (RED 4/0 )

1

RELAY ENG STARTER 1 (ESREL1)

85

SLREL 58E-06-10020 SLREL

11-020-NN1 (RED 16ga ) 11-021-NN1 (RED 16ga )

PLON

PLREL

1

0-048-AJ1 (BLK 14ga )

30 (C)

11-029-NN1 (RED 16ga ) 11-030-NN1 (RED 16ga )

1

11-001-KK3 (RED 4/0 )

BAT(-)-001-KK4 (BLK 4/0 )

0-032-NN1 (BLK 16ga )

(NC)87A

86

EC1725

VZ0639

-

1

1 1

0-517-KK7 (BLK 4/0 )

30 (C)

71PS-000-NN1 (LBL 16ga )

(NO) 87

RELAY STARTER LOCKOUT (+) (-)

1

0-026-NN1 (BLK 16ga )

MLLON

1

RED

2

BLACK

58E-06-01990

LAMP LED MASTER DISCONNECT OPEN

1M-000-NN1 (LTG 16ga ) BAT(-)-004-NN1 (BLK 16ga ) MLLO

25A-000-EK1 (DGR 6ga )

54 54

0-049-AJ1 (BLK 14ga )

21PT-001-AA1 (DBL 14ga )

53 53

21PT-000-AJ1 (DBL 14ga )

J12

1

RED

2

BLACK

58E-06-01990

GB70 FRAME GND 1 A1 A2 1 B2

0-001-EJ1 (BLK 2/0 )

P12

1

11-007-AK1 (RED 2/0 )

0-002-AJ3 (BLK 2/0 )

SH5:E-5

11-007-AK1 (RED 2/0 )

SH5:A-3

11-013-EK1 (RED 12ga ) 11-027-EK2 (RED 2/0 )

25B-000-EK1 (LTG 6ga ) M0TOR STARTER 1 (STRT1)

SEN 1 (+)

ALT (+)

ALT_SEN (-) 1

2A 1

1 3

25A-000-EK1 (DGR 6ga )

1 1A

11ST-001-EN2 (RED 4/0 )

MOTOR

1B

ALT (-)

1 1C

24VDC ALTERNATOR

XA3660

ENGINE STARTERS

MOTOR STARTER 2 (STRT2)

1 1A

2B 1 2C

4A

2A 1

1 3

25B-000-EK1 (LTG 6ga )

1

11ST-003-EE9 (BLK 2/0 )

MOTOR

1B

2C

1C

4B

2B 1

4A

XA3660

4B

1

SH5:D-2

0-050-AA1 (BLK 14ga )

1

SH5:I-5

1

+ 1

11-028-NN1 (RED 16ga )

11-026-KK1 (RED 6ga )

1

BATT3

CH5510

PLREL

VZ0639

1

-

3

LAMP LED PROPEL LOCKOUT ON

72RRQ-001-NN1 (DBL 16ga )

85

86

2

0-516-KK6 (BLK 4/0 )

VZ0639

1

1 2

1 2

+ 1

1

-

BATT2

RELAY 1 PROPEL LOCKOUT (+) (-)

ENGINE JUMP START2

BAT(-)-010-CH5509 (BLK 2/0 )

1

1

BATT1

3

D70

PC2528

BATTERY BOX

4

SWITCH PROPEL LOCKOUT (PLOS)

11-029-NN1 (RED 16ga ) 11-028-NN1 (RED 16ga )

BAT(-)-020-CH5510 (BLK 2/0 )

4

0-028-EE10 (BLK 2/0 ) 11ST-003-EE9 (BLK 2/0 )

11ST-000-EN5 (RED 1/0 ) R S F G

11SM2-000-EE1 (DGR 14ga )

11SM1-000-EE1 (GRY 14ga ) SWITCH ENGINE PRELUBE OIL PRESS (PLPSW)

2

C

NO 1

PLPSW

SP108

21PS-004-EE2 (BRN 14ga )

1 2

21PS-003-EE2 (BRN 14ga ) 21PT-006-EE2 (DBL 14ga )

P815

PLPSW

1 2

21PS-002-EE1 (BRN 14ga ) 21PT-002-EE1 (DBL 14ga )

J801

J815

R S F G

11SM2-001-AE2 (DGR 14ga ) 11SM1-001-AE2 (GRY 14ga ) 21PS-001-AE2 (BRN 14ga ) 21PT-007-AE2 (DBL 14ga )

SH4:K-11 SH4:K-11 SH4:K-11 SH5:D-2

P801

D87

21PT-003-EE2 (DBL 14ga )

SP107

21PT-004-EE2 (DBL 14ga )

21PT-012-EE2 (DBL 14ga )

86 86

85

87

87

87A

87A

P800

PC1146

1

NOTE: DIODE D87 PROVIDES CONTINUOUS PRE-LUBE DURING CRANKING

PC2834

21PL-001-EE2 (DBL 14ga )

RELAY ENGINE PRELUBE 85

2

21PT-005-EE2 (DBL 14ga )

30 30

ENGINE START PRE-LUBE

21PS-005-EE2 (BRN 14ga )

P800

0-042-EE2 (BLK 14ga ) GB3 ENG GND BLOCK

RELAY ENGINE PRELUBE MAG SWITCH (PLMS) 1

21PL-000-EE2 (DBL 14ga ) 1

FUSE LINK1 (150A) 1 2 1

2

FUSE LINK2 (150A)

1

11PL-000-EN6 (RED 1/0 )

+

-

1 1

VL6217

1 2 1

0-041-EE2 (BLK 14ga ) ENGINE PRELUBE HIGH VOLUME PUMP

11PF-000-EE4 (RED 1/0 )

1

PLPM-(+)

+

PUMP

-

XA4488

1

0-040-EE5 (BLK 1/0 )

PLPM-(-)

1 B1

1 B3

58E-06-02000-00 NOV 11 ELECTRICAL SCHEMATIC 830E-1AC A40851 & UP Sheet 3 of 20

71GH-001-AJ1 (ORG 16ga )

30 30

SH3:C-21

72RQ-001-AJ1 (GRY 16ga )

29 29

P12

71GH-002-AA1 (ORG 16ga )

J12 SH14:I-8

SWITCH LEFT GROUND LEVEL SHUTDOWN (ESDS)

1

B

1-1

1-2

1-3

A B C

A

1

A

11S-004-JJ5 (RED 16ga )

2-2

2-3

2-4

J536_CP

A B

39G-001-AA4 (DBL 16ga )

21 21

11S-003-AJ1 (RED 16ga )

23 23

11KS-001-AJ1 (BRN 16ga )

1

TB34 T2 T1

1

39G-000-AA1 (DBL 16ga )

11S-001-AA1 (RED 16ga )

SP106

11S-000-AA1 (RED 16ga )

E

2E

C

3C

F17

2F

5

F

SH5:B-3

11-010-AA1 (RED 16ga )

71GG-002-AA1 (YEL 16ga )

F18 VEC-90

15

71CK BUSS

11KS-002-AA1 (BRN 16ga )

P12

VEC-90

F15

86

5

C

P536

PARK BRAKE STATUS RELAY 28 0 BUSS

J536

85

1D

D

11KS-003-AA1 (BRN 16ga )

1

B

1-1

1-2

1-3

1-4

2-1

2-2

2-3

1H

H

SWITCH RIGHT GROUND LEVEL SHUTDOWN (OPT LOCATION) (ESDSR)

11KS-002-AA1 (BRN 16ga )

H1 H2

86

1

11KS-004-AC3 (BRN 16ga ) 30

1

11S-006-HH5 (RED 16ga )

2-4

A

A

A

11S-005-AH1 (RED 16ga )

51 51

B

B

B

11KS-007-AH1 (BRN 16ga )

52 52

C

C

J533

J533_CP

P533

P11

11S-002-AA1 (RED 16ga ) 11KS-008-AA1 (BRN 16ga )

J11

PC1375

48 48

11KS-009-HH5 (BRN 16ga )

1

11KS-006-CC3 (BRN 16ga )

BATT

ON

1

SH5:A-10

87

1A

TO VEC-90 ENGINE RUN RELAY 21 (30)

87a

H

71GG-003-AA3 (YEL 18ga )

N

1

L1 L2

1

71GH-003-AA3 (ORG 18ga )

M PROPEL LOCKOUT INTERRUPT1

TB25

SH7:F-19 C

49-006-CC2 (TAN 16ga )

1

TB22 G

23FA-000-AA1 (YEL 16ga )

C

1

SH6:F-16

23D-000-AA1 (PNK 18ga )

1

23F-000-AA1 (TAN 16ga )

1

SWITCH CAB SECONDARY ENGINE SHUTDOWN (ESS)

510E-000-AA1 (DGR 18ga )

L1 L2

1

23F-001-AC2 (TAN 16ga )

AHT AUXBOX CONNECTOR (OPT)

5

P02

5

23F-002-CC2 (TAN 16ga )

J02

A

B

1-1

1-2

1-3

1-4

2-1

2-2

2-3

2-4

1

A

N1 N2

P303 1

R

510E-001-AA3 (DGR 18ga )

PROPEL LOCKOUT INTERRUPT2

PARK BRAKE RELEASED

P304 SH7:D-14

0-310-CC2 (BLK 18ga ) 439-000-CC2 (YEL 16ga )

17 17

439-001-AC2 (YEL 16ga )

1 1

1

J02 SH6:A-8 SH4:H-9

PC1375

TB27 R1 R2

1

R3 R4

1

w

439-002-AA3 (YEL 18ga )

ENG IGNITION

P302

P02

439-003-AE1 (YEL 16ga ) 439-005-AA1 (YEL 20ga ) SH5:A-13

712M-000-AA1 (PNK 20ga )

r

712-001-AA3 (ORG 18ga )

KEY SW +24V TO CNTRL PWR SW

P305

712IM-000-AA1 (ORG 16ga )

J03

0-006-AA2 (BLK 16ga )

49 49

21S-000-CC3 (YEL 16ga )

23 23

TB23 1

712K-001-AC3 (LBL 16ga )

N1 N2

1

N4

1

712K-003-AA1 (LBL 20ga )

0808610000 J03

RELAY KEY SWITCH (KSWPR) KSWPR-(-) KSWPR-(+) + 1

0-014-AA2 (BLK 16ga )

85

1 30

712-000-AA2 (ORG 8ga )

SH11:B-11

712K-000-CC3 (LBL 16ga )

START 1

P03

KEY SWITCH / ENGINE SHUTDOWN

1C

712K-004-CC3 (LBL 16ga )

OFF

SH8:K-9

1

712K-002-AA1 (LBL 16ga ) SWITCH KEY (KEYSW)

SH5:C-11

85

TIMED ENGINE SHUTDOWN RELAY 20

11KS-004-AC3 (BRN 16ga )

K1 K2

SH4:H-16

73S-000-AA1 (LBL 18ga )

ENGINE INTERLOCK RELAY 19

TB24 1

4G

30

87a D1

4C

G

1

86

87

11KS-005-JJ5 (BRN 16ga )

A

3H

30

87a

71GH-002-AA1 (ORG 16ga ) 3G

85

87

J12

PC1375

GE CONTROL INTERFACE

TB25

B

1-4

2-1

SH12:M-5

72RQ-002-AA1 (GRY 14ga )

J702

SH3:C-21

71GG-002-AA1 (YEL 16ga )

P702

31 31

20 20

71GG-001-AJ1 (YEL 16ga )

19 19

SH3:C-21

KSWPR-30

PB7276

86

1

87 1

TB22

P03 1

21S-001-AC3 (YEL 16ga )

712IM-000-AA1 (ORG 16ga )

H1 H2

1

H4

1

21S-003-AA1 (YEL 20ga ) 21S-002-AA1 (YEL 16ga )

SH5:A-6

11-004-AA2 (RED 8ga )

KSWPR-87

INTERFACE MODULE SECONDARY ENGINE SHUT DOWN

E

SH4:D-18

439-005-AA1 (YEL 20ga )

HYD BRAKE CABINET

TB32

IM3

SH4:C-13

PARK BRAKE RELEASED M

1

73S-000-AA1 (LBL 18ga )

73S-001-AA1 (LBL 20ga )

SWITCH PARK BRAKE RELEASE PRESSURE

M1 M2

1

N2

1

73S-002-AB1 (LBL 14ga ) 52A-001-AB1 (DBL 14ga )

E

E

73S-003-BB1 (LBL 14ga )

C NO

F

F

52A-000-BB1 (DBL 14ga )

A NC

IM2 ENGINE SHUTDOWN DELAY

F

PBRPS GB31-B AUXBOX GND BLCK

SH6:C-10

21NSL-003-AA1 (LTG 20ga )

D4

IM3

1

0-225-AB1 (BLK 14ga ) 0-226-AB1 (BLK 14ga )

H

H

P

P

P240

ENGINE SHUTDOWN DELAY RELAY H

C

PC2469

B

0-051-BB1 (BLK 16ga )

PBRPS

GB8 BRAKE CABINET 1

0-227-BB1 (BLK 14ga )

1

0-228-BB1 (BLK 14ga )

J240

712M-000-AA1 (PNK 20ga )

IM1 KEY SW DIRECT

P

CRANK REQUEST

j

712K-003-AA1 (LBL 20ga )

21S-003-AA1 (YEL 20ga )

IM2

SH13:I-11

+24V OUT W

24VIM-008-AA1 (LBL 16ga ) 1

24VIM-000-AA1 (LBL 20ga )

START ENABLE

B

24VIM-006-AC4 (LBL 16ga )

R

11SM1-002-AA1 (PNK 20ga )

1

START MOTOR 2

S

11SM2-002-AA1 (ORG 20ga )

1

TB28

SH3:M-17

F

1

1

SH8:F-12

24VIM-005-AC1 (LBL 16ga )

G4

F

21PS-001-AE2 (BRN 14ga )

F2 F1

1

11SM1-001-AE2 (GRY 14ga )

SH3:M-17

G2 G1

1

11SM2-001-AE2 (DGR 14ga )

SH3:M-17

IM3

VBATT2

G2 G1

VEC91-P4

TB28

START MOTOR 1

A

24VIM-001-AA1 (LBL 18ga )

21SL-000-AA1 (TAN 20ga )

IM1

VBATT

1

H4

EB7418

SH8:D-16

H2 H1

SH13:B-20

24VIM-002-AA1 (LBL 18ga )

TB32

1

H2 H1

1

21PS-000-AA1 (BRN 18ga )

H

G

E

85 87

3H

87a

VEC91-P3

VEC91-P3

11INT-000-AA1 (PNK 20ga )

VEC-91

4F

3G

4E

VEC-91

2D

30

2C

F27

F28 10

D

C

VEC91-P2

START ENABLE RELAY 30

10 VEC-91

86

11 BUSS

11 BUSS

VEC91-P4

IM1

11IM2-000-AA1 (WHT 20ga )

INTERFACE MODULE

58E-06-02000-00 NOV 11 ELECTRICAL SCHEMATIC 830E-1AC A40851 & UP Sheet 4 of 20

24VDC AUXBOX BUSS

SH3:I-11

1 A1 A2 1

11-007-AK1 (RED 2/0 )

TB24

SH4:F-10

11-004-AA2 (RED 8ga )

1 A3 A4 1

SH4:B-9

INTERFACE MODULE

+12V LOADS

11-012-AA2 (RED 8ga )

71GE-002-AA1 (BRN 20ga )

U

1

J3

J4

1

K1 K2

1

K3 K4

1

SH4:D-19 SH14:L-19 SH14:M-19

712-001-AA3 (ORG 18ga ) 712-006-AA2 (ORG 18ga ) 712-007-AA2 (ORG 18ga ) 712-003-AA2 (ORG 10ga )

712-003-AA2 (ORG 10ga )

1

0-005-AA2 (BLK 10ga )

1

71CK-001-AA2 (PNK 8ga )

1

21PT-010-AA1 (DBL 20ga )

TB24 1 N

1

71GE-000-AA3 (BRN 16ga )

G1 G2

1

G3

10H H

D15

G 10G

71GE-001-AA1 (BRN 16ga )

VEC-91

D14

712 BUSS

RELAY KEY / GE CNTRL PWR (KCNPR) 1

71C-000-AA1 (ORG 16ga )

VEC91-P10

-

+

86

85

1 87

11-005-AA2 (RED 8ga )

VEC91-P10

SH4:F-6

0-006-AA2 (BLK 16ga )

1

11-012-AA2 (RED 8ga )

33H-000-AA3 (PUR 18ga )

k

12VDC CONVERTER (12VCN)

21PT-008-AA3 (DBL 18ga )

30 1

1

71CK-000-AA2 (PNK 8ga )

SH3:I-3

21PT-001-AA1 (DBL 14ga )

1

SH3:M-17

21PT-007-AE2 (DBL 14ga )

1

J3

J4

1

11B5-000-AA2 (DBL 8ga )

N1 N2

1

11-006-AA2 (RED 8ga )

1

712-005-AA1 (ORG 16ga )

1

11B1-000-AA2 (LBL 10ga )

GNDa 1

21PT-008-AA3 (DBL 18ga )

1

11B1-001-AA2 (LTG 8ga )

12Vb 1 1

50.0

1

0-009-AA2 (BLK 8ga )

GNDb

85

1 87

11B1-001-AA2 (LTG 8ga )

TB24

+

86

N4

1

71CK-003-AA3 (PNK 18ga ) 71CK-001-AA2 (PNK 8ga ) 71CK-002-AA2 (PNK 8ga ) 0-005-AA2 (BLK 10ga )

1

0-007-AA2 (BLK 16ga )

0-012-AA2 (BLK 10ga )

SH3:I-11

B1

S6B 11 BUSS S8A

DL1

58E-06-02050 VEC-90 71CK BUSS 1 S8A

L1 L3 L4

1

12V-000-AA2 (ORG 8ga )

0-012-AA2 (BLK 10ga )

1

1

1

0-011-AA2 (BLK 10ga )

1

712-004-AA2 (ORG 10ga )

1

11-011-AA2 (RED 8ga )

C2

1

0-413-AA1 (BLK 6ga )

SH8:L-11 SH8:L-11 SH8:N-10 SH8:P-10 SH9:C-16 SH10:G-17

0-129-AA1 (BLK 14ga ) 0-128-AA1 (BLK 14ga ) 0-055-AA1 (BLK 14ga ) 0-094-AA1 (BLK 14ga ) 0-425-AA1 (BLK 14ga ) 0-424-AA1 (BLK 14ga )

GB31-A AUXBOX GND BLCK

SP12

D2

1

0-414-AA1 (BLK 6ga )

SP13

GB31-B AUXBOX GND BLCK A2

1

0-160-AA1 (BLK 6ga )

SP14

GB31-B AUXBOX GND BLCK B2

1

0-415-AA1 (BLK 6ga )

SP15

0-219-AA1 (BLK 14ga ) 0-162-AA1 (BLK 14ga ) 0-163-AA1 (BLK 14ga ) 0-216-AA1 (BLK 14ga ) 0-080-AA1 (BLK 16ga ) 0-050-AA1 (BLK 14ga )

SH6:N-10 SH9:F-15 SH9:F-15 SH6:N-10 SH7:P-6 SH3:I-3

0-423-AA1 (BLK 18ga ) 0-270-AA1 (BLK 14ga ) 0-147-AA1 (BLK 16ga ) 0-161-AA1 (BLK 14ga ) 0-334-AA1 (BLK 16ga ) 0-333-AA1 (BLK 16ga ) 0-341-AA1 (BLK 16ga )

SH13:I-12 SH10:C-16 SH9:K-15 SH9:G-15 SH13:O-6 SH13:N-6 SH13:I-12

0-242-AA1 (BLK 14ga ) 0-240-AA1 (BLK 14ga ) 0-146-AA1 (BLK 16ga ) 0-241-AA1 (BLK 14ga ) 0-325-AA1 (BLK 16ga )

SH11:B-12 SH11:B-12 SH9:L-15 SH11:B-12 SH13:E-10

E

10E

10

VEC91-P10

85 30

11 BUSS

A2

1

0-130-AA1 (BLK 6ga )

SP10

GB31-A AUXBOX GND BLCK B2

1

0-131-AA1 (BLK 6ga )

SP11

0-222-AA1 (BLK 14ga ) 0-104-AA1 (BLK 14ga ) 0-127-AA1 (BLK 14ga ) 0-008-AA1 (BLK 14ga ) 0-223-AA1 (BLK 14ga ) 0-420-AA1 (BLK 14ga )

SH6:P-10 SH9:B-16 SH8:M-11 SH8:O-10 SH6:P-10 SH10:G-17

0-084-AA1 (BLK 14ga ) 0-165-AA1 (BLK 14ga ) 0-164-AA1 (BLK 14ga ) 0-126-AA1 (BLK 14ga ) 0-344-AA1 (BLK 16ga ) 0-075-AA1 (BLK 16ga )

SH8:P-10 SH9:D-15 SH9:E-15 SH8:N-11 SH13:O-15 SH7:O-9

0-422-AA1 (BLK 14ga ) 0-263-AA1 (BLK 14ga ) 0-134-AA1 (BLK 16ga ) 0-426-AA1 (BLK 14ga ) 0-402-AA1 (BLK 14ga ) 0-407-AA1 (BLK 14ga )

SH11:L-11 SH11:F-10 SH9:J-15 SH10:F-17 SH14:D-7 SH14:C-8

VEC-91

5

C3

1

12E E

1

11C

11B

1

11ER-000-AA1 (RED 12ga )

VEC91-P11 B

11FS-000-AA1 (RED 16ga )

1

12VREG-000-AA1 (LBL 12ga )

VEC91-P11 C

TB24

10 10

20

SP100

0-019-AA2 (BLK 16ga ) 712L-002-AA2 (DBL 16ga )

A

S7A

S6A S6B S8A

12V BUSS

B

712L-003-AA2 (DBL 16ga )

A

0-021-AA2 (BLK 16ga )

B

712L-004-AA2 (DBL 16ga )

A

1

DL5

0-017-AA2 (BLK 16ga )

712 BUSS

SP103 SP102

S8B 11 BUSS 1 S5A

0-022-AA2 (BLK 16ga )

B

712L-005-AA2 (DBL 16ga )

A

PC3010

DL5

DL6

AUX BOX DOME LIGHTS

PC3010

DL4

GB31-A AUXBOX GND BLCK B3

PC3010

DL3

DL4

0 BUSS

PC3010

DL2

0-020-AA2 (BLK 16ga )

58E-06-10530 VEC-91

0-023-AA2 (BLK 16ga )

B

712L-006-AA2 (DBL 16ga )

A

PC3010

DL6

1

TB22 F1 F2

0-202-CC4 (BLK 18ga )

1

65A-003-AC4 (WHT 16ga )

4

4

65A-004-CC4 (WHT 18ga )

D1 D2

1

65-002-AC4 (TAN 16ga )

1

1

65-003-CC4 (TAN 18ga )

TB22 D1 D2 D3

GB31-A 1

C1

1

GB31-A C4

B1 B2

1

12VREG-001-AC3 (LBL 14ga )

12 12

12VREG-003-CC3 (LBL 14ga )

B3

1

12VREG-002-AC3 (LBL 14ga )

13 13

12VREG-004-CC3 (LBL 14ga )

21 21

11ER-003-CC3 (RED 14ga )

1

11ER-001-AC3 (RED 14ga )

1

22 22

11ER-002-AC3 (RED 14ga ) 0-203-AC3 (BLK 14ga )

67 67

0-204-AC3 (BLK 14ga )

68 68

1

69 69

0-205-AC3 (BLK 14ga ) 0-206-AC3 (BLK 14ga )

70 70

11FS-001-AC3 (RED 16ga )

26 26

11ER-004-CC3 (RED 14ga ) 0-207-CC3 (BLK 14ga ) 0-208-CC3 (BLK 14ga )

SP156

12VREG-005-CC3 (LBL 12ga )

11ER-005-CC3 (RED 12ga )

SP155 GB12

1 A1 A2 1

GB12

0-209-CC3 (BLK 14ga )

3

1

1

2

2

0-212-CC3 (BLK 12ga )

4

4

J601

0-210-CC3 (BLK 14ga )

3

0-211-CC3 (BLK 12ga )

1 B1

0-213-CC3 (BLK 16ga ) 11FS-002-CC3 (RED 16ga )

J03

ENTERTAINMENT RADIO

CUSTOMER OP-CAB COMMUNICATION RADIO CONNECTION

ENTERTAINMENT RIGHT FRT SPEAKER

ENTERTAINMENT LEFT FRT SPEAKER

P601_CP

B

B

A

A

C

C

J602

9H

12VDC POWER PORT #1

TB24 H

VEC91-P9

67C-000-AA1 (BRN 12ga )

1

V1 V2

1

V4

1

67C-001-AC3 (BRN 14ga )

29 29

0-385-AC3 (BLK 14ga )

40 40

67C-002-AC3 (BRN 14ga )

30 30

0-386-AC3 (BLK 14ga )

12VDC SUPPLY & CUSTOMER OPTIONAL ACCESSORY POWER

41 41

P03

J03

67C-003-CC3 (BRN 14ga ) 0-383-CC3 (BLK 14ga ) 67C-004-CC3 (BRN 14ga ) 0-384-CC3 (BLK 14ga )

1 1

2 1

PC1374

CAB ENTERTAINMENT RADIO

J04

P602_CP

CUSTOMER OP-CAB FIRE SUPPRESSION CONNECTION

ENTERTAINMENT LEFT REAR SPEAKER

ENTERTAINMENT RIGHT REAR SPEAKER VEC-91

712L-000-AA2 (DBL 16ga )

B

DL3

F1 F2

P04

P03

F63

DL2

SP104

0-091-AC4 (BLK 16ga )

TB21

VEC91-P11

12V BUSS

DL1

SH14:O-15

0-234-AA2 (BLK 16ga )

65-000-AA1 (TAN 16ga )

11G G

20

1

A

SH12:E-6

0-233-AA2 (BLK 16ga )

GB31-A

1

65A-000-AA1 (WHT 16ga )

VEC91-P12

VEC-91

3

712L-001-AA2 (DBL 16ga )

PC3010

AUXBOX TB POINT GROUNDS

SH14:E-8

87a

20

F41

SP09

GB31-A AUXBOX GND BLCK

12F F

87

F22

F40

0-417-AA1 (BLK 6ga )

SH14:D-7 SH10:G-17 SH9:L-15 SH11:E-10 SH14:B-8 SH13:M-6

86

ENTERTAINMENT RADIO RELAY 37

11 BUSS

1

0-401-AA1 (BLK 14ga ) 0-421-AA1 (BLK 14ga ) 0-135-AA1 (BLK 16ga ) 0-255-AA1 (BLK 14ga ) 0-403-AA1 (BLK 14ga ) 0-336-AA1 (BLK 16ga )

VEC-91

712 BUSS

F23

SP08

2

B

SH5:D-9

11B1-002-AA1 (LBL 10ga )

0 BUSS

0-416-AA1 (BLK 6ga )

GB31-B AUXBOX GND BLCK D2

GB31-A AUXBOX GND BLCK

1

1

SR8325

S5B

C2

712 BUSS

0-018-AA2 (BLK 16ga )

S7B

S7B

GB31-B AUXBOX GND BLCK

F55 5

712A-000-AA1 (WHT 16ga )

S8B 0 BUSS 1 S7A

SH5:K-5

11B1-002-AA1 (LBL 10ga )

VEC BLOCK / GROUND / POWER DISTRIBUTION

AUXBOX FRAME GROUND CONNECTIONS

VEC-91

SWITCH AUX BOX DOME LIGHT (DLS)

1

1

9F

30 1

1 A1 A3 1

0-002-AJ3 (BLK 2/0 )

S7B 71CK BUSS S6A

PB7276

GB31-A AUXBOX GND BLCK

PC1110

S5B 0 BUSS S7A

F

12V POWER RELAY (12VPR) -

VEC-89

71CK-002-AA2 (PNK 8ga )

71CK-003-AA3 (PNK 18ga )

PB8460

12Va 1

J1

2

CB60

24Vb

TB28

2000.0

R44

24Va 1

21PT-010-AA1 (DBL 20ga )

P304

1

33H-000-AA3 (PUR 18ga )

S5A

712 BUSS

S8B

58B-06-00120

g

1

58E-06-02070

TB24

PB7276

P305

ENGINE STARTER REQUEST

J2

11-006-AA2 (RED 8ga )

GE CONTROL INTERFACE

SW TO GND FOR LAMP TEST

1

J1

11B1-003-AA1 (LBL 20ga )

IM3

CNTRL PWR ON SIG

11-012-AA2 (RED 8ga ) 712-005-AA1 (ORG 16ga )

11B1-003-AA1 (LBL 20ga )

GE CNTRL PWR ON SIG M

CRANK SENSE

EB7418

B4 1

h

1

712-000-AA2 (ORG 8ga )

11-005-AA2 (RED 8ga )

1 B1 B2 1

11-010-AA1 (RED 16ga )

SH4:F-6

+

1

RF(+)-001-CC4 (WHT 18ga )

-

2

RF(-)-001-CC4 (BLK 18ga )

PC0724

A B C D E F

P211

+

1

-

2

LF(+)-001-CC4 (WHT 18ga ) LF(-)-001-CC4 (BLK 18ga )

PC0724

+

1

-

2

LR(+)-001-CC4 (WHT 18ga ) LR(-)-001-CC4 (BLK 18ga )

A B C D E F

J210

A B C D E F

J211 A B C D E F

P210

65-001-CC5 (ORG 18ga ) LF(+)-000-CC5 (WHT 18ga ) RF(+)-000-CC5 (WHT 18ga ) 65A-001-CC5 (TAN 18ga ) 65A-002-CC5 (TAN 18ga ) RF(-)-000-CC5 (BLK 18ga ) LF(-)-000-CC5 (BLK 18ga ) 0-099-CC5 (BLK 18ga ) LR(+)-000-CC5 (WHT 18ga ) RR(+)-000-CC5 (WHT 18ga ) RR(-)-000-CC5 (BLK 18ga ) LR(-)-000-CC5 (BLK 18ga )

7 13 11 4

(+) 12V SUPPLY SPEAKER LEFT FRONT (+) SPEAKER RIGHT FRONT (+) IGNITION

6

DIMMER

12 SPEAKER RIGHT FRONT (-) 14 SPEAKER LEFT FRONT (-) 8 15 9 10 16

P737

GROUND SPEAKER LEFT REAR (+) SPEAKER RIGHT REAR (+) SPEAKER RIGHT REAR (-) SPEAKER LEFT REAR (-)

PC2172

PC0724

+

1

-

2

RR(+)-001-CC4 (WHT 18ga ) RR(-)-001-CC4 (BLK 18ga )

PC0724

12VDC POWER PORT #2 1 1

2 1

PC1374

58E-06-02000-00 NOV 11 ELECTRICAL SCHEMATIC 830E-1AC A40851 & UP Sheet 5 of 20

ENGINE QSK60 INTERFACE TIER II

J

BATTERY GROUND 2

K

BATTERY GROUND 3

0-060-EE1 (BLK 12ga )

SP115

0-061-EE1 (BLK 12ga )

L

SP116

0-062-EE1 (BLK 12ga )

0-063-EE1 (BLK 14ga ) 0-064-EE1 (BLK 14ga ) 0-065-EE1 (BLK 14ga ) 0-066-EE1 (BLK 14ga ) 0-067-EE1 (BLK 14ga ) 0-068-EE1 (BLK 14ga ) SP117

P804

4 4 64 64 65 65 66 66 67 67 68 68 69 69

11E4-001-AE1 (BRN 14ga )

GB31-B

0-069-AE1 (BLK 14ga ) 0-070-AE1 (BLK 14ga ) 0-071-AE1 (BLK 14ga ) 0-072-AE1 (BLK 14ga ) 0-073-AE1 (BLK 14ga ) 0-074-AE1 (BLK 14ga )

1 C1 1 B4 1

D1

11E1-000-AA1 (YEL 12ga )

1

A3

1

B1 B2

1

11E2-000-AA1 (LBL 12ga )

1

B3

1

C1 C2

1

11E3-000-AA1 (DBL 12ga )

1

C3

1

D1 D2

1

1

M1 M2

1

A

VEC91-P2

H

VEC91-P2 G

11E4-000-AA1 (BRN 14ga ) 65S-000-AA1 (BRN 16ga )

VEC-91

2B

B

VEC91-P2

20 F37

11 BUSS

20 VEC-91

2H

F38

11 BUSS

20 VEC-91

2G

F39

11 BUSS

20

VEC91-P2 12G G

VEC-91 0 BUSS

VEC91-P12

85 F25

712 BUSS SHUTTER CONTROL

A

ENGINE DELAY SHUTDOWN

E

COOLANT LEVEL SWITCH 15V SUPPLY

J

65S-002-EE1 (BRN 16ga )

25 25

21NSL-000-EE1 (LTG 16ga )

12 12

COOLANT LEVEL SIGNAL W

1

SWITCH COOLANT LEVEL TIER 2

924-000-EE1 (PNK 18ga )

E1 E2

1

E4

1

A + V SUPPLY B SIGNAL LOW C GROUND

926-000-EE1 (WHT 18ga )

X

ETHER START CONTROL

C

28EC-001-EE1 (DBL 16ga )

18 18

28EC-002-AE1 (DBL 16ga )

1

H1 H2

1

RESERVE OIL LEVEL LOW SIGNAL

K

21OR-000-EE1 (YEL 16ga )

16 16

21OR-001-AE1 (YEL 16ga )

1

K1 K3

1

RESERVE OIL LEVEL SENSOR RETURN

N

21ORR-000-EE1 (WHT 16ga )

11 11

21ORR-001-AE1 (WHT 16ga )

925-000-EE1 (TAN 18ga )

P802

1

60 60

THROTTLE SIGNAL INPUT 15 THROTTLE SIGNAL RETURN 28

952M/0-002-AE1 (BLK 16ga )

916M-003-EE1 (RED 18ga )

62 62

916M-002-AE1 (RED 16ga )

SENSOR SUPPLY +5 VOLT (THROTTLE) 20 DIAGNOSTIC FLASH CODE TEST

1

SHIELD-267

ENGINE MAINTENANCE LIGHT BLUE (OUTPUT) 18

63 63

528A-001-EE1 (LBL 16ga )

22 22

CHECK ENGINE LIGHT AMBER (OUTPUT) 17

419I-000-EE1 (DBL 16ga )

20 20

6

509-000-EE1 (PNK 16ga )

21 21

RED LIGHT FAULT INPUT

ENGINE FAULT LIGHT RED (OUTPUT) 16

ENGINE TEST / FAN CLUTCH

6

509-001-EE1 (GRY 16ga )

2

2

FAN CLUTCH ON FULL

5

1

556-001-AE1 (WHT 16ga )

419I-003-AE1 (DBL 16ga )

6

509-003-AE1 (GRY 16ga ) TB31

1

22FO-001-AE1 (TAN 16ga )

FAN ON FULL ENGINE TEST

X1

1

T3 W4

1

1

W1 W2

1

1

V1 W3

1

V2

1

1

X1 X2

1

1

F1 F2

1

F4

1

1

S1 S2

1

1

S3

1

S4

GE CONTROL INTERFACE

2 3 4 1

B

CAN J1939 SHLD

C

MC204

SH14:O-15 SH13:I-13

0-235-AA2 (BLK 16ga ) 0-267-AA2 (BLK 16ga )

G1

939YE-000-EE1 (YEL 18ga )

57 57

939GE-000-EE1 (GRN 18ga )

58 58

SHIELD-208

SHIELD-208 WIF

1

27WS-000-EE1 (WHT 16ga )

WATER IN FUEL SENSOR RETURN

2

27WR-000-EE1 (BLK 16ga )

2

FUEL FILTER SENSOR SIGNAL

3

27LPS-000-EE1 (WHT 16ga )

1

FUEL FILTER SENSOR RETURN

4

27LPR-000-EE1 (BLK 16ga )

2

ENGINE WATER IN FUEL SENSOR (TIER II ONLY)

1

419I-005-AA2 (DBL 16ga )

2000.0

1

509-006-AA2 (GRY 16ga )

2000.0

41 41 42 42

34 34

J808

P808

1

928-001-AE1 (BLK 18ga )

1

929-001-AE1 (WHT 18ga )

1 1

SHIELD-782

SHIELD-782 MC684

33 33

W1 W2

1

900-001-AE1 (WHT 18ga )

1

901-001-AE1 (BLK 18ga ) SHIELD-781

SHIELD-781

712 BUSS

BRAKE CABINET

TB31

MC686

C

67 67

928-003-CC2 (BLK 18ga )

B

68 68

929-003-CC2 (WHT 18ga )

927-002-AC2 (RED 18ga )

66 66

B1 B2

1

928-002-AC2 (BLK 18ga )

C1 C2

1

929-002-AC2 (WHT 18ga )

D1 D2

1

TB28

SHIELD-787

SHIELD-787

T1 T2

1

900-002-AC2 (WHT 18ga )

1

V1 V2

1

901-002-AC2 (BLK 18ga )

1

S1 S2

1

MC687

69 69

RECDR

C1

NC1

PC1804

65C-000-EE1 (DBL 14ga )

51 51

VEC-91

F49

9A

15

1

P803

XB7317

P803

65T-001-EE1 (DBL 14ga ) 36-000-EE1 (YEL 14ga )

C

NO 1

SG3290

0-092-EE1 (BLK 14ga ) 11ORS-000-EE1 (YEL 14ga ) SWITCH ENGINE OIL RESERVE PRESS T2 (ORPS)

1

C

NO 1

SG3290

ENGINE INTERFACE TIER II OPTION (TIER I - SEE SHEET 7)

DIAG2

ENG CAUTION INPUT

v

ENG WARN INPUT

J3

J4

1

SH4:C-13

23D-000-AA1 (PNK 18ga )

58B-06-00120 1

23D-001-AA2 (PNK 18ga )

2000.0

2

1

531SC-001-AA2 (DGR 18ga )

TB27 P1 P2

1

c

ALTERNATE 1400 RPM DIG IN OPT

e

SYS RUN TO ENG ECU

79RD-001-AA3 (BRN 18ga )

b

REVERSE OUT

72FD-001-AA3 (WHT 18ga )

a

FORWARD OUT

531SC-000-AA3 (DGR 18ga )

A

1

12H-000-AA1 (LBL 16ga )

1

X1 X4

1

X2

1

TB28 A1 A2

1

72FD-000-AA1 (WHT 18ga )

72CPU-001-AA3 (BLK 18ga )

S1 S2

1

R1 R2

1

B C

NO

C

NC

A

K

44R-004-BB1 (GRY 14ga )

2

1

XA3347 D2 1

52CS-004-BB1 (GRY 14ga )

SP161

52CS-006-BB1 (GRY 14ga )

PBS

J

J

G

G

J240

2

44R-005-AB1 (GRY 14ga ) SH11:G-4

SBPS

PC1677

K

52CS-005-BB1 (GRY 14ga )

44R-003-AA1 (GRY 18ga )

71BC-003-AB1 (DGR 14ga )

52CS-003-AB1 (GRY 14ga )

1 1

TB35

P302

F1 F2

1

F3 F4

1

44R-000-AA3 (GRY 18ga ) 44R-001-AA1 (GRY 20ga )

SH7:H-19

B

SERVICE BRAKES APPLIED

P303

SH7:F-10

SH7:I-11

P240

ENGINE INTERFACE CIRCUITS

TIER I ENGINE CENSE J1587 SH15:C-15 CAB DIAGNOSTIC DIAG2 CONNECTOR (OPT)

901-003-CC2 (BLK 18ga ) SHIELD-794

J02

P140 1

G1 G2

SH7:K-16 SH10:J-20

12H-001-AC3 (LBL 16ga )

65T-003-AC3 (DBL 16ga ) SH7:O-6

65T-000-AA1 (DBL 16ga )

1

1

79RD-000-AA1 (BRN 18ga )

TB29

SH15:C-15

900-003-CC2 (WHT 18ga )

TB22

1

11 BUSS

11 BUSS

1

u

2

2

1

1

P03

12H-002-CC3 (LBL 16ga )

OP-CAB HVAC MODULE PC2600

65T-004-CC3 (DBL 16ga )

J03

OPERATOR CAB HVAC

SH7:G-9

36-002-AA1 (YEL 18ga )

A B C D

0-090-CC3 (BLK 16ga ) 41TS-011-CC3 (DGR 16ga )

2

0-088-EE1 (BLK 14ga )

SWITCH ENGINE RUN OIL PRESSURE T2 (EOPSW)

A

A/C COMPRESSOR CLUTCH T2

RECDR

1

TIER I ENGINE CENSE RS232 CAB DIAGNOSTIC DIAG2 CONNECTOR (OPT)

MC689

49 49

SHIELD-788

MC688

SHIELD-793

50 50

SHIELD-788

36-001-AE2 (YEL 14ga )

GB3 ENG GND BLOCK

2

1

SWITCH SERVICE BRAKE PSI

71BC-005-BB1 (DGR 14ga )

927-003-CC2 (RED 18ga )

1

65T-002-AE2 (DBL 14ga )

22C-000-EE1 (GRY 16ga )

1

J1

SOLENOID PARK BRAKE

MC688

TB30

1 A3

J2

71BC-007-BB1 (DGR 14ga )

PC1150

A2

A1

ANALOG ENG RPM COMMAND SHIELD

509-004-AA3 (GRY 18ga )

1

SBPS 1 2 3 4

VEC91-P9

0-087-EE1 (BLK 16ga )

23D-002-AA2 (PNK 18ga )

TB27

SH7:M-9

72CPU-001-AA3 (BLK 18ga )

P02

C2

2

PBS

40 40

LP

4

509-004-AA3 (GRY 18ga )

SH7:M-9

SH15:B-2

927-001-AE1 (RED 18ga )

x

23D-003-AA2 (PNK 18ga )

SHIELD-270

32 32

3

2

R4 58B-06-00120

SH15:B-2

939GE-001-AE1 (GRN 18ga )

39 39

PRE-ENGINE FUEL SENSOR (TIER II ONLY)

ANALOG ENG RPM COMMAND SIG

419I-001-AA3 (DBL 18ga )

PC2834

PC2098

NO2

419I-001-AA3 (DBL 18ga )

58B-06-00120

71BC-006-BB1 (DGR 14ga )

MC258

MC685

s

SHIELD-202

FAN ON FULL TEST POINT

939YE-001-AE1 (YEL 18ga )

ANALOG ENG RPM COMMAND COMM

SHIELD-202

71BC-004-BB1 (DGR 14ga ) 1

WATER IN FUEL SENSOR SIGNAL

P826

59 59

MC258

r

R5

1

1

22C-005-AE1 (GRY 16ga )

ANALOG ENG RPM COMMAND SUPP

916M-001-AA3 (RED 18ga )

72CPU-001-AA3 (BLK 18ga )

TB27

q

952M/0-001-AA3 (BLK 18ga )

JB4A

P820

SWITCH A/C RECIEVER DRYER T2

556-000-AA3 (WHT 18ga )

R3

72CPU-000-AE1 (BLK 16ga )

31 31

22C-001-EE1 (GRY 16ga ) 22C-000-EE1 (GRY 16ga )

MC202

11POR-000-EE1 (GRY 14ga ) 1

18AZ-000-EE1 (DGR 14ga )

N

N

B

B

C

C

D

D

E

E

J

J

SPR_2

F31 15 F32 15

GB31-B 1 A1

0-215-AE2 (BLK 14ga )

18AZ-001-AE2 (DGR 14ga )

VEC-91

VEC-91

4C

C

4A

A

VEC91-P4

VEC91-P4

11RCNT-000-AA1 (TAN 14ga ) 1

11POR-001-AE2 (GRY 14ga )

1

P801

TB28 D1 D2

1

E1 E2

1

ENGINE OIL RESERVE SYSTEM (OPT) 11POR-003-AA1 (GRY 14ga )

11POR-002-AA1 (GRY 14ga )

SPR_3 J801

SH15:O-15

0-519-AJ1 (BLK 16ga )

11ORS-001-AE2 (YEL 14ga )

1

ENGINE OIL RESERVE SYSTEM OPTION

11ORS-002-AA1 (LBL 14ga )

1

11RCNT-003-AA1 (TAN 14ga )

TB28

SH5:I-5 SH5:I-5

11RCNT-001-AA1 (TAN 14ga )

J506

55 55

11POR-005-AJ1 (GRY 14ga )

56 56

0-217-AJ1 (BLK 14ga )

57 57

0-518-AJ1 (BLK 14ga )

21OR-005-AA1 (LBL 16ga )

SH6:D-9

21ORR-005-AA1 (DGR 16ga )

SH6:D-9

21ORR-003-AA1 (DGR 16ga )

11POR-002-AA1 (GRY 14ga ) SH5:H-9

0-222-AA1 (BLK 14ga )

11RCNT-003-AA1 (TAN 14ga ) SH5:I-9

0-223-AA1 (BLK 14ga )

2

1

1

1

1

2

2

2

P505-

59 59

21OR-006-AJ1 (LBL 16ga )

1

1

60 60

21ORR-006-AJ1 (DGR 16ga )

2

2

J12

21OR-002-AA1 (LBL 16ga )

2

WHT BLK

0-218-AJ1 (BLK 14ga )

P504

SH6:D-9

2

P506

0-216-AA1 (BLK 14ga ) 0-219-AA1 (BLK 14ga )

SH6:D-9

1

11RCNT-002-AJ1 (TAN 14ga )

58 58

L1

SP777

P506_CP 1

J505_CP

BLK

J505

OIL RESERVE LEVEL SW (OPT)

J504_CP

P12

25 25

21OR-004-AH1 (LBL 16ga )

26 26

21ORR-004-AH1 (DGR 16ga )

28 28 29 29

1

1

2

2

P170

27 27

OIL RESERVE LEVEL SW (OPT)

J170_CP

11POR-004-AH1 (GRY 14ga )

1

1

0-221-AH1 (BLK 14ga )

2

2

J190

11RCNT-004-AH1 (TAN 14ga )

30 30

0-220-AH1 (BLK 14ga ) J11

WHT

BLK

A

11A

MC202

PC1150

CAN J1939 LOW

VEC91-P12

1

JB41

P806

SH7:P-6

28E-000-AA1 (DBL 16ga )

1 D3

0-086-AE1 (BLK 14ga )

26 26

1000 ENGINE RPM COMMAND (NOT USED) 14

CAN J1939 HIGH

87a

TB24

22C-003-EE1 (GRY 16ga )

1400 ENGINE RPM COMMAND (NOT USED) 25

T1 T2

509-002-AE1 (PNK 16ga )

22C-002-EE1 (GRY 16ga )

FAN CLUTCH 5VDC SUPPLY 26

1

SHIELD-205

70 70

0-085-EE1 (BLK 14ga )

1000.0

12C C

87

TB27

MC203

R50

GB31-B

CHASSIS GROUND RETURN 22

SH6:N-10 SH6:O-11

21ORR-005-AA1 (DGR 16ga ) 21ORR-003-AA1 (DGR 16ga )

VEC-91

86

30

10

SH7:O-6

65SR-000-AA1 (ORG 16ga )

VEC91-P12

ETHER START (OPT) RELAY 36

SHIELD-205

17 17

22FO-000-EE1 (TAN 16ga )

1

556A-001-AE1 (GRN 16ga )

61 61

F21

11 BUSS

58B-06-00130

952M/0-003-EE1 (BLK 18ga )

85

21OR-005-AA1 (LBL 16ga ) SH6:N-10 21OR-002-AA1 (LBL 16ga ) SH6:O-11 CONNECTION FOR LOW LEVEL SENSOR EB7418 FOR RESERVE OIL TANK OPTION

556-002-AE1 (WHT 16ga )

47 47

556A-002-EE1 (WHT 18ga )

VEC91-P12

0-388-AA2 (BLK 18ga )

28EC-000-AA1 (DBL 18ga )

L1 L2 L3

MC203

1

1000.0

0 BUSS

R51

K2

P805

MC256

2

TB27

XA4486

D 12D

58B-06-00130

21NSL-004-AA2 (LTG 18ga )

COOLANT LEVEL SWITCH RETURN

SH4:H-9

21NSL-003-AA1 (LTG 20ga )

87a

SHUTTER CONTROL (OPT) RELAY 39

TB27

21NSL-001-AE1 (LTG 16ga )

12H H

87

30

10

65S-001-AE1 (BRN 16ga )

86

(OPTIONAL)

BATTERY GROUND 1

SP114

11E4-002-EE1 (BRN 14ga )

1

PC2799

F

A2

ENGINE INTERFACE CIRCUITS

11 BUSS

AFC500 AUTO REFILL CONTROL BOX (OPTIONAL)

BATTERY 24V UNSWITCHED 4

A1

F36

MOTOR

D

1

VEC-91

2A

VAL -24V+24V

BATTERY 24V UNSWITCHED 3

11E1-001-AE1 (YEL 14ga ) 11E1-002-AE1 (YEL 14ga ) 11E2-001-AE1 (LBL 14ga ) 11E2-002-AE1 (LBL 14ga ) 11E3-001-AE1 (DBL 14ga ) 11E3-002-AE1 (DBL 14ga )

TB27

COM LO

C

SH4:D-18

439-003-AE1 (YEL 16ga )

HI

BATTERY 24V UNSWITCHED 2

5 1 7 2 8 3 9

WHT GRN

A

5 1 7 2 8 3 9

P11

P190_CP

1

1

2

2

P180

J180_CP

1 2 3

BATTERY 24V UNSWITCHED 1

439-004-EE1 (YEL 16ga ) 11E1-003-EE1 (YEL 14ga ) 11E1-005-EE1 (YEL 12ga ) 11E1-004-EE1 (YEL 14ga ) SP112 11E2-003-EE1 (LBL 14ga ) 11E2-005-EE1 (LBL 12ga ) 11E2-004-EE1 (LBL 14ga ) SP113 11E3-003-EE1 (DBL 14ga ) 11E3-005-EE1 (DBL 12ga ) 11E3-004-EE1 (DBL 14ga )

RESERVE OIL LEVEL SENSOR

H

FILL VALVE

IGNITION 24V SIGNAL

RIGHT SIDE OIL RESERVE SYSTEM OPT. LOCATION

58E-06-02000-00 NOV 11 ELECTRICAL SCHEMATIC 830E-1AC A40851 & UP Sheet 6 of 20

ENGINE QSK60 INTERFACE TIER I

D

P806-

G

UNSWITCHED BATTERY POWER 2

5 1 7 2 8 3 9

439-006-EE3 (WHT 16ga ) 11E1-006-EE3 (RED 14ga ) 11E2-006-EE3 (RED 14ga )

P805-

BATTERY GROUND 2 23

VEC-89

F56

712 BUSS

10

4B

B

P806SHUTTER CONTROL

A

65S-003-EE3 (BRN 16ga )

ENGINE DELAY SHUTDOWN (3 MIN)

C

21NSL-002-EE3 (LBL 16ga ) P805-

4

COOLANT LVL SWITCH V RETURN

6

S

COOLANT LEVEL SWITCH LOW

T

C +5V B GND D HIGH A LOW

930-001-EE3 (LTG 16ga ) 926-001-EE3 (WHT 16ga )

XA3603

P802-

28EC-003-EE3 (DBL 16ga )

+5V REFERENCE M P

ENGINE RPM COMMAND SIGNAL (PWM)

L

OPERATOR CAB PASSENGER AIR SEAT MOTOR CONNECTOR

A

2

1 2 3 4

712DS-002-CC2 (ORG 14ga ) 712DS-003-CC2 (ORG 14ga ) 712DS-004-CC2 (ORG 14ga )

J02

JB4E

PC1150

712DS-003-CC2 (ORG 14ga )

B

0-309-CC2 (BLK 14ga )

J228

712DS-004-CC2 (ORG 14ga )

B

0-308-CC2 (BLK 14ga )

J229

JB6C

16 11

P806-

ENGINE RPM COMMAND SIGNAL REFERENCE

A

OPERATOR CAB SEATS

18

P805ENGINE ETHER START OUTPUT 26

2

712DS-001-AC2 (ORG 14ga )

12

SWITCH COOLANT LEVEL TIER 1

925-001-EE3 (TAN 16ga )

P806COOLANT LEVEL SWITCH HIGH

OPERATOR CAB DRIVERS AIR SEAT MOTOR CONNECTOR

25

924-001-EE3 (PNK 16ga )

1

GB12 REAR CAB

1 2 3 4 5 6

1 D3

0-266-CC2 (BLK 14ga ) 0-260-CC2 (BLK 18ga ) 0-310-CC2 (BLK 18ga ) 0-311-CC2 (BLK 18ga )

SH7:F-20

SH4:C-18 SH10:I-9

56B0611510

5EFQ-000-EE3 (BLK 16ga ) MC680

60

556-003-EE3 (WHT 18ga )

J2-AA7 (BLK 18ga )

47

P805-

ENGINE RPM COMMAND 10

62

916M-000-EE3 (BLK 18ga )

AHT AUXBOX CONNECTOR (OPT)

63

SHIELD-771 ENGINE BLUE LIGHT FAULT 17

528A-000-EE3 (LBL 16ga )

22

ENGINE YELLOW LIGHT FAULT 16

419I-004-EE3 (DBL 16ga )

20

p

FWD DIR REQ

1

79BA-001-AA3 (YEL 18ga )

TB23 X1 X2

1

22FO-002-EE3 (TAN 16ga )

ENGINE RED LIGHT INPUT

K

BATTERY GROUND 1

X

ROCKFORD FAN CLUTCH CONTROL

H

79BA-000-AA3 (YEL 18ga )

H

SEL SW IN REVERSE

52CA-000-AA3 (BRN 18ga )

K

PARK BRAKE SW CLOSED

JB6B

1 2 3 4 5 6

ENGINE FAN CLUTCH CONTROL 11

A

CAN J1939 LOW

B

CAN J1939 SHLD

C

31

22C-006-EE3 (GRY 16ga )

71CK BUSS

72CPU-002-EE3 (BLK 16ga ) MC683

939YE-002-EE3 (YEL 18ga )

57

939GE-002-EE3 (GRN 18ga )

58

SHIELD-775

SHIELD-775

MC682

L

SHIELD-774

SHIELD-774

P804-

MC681

2

ENGINE QUANTUM J1587 DIAGNOSTIC SUPPLY

85

SHIELD-773

P304

79B-002-AA1 (YEL 18ga ) 9B

B

72N-002-AA1 (PNK 18ga )

D14

72-003-AA3 (GRY 18ga ) D2

TO VEC-90 RELAY 20 (87a)

D3 D4

D13

72-002-AA1 (GRY 18ga ) 1G 1F 1E

11B

87

G

42

0 BUSS

E

1

52PB-000-AA1 (PUR 16ga )

0 BUSS

34

86 11A

87

30

SH6:H-18

TB24

1

52CS-003-AB1 (GRY 14ga )

A

12D

K1 K2

1

1

L1 L2

1

1

L3

1

M1 M2

1

52C-001-AC2 (BRN 18ga )

13 13

79B-001-AC2 (YEL 18ga )

14 14

P806-

J808-

86

D5

87

30

1

52CS-000-AA1 (GRY 16ga )

72N-001-AC2 (PNK 18ga )

B1 B2

1

B4

1

TB32 K1 K2

N1

1

N3 N2

1

12A

P2

1

87

9D

P803-

XB7317

SWITCH ENGINE RUN OIL PRESSURE T1 (EOPSW)

N B

SWITCH ENGINE OIL RESERVE PRESS T1 (ORPS)

1

C

1

D10

C

J02

P250

SH13:M-16 SH13:I-13

0-231-AA2 (BLK 18ga ) 0-345-AA2 (BLK 18ga ) 0-238-AA2 (BLK 16ga )

1

X3

R18

1

X4

2

1

TB24 M1 M2

B1 B2

1

EM5648

2

71SS-002-CC2 (LBL 18ga )

P250

PC1817a

TO CAMERA SYSTEM

SH15:J-3

INTERFACE MODULE

SH6:G-20

44R-001-AA1 (GRY 20ga )

C

SERVICE BRAKE PRESS SW

SH7:F-14

52CA-003-AA1 (BRN 20ga )

T

SELECTOR SWITCH PARK

V

PARK BRAKE RELEASE REQUEST

P

HYD LADDER NOT UP

510E2-001-AA1 (DGR 20ga )

IM3

TB21

58B-06-00290

50.0

F

SH12:E-5

1

X1 X2

0-230-AA1 (BLK 20ga )

C

IM GROUND

E

PARK BRAKE SOLENOID

N

SELECTOR SW (NOT IN PARK)

IM1 1

72FNR-001-AA1 (DBL 20ga )

IM2 1

L4

1

L

712BL-001-AA1 (DGR 20ga ) 712BL-002-AC3 (DGR 16ga )

712BL-002-AC3 (DGR 16ga )

1

1

0-095-CC3 (BLK 16ga ) 0-090-CC3 (BLK 16ga )

52B1-003-CC3 (PUR 16ga )

25 25

52B1-001-AC3 (PUR 16ga ) 39HA-001-AC3 (YEL 16ga )

31 31

39H-001-AC3 (YEL 16ga )

28 28

52B1-001-AC3 (PUR 16ga )

IM1

SWITCH BRAKE LOCK

SH6:J-12

52B1-002-CC3 (PUR 16ga )

3 3

39HA-000-CC3 (YEL 16ga )

1 1 6

6

4

39H-000-CC3 (YEL 16ga ) 0-096-CC3 (BLK 16ga )

5 5

PARK BRAKE PROTECTION (OPT)

i

BRAKE LOCK

24 24

712BL-003-CC3 (DGR 16ga ) 0-320-CC3 (BLK 16ga )

4

SH12:P-7

J03

P03

C C

D D

J03

2

R

IM2

A A 2

BRAKE LOCK SWITCH POWER SUPPLY

IM3

52ABA-000-AA1 (TAN 20ga )

P39

PC1766

P39

0-097-CC3 (BLK 16ga )

RELAY PARK BRAKE PROTECTION (930 OPTION ONLY) 1 D1

71ABA-001-AA1 (YEL 16ga ) 11D

87a

D

1 F1

71ABA-000-AA1 (YEL 16ga )

GE INTERFACE RELAY 27

71ABA-002-AA1 (YEL 16ga )

1

TB32

VEC RTMR1 85

86

87

30

87a

52B-001-AA1 (PUR 20ga )

F2 1

52ABA-001-AA1 (TAN 20ga )

D2 1

SOLENOID BRAKE LOCK

TB32

52B-000-AA1 (PUR 16ga )

52B-002-AA1 (PUR 16ga )

1

J1

J4

1

52B-003-AB1 (PUR 14ga )

E2

52B-003-AB1 (PUR 14ga )

L

P240

RELAY - R2

L

52B-004-BB1 (PUR 14ga )

SP160

52B-005-BB1 (PUR 14ga )

2

1

XA3347

BLS

J240

52B-006-BB1 (PUR 16ga )

T1

SH6:F-14

D3

1

2

GB8

0-098-BB1 (BLK 14ga )

1

3

BLS

0-239-BB1 (BLK 16ga )

PC2834

SH6:G-14

1

72FD-000-AA1 (WHT 18ga )

SH14:J-8

39H1-001-AA4 (YEL 16ga )

A/C SHUTTER CONTROL SH6:K-11

65T-000-AA1 (DBL 16ga )

65SR-000-AA1 (ORG 16ga )

1 A1 1 C1

86

VEC RTMR1 85 87

30

87a RELAY - R1

C2 1

1

TB22 X1 X2

1

39H1-000-AA1 (YEL 18ga )

GB31-A AUXBOX GND BLCK

0-079-AA1 (BLK 18ga )

AHT AUXBOX CONNECTOR (OPT)

TB23

1

39H-002-AA1 (YEL 18ga )

A1

V2

1

39HA-001-AC3 (YEL 16ga )

A2

1

39H-001-AC3 (YEL 16ga )

ENGINE SHUTTERS / ETHER START OPTIONS

1 D1

SOLENOID ENGINE SHUTTER (OPT)

A2 B2 1

58 58 59 59

65SS-000-AA1 (LBL 16ga ) 0-075-AA1 (BLK 16ga )

SH5:I-9

65SS-001-AH1 (LBL 16ga ) 0-076-AH1 (BLK 16ga )

15 15 16 16

J543

J11 P11

J815-

71SR-000-CC2 (LTG 18ga )

J12-CC3 (WHT 16ga )

87

79RD-000-AA1 (BRN 18ga )

ENGINE INTERFACE TIER I OPTION (SEE SHEET 6 FOR TRUCK INTERFACE)

1 2

1

J

18AZ-002-EE3 (DGR 14ga )

SH6:C-15

P108

1

P03

85

86

J801-

R S F G

1

52B1-000-AA1 (PUR 16ga )

PARK BRAKE LATCH RELAY 26

30

SPR_1

SG3290

11SM2-003-EE3 (DGR 14ga ) 11SM1-003-EE3 (GRY 14ga )

9F

E

11POR-006-EE3 (GRY 14ga )

NO 1

EXT ENGINE HARNESS TIER I OPTION

F

D9

D

11ORS-003-EE3 (YEL 14ga )

NO 1

E

9E

C

0-359-EE3 (BLK 14ga )

SG3290

1

9

0-229-AA2 (BLK 16ga )

30

87a

P803-

9C

P702

RECDR-T1

36-003-EE3 (YEL 14ga )

1

72T-000-CC2 (YEL 18ga )

8 T

SH13:B-13

1

TB23

J702

PC1804

65C-003-EE3 (DBL 14ga )

D8

86

87

2

65T-005-EE3 (DBL 14ga )

C

7

LADDER RELAY

52CS-002-AA2 (GRY 18ga )

D7

2

NC1

1

0-357-EE3 (BLK 14ga )

1

72-000-CC2 (GRY 18ga )

SH15:M-16 TO HYD ACCESS

52PB-001-AC3 (PUR 16ga )

52B-000-AA1 (PUR 16ga )

2

RECDR-T1

C1

2

85

D

J02

SHIFTER CURRENT LIMIT RESISTOR

P108

6 N

B B

87a

71SS-002-CC2 (LBL 18ga )

SH7:D-15

0-260-CC2 (BLK 18ga )

79B-005-CC2 (YEL 18ga )

D6

1

1

0 BUSS

A/C COMPRESSOR CLUTCH T1

5 R

79B-004-CC2 (YEL 18ga )

2

C 3

P

72N-000-CC2 (PNK 18ga )

P02

72T-001-AC2 (YEL 18ga )

A4

GB3 ENG GND BLOCK

0-358-EE3 (BLK 16ga )

SP159

B

52PB-003-AA1 (PUR 20ga )

1

L1 L2

S1

TRUCK MOVING RELAY 25

C2

79B-000-CC2 (YEL 18ga )

GB10 FRT CAB GND

30

1 A1

4

A

TB23 1

712BL-000-AA1 (DGR 16ga )

TB32

85

22C-007-EE3 (GRY 16ga )

4

1

52CS-001-AA1 (GRY 20ga )

A

3

SHIFTER DIRECTION SELECTOR

72-001-AC2 (GRY 18ga )

K3

87a

86

3

SH10:I-6 SH10:J-9

16 16 9

1

0 BUSS

NO2

49-007-CC2 (TAN 16ga ) 49-008-CC2 (TAN 16ga )

52C-000-CC2 (BRN 18ga )

D

PARK BRAKE SWITCH RELAY 24

SWITCH A/C RECIEVER DRYER T1

SH4:C-16

15 15

72FNR-000-AA1 (DBL 16ga ) 85

3

71SS-001-AC2 (LBL 18ga )

87a

PARK BRAKE RELEASE RELAY 23

0 BUSS

SH8:J-7

49-006-CC2 (TAN 16ga )

79B-002-AA1 (YEL 18ga )

B

1

T2 T1

72N-002-AA1 (PNK 18ga )

87a

85

49-003-CC2 (TAN 16ga )

49-004-CC2 (TAN 16ga )

1

72-002-AA1 (GRY 18ga )

F

1

71SS-000-AA1 (LBL 18ga )

VEC-89

56B0611510

PARK BRAKE REQUEST RELAY 22

9

PC3178

SH7:H-19

52CA-003-AA1 (BRN 20ga )

52C-002-AA3 (BRN 18ga )

86

30

33

901-000-EE3 (BLK 18ga )

30

ENGINE RUNNING RELAY 21

59

ENGINE 1400 RPM COMMAND 21 ENGINE 1000 RPM COMMAND

1

71BC-000-AA1 (DGR 16ga )

86

87a

32

900-000-EE3 (WHT 18ga )

3

ENGINE QUANTUM J1587 DIAGNOSTIC RETURN

E4

SH6:G-18

71BC-003-AB1 (DGR 14ga )

VEC-90

87

41

929-000-EE3 (WHT 18ga )

P

CENSE COMM RS232 SHLD

V3 V4

1

SH6:K-11

85

40

928-000-EE3 (BLK 18ga )

N

CENCE COMM RS232 GROUND

1

10

39

927-000-EE3 (RED 18ga )

CENSE COMM RS232 RECIEVE M

V1 V2

F19

H 9H

P820CENSE COMM RS232 TRANSMIT

71BC-001-AA2 (DGR 18ga )

1

36-002-AA1 (YEL 18ga )

P806CAN J1939 HIGH

1

1

79B-003-AA3 (YEL 18ga ) PC1150

8

GE CPU RUNNING SIGNAL

71BC-002-AA2 (DGR 18ga )

TB25

E1 E2

TB21

26

1 2 3 4

22C-009-EE3 (GRY 16ga ) 22C-008-EE3 (GRY 16ga ) 22C-007-EE3 (GRY 16ga )

P805-

SH12:B-9 SH12:A-9

JB41-

F

ENGINE FAN CLUTCH CONTROL (LOW)

70

0-356-EE3 (BLK 14ga )

1

52CA-001-AA3 (BRN 18ga )

17

P806-

1

TB23 A

SH11:C-4

79BA-002-AA1 (YEL 18ga )

TB24 ENGINE TEST MODE FAN CLUTCH (LOW) 27

4A

P02

6

509-005-EE3 (GRY 16ga )

F43

71CK BUSS

GE CONTROL INTERFACE

72AF-000-AA3 (GRY 18ga )

21

509-007-EE3 (PNK 16ga ) ENGINE RED LIGHT FAULT 18

J3-AA7 (BLK 18ga )

DIRECTIONAL SHIFTER / PARK BRAKE

61

10 11 12 1 2 3

COOLANT LVL SWITCH +V SUPPLY

TB24 C1 C2

P02

4 64 65 66 67 68 69

0-355-EE3 (BLK 14ga )

1

712DS-000-AA1 (ORG 14ga )

P701

UNSWITCHED BATTERY POWER 1

J701

1

10 11 12 1 2 3

FUEL IGNITION SIGNAL

65SS-002-HL1 (LBL 16ga ) 0-077-HL1 (BLK 16ga )

1 2

P520

P543

1 2

1 2

J520

J520SOLENOID ETHER START (OPT)

21PS-006-EE3 (BRN 14ga ) 21PT-011-EE3 (DBL 14ga ) SH6:C-15

28E-000-AA1 (DBL 16ga )

51 51 52 52

28E-001-AJ1 (DBL 16ga ) 0-081-AJ1 (BLK 16ga )

15 15 16 16

28E-002-JL1 (DBL 16ga ) 0-082-JL1 (BLK 16ga )

1 2

ETHER1 J12 SH5:I-5

0-080-AA1 (BLK 16ga )

P12

J542

P542

65SS-003-HL2 (LBL 16ga ) 0-078-HL2 (BLK 16ga )

1 2

ETHER2

1 2

28E-003-JL2 (DBL 16ga ) 0-429-JL2 (BLK 16ga )

2

1

ESOL PC0436 ESOL

2

1

ESSOL PC0436 ESSOL

58E-06-02000-00 NOV 11 ELECTRICAL SCHEMATIC 830E-1AC A40851 & UP Sheet 7 of 20

ELECTRONIC GAUGE DISPLAY

0-180-CC1 (BLK 16ga ) SWITCH DISPLAY MODE #2

SH9:C-5

A

71LS-005-CC1 (DGR 16ga ) GB10 B4

1

2

0-179-CC1 (BLK 16ga )

GB10-B4

A 2

+7.5V GND LIN

A

1 2 3 4

1 2 3 4

PC1943 PC1943

+7.5V GND LIN

COOLANT TEMP GAUGE

FUEL GAUGE +7.5V GND LIN

2

A

1 2 3 4

+7.5V 1 GND 2 LIN 3 4

PC1942

25 25

55B-001-AC1 (DBL 16ga )

1

P1 P2

1

55B-002-AA1 (DBL 20ga )

J

MODE SW 2

K

MODE SW 3

IM3

B B

TB26

1

3 3 4 4

55C-000-CC1 (YEL 16ga )

26 26

55D-000-CC1 (PUR 16ga )

27 27

6 6

J01

D D PC1944

LEFT TURN RIGHT TURN HIGH BEAM KEY SWITCH

1 2 3 4 POWER

RIGHT

LEFT TURN

HIGH BEAM

DIMMER

TURN

WARNING LAMP RETURN WARNING LAMP +24V

F1 F2

1

31 31 30 30

1

+

1

-

1

SH9:K-12 SH9:K-12

45LL-006-AC1 (BRN 16ga ) 45RL-006-AC1 (DBL 16ga )

6 3 4

1

3

24VIM-007-CC4 (LBL 16ga )

24V BATT+

31IML-002-CC4 (BRN 16ga )

GROUND BATT CAN/RPC-H CAN/RPC-L

CAN TERMINATOR

CAN TERMINATOR

H1 H2

1

H4

1

SP723

J04

SH8:J-7

49-002-CC1 (TAN 16ga ) 11ONS-000-CC1 (LBL 16ga ) MC254

MC254

939YP-001-CC1 (YEL 18ga ) 939GP-001-CC1 (GRN 18ga )

SH15:E-18 SH15:E-18

SHIELD-263

11D-000-AA1 (PNK 16ga )

1

A1

A2

1

11D-001-AC3 (PNK 16ga )

5

5

2

11D-002-CC3 (PNK 16ga )

VEC-89

P03

11D-003-CC3 (PNK 16ga )

J03

SH9:L-4

1

1

11DISP-001-AC1 (YEL 16ga )

1

2

2

11ONS-001-AC1 (LBL 16ga )

1

J01

18 18

41TS-003-AC2 (DGR 16ga )

31IML-001-AC4 (BRN 16ga )

1

TB34 N1 N2

1

31ILM-000-AA1 (BRN 20ga )

M SONALERT

1

11RWL-002-AA1 (PUR 20ga )

G

RED WARNING LAMP

K

IM ON SIGNAL

P04

TB35

G1 G2

VEC91-P9

TB35 T1 T2

1

E

11DISP-000-AA1 (YEL 16ga )

VEC-91

9C

F54 5

P1 P2

VEC-91

2E

712 BUSS

F26 15

11 BUSS

VEC91-P2 1

11ONS-002-AA1 (LBL 20ga )

IM1

P01

HEADLIGHT LAMP SWITCH

P02

J02

SH7:F-19

49-003-CC2 (TAN 16ga )

1

SH8:G-9

49-002-CC1 (TAN 16ga )

1

2

B 1

SH8:K-2

3 3

4 4

D D PC1501a

1

41L-000-CC3 (LBL 16ga )

4

41L-001-CC3 (LBL 16ga )

L1

41H-004-CC3 (TAN 16ga )

SWITCH COMBO

TB10

6 6

A1

1

A3 A4

1

0-100-CC3 (BLK 16ga )

DIMMER SW

P121

P25

PC1709

SH8:E-9

D4 D2

1

D3

SH10:J-20

41TS-010-CC3 (DGR 16ga )

3 5

41H-000-CC3 (TAN 16ga )

P121

SPR1-000-AC3 (DGR 14ga )

59 59

SPR1-001-CC3 (DGR 14ga )

1

1

SPR2-000-AC3 (DGR 14ga )

60 60

SPR2-001-CC3 (DGR 14ga )

1

1

SPR3-000-AC3 (DGR 14ga )

61 61

SPR3-001-CC3 (DGR 14ga )

1

1

SPR4-000-AC3 (DGR 14ga )

62 62

SPR4-001-CC3 (DGR 14ga )

1

1

SPR5-000-AC3 (DGR 14ga )

63 63

SPR5-001-CC3 (DGR 14ga )

1

1

SPR6-000-AC3 (DGR 14ga )

64 64

SPR6-001-CC3 (DGR 14ga )

1

K1

1

K3

P03

2 2

58B-06-00290

3 3

2

P18

R27

TB34

SH8:I-14

41H-004-CC3 (TAN 16ga )

18 18

1

41H-001-AC3 (TAN 16ga )

B1 B2

1

41H-002-AA1 (TAN 18ga ) F6

11 BUSS

25

12F

F

1 88

11HL-000-AA1 (BRN 10ga )

VEC-89

41L-002-CC3 (LBL 16ga )

4

4

1

41L-004-AC3 (LBL 16ga )

C1 C2

1

5690661711

GB10 FRT CAB GND

0-178-CC1 (BLK 16ga ) 0-187-CC1 (BLK 16ga )

1 B2

1

SPR7-000-AC4 (DGR 14ga )

20 20

SPR7-001-CC4 (DGR 14ga )

1

1

SPR8-000-AC4 (DGR 14ga )

21 21

SPR8-001-CC4 (DGR 14ga )

1

OP-CAB OVERHEAD SPARE WIRES

J04

GB31-B 1 B1

0-015-AA2 (BLK 16ga )

LAMP HIGH MOUNT LEFT HI-BEAM

TB34 1

41HB-000-AA2 (LTG 10ga )

F1 F2

1

F4

1

41HB-001-AA1 (LTG 14ga ) SH5:H-5

0-129-AA1 (BLK 14ga )

41 41 42 42

41HB-005-AJ1 (LTG 14ga )

5

5

41HB-006-JL1 (LTG 14ga )

0-110-AJ1 (BLK 14ga )

6

6

0-111-JL1 (BLK 14ga )

1 2

HMLHB PC2617

41L-005-AA1 (LBL 16ga )

LAMP LOW MOUNT LEFT HI-BEAM

41HB-002-AA1 (LTG 14ga ) J03

OP-CAB LOWER FRT SPARE WIRES

SH4:F-6

PC1903

TB34

SH8:J-14

88a 1

0-014-AA2 (BLK 16ga )

OP-CAB LOWER DASH SPARE WIRES

J03

P04 RELAY HI-BEAM HEADLIGHT (HBHR) 86 85 1 1 +

OP-CAB CENTER CONSL SPARE WIRES

1 1

49-001-CC1 (TAN 16ga ) 1

SH8:L-2

1

TB10

1

AUX BOX SPARE WIRES

41H-006-CC1 (TAN 16ga )

41L-002-CC3 (LBL 16ga )

ACTIA DISPLAY PANEL DIMMER

41TS-006-CC1 (DGR 16ga ) 49-005-CC1 (TAN 16ga )

SPARE WIRES - AUXB TO CAB

SH9:G-5

0-186-CC3 (BLK 16ga )

41TS-000-CC3 (DGR 16ga )

TB10

1

1

C C

11L-010-CC3 (YEL 16ga )

41TS-002-CC2 (DGR 16ga )

B

5 5

P25

1

SH4:J-10

P903

A A

A1 A2

24VIM-006-AC4 (LBL 16ga )

1

1 D3

TB22

1

SH8:F-13

SH8:D-16

712G-001-AC4 (LTG 16ga )

SWITCH HEADLIGHTS

41TS-005-AA1 (DGR 18ga )

712G-001-AC4 (LTG 16ga )

712G-000-AA1 (LTG 16ga )

41TS-001-CC3 (LBL 16ga )

TB34

3

23 23

31IML-004-CC4 (BRN 16ga )

C

11DISP-003-CC1 (YEL 16ga ) 1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

DIMMER IM ON SIGNAL

MODE SW 4

PC2834

TB23

CNP1 (GRAY)

q

SH4:J-13

24VIM-005-AC1 (LBL 16ga )

PC1938

SH9:I-8

2

31IML-003-CC4 (BRN 16ga )

712G-002-AC1 (LTG 16ga )

PC1939

0-185-CC1 (BLK 16ga )

D

55D-002-AA1 (PUR 20ga )

11RWL-001-AC1 (PUR 16ga )

IM ON SIGNAL

5

22 22

GB10 FRT CAB GND

2D

55C-002-AA1 (YEL 20ga )

D10

P902

PC1339

712 BUSS

1

TB23 6 3 4

11RWL-CC1 (PUR 16ga ) 24VIM-004-CC1 (LBL 16ga )

KEY SWITCH LEFT TURN RIGHT TURN

F64

S1 S2

712G-005-CC4 (LTG 16ga )

SONALERT (SONA)

58B-06-00190 470.0

2

1

R16

SH8:J-14

55D-001-AC1 (PUR 16ga )

1

IM2

PC2834

24SON-002-CC4 (LBL 16ga ) 24SON-003-CC4 (LBL 16ga ) 24SON-000-CC4 (LBL 16ga ) 24SON-001-CC4 (LBL 16ga )

712G-003-CC1 (LTG 16ga )

45LL-005-CC1 (BRN 16ga ) 45RL-005-CC1 (DBL 16ga ) 41H-006-CC1 (TAN 16ga )

1

D9

P21

2

1

R1 R2

P01

PB1951 1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1

712G-004-CC1 (LTG 16ga )

CNP2 (BLACK)

55C-001-AC1 (YEL 16ga )

1

0-184-CC1 (BLK 16ga )

PC1150

24V BATT+ GND CAN/RPC-H CAN/RPC-L

1 2 3 4 5 6 7 8

55B-000-CC1 (DBL 16ga )

4

1 2 3 4

OIL TEMP GAUGE

RIGHT TURN

WARNING LAMP RETURN WARNING LAMP +24V PC1938

3 3

TB10

LEFT

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

MODE SW 1

JB4D

HIGH BEAM

WARNING LAMP 1 2

H

+7.5V 1 GND 2 LIN 3 4

COMMUNICATION TO SLAVE DEVICES

DRIVE SYSTEM TEMP GAUGE

55A-002-AA1 (LBL 20ga )

1

2

P21

+7.5V 1 GND 2 LIN 3 4

+7.5V GND LIN

1

P20

C C

71LS-008-CC1 (DGR 16ga )

SPEEDOMETER & DISPLAY (MASTER GAUGE)

N1 N2

PC1945

5 5

PC1942

PC1942

POWER 7.5V GND LIN

+7.5V 1 GND 2 LIN 3 4

1

6 6

3 4 5 6 7 8

HIGH BEAM

POWER LEFT TURN

HIGH BEAM RIGHT TURN

NOT USED

1 2 3 4

55A-001-AC1 (LBL 16ga )

SWITCH DISPLAY MODE #1

PC3385

INTERFACE MODULE

24 24

D D

1 2

1 2 3 4

1 2 3 4

TB26

55A-000-CC1 (LBL 16ga )

0-182-CC1 (BLK 16ga ) 0-183-CC1 (BLK 16ga )

ACTIA DASH DISPLAY

+7.5V 1 GND 2 LIN 3 4

PC1942

0-181-CC1 (BLK 16ga )

1

4

C C

P20

1 2 3 4

1

5 5

71LS-006-CC1 (DGR 16ga ) 71LS-007-CC1 (DGR 16ga )

ACTIA STATUS PANEL PC3588

B B

P03

SH5:H-5

0-128-AA1 (BLK 14ga )

43 43

41HB-007-AJ1 (LTG 14ga )

7

7

41HB-008-JL1 (LTG 14ga )

44 44

0-112-AJ1 (BLK 14ga )

8

8

0-121-JL1 (BLK 14ga )

1 2

LMLHB PC2617 J12

P12

J542

P542

LAMP HIGH MOUNT RIGHT HI-BEAM

41HB-003-AA1 (LTG 14ga ) SH5:H-9

0-127-AA1 (BLK 14ga )

41 41 42 42

41HB-009-AH1 (LTG 14ga )

5

5

41HB-010-HL1 (LTG 14ga )

0-122-AH1 (BLK 14ga )

6

6

0-123-HL1 (BLK 14ga )

1 2

HMRHB PC2617 LAMP LOW MOUNT RIGHT HI-BEAM

41L-006-AA1 (LBL 16ga )

11 BUSS

F4 15

9A

A

11LL-000-AA1 (GRY 10ga )

RELAY HEADLIGHT LOW MOUNT (HLMR) +

1

86

85

1 87

1

41HB-004-AA1 (LTG 14ga ) 0-016-AA2 (BLK 16ga )

SH9:F-14

0-126-AA1 (BLK 14ga )

30 1

41LM-000-AA1 (GRY 14ga ) SH5:H-5

11 BUSS

F5 15

9G VEC-89

G

11LR-000-AA1 (PNK 10ga )

1

RELAY HEADLIGHT HIGH MOUNT (HHMR) +

86

85

1 87

1

30 1 PB7276

0-055-AA1 (BLK 14ga )

41HB-012-HL1 (LTG 14ga )

1

0-124-AH1 (BLK 14ga )

8

8

0-125-HL1 (BLK 14ga )

2

41LM-001-AA1 (GRY 14ga ) SH5:I-9

0-013-AA2 (BLK 16ga ) 0-157-AA2 (BLK 16ga )

0-008-AA1 (BLK 14ga )

P543

LAMP LOW MOUNT LEFT LOW-BEAM

39 39

41LM-002-AJ1 (GRY 14ga )

3

3

41LM-003-JL1 (GRY 14ga )

40 40

0-114-AJ1 (BLK 14ga )

4

4

0-113-JL1 (BLK 14ga )

P12

39 39 40 40

J11

41HM-000-AA1 (PNK 14ga )

J542

1 2

LAMP LOW MOUNT RIGHT LOW-BEAM

P542

41LM-004-AH1 (GRY 14ga )

3

3

41LM-005-HL1 (GRY 14ga )

1

0-116-AH1 (BLK 14ga )

4

4

0-115-HL1 (BLK 14ga )

2

0-094-AA1 (BLK 14ga )

P11

J543

45 45

41HM-002-AJ1 (PNK 14ga )

46 46

0-118-AJ1 (BLK 14ga )

9

P543 9

10 10

LAMP HIGH MOUNT LEFT LOW-BEAM

41HM-003-JL1 (PNK 14ga )

1

0-117-JL1 (BLK 14ga )

2

HMLLB PC2618 J12

SH5:I-9

J543

LMRLB PC2618

SH11:D-11

SH5:H-5

P11

LMLLB PC2618

41HM-001-AA1 (PNK 14ga )

HEADLIGHT LAMPS

7

LMRHB PC2617 J11

J12

41L-006-AA1 (LBL 16ga )

44 44

41HB-011-AH1 (LTG 14ga )

7

0-013-AA2 (BLK 16ga )

PB7276

VEC-89

SH5:I-9

43 43

0-084-AA1 (BLK 14ga )

P12

J542

45 45

41HM-004-AH1 (PNK 14ga )

46 46

0-119-AH1 (BLK 14ga )

9

LAMP HIGH MOUNT RIGHT LOW-BEAM

P542 9

10 10

41HM-005-HL1 (PNK 14ga )

1

0-120-HL1 (BLK 14ga )

2

HMRLB PC2618 J11

P11

J543

P543

58E-06-02000-00 NOV 11 ELECTRICAL SCHEMATIC 830E-1AC A40851 & UP Sheet 8 of 20

J11-CC3 (WHT 18ga ) SWITCH FOG LAMP (OPT)

A A

2

71LS-003-CC3 (DGR 16ga ) 71LS-004-CC3 (DGR 16ga )

SH11:C-8

0-268-CC3 (BLK 16ga )

B B

FOG LAMPS

0-150-CC3 (BLK 16ga )

3 3

2

1 1 6

5 5

4 C C

6

1

48F-001-AC3 (GRY 16ga )

E1 E2

LAMP RIGHT FOG 1

B

48F-002-AA1 (GRY 18ga )

48LF-001-AA1 (GRY 14ga )

1B 0 BUSS

4

J03

GB10

D D

P22

55 55

48F-000-CC3 (GRY 16ga )

TB34

1 A3

0-151-CC3 (BLK 16ga )

P03

85

F62

11 BUSS

87

15

TB10

TB23

SH14:D-1

71LS-011-CC3 (DGR 16ga )

1

C2 C1

1

SH15:H-2

71LS-009-CC2 (DGR 16ga )

1

C4 C3

1

5

71LS-002-CC1 (DGR 16ga ) 71LS-005-CC1 (DGR 16ga )

5

1

71LS-001-AC1 (DGR 16ga )

M2 M1

1

D

71LS-000-AA1 (DGR 16ga )

F44

4D

D

1

48LF-000-AA1 (GRY 12ga )

D1 D2

J01

38 38

J11 1

48LF-003-AH1 (GRY 14ga )

1

1

48LF-005-HL1 (GRY 14ga )

1

0-103-AH1 (BLK 14ga )

2

2

0-102-HL1 (BLK 14ga )

2

P11

J543

PC2619

P543

48LF-001-AA1 (GRY 14ga )

LAMP LEFT FOG

48LF-002-AA1 (GRY 14ga )

37 37

SH5:H-5

38 38

0-425-AA1 (BLK 14ga )

J12

71CK BUSS

5

VEC-89

SH8:B-8

0-104-AA1 (BLK 14ga )

TB34

FOG LAMP (OPT) RELAY 40

J10-CC3 (WHT 18ga ) 71LS-003-CC3 (DGR 16ga )

1D

30

87a

P22

PC1496

SH5:H-9

VEC-89

86

37 37

48LF-004-AJ1 (GRY 14ga )

1

1

48LF-006-JL1 (GRY 14ga )

1

0-106-AJ1 (BLK 14ga )

2

2

0-105-JL1 (BLK 14ga )

2

P12

J542

PC2619

P542

P01

RIGHT DECK LAMPS LAMP DECK LADDER LIGHT #1

48-001-AA1 (DBL 14ga ) SH5:I-9

LADDER LAMPS

48-002-AA1 (DBL 14ga ) A

A

48A-007-JJ2 (YEL 16ga )

B

B

48B-007-JJ2 (PUR 16ga )

C

C

48C-007-JJ2 (ORG 16ga )

2 1

1 1

48B-006-CC3 (PUR 16ga )

3

1

P535

VA2828 SWITCH CAB LADDER LIGHT

A A

2

11L-008-CC3 (YEL 16ga )

2

53 53

48B-001-AC3 (PUR 16ga )

1

K1 K2

1

48B-002-AA1 (PUR 18ga )

26 26

1 1

48A-000-CC3 (YEL 16ga )

54 54

48A-001-AC3 (YEL 16ga )

1

J1

J2

1

48A-002-AA1 (YEL 18ga )

25 25

4 C C

4

J03

D D PC1502

J12

P03

48B-003-AJ1 (PUR 16ga )

A4

J535 27 27

48B-003-AJ1 (PUR 16ga )

P12

P24

48A-004-AA1 (YEL 18ga )

11DSL-000-AA1 (RED 12ga )

1 1

48C-003-AH1 (ORG 16ga )

48B-005-AH1 (PUR 16ga )

P11

48B-008-HH2 (PUR 16ga )

C

C

J3

J1

2

1

48A-008-HH2 (YEL 16ga )

B

B

A

A

P121

J03

45R-000-CC3 (LBL 16ga )

11

PC1709

1

41TS-005-AA1 (DGR 18ga )

F

11F 0 BUSS

1

R1 R2

1

712T-000-AA1 (BRN 16ga )

H 11H

VEC91-P11 A

11L-000-AA1 (YEL 14ga )

F52

VEC-91 VEC-91

3A

5

1

45R-001-CC3 (LBL 16ga )

11 BUSS

P1 P2

1

R1 R2

1

19 19

J03 D13

TB22

1

45L-003-AC3 (DGR 16ga ) 45R-003-AC3 (LBL 16ga )

1

P121

TB23

712T-001-AC3 (BRN 16ga )

TB10 M3 M1

45L-004-AA1 (DGR 16ga )

D

0 BUSS

45R-004-AA1 (LBL 16ga )

45R-002-CC3 (LBL 16ga )

B

2

SH8:I-8

11L-004-CC3 (YEL 16ga ) TB22

TB10

C4

1

9

P03

9

J03

11L-002-CC3 (YEL 14ga ) SH9:F-1 SH14:D-1

11L-008-CC3 (YEL 16ga )

1

G1 G3

1

H2 H1

A A

SP732

2

11L-009-CC3 (YEL 16ga ) 11L-006-CC3 (YEL 16ga )

B B

5 5

6

C C

11L-003-CC3 (YEL 14ga )

P36

2

11L-005-CC4 (YEL 16ga )

1

48-000-AA1 (DBL 8ga )

T1 T2

1

V2

1

0-162-AA1 (BLK 14ga )

CDL P04

J04

VE5837

48 48

0-170-AJ1 (BLK 14ga )

29 29

0-171-GJ1 (BLK 14ga )

PC0493

1

2

LDLLT AK7503 LDLLT

48-013-AJ1 (DBL 14ga )

22 22

0-172-AJ1 (BLK 14ga )

23 23

48-014-GJ1 (DBL 14ga )

1

1

1

0-173-GJ1 (BLK 14ga )

2

2

2

J544_CP

J544

P544 J12

P12

J540

1

48-019-JJ4 (DBL 14ga )

2

LDLT AK7503 LDLT

0-449-JJ4 (BLK 14ga )

P540 LAMP CONTROL CABINET WORK LIGHT #1

0-161-AA1 (BLK 14ga )

16 16

48-015-AJ2 (DBL 14ga )

17 17

0-174-AJ2 (BLK 14ga )

1

1

2

2

P565

11G

48-016-JT1 (DBL 14ga ) 0-175-JT1 (BLK 14ga )

SP151

48-017-JT1 (DBL 14ga )

SP150

1

2

CDL1 AK4619 CDL1

J565

0-176-JT1 (BLK 14ga )

P14

LAMP CONTROL CABINET WORK LIGHT #2 1

2

TB35 G

41T-000-AA1 (TAN 14ga )

1

E1 E2

1

E4

1

F11 15

LAMP MARKER/TURN LEFT SIDE DECK

45LL-001-AA1 (BRN 16ga ) 41T-001-AA1 (TAN 16ga )

PWR LOAD

SH5:J-9

GND

0-134-AA1 (BLK 16ga )

1

1

45LL-002-AJ1 (BRN 16ga )

1

1

45LL-003-GJ1 (BRN 16ga )

A

A

2

2

41T-003-AJ1 (TAN 16ga )

2

2

41T-004-GJ1 (TAN 16ga )

B

B

3

3

0-136-AJ1 (BLK 16ga )

3

3

0-137-GJ1 (BLK 16ga )

C

C

85

J12

P12

J540

P36

P540

P503 SH14:I-19

45LL-004-GG1 (BRN 16ga )

30

C

85

45LL-000-AA1 (BRN 14ga ) SH8:E-12

45LL-006-AC1 (BRN 16ga )

1 1

TB35 J1

J2

1

J3

J4

1

41T-013-AA1 (TAN 16ga ) 45LL-007-AA1 (BRN 16ga ) SH5:I-5

B

24 24

45LL-011-AJ2 (BRN 16ga )

A

0-149-AJ2 (BLK 16ga )

C

12A

A

45RL-000-AA1 (DBL 14ga ) SH8:E-12

45RL-006-AC1 (DBL 16ga )

TB35

1

K1 K2

1

1

K3 K4

1

45RL-001-AA1 (DBL 16ga ) 41T-002-AA1 (TAN 16ga ) SH5:H-9

0-135-AA1 (BLK 16ga )

1

0-139-GG1 (BLK 16ga )

J503

LAMP MARKER/TURN LEFT FRT DECK A

45LL-010-GG1 (BRN 16ga )

1

45RL-002-AH1 (DBL 16ga )

1

1

45RL-003-FH1 (DBL 16ga )

A

A

2

2

41T-008-AH1 (TAN 16ga )

2

2

41T-009-FH1 (TAN 16ga )

B

B

3

3

0-141-AH1 (BLK 16ga )

3

3

0-142-FH1 (BLK 16ga )

C

C

45RL-004-FF1 (DBL 16ga )

P502

SH14:G-19

SH5:J-5

SP145

SP146

41T-010-FF1 (TAN 16ga )

0-146-AA1 (BLK 16ga ) 41T-015-AA1 (TAN 16ga ) 45RL-008-AA1 (DBL 16ga ) 45LL-008-AA1 (BRN 16ga )

14 14

19 19

J502

SP149

41T-016-AH2 (TAN 16ga ) 45RL-010-AH2 (DBL 16ga )

SP148

C B

41T-017-AH2 (TAN 16ga )

A

45RL-011-AH2 (DBL 16ga )

P731

18 18

41T-018-AH2 (TAN 16ga ) P16

45RL-012-AH2 (DBL 16ga ) 45LL-012-AH2 (BRN 16ga )

45RL-007-FF1 (DBL 16ga ) 41T-011-FF1 (TAN 16ga )

C

A

RCL1

B

RCL1

XB3719

0-144-FF1 (BLK 16ga ) LAMP MARKER/TURN RIGHT SIDE DECK

0-364-FF1 (BLK 16ga )

0-156-AH2 (BLK 16ga )

15 15

XB3719

LAMP MARKER/TURN RIGHT FRT DECK

0-143-FF1 (BLK 16ga ) SP147

P541

LCL2

0-140-GG1 (BLK 16ga )

P14

J541

C

B

LCL2

OPTIONAL LEFT SIDE MARKER/ TURN

1

P11

XB3719

J732_CP

P732 J14

86 30

41T-014-AJ2 (TAN 16ga )

1

0-147-AA1 (BLK 16ga )

J11

SH12:O-10

LCL1

0-363-GG1 (BLK 16ga )

12 12

LCL1

B

41T-006-GG1 (TAN 16ga )

41T-007-GG1 (TAN 16ga ) 12C

C

A

45LL-009-GG1 (BRN 16ga )

0-138-GG1 (BLK 16ga )

0-133-CC3 (BLK 16ga )

0-132-CC3 (BLK 16ga )

SP143

41T-005-GG1 (TAN 16ga )

86

RIGHT TURN RELAY 12

4

SP144

SP142

J16

1

48-012-GJ1 (DBL 14ga )

50 50

LAMP CAB DOME 2

28 28

6

D D

J21-CC3 (BLK 18ga )

11L-007-AC4 (YEL 16ga )

48-011-AJ1 (DBL 14ga )

1 1

4

EB7418

SH5:I-5

TB26 1

3 3

2

47 47

49 49

48-004-AA1 (DBL 14ga )

VEC-89

87a

45LR-007-CC3 (DGR 16ga )

11L-010-CC3 (YEL 16ga )

LEFT DECK LAMPS

VEC-89

30

87a

87

45LR-002-CC3 (LTG 16ga )

SWITCH HAZARD LIGHTS

11L-001-AC3 (YEL 14ga )

87

12B

D4 1

P541

VEC-89

LEFT TURN RELAY 11 0 BUSS

PC2834

1

86

87a

45L-002-CC3 (DGR 16ga )

C1 C2

15

12D

P03

11 BUSS

15

J541

FLASHER RELAY 13

712 BUSS

VEC91-P3

1

F8

85

87

F35

P11

RDLT AK7503 RDLT

0-169-FH1 (BLK 14ga )

48C-003-AH1 (ORG 16ga )

45L-001-CC3 (DGR 16ga ) 17 17

22 22

2

0-177-JT1 (BLK 14ga )

11 BUSS

SWITCH COMBO

0-168-AH1 (BLK 14ga )

48A-005-AH1 (YEL 16ga )

0 BUSS 1

50 50

1

48-010-FH1 (DBL 14ga )

LAMP DECK LIGHT #1 (OPT LOCATION) SH8:N-9

0-016-AA2 (BLK 16ga )

MARKER LAMP RELAY 8

1

21 21

0-237-AA2 (BLK 16ga )

PC1903

G

48-009-AH1 (DBL 14ga )

CDL2 AK4619 CDL2

TB10

P03

2

RDLLT AK7503 RDLLT

0-167-FH1 (BLK 14ga )

48B-005-AH1 (PUR 16ga )

45L-000-CC3 (DGR 16ga )

10

88a 1

49 49

J14

45L-005-CC2 (DGR 16ga )

9

1 88

0-163-AA1 (BLK 14ga )

SH5:I-5

45R-005-CC2 (LBL 16ga )

SH15:J-3

12G

RELAY ACCESS LADDER LIGHT (ALLR) 86 85 1 +

J11

FRONT TURN / CLEARANCE LAMPS / HAZARD SWITCH

712T-002-CC3 (BRN 16ga )

29 29

48-018-JT1 (DBL 14ga )

SH8:J-4

56 56

0-166-AH1 (BLK 14ga )

J534

1

48C-008-HH2 (ORG 16ga )

20

48-003-AA1 (DBL 14ga )

24 24

P11

3

VA2828

SH15:J-3

F10

1

48-005-AA1 (DBL 14ga )

48A-005-AH1 (YEL 16ga )

P534

1

48C-000-AA1 (ORG 18ga )

P12

23 23

SWITCH RIGHT LADDER LIGHT GND LVL (OPT LOCATION) (RLSW)

L1

48A-003-AJ1 (YEL 16ga )

22 22

J11

1

J12

11 BUSS

48B-004-AA1 (PUR 18ga )

TURN SW

48 48

1

48-007-FH1 (DBL 14ga )

LAMP DIAGONAL LADDER LIGHT #1

SH5:I-5

TB34

48C-001-AA1 (ORG 18ga ) 48C-002-AA1 (ORG 18ga )

SH8:I-11

0-186-CC3 (BLK 16ga )

48A-006-CC3 (YEL 16ga )

TO CAMERA SYSTEM

28 28

J11

GB31-A AUXBOX GND BLCK

TB34

48B-000-CC3 (PUR 16ga )

6

5 5

0-188-CC3 (BLK 16ga )

0-164-AA1 (BLK 14ga )

48A-003-AJ1 (YEL 16ga )

48C-004-AJ1 (ORG 16ga )

3 3 6

SH5:I-9

48C-004-AJ1 (ORG 16ga )

SH11:B-8

0-101-CC3 (BLK 16ga )

B B

P24

48-006-AH1 (DBL 14ga )

LAMP DECK LIGHT #2 SWITCH LEFT LADDER LIGHT GND LVL (LLSW)

SH9:L-3

0-165-AA1 (BLK 14ga )

47 47

45RL-009-FF1 (DBL 16ga ) 41T-012-FF1 (TAN 16ga )

OPTIONAL RIGHT SIDE MARKER/ TURN

C

A

RCL2

B

RCL2

XB3719

0-145-FF1 (BLK 16ga )

J731_CP SH11:F-12 SH11:G-11 SH11:G-11

TO REAR AXLE TURN / CLEARANCE LIGHTING

58E-06-02000-00 NOV 11 ELECTRICAL SCHEMATIC 830E-1AC A40851 & UP Sheet 9 of 20

GE CONTROL INTERFACE REVERSE MODE RELAY DRIVER

S

1

72A-000-AA3 (PNK 18ga )

GE INTERFACE AND WHEEL MOTOR SPEED SENSORS VEC-91

TB21 E1

TB33

P304

1

MC242

RH FT WHEEL SP +15V Q

M1 M2

1

L4

1

MC242

15SRW-002-AA3 (RED 18ga )

RH FT WHEEL SP SIGNAL

X

33RF-002-AA3 (WHT 18ga )

1

L1 L2

1

RH FT WHEEL SP COMM

P

0RF-002-AA3 (BLK 18ga )

1

K1 K2

1

RH FT WHEEL SP COMM 2

S

0RF-003-AA3 (BLK 18ga )

1

K3

RH FT WHEEL SP SHIELD

V

1

J1

SHIELD-245

SHIELD-245

LH FT WHEEL SP +15V

J

15SLW-002-AA3 (RED 18ga )

LH FT WHEEL SP SIGNAL W

1

MC244

R4

1

33LF-002-AA3 (WHT 18ga )

1

R1 R2

1

H

0LF-002-AA3 (BLK 18ga )

1

P1 P2

1

LH FT WHEEL SP COMM 2

L

0LF-003-AA3 (BLK 18ga )

1

P3

LH FT WHEEL SP SHIELD

O

LH FT WHEEL SP COMM

SHIELD-246

SHIELD-246

1

1 2

AHT RH WHEEL SPD RESISTOR (OPT) R56

J56_CP P56 MC239

1

1

33RF-001-AA1 (WHT 18ga )

2

2

0RF-001-AA1 (BLK 18ga )

3

3

4

4

15RFWS-001-AA1 (RED 18ga )

SHIELD-240

B

15SLW-001-AA1 (RED 18ga )

VEC-91

F59

1B

1A

1

MC238

A

15LFWS-003-AA1 (RED 18ga )

SP729

1 2

15LFWS-002-AA1 (RED 18ga )

0LF-001-AA1 (BLK 18ga )

LH RR WHEEL SP +15V

B

LH RR WHEEL SP COMM

A

77P-003-AA3 (RED 18ga ) TW1

1

A1

A2

1

77G-003-AA3 (BLK 18ga ) TW1

1

B1 B2

1

77P-002-AA1 (RED 18ga )

MC217

2C C

1

33RF-000-AR1 (WHT 16ga )

B

SIGNAL

0RF-000-AR1 (BLK 16ga )

C

GROUND

SHIELD-230 D SHIELD

SHIELD-230

J57_CP

MC238

5

5

33LF-001-AA1 (WHT 18ga )

6

6

0LF-001-AA1 (BLK 18ga )

7

7

8

8

15LFWS-001-AA1 (RED 18ga )

F1

2F

F

+V SUPPLY

VEC-89

77G-001-AA1 (BLK 18ga ) TW1

1

1

2

2

MC234

15LFWS-000-AR1 (RED 16ga )

A

+V SUPPLY

33LF-000-AR1 (WHT 16ga )

B

SIGNAL

0LF-000-AR1 (BLK 16ga )

C

GROUND

MC205

MC205

15LRW-000-AD1 (RED 18ga ) TW1

A

A

77G-000-AD1 (BLK 18ga ) TW1

B

B

C1 C2

1

77C-001-AA1 (WHT 18ga ) TW2

3

3

77C-000-AD1 (WHT 18ga ) TW2

D

D

LH RR WHEEL SP SIGNAL -V2 D

77DP-003-AA3 (BLK 18ga ) TW2

1

D1 D2

1

77DP-001-AA1 (BLK 18ga ) TW2

4

4

77DP-000-AD1 (BLK 18ga ) TW2

F

F

5

5

77B-000-AD1 (GRN 18ga ) TW3

C

C

6

6

77DN-000-AD1 (BLK 18ga ) TW3

E

E

G

G

E1 E2

1

77B-001-AA1 (GRN 18ga ) TW3

LH RR WHEEL SP SIGNAL -V1

F

77DN-003-AA3 (BLK 18ga ) TW3

1

F1 F2

1

77DN-001-AA1 (BLK 18ga ) TW3

LH RR WHEEL SP SHIELD

G

P301 CONTINUITY CHECK2

y

P301 CONTINUITY CHECK1

z

RH RR WHEEL SP +15V

k

RH RR WHEEL SP COMM

SHIELD-227

SHIELD-277-AA3 (BLK 18ga )

SHIELD-227

1

1

G1 G2

SP766

SHIELD-217

SHIELD-217-AA1 (BLK 18ga )

7

7

SHIELD-211

SP768 SHIELD-211

SP767

SHIELD-205-AD1 (BLK 18ga )

SHIELD-205A-AD1 (BLK 18ga )

SP742

MC221 TB29

MC221

714P-003-AA3 (RED 18ga ) TW1

H1 H2

j

714G-003-AA3 (BLK 18ga ) TW1

1

J1

J2

1

RH RR WHEEL SP SIGNAL +V2 m

714A-003-AA3 (WHT 18ga ) TW2

1

K1 K2

RH RR WHEEL SP -V2 n

714DP-003-AA3 (BLK 18ga ) TW2

1

p

714B-003-AA3 (GRN 18ga ) TW3

RH RR WHEEL SP -V1 q

714DN-003-AA3 (BLK 18ga ) TW3 SHIELD-223-AA3 (BLK 18ga )

SHIELD-223

F

VEC-91

F60

2F

MC213

3F F

1

MC213

15RRW-001-AA1 (RED 18ga ) TW1

714G-001-AA1 (BLK 18ga ) TW1

14 14

714G-000-AD1 (BLK 18ga ) TW1

B

B

1

714A-001-AA1 (WHT 18ga ) TW2

15 15

714A-000-AD1 (WHT 18ga ) TW2

D

D

L1 L2

1

714DP-001-AA1 (BLK 18ga ) TW2

16 16

714DP000-AD1 (BLK 18ga ) TW2

F

F

1

M1 M2

1

714B-001-AA1 (GRN 18ga ) TW3

17 17

714B-000-AD1 (GRN 18ga ) TW3

C

C

1

N1 N2

1

714DN-001-AA1 (BLK 18ga ) TW3

18 18

714DN-000-AD1 (BLK 18ga ) TW3

E

E

1

P1 P2

1

G

G

SHIELD-213

SP765

SHIELD-213

SHIELD-213-AA1 (BLK 18ga )

ENG SP REF PASS MAG PICK-UP

s

ENG SP COMM

x

ENG SP SHIELD

w

TB33

74X-002-AA3 (WHT 18ga ) 74Z-002-AA3 (BLK 18ga )

SHIELD-257

SHIELD-257

1

T1 T2

1

1

W1 W2

1

1

V1 V2

1

P301 P

BUFFERED RH RR SP SIG POS

Q

BUFFERED RH RR SP SIG RET

R

BUFFERED LH RR SP SIG RET

X

714Z-000-AA3 (WHT 18ga ) MC246 MC248

BUFFERED LH RR SP SIG POS W BUFFERED LH RR SP SIG SHIELD

Y

P305 CONN INSTALL CHECK

z

714Y-000-AA3 (BLK 18ga )

MC246 MC248

77Y-000-AA3 (BLK 18ga ) 77Z-000-AA3 (WHT 18ga )

SHIELD-252

SHIELD-252

1

G1

1

C1

1

D1

1

E1

1

F1

1

H1

74X-001-SS1 (WHT 18ga )

SHIELD-260

MC252

SHIELD-260

1

C

SH7:F-19

1

49-007-CC2 (TAN 16ga )

1

71H-002-CC2 (LBL 16ga )

1

R1 R2

1

71H-001-AC2 (LBL 16ga )

11 11

STORE DATA

J

73DS-000-AA3 (TAN 18ga )

1

S1 S2

1

73DS-001-AC2 (TAN 16ga )

12 12

1

31RR-002-AA3 (LTG 18ga ) P304

P

J

RETARD SP CONT POT WIPER

A

RETARD SP CONT POT GND

K

72AUT-000-AA3 (BLK 18ga ) SHIELD-277

E1 E2

73DS-003-AC4 (TAN 16ga )

TB21

y t

ACCEL SHIELD

u

1

33RR-002-AC2 (WHT 18ga )

63 63

0-316-AA3 (BLK 18ga )

1

G1 G2

1

0-315-AC2 (BLK 18ga )

62 62

1

G3

1

M1 M2

1

M3 M4

1

MC262

10V-000-AA3 (LBL 18ga )

0ACL-002-AA3 (BLK 18ga )

SHIELD-274

SHIELD-274

N1 N3

MC261

1

10V-001-AC2 (RED 18ga )

MC261

10V-008-AC1 (RED 18ga )

64 64

TB31

1

10V-010-AC1 (RED 18ga )

W4 W2

1

0ACL-001-AC1 (BLK 18ga )

V3 V2

1

V1 V4

1

1

1

MC270

T

RETARD LEVER SIG

S

P302 CONN INSTALL CHECK

Z

J701

1

1

S1 S2

1

AHT AUXBOX CONNECTOR (OPT)

74N-002-AA3 (WHT 16ga )

J6-AA7 (BLK 18ga )

0LEV-002-AA3 (BLK 18ga )

8 8

J5-AA7 (BLK 18ga )

P701 J701

AHT AUXBOX CONNECTOR (OPT)

52R-002-AA3 (WHT 18ga ) 5

52RA-001-AA3 (WHT 18ga ) 5

P303

SP740

TB31

2-3

2-4

1

J3

J2

1

J4

1

F45

2E

E

71P-000-AA1 (BRN 14ga )

SP166

C

C

J563_CP

0-272-JJ1 (BLK 14ga )

J563

P14

21 21

J540

42SL-002-GJ1 (ORG 16ga )

P540 SWITCH RIGHT ENGINE SERVICE LAMP (RESLS)

2 1 3

1

42A-000-GJ1 (LTG 16ga )

19 19

42A-001-AJ1 (LTG 16ga )

19 19

42A-002-AA1 (LTG 16ga )

19 19

42A-003-AH1 (LTG 16ga )

19 19

42A-004-FH1 (LTG 16ga )

42B-000-GJ1 (BRN 16ga )

20 20

42B-001-AJ1 (BRN 16ga )

20 20

42B-002-AA1 (BRN 16ga )

20 20

42B-003-AH1 (BRN 16ga )

20 20

42B-004-FH1 (BRN 16ga )

2 3

1

VA2828 P540

J540

42-008-AA1 (BRN 14ga ) 42-007-AA1 (BRN 14ga )

P12 TB35

1

M1 M2

1

M3

1

J12

J11

P11

J541

P541

42-001-AA1 (BRN 14ga )

0-288-FH1 (BLK 16ga )

LAMP LEFT UPPER ENGINE SERVICE 1

2

42-012-GJ1 (BRN 14ga )

15 15

42-009-AJ1 (BRN 14ga )

15 15

16 16

0-276-AJ1 (BLK 14ga )

16 16

17 17

42-010-AJ1 (BRN 14ga )

17 17

18 18

0-279-AJ1 (BLK 14ga )

18 18

LAMP RIGHT UPPER ENGINE SERVICE

LUESL AK7503 LUESL

0-277-GJ1 (BLK 14ga )

LAMP LEFT LOWER ENGINE SERVICE 1

2

42-011-GJ1 (BRN 14ga )

15 15

SH5:J-9

0-426-AA1 (BLK 14ga )

0-280-GJ1 (BLK 14ga )

SH5:H-9

16 16

0-421-AA1 (BLK 14ga )

J540

P12

2

17 17

42-004-AH1 (BRN 14ga )

0-283-FH1 (BLK 14ga )

LAMP RIGHT LOWER ENGINE SERVICE 1

42-005-FH1 (BRN 14ga )

2

0-287-FH1 (BLK 14ga )

RLESL AK7503 RLESL

SH5:I-9

J12

1

42-006-FH1 (BRN 14ga )

16 16

0-282-AH1 (BLK 14ga )

17 17

SH5:H-5

0-424-AA1 (BLK 14ga )

15 15

42-003-AH1 (BRN 14ga )

RUESL AK7503 RUESL

LLESL AK7503 LLESL

18 18

0-420-AA1 (BLK 14ga )

18 18

0-285-AH1 (BLK 14ga )

P11

J541

SP165

0-286-FH1 (BLK 14ga )

P541

71CK BUSS

15

VEC-91

9E

E

F56

11 BUSS

20

JB4B

SWITCH DATA STORE (DSSW)

1

C

D2

1

PC1150

T2 T1

SWITCH LEFT WINDOW

1

1

3

0-191-CC3 (BLK 14ga ) 1

32 32

67P-001-AC3 (YEL 14ga )

67P-004-CC3 (YEL 14ga )

33 33

67P-002-AC3 (YEL 14ga )

67P-003-CC3 (YEL 14ga )

SP135

1 6

67P-005-CC3 (YEL 14ga ) 67P-006-CC3 (YEL 14ga )

SWITCH RETARD SPEED CONTROL (RSCS)

NO

1

49-008-CC2 (TAN 16ga ) 33RS-000-CC2 (LBL 16ga ) 0-312-CC2 (BLK 18ga )

A

B

2

1

6

MOTOR LEFT WINDOW

2

67M-001-CC3 (GRY 14ga )

5 5

1

1

1

1

1

1

1

SWITCH RIGHT WINDOW

GB12 REAR CAB

33RR-001-CC2 (WHT 16ga )

C2

1

1

S2 S1

3

0-198-CC3 (BLK 14ga )

TB24 1

34 34

67R-001-AC3 (PUR 14ga )

35 35

67R-002-AC3 (PUR 14ga )

P03

67R-004-CC3 (PUR 14ga ) 67R-003-CC3 (PUR 14ga )

SP138

67R-005-CC3 (PUR 14ga ) 67R-006-CC3 (PUR 14ga ) 0-200-CC3 (BLK 14ga )

4 4

A A

MC260

RSP

G

67R-000-AA1 (PUR 12ga )

9G

VEC-91

F62

2

1 2 3 4

41TS-010-CC3 (DGR 16ga )

SH8:J-10

41TS-011-CC3 (DGR 16ga )

SH6:J-12

SM2740

MOTOR RIGHT WINDOW

67S-001-CC3 (DBL 14ga ) 67T-001-CC3 (LBL 14ga )

C C PC0490

P059

MOTOR

41TS-008-CC3 (DGR 16ga )

2

67S-000-CC3 (DBL 16ga )

SP782

67T-000-CC3 (LBL 16ga )

SP783

B A

P058

MOTOR

SM2740

41TS-007-CC3 (DGR 16ga )

P071

OP-CAB WINDOW MOTOR

11 BUSS

20

JB6A

PC1150

5 5

D D

P071

RETARD SPEED CONTROL C C

3

1 1 6 6

0-201-CC3 (BLK 18ga )

J03

A A

B B

0-197-CC3 (BLK 18ga )

67L-000-CC3 (PNK 16ga )

SP779

B A

41TS-009-CC3 (DGR 16ga ) 41TS-004-CC3 (DGR 16ga )

P072

PC0490

67M-000-CC3 (GRY 16ga )

SP778

67L-001-CC3 (PNK 14ga )

C C

D D

P072

0-314-CC2 (BLK 18ga ) 33RS-000-CC2 (LBL 16ga )

10V-006-CC2 (RED 18ga )

3

4 4

0-195-CC3 (BLK 14ga ) 0-194-CC3 (BLK 18ga )

71P-002-CC2 (BRN 16ga )

A A

B B

0-192-CC3 (BLK 18ga )

TB24

71P-004-CC2 (BRN 16ga )

1

1

D1

GB12 REAR CAB

1 2 3 4

71P-003-CC2 (BRN 16ga )

SHIELD-286

MC266

10V-008-AC1 (RED 18ga )

525-001-AC1 (WHT 18ga ) SHIELD-286

MC266

SHIELD-287

R1 R2

1

1

P1 P2

1

10V-009-AC1 (RED 18ga )

74N-001-AC1 (WHT 18ga ) SHIELD-287

10 10

XC2455

SHIELD-282

10V-003-CC1 (RED 18ga )

+VDC SUPPLY

9

0ACL-000-CC1 (BLK 18ga )

A

GROUND

8

525-000-CC1 (WHT 18ga )

B

PEDAL SIGNAL

7

9 8

14 14

MC265

MC265

TB31

1

J1

J2

1

1

L1 L2

1

L3

1

K1 K2

1

1

SHIELD-288

10V-010-AC1 (RED 18ga ) 0LEV-001-AC1 (BLK 18ga ) 52R-001-AC1 (WHT 18ga ) MC268

0-600-AA2 (BLK 18ga ) 0-601-AA2 (BLK 18ga )

SH10:M-7 SH12:A-5

MC268

18 18

10

10F

TB23 F

MC264

712H-004-AA1 (LBL 16ga )

10V-004-CC1 (RED 18ga ) 0RET-000-CC1 (BLK 18ga )

A

GROUND

74N-000-CC1 (WHT 18ga )

B

PEDAL SIGNAL

P235

22 22

RETARD CONTROL LEVER (OPT)

C

+VDC SUPPLY

17 17

0LEV-000-CC1 (BLK 18ga )

A

GROUND

16 16

52R-000-CC1 (WHT 18ga )

B

LEVER SIGNAL

J01

MC263

P237

53H-002-AH2 (PNK 16ga )

1 1

SWITCH HOIST LIMIT

K1 K2

1

J2

1

J1

712H-002-DD1 (LBL 16ga )

3 4

HLS J16

1

TB35 N1 N2

3

1

4

2

PC2818

1 2

HLS

53H-000-DD1 (PNK 16ga )

P16 SOLENOID HOIST LIMIT

1

53H-003-AB1 (PNK 14ga )

R

R

53H-004-BB1 (PNK 14ga )

1

HS

10V-005-CC1 (RED 18ga )

MC263

712H-001-AH2 (LBL 16ga )

RETARD CONTROL PEDAL

+VDC SUPPLY

SHIELD-280

W1

TB60

C

MC264

1

712H-003-AA1 (LBL 16ga )

30 30

15 15

P01

VEC-91

F51

53H-001-AA1 (PNK 16ga )

12 12

SHIELD-288

712 BUSS

P236

SHIELD-281

13 13

MC267

ACCELERATOR PEDAL

C

7

11 11

0RET-001-AC1 (BLK 18ga )

1

52RA-000-AA3 (WHT 18ga )

71CN2-000-AA3 (PNK 18ga )

A1

42SL-001-AJ1 (ORG 16ga )

JB4B

P701

9

9

4

4

MC271

74NA-001-AA3 (WHT 18ga )

SHIELD-297

Z

2-2

74NA-000-AA3 (WHT 18ga )

0LEV-002-AA3 (BLK 18ga )

0-273-JJ1 (BLK 14ga )

VA2828

67P-000-AA1 (YEL 12ga )

0ACL-001-AC1 (BLK 18ga )

T1 T2

P302 P303 CONN INSTALL CHECK

TB31

1

SHIELD-296

MC271

2-1

SH10:P-8

0-600-AA2 (BLK 18ga )

J701

RETARD LEVER COMMON

2

SWITCH LEFT ENGINE SERVICE LAMP (LESLS) 1 1

P701

U

1

0RET-001-AC1 (BLK 18ga )

AHT AUXBOX CONNECTOR (OPT) J4-AA7 (BLK 18ga )

7

RETARD LEVER SHIELD

1-4

MC267

SP739

LAMP HYDRAULIC PUMP MOD (OPT)

10V-009-AC1 (RED 18ga )

525-002-AA3 (WHT 18ga )

7

P302

0-274-JJ1 (BLK 16ga )

HPMS-3

J02

W1 N4

6

P

1-3

MC260

1

6

RETARD PEDAL SIG

MC270

B

1

VA2828

10V-008-AC1 (RED 18ga )

525A-001-AA3 (WHT 18ga )

0RET-002-AA3 (BLK 18ga )

HPMS-1

3

SH12:F-5

0-313-CC2 (BLK 18ga )

W3 N2

SHIELD-295

SP738

1 1

42PMS-002-JJ1 (DBL 16ga )

SH12:M-4

33RR-000-CC2 (WHT 18ga )

1

EB7418

525A-000-AA3 (WHT 18ga )

SHIELD-296

J1

SHIELD-272

61 61

P02

SH12:G-9

10V-007-AC2 (LBL 18ga )

0ACL-002-AA3 (BLK 18ga ) MC269 0ACL-003-AA3 (BLK 18ga )

0ACL-003-AA3 (BLK 18ga )

B

P563

P12

J12

NC PC2644

P721

71P-005-AA1 (BRN 16ga )

31RR-000-CC2 (LTG 16ga )

SHIELD-295

V

22 22

42SL-000-AA1 (ORG 16ga )

NO 1

1 C

B B

0RET-002-AA3 (BLK 18ga )

RETARD PEDAL COMMON

1-2

73DS-002-CC2 (TAN 16ga )

P304

RETARD PEDAL SHIELD W

3 1

PC1376

F1 F2

0-446-AA1 (BLK 18ga )

A

TIMER (1HR) ENGINE SERVICE LAMP (ESLT) T

H1

TB31

C

0-271-AJ2 (BLK 14ga )

GB12 REAR CAB

NC

65 65

P303 ACCEL PEDAL POT WIPER -

1-1

31RR-001-AC2 (LTG 16ga )

1

MC269

B

D4

33RR-003-AA3 (WHT 18ga )

EB7418

ACCEL PEDAL POW WIPER +

11SL-000-AA1 (DBL 14ga )

P540

SH7:D-14

0-311-CC2 (BLK 18ga )

GB12 REAR CAB

1

1

t

A

1

SH13:F-5

H1 H2

MC262

ACCEL PEDAL POT LOW REF m

TB31

42PML-001-AJ2 (ORG 14ga )

25 25

0-270-AA1 (BLK 14ga )

J14

71P-006-CC2 (BRN 14ga )

PB8624 SH7:F-19

SHIELD-277 1

SH12:F-20 ACCEL, RSC, RET PEDAL/LEVER POT HI REF

1

1

71P-001-AC2 (BRN 14ga )

P02

PC1377

71H-000-AA3 (LBL 18ga )

RETARD SP CONT POT SHIELD

1

SWITCH BODYUP OVERRIDE / RESET (ORS)

h

AUTONOMOUS MODE REQUEST

15

P15

VEC-89

J02

RESET/BODY UP OVERRIDE

P

SHIELD-209A-AD1 (BLK 18ga )

TB23

TB21

1

SHIELD-214

71P-007-AC3 (DGR 16ga )

A

74Z-001-SS1 (BLK 18ga )

z

RETARD SP CONT

SP770

SHLD_209-AD1 (BLK 18ga )

B

P304 CONN INSTALL CHECK

S4

B

A

SENSOR GE ALTERNATOR SPEED

MC252

P305

71CN1-000-AA3 (PNK 18ga )

SP769

TB33

SHIELD-251

SHIELD-251

SHIELD-214

33 33

J11

SH11:H-5

10 10

BUFFERED RH RR SP SIG SHIELD

19 19

J15

MC250

MC209

A

74ZA-000-AA3 (DGR 18ga ) MC250

MC209

13 13

A

42PMS-001-AJ2 (DBL 16ga )

HPML AK4619 HPML

SH5:I-5

TB24

4D D

SENSOR RIGHT REAR WHEEL SPEED A

SP741

t

42PML-000-AA1 (ORG 14ga )

35 35

42PML-002-JJ1 (ORG 14ga )

P720

15RRW-000-AD1 (RED 18ga ) TW1

714P-001-AA1 (RED 18ga )

P301

DIG OUT (EXT RETARD LIGHT)

1

42-000-AA2 (BRN 12ga )

1

RH RR WHEEL SP SHIELD M

VEC-91

F34

71CNCK-000-AA3 (PNK 18ga )

1

RH RR WHEEL SP +V1

2

42PMS-000-AA1 (DBL 16ga )

11SL-001-AA1 (DBL 14ga )

1

1

11 BUSS

P13

77C-003-AA3 (WHT 18ga ) TW2

77B-003-AA3 (GRN 18ga ) TW3

SWITCH HYDRAULIC PUMP MOD LAMP (OPT)

PC2644

SHIELD-233 D SHIELD

SHIELD-233

LH RR WHEEL SP SIGNAL +V2 C

E

1

1

11SL-002-AA1 (DBL 14ga )

SENSOR LEFT FRONT WHEEL SPEED MC234 P507

SENSOR LEFT REAR WHEEL SPEED

MC217

15LRW-001-AA1 (RED 18ga ) TW1

LH RR WHEEL SP SIGNAL +V1

ENGINE AND PUMP MODULE SERVICE LAMPS T

J13

MC228 TB29

A

TIMER (1HR) HYDRAULIC PUMP MOD (HPLT)

SHIELD-239

MC228

15RFWS-000-AR1 (RED 16ga )

MC232 P501

1 2

P57

33LF-003-AA1 (WHT 18ga )

33LF-001-AA1 (WHT 18ga )

SENSOR RIGHT FRONT WHEEL SPEED

MC232

AHT LH WHEEL SPD RESISTOR (OPT) R57

1

N1 N2

1 2

15RFWS-003-AA1 (RED 18ga )

SHIELD-240

1

S1 S2

1

SP728

15RFWS-002-AA1 (RED 18ga )

MC239

TB33

MC244

1C C

33RF-003-AA1 (WHT 18ga )

1

J2

F58-2

D 1D

15SRW-001-AA1 (RED 18ga )

BODY HOIST LIMIT

P240

J240

PC1372

58E-06-02000-00 NOV 11 ELECTRICAL SCHEMATIC 830E-1AC A40851 & UP Sheet 10 of 20

0-101-CC3 (BLK 16ga )

1

T2 T1

1

51 51

47S-001-AC3 (LBL 16ga )

P03

3 3

47S-000-CC3 (LBL 16ga )

J03

6

SH9:A-5

SH7:E-15

79BA-002-AA1 (YEL 18ga )

85

F3

11 BUSS

87

15

11C

87a

D14

BACKUP HORN RELAY 3

D

9C

25

1

0-246-DD1 (BLK 10ga )

1 A1

SH5:J-5

0-241-AA1 (BLK 14ga )

2

2

0-244-AH2 (BLK 14ga )

1

B1 B2

1

0-247-DD1 (BLK 10ga )

1 A2

SH5:J-5

0-242-AA1 (BLK 14ga )

3

3

0-245-AH2 (BLK 14ga )

1

C1 A4

1

SH11:M-14

0-295-DD2 (BLK 10ga )

29 29

1

79A-001-AH2 (DBL 14ga )

TB60

1

G1 G2

LRBH-(+)

79A-002-DD1 (DBL 16ga ) 79A-003-DD1 (DBL 16ga )

TB35

47-008-AA1 (GRY 14ga )

1

L1 L2

1

L3

1

10 10

47-001-AA1 (GRY 14ga )

47-003-AH2 (GRY 14ga )

13 13

47-002-AA1 (GRY 14ga )

47-012-AA1 (GRY 14ga )

J16

1

TB60

1

F4

1

F3

1

P16

86

85

BULR-87

2

47-011-FF1 (GRY 14ga )

RBUL AK7519 RBUL

H

H

47-010-FH1 (GRY 14ga )

8

8

47-009-AH1 (GRY 14ga )

8

8

J

J

0-257-FH1 (BLK 14ga )

9

9

0-256-AH1 (BLK 14ga )

9

9

1

P502

P541

J541

P11

47-015-GG1 (GRY 14ga )

47-005-DD1 (GRY 16ga ) 1 2

47-006-DD1 (GRY 16ga )

LBUL AK7519 LBUL

H

47-014-GJ1 (GRY 14ga )

8

8

47-013-AJ1 (GRY 14ga )

8

8

J

J

0-261-GJ1 (BLK 14ga )

9

9

0-262-AJ1 (BLK 14ga )

9

9

47-007-DD1 (GRY 16ga )

HIDBL

HIDBL_CP

P503

P540

J540

P12

EM4520

47-000-AA2 (GRY 10ga )

1

GB1 - REAR AXLE 1 B1

2

0-252-DD1 (BLK 16ga )

LRBL AK7513 LRBL

47-008-AA1 (GRY 14ga ) SH5:H-9

LAMP STOP/TAIL LEFT A

44-004-DD1 (GRY 16ga )

47-012-AA1 (GRY 14ga )

SH9:M-19

SH5:J-9

0-263-AA1 (BLK 14ga )

0-251-DD1 (BLK 16ga )

LAMP BACKUP REAR LEFT

BULR-30

0-255-AA1 (BLK 14ga )

2

RRBL AK7513 RRBL

TB61

1

41T-018-AH2 (TAN 16ga )

B

A

1

M4

1

C

C

0-264-DD1 (BLK 16ga )

LRSTL

B

PC1913

LRSTL

M1 M2

0-259-GG1 (BLK 14ga ) J503

0-249-DD1 (BLK 16ga )

RRBH-(-)

1 2

1

J11

H

0-248-DD1 (BLK 16ga )

LAMP HID BACKUP BERM AXLE (OPT)

LAMP BACKUP LIGHT LEFT DECK (OPT) 2

- 1

736131C2

41T-019-DD1 (TAN 16ga )

1

736131C2

1

SH8:O-9

0-157-AA2 (BLK 16ga )

BULR-(-)

0-258-FF1 (BLK 14ga ) J502

LRBH-(-)

HORN BACKUP LEFT

LAMP BACKUP LIGHT RIGHT DECK (OPT) 1

- 1

LAMP BACKUP REAR RIGHT

30 1 PB7276

1

0-250-DD1 (BLK 16ga )

F1 F2

47-004-AH2 (GRY 14ga )

1 A3

HORN BACKUP RIGHT

RRBH-(+)

47-000-AA2 (GRY 10ga )

-

+

1 87

47B-000-AA1 (TAN 10ga )

A1 A2

RELAY BACKUP LIGHT (BULR) 1

C

1

P23

PC1500

47A-000-AA1 (PNK 16ga )

VEC-89

0-243-AH2 (BLK 14ga )

C C

BULR-(+)

F2

11 BUSS

11D

1

79A-000-AA1 (DBL 14ga )

79A-000-AA1 (DBL 14ga )

D15

11E

E

47S-002-AA1 (LBL 16ga )

C

1

4

47S-003-CC3 (LBL 16ga )

30

0-240-AA1 (BLK 14ga )

SH4:E-11

712K-004-CC3 (LBL 16ga )

J22-CC3 (WHT 16ga )

VEC-89

86

2

5 5

D D

0-268-CC3 (BLK 16ga )

P23

11B 0 BUSS

2

1 1 6 4

B

A A

B B

0-269-CC3 (BLK 16ga )

TB22

GB1 - REAR AXLE

TB61

SH5:J-5

+

SH9:F-5

SWITCH MANUAL BACKUP LIGHT

+

BACKUP LAMPS

LAMP STOP/TAIL RIGHT

41T-019-DD1 (TAN 16ga ) 41T-020-DD1 (TAN 16ga )

A

44-005-DD1 (GRY 16ga )

41T-022-DD1 (TAN 16ga ) 41T-021-DD1 (TAN 16ga )

B

41T-020-DD1 (TAN 16ga )

J12

A

C

C

0-265-DD1 (BLK 16ga )

RRSTL

B

RRSTL

PC1913

0-265-DD1 (BLK 16ga )

LAMP BODY RIGHT SIDE MARKER

SH6:G-17

44R-003-AA1 (GRY 18ga )

SH9:M-19

11H

H

0 BUSS

85 F9

11 BUSS

SH10:G-4

74ZA-000-AA3 (DGR 18ga )

1

TB21

12E

87

30

10

VEC-89

86

E

44-000-AA1 (GRY 14ga )

1

87a

TB35 G1 G2

1

G4

1

J16

1

D4

1

74ZA-001-AA1 (DGR 18ga )

C

1C 71CK BUSS

86 F13

11 BUSS

10

A1

A2

1

1

H1 H2

1

1

D1 D2

1

D4

1

45RL-013-DD1 (DBL 16ga )

1F

F

44D-000-AA1 (LBL 16ga )

87a

1

44-004-DD1 (GRY 16ga )

41T-022-DD1 (TAN 16ga )

44-005-DD1 (GRY 16ga )

0-300-DD1 (BLK 16ga )

1

H4

1

17 17

44D-001-AA1 (LBL 16ga )

B

B

41T-023-MM1 (TAN 16ga )

C

C

0-305-MM1 (BLK 16ga )

1

E4

1

44D-005-DD1 (LBL 16ga )

1

44D-005-DD1 (LBL 16ga )

44D-006-DD1 (LBL 16ga )

P16

1

GB1 - REAR AXLE

LAMP SERVICE BRAKE OP-CAB

RETARD SWITCH INPUT 7

7

1

44-006-CC4 (GRY 16ga )

SBL

IM3

A4

1

B3

1

0-254-DD1 (BLK 16ga ) 0-253-DD1 (BLK 16ga ) 0-265-DD1 (BLK 16ga ) 0-300-DD1 (BLK 16ga ) 0-301-DD1 (BLK 16ga )

5

44D-002-AC4 (LBL 16ga )

EM8073

10C C

63-009-AA1 (PNK 14ga )

1

R1 R2

1

45LL-013-DD1 (BRN 16ga )

1

E1 E2

1

RELAY VEHICLE HORN POWER (HPR)

63-001-CC3 (PNK 14ga )

63-003-CC3 (PNK 14ga ) 63-004-CC3 (PNK 16ga )

63-008-CC3 (PNK 16ga )

HPR-87

P03

63-008-CC3 (PNK 16ga )

SWITCH COMBO 8

P121

WASHER SW WIPER CONT SW

INT

PARK

LO

HI

PC1709

X

T

P

87

P10

63W-001-CC3 (GRY 16ga )

63H1-000-CC3 (LTG 16ga )

P121

D15

1

0-379-CC3 (BLK 16ga )

J03

1

WW+

0-377-AC3 (BLK 16ga )

+

PUMP

-

4B

B

85

30 (C)

VE5339

P09

PC1730

63P-000-CC3 (DBL 16ga )

P240

86

30 (C)

P08

85

(NO) 87 (NC)87A

PC1730

6

63P-000-CC3 (DBL 16ga )

P09

RELAY WIPER MOTOR HIGH (+) (-)

P08

41T-025-MM2 (TAN 16ga )

C

C

0-302-MM2 (BLK 16ga )

5 6

4 4

MOTOR

2 2

P07

SH15:M-20

0-378-CC3 (BLK 16ga ) 0-376-CC3 (BLK 16ga ) 63H-000-CC3 (TAN 16ga )

LSCL2

SP177

P54

LSCL2

B

XB3940

0-303-MM2 (BLK 16ga )

P120

J03

13 13

11HS-002-GJ1 (DBL 14ga )

N

N

14 14

0-290-AJ1 (BLK 14ga )

14 14

0-291-GJ1 (BLK 14ga )

O

O

P12

P540

J540

B

PC1621

11HS-003-GG1 (DBL 14ga )

HORN FRONT VEHICLE SP167

0-292-GG1 (BLK 14ga )

11HS-004-GG1 (DBL 14ga ) 0-293-GG1 (BLK 14ga )

SP168

A

B

B

AHS

J503

P503

A

PC0244

0-294-GG1 (BLK 16ga ) PC2834 1

TB35 A1

1

A2

4

11A-002-AA1 (TAN 16ga )

4

11A-005-AH2 (TAN 14ga )

1

TB60 L1 L2

1

1

B1 B2

1

B3 B4

1

J16

D1

11A-006-DD2 (TAN 16ga )

P16

2

D1

1

1

11A-007-DD3 (TAN 16ga )

2

2

0-297-DD3 (BLK 16ga )

P704

J704

GB1 - REAR AXLE

SH11:B-16

0-295-DD2 (BLK 10ga )

1 B2 B4 1

0-296-DD2 (BLK 16ga )

11A-004-AC2 (TAN 18ga )

C

1 2

11A-008-BB1 (TAN 14ga )

J240

1 1

0-298-DD3 (BLK 14ga )

HLSW-1

SR8325

11A1-000-BB1 (LBL 16ga )

GB8 BRAKE CABINET 4

1

SP171

11A1-001-BB1 (LBL 16ga )

0-445-BB1 (BLK 16ga )

GB8-4

1 1

A

PC3010

LAMP HYDRAULIC CABINET #2

P07

0-382-CC3 (BLK 16ga ) SH15:M-20

11A1-002-BB1 (LBL 16ga )

HYD CABINET LAMP

0-444-BB1 (BLK 16ga )

A B

HL2

LAMP REAR SERVICE 2

B

HL1

3 3

PB9923

41T-026-MM2 (TAN 16ga )

SP176

C

A

SWITCH HYDRAULIC LAMP C

HLSW-2

5

XB3940

11A-003-AB1 (TAN 14ga )

WW-

MOTOR WINDSHIELD WIPER

63L-000-CC3 (DGR 16ga )

(NO) 87 (NC)87A

B

45LL-016-MM2 (BRN 16ga )

45LL-014-MM2 (BRN 16ga )

11HS-005-GG1 (DBL 16ga )

1

11A-000-AA1 (TAN 12ga )

LSCL1

B

1

P03

RELAY WIPER MOTOR LOW (+) (-) 86

SP175

B

1 A 2

11H-002-CC3 (DGR 16ga )

11HS-001-AJ1 (DBL 14ga )

LAMP HYDRAULIC CABINET #1

PC1150JB4H

WINDSHIELD WIPER / WASHER

15

VEC-91

MOTOR WINDSHIELD WASHER

D15

63L1-000-CC3 (BRN 16ga ) 63L1-001-CC3 (BRN 16ga ) 63L1-002-CC3 (BRN 16ga ) 63L1-003-CC3 (BRN 16ga )

57 57

13 13

J12

EB7418

VEC91-P4 SH15:D-14

63W-003-AC3 (GRY 16ga )

66 66

F33

11 BUSS

GB12-C3

JB4H 1 2 3 4

65 65

63W-000-CC3 (GRY 16ga )

1

PC2834

0-422-AA1 (BLK 14ga )

41T-027-MM2 (TAN 16ga )

0-304-MM2 (BLK 16ga )

A3

6

GB12

D15 2

11HS-000-AA1 (DBL 14ga )

HPR-30

11A-001-AA1 (TAN 12ga )

4

WADT-6

C3

63L2-000-CC3 (LBL 16ga )

1

63W-000-CC3 (GRY 16ga )

12 2 1 6

11H-001-AC3 (DGR 16ga )

P03

1

WADT-4 5

0-380-CC3 (BLK 16ga ) 63W-002-CC3 (GRY 16ga )

63W-002-CC3 (GRY 16ga )

7

1

0-380-CC3 (BLK 16ga )

85

1

HPR-(-)

30 1 PB7276

B1 B2

RRL

C

A

SWITCH HORN BUTTON

1

WADT-2 3

L

63L1-003-CC3 (BRN 16ga )

85

1

11H-000-AA1 (DGR 16ga )

TB22

45LL-015-MM2 (BRN 16ga )

LSCL1

D1

WADT-1 1 2

63-007-CC3 (PNK 16ga )

XB3940

LAMP BODY LEFT SIDE MARKER

A

TIMER WASHER DELAY (WADT)

63L1-002-CC3 (BRN 16ga )

86

63T1-000-CC3 (PUR 16ga )

PC1150JB4C

86

SH5:J-9

1

RSCL2

B

RSCL2

A

J54

EM8074

FRONT VEHICLE HORN PC0566 TIMER WIPER DELAY

63W-000-CC3 (GRY 16ga ) 63W-001-CC3 (GRY 16ga ) 63W-002-CC3 (GRY 16ga )

0-301-DD1 (BLK 16ga )

63-006-CC3 (PNK 16ga )

63-007-CC3 (PNK 16ga )

JB4C

-

+

1 87

11A-001-AA1 (TAN 12ga )

JB6G 56B0611510

1 2 3 4

1

HPR-(+)

58 58

J03

41T-021-DD1 (TAN 16ga )

J04

11A-011-AA1 (TAN 16ga )

63-002-CC3 (PNK 16ga ) 1 2 3 4 5 6

P04

63-000-AC3 (PNK 14ga )

TB10

LRL

C

A

LAMP BODY LEFT REAR MARKER

1

44D-004-CC4 (LBL 16ga )

TB24

VEC91-P10

JB6G

5

DRL

REAR TURN / TAIL / STOP LAMPS

10

41T-028-MM1 (TAN 16ga )

0-253-DD1 (BLK 16ga )

LAMP RETARD OP-CAP

712 BUSS

45RL-016-MM1 (DBL 16ga )

2

RRL PC1914

44-002-AC4 (GRY 16ga )

VEC-91

LAMP BODY RIGHT REAR MARKER

LAMP RETARD RIGHT REAR

INTERFACE MODULE

F50

XB3940

0-307-MM1 (BLK 16ga )

SP174

2

LRL PC1914

44D-006-DD1 (LBL 16ga )

Z

RSCL1

J55

RSCL1

B

41T-024-MM1 (TAN 16ga )

LAMP RETARD LEFT REAR

E1 E2

44D-003-AH2 (LBL 14ga )

SP173

45RL-014-MM1 (DBL 16ga )

C

A

0-306-MM1 (BLK 16ga ) J16

RETARD LAMPS RELAY 15

74ZA-002-AA1 (DGR 20ga )

A

P55

1

H1 H2

A

45RL-013-DD1 (DBL 16ga )

P16

TB35

45RL-015-MM1 (DBL 16ga )

45LL-013-DD1 (BRN 16ga )

TB60

87

30

44-003-AH2 (GRY 14ga )

1

VEC-89

85

SP172

TB60

45RL-012-AH2 (DBL 16ga )

16 16

44-001-AA1 (GRY 14ga )

SERVICE BRAKE LAMP RELAY 9

D1 D2

45LL-012-AH2 (BRN 16ga )

SH9:M-19

PC3010

1

PL AK7513 PL

0-297-DD3 (BLK 16ga )

SP169

TIMER REAR SERVICE LAMP (PLT)

0-299-DD3 (BLK 16ga )

1 3

T

11AL-000-DD3 (BRN 16ga )

PLT-3

11ALT-000-DD3 (WHT 14ga )

REAR AXLE SERVICE LAMP

SWITCH REAR SERVICE LAMP (PLS) 1 2

PLS-2

1 NO

SR8325

3 1

PLS-3

C 1

PLT-NO NC PC2644

PLT-C

58E-06-02000-00 NOV 11 ELECTRICAL SCHEMATIC 830E-1AC A40851 & UP Sheet 11 of 20

GB31-A AUXBOX GND BLCK

GE CONTROL INTERFACE

D4

ADVANCED IDLE #1 REQ

z

1

58B-06-00120

0-443-AA2 (BLK 18ga ) 0-601-AA2 (BLK 18ga )

SH10:P-8

33ES1-001-AA3 (GRY 18ga ) NOTE: REMOVE JUMPER BAR AND GROUND WIRE (0-443) FOR 930E-4 MODEL TRUCKS

ADVANCED IDLE #2 REQ

g

EB7418

33ES2-001-AA3 (YEL 18ga )

TB26

2

1

A4 A1

1

1

A2 A3

1

B2 B1

1

B4 B3

1

1

1

2000.0

SH7:F-8

71BC-001-AA2 (DGR 18ga )

R23

33ES1-002-AA2 (GRY 18ga )

33ES1-000-AA1 (GRY 20ga )

SH13:A-2

33ES2-000-AA1 (YEL 20ga )

SH13:A-2

33ES2-002-AA2 (YEL 18ga ) 58B-06-00120 2

P302 SP LIMIT-ON/SYS NOT READY-ON W

79W-001-AA3 (GRY 18ga )

1

TB26

1

2000.0

SH7:F-8

71BC-002-AA2 (DGR 18ga )

R34

C2 C1

1

79W-000-AA1 (GRY 20ga )

SH13:B-2

E2 E1

1

75NP-001-AA3 (WHT 18ga )

1

75NP-000-AA1 (WHT 20ga )

SH13:B-2

NO PROPEL / NO RETARD DRIVER M

75-GP-001-AA3 (LBL 18ga )

1

F2 F1

1

75-GP-000-AA1 (LBL 20ga )

SH13:B-2

LINK ENERGIZED LIGHT DRIVER

Y

75LE-001-AA3 (TAN 18ga )

1

G2 G1

1

75LE-000-AA1 (TAN 20ga )

SH13:B-2

RETARD REDUCED LVL DRIVER

f

76LR-001-AA3 (DBL 18ga )

1

H2 H1

1

76LR-000-AA1 (DBL 20ga )

SH13:C-2

PROPEL SYS REST LIGHT DRIVER

T

PROPEL SYS NOT READY DRIVER

N

NO PROPEL DRIVER-LOW D

TB22

72PR-001-AA3 (YEL 18ga )

1

72NR-001-AA3 (DBL 18ga )

1

J1

1

K2 K1

1

J2

D11

A 4A

72PR-000-AA1 (YEL 20ga ) 72NR-000-AA1 (DBL 20ga )

H 4H

4B

B

72NR1-000-AA1 (LBL 20ga )

VHMS MODULE / ORBCOMM MODULE / KWB MODULE

SH13:C-2

D12

KOMTRAX PLUS MODULE

VEC-90

COMM_CAN_H_0 (RPC)

TB26 REDUCED PROPEL DRIVER

F

PROPEL SYS OVERTEMP LIGHT

Z

P304

TRUCK SPEED FM SIGNAL

TRUCK SP FM SIG

J2

J1

1

72LP-000-AA1 (BRN 20ga )

SH13:C-2

34TW-001-AA3 (GRY 18ga )

1

D2 D1

1

34TW-000-AA1 (GRY 20ga )

SH13:D-2

MC722

SH15:K-3 SH15:J-3

SHIELD-908

ACCEL INHIBIT

G

MC276

19 19 20 20 21 21

J02

MC275

MC276

77-002-AC2 (WHT 18ga ) 77A-002-AC2 (BLK 18ga )

P02

MC274

TB21 1

510E2-000-AA3 (DGR 18ga )

A1

HYD LADDER ACCEL INHIBIT (OPT)

P303

b

A2

1

510E2-001-AA1 (DGR 20ga )

SH7:H-19

A4

1

510E2-003-AA1 (DGR 18ga )

SH15:N-14

1

75A2-000-AA3 (BRN 18ga )

TB35 V1 V2

SHIELD-618 SHIELD-613

SH12:F-18 SH5:J-12 1

77-003-AA4 (WHT 18ga ) 77A-003-AA4 (BLK 18ga )

TB26

1

K2 K1

1

1

K4 K3

1

1

L2 L1

1

1

L4 L3

1

1

M2 M1

1

1

M4 M3

1

28 28

71P-005-AA1 (BRN 16ga )

26 26

MC272

SH14:K-8 SH14:K-8

u

1

71F-000-AA3 (LTG 18ga ) SH14:J-8

71F-002-AA4 (LTG 16ga )

1

TB35

1

S3

1

S4

J16

P301

SHIELD-616

1 C

SHIELD-610

NO

1

75A2-002-DD4 (WHT 18ga )

C

C

NC

1

75A1-000-DD4 (RED 18ga )

A

A

B

B

EM1179

71P-010-AH2 (BRN 14ga )

SP180

71P-014-DD4 (BLK 18ga ) 1 1

71P-011-AH2 (BRN 16ga )

TB61 J2

1

H1 H2

1

J1

J703

15VDI-002-AA3 (WHT 18ga )

1

SNSR & CNTRL +15V SUPP2

J

15VDI-003-AA3 (WHT 18ga )

SNSR & CNTRL -15V SUPP1

L

-15VDI-002-AA3 (LTG 18ga )

SNSR & CNTRL +5V SUPP1 A SNSR & CNTRL +5V SUPP2 C SNSR & CNTRL +5V SUPP3 E SNSR & CNTRL +5V COMM1 SNSR & CNTRL +5V COMM2 SNSR & CNTRL +5V COMM3 SNSR & CNTRL -15V COMM1 SNSR & CNTRL +15V COMM1 SNSR & CNTRL +15V COMM2

5VDI-002-AA3 (YEL 18ga ) 5VDI-003-AA3 (YEL 18ga ) 5VDI-004-AA3 (YEL 18ga )

B D F M H K

H

DID PANEL RS232 RECEIVE

D

DID PANEL RS232 TRANSMIT

C

DID PANEL COMM RS232 SHIELD

PSC RS232 RECEIVE

O

1 2

MC279

270.0

22 22

15VDI-000-CC2 (WHT 14ga )

6

6

1

V1 V2

1

-15VDI-001-AC2 (LTG 14ga )

23 23

-15VDI-000-CC2 (LTG 14ga )

9

9

1

W1 W2

1

5VDI-001-AC2 (YEL 14ga )

25 25

5VDI-000-CC2 (YEL 14ga )

5

5

0COM-003-AA3 (BLK 14ga )

SP182

24 24

MC279

TB25

1

A1 A2

90DIR-000-AA3 (WHT 18ga )

1

B1 B2

1

90DIT-000-AA3 (RED 18ga )

1

C1 C2

1

MC280

90CAR-000-AA3 (WHT 18ga )

1

1

D1 D2

TB25

MC277

1

1

E1 E2

1

MC277

90DIG-001-AC2 (BLK 18ga ) 90DIR-001-AC2 (WHT 18ga )

31 31

90DIT-001-AC2 (RED 18ga )

30 30

SHIELD-620

SHIELD-620

33 33

P02

MC286

MC286

90CAR-001-AC2 (WHT 18ga )

MC278

32 32

MC278

3

3

90DIR-002-CC2 (WHT 18ga )

2

2

90DIT-002-CC2 (RED 18ga )

1

1

90DIG-002-CC2 (BLK 18ga )

DID

SHIELD-621

MC283

42 42

90CAR-002-CC2 (WHT 20ga )

MC283

3

F1 F2

1

90CAT-001-AC2 (RED 18ga )

41 41

90CAT-002-CC2 (RED 20ga )

2

PSC RS232 GND

d

90CAG-000-AA3 (BLK 18ga )

1

G1 G2

1

90CAG-001-AC2 (BLK 18ga )

43 43

90CAG-002-CC2 (BLK 20ga )

5

PSC RS232 SHIELD

X

1

H1 H2

1

TCI RS232 RECEIVE

k

TCI RS232 TRANSMIT

q

TCI RS232 GND

r

TCI RS232 SHIELD

s

MMS RS232 TRANSMIT

MMS RS232 GND

MMS RS232 SHIELD

x

MC287

MC287

44 44

JUMPER7 JUMPER2 JUMPER6 JUMPER5 JUMPER1 CONNECTOR_SEL2_(GND) GND_SIG4 JUMPER8

MC284

MC284

1

90TCT-000-AA3 (RED 18ga )

1

R1 R2

1

90TCT-001-AC2 (RED 18ga )

56 56

90TCT-002-CC2 (RED 20ga )

2

90TCG-000-AA3 (BLK 18ga )

1

S1 S2

1

90TCG-001-AC2 (BLK 18ga )

58 58

90TCG-002-CC2 (BLK 20ga )

5

1

T1 T2

1

MC282

90MMR-000-AA3 (WHT 18ga )

1

1

1

90MMG-000-AA3 (BLK 18ga )

SHIELD-630

SHIELD-630

1

TB36 G1 G2

1

F1 F2

1

F4

1

H1 H2

1

H4

1

J2

J1

MC288

MC288

90MMR-001-AC2 (WHT 18ga )

SEE NOTE 1

1

57 57

SHIELD-635

1

G4

90TCR-001-AC2 (WHT 18ga )

SHIELD-635

59 59

90TCR-002-CC2 (WHT 20ga )

MC285

90MMR-002-CC2 (WHT 20ga )

MC285

2

90MMG-001-AC2 (BLK 18ga )

26 26

90MMG-002-CC2 (BLK 20ga )

5

29 29

P02

MC289

J02

SHIELD-654

72RQ-003-AA3 (GRY 18ga )

K1 K2

1

GB10 FRT CAB GND

K4

1

72RQ-004-AC3 (GRY 16ga ) 72RQ-002-AA1 (GRY 14ga )

P304

46 46

B

0-317-CC3 (BLK 16ga )

72RQ-005-CC3 (GRY 16ga )

1

D71

2

A

71P-007-AC3 (DGR 16ga )

27 27

1

72GD-000-AA3 (DBL 18ga )

TB23 S1 S2

1

72GD-001-AC3 (TAN 16ga )

8

8

90VHR-004-AA1 (RED 20ga )

90VHG-003-AC4 (BLK 18ga )

T1 T2

1

90VHG-004-AA1 (BLK 20ga )

5

1

X1 X2

1

SH12:E-6

7

PWR_IN_BRY_1

8

71VHM-003-CC4 (DGR 16ga )

PWR_IN_BRY_2

9

71VHM-004-CC4 (DGR 16ga )

GND_PWR2 12 GND_PWR3 19

8

8

71VHM-001-AC4 (DGR 16ga )

1

85-001-AC4 (GRY 14ga )

1

GND_PWR4 20

1

B1 B2

1

C1 C2

1

85-002-CC4 (GRY 14ga ) 85-003-CC4 (GRY 16ga )

SP187

GND_COMM (ORBCOMM) 1

GE - TCI DIAGNOSTIC DIAG 3 CONNECTOR

VEC-90

F47 5

VEC-91

4H

1 2 3 4 5 6

85-004-CC4 (GRY 16ga ) 85-005-CC4 (GRY 20ga ) 85-006-CC4 (GRY 20ga ) 85-007-CC4 (GRY 20ga )

10

0-347-CC4 (BLK 14ga ) 0-348-CC4 (BLK 18ga ) 0-349-CC4 (BLK 18ga ) 0-350-CC4 (BLK 18ga ) 0-351-CC4 (BLK 18ga )

1 2 3 4 5 6 7 8

85-007-CC4 (GRY 20ga ) 85-006-CC4 (GRY 20ga ) 85-005-CC4 (GRY 20ga )

56B0611530

40 PWR_IN_BATT2 36 POWER_CTR_KEY

38 GROUND2 37 GROUND1 29 DOUT (GND)

7HMWU-000-CC4 (YEL 20ga )

19 WAKE UP

COMM_232C_RXD_1 (ORBCOMM) 10

900CT-000-CC4 (WHT 20ga )

5

RS232 VHMS-R/ORB-T

900CR-000-CC4 (RED 20ga )

4

RS232 VHMS-T/ORB-R

P4B GND_SIG2

9

CNA

SHIELD-911

COMM_LAN_TX_+

1

J14-CC7 (BLK 18ga )

71VHM-005-CC4 (DGR 20ga ) 0-354-CC4 (BLK 20ga ) MC679

MC679

90ER1-000-CC4 (ORG 24ga ) TW1

COMM_LAN_TX_- 2 COMM_LAN_RX_+

90ER2-000-CC4 (W-OR 24ga ) TW1

3

90ET1-000-CC4 (GRN 24ga ) TW2

COMM_LAN_RX_- 6

90ET2-000-CC4 (W-GR 24ga ) TW2

P5

SH13:L-2 DIS_L_SNAPSHOT.SW1

2

DOS_L_LAMP 16

7826122502

73DS-005-CC4 (TAN 18ga )

SH13:F-2

74DS-000-CC4 (GRY 18ga )

SH13:F-2

KOMATSU WIRELESS BRIDGE (OPT) KWB

6

5

7

6

GND

2

24VDC

4

TX (+)

11 3

TX (-)

1

2

RX (+)

12 1

RX (-)

P653

P3B

72RR-001-CC3 (ORG 16ga )

ANTENNA KWB MODULE (OPT)

T3

CONN_SEL3 (OPEN) 12

GE - MM DIAGNOSTIC DIAG 8 CONNECTOR

T1

39 PWR_IN_BATT1

11 RS232 GND

9

ANTENNA ORBCOMM SATELLITE / GPS (OPT)

ORBCOMM MODULE (OPT)

900CG-000-CC4 (BLK 20ga )

GND_COMM (ORBCOMM) 2

11 BUSS

JB6E

3

4

F29

JB8A

P2A

COMM_232C_TXD_1 (ORBCOMM)

71CK BUSS

56B0611510

0-351-CC4 (BLK 18ga )

PWR_CTR_EXT 17

H

1B

VEC91-P4

SH14:E-8

P04

B

85-000-AA1 (GRY 14ga )

0-353-CC4 (BLK 20ga )

GE - PSC DIAGNOSTIC DIAG 1 CONNECTOR

SH10:L-3

0-446-AA1 (BLK 18ga )

71VHM-000-AA1 (DGR 16ga )

9

P1

58B-06-00110

TB28

85-004-CC4 (GRY 16ga )

0-350-CC4 (BLK 18ga )

X4

J6

85-003-CC4 (GRY 16ga )

0-349-CC4 (BLK 18ga )

1 X5

0-232-AA2 (BLK 16ga )

VHMS

SHIELD-825

J653_CP

EM8041

P35

PC2146

71P-008-CC3 (DGR 16ga )

72GD-003-CC3 (TAN 16ga )

SWITCH GRID DRY

3 3

72GD-002-CC3 (TAN 16ga )

2

6

GB31-B AUXBOX GND BLCK 1 B3

0-319-CC3 (BLK 16ga )

7826148502

A A

B B

4

0-322-AA3 (BLK 18ga ) 0-323-AA3 (BLK 18ga )

V1 V2

1

72RR-001-CC3 (ORG 16ga )

1 1 6

BATT CHG SYS FAIL IND RTN h DIG OUT RET-CONN TO GND k

90VHR-003-AC4 (RED 18ga )

3

SHIELD-824

AUXBOX KOMTRAX DIAGNOSTIC CONNECTOR

2

5

6

0-318-CC3 (BLK 16ga ) b

6

PWR_IN_BATT2

MC702

1

90VHT-004-AA1 (WHT 20ga )

P1

P35 SH10:H-12

ENG WARMUP REQ

PWR_IN_BATT1

MC702

1

SHIELD-824

P04

TB29

2

3 4

72RR-000-CC3 (ORG 16ga )

PC2834

SH4:B-4

J04

(BLK 20ga ) (BLK 20ga ) (BLK 20ga ) (BLK 20ga )

J04

SH13:L-2

SWITCH DC POWER OFF - REST SWITCH 1

J23-CC8 J24-CC8 J25-CC8 J26-CC8

71VHM-002-CC4 (DGR 16ga )

SH13:L-2

90MMG-003-AA1 (BLK 20ga )

C1

1 2 3 4 5 6

19 19

1

1

17 17 18 18

MC701

W1 W2

90VHT-003-AC4 (WHT 18ga )

0-346-AC4 (BLK 14ga )

DIAG8

SHIELD-633

90MMT-003-AA1 (RED 20ga )

TB23 1

3

90MMT-002-CC2 (RED 20ga )

1

O

1 SE1-000-CC4 (BLK 20ga ) 2 SE2-000-CC4 (BLK 20ga ) 3 SE3-000-CC4 (BLK 20ga ) 4 SE4-000-CC4 (BLK 20ga ) 5 SE5-000-CC4 (BLK 20ga ) 6 SE6-000-CC4 (BLK 20ga ) SE9-000-CC4 (BLK 20ga ) SP730 SE7-000-CC4 (BLK 20ga ) P6A SE8-000-CC4 (BLK 20ga )

MC701

16 16

P2B

27 27

SHIELD-636

TERMINAL BLOCK SPLIT UP. SEE CONNECTOR CHART FOR LOCATIONS

3

90MMT-001-AC2 (RED 18ga )

90MMR-003-AA1 (WHT 20ga )

MC700

GE DID PANEL

DIAG3

SHIELD-632

28 28

SHIELD-636

J5 1

P303

REST REQUEST

16 5 15 14 3 9 13 4

71VHM-002-CC4 (DGR 16ga )

DIAG1

SHIELD-631

P1 P2

90MMT-000-AA3 (RED 18ga )

z

SHIELD-634

1

SHIELD-629

MC282

w

TB25

MC281

90TCR-000-AA3 (WHT 18ga )

SHIELD-629

y

SHIELD-634

SHIELD-821

0-352-CC4 (BLK 20ga )

1

SHIELD-628

5

90VHG-001-CC4 (BLK 20ga )

J02

90CAT-000-AA3 (RED 18ga )

SHIELD-628

3

SHIELD-823

10 10

0COM-000-CC2 (BLK 14ga )

PSC RS232 TRANSMIT W

MMS RS232 RECEIVE

SHIELD-822

GND_PWR1 11

SHIELD-625

MC281

SP194

OP-CAB KOMTRAX DIAGNOSTIC DIAG-6 CONNECTOR

2

90VHR-001-CC4 (RED 20ga )

SP193

90VHG-000-CC4 (BLK 18ga )

MC698

90VHT-001-CC4 (WHT 20ga )

SP192

90VHR-000-CC4 (RED 18ga )

9

MC698

90VHG-002-CC4 (BLK 18ga )

W3

S3

SP191

9

15VDI-001-AC2 (WHT 14ga )

0COM-001-AC2 (BLK 14ga )

MC699

13 13

1

1

90VHT-000-CC4 (WHT 18ga )

SH10:L-5

10V-007-AC2 (LBL 18ga )

R17

1

SHIELD-817

SH13:G-5

71F-003-AA1 (LTG 20ga )

T3 T4

S1 S2

SH15:C-20

939GE-010-CC4 (GRN 20ga )

P3A

BUSW

1

1

SH15:C-20

90VHR-002-CC4 (RED 18ga )

71P-013-DD2 (BRN 16ga )

1

0COM-002-AA3 (BLK 14ga )

SP181

90DIG-000-AA3 (BLK 18ga )

MC280

15VDI-004-AC2 (WHT 18ga )

2

MC696

939YE-010-CC4 (YEL 20ga )

P703

1 2

PC2818

BUSW

1

MC696

75A2-004-DD2 (BRN 16ga )

T1 T2

1

SHIELD-625

V

P16

3 4

SH15:E-20

90VHT-002-CC4 (WHT 18ga )

TB22

0COM-004-AA3 (BLK 18ga ) 0COM-005-AA3 (BLK 18ga ) 0COM-006-AA3 (BLK 18ga ) 0COM-007-AA3 (BLK 18ga ) 0COM-008-AA3 (BLK 18ga ) 0COM-009-AA3 (BLK 18ga )

P302 DID PANEL RS232 GND

3 4

71F-004-AH2 (LTG 16ga )

SH15:E-20

SHIELD-816

P4A

58B-06-00970

SNSR & CNTRL +15V SUPP1 G

4

GND_COMM (PC TOOL)

SH13:E-2

77A-001-AA1 (BLK 20ga ) SWITCH TRACTION MOTOR PRESSURE (BPSW)

75A2-003-AH2 (BRN 16ga )

25 25

71F-001-AA1 (LTG 18ga )

TB21

COMM_CAN_H_1 (J1939)

MC695

939YP-010-CC4 (YEL 20ga ) 939GP-010-CC4 (GRN 20ga )

COMM_232C_RXD_0 (PC TOOL) 10

SWITCH BODY-UP PROXIMITY

S1 S2

5

COMM_232C_TXD_0 (PC TOOL) 11

71P-012-AH2 (BRN 16ga )

DIG IN (BODY DOWN)

COMM_CAN_SH_0 (RPC)

COMM_CAN_L_1 (J1939) 12

SH13:D-2

77-001-AA1 (WHT 20ga )

1 M5

0-232-AA2 (BLK 16ga ) 0-233-AA2 (BLK 16ga )

75A2-001-AA1 (BRN 16ga ) SH10:H-12

COMM_CAN_L_0 (RPC) 14

COMM_CAN_SH_1 (J1939) 13

77A-000-AA3 (BLK 18ga ) SHIELD-613

MC275

SHIELD-618

77-000-AA3 (WHT 18ga )

f Y

MC722

77-005-CC2 (WHT 18ga ) 77A-005-CC2 (BLK 18ga )

MC274

R

DIFF TRUCK SPEED SIG SHIELD

N.O. AXLE BOX AIR PRESS SW

72LP-001-AA3 (BRN 18ga )

1

MC695

6

2

71P-009-CC3 (DGR 16ga )

5 5

4 C C

D D

P34

PC2317

P34

J20-CC3 (WHT 16ga )

PRESHIFT BK TEST LIGHT DRIVER PRESHIFT BRAKE TEST

j a

1

33SBA-000-AA3 (YEL 18ga )

1

72SBT-000-AA3 (WHT 18ga )

TB25 W1 W2 X1 X2

SWITCH BRAKE TEST 1 1

33SBA-001-AC3 (YEL 16ga ) 72SBT-001-AC3 (DBL 16ga )

37 37 43 43

33SBA-002-CC3 (YEL 16ga )

B B

72SBT-002-CC3 (DBL 16ga )

3 3

P305

33SBA-003-CC3 (YEL 16ga )

0-320-CC3 (BLK 16ga )

6

F57 10

VEC-89

4G

TB35 G

712P-000-AA1 (YEL 16ga )

1

D1 D2

1

712P-001-AC3 (YEL 16ga )

15 15

P03

J03

712P-002-CC3 (YEL 16ga )

712P-003-CC3 (YEL 16ga )

2

5 5

4

0-132-CC3 (BLK 16ga )

SH9:M-9

C C

D D

P37 712 BUSS

2

1 1 6 4

SH7:K-19

A A

PC2648

P37

0-321-CC3 (BLK 16ga ) J13-CC3 (WHT 16ga )

GE INTERFACE

NOTES: ---------------------------------------------------------------------------1) DISSCONNECT WIRE 90MMR-003 AT TB36-G4 WHEN MODULAR MINING IS CONNECTED.

58E-06-02000-00 NOV 11 ELECTRICAL SCHEMATIC 830E-1AC A40851 & UP Sheet 12 of 20

INTERFACE MODULE SWITCH DRIVERS SEAT BELT

TB28

SH12:A-9

L

33ES1-000-AA1 (GRY 20ga )

BRAKE COOLING RPM ADVANCE 1

OPERATOR SEAT BELT SWITCH

g

62SB-000-AA1 (ORG 20ga )

IM2

SH12:A-9

X

33ES2-000-AA1 (YEL 20ga )

1

1

X1 X2

62SB-001-AC2 (ORG 18ga )

BRAKE COOLING RPM ADVANCE 2

1

0-330-AC2 (BLK 18ga )

SEAT BELT ALARM OPTION

79W-000-AA1 (GRY 20ga )

t

PROP SYSTEM CAUTION

SH12:B-9

75NP-000-AA1 (WHT 20ga )

p

PROP SYSTEM NO PROPEL

SH12:B-9

75-GP-000-AA1 (LBL 20ga )

n

PROP SYSTEM NO PROP/RET

SH12:B-9

75LE-000-AA1 (TAN 20ga )

b

LINK VOLTAGE

SH12:C-9

76LR-000-AA1 (DBL 20ga )

r

PROP SYSTEM LOW RETARD

SH12:B-9

STEERING BLEED SOLENOID

J

SH12:C-10

P

1

33JB-000-AA1 (LTG 20ga )

TB30

c

72NR1-000-AA1 (LBL 20ga )

10 10

J14

SH12:C-9

72LP-000-AA1 (BRN 20ga )

SH12:D-9

34TW-000-AA1 (GRY 20ga )

A

PROP SYSTEM REDUCED LEVEL PROP SYSTEM TEMP CAUTION

KEYSWITCH OR INPUT

FUEL LEVEL SENSOR

IM3

SH12:D-9

MANUAL MODE AUTO APPLY PRESSURE SWITCH

33JB-002-AJ2 (LTG 16ga )

2

33JB-003-AJ2 (LTG 16ga )

SP183

1

BF4493

ACCBD

77-001-AA1 (WHT 20ga )

g

P14

D26

2

D26

TB35

1

38G-000-AA1 (GRY 20ga )

C1 C2

1

C4

1

h

77A-001-AA1 (BLK 20ga )

1

PC2834

MC705

939YE-008-AA1 (YEL 20ga )

SH15:C-9

939GE-008-AA1 (GRN 20ga )

r

CAN/J1939-HI

s

CAN/J1939-LO

q

CAN/J1939-SHLD

12 12

SH12:L-16

11 11

74DS-000-CC4 (GRY 18ga )

J04

f

1

33-002-AA1 (BRN 20ga )

SH10:J-5

73DS-003-AC4 (TAN 16ga )

1

74DS-001-AC4 (GRY 18ga )

M2 M1

1

L

74DS-002-AA1 (GRY 20ga )

SNAPSHOT IN PROGRESS

BRAKE ACCUMULATOR PRESSURE

U

1

33BP-002-AA1 (WHT 20ga )

R

71F-003-AA1 (LTG 20ga )

BODY DOWN SWITCH

MC653

1

18VIM-002-AJ2 (BLK 18ga )

2

MC653

26 26

33SP-002-AJ2 (WHT 18ga )

SPS

28 28

SENSOR HOIST PRESSURE #1

2

MC651

1

18VIM-004-AH2 (BLK 18ga )

2

MC651

SHIELD-732

BRAKE PRESSURE DEGRADATION

V

18VIM-003-AA1 (BLK 18ga ) 33HP1-001-AA1 (WHT 18ga )

SHIELD-733

SHIELD-001-AA1 (BLK 16ga )

1

1

33T-002-AA1 (DBL 20ga )

1 2

1

18VIM-006-AH2 (BLK 18ga )

2

MC649

33HP2-002-AH2 (WHT 18ga )

HPS2

PC1537

5

SHIELD-730

5

6

6

7

7

P16

MC650

B

DIAGNOSTIC RS232/GND

C

1

N1

SHLD_731-AA1 (BLK 18ga )

SP773

P702 12 12

1

39AP-001-AH2 (YEL 16ga )

1

18VIM-005-AA1 (BLK 18ga )

TB28 1

HOIST PRESSURE 1

CAN/RPC-SHLD

21 21

TB32 D1 D2

TB32 E1 E2

4

0-326-AH2 (BLK 16ga )

P16

J730

TB32 F1 F2

1

HOIST PRESSURE 2

LOW HYD TANK LEVEL

IM3

K1

2

PC1537

2

33BPS-002-BB1 (WHT 14ga )

MC647

SHIELD-728 SP774

BPS

SHLD-647-BB1 (BLK 14ga )

A

B

B

M M

j c i

r

MC648

D

SHIELD-729 SP775

SH13:K-12

LEFT FRONT BRAKE TEMPERATURE

BRAKE PRESSURE

P240

AMBIENT AIR TEMPERATURE D

HFSW1

XA5166

S

S

A NC

C

t

1

N

33T-001-AB1 (DBL 14ga )

MC720

MC703

N

p

C

e

90MMR-003-AA1 (WHT 20ga )

SH12:L-10

90MMT-003-AA1 (RED 20ga )

E

MMS RS232/TRANSM

SH12:L-10

90MMG-003-AA1 (BLK 20ga )

F

MMS RS232/GND

SP185

SFSW

XA5166

SFSW

0-328-HH4 (BLK 16ga )

GB8 BRAKE CABINET 1

0-338-BB1 (BLK 16ga )

2

LBPS

C

TB30

EB7418

1

A1 A2

1

L1 L2

1

MC718

MC718

N1 N4

90IMR-002-AC2 (WHT 18ga )

53 53

90IMR-003-CC2 (WHT 20ga )

3

1

P1 P4

1

90IMG-002-AC2 (BLK 18ga )

54 54

90IMG-003-CC2 (BLK 20ga )

5

1

R1 R4

1

R2

SHIELD-894

1

0-361-AA1 (BLK 18ga )

1

1

1

C1 C2

1

K2

1

H1 H2

1

K3

C4

1

B4 B3

1

G1 G2

1

K4

1

1

1

M2 M1

1

B1

1

J2

1

L4

1

J1

MC719

29 29 31 31 30 30 32 32

0-423-AA1 (BLK 18ga )

2

SH13:H-14

19 19

34BT2-000-AA1 (WHT 18ga )

SHIELD-711

SHIELD-725

SHIELD-712 MC642

MC648 33BPS-001-AB1 (WHT 14ga )

P712

MC634

34BT4-000-AJ2 (WHT 16ga )

EK8243 SENSOR HYDRAULIC TANK TEMP A B

5VIM-005-AJ2 (BLK 16ga )

1 2

P711

SHIELD-700

AK7339

40 40 39 39 38 38 37 37

MC642

5VIM-003-AA1 (BLK 18ga )

MC634

14 14

SHIELD-711

34BT1-000-AA1 (WHT 18ga )

A +VDC SUPPLY B GROUND C SIGNAL

15 15

MC641

5VIM-004-AA1 (BLK 18ga )

24VIM-009-AJ2 (RED 16ga ) 0-340-AJ2 (BLK 16ga ) 34LL-002-AJ2 (WHT 16ga )

13 13

MC640

5VIM-002-AA1 (BLK 18ga )

SENSOR HYDRAULIC TANK LEVEL

MC635

SHIELD-701

20 20

SHIELD-710

34BT3-000-AA1 (WHT 18ga )

MC641

AUXBOX IM DIAGNOSTIC CONNECTOR

MC635

18 18

MC639

5VIM-006-AA1 (BLK 18ga )

MC640

DIAG5

5

34BT4-001-AA1 (WHT 18ga )

0-447-AA1 (BLK 18ga )

OP-CAB IM DIAGNOSTIC DIAG-5 CONNECTOR

J372

24VIM-008-AA1 (LBL 16ga ) 0-341-AA1 (BLK 16ga )

SHIELD-710

2

J02

SH6:E-12 SH7:I-16

34LL-001-AA1 (BRN 20ga )

90IMT-003-CC2 (RED 20ga )

SHIELD-893

3

SHIELD-709

SHIELD-709

1

P02

SH13:J-12

0-447-AA1 (BLK 18ga )

0-267-AA2 (BLK 16ga ) 0-238-AA2 (BLK 16ga )

1

SH5:J-5

1

55 55

SHIELD-894

GB31-B AUXBOX

90IMG-001-AA1 (BLK 20ga ) X3 X1

MC717

1

90IMR-001-AA1 (WHT 20ga )

MC639

1

MC717

52 52

K1 B2

0-339-BB1 (BLK 16ga )

BDS

PC1678

90IMT-001-AA1 (RED 20ga )

TB24 1

B

90IMT-002-AC2 (RED 18ga )

SH5:I-5 1

34BT4-002-AA1 (WHT 20ga )

34AT-002-AA1 (WHT 20ga )

B

0-337-BB1 (BLK 16ga )

B

PC2552

BDS

TB28

1

34LL-001-AA1 (BRN 20ga )

MMS RS232/RECIEV

SH12:L-10

J240

SH15:E-7

SH4:J-10

33BPS-000-AA1 (WHT 20ga )

C

A NC

39SP-000-HH4 (BRN 16ga )

PBPSW

PC2469

C NO

33T-000-BB1 (DBL 14ga )

SH15:E-7

SP198 SHIELD-834

34BT1-001-AA1 (WHT 20ga )

B

75 PSI

C NO

33BP-000-BB1 (WHT 14ga )

90IMG-000-AA1 (BLK 20ga )

SHIELD-001-AA1 (BLK 16ga ) SHLD_731-AA1 (BLK 18ga )

B

C NO

HFSW2

XA5166

HFSW2

33-000-BB1 (BRN 14ga )

90IMR-000-AA1 (WHT 20ga )

34BT2-001-AA1 (WHT 20ga )

C

A NC

39HP-000-HH4 (LBL 16ga )

LBPS

SHLD-648-AB1 (BLK 14ga )

MC289

D

1

34BT3-001-AA1 (WHT 20ga )

PC2810

SWITCH PARK BRAKE SET

33BP-001-AB1 (WHT 14ga )

939GP-008-AA1 (GRN 20ga )

SH13:H-6 SH13:I-6

18VIM-007-AB1 (BLK 14ga ) 33BPS-001-AB1 (WHT 14ga )

B

P730

1

5VIM-001-AA1 (ORG 20ga ) 5VIM-000-AA1 (ORG 20ga )

GROUND

SWITCH SERVICE BRAKE DEGRADE PRESSURE

939YP-008-AA1 (YEL 20ga )

k

2

0-327-HH4 (BLK 16ga )

M1 M4

SHLD-834-AA1 (BLK 20ga )

+ VDC SIGNAL

SWITCH STEERING FILTER #1

SWITCH LOW BRAKE ACCUM PRESSURE 1

90IMT-000-AA1 (RED 20ga )

J16

A

J240

i

HYDRAULIC TANK TEMPERATURE m

SHIELD-731

RIGHT FRONT BRAKE TEMPERATURE

18VIM-008-BB1 (BLK 14ga )

C

PBPSW

IM2

NC2

1

C NO

NO

4

33-001-AB1 (BRN 14ga )

IM1

+5V SENSOR

1

MC703

1

0-324-HH4 (BLK 16ga )

P730 SWITCH HYDRAULIC FILTER #2

C NO

0-387-AA1 (BLK 20ga )

+5V SENSOR MONITOR

SENSOR BRAKE PRESSURE MC647

j

SENSOR FUEL LEVEL

3

J730

A NC

39AP-002-HH4 (YEL 16ga )

SHIELD-130

SH13:K-10 q

P16

C

SHIELD-896

CAN/RPC-LO k

s

3

38G-003-AH2 (GRY 14ga )

SWITCH HYDRAULIC FILTER #1

+18V SENSOR

CAN/RPC-HI

33HP2-000-AA1 (WHT 20ga )

33HP2-001-AA1 (WHT 18ga )

DIAGNOSTIC RS232/RECIEV

MC720

W1 W4

J3

11 11

J16

IM2 b

18VIM-000-AA1 (WHT 20ga )

TB30

1

SHIELD-731 MC649

A

SH13:K-10

33HP1-000-AA1 (WHT 20ga )

SENSOR HOIST PRESSURE #2

STEERING PRESSURE

DIAGNOSTIC RS232/TRANSM

SP737

SHIELD-735 SHIELD-733 MC652

33 33

d

33SP-000-AA1 (WHT 20ga )

J14

32 32

HPS1

PC1537

T1

SHIELD-735

31 31

33HP1-002-AH2 (WHT 18ga )

1

VEC-89

87-000-AA1 (TAN 18ga )

71CK BUSS

5

38G-004-HH4 (GRY 16ga )

P240

TB30

33SP-001-AA1 (WHT 18ga )

SHIELD-734

P14

1

18VIM-001-AA1 (BLK 18ga )

1

F42

4H

H

87-000-AA1 (TAN 18ga )

A NC

MC654

27 27

1

87-002-AA2 (TAN 18ga )

J2

11 BUSS

10

STEERING BLEED PWR RELAY 14

2

560.0

IM2

SENSOR STEERING PRESSURE

J1

F12

30

87a

J14

A NC

P04 SH12:G-9

TB21

1

AHT ) J9-AA8 (BLK 16ga AUXBOX CONNECTOR (OPT)

0-325-AA1 (BLK 16ga )

IM1

73DS-005-CC4 (TAN 18ga )

D26

HFSW1

PARK BRAKE APPLY PSW

E

33J-000-AA1 (GRY 16ga )

0 BUSS

85

FLS

39AP-000-AA1 (YEL 16ga )

SH5:J-5

7

P14

1

86

1E

R15

J16

SH12:L-16

SP184

71CK BUSS

15

SEAT BELT ALARM (OPT) RELAY 41

VEC-89

33J-003-AJ2 (GRY 16ga )

38G-002-AA2 (GRY 18ga )

15 15

J702

SH15:C-9

7

SH4:J-13

24VIM-002-AA1 (LBL 18ga )

71CK BUSS

1

L2

F63

30

87a

TB32

33J-001-AJ2 (GRY 16ga )

TRUCK SPEED IN -

Y

62SBA-000-AA1 (ORG 14ga )

21 21

52AA2-000-AA1 (BRN 20ga ) 39-000-AA1 (TAN 20ga )

HYDRAULIC PUMP FILTERS PRESSURE

MC705

33J-002-AJ2 (GRY 16ga )

58B-06-00160

16 16

SH12:E-9

87

2G G

86

87

38G-001-AA1 (GRY 16ga )

TRUCK SPEED IN +

H 2H

VEC-89

ACCBD

87-001-AA1 (TAN 20ga )

d

85

SOLENOID STEERING BLEED DOWN

G

g

2A

A

SH7:I-16

0-229-AA2 (BLK 16ga )

R19

IM3 MC272

2

1

33JB-005-AA2 (LTG 18ga )

33JB-004-AJ2 (LTG 16ga ) B

P212

62A-000-AA1 (YEL 20ga )

1

D4

1 1

J02

SEAT BELT ALARM CUSTOMER ATTACHMENT (OPT)

PROPEL SYS AT REST OR NOT READY

XK1267

0-329-CC2 (BLK 18ga )

58B-06-00290

1

D1 D2

IM1

IM2

PC1538

1

2 2

62SB-002-CC2 (ORG 18ga )

62A-000-AA1 (YEL 20ga )

33JB-001-AA1 (GRY 16ga )

2

1

P02 IM1

1

4

P212

GB31-B AUXBOX GND BLCK A4

4

36 36

SH13:K-5 23 23 21 21

SHIELD-725

34AT-001-AA1 (WHT 18ga ) 5VIM-008-AA1 (BLK 18ga )

MC645

34AT-000-AJ2 (WHT 16ga )

22 22

MC646

MC646

IM3

SHIELD-723

A B

5VIM-007-AJ2 (BLK 16ga )

1 2

SENSOR DUCT AIR TEMPERATURE AK7339

ATS J14

P14 SWITCH AUTOLUBE PRESSURE

AUTOLUBE PRESSURE SWITCH

Y

68P-003-AA1 (PUR 20ga ) 68P-004-AA1 (PUR 16ga )

51A2-000-AR1 (BRN 16ga )

C

1

1

W1 W2

1

TB60 1

68P-002-AA1 (PUR 16ga ) 68T-002-AA1 (DBL 16ga )

W3

IM3

SWITCH ACCUMULATOR PRESSURE #1 (ACCP1) 1 NO

TB35

AUTOLUBE SOLENOID

51A1-001-AR1 (LBL 16ga )

19 19

51A1-000-AA1 (LBL 20ga )

T

68T-004-AA1 (DBL 20ga )

IM1

1

R1 R2

1

1

R3 R4

1

C

1

0-335-AR1 (BLK 16ga )

PC0909

P13

SWITCH LOW STEERING PRESSURE C NO

C

A NC

ACPSW

B

20 20

0-336-AA1 (BLK 16ga )

33F-000-AJ2 (DBL 16ga )

6

6

4C

VEC-89

85

33F-001-AA1 (DBL 20ga )

S

4E

NO

C

NC

A

PC1677

SABS

B1 B2

1

24 24

68T-001-AH2 (DBL 14ga )

1

M1 M2

1

10

87a

J16

P16

1

68T-005-AA2 (DBL 18ga )

2

0-345-AA2 (BLK 18ga )

R30

B

68ES-003-AA1 (DBL 16ga )

71CK BUSS 4F

NO

C

NC

A

PC1654

LLPS

58B-06-00290

SP785

68ES-004-AA1 (DBL 16ga ) 68-005-AA1 (TAN 16ga ) 68LS-003-AA1 (DGR 20ga )

F

SH7:I-16

32 32 33 33 34 34

J12

P12 SOLENOID AUTO LUBE

2

2

0-333-AA1 (BLK 16ga )

9

9

AUTOLUBE SOLENOID SENSE

SH5:J-5

33JA-001-AA1 (YEL 20ga )

Z

0-334-AA1 (BLK 16ga )

1

M1 M2

1

68ES-000-AA1 (DBL 16ga )

68-005-AA1 (TAN 16ga ) 68-002-AA1 (TAN 16ga )

P14

1

B2

E

E

54 54

68-003-AH1 (TAN 14ga )

B

B

68LS-002-AA1 (DGR 20ga )

SP786

68LS-004-AA1 (DGR 20ga )

56 56

68LS-001-AH1 (DGR 16ga )

C

C

72AT-000-AA1 (PNK 20ga )

e

AUTO MODE OPERATION REQUEST

72MAN-000-AA1 (LTG 20ga )

s

MANUAL MODE OPERATOR REQUEST

IM2

68ES-002-HH3 (DBL 14ga )

2

LLSOL

68-004-HH3 (TAN 14ga )

1

PC2436

LLSOL

IM3

68LS-000-HH3 (DGR 16ga )

C NO A NC

0-344-AA1 (BLK 16ga )

55 55

J11

TB33

1

68ES-001-AH1 (DBL 14ga )

SH5:I-5

J14

A2

57 57

SWITCH AUTOLUBE LEVEL (OPT) AUTOLUBE GREASE LEVEL W

34 34

68-001-AA1 (TAN 16ga ) 68-000-AA1 (TAN 20ga )

STEERING BLEED PRESSURE SW

33JA-000-AJ2 (YEL 16ga ) 0-332-AJ2 (BLK 16ga )

X

TB34

SH5:I-9

INTERFACE MODULE

LLPS

AUTO LUBE RELAY 29

LOW STEERING PRESSURE

B C

68P-000-DD1 (PUR 14ga )

68T-000-DD1 (DBL 14ga )

2B

30

ACPSW

PC1693

F20

86

87

J13

SWITCH STEERING BLEED PRESSURE

SABS

C

E

0-331-AJ2 (BLK 16ga )

B C

SH5:H-9

1

68T-003-AA1 (DBL 16ga )

SWITCH ACCUMULATOR PRESSURE #2 (ACCP2) 1 NO

68P-001-AH2 (PUR 14ga )

TB35

W LOW STEERING PRE-CHARGE

PC0909

23 23

P11

0-342-AH1 (BLK 16ga )

A

J511

A

P511

ALLSW

0-343-HH3 (BLK 16ga )

XA3247

C

B

ALLSW

58E-06-02000-00 NOV 11 ELECTRICAL SCHEMATIC 830E-1AC A40851 & UP Sheet 13 of 20

SWITCH HEATED MIRROR (OPT)

71LS-015-CC3 (DGR 16ga ) 71LS-014-CC3 (DGR 16ga )

A A

2

B B

2

6 4

C C

P33

TB28 39 39

69MA-000-CC3 (YEL 16ga )

1

69MA-001-AC3 (YEL 16ga )

1

W1 W2

HEATED MIRROR OPTION

1 1

5 5

71LS-013-CC3 (DGR 16ga )

J19-CC3 (BLK 18ga )

3 3 6

J03

P03

4

D D

J18-CC3 (BLK 18ga )

MIRROR HEATED RIGHT DECK (OPT)

69M-001-AA1 (YEL 14ga ) 0-403-AA1 (BLK 14ga )

P33

PC2238

6 7

SH5:H-9

6 7

6 7

69M-003-AH1 (YEL 14ga ) 0-404-AH1 (BLK 14ga )

6 7

69M-005-FH1 (YEL 14ga ) 0-405-FH1 (BLK 14ga )

F G

F G

69M-007-FF1 (YEL 14ga ) 0-406-FF1 (BLK 14ga )

P546

69MA-002-AA1 (YEL 18ga ) J11

G 1G

0 BUSS

85 F53

11 BUSS

86

30

20

1H

87

P11

1

69M-000-AA1 (YEL 12ga )

F1 F2

SH9:M-3

A A

2

11L-003-CC3 (YEL 14ga )

GB10 FRT CAB GND D2

1

B B

VEC-89

SH5:H-9

2

6 4

71LS-012-CC3 (DGR 16ga )

C C

P32

6

J03

1

11RB-001-AC3 (DGR 14ga )

6 7

1

E4

1

E3

1

P03

6 7

69M-006-GJ1 (YEL 14ga ) 0-409-GJ1 (BLK 14ga )

F G

F G

69M-008-GG1 (YEL 14ga ) 0-410-GG1 (BLK 14ga )

1 2

1 2

1 2

J547_CP

L547

1

1

2

2

MIRROR1

J540

P540

4 5

11RB-005-AH1 (DGR 14ga ) 0-395-AH1 (BLK 14ga )

P503

4 5

69M-010-GG2 (YEL 14ga ) 0-431-GG2 (BLK 14ga )

PC2930

D E

11RB-007-FH1 (DGR 14ga ) 0-396-FH1 (BLK 14ga )

D E

1 2

11RB-009-FF1 (DGR 14ga ) 0-397-FF1 (BLK 14ga )

P11

4 5

11RB-003-AA1 (DGR 14ga ) 0-402-AA1 (BLK 14ga )

J541

4 5

4 5

11RB-006-AJ1 (DGR 14ga ) 0-398-AJ1 (BLK 14ga )

P541

4 5

P502

D E

11RB-008-GJ1 (DGR 14ga ) 0-399-GJ1 (BLK 14ga )

J540

P540

P503

1

2

2

PC2930

RIGHT DECK ROTATING BEACON OPTION

1 2

J548_CP

J502

D E

1 2

11RB-010-GG1 (DGR 14ga ) 0-400-GG1 (BLK 14ga )

P549 P12

1

MIRROR2

J503

P548

J12

LEFT DECK ROTATING BEACON OPTION

1 2

J549_CP

J503

J16-CC3 (BLK 18ga ) 11RB-004-AC4 (DGR 14ga )

P32

PC2272

SH5:J-9

6 7

69M-004-AJ1 (YEL 14ga ) 0-408-AJ1 (BLK 14ga )

P12

4 5

J11

E1 E2

4

D D

R546

J502

P547

4 5

11RB-002-AA1 (DGR 14ga ) 0-401-AA1 (BLK 14ga )

TB22 38 38

11RB-000-CC3 (DGR 14ga )

1 1

5 5

0-411-CC3 (BLK 18ga )

J17-CC3 (BLK 18ga )

3 3

P502

J546_CP

69M-009-FF2 (YEL 14ga ) 0-430-FF2 (BLK 14ga )

MIRROR HEATED LEFT DECK (OPT) 6 7

69M-002-AA1 (YEL 14ga ) SH5:J-9 0-407-AA1 (BLK 14ga )

SWITCH ROTATING BEACON (OPT)

71LS-011-CC3 (DGR 16ga )

P541

1 2

1

J12

SH9:C-1

J541

1 2

TB23 H

87a

HEATED MIRROR (OPT) RELAY 39

1 2

GB31-A AUXBOX GND BLCK

ROTATING BEACON OPTION

B4

1

0-427-AC4 (BLK 14ga ) 0-346-AC4 (BLK 14ga ) SH12:G-18 0-091-AC4 (BLK 16ga ) SH5:K-10

GB31A-B4

14 14

11RB-011-CC4 (DGR 14ga )

1

15 15

0-428-CC4 (BLK 14ga )

1

P04

CAB MOUNT ROTATING BEACON OPTION

J04

LAMP RED PAYLOAD RIGHT G

39A-001-AA1 (LTG 18ga )

2G

VEC-90 0 BUSS

PAYLOAD METER III

71CK BUSS

85 F14

30

5

TB34

39A-000-AA4 (LTG 18ga ) 39B-000-AA4 (BRN 18ga ) 39C-000-AA4 (DBL 18ga )

1

S1 S2

1

1

R1 R2

1

1

P1 P2

1

3A

87

39B-001-AA1 (BRN 18ga )

85 30

B

39C-001-AA1 (DBL 18ga )

1

39AA-000-AA1 (DGR 16ga )

3B

K

0 BUSS

85 30

2

0-189-FF1 (BLK 16ga )

RPLR EK9380 RPLR

11 11

11 11

39BA-002-AH1 (LBL 16ga )

L

39BA-004-FH1 (LBL 16ga )

L

1

39BA-005-FF1 (LBL 16ga )

2

RPLA EK9381

0-199-FF1 (BLK 16ga )

SP195

RPLA

LAMP GREEN PAYLOAD RIGHT

B

C

1

39BA-000-AA1 (LBL 16ga )

12 12

12 12

39CA-002-AH1 (YEL 16ga )

M M

39CA-004-FH1 (YEL 16ga )

1

39CA-005-FF1 (YEL 16ga )

TB23

RPLG

D1

J11

87a

P11

J541

P541

P502

J502

2

EK9382

0-158-FF1 (BLK 16ga )

RPLG

SH9:L-18

PAYLOAD AMBER LAMP RELAY 17

2B

1

39AA-005-FF1 (DGR 16ga )

LAMP AMBER PAYLOAD RIGHT

39CA-001-AA1 (YEL 16ga ) 2C

K

39AA-004-FH1 (DGR 16ga )

C1

86 87

10 10

39AA-002-AH1 (DGR 16ga )

TB23

39BA-001-AA1 (LBL 16ga )

2D 0 BUSS

A

87a

PAYLOAD RED LAMP RELAY 16 D

10 10

39AA-001-AA1 (DGR 16ga )

86

0-364-FF1 (BLK 16ga )

LAMP RED PAYLOAD LEFT

39AA-006-AA1 (DGR 16ga )

86 2A

87

A

1

39CA-000-AA1 (YEL 16ga )

10 10

10 10

39AA-007-AJ1 (DGR 16ga )

K

39AA-008-GJ1 (DGR 16ga )

K

1

39AA-009-GG1 (DGR 16ga )

TB23

2

LPLR EK9380

E1

0-367-GG1 (BLK 16ga )

LPLR

LAMP AMBER PAYLOAD LEFT

87a

11 11

39BA-006-AA1 (LBL 16ga )

PAYLOAD GREEN LAMP RELAY 18

11 11

39BA-007-AJ1 (LBL 16ga )

L

39BA-008-GJ1 (LBL 16ga )

L

1

39BA-009-GG1 (LBL 16ga )

2

LPLA EK9381

SP196

0-368-GG1 (BLK 16ga )

LPLA

LAMP GREEN PAYLOAD LEFT

39C-000-AA4 (DBL 18ga ) 39B-000-AA4 (BRN 18ga ) 39A-000-AA4 (LTG 18ga ) SH4:B-3 F46

71CK BUSS

5

4D VEC-90

D

712PL-000-AA1 (LTG 16ga )

1

TB34 V1 V2

39G-001-AA4 (DBL 16ga )

1

1

GREEN LAMP DRIVE AMBER LAMP DRIVE RED LAMP DRIVE

1

+24VDC POWER

J12

3

0-365-AA4 (BLK 16ga )

SCORE BOARD RIGHT (OPT) PWR & COMM GND 1 N/C 1 SIGN TX SIGN RX 24 VDC PWR IN

SH12:G-3

712SL-000-AA1 (DGR 16ga )

28 BRAKE LOCK

39H1-001-AA4 (YEL 16ga )

18 BODY UP

71F-002-AA4 (LTG 16ga )

SH12:D-9 SH12:D-9

MC275

77-003-AA4 (WHT 18ga ) 77A-003-AA4 (BLK 18ga )

MC605

1

P1 P2

1

1

S1 S2

1

35L10-000-FG1 (WHT 16ga ) 712SL-002-FG1 (RED 16ga )

MC607

35L8-001-AF1 (WHT 16ga )

D

SIGN RX

C

SIGN TX

A

PWR & COMM GND 1

T1 T2

1

35L9-001-AF1 (BRN 16ga )

35L7-000-AA4 (BLK 18ga )

1

R1 R2

1

35L7-001-AF1 (BLK 16ga )

15 SPEED INPUT - LO PASSIVE 25 SPEED INPUT - HI PASSIVE

TB34 4

1

73MSL-000-AA4 (BRN 18ga )

X1 X2

1

1

2

1

39F-007-AR1 (BLK 16ga )

2

39FC-003-AR1 (WHT 16ga ) P150

58E-06-10050

14 14 15 15

SHIELD-877

13 13

2

MC713

1

39F-008-AR1 (BLK 16ga )

2

39FD-003-AR1 (WHT 16ga )

58E-06-10050 P151

SHIELD-661

17 17

MC294

16 16

SHIELD-878

18 18

P13

TB36

39FC-001-AA1 (WHT 16ga )

SENSOR PAYLOAD PRESSURE LEFT FRONT 1

39F-001-AA1 (BLK 16ga )

2

1

MC743

2

39F-003-DD1 (BLK 16ga )

SHIELD-661

39F-002-AA1 (BLK 16ga )

2

58E-06-10050

1

MC744

2

P153

1

1

B1 B2

1

C1 C2

1

1

C3 C4

1

1

J3

1

MC294

SHIELD-660

SHIELD-660

J13

J4

39FC-000-AA4 (BLK 18ga )

MC603

0-375-AA4 (BLK 18ga )

SHIELD-663

E

73MSL-001-AA1 (BRN 18ga )

TB61

SHIELD-884

SHIELD-884

40 40 SHIELD-883

D1 D2

1

1

E1 E2

1

39FB-002-AH2 (BLK 16ga )

37 37

39FB-001-AA1 (BLK 18ga )

1

D1 D2

1

39FB-000-AA4 (BLK 18ga )

39F-004-DD1 (BLK 16ga )

1

F1 F2

1

39FA-002-AH2 (WHT 16ga )

39 39

39FA-001-AA1 (WHT 18ga )

1

E1 E2

1

39FA-000-AA4 (WHT 18ga )

39FA-004-DD1 (WHT 16ga )

1

G1 G2

1

39F-011-AH2 (RED 16ga )

38 38

MC744

MC715

MC715 P16

REAR AXLE JUNCTION BOX

J16

TB36

GROUND SIGNAL +18V SUPPLY

7861925330

1 2 3

P246

MC298

39FG-000-AA4 (BLK 18ga ) 39FE-000-AA4 (WHT 18ga ) 39F-012-AA4 (RED 18ga )

SHIELD-664

MC298

J503

1

1

0-369-GG1 (BLK 16ga )

LPLG

SH9:J-18

1

0-363-GG1 (BLK 16ga )

PC1137

85 30

86

VEC-91 TB21

1F

87

F

73MS-000-AA1 (DGR 18ga )

87a

0 BUSS

85

0 BUSS

30

SP744

1

G1 G2

1

G3

1

73MS-001-AA3 (DGR 18ga )

d

0V=70% LOAD, 24V=NOT 70% LOAD

a

0V=100% LOAD, 24V=NOT 100% LOAD

n

24V=OVRLD, 0V=NOT OVRLD

58B-06-00120 1

73MS-002-AA2 (DGR 18ga )

2000.0

2

R21

SH5:A-13

86 1H

87

712-006-AA2 (ORG 18ga )

TB21

H

87a

73LS-000-AA1 (WHT 18ga )

VEC91-P1

PAYLOAD 100 % RELAY 35

1

F1 F2

1

F3

1

73LS-001-AA3 (WHT 18ga ) 58B-06-00120 1

73LS-002-AA2 (WHT 18ga )

2000.0

2

R20

SH5:A-13

TB21 TCI OVER 110%

MC297

9

MC601

MC601

CAN HI 1 11 CAN LO1 21 CAN GND 1 31

19 INCLINOMETER GND 29 INCLINOMETER - SIGNAL

CAN HI 2 12 CAN LO2 22 CAN GND 2 32

P264 EJ3060

939YP-007-AA4 (YEL 20ga ) 939GP-007-AA4 (GRN 20ga )

MC711

SHIELD-860 MC710 SHIELD-858

P264

939YE-009-AA4 (YEL 20ga ) 939GE-009-AA4 (GRN 20ga )

MC710

L1 L2

1

L4

1

M1 M2

1

M4

1

1

N1 N2

1

1

K3 N4

1

1

K4 K2

1

1

K1 K5

1

1

35L4-000-AA4 (WHT 18ga )

MC711

TB36 1

35L2-000-AA4 (BLK 18ga )

35L3-000-AA4 (RED 18ga )

RS232 T1 23

30 SUSPENSION PRESSURE - LR

1

72IP-000-AA4 (DGR 18ga )

40 SUSPENSION PRESSURE - RR

SP743

EK9382

GB LEFT DECK

PAYLOAD 70 % RELAY 34

G 1G

73LSL-001-AA1 (LTG 18ga )

LPLG

2

GE CONTROL INTERFACE

1E

VEC91-P1

39F-009-AA1 (RED 18ga ) MC714 INCLINOMETER

W1 W2

20 SUSPENSION PRESSURE - RF

RS232 GND 1 33

1

1

73LSL-000-AA4 (LTG 18ga )

CNLIN

1 C3

36 18VDC SENSOR SUPPLY

39F-000-AA4 (RED 18ga ) 39F-010-AA4 (RED 18ga )

2

TB34

MC607

GB31-B AUXBOX GND BLCK

SHIELD-673

39 SUSPENSION PRESSURE - LF

39FD-000-AA4 (WHT 18ga ) SHIELD-669

TCI 100%

RS232 R1 13

SHIELD-950 SHIELD-951

SENSOR PAYLOAD PRESSURE RIGHT REAR 1

A2

SHIELD-AA4 (BLK 18ga ) TERMINAL BLOCK SPLIT UP. SEE CONNECTOR CHART FOR LOCATIONS

39FD-001-AA1 (WHT 16ga )

MC743

39FB-003-DD1 (WHT 16ga )

58E-06-10050 P152

A1

1

SENSOR PAYLOAD PRESSURE LEFT REAR 1

1

MC603

SHIELD-883

1

MC295

CNLO

24 VDC PWR IN

1

R4

MC606

712SL-001-AF1 (RED 16ga )

35L9-000-AA4 (RED 18ga )

SHIELD-671

1

39CA-009-GG1 (DGR 16ga )

PWR & COMM GND 2 PWR & COMM GND 3 N/C 2 SIGN TX2 REBROADCAST 24 VDC PWR OUT

N/C 1

RS232 R2 14 RS232 GND 2 34

A B C D E

E

0 BUSS

MC295

P503

B

0 BUSS

MC712

P540

0-370-FG1 (BLK 16ga )

35L8-000-AA4 (WHT 18ga )

TCI 70%

SENSOR PAYLOAD PRESSURE RIGHT FRONT

M M

39CA-008-GJ1 (YEL 16ga )

SCORE BOARD LEFT (OPT)

MC606

A B C D E

RS232 T2 24

MC605 MC275

J540

P12

CNRIN

PC1137

PLM3 GROUND

TB36

SH7:N-8

12 12

39CA-007-AJ1 (YEL 16ga )

SHIELD-929

17 KEYSWITCH

712PL-001-AA4 (LTG 18ga )

GB31-B AUXBOX GND BLCK A3

7 6 5

12 12

39CA-006-AA1 (YEL 16ga )

PAY LOAD METER 3

TO RPC SH15:E-4 NETWORK SH15:E-4 CONNECTOR

MC290

CONNECTOR

1

712-007-AA2 (ORG 18ga ) 72IP-001-AA3 (DGR 18ga )

P304 5

35L2-001-AA4 (BLK 20ga )

35L3-001-AA4 (RED 20ga )

3

35L4-001-AA4 (WHT 20ga )

2

AUXBOX PLM3 DIAGNOSTIC CONNECTOR

J362 SHIELD-656 SHIELD-668

35L2-002-AC2 (BLK 18ga ) 35L3-002-AC2 (RED 18ga ) 35L4-002-AC2 (WHT 18ga )

TO J1939

SH15:C-6 NETWORK SH15:C-6

C1 C2

0-234-AA2 (BLK 16ga ) 0-235-AA2 (BLK 16ga )

SH5:J-12 SH6:E-12

MC602

SHIELD-668

34 34 35 35 36 36 37 37

P02

MC622

SHIELD-688

35L2-003-CC2 (BLK 20ga ) 35L3-003-CC2 (RED 20ga ) 35L4-003-CC2 (WHT 20ga )

MC622

5 3 2

DIAG7

OP-CAB PLM3 DIAGNOSTIC DIAG-7 CONNECTOR

J02

58E-06-02000-00 NOV 11 ELECTRICAL SCHEMATIC 830E-1AC A40851 & UP Sheet 14 of 20

FROM ENGINE CAN J1939

MC258

MC258

SH6:H-9 SH6:H-9

IM CAN TEE

PLM3 CAN TEE CAN TEE J1939 # 1

939YE-001-AE1 (YEL 18ga ) 939GE-001-AE1 (GRN 18ga )

SHIELD-270

MC690 A2 A P303B B2 B C2 C

A A1 B B1 C C1

P301B

A3 A B3 B C3 C

MC690

939YE-003-AA6 (YEL 18ga ) 939GE-003-AA6 (GRN 18ga )

SHIELD-799 MC710

CAN TEE J1939 # 2 A A1 B B1 C C1

SHIELD-799 P304B SH14:O-13 SH14:O-13

939YE-009-AA4 (YEL 20ga ) 939GE-009-AA4 (GRN 20ga )

SHIELD-858

P315B

939YE-008-AA1 (YEL 20ga ) 939GE-008-AA1 (GRN 20ga )

SHIELD-962

MC705

A A1 B B1 C C1

A2 A B2 B C2 C

P316B

SH13:E-4 SH13:E-4

SHIELD-836 P306D

PC0616

MC749

939YE-011-AA10 (YEL 18ga ) 939GE-011-AA10 (GRN 18ga )

SHIELD-962 MC705

A3 A B3 B C3 C

P302D

PC0616

A2 A B2 B C2 C

GE CAN TEE CAN TEE J1939 # 5

A3 A B3 B C3 C

DIAG CAN TEE

MC691

P305B

939YE-004-AC2 (YEL 18ga ) 939GE-004-AC2 (GRN 18ga )

SHIELD-802

SHIELD-802

939YE-012-AA12 (YEL 18ga ) 939GE-012-AA12 (GRN 18ga ) SHIELD-966

SHIELD-966

P317D

PC0616

MC691

A B C

GE CAN J1939 CONNECTION

46 46 45 45 47 47

P02

MC692

MC692

939YE-005-CC2 (YEL 18ga ) 939GE-005-CC2 (GRN 18ga )

P307B

A3 A B3 B C3 C

J02

P318D

SH11:M-11

CAN J1939 NETWORK (RED)

TERM#2 PC0618

PLM3 CAN TEE CAN TEE RPC # 1 A A1 B B1 C C1

A2 A B2 B C2 C

SEE NOTE #1 FOR AHT OPT

939YP-000-AA5 (YEL 18ga ) 939GP-000-AA5 (GRN 18ga )

SHIELD-835 MC711

A3 A B3 B C3 C

939YP-007-AA4 (YEL 20ga ) 939GP-007-AA4 (GRN 20ga )

IM CAN TEE CAN TEE RPC # 2

MC704 SHIELD-835

MC711

SH14:N-13 SH14:N-13

SHIELD-860

A A1 B B1 C C1

P204B

MC748

SHIELD-959 MC703

A3 A B3 B C3 C

P202D

PC0616

A2 A B2 B C2 C

P215B

939YP-012-AA9 (YEL 18ga ) 939GP-012-AA9 (GRN 18ga )

SHIELD-959

MC703

939YP-008-AA1 (YEL 20ga ) 939GP-008-AA1 (GRN 20ga )

GE CAN TEE CAN TEE RPC # 6

MC748

A3 A B3 B C3 C

P206D

PC0616

A2 A B2 B C2 C

P216B

SH13:H-11 SH13:I-11

SHIELD-834

A A1 B B1 C C1

PC0616

MC706

939YP-002-AC1 (YEL 18ga ) 939GP-002-AC1 (GRN 18ga )

SHIELD-842

939YP-009-AA11 (YEL 18ga ) 939GP-009-AA11 (GRN 18ga ) SHIELD-965

SHIELD-965

P218D

A B C

GE CAN RPC CONNECTION

21 21 20 20 22 22

P01

MC707

CAN TEE RPC # 3

MC707

48 48

11A-004-AC2 (TAN 18ga )

939YP-003-CC1 (YEL 18ga ) 939GP-003-CC1 (GRN 18ga )

SHIELD-843

SHIELD-843

A A1 B B1 C C1

A2 A B2 B C2 C

P207B

A3 A B3 B C3 C

J01

P219D

PC0616

MC708

P208B

11 BUSS

71CK BUSS

CAN RPC NETWORK (YELLOW)

939YP-004-CC1 (YEL 18ga ) 939GP-004-CC1 (GRN 18ga )

SHIELD-844 MC255

SH9:C-1

71LS-009-CC2 (DGR 16ga ) 71LS-010-CC2 (DGR 16ga )

2

1

2

P31

1 12 12

86A-000-CC2 (RED 16ga )

6

79RC-000-CC2 (ORG 18ga )

PC3206

1

12

6

86A-002-CC6 (RED 16ga )

6

SP702

712MM-000-AA1 (DBL 16ga )

1

P1 P2

1

11M-001-AC2 (LTG 14ga )

39 39

R1 R2

1

712MM-001-AC2 (DBL 16ga )

40 40

A A1 B B1 C C1

A2 A B2 B C2 C

P210B

A3 A B3 B C3 C

SHIELD-265 P209D

1

1

1

7

7

7

SH9:I-3

45R-005-CC2 (LBL 16ga )

8

8

8

SH9:I-3

45L-005-CC2 (DGR 16ga ) MC722

77A-005-CC2 (BLK 18ga )

9

MC722

77-005-CC2 (WHT 18ga ) SHIELD-908

9

9

10 10

10

11 11

11

2

P651

1

2

C2

1

D2

1

E1

1

E2

1

D4

712MM-004-CC2 (DBL 16ga )

6

4 2 3 1

0-500-JJ6 (BLK 8ga ) 86-500-JJ6 (GRN 8ga )

MC723

1

1

G3

1

H1

1

H2

1

F4

87-500-JJ6 (WHT 8ga )

J712

D3

1

1

J2

1

J3

1

K1

1

K2

1

K4

HOTSTART JUNCTION BOX

P Q R S

46GA-007-FH1 (LBL 14ga ) 46YA-007-FH1 (TAN 14ga ) 46RA-007-FH1 (LTG 14ga ) 0-440-FH1 (BLK 14ga )

P Q R S

1 2 3 4

46GA-008-FF1 (LBL 14ga ) 46YA-008-FF1 (TAN 14ga ) 46RA-008-FF1 (LTG 14ga ) 0-441-FF1 (BLK 14ga )

J541

61 61 62 62 63 63 64 64

P541

24 24 25 25 26 26 27 27

46GA-003-AJ1 (LBL 14ga ) 46YA-003-AJ1 (TAN 14ga ) 46RA-003-AJ1 (LTG 14ga ) 0-435-AJ1 (BLK 14ga )

P502 P Q R S

46GA-009-GJ1 (LBL 14ga ) 46YA-009-GJ1 (TAN 14ga ) 46RA-009-GJ1 (LTG 14ga ) 0-436-GJ1 (BLK 14ga )

46GA-005-AA1 (LBL 14ga ) 46GA-000-AA1 (LBL 14ga )

7

REVERSE INPUT

45R-006-CC6 (LBL 18ga )

8

RIGHT TURN

9

MC721

MC721

77A-006-CC6 (BLK 18ga )

2

LEFT TURN

10 SPEED INPUT (+) 11 SPEED INPUT (-)

77-006-CC6 (WHT 18ga ) SHIELD-904

P652

1

PC3190

GROUND

1

1

POWER SUPPLY

2

GROUND

CAM 1

2

72FC-000-CC6 (LTG 16ga )

3

CAM 1 SELECT

CAM 2

3

45RA-000-CC6 (LBL 16ga )

4

CAM 2 SELECT

CAM 3

4

45LA-000-CC6 (DGR 16ga )

5

CAM 3 SELECT

CAM 4

5

79R-000-CC6 (DBL 16ga )

6

CAM 4 SELECT

P652

1

A1

A2

TB32 B1 B2

1

P12

J540

AHT AUXBOX CONNECTOR (OPT)

4

4

5 6 7

5 6 7

46GA-000-AA1 (LBL 14ga ) 46YA-005-AA1 (TAN 14ga ) 46RA-000-AA1 (LTG 14ga ) 46YA-000-AA1 (TAN 14ga )

1

C1 C2

1

J502 P Q R S

1 2 3 4

46GA-010-GG1 (LBL 14ga ) 46YA-010-GG1 (TAN 14ga ) 46RA-010-GG1 (LTG 14ga ) 0-437-GG1 (BLK 14ga )

46YA-002-AA1 (TAN 14ga )

MC728

33PG-000-AA1 (BLK 18ga ) 5VDI-009-AA1 (RED 18ga ) 33PRR-000-AA1 (WHT 18ga )

8 8 9 9 10 10

P702

27 27 34 34 35 35 36 36

1

0-433-AH2 (BLK 14ga ) 46GA-001-AH2 (LBL 14ga ) 46RA-001-AH2 (LTG 14ga ) 46YA-001-AH2 (TAN 14ga )

4 1 2 3

RBML SHIELD-918

MC727

33PG-002-AA1 (BLK 18ga ) 5VDI-011-AA1 (RED 18ga ) 33PLR-000-AA1 (WHT 18ga )

SHIELD-917

SHIELD-917

17 17

39AP-003-AA1 (YEL 16ga )

18 18

39-001-AA1 (TAN 16ga )

8

8

11 11

J702

J14

1 2 3 4

AHT LEFT DECK MODE LAMPS CONNECTOR (OPT)

LDML_CP

J503

46RA-002-AA1 (LTG 14ga )

SHIELD-918

P650

P503

RDML_CP

AHT RIGHT DECK MODE LAMPS CONNECTOR (OPT)

0-432-AA1 (BLK 14ga ) 46GA-002-AA1 (LBL 14ga )

TB32 12 12 13 13 14 14

P540

1 2 3 4

8 8 9 9 10 10 11 11

20 20 21 21 22 22 23 23

J16

MC726

P16 1 3 2

33PG-001-AD1 (BLK 18ga ) 5VDI-010-AD1 (RED 18ga ) 33PRR-001-AD1 (WHT 18ga )

SHIELD-914

RRBPS

MC725

1 3 2

33PG-003-AD1 (BLK 18ga ) 5VDI-012-AD1 (RED 18ga ) 33PLR-001-AD1 (WHT 18ga )

SHIELD-913

LRBPS

P15

39AP-004-AJ2 (YEL 16ga )

1

1

39-002-AJ2 (TAN 16ga )

2

2

RRBPS_CP

LRBPS_CP

4 1 2 3

4 1 2 3

RBML_CP

RBML1

4 1 2 3

0-442-DD1 (BLK 14ga ) 46GA-011-DD1 (LBL 14ga ) 46RA-011-DD1 (LTG 14ga ) 46YA-011-DD1 (TAN 14ga )

RBML2

4 1 2 3

AHT REAR AXLE MODE LAMPS CONNECTOR (OPT)

RBML2_CP

AHT RIGHT REAR BRAKE PRESSURE SENSOR (OPT)

AHT LEFT REAR BRAKE PRESSURE SENSOR (OPT)

AHT HYDRAULIC FILTER SWITCHES (OPT)

ATFS_CP

P14

THERMOSTAT OIL RESERVE TANK

90-510-JJ8 (BLK 14ga ) 86-511-JJ8 (BLK 14ga )

A A B B C C

EG1968

ECHTR1 A B C

86-510-JJ7 (TAN 14ga ) 0-514-JJ7 (BLK 14ga )

HEATER OIL RESERVE TANK

A B C

87-511-JJ8 (BLK 14ga ) 90-510-JJ8 (BLK 14ga ) 0-515-JJ8 (BLK 14ga )

A A B B C C

EG1966

ECHTR2

A A B B C C

87-503-EJ3 (BLK 14ga ) 90-500-EJ3 (BLK 14ga ) 0-504-EJ3 (BLK 14ga )

SP706

HEATER ENGINE OIL LH

EOTS PARALLEL JUNCTION BLOCK

86-503-EJ3 (BLK 14ga ) 90-500-EJ3 (BLK 14ga ) 0-506-EJ3 (BLK 14ga )

SP703 SP704 SP705

86-504-EJ3 (BLK 14ga ) 90-501-EJ3 (BLK 14ga ) 0-507-EJ3 (BLK 14ga )

A A B B C C

PC0292

EOH1

A B C

CON1

A B C

86-507-JJ3 (BLK 14ga ) 87-507-JJ3 (BLK 14ga ) 0-510-JJ3 (BLK 14ga )

SP707 SP708 SP709

1A1

1

1A2

1

1B1

1

1B2

1

1C1

1

1C2

1

HEATER ENGINE OIL RH

86-505-EJ3 (BLK 14ga ) 90-502-EJ3 (BLK 14ga ) 0-508-EJ3 (BLK 14ga )

A A B B C C

PC0292

EOH2

90-503-JJ3 (BLK 14ga ) 87-507-JJ3 (BLK 14ga )

86-506-JJ7 (PNK 14ga ) 87-506-JJ7 (TAN 14ga ) 0-509-JJ7 (BLK 14ga )

GE ALTERNATOR & WHEEL MOTOR POWER CIRCUIT GE CONTROL CABINET

THERMOSTAT ENGINE OIL

TB-HTST 1

24 24 25 25 26 26 27 27

46GA-006-AH1 (LBL 14ga ) 46YA-006-AH1 (TAN 14ga ) 46RA-006-AH1 (LTG 14ga ) 0-439-AH1 (BLK 14ga )

P11

J12

TB32

POWER +24VDC 12

THERMOSTAT HYDRAULIC OIL

J1

CAN RPC NETWORK (YELLOW)

12

46GA-004-AA1 (LBL 14ga ) 46YA-004-AA1 (TAN 14ga ) 46RA-004-AA1 (LTG 14ga ) 0-434-AA1 (BLK 14ga )

GB31-A

CAMERA CONTROLLER (OPT)

79B-006-CC6 (YEL 18ga )

XB7269

1

G2

NOTE: 1) OPTIONAL AHT CONNECTION TO CAN RPC REMOVES TERM #2 RESISTOR FROM RPC CAN TEE #1 AND AHT CONNECTOR P216B CONNECTS TO RPC CAN TEE #1

RDML

CAMERA SYSTEM (OPT)

CAM 4 MAN

TB-HTST G1

SHIELD-816

MM/RPC

61 61 62 62 63 63 64 64

SH12:C-16 SH12:C-16

P214D

OP-CAB MODULAR MINING CONNECTION

11

MC695

939YP-010-CC4 (YEL 20ga ) 939GP-010-CC4 (GRN 20ga )

XB7268

87-502-JJ8 (WHT 14ga ) 0-502-JJ8 (DGR 14ga ) 86-502-JJ8 (BLK 14ga )

0-505-EJ3 (BLK 14ga )

SUPPLY POWER SINGLE PHASE 240 VAC FULL LOAD AMPS: 35

MC695

A3 A B3 B C3 C

10

J11

0-394-CC6 (BLK 16ga ) 0-393-CC6 (BLK 16ga )

6

45L-006-CC6 (DGR 18ga )

SERIES JUNCTION BLOCK

POWER RECEPTACLE ON FRONT LH BUMPER

P213B

PC0618

3

0-214-CC2 (BLK 14ga )

46RA-005-AA1 (LTG 14ga ) 46RA-000-AA1 (LTG 14ga )

HEATER COOLANT RH

1

MC255

TERM#3

A2 A B2 B C2 C

A A1 B B1 C C1

PC0616

2

ATFS

1

SH8:H-9 SH8:H-9

SHIELD-263

712MM-003-CC2 (DBL 16ga )

46GA-005-AA1 (LBL 14ga ) 46YA-005-AA1 (TAN 14ga ) 46RA-005-AA1 (LTG 14ga ) 0-438-AA1 (BLK 14ga )

0-392-CC6 (BLK 16ga )

J651_CPJ651

87-501-HH7 (WHT 14ga ) 0-501-HH7 (DGR 14ga ) 86-501-HH7 (BLK 14ga )

VHMS CAN TEE CAN TEE RPC # 5

SHIELD-845

939YP-001-CC1 (YEL 18ga ) 939GP-001-CC1 (GRN 18ga )

SP157

AHT CONNECTIONS OPTION

HEATER COOLANT LH

C1

SHIELD-845 MC254

SH12:D-16 SH12:D-16

CAN J1939 NETWORK (RED)

H J

MC709

MC696

SHIELD-817

OP-CAB CONNECTOR ENGINE DATALINK TIER 1 OR TIER 2 DIAGNOSTIC DIAG4

939YP-005-CC4 (YEL 18ga ) 939GP-005-CC4 (GRN 18ga )

1

J15

TB-HTST

MC709

939YE-010-CC4 (YEL 20ga ) 939GE-010-CC4 (GRN 20ga )

P311D

PC0616

P212D

PC0616

712MM-002-CC2 (DBL 16ga )

11 11

HOT START OPTION

P211B

939YP-006-CC2 (YEL 18ga )

B2

B A

0-362-CC2 (BLK 18ga )

11M-002-CC2 (LTG 14ga )

J02

F G

MC696

LDML

SP701

79B-005-CC2 (YEL 18ga )

SH12:D-3

1

ACTIA CAN TEE CAN TEE RPC # 4

SHIELD-844

A3 A B3 B C3 C

PC0618

79C-001-CC6 (ORG 18ga )

P31

SH7:H-19

SH12:D-3

1

86A-004-CC6 (RED 16ga ) 86A-003-CC6 (RED 16ga )

D D

J15-CC2 (BLK 18ga ) 0-390-CC2 (BLK 16ga ) 0-389-CC2 (BLK 16ga )

GB10 FRT CAB GND D4

B

6 6

C C

C4

SHIELD-265

CAMERA SYSTEM OPTION

3 3 4 4

5 5

E

11M-000-AA1 (LTG 12ga )

TB32

MC689

GB12 REAR CAB

GB12 REAR CAB

SWITCH CAMERA (OPT) B

4E VEC-90

5

G

P02

86A-001-CC2 (RED 16ga )

A A

4G

20 F48

J02

939GP-006-CC2 (GRN 18ga )

VEC-91

C D E

11A-012-CC2 (TAN 18ga )

MC708

OPERATOR CAB CAN RPC F30

939YE-007-CC2 (YEL 20ga ) 939GE-007-CC2 (GRN 20ga )

900-003-CC2 (WHT 18ga ) 901-003-CC2 (BLK 18ga )

MM CAN TEE

P205B MC706

P310B

MC694

TERM#1

A2 A B2 B C2 C

A A1 B B1 C C1

SHIELD-811

MC689

P02

MC704

P203B

SHIELD-808

SHIELD-811 SH6:I-13 SH6:I-13

CAN TEE J1939 # 4

MC693

939YE-006-CC4 (YEL 18ga ) 939GE-006-CC4 (GRN 18ga )

SHIELD-808 MC694

P309D

PC0616

OPERATOR CAB CAN J1939

MC693

A2 A P308B B2 B C2 C

A A1 B B1 C C1

SHIELD-805

SHIELD-805

VHMS CAN TEE

CAN TEE J1939 # 3

A A B B C C

EG1968

HEATER HYDRAULIC OIL #1

86-508-JJ3 (BLK 14ga ) 90-506-JJ3 (BLK 14ga ) 0-511-JJ3 (BLK 14ga )

CON2

A A B B C C

EG1966

HOHTR1 HEATER HYDRAULIC OIL #2

86-509-JJ3 (BLK 14ga ) 90-507-JJ3 (BLK 14ga ) 0-512-JJ3 (BLK 14ga )

A A B B C C

HOHTR2

EG1966

2A1

1

2A2

1

2B1

1

2B2

1

2C1

1

2C2

1

CMTAFSE

1

AFSE

1

IPT1AX2 IPT1AX3 IPT1BX2 IPT1BX3 IPT1CX2 IPT1CX3 IPT2AX2 IPT2AX3 IPT2BX2 IPT2BX3 IPT2CX2 IPT2CX3 T19 T20

7M1A1-DT1 (GRY 4/0-MCM ) 7M1A2-DT2 (GRY 4/0-MCM ) 7M1B1-DT3 (GRY 4/0-MCM ) 7M1B2-DT4 (GRY 4/0-MCM ) 7M1C1-DT5 (GRY 4/0-MCM ) 7M1C2-DT6 (GRY 4/0-MCM ) 7M2A1-DT7 (GRY 4/0-MCM ) 7M2A2-DT8 (GRY 4/0-MCM ) 7M2B1-DT9 (GRY 4/0-MCM ) 7M2B2-DT10 (GRY 4/0-MCM ) 7M2C1-DT11 (GRY 4/0-MCM ) 7M2C2-DT12 (GRY 4/0-MCM ) 71J-000-ST1 (GRY 2/0-MCM ) 74D-000-ST2 (GRY 2/0-MCM )

M1-TA1 M1-TA2 M1-TB1 M1-TB2 M1-TC1 M1-TC2 M2-TA1 M2-TA2 M2-TB1 M2-TB2 M2-TC1

1

MOTOR WHEEL DRIVE # 1 A1

1

A2

1

B1

1

B2

1

C1

1

1

ALT2

SH7:H-15

1 2 3 4

C2

A1

1

A2

1

B1

1

B2

1

C1

1

C2

1

PIN1

1

PIN2

NOTE: USE GE SCHEMATIC FOR ADDITIONAL CABLES TO ALTERNATOR

7

52PB-001-AC3 (PUR 16ga )

P03

MOTOR WHEEL DRIVE # 2

M2-TC2 ALTERNATOR PROPULSION DRIVE ALT1

HYDRAULIC LADDER OPTION

SH12:E-5

510E2-003-AA1 (DGR 18ga )

24 24

J12 SH6:L-14

OPTIONAL HYD ACCESS LADDER UP SWITCH

510E2-002-AJ1 (DGR 16ga )

P12

0-519-AJ1 (BLK 16ga )

1 2

P830

1 2

J262_CP

SH11:P-8 RELAY HYDRAULIC LADDER PK STATUS (OPT) 7

52PB-004-CC3 (PUR 16ga )

J03

1 2 3 4

86

(+)

85

GB10 FRT CAB GND 1 C3

0-381-CC3 (BLK 16ga ) 0-376-CC3 (BLK 16ga )

SH11:P-8

GB10-C3

(NO) 87

30 (C)

P263

(-)

0-382-CC3 (BLK 16ga )

(NC)87A

PC1730

52RS1-000-CC3 (YEL 16ga ) 52RS2-000-CC3 (DGR 16ga )

P263

P262

J30-JJ9 (BLK 16ga )

J830

58E-06-02000-00 NOV 11 ELECTRICAL SCHEMATIC 830E-1AC A40851 & UP Sheet 15 of 20

WIRE TABLE WIRE LIST NAME

WIRE LIST

DEVICE FROM -15VDI-000 -15VDI-001 TB21

CONN FROM DEVICE TO GE DID PANEL J02 TB21-V2

CONN TO DID

-15VDI-002 GE CONTROL INTERFACE GB70 FRAME GND 0-000

P302

TB21

TB21-V1

NAME DEVICE FROM CONN FROM DEVICE TO RELAY BACKUP LIGHT (BULR) 0-157 RELAY HEADLIGHT HIGH MOUNT (HH... HHMR-(-) LAMP GREEN PAYLOAD RIGHT 0-158 SP195 SP14 GB31A-A2 0-160 GB31-B AUXBOX GND BLCK

GB70-A2

BUSS BAR 0

DISC(-)-5

0-161

-

J14

P02

CONTINUED ON DIAGRAM 17 & 18

WIRE LIST CONN TO BULR-(-)

NAME DEVICE FROM 0-298 SP169

RPLG

0-299

SP169

CONN FROM DEVICE TO LAMP REAR SERVICE TIMER REAR SERVICE LAMP (PLT) -

-

0-300

GB1 - REAR AXLE

GB1-B3

-

SP14

-

0-301

GB1 - REAR AXLE

GB1-B3

WIRE LIST CONN TO PL

NAME 0-435

DEVICE FROM -

PLT-3

0-436

-

CONN FROM DEVICE TO P12 P540

P55

0-437

-

J503

-

-

J54

0-438

-

J11

WIRE LIST

WIRE LIST

CONN TO J540

NAME 11A-000

DEVICE FROM VEC-91

P503

11A-001

TB35

CONN FROM DEVICE TO TB35 VEC91-P4 RELAY VEHICLE HORN POWER (HPR) TB35-A1

CONN TO TB35-B3

NAME

DEVICE FROM 11RCNT-004 ACTIA DASH DISPLAY 11RWL

CONN FROM DEVICE TO P11 P902

LDML

11A-002

TB35

TB35-A2

-

J16

P01

TB35

TB35-P1

P240

11RWL-001 11RWL-002 TB35

GB31-A AUXBOX GND BLCK

GB31A-D3

11A-003

TB35

TB35-B2

-

TB35-P2

INTERFACE MODULE

IM1

HPR-87

CONN TO P180 J01

0-001

24VDC ALTERNATOR

ALT (-)

GB70 FRAME GND

GB70-A1

0-162

-

J12

SP13

-

0-302

-

P54

SP177

-

0-439

-

J541

-

P11

11A-004

TB35

TB35-B4

-

P02

11S-000

VEC-90

VEC90-P3

SP106

-

0-002

GB70 FRAME GND

GB70-B2

GB31-A AUXBOX GND BLCK

GB31A-A1

0-163

-

J12

SP13

-

0-303

SP177

-

LAMP BODY LEFT REAR MARKER

LSCL2

0-440

-

P541

-

P502

11A-005

-

P16

TB60

TB60-L1

11S-001

SP106

-

-

J12

0-003

BUSS BAR 0

DISC(-)-4

M0TOR STARTER 1 (STRT1)

STRT1-2A

0-164

-

J11

SP10

-

0-304

LAMP BODY LEFT SIDE MARKER

LSCL1

SP177

-

0-441

-

RDML

-

J502

11A-006

TB60

TB60-L2

-

P704

11S-002

SP106

-

-

J11

0-004

BUSS BAR 0

DISC(-)-3

MOTOR STARTER 2 (STRT2)

STRT2-2A

0-165

-

J11

SP10

-

0-305

-

J55

SP174

-

0-442

-

RBML1

-

RBML2

11A-007

-

J704

SWITCH REAR SERVICE LAMP (PLS)

PLS-3

11S-003

-

P12

-

P536

0-005

VEC-90

VEC90-S7A

VEC-89

VEC89-S7A

0-166

-

P11

-

J541

0-306

SP174

-

LAMP BODY RIGHT REAR MARKER

RSCL2

0-443

GB31-A AUXBOX GND BLCK

GB31A-D4

TB26

TB26-A2

11A-008

-

J240

SWITCH HYDRAULIC LAMP

HLSW-2

11S-004

-

J536

0-006

RELAY KEY / GE CNTRL PWR (KCNP...

KCNPR-(-)

RELAY KEY SWITCH (KSWPR)

KSWPR-(-)

0-167

-

P541

LAMP DECK LADDER LIGHT #1

RDLLT

0-307

LAMP BODY RIGHT SIDE MARKER

RSCL1

SP174

-

0-444

LAMP HYDRAULIC CABINET #2

HL2

GB8 BRAKE CABINET

GB8-4

11A-011

RELAY VEHICLE HORN POWER (HPR)

HPR-87

RELAY VEHICLE HORN POWER (HPR)

HPR-(+)

11S-005

-

P11

SWITCH LEFT GROUND LEVEL SHUTD... ESDS-2 P533 -

0-007

RELAY KEY / GE CNTRL PWR (KCNP...

KCNPR-(-)

12V POWER RELAY (12VPR)

12VPR-(-)

0-168

-

J541

-

P11

0-308

JB6C

JB6C

-

J229

0-445

GB8 BRAKE CABINET

GB8-4

LAMP HYDRAULIC CABINET #1

HL1

11A-012

-

DIAG4

-

J02

11S-006

-

J533

0-008

-

J11

SP09

-

0-169

LAMP DECK LIGHT #2

RDLT

-

P541

0-309

JB6C

JB6C

-

J228

0-446

TB31

TB31-G3

TB29

TB29-X4

11A1-000

SWITCH HYDRAULIC LAMP

HLSW-1

SP171

-

11SL-000

VEC-91

VEC91-P4

SWITCH RIGHT GROUND LEVEL SHUT... ESDSR-2 TB24-A1 TB24

0-009

12VDC CONVERTER (12VCN)

0-170

-

J540

-

P12

0-310

JB6C

JB6C

TB30

TB30-B2

TB28

TB28-R2

11A1-001

LAMP HYDRAULIC CABINET #1

HL1

SP171

-

11SL-001

TB24

TB24-A1

TIMER (1HR) ENGINE SERVICE LAM...

GB31A-B1

0-171

LAMP DIAGONAL LADDER LIGHT #1

LDLLT

-

P540

0-311

JB6C

JB6C

SWITCH CAB SECONDARY ENGINE SH... ESS-B SWITCH BODYUP OVERRIDE / RESET... ORS-B

0-447

VEC-91

12VCN-GND GB31-A AUXBOX GND BLCK VEC91-S6B GB31-A AUXBOX GND BLCK

GB31A-A3

0-011

0-448

RELAY MASTER DISCONNECT

MLREL

JB1

JB1

11A1-002

SP171

-

LAMP HYDRAULIC CABINET #2

HL2

11SL-002

TB24

TB24-A1

0-012

VEC-91

VEC91-S6A

TIMER REAR SERVICE LAMP (PLT)

PLT-C

SWITCH REAR SERVICE LAMP (PLS)

PLS-2

11SM1-000

M0TOR STARTER 1 (STRT1)

STRT1-4B

TIMER (1HR) HYDRAULIC PUMP MOD... HPLT-C J801 -

0-013

PLT-NO

LAMP REAR SERVICE

PL

11SM1-001

-

P801

TB28

TB28-F1

0-014

RELAY HEADLIGHT LOW MOUNT (HLM... HLMR-(-) HBHR-85 RELAY HI-BEAM HEADLIGHT (HBHR)

TB24-L1

11SM1-002

TB28

TB28-F2

INTERFACE MODULE

IM3

0-015

RELAY HI-BEAM HEADLIGHT (HBHR)

12VPR-87

11SM1-003

-

J801-

-

STRT1-4B-

0-016 0-017

RELAY HEADLIGHT LOW MOUNT (HLM... HLMR-(-) SP103

0-018

DL1

0-019

ESLT-C

VEC90-S7B

0-172

-

J540

-

P12

0-312

SWITCH RETARD SPEED CONTROL (R...

RSCS_1-3

GB12 REAR CAB

GB12-D4

0-449

LAMP DECK LIGHT #1 (OPT LOCATI...

LDLT

-

J544

11AL-000

RELAY HEADLIGHT HIGH MOUNT (HH... HHMR-(-) KSWPR-(-) RELAY KEY SWITCH (KSWPR)

0-173

-

P540

-

P544

0-313

-

J02

RETARD SPEED CONTROL

RSP

0-500

-

J712

TB-HTST

TB-HTST-D4

0-174

-

P565

-

P14

0-314

SWITCH RETARD SPEED CONTROL (R...

RSCS-B

0-501

HEATER COOLANT LH

-

TB-HTST

TB-HTST-C1

GB31-B AUXBOX GND BLCK

GB31B-B1

0-175

-

J565

SP151

-

0-315

-

P02

SWITCH RETARD SPEED CONTROL (R... RSCS_1-3 TB31-G2 TB31

11ALT-000 TIMER REAR SERVICE LAMP (PLT) 12VDC CONVERTER (12VCN) 11B1-000

0-502

HEATER COOLANT RH

-

TB-HTST

TB-HTST-C2

11B1-001

12VDC CONVERTER (12VCN)

12VCN-12VB TB24 12VCN-12VA 12V POWER RELAY (12VPR)

RELAY ACCESS LADDER LIGHT (ALL...

ALLR-85

0-176

SP151

-

0-316

GE CONTROL INTERFACE

P303

TB31

TB31-G1

0-504

SP706

-

THERMOSTAT ENGINE OIL

EOTS

11B1-002

TB24

TB24-L4

VEC-91

VEC91-P10

11SM2-000

MOTOR STARTER 2 (STRT2)

STRT2-4A

-

J801

GB31-A AUXBOX GND BLCK

GB31A-B3

0-177

LAMP CONTROL CABINET WORK LIGH... CDL1 LAMP CONTROL CABINET WORK LIGH... CDL2

SP151

-

0-317

SWITCH DC POWER OFF - REST SWI...

P35

GB10 FRT CAB GND

GB10-C1

0-505

SP706

-

TB-HTST

TB-HTST-E1

11B1-003

TB24

TB24-L3

INTERFACE MODULE

IM3

11SM2-001

-

P801

TB28

TB28-G1

DL1

SP104

-

0-178

GB10 FRT CAB GND

GB10-B2

ACTIA DISPLAY PANEL DIMMER

P18

0-318

SWITCH GRID DRY

P34

GB10 FRT CAB GND

GB10-C1

0-506

SP706

-

SP705

-

11B5-000

CB60

CB60-2

12VDC CONVERTER (12VCN)

12VCN-24VA

11SM2-002

TB28

TB28-G2

INTERFACE MODULE

IM3

SP104

-

DL2

DL2

0-179

SWITCH DISPLAY MODE #2

P20

GB10 FRT CAB GND

GB10-B4

0-319

SWITCH GRID DRY

P34

SWITCH GRID DRY

P34

0-507

HEATER ENGINE OIL LH

EOH1

SP705

-

11D-000

VEC-89

VEC89-P2

TB22

TB22-A1

11SM2-003

-

J801-

-

STRT2-4A-

0-020

DL3

DL3

SP104

-

0-180

SWITCH DISPLAY MODE #2

P20

SWITCH DISPLAY MODE #2

P20

0-320

SWITCH BRAKE TEST

P37

SWITCH BRAKE LOCK

P39

0-508

SP705

-

HEATER ENGINE OIL RH

EOH2

11D-001

TB22

TB22-A2

-

P03

11ST-000

BUSS BAR 11ST

SDISC-4

FUSE LINK1 (150A)

FUS-1

0-021

DL4

DL4

SP103

-

0-181

SWITCH DISPLAY MODE #2

P20

SWITCH DISPLAY MODE #2

P20

0-321

SWITCH BRAKE TEST

P37

SWITCH BRAKE TEST

P37

0-509

TB-HTST

CON1

11D-002

-

J03

SWITCH HEADLIGHTS

P25

11ST-001

BUSS BAR 11ST

SDISC-3

M0TOR STARTER 1 (STRT1)

STRT1-1A

0-022

DL5

DL5

SP103

-

0-182

SWITCH DISPLAY MODE #2

P20

SWITCH DISPLAY MODE #1

P21

0-322

GE CONTROL INTERFACE

P305

GB31-B AUXBOX GND BLCK

GB31B-B3

0-510

SP709

TB-HTST-D2 -

CON2

11D-003

SWITCH HEADLIGHTS

P25

SWITCH HEADLIGHTS

P25

11ST-002

BUSS BAR 11ST

SDISC-5

MOTOR STARTER 2 (STRT2)

STRT2-1A

0-023

DL6

DL6

SP103

-

0-183

SWITCH DISPLAY MODE #1

P21

SWITCH DISPLAY MODE #1

P21

0-323

GE CONTROL INTERFACE

P305

GB31-B AUXBOX GND BLCK

GB31B-B3

0-511

HEATER HYDRAULIC OIL #1

HOHTR1

SP709

-

VEC91-P2

TB23

TB23-G2

11ST-003

M0TOR STARTER 1 (STRT1)

STRT1-1C

MOTOR STARTER 2 (STRT2)

STRT2-1B

0-024

SP104

-

SP103

-

0-184

SWITCH DISPLAY MODE #1

P21

SWITCH DISPLAY MODE #1

P21

0-324

SENSOR FUEL LEVEL

FLS

SP185

-

0-512

SP709

-

HEATER HYDRAULIC OIL #2

HOHTR2

11DISP-000 VEC-91 11DISP-001 TB23

TB23-G1

-

P01

11ST-005

BUSS BAR 11ST

SDISC-8

RELAY STARTER LOCKOUT

SLREL

0-025

SP100

-

SP102

-

0-185

ACTIA DASH DISPLAY

P903

GB10 FRT CAB GND

GB10-D3

0-325

-

J16

SP15

-

0-514

-

CON3

TB-HTST

TB-HTST-E2

J01

ACTIA DASH DISPLAY

P903

11ST-006

BUSS BAR 11ST

SDISC-8

0-026

LAMP LED MASTER DISCONNECT CL...

MLLON

BUSS BAR 0

DISC(-)-7

0-186

SWITCH CAB LADDER LIGHT

P24

SWITCH HEADLIGHTS

P25

0-326

-

J730

-

P16

0-515

HEATER OIL RESERVE TANK

ECHTR2

-

CON4

11DISP-003 11DSL-000 VEC-89

VEC89-P12

RELAY ACCESS LADDER LIGHT (ALL...

ALLR-88

12H-000

VEC-91

VEC91-P9

LAMP LED STARTER LOCKOUT CLOSE... SLON TB22-G1 TB22

0-027

JB1

JB1

BUSS BAR 0

DISC(-)-7

0-187

R27

R27

GB10 FRT CAB GND

GB10-B2

0-327

SP185

-

-

P730

0-516

BATT1

BAT1(+)

BATT2

BAT2(-)

11E1-000

TB27

TB27-A2

VEC-91

VEC91-P2

12H-001

TB22

TB22-G2

-

P03

0-028

M0TOR STARTER 1 (STRT1)

STRT1-2B

MOTOR STARTER 2 (STRT2)

STRT2-2B

0-188

SWITCH CAB LADDER LIGHT

P24

SWITCH CAB LADDER LIGHT

P24

0-328

SWITCH STEERING FILTER #1

SFSW

SP185

-

0-517

BATT3

BAT3(+)

BATT4

BAT4(-)

11E1-001

TB27

TB27-A1

-

P808

12H-002

-

J03

-

P140

0-030

RELAY 1 PROPEL LOCKOUT

PLREL

JB1

JB1

0-189

LAMP RED PAYLOAD RIGHT

RPLR

SP195

-

0-329

-

J02

SWITCH DRIVERS SEAT BELT

P212

0-518

SP777

-

-

J506

11E1-002

TB27

TB27-A3

-

P808

12V-000

12V POWER RELAY (12VPR)

12VPR-30

VEC-91

VEC91-S7A

0-031

RELAY STARTER LOCKOUT

SLREL

JB1

JB1

0-191

SWITCH LEFT WINDOW

P072

GB12 REAR CAB

GB12-D2

0-330

-

P02

GB31-B AUXBOX GND BLCK

GB31B-A4

0-519

SP777

-

-

P830

11E1-003

-

J808

SP112

-

VEC91-P11

TB21

TB21-B1

0-032

JB1

JB1

LAMP LED PROPEL LOCKOUT ON

PLON

0-192

GB12 REAR CAB

GB12-D1

SWITCH LEFT WINDOW

P072

0-331

SWITCH LOW STEERING PRESSURE

ACPSW

-

P14

0-600

TB31

TB31-V4

TB31

TB31-L3

11E1-004

SP112

-

-

J808

12VREG-000 VEC-91 12VREG-001 TB21

TB21-B2

-

P03

0-033

LAMP LED PROPEL LOCKOUT LOCKED... PLLO SLLO LAMP LED STARTER LOCKOUT OPEN

JB1

JB1

0-194

SWITCH LEFT WINDOW

P072

SWITCH LEFT WINDOW

P072

0-332

SWITCH STEERING BLEED PRESSURE

SABS

-

P14

0-601

GB31-A AUXBOX GND BLCK

GB31A-D4

TB31

TB31-L3

11E1-005

ENGINE QSK60 INTERFACE TIER II

P804

SP112

-

TB21-B3

-

P03

JB1

JB1

0-195

SWITCH LEFT WINDOW

P072

GB12 REAR CAB

GB12-D2

0-333

-

J14

SP14

-

0ACL-000

-

J01

ACCELERATOR PEDAL

P236

11E1-006

-

J808-

ENGINE QSK60 INTERFACE TIER I

P805-

12VREG-002 TB21 12VREG-003 -

J03

SP156

-

GB3 ENG GND BLOCK

GB3-B3

0-197

SWITCH RIGHT WINDOW

P071

GB12 REAR CAB

GB12-D1

0-334

-

J14

SP14

-

0ACL-001

TB31

TB31-W2

-

P01

11E2-000

TB27

TB27-B2

VEC-91

VEC91-P2

SP156

-

GB3 ENG GND BLOCK

GB3-B1

0-198

SWITCH RIGHT WINDOW

P071

GB12 REAR CAB

GB12-C2

0-335

-

P13

0ACL-002

GE CONTROL INTERFACE

P303

TB31

TB31-W3

11E2-001

-

P808

TB27

TB27-B1

-

-

J601

0-042

RELAY ENGINE PRELUBE

P800

0-199

SP195

-

LAMP AMBER PAYLOAD RIGHT

RPLA

0-336

SP08

-

0ACL-003

GE CONTROL INTERFACE

P304

TB31

TB31-W1

11E2-002

-

P808

TB27

TB27-B3

SENSOR LEFT FRONT WHEEL SPEED

P507

RELAY ENG STARTER 1 (ESREL1)

ESREL1-85

0-200

GB12 REAR CAB

GB12-C2

SWITCH RIGHT WINDOW

P071

0-337

SWITCH PARK BRAKE SET

GB8 BRAKE CABINET

GB8-2

0COM-000

-

J02

GE DID PANEL

DID

11E2-003

-

J808

SP113

-

15LFWS-000 15LFWS-001 SP729

P13

0-048

RELAY ENGINE PRELUBE MAG SWITC... PLMS-(-) ESREL2-85 RELAY ENG STARTER 2 (ESREL2)

SWITCH ACCUMULATOR PRESSURE #2... ACCP2-C J13 -

12VREG-004 12VREG-005 SP156

J03

0-041

ENGINE PRELUBE HIGH VOLUME PUM... PLPM-(-) RELAY ENGINE PRELUBE MAG SWITC... PLMS-(-)

-

-

J13

0-049

-

P12

RELAY ENG STARTER 1 (ESREL1)

ESREL1-85

0-201

SWITCH RIGHT WINDOW

P071

SWITCH RIGHT WINDOW

P071

0-338

GB8 BRAKE CABINET

GB8-2

0COM-001

-

P02

TB22

TB22-S2

11E2-004

SP113

-

-

J808

-

P57

-

J12

SP13

-

0-202

-

J210

-

J04

0-339

GB8 BRAKE CABINET

GB8-2

0COM-002

TB22

TB22-S1

SP181

-

11E2-005

ENGINE QSK60 INTERFACE TIER II

P804

SP113

-

15LFWS-002 SP729 15LFWS-003 VEC-91

-

0-050

SWITCH LOW BRAKE ACCUM PRESSUR... LBPS SWITCH SERVICE BRAKE DEGRADE P... BDS

VEC91-P1

SP729

-

0-051

GB8 BRAKE CABINET

GB8-1

0-203

-

P03

GB31-A AUXBOX GND BLCK

GB31A-C1

0-340

-

P14

SENSOR HYDRAULIC TANK LEVEL

P712

0COM-003

TB22

TB22-S3

SP182

-

11E2-006

-

J808-

ENGINE QSK60 INTERFACE TIER I

P805-

SENSOR LEFT REAR WHEEL SPEED

P720

-

J12

0-204

-

P03

GB31-A AUXBOX GND BLCK

GB31A-C1

0-341

-

J14

SP14

-

0COM-004

GE CONTROL INTERFACE

P302

SP181

-

11E3-000

TB27

TB27-C2

VEC-91

VEC91-P2

15LRW-000 15LRW-001 VEC-89

P15

0-055

SWITCH PARK BRAKE RELEASE PRES... PBRPS SP12

VEC89-P2

-

J15

0-060

ENGINE QSK60 INTERFACE TIER II

P804

SP115

-

0-205

-

P03

GB31-A AUXBOX GND BLCK

GB31A-C4

0-342

-

J511

-

P11

0COM-005

GE CONTROL INTERFACE

P302

SP181

-

11E3-001

-

P808

TB27

TB27-C1

P13

SENSOR RIGHT FRONT WHEEL SPEED

P501

0-061

ENGINE QSK60 INTERFACE TIER II

P804

SP116

-

0-206

-

P03

GB31-A AUXBOX GND BLCK

GB31A-C4

0-343

SWITCH AUTOLUBE LEVEL (OPT)

ALLSW

-

P511

0COM-006

GE CONTROL INTERFACE

P302

SP181

-

11E3-002

-

P808

TB27

TB27-C3

15RFWS-000 15RFWS-001 -

J13

SP728

-

0-062

ENGINE QSK60 INTERFACE TIER II

P804

SP117

-

0-207

-

J03

GB12 REAR CAB

GB12-A1

0-344

-

J11

SP10

-

0COM-007

GE CONTROL INTERFACE

P302

SP182

-

11E3-003

-

J808

SP114

-

VEC91-P1

SP728

-

0-063

-

J808

SP115

-

0-208

-

J03

GB12 REAR CAB

GB12-A1

0-345

R30

R30

TB21

TB21-X3

0COM-008

GE CONTROL INTERFACE

P302

SP182

-

11E3-004

-

J808

SP114

-

15RFWS-002 VEC-91 15RFWS-003 SP728

-

-

P56

0-064

SP115

-

-

J808

0-209

-

J03

GB12 REAR CAB

GB12-B1

0-346

-

P04

GB31-A AUXBOX GND BLCK

GB31A-B4

0COM-009

GE CONTROL INTERFACE

P302

SP182

-

11E3-005

ENGINE QSK60 INTERFACE TIER II

P804

SP114

-

P15

SENSOR RIGHT REAR WHEEL SPEED

P721

0-065

-

J808

SP116

-

0-210

-

J03

GB12 REAR CAB

GB12-B1

0-347

-

J04

JB8A

JB8A

0LEV-000

-

J01

RETARD CONTROL LEVER (OPT)

P237

11E4-000

TB27

TB27-D2

VEC-91

VEC91-P2

15RRW-000 15RRW-001 -

J15

VEC-91

VEC91-P3

0-066

SP116

-

-

J808

0-211

GB12 REAR CAB

GB12-A2

-

J601

0-348

JB8A

JB8A

KOMTRAX PLUS MODULE

P1

0LEV-001

TB31

TB31-L2

-

P01

11E4-001

TB27

TB27-D1

-

P808

VEC91-P1

TB33

TB33-S2

0-067

-

J808

SP117

-

0-212

GB12 REAR CAB

GB12-A2

-

J601

0-349

JB8A

JB8A

KOMTRAX PLUS MODULE

P1

0LEV-002

GE CONTROL INTERFACE

P302

TB31

TB31-L1

11E4-002

ENGINE QSK60 INTERFACE TIER II

P804

-

J808

15SLW-001 VEC-91 15SLW-002 GE CONTROL INTERFACE

P301

TB33

TB33-S1

0-068

SP117

-

-

J808

0-213

GB12 REAR CAB

GB12-B1

-

J602

0-350

JB8A

JB8A

KOMTRAX PLUS MODULE

P1

0LF-000

-

P13

SENSOR LEFT FRONT WHEEL SPEED

P507

11ER-000

VEC-91

VEC91-P11

TB22

TB22-D1

VEC91-P1

TB33

TB33-M2

0-069

-

P808

GB31-B AUXBOX GND BLCK

GB31B-C1

0-214

-

MM/RPC

GB12 REAR CAB

GB12-B2

0-351

JB8A

JB8A

KOMTRAX PLUS MODULE

P1

0LF-001

TB33

TB33-P2

-

J13

11ER-001

TB22

TB22-D2

-

P03

15SRW-001 VEC-91 15SRW-002 GE CONTROL INTERFACE

P301

TB33

TB33-M1

0-070

-

P808

GB31-B AUXBOX GND BLCK

GB31B-C1

0-215

-

P801

GB31-B AUXBOX GND BLCK

GB31B-A1

0-352

JB8A

JB8A

ORBCOMM MODULE (OPT)

CNA

0LF-002

GE CONTROL INTERFACE

P301

TB33

TB33-P1

11ER-002

TB22

TB22-D3

-

P03

15VDI-000

-

J02

GE DID PANEL

DID

0-071

-

P808

GB31-B AUXBOX GND BLCK

GB31B-B4

0-216

-

J12

SP13

-

0-353

ORBCOMM MODULE (OPT)

CNA

JB8A

JB8A

0LF-003

GE CONTROL INTERFACE

P301

TB33

TB33-P3

11ER-003

-

J03

SP155

-

15VDI-001

-

P02

TB21

TB21-T4

0-072

-

P808

GB31-B AUXBOX GND BLCK

GB31B-B4

0-217

-

P12

SP777

-

0-354

JB8A

JB8A

-

P653

0RET-000

-

J01

RETARD CONTROL PEDAL

P235

11ER-004

-

J03

SP155

-

15VDI-002

GE CONTROL INTERFACE

P302

TB21

TB21-T1

0-073

-

P808

GB31-B AUXBOX GND BLCK

GB31B-D1

0-218

-

P12

-

P505-

0-355

-

J808-

ENGINE QSK60 INTERFACE TIER I

P806-

0RET-001

TB31

TB31-V2

-

P01

11ER-005

-

J601

SP155

-

15VDI-003

GE CONTROL INTERFACE

P302

TB21

TB21-T3

0-074

-

P808

GB31-B AUXBOX GND BLCK

GB31B-D1

0-219

-

J12

SP13

-

0-356

-

J808-

ENGINE QSK60 INTERFACE TIER I

P805-

0RET-002

GE CONTROL INTERFACE

P302

TB31

TB31-V1

11FS-000

VEC-91

VEC91-P11

TB22

TB22-F1

15VDI-004

TB21

TB21-T2

R17

R17

0-075

-

J11

SP10

-

0-220

-

P11

-

P180

0-357

A/C COMPRESSOR CLUTCH T1

P803-

GB3 ENG GND BLOCK

GB3-A1

0RF-000

-

P13

SENSOR RIGHT FRONT WHEEL SPEED

P501

11FS-001

TB22

TB22-F2

-

P03

18AZ-000

-

J801

-

SPR_2

0-076

-

J543

-

P11

0-221

-

P11

-

J190

0-358

GB3 ENG GND BLOCK

GB3-A1

SWITCH A/C RECIEVER DRYER T1

RECDR-T1

0RF-001

-

J13

TB33

TB33-K2

11FS-002

-

J602

-

J03

18AZ-001

-

P801

-

SPR_3

0-077

-

P520

-

P543

0-222

-

J11

SP09

-

0-359

SWITCH ENGINE RUN OIL PRESSURE...

EOPSW2

-

J801-

0RF-002

GE CONTROL INTERFACE

P301

TB33

TB33-K1

11H-000

TB22

TB22-B1

RELAY VEHICLE HORN POWER (HPR)

HPR-(-)

18AZ-002

-

J801-

-

SPR_1

0-078

SOLENOID ENGINE SHUTTER (OPT)

ESSOL

-

J520-

0-223

-

J11

SP09

-

0-361

TB28

TB28-R2

GB31-B AUXBOX GND BLCK

GB31B-C4

0RF-003

GE CONTROL INTERFACE

P301

TB33

TB33-K3

11H-001

-

P03

TB22

TB22-B2

18VIM-000

INTERFACE MODULE

IM3

TB30

TB30-W1

0-079

VEC RTMR1

RTMR1-C2

GB31-A AUXBOX GND BLCK

GB31A-D1

0-225

GB31-B AUXBOX GND BLCK

GB31B-D4

-

P240

0-362

-

DIAG4

GB12 REAR CAB

GB12-C4

1M-000

RELAY MASTER DISCONNECT

MLREL

11H-002

-

J03

SWITCH HORN BUTTON

P120

18VIM-001

TB30

TB30-W1

-

J14

0-080

-

J12

SP13

-

0-226

-

P240

GB31-B AUXBOX GND BLCK

GB31B-D4

0-363

SP142

-

SP196

-

1S-000

RELAY STARTER LOCKOUT

SLREL

LAMP LED MASTER DISCONNECT OPE... MLLO SLLO LAMP LED STARTER LOCKOUT OPEN

11HL-000

VEC-89

VEC89-P12

RELAY HI-BEAM HEADLIGHT (HBHR)

HBHR-88

18VIM-002

-

P14

SENSOR STEERING PRESSURE

SPS

0-081

-

P12

-

J542

0-227

-

J240

GB8 BRAKE CABINET

GB8-1

0-364

SP147

-

SP195

-

5EFQ-000

ENGINE QSK60 INTERFACE TIER I

P805-

ENGINE QSK60 INTERFACE TIER I

P805-

11HS-000

RELAY VEHICLE HORN POWER (HPR)

HPR-30

-

J12

18VIM-003

-

J16

TB30

TB30-W1

0-082

-

P542

-

ETHER1

0-228

-

J240

GB8 BRAKE CABINET

GB8-1

0-365

PAY LOAD METER 3

P264

GB31-B AUXBOX GND BLCK

GB31B-A3

5VDI-000

-

J02

GE DID PANEL

DID

11HS-001

-

P12

-

J540

18VIM-004

-

P16

SENSOR HOIST PRESSURE #1

HPS1

0-084

-

J11

SP10

-

0-229

TB21

TB21-X1

R19

R19

0-366

JB1

JB1

5VDI-001

TB21

TB21-W2

-

P02

11HS-002

-

P540

-

P503

18VIM-005

-

J16

TB30

TB30-W1

0-085

ENGINE QSK60 INTERFACE TIER II

P806

-

J808

0-230

INTERFACE MODULE

IM1

TB21

TB21-X2

0-367

LAMP LED STARTER LOCKOUT CLOSE... SLON SP196

LAMP RED PAYLOAD LEFT

LPLR

5VDI-002

TB21

TB21-W1

GE CONTROL INTERFACE

P302

11HS-003

-

J503

SP167

-

18VIM-006

-

P16

SENSOR HOIST PRESSURE #2

HPS2

0-086

-

P808

GB31-B AUXBOX GND BLCK

GB31-D3

0-231

R18

R18

TB21

TB21-X3

0-368

SP196

-

LAMP AMBER PAYLOAD LEFT

LPLA

5VDI-003

GE CONTROL INTERFACE

P302

TB21

TB21-W1

11HS-004

SP167

-

HORN FRONT VEHICLE

AHS

18VIM-007

-

P240

TB30

TB30-W4

0-087

SWITCH A/C RECIEVER DRYER T2

RECDR

GB3 ENG GND BLOCK

GB3-A3

0-232

TB29 X5

TB29-X5

TB26 M5

TB26-M5

0-369

LAMP GREEN PAYLOAD LEFT

LPLG

SP196

-

5VDI-004

TB21

TB21-W3

GE CONTROL INTERFACE

P302

11HS-005

D1

D1

SP167

-

18VIM-008

SENSOR BRAKE PRESSURE

BPS

-

J240

0-088

A/C COMPRESSOR CLUTCH T2

P803

GB3 ENG GND BLOCK

GB3-A3

0-233

TB26 M5

TB26-M5

GB31-A AUXBOX GND BLCK

GB31A-C3

0-370

SCORE BOARD RIGHT (OPT)

CNRIN

SCORE BOARD LEFT (OPT)

CNLO

5VDI-009

-

J15

-

J702

11IM2-000

VEC-91

VEC91-P4

INTERFACE MODULE

IM1

21NSL-000

ENGINE QSK60 INTERFACE TIER II

P805

-

J808

0-090

-

P140

GB10 FRT CAB GND

GB10-A4

0-234

GB31-A AUXBOX GND BLCK

GB31A-C3

TB36

TB36-K1

0-375

TB36

TB36-R4

GB31-B AUXBOX GND BLCK

GB31B-C3

5VDI-010

-

P15

-

RRBPS

11INT-000

VEC-91

VEC91-P3

INTERFACE MODULE

IM1

21NSL-001

-

P808

TB27

TB27-E1

0-091

GB31-A AUXBOX GND BLCK

GB31A-B4

-

P04

0-235

TB36

TB36-K1

TB27

TB27-W3

0-376

RELAY WIPER MOTOR HIGH

P08

5VDI-011

-

J15

-

J702

11KS-001

-

P12

-

P536

21NSL-002

ENGINE QSK60 INTERFACE TIER I

P805-

-

J808-

0-092

SWITCH ENGINE RUN OIL PRESSURE...

EOPSW-2

-

J801

0-237

RELAY ACCESS LADDER LIGHT (ALL...

ALLR-85

GB31-A AUXBOX GND BLCK

GB31A-A4

0-377

MOTOR WINDSHIELD WASHER

WW-

RELAY HYDRAULIC LADDER PK STAT... P263 P03 -

5VDI-012

-

P15

-

LRBPS

11KS-002

-

J12

TB24

TB24-H1

21NSL-003

TB27

TB27-E2

INTERFACE MODULE

IM3

0-094

-

J12

SP12

-

0-238

TB24

TB24-X1

TB21

TB21-X4

0-378

RELAY WIPER MOTOR LOW

P09

RELAY WIPER MOTOR HIGH

P08

5VIM-000

TB30

TB30-K1

INTERFACE MODULE

IM3

11KS-003

TB24

TB24-H1

VEC-90

VEC90-P1

21NSL-004

TB27

TB27-E4

R51

R51

0-095

GB10 FRT CAB GND

GB10-A4

SWITCH BRAKE LOCK

P39

0-239

GB8 BRAKE CABINET

GB8-3

D3

D3

0-379

-

J03

GB12 REAR CAB

GB12-C3

5VIM-001

TB30

TB30-K1

INTERFACE MODULE

IM3

11KS-004

-

P03

TB24

TB24-H2

21OR-000

ENGINE QSK60 INTERFACE TIER II

P805

-

J808

0-096

SWITCH BRAKE LOCK

P39

SWITCH BRAKE LOCK

P39

0-240

-

J16

SP15

-

0-380

TIMER WASHER DELAY (WADT)

WADT-4

RELAY WIPER MOTOR LOW

P09

5VIM-002

-

J14

TB30

TB30-K2

11KS-005

-

J536

SWITCH LEFT GROUND LEVEL SHUTD...

ESDS -1

21OR-001

-

P808

TB27

TB27-K1

0-097

SWITCH BRAKE LOCK

P39

SWITCH BRAKE LOCK

P39

0-241

-

J16

SP15

-

0-381

GB10 FRT CAB GND

GB10-C3

5VIM-003

TB30

TB30-K4

-

J14

11KS-006

-

J03

SWITCH KEY (KEYSW)

KEYSW-B

21OR-002

-

J11

TB27

TB27-K3

0-098

SOLENOID BRAKE LOCK

BLS

GB8 BRAKE CABINET

GB8-3

0-242

SP15

-

-

J16

0-382

RELAY HYDRAULIC LADDER PK STAT... P263 P07 MOTOR WINDSHIELD WIPER

GB10 FRT CAB GND

GB10-C3

5VIM-004

TB30

TB30-K3

-

J14

11KS-007

-

P11

-

P533

21OR-004

-

P11

-

P170

0-099

-

P210

ENTERTAINMENT RADIO

P737

0-243

-

P16

TB61

TB61-A1

0-383

12VDC POWER PORT #1

PWR1-2

-

J03

5VIM-005

SENSOR HYDRAULIC TANK TEMP

P711

-

P14

11KS-008

-

J11

TB24

TB24-H1

21OR-005

-

J12

TB27

TB27-K3

0-100

SWITCH HEADLIGHTS

P25

SWITCH HEADLIGHTS

P25

0-244

-

P16

TB61

TB61-B1

0-384

12VDC POWER PORT #2

PWR2-2

-

J03

5VIM-006

-

J14

TB30

TB30-L2

11KS-009

-

J533

SWITCH RIGHT GROUND LEVEL SHUT...

ESDSR-1

21OR-006

-

P12

-

P504

0-101

SWITCH CAB LADDER LIGHT

P24

SWITCH MANUAL BACKUP LIGHT

P23

0-245

-

P16

TB61

TB61-C1

0-385

-

P03

GB31-A AUXBOX GND BLCK

GB31A-C1

5VIM-007

SENSOR DUCT AIR TEMPERATURE

ATS

-

P14

11L-000

VEC-91

VEC91-P3

TB22

TB22-C1

P805

-

J808

0-102

LAMP RIGHT FOG

RFLT

-

P543

0-246

TB61

TB61-A2

GB1 - REAR AXLE

GB1-A1

0-386

-

P03

GB31-A AUXBOX GND BLCK

GB31A-C4

5VIM-008

-

J14

TB30

TB30-L4

11L-001

TB22

TB22-C2

-

P03

21ORR-000 ENGINE QSK60 INTERFACE TIER II 21ORR-001 -

P808

TB27

TB27-L1

0-103

-

J543

-

P11

0-247

TB61

TB61-B2

GB1 - REAR AXLE

GB1-A2

0-387

SP198

-

TB24

TB24-X3

P2A

ORBCOMM MODULE (OPT)

CNA

11L-002

-

J03

TB10

TB10-G1

TB27

TB27-L3

-

J11

SP09

-

0-248

HORN BACKUP RIGHT

LRBH-(-)

GB1 - REAR AXLE

GB1-A3

0-388

R51

R51

TB27

TB27-W4

IPT1AX2

MOTOR WHEEL DRIVE # 1

M1-TA1

11L-003

TB10

TB10-H2

SWITCH ROTATING BEACON (OPT)

P32

21ORR-003 21ORR-004 -

J11

0-104

7HMWU-000 KOMTRAX PLUS MODULE GE CONTROL CABINET 7M1A1

P11

-

P170

0-105

LAMP LEFT FOG

LFLT

-

P542

0-249

HORN BACKUP LEFT

RRBH-(-)

GB1 - REAR AXLE

GB1-A3

0-389

-

P651

GB10 FRT CAB GND

GB10-D4

7M1A2

GE CONTROL CABINET

IPT1AX3

MOTOR WHEEL DRIVE # 1

M1-TA2

11L-004

TB10

TB10-G1

SP732

-

J12

TB27

TB27-L3

0-106

-

J542

-

P12

0-250

GB1 - REAR AXLE

GB1-A3

-

HIDBL

0-390

SWITCH CAMERA (OPT)

P31

GB10 FRT CAB GND

GB10-D4

7M1B1

GE CONTROL CABINET

IPT1BX2

MOTOR WHEEL DRIVE # 1

M1-TB1

11L-005

-

J04

LAMP CAB DOME

CDL

21ORR-005 21ORR-006 -

P12

-

P504

0-110

-

J542

-

P12

0-251

LAMP BACKUP REAR RIGHT

RRBL

GB1 - REAR AXLE

GB1-B1

0-391

SWITCH CAMERA (OPT)

P31

SWITCH CAMERA (OPT)

P31

7M1B2

GE CONTROL CABINET

IPT1BX3

MOTOR WHEEL DRIVE # 1

M1-TB2

11L-006

SWITCH HAZARD LIGHTS

P36

SWITCH HAZARD LIGHTS

P36

21PL-000

RELAY ENGINE PRELUBE

P800

0-111

LAMP HIGH MOUNT LEFT HI-BEAM

HMLHB

-

P542

0-252

LAMP BACKUP REAR LEFT

LRBL

GB1 - REAR AXLE

GB1-B1

0-392

-

J651

SP701

-

7M1C1

GE CONTROL CABINET

IPT1CX2

MOTOR WHEEL DRIVE # 1

M1-TC1

11L-007

TB22

TB22-C4

-

P04

21PL-001

D87

D87

RELAY ENGINE PRELUBE MAG SWITC... PLMS-(+) RELAY ENGINE PRELUBE MAG SWITC... PLMS-(+)

0-112

-

J542

-

P12

0-253

LAMP RETARD LEFT REAR

LRL

GB1 - REAR AXLE

GB1-A4

0-393

CAMERA CONTROLLER (OPT)

P652

SP701

-

7M1C2

GE CONTROL CABINET

IPT1CX3

MOTOR WHEEL DRIVE # 1

M1-TC2

11L-008

TB10

TB10-H2

SWITCH CAB LADDER LIGHT

P24

21PS-000

VEC-91

VEC91-P3

TB28

TB28-H1

0-113

LAMP LOW MOUNT LEFT LOW-BEAM

LMLLB

-

P542

0-254

GB1 - REAR AXLE

GB1-A4

LAMP RETARD RIGHT REAR

RRL

0-394

SP701

-

-

P650

7M2A1

GE CONTROL CABINET

IPT2AX2

MOTOR WHEEL DRIVE # 2

M2-TA1

11L-009

SP732

-

SWITCH HAZARD LIGHTS

P36

21PS-001

TB28

TB28-H2

-

P801

0-114

-

J542

-

P12

0-255

-

J11

SP08

-

0-395

-

J541

-

P11

7M2A2

GE CONTROL CABINET

IPT2AX3

MOTOR WHEEL DRIVE # 2

M2-TA2

11L-010

SP732

-

SWITCH HEADLIGHTS

P25

21PS-002

-

J801

-

J815

0-115

-

P543

0-256

-

J541

-

P11

0-396

-

P502

-

P541

7M2B1

GE CONTROL CABINET

IPT2BX2

MOTOR WHEEL DRIVE # 2

M2-TB1

11LL-000

VEC-89

VEC89-P9

SP108

-

-

P815

-

J543

0-257

-

P502

-

P541

0-397

-

P548

-

J502

7M2B2

GE CONTROL CABINET

IPT2BX3

MOTOR WHEEL DRIVE # 2

M2-TB2

11LR-000

VEC-89

VEC89-P9

RELAY HEADLIGHT LOW MOUNT (HLM... HLMR-(87) RELAY HEADLIGHT HIGH MOUNT (HH... HHMR-(87)

21PS-003

0-116

LAMP LOW MOUNT RIGHT LOW-BEAM LMRLB P11 -

21PS-004

SP108

-

0-117

-

P542

LAMP HIGH MOUNT LEFT LOW-BEAM

HMLLB

0-258

LAMP BACKUP LIGHT RIGHT DECK (...

RBUL

-

J502

0-398

-

J540

-

P12

7M2C1

GE CONTROL CABINET

IPT2CX2

MOTOR WHEEL DRIVE # 2

M2-TC1

11M-000

VEC-91

VEC91-P4

TB32

TB32-P1

21PS-005

SWITCH ENGINE PRELUBE OIL PRES... PLPSW SP108

RELAY ENGINE PRELUBE

P800

0-118

-

J542

-

P12

0-259

LAMP BACKUP LIGHT LEFT DECK (O...

LBUL

-

J503

0-399

-

P503

-

P540

7M2C2

GE CONTROL CABINET

IPT2CX3

MOTOR WHEEL DRIVE # 2

M2-TC2

11M-001

TB32

TB32-P2

-

P02

21PS-006

-

J801-

-

J815-

0-119

-

J543

-

P11

0-260

SHIFTER DIRECTION SELECTOR

P108

JB6C

JB6C

0-400

-

P549

-

J503

10V-000

GE CONTROL INTERFACE

P303

TB31

TB31-M1

11M-002

-

J02

-

MM/RPC

21PT-000

-

P12

RELAY ENG STARTER 1 (ESREL1)

ESREL1-86

0-120

-

P543

0-261

-

P503

-

P540

0-401

-

J11

SP08

-

10V-001

-

P02

TB31

TB31-M2

ACTIA DASH DISPLAY

P903

21PT-001

-

J12

TB28

TB28-J1

LAMP LOW MOUNT LEFT HI-BEAM

LMLHB

0-262

-

J540

-

P12

0-402

-

J12

SP11

-

10V-003

-

J01

ACCELERATOR PEDAL

P236

11ONS-000 11ONS-001 -

J01

0-121

LAMP HIGH MOUNT RIGHT LOW-BEAM HMRLB P542 -

P01

TB35

TB35-T1

21PT-002

-

J801

-

J815

0-122

-

P11

-

J543

0-263

-

J12

SP11

-

0-403

-

J11

SP08

-

10V-004

-

J01

RETARD CONTROL PEDAL

P235

TB35-T2

INTERFACE MODULE

IM1

21PT-003

-

-

P543

LAMP HIGH MOUNT RIGHT HI-BEAM

HMRHB

0-264

GB1 - REAR AXLE

GB1-B1

LAMP STOP/TAIL LEFT

LRSTL

0-404

-

J541

-

P11

10V-005

-

J01

RETARD CONTROL LEVER (OPT)

P237

J801

SWITCH ENGINE OIL RESERVE PRES...

ORPS-1

21PT-004

SWITCH ENGINE PRELUBE OIL PRES... PLPSW SP107

SP107

0-123

11ONS-002 TB35 11ORS-000 -

RELAY ENGINE PRELUBE

P800

0-124

-

P11

-

J543

0-265

LAMP STOP/TAIL RIGHT

RRSTL

GB1 - REAR AXLE

GB1-B3

0-405

-

P502

-

P541

10V-006

-

J02

RETARD SPEED CONTROL

RSP

P801

TB28

TB28-D1

21PT-005

SP107

-

RELAY ENGINE PRELUBE

P800

0-125

-

P543

LAMP LOW MOUNT RIGHT HI-BEAM

LMRHB

0-266

JB6C

JB6C

GB12 REAR CAB

GB12-D3

0-406

-

P546

-

J502

10V-007

TB31

TB31-N3

R17

R17

11ORS-001 11ORS-002 VEC-91

VEC91-P4

TB28

TB28-D2

21PT-006

-

P815

SP107

-

0-126

-

J11

SP10

-

0-267

TB24

TB24-X1

TB27

TB27-W3

0-407

-

J12

SP11

-

10V-008

TB31

TB31-M4

-

P01

-

J801-

21PT-007

-

P801

TB28

TB28-J3

0-127

-

J11

SP09

-

0-268

SWITCH FOG LAMP (OPT)

P22

SWITCH MANUAL BACKUP LIGHT

P23

0-408

-

J540

-

P12

10V-009

TB31

TB31-N2

-

P01

21PT-008

GE CONTROL INTERFACE

P304

TB28

TB28-J4

0-128

-

J12

SP12

-

0-269

SWITCH MANUAL BACKUP LIGHT

P23

SWITCH MANUAL BACKUP LIGHT

P23

0-409

-

P503

-

P540

10V-010

TB31

TB31-N4

-

P01

21PT-009

RELAY ENG STARTER 1 (ESREL1)

ESREL1-86

RELAY ENG STARTER 2 (ESREL2)

ESREL2-86

0-129

-

J12

SP12

-

0-270

-

J14

SP14

-

0-410

-

P547

-

J503

11-000

BATT2

BAT2(+)

BUSS BAR 24VDC BATT BOX

BUS24V-1

0-130

SP10

-

GB31-A AUXBOX GND BLCK

GB31B-A2

0-271

-

P563

-

P14

0-411

SWITCH ROTATING BEACON (OPT)

P32

GB10 FRT CAB GND

GB10-D2

11-001

BATT4

BAT4(+)

BUSS BAR 24VDC BATT BOX

BUS24V-6

0-131

SP11

-

GB31-A AUXBOX GND BLCK

GB31B-B2

0-272

-

J563

SP166

-

0-412

GB10 FRT CAB GND

GB10-D2

SWITCH HEATED MIRROR (OPT)

P33

11-002

BUSS BAR 24VDC BATT BOX

BUS24V-11

BUSS BAR 11

SDISC-1

0-132

SWITCH HAZARD LIGHTS

P36

SWITCH BRAKE TEST

P37

0-273

SP166

-

LAMP HYDRAULIC PUMP MOD (OPT)

HPML

0-413

GB31-A AUXBOX GND BLCK

GB31A-C2

SP12

-

11-003

BUSS BAR 24VDC BATT BOX

BUS24V-10

BUSS BAR 11

SDISC-2

0-133

SWITCH HAZARD LIGHTS

P36

SWITCH HAZARD LIGHTS

P36

0-274

SP166

-

0-414

GB31-A AUXBOX GND BLCK

GB31A-D2

SP13

-

11-004

24VDC AUXBOX BUSS

24VDC-A2

RELAY KEY SWITCH (KSWPR)

KSWPR-87

0-134

-

J12

SP11

-

0-276

SWITCH HYDRAULIC PUMP MOD LAMP... HPMS-3 J540 -

-

P12

0-415

GB31-B AUXBOX GND BLCK

GB31A-B2

SP15

-

11-005

24VDC AUXBOX BUSS

24VDC-A4

RELAY KEY / GE CNTRL PWR (KCNP...

KCNPR-87

0-135

-

J11

SP08

-

0-277

LAMP LEFT UPPER ENGINE SERVICE

LUESL

-

P540

0-416

GB31-B AUXBOX GND BLCK

GB31B-C2

SP08

-

11-006

CB60

CB60-1

24VDC AUXBOX BUSS

24VDC-A3

0-136

-

P12

-

J540

0-279

-

J540

-

P12

0-417

GB31-B AUXBOX GND BLCK

GB31B-D2

SP09

-

11-007

BUSS BAR 24VDC BATT BOX

BUS24V-8

24VDC AUXBOX BUSS

0-137

-

P540

-

P503

0-280

LAMP LEFT LOWER ENGINE SERVICE

LLESL

-

P540

0-420

SP09

-

-

J11

11-008

ENGINE JUMP START1

-

0-138

-

J503

SP142

-

0-282

-

J541

-

P11

0-421

SP08

-

-

J11

11-009

ENGINE JUMP START2

0-139

SP142

-

0-283

LAMP RIGHT UPPER ENGINE SERVIC...

RUESL

-

P541

0-422

SP11

-

-

J12

11-010

0-140

SP142

-

LAMP MARKER/TURN LEFT SIDE DEC... LCL1 LAMP MARKER/TURN LEFT FRT DECK LCL2

0-285

-

J541

-

P11

0-423

-

J14

SP14

-

0-141

-

P11

-

J541

0-286

-

P541

SP165

-

0-424

-

J12

SP12

0-142

-

P541

-

P502

0-287

SP165

-

0-425

-

J12

0-143

-

J502

SP147

-

0-288

SWITCH RIGHT ENGINE SERVICE LA...

RESLS-1

LAMP RIGHT LOWER ENGINE SERVIC... RLESL SP165

0-426

-

0-144

SP147

-

0-290

-

J540

-

P12

0-427

0-145

SP147

-

LAMP MARKER/TURN RIGHT FRT DEC... RCL1 LAMP MARKER/TURN RIGHT SIDE DE... RCL2

0-291

-

P503

-

P540

0-146

-

J16

SP15

-

0-292

-

J503

SP168

0-147

-

J14

SP14

-

0-293

HORN FRONT VEHICLE

AHS

0-149

-

P14

-

P732

0-294

D1

0-150

SWITCH FOG LAMP (OPT)

P22

SWITCH FOG LAMP (OPT)

P22

0-295

0-151

SWITCH FOG LAMP (OPT)

P22

GB10 FRT CAB GND

GB10-A3

0-156

-

P16

-

P731

0-034 0-040

HBHR-85

VEC-90

PBPSW

11ORS-003 SWITCH ENGINE OIL RESERVE PRES... ORPS1 RELAY ENGINE PRELUBE MAG SWITC... PLMS-2 11PF-000 FUS-2 FUSE LINK1 (150A) 11PL-000

ENGINE PRELUBE HIGH VOLUME PUM... PLPM-(+) RELAY ENGINE PRELUBE MAG SWITC... PLMS-1

11POR-000 11POR-001 -

J801

SWITCH ENGINE OIL RESERVE PRES...

ORPS-2

21PT-010

INTERFACE MODULE

IM3

TB28

TB28-J1

P801

TB28

TB28-E1

21PT-011

-

J801-

-

J815-

11POR-002 TB28 11POR-003 TB28

TB28-E2

-

J11

21PT-012

D87

D87

SP107

-

TB28-E2

-

J12

21S-000

SWITCH KEY (KEYSW)

KEYSW-C

-

J03

11POR-004 11POR-005 -

P11

-

J190

21S-001

-

P03

TB22

TB22-H1

P12

-

J506

21S-002

TB22

TB22-H4

VEC-91

VEC91-P2

J801-

SWITCH ENGINE OIL RESERVE PRES...

ORPS2

21S-003

TB22

TB22-H2

INTERFACE MODULE

IM2

24VDC-A1

11POR-006 SWITCH ROTATING BEACON (OPT) 11RB-000

P32

-

J03

21SL-000

VEC-91

VEC91-P4

INTERFACE MODULE

IM1

BUSS BAR 24VDC BATT BOX

BUS24V-2

11RB-001

-

P03

TB22

TB22-E1

22C-000

JB41

JB41

SWITCH A/C RECIEVER DRYER T2

RECDR

-

BUSS BAR 24VDC BATT BOX

BUS24V-3

11RB-002

TB22

TB22-E2

-

J11

22C-001

JB41

JB41

-

J808

24VDC AUXBOX BUSS

24VDC-B1

VEC-90

VEC90-P2

11RB-003

-

J12

TB22

TB22-E4

22C-002

ENGINE QSK60 INTERFACE TIER II

P806

JB41

JB41

11-011

24VDC AUXBOX BUSS

24VDC-B4

VEC-91

VEC91-S5A

11RB-004

TB22

TB22-E3

-

P04

22C-003

ENGINE QSK60 INTERFACE TIER II

P806

JB41

JB41

-

11-012

24VDC AUXBOX BUSS

24VDC-B2

VEC-89

VEC89-S8A

11RB-005

-

P11

-

J541

22C-005

-

P808

TB27

TB27-G1

SP12

-

11-013

24VDC ALTERNATOR

ALT_SEN

BUSS BAR 24VDC BATT BOX

BUS24V-9

11RB-006

-

J540

-

P12

22C-006

-

J808-

JB41-

JB41-

J12

SP11

-

11-020

BUSS BAR 11

SDISC-7

11RB-007

-

P541

-

P502

22C-007

SWITCH A/C RECIEVER DRYER T1

RECDR-T1

JB41-

JB41-

-

P04

GB31-A AUXBOX GND BLCK

GB31A-B4

11-021

LAMP LED MASTER DISCONNECT CL... MLLON SDISC-7 BUSS BAR 11

RELAY MASTER DISCONNECT

MLREL

11RB-008

-

P503

-

P540

22C-008

JB41-

JB41-

ENGINE QSK60 INTERFACE TIER I

P806-

0-428

-

J04

-

RRBB2

11-022

RELAY MASTER DISCONNECT

MLREL

RELAY MASTER DISCONNECT

MLREL

11RB-009

-

J502

-

P548

22C-009

JB41-

JB41-

ENGINE QSK60 INTERFACE TIER I

P805-

-

0-429

SOLENOID ETHER START (OPT)

ESOL

-

ETHER2-

11-025

RELAY ENG STARTER 1 (ESREL1)

ESREL1-88

BUSS BAR 24VDC BATT BOX

BUS24V-4

11RB-010

-

P549

-

J503

22FO-000

ENGINE QSK60 INTERFACE TIER II

P806

-

J808

SP168

-

0-430

-

R546

MIRROR HEATED RIGHT DECK (OPT)

MIRROR1

11-026

BUSS BAR 24VDC BATT BOX

BUS24V-5

RELAY ENG STARTER 2 (ESREL2)

ESREL2-88

11RB-011

-

J04

-

RRBB1

22FO-001

-

P808

TB31

TB31-X1

D1

SP168

-

0-431

-

L547

MIRROR HEATED LEFT DECK (OPT)

MIRROR2

11-027

BUSS BAR 24VDC BATT BOX

BUS24V-7

24VDC ALTERNATOR

ALT (+)

VEC91-P4

TB28

TB28-L1

22FO-002

ENGINE QSK60 INTERFACE TIER I

P806-

-

J808-

TB61

TB61-A4

GB1 - REAR AXLE

GB1-B2

0-432

-

J16

GB31-A AUXBOX GND BLCK

GB31A-D3

11-028

SWITCH PROPEL LOCKOUT (PLOS)

PLOS-F2

RELAY 1 PROPEL LOCKOUT

PLREL

11RCNT-000 VEC-91 11RCNT-001 TB28

TB28-L1

-

J12

23D-000

VEC-90

VEC90-P4

TB27

TB27-J1

0-296

-

P704

GB1 - REAR AXLE

GB1-B4

0-433

-

P16

-

RBML

11-029

SWITCH PROPEL LOCKOUT (PLOS)

PLOS-F2

BUSS BAR 11

SDISC-6

P12

-

P505-

23D-001

R5

R5

TB27

TB27-J4

0-297

-

J704

SP169

-

0-434

-

J12

GB31-A AUXBOX GND BLCK

GB31A-D3

11-030

BUSS BAR 11

SDISC-6

RELAY STARTER LOCKOUT

SLREL

11RCNT-002 11RCNT-003 TB28

TB28-L1

-

J11

23D-002

R3

R3

TB27

TB27-J3

58E-06-02000-00 NOV 11 ELECTRICAL SCHEMATIC 830E-1AC A40851 & UP Sheet 16 of 20

WIRE TABLE WIRE LIST NAME

WIRE LIST

23D-003

DEVICE FROM R4

23F-000

-

CONN FROM DEVICE TO TB27 R4 TB22 J702

CONN TO TB27-J2

23F-001

TB22

TB22-L2

-

23F-002

-

J02

23FA-000

VEC-90

VEC90-P4

SWITCH CAB SECONDARY ENGINE SH... ESS_1-3 J702

24SON-000 JB4D 24SON-001 R16

JB4D

SONALERT (SONA)

SONA(+)

R16

JB4D

JB4D

24SON-002 D9 24SON-003 JB4D

D9

JB4D

JB4D

JB4D

D10

D10

24VIM-000 INTERFACE MODULE 24VIM-001 TB32

IM1

TB32

TB32-H2

TB32-H1

VEC-91

VEC91-P2

24VIM-002 TB32 24VIM-004 ACTIA DASH DISPLAY

TB32-H1

VEC-89

VEC89-P2

35L9-001 SCORE BOARD LEFT (OPT) 35L10-000 SCORE BOARD RIGHT (OPT)

P902

-

J01

36-000

24VIM-005 TB32 24VIM-006 TB32

TB32-G1

-

P01

TB32-G4

-

24VIM-007 D10 24VIM-008 TB32

D10

24VIM-009 RELAY ENG STARTER 1 (ESREL1) 25A-000

TB22-L1 P02

NAME

CONTINUED FROM DIAGRAM 16 & 18

WIRE LIST

DEVICE FROM 35L3-003 35L4-000 PAY LOAD METER 3

CONN FROM DEVICE TO J02 TB36 P264

CONN TO DIAG7

35L4-001 35L4-002 TB36

J362

TB36

TB36-N2

TB36-N4

-

P02

35L4-003 35L7-000 PAY LOAD METER 3

J02

-

DIAG7

P264

TB36

TB36-R1

35L7-001 SCORE BOARD LEFT (OPT) 35L8-000 PAY LOAD METER 3

CNLIN

TB36

P264

35L8-001 SCORE BOARD LEFT (OPT) 35L9-000 PAY LOAD METER 3

TB36-N1

NAME

DEVICE FROM CONN FROM DEVICE TO 41LM-000 RELAY HEADLIGHT LOW MOUNT (HLM... HLMR-(30) RELAY HEADLIGHT LOW MOUNT (HLM... J11 41LM-001 P12 41LM-002 -

WIRE LIST CONN TO J12

NAME 45R-005

DEVICE FROM TB10

HLMR-(30)

45R-006

-

J542

45RA-000 CAMERA CONTROLLER (OPT) 45RL-000 VEC-89

P652

-

VEC89-P12

45RL-001 TB35 45RL-002 -

41LM-003 LAMP LOW MOUNT LEFT LOW-BEAM 41LM-004 -

LMLLB

-

P542

P11

-

J543

LMRLB

-

P543

TB36-R2

41LM-005 LAMP LOW MOUNT RIGHT LOW-BEAM VEC-89 41T-000

VEC89-P11

TB35

TB35-E1

TB36

TB36-S1

41T-001

TB35

TB35-E2

-

J12

CNLIN

TB36

TB36-S2

41T-002

TB35

TB35-E4

-

J11

P264

TB36

TB36-T1

41T-003

-

P12

-

J540

CNLIN

TB36

TB36-T2

41T-004

-

P540

-

P503

CNRIN

SCORE BOARD LEFT (OPT)

CNLO

41T-005

-

J503

SP143

-

-

J801

SWITCH ENGINE RUN OIL PRESSURE...

EOPSW-1

41T-006

SP143

-

LAMP MARKER/TURN LEFT SIDE DEC...

LCL1

36-001

-

P801

TB28

TB28-A1

41T-007

SP143

-

LAMP MARKER/TURN LEFT FRT DECK

LCL2

P04

36-002

TB28

TB28-A2

VEC-90

VEC90-P9

41T-008

-

P11

-

J541

-

J04

36-003

-

J801-

SWITCH ENGINE RUN OIL PRESSURE...

EOPSW1

41T-009

-

P541

-

P502

TB32-H2

-

J14

38G-000

TB35

TB35-C1

INTERFACE MODULE

IM3

41T-010

-

J502

SP146

-

P14

SENSOR HYDRAULIC TANK LEVEL

P712

38G-001

TB35

TB35-C4

-

J16

41T-011

SP146

-

LAMP MARKER/TURN RIGHT FRT DEC...

RCL1

ESREL1-88a M0TOR STARTER 1 (STRT1) ESREL2-88a MOTOR STARTER 2 (STRT2)

STRT1-3

38G-002

R15

R15

TB35

TB35-C2

41T-012

SP146

-

LAMP MARKER/TURN RIGHT SIDE DE...

RCL2

STRT2-3

38G-003

-

P16

-

J730

41T-013

TB35

TB35-E4

-

J14

27LPR-000 ENGINE QSK60 INTERFACE TIER II 27LPS-000 ENGINE QSK60 INTERFACE TIER II

P826

-

LP

38G-004

SENSOR FUEL LEVEL

FLS

-

P730

41T-014

-

P14

-

P732

P826

-

LP

39-000

-

J702

INTERFACE MODULE

IM2

41T-015

TB35

TB35-E2

-

J16

27WR-000 ENGINE QSK60 INTERFACE TIER II 27WS-000 ENGINE QSK60 INTERFACE TIER II

P826

-

WIF

39-001

-

J702

-

J14

41T-016

-

P16

SP149

-

P826

-

WIF

39-002

-

P14

-

ATFS

41T-017

SP149

-

-

P731

25B-000

RELAY ENG STARTER 2 (ESREL2)

CONN FROM DEVICE TO TB10-M3 CAMERA CONTROLLER (OPT) J651

WIRE LIST CONN TO P651

NAME 48LF-005

DEVICE FROM -

P652

48LF-006

P650

49-001

TB35

TB35-K1

TB35-K2

-

P11

45RL-003 45RL-004 -

WIRE LIST CONN TO RFLT

NAME 67L-000

DEVICE FROM MOTOR LEFT WINDOW

-

CONN FROM DEVICE TO LAMP RIGHT FOG P543 LAMP LEFT FOG P542

LFLT

67L-001

SWITCH LEFT WINDOW

CONN FROM DEVICE TO SP779 P059 SP779 P072

CONN TO -

ACTIA DISPLAY PANEL DIMMER

P18

TB10

TB10-D2

67M-000

MOTOR LEFT WINDOW

P059

SP778

-

49-002

ACTIA DASH DISPLAY

P903

TB10

TB10-D3

67M-001

SWITCH LEFT WINDOW

P072

SP778

-

J11

49-003

JB6B

JB6B

TB10

TB10-D4

67P-000

TB24

TB24-T2

VEC-91

VEC91-P9

-

J541

49-004

SHIFTER DIRECTION SELECTOR

P108

JB6B

JB6B

67P-001

TB24

TB24-T1

-

P03

P541

-

P502

49-005

R27

R27

TB10

TB10-D2

67P-002

TB24

TB24-T1

-

P03

J502

SP145

-

49-006

JB6B

JB6B

67P-003

-

J03

SP135

-

45RL-005 ACTIA DASH DISPLAY 45RL-006 -

P902

-

J01

49-007

JB6B

JB6B

SWITCH CAB SECONDARY ENGINE SH... ESS-A SWITCH BODYUP OVERRIDE / RESET... ORS-A

67P-004

-

J03

SP135

-

P01

TB35

TB35-K3

49-008

JB6B

JB6B

SWITCH RETARD SPEED CONTROL (R...

RSCS-A

67P-005

SP135

-

SWITCH LEFT WINDOW

P072

45RL-007 SP145 45RL-008 TB35

-

51A1-000

-

J13

INTERFACE MODULE

IM2

67P-006

SWITCH LEFT WINDOW

P072

SP135

-

TB35-K4

LAMP MARKER/TURN RIGHT FRT DEC... RCL1 J16 -

51A1-001

-

P13

67R-000

TB24

TB24-S2

VEC-91

VEC91-P9

45RL-009 SP145 45RL-010 -

-

LAMP MARKER/TURN RIGHT SIDE DE...

RCL2

51A2-000

67R-001

TB24

TB24-S1

-

P03

P16

SP148

-

52A-000

SWITCH ACCUMULATOR PRESSURE #1... ACCP1-NO J240 -

SWITCH ACCUMULATOR PRESSURE #1... ACCP1-C SWITCH ACCUMULATOR PRESSURE #2... ACCP2-NO

67R-002

TB24

TB24-S1

-

P03

45RL-011 SP148 45RL-012 SP148

-

-

P731

52A-001

-

P240

SWITCH PARK BRAKE RELEASE PRES... PBRPS TB32-N2 TB32

67R-003

-

J03

SP138

-

-

TB60

TB60-H1

IM2

-

J702

67R-004

-

J03

SP138

-

45RL-013 TB60 45RL-014 -

TB60-H2

-

P55

52AA2-000 INTERFACE MODULE 52ABA-000 INTERFACE MODULE

IM1

TB32

TB32-S1

67R-005

SP138

-

SWITCH RIGHT WINDOW

P071

J55

SP172

-

TB32-S1

VEC RTMR1

RTMR1-F2

67R-006

SWITCH RIGHT WINDOW

P071

SP138

-

45RL-015 LAMP BODY RIGHT SIDE MARKER 45RL-016 LAMP BODY RIGHT REAR MARKER

RSCL1

SP172

-

52ABA-001 TB32 VEC-90 52B-000

VEC90-P9

TB32

TB32-J1

67S-000

MOTOR RIGHT WINDOW

P058

SP782

-

RSCL2

SP172

-

52B-001

INTERFACE MODULE

IM2

TB32

TB32-J1

67S-001

SWITCH RIGHT WINDOW

P071

SP782

-

46GA-000 TB32 46GA-001 -

TB32-A1

-

J702

52B-002

VEC RTMR1

RTMR1-D2

TB32

TB32-J1

67T-000

MOTOR RIGHT WINDOW

P058

SP783

-

P16

-

RBML

52B-003

TB32

TB32-J4

-

P240

67T-001

SWITCH RIGHT WINDOW

P071

SP783

-

46GA-002 46GA-003 -

J16

TB32

TB32-A2

52B-004

-

J240

SP160

-

68-000

TB34

TB34-M1

INTERFACE MODULE

IM3

P12

-

J540

52B-005

SP160

-

SOLENOID BRAKE LOCK

BLS

68-001

TB34

TB34-M1

VEC-89

VEC89-P4

46GA-004 46GA-005 TB32

J12

TB32

TB32-A2

52B-006

SP160

-

D3

D3

68-002

TB34

TB34-M1

-

J11

TB32-A1

-

J11

52B1-000

VEC-90

VEC90-P9

TB23

TB23-B1

68-003

-

J511

-

P11

46GA-006 46GA-007 -

J541

-

P11

52B1-001

-

P03

TB23

TB23-B2

68-004

SOLENOID AUTO LUBE

LLSOL

-

P511

P502

-

P541

52B1-002

-

J03

SWITCH BRAKE LOCK

P39

68-005

-

J12

TB34

TB34-M2

46GA-008 46GA-009 -

RDML

-

J502

52B1-003

SWITCH BRAKE LOCK

P39

SWITCH BRAKE LOCK

P39

68ES-000

-

J11

SP785

-

P503

-

P540

52C-000

SHIFTER DIRECTION SELECTOR

P108

-

J02

68ES-001

-

J511

-

P11

46GA-010 46GA-011 -

J503

-

LDML

52C-001

-

P02

TB21

TB21-K2

68ES-002

SOLENOID AUTO LUBE

LLSOL

-

P511

RBML1

-

RBML2

52C-002

TB21

TB21-K1

-

J701

68ES-003

VEC-89

VEC89-P2

SP785

-

46RA-000 TB32 46RA-001 -

TB32-B1

-

J702

52CA-000

TB24

TB24-E2

GE CONTROL INTERFACE

P304

68ES-004

-

J12

SP785

-

P16

-

RBML

52CA-001

-

J701

TB24

TB24-E1

68LS-000

SWITCH AUTOLUBE LEVEL (OPT)

ALLSW

-

P511

46RA-002 46RA-003 -

J16

TB32

TB32-B2

52CA-003

TB24

TB24-E4

INTERFACE MODULE

IM3

68LS-001

-

J511

-

P11

P12

-

J540

52CS-000

VEC-90

VEC90-P11

TB32

TB32-K3

68LS-002

INTERFACE MODULE

IM3

SP786

-

46RA-004 46RA-005 -

J12

TB32

TB32-B2

52CS-001

TB32

TB32-K3

INTERFACE MODULE

IM1

68LS-003

-

J12

SP786

-

J11

TB32

TB32-B1

52CS-002

TB32

TB32-K2

R18

R18

68LS-004

-

J11

SP786

-

46RA-006 46RA-007 -

J541

-

P11

52CS-003

-

P240

TB32

TB32-K1

68P-000

TB60

TB60-B2

SWITCH AUTOLUBE PRESSURE

LLPS

P541

-

P502

52CS-004

SOLENOID PARK BRAKE

PBS

SP161

-

68P-001

TB60

TB60-B1

-

P16

46RA-008 46RA-009 -

RDML

-

J502

52CS-005

D2

D2

SP161

-

68P-002

TB35

TB35-W2

-

J16

P540

-

P503

52CS-006

SP161

-

-

J240

68P-003

TB35

TB35-W1

INTERFACE MODULE

IM3

46RA-010 46RA-011 -

J503

-

LDML

52PB-000

VEC-90

VEC90-P11

TB24

TB24-B1

68P-004

TB35

TB35-W3

VEC-89

VEC89-P4

RBML1

-

RBML2

52PB-001

TB24

TB24-B4

-

P03

68T-000

SWITCH AUTOLUBE PRESSURE

LLPS

TB60

TB60-M2

46YA-000 TB32 46YA-001 -

TB32-C1

-

J702

52PB-003

TB24

TB24-B2

INTERFACE MODULE

IM3

68T-001

TB60

TB60-M1

-

P16

P16

-

RBML

52PB-004

-

J03

68T-002

TB35

TB35-R2

-

J16

46YA-002 46YA-003 -

J16

TB32

TB32-C2

52R-000

-

J01

RELAY HYDRAULIC LADDER PK STAT... P263 P237 RETARD CONTROL LEVER (OPT)

68T-003

VEC-89

VEC89-P4

TB35

TB35-R3

P12

-

J540

52R-001

TB31

TB31-K2

-

P01

68T-004

TB35

TB35-R1

INTERFACE MODULE

IM1

46YA-004 46YA-005 -

J12

TB32

TB32-C2

52R-002

TB31

TB31-K1

-

J701

68T-005

TB35

TB35-R4

R30

R30

J11

TB32

TB32-C1

52RA-000

GE CONTROL INTERFACE

P302

SP740

-

69M-000

VEC-89

VEC89-P1

TB23

TB23-F1

46YA-006 46YA-007 -

J541

-

P11

52RA-001

SP740

-

-

J701

69M-001

TB23

TB23-F2

-

J11

P541

-

P502

-

P262

69M-002

TB23

TB23-F2

-

J12

46YA-008 46YA-009 -

RDML

-

J502

-

P262

69M-003

-

P11

-

J541

P503

-

P540

52RS1-000 RELAY HYDRAULIC LADDER PK STAT... P263 52RS2-000 RELAY HYDRAULIC LADDER PK STAT... P263 HLS SWITCH HOIST LIMIT 53H-000

TB60

TB60-J2

69M-004

-

P12

-

J540

J503

-

LDML

53H-001

-

J16

TB35

TB35-N1

69M-005

-

P541

-

P502

RBML1

-

RBML2

53H-002

TB60

TB60-J1

-

P16

69M-006

-

P540

-

P503

-

28E-000

VEC-91

VEC91-P12

-

J12

39A-000

PAY LOAD METER 3

P264

TB34

TB34-S1

41T-018

SP149

-

TB61

TB61-M1

28E-001

-

P12

-

J542

39A-001

VEC-90

VEC90-P2

TB34

TB34-S2

41T-019

LAMP STOP/TAIL LEFT

LRSTL

TB61

TB61-M2

28E-002

-

P542

-

ETHER1

VEC90-P3

TB23

TB23-C1

41T-020

LAMP STOP/TAIL RIGHT

RRSTL

TB61

TB61-M2

28E-003

-

ETHER2-

SOLENOID ETHER START (OPT)

ESOL

39AA-000 VEC-90 39AA-001 TB23

TB23-C1

-

J11

41T-021

TB61

TB61-M4

-

J54

28EC-000

VEC-91

VEC91-P12

TB27

TB27-H2

P11

-

J541

41T-022

TB61

TB61-M4

-

P55

28EC-001

ENGINE QSK60 INTERFACE TIER II

P805

-

J808

39AA-002 39AA-004 -

P541

-

P502

41T-023

-

J55

SP173

-

28EC-002

-

P808

TB27

TB27-H1

J502

LAMP RED PAYLOAD RIGHT

RPLR

41T-024

LAMP BODY RIGHT SIDE MARKER

RSCL1

SP173

-

28EC-003

ENGINE QSK60 INTERFACE TIER I

P806-

-

J808-

39AA-005 39AA-006 TB23

TB23-C1

-

J12

41T-025

-

P54

SP176

-

31ILM-000 INTERFACE MODULE 31IML-001 TB34

IM1

TB34

TB34-N2

P12

-

J540

41T-026

SP176

-

LAMP BODY LEFT REAR MARKER

LSCL2

TB34-N1

-

P04

39AA-007 39AA-008 -

P540

-

P503

41T-027

LAMP BODY LEFT SIDE MARKER

LSCL1

SP176

-

31IML-002 SONALERT (SONA) 31IML-003 SP723

SONA(-)

SP723

-

J503

LAMP RED PAYLOAD LEFT

LPLR

41T-028

LAMP BODY RIGHT REAR MARKER

RSCL2

SP173

-

-

R16

R16

39AA-009 39AP-000 -

J16

-

J702

41TS-000

SWITCH HEADLIGHTS

P25

TB10

TB10-A1

31IML-004 31RR-000 -

J04

SP723

-

P16

-

J730

41TS-001

SWITCH HEADLIGHTS

P25

SWITCH HEADLIGHTS

P25

J02

SWITCH RETARD SPEED CONTROL (R...

RSCS_2-1

39AP-001 39AP-002 -

P730

SWITCH HYDRAULIC FILTER #1

HFSW1

41TS-002

TB10

TB10-A3

-

J02

31RR-001

-

P02

TB31

TB31-E2

J702

-

J14

41TS-003

-

P02

TB34

TB34-A2

31RR-002

GE CONTROL INTERFACE

P304

TB31

TB31-E1

39AP-003 39AP-004 -

P14

-

ATFS

41TS-004

SWITCH LEFT WINDOW

P072

JB6A

JB6A

33-000

-

J240

SWITCH PARK BRAKE SET

PBPSW

39B-000

PAY LOAD METER 3

P264

TB34

TB34-R1

41TS-005

VEC-89

VEC89-P11

TB34

TB34-A1

33-001

TB32

TB32-D2

-

P240

39B-001

VEC-90

VEC90-P2

TB34

TB34-R2

41TS-006

ACTIA DISPLAY PANEL DIMMER

P18

TB10

TB10-A4

33-002

TB32

TB32-D1

INTERFACE MODULE

IM2

VEC90-P2

TB23

TB23-D1

41TS-007

SWITCH RIGHT WINDOW

P071

JB6A

JB6A

33BP-000

-

J240

TB23-D1

-

J11

41TS-008

SWITCH RIGHT WINDOW

P071

SWITCH RIGHT WINDOW

P071

33BP-001

TB32

TB32-E2

SWITCH LOW BRAKE ACCUM PRESSUR... LBPS P240 -

39BA-000 VEC-90 39BA-001 TB23

P11

-

J541

41TS-009

SWITCH LEFT WINDOW

P072

SWITCH LEFT WINDOW

P072

33BP-002

TB32

TB32-E1

INTERFACE MODULE

IM2

39BA-002 39BA-004 -

P541

-

P502

41TS-010

JB6A

JB6A

TB10

TB10-A1

33BPS-000 INTERFACE MODULE 33BPS-001 -

IM3

TB30

TB30-M2

J502

LAMP AMBER PAYLOAD RIGHT

RPLA

41TS-011

-

P140

JB6A

JB6A

P240

TB30

TB30-M1

39BA-005 39BA-006 TB23

TB23-D1

-

J12

42-000

TIMER (1HR) ENGINE SERVICE LAM...

ESLT-NO

TB35

TB35-M1

33BPS-002 SENSOR BRAKE PRESSURE 33ES1-000 INTERFACE MODULE

BPS

-

J240

P12

-

J540

42-001

-

J11

TB35

TB35-M2

IM1

TB26

TB26-A3

39BA-007 39BA-008 -

P540

-

P503

42-002

-

J11

TB35

TB35-M2

33ES1-001 TB26 33ES1-002 R23

TB26-A4

GE CONTROL INTERFACE

P302

J503

LAMP AMBER PAYLOAD LEFT

LPLA

42-003

-

J541

-

P11

R23

TB26

TB26-A1

39BA-009 39C-000 PAY LOAD METER 3

P264

TB34

TB34-P1

42-004

-

J541

-

P11

33ES2-000 INTERFACE MODULE 33ES2-001 TB26

IM1

TB26

TB26-B3

39C-001

VEC-90

VEC90-P2

TB34

TB34-P2

42-005

-

P541

LAMP RIGHT LOWER ENGINE SERVIC...

RLESL

TB26-B4

GE CONTROL INTERFACE

P302

VEC90-P2

TB23

TB23-E1

42-006

-

P541

LAMP RIGHT UPPER ENGINE SERVIC...

RUESL

33ES2-002 R34 33F-000

R34

TB26

TB26-B1

39CA-000 VEC-90 39CA-001 TB23

TB23-E1

-

J11

42-007

-

J12

TB35

TB35-M3

P14

SWITCH LOW STEERING PRESSURE

ACPSW

39CA-002 39CA-004 -

P11

-

J541

42-008

-

J12

TB35

TB35-M3

46YA-010 46YA-011 -

P541

-

P502

42-009

-

J540

-

P12

47-000

RELAY BACKUP LIGHT (BULR)

BULR-30

TB35

TB35-L1

53H-003

TB35

TB35-N2

-

P240

69M-007

-

J502

-

P546

39CA-005 39CA-006 TB23

J502

LAMP GREEN PAYLOAD RIGHT

RPLG

42-010

-

J540

-

P12

47-001

TB35

TB35-L2

-

J16

53H-004

-

J240

SOLENOID HOIST LIMIT

HS

69M-008

-

J503

-

P547

TB23-E1

-

J12

42-011

LAMP LEFT LOWER ENGINE SERVICE

LLESL

-

P540

47-002

TB35

TB35-L2

-

J16

55A-000

SWITCH DISPLAY MODE #2

P20

-

J01

69M-009

-

R546

MIRROR HEATED RIGHT DECK (OPT)

MIRROR1

39CA-007 39CA-008 -

P12

-

J540

42-012

LAMP LEFT UPPER ENGINE SERVICE

LUESL

-

P540

47-003

-

P16

TB60

TB60-F1

55A-001

-

P01

TB26

TB26-N1

69M-010

-

L547

MIRROR HEATED LEFT DECK (OPT)

MIRROR2

P540

-

P503

42A-000

SWITCH LEFT ENGINE SERVICE LAM...

LESLS-2

-

P540

47-004

-

P16

TB60

TB60-F1

55A-002

TB26

TB26-N2

INTERFACE MODULE

IM3

69MA-000

SWITCH HEATED MIRROR (OPT)

P33

-

J03

J503

LAMP GREEN PAYLOAD LEFT

LPLG

42A-001

-

J540

-

P12

47-005

TB60

TB60-F2

-

HIDBL

55B-000

SWITCH DISPLAY MODE #2

P20

-

J01

69MA-001

-

P03

TB28

TB28-W1

P264

TB36

TB36-C2

42A-002

-

J12

-

J11

47-006

TB60

TB60-F4

LAMP BACKUP REAR RIGHT

RRBL

55B-001

-

P01

TB26

TB26-P1

69MA-002

TB28

TB28-W2

VEC-89

VEC89-P1

33F-001

-

J14

INTERFACE MODULE

IM2

33H-000

R44

R44

GE CONTROL INTERFACE

P304

33HP1-000 INTERFACE MODULE 33HP1-001 TB30

IM3

TB30

TB30-N1

TB30-N1

-

J16

33HP1-002 SENSOR HOIST PRESSURE #1 33HP2-000 TB28

HPS1

-

P16

TB28-K1

INTERFACE MODULE

IM3

33HP2-001 33HP2-002 -

J16

TB28

TB28-K1

39CA-009 39F-000 PAY LOAD METER 3

P16

SENSOR HOIST PRESSURE #2

HPS2

39F-001

TB36

TB36-C1

-

J13

42A-003

-

P11

-

J541

47-007

TB60

TB60-F3

LAMP BACKUP REAR LEFT

LRBL

55B-002

TB26

TB26-P2

INTERFACE MODULE

IM3

71ABA-000

TB32

TB32-T1

VEC RTMR1

RTMR1-F1

33J-000

VEC-89

VEC89-P1

-

J14

39F-002

TB36

TB36-C1

-

J13

42A-004

-

P541

SWITCH RIGHT ENGINE SERVICE LA...

RESLS-2

47-008

TB35

TB35-L3

-

J11

55C-000

SWITCH DISPLAY MODE #1

P21

-

J01

71ABA-001

VEC RTMR1

RTMR1-D1

VEC RTMR1

RTMR1-F1

33J-001

SP184

-

-

P14

39F-003

SENSOR PAYLOAD PRESSURE LEFT R...

P152

TB61

TB61-F1

42B-000

-

P540

SWITCH LEFT ENGINE SERVICE LAM...

LESLS-3

47-009

-

P11

-

J541

55C-001

-

P01

TB26

TB26-R1

71ABA-002

TB32

TB32-T1

VEC-90

VEC90-P11

33J-002

SOLENOID STEERING BLEED DOWN

ACCBD

SP184

-

39F-004

SENSOR PAYLOAD PRESSURE RIGHT ...

P153

TB61

TB61-F1

42B-001

-

P12

-

J540

47-010

-

P541

-

P502

55C-002

TB26

TB26-R2

INTERFACE MODULE

IM3

71BC-000

VEC-90

VEC90-P9

TB25

TB25-V4

33J-003

D26

D26

SP184

-

39F-007

-

P13

SENSOR PAYLOAD PRESSURE RIGHT ...

P150

42B-002

-

J11

-

J12

47-011

-

J502

LAMP BACKUP LIGHT RIGHT DECK (...

RBUL

55D-000

SWITCH DISPLAY MODE #1

P21

-

J01

71BC-001

TB25

TB25-V3

R23

R23

33JA-000

-

P14

SWITCH STEERING BLEED PRESSURE

SABS

39F-008

-

P13

SENSOR PAYLOAD PRESSURE LEFT F...

P151

42B-003

-

J541

-

P11

47-012

TB35

TB35-L3

-

J12

55D-001

-

P01

TB26

TB26-S1

71BC-002

TB25

TB25-V1

R34

R34

33JA-001

-

J14

INTERFACE MODULE

IM2

39F-009

TB36

TB36-C3

-

J16

42B-004

SWITCH RIGHT ENGINE SERVICE LA...

RESLS-3

-

P541

47-013

-

P12

-

J540

55D-002

TB26

TB26-S2

INTERFACE MODULE

IM2

71BC-003

TB25

TB25-V2

-

P240

33JB-000

INTERFACE MODULE

IM1

TB30

TB30-D1

39F-010

TB36

TB36-C4

SP744

-

J14

TIMER (1HR) HYDRAULIC PUMP MOD...

HPLT-NO

47-014

-

P540

-

P503

62A-000

VEC-89

VEC89-P2

INTERFACE MODULE

IM1

71BC-004

JB4A

JB4A

D2

D2

33JB-001

TB30

TB30-D4

-

J14

39F-011

-

P16

TB61

TB61-F2

42PML-000 42PML-001 -

P563

-

P14

47-015

-

J503

LAMP BACKUP LIGHT LEFT DECK (O...

LBUL

62SB-000

INTERFACE MODULE

IM2

TB28

TB28-X1

71BC-005

JB4A

JB4A

SOLENOID PARK BRAKE

PBS

33JB-002

-

P14

SP183

-

39F-012

SP744

-

INCLINOMETER

P246

J563

LAMP HYDRAULIC PUMP MOD (OPT)

HPML

47A-000

VEC-89

VEC89-P11

RELAY BACKUP LIGHT (BULR)

BULR-(+)

62SB-001

TB28

TB28-X2

-

P02

71BC-006

JB4A

JB4A

SWITCH SERVICE BRAKE PSI

SBPS

33JB-003

SOLENOID STEERING BLEED DOWN

ACCBD

SP183

-

TB36-E2

PAY LOAD METER 3

P264

J14

TIMER (1HR) HYDRAULIC PUMP MOD...

HPLT-3

47B-000

VEC-89

VEC89-P9

RELAY BACKUP LIGHT (BULR)

BULR-87

62SB-002

-

J02

SWITCH DRIVERS SEAT BELT

P212

71BC-007

JB4A

JB4A

-

J240

33JB-004

D26

D26

SP183

-

39FA-000 TB36 39FA-001 TB36

42PML-002 42PMS-000 -

TB36-E1

-

J16

P563

-

P14

47S-000

SWITCH MANUAL BACKUP LIGHT

P23

-

J03

TB32

TB32-L2

71C-000

VEC-91

VEC91-P10

RELAY KEY / GE CNTRL PWR (KCNP...

KCNPR-(+)

R19

R19

TB30

TB30-D2

P16

TB61

TB61-G2

J563

-

P03

TB22

TB22-T1

TB24-R2

-

P03

71CK-000

TB24-N1

P13

SENSOR LEFT FRONT WHEEL SPEED

P507

P153

TB61

TB61-G1

42SL-000

TIMER (1HR) ENGINE SERVICE LAM...

ESLT-3

47S-002

TB22

TB22-T2

VEC-89

VEC89-P11

63-001

-

J03

TB10

TB10-E2

71CK-001

RELAY KEY / GE CNTRL PWR (KCNP... KCNPR-30 VEC89-S6A VEC-89

TB24

-

SWITCH HYDRAULIC PUMP MOD LAMP... HPMS-1 J12 -

47S-001

33LF-000

39FA-002 39FA-004 SENSOR PAYLOAD PRESSURE RIGHT ...

62SBA-000 VEC-89 TB24 63-000

VEC89-P2

33JB-005

42PMS-001 42PMS-002 -

VEC-90

VEC90-S8A

33LF-001

TB33

TB33-R2

-

J13

TB36-D2

PAY LOAD METER 3

P264

42SL-001

-

P12

-

J540

47S-003

SWITCH MANUAL BACKUP LIGHT

P23

SWITCH MANUAL BACKUP LIGHT

P23

63-002

TB10

TB10-E1

SWITCH COMBO

P121

71CK-002

VEC-90

VEC90-S8B

TB24

TB24-N2

33LF-002

TB33

TB33-R1

GE CONTROL INTERFACE

P301

39FB-000 TB36 39FB-001 TB36

TB36-D1

-

J16

42SL-002

-

P540

SWITCH LEFT ENGINE SERVICE LAM...

LESLS-1

48-000

RELAY ACCESS LADDER LIGHT (ALL...

ALLR-88A

TB26

TB26-T1

63-003

TB10

TB10-E1

JB6G

JB6G

71CK-003

TB24

TB24-N4

R44

R44

33LF-003

TB33

TB33-R4

-

P57

P16

TB61

TB61-E2

44-000

VEC-89

VEC89-P12

TB35

TB35-G1

48-001

TB26

TB26-T2

-

J11

63-004

JB6G

JB6G

RELAY WIPER MOTOR LOW

P09

71CN1-000

GE CONTROL INTERFACE

P305

GE CONTROL INTERFACE

P304

33PG-000

-

J15

-

J702

39FB-002 39FB-003 SENSOR PAYLOAD PRESSURE LEFT R...

P152

TB61

TB61-E1

44-001

TB35

TB35-G2

-

J16

48-002

-

J11

TB26

TB26-T2

63-005

JB6G

JB6G

RELAY WIPER MOTOR HIGH

P08

71CN2-000

GE CONTROL INTERFACE

P303

GE CONTROL INTERFACE

P302

33PG-001

-

P15

-

RRBPS

P264

TB36

TB36-A2

44-002

TB35

TB35-G4

-

P04

48-003

TB26

TB26-V2

-

J12

63-006

JB6G

JB6G

MOTOR WINDSHIELD WIPER

P07

GE CONTROL INTERFACE

P301

-

J15

-

J702

TB36-A1

-

J13

44-003

-

P16

TB60

TB60-D1

48-004

-

J12

TB26

TB26-V2

63-007

JB6G

JB6G

TIMER WASHER DELAY (WADT)

WADT-2

71CNCK-000 GE CONTROL INTERFACE TB35 71F-000

P301

33PG-002

39FC-000 PAY LOAD METER 3 39FC-001 TB36

TB35-S1

GE CONTROL INTERFACE

P301

33PG-003

-

P15

-

LRBPS

P13

SENSOR PAYLOAD PRESSURE RIGHT ...

P150

44-004

TB60

TB60-D2

LAMP STOP/TAIL LEFT

LRSTL

48-005

-

J14

TB26

TB26-V2

63-008

JB6G

JB6G

TIMER WIPER DELAY

P10

71F-001

-

J16

TB35

TB35-S2

33PLR-000 33PLR-001 -

J15

-

J702

39FC-003 39FD-000 PAY LOAD METER 3

P264

TB36

TB36-B2

44-005

TB60

TB60-D4

LAMP STOP/TAIL RIGHT

RRSTL

48-006

-

J541

-

P11

63-009

VEC-91

VEC91-P10

TB24

TB24-R1

71F-002

TB35

TB35-S3

PAY LOAD METER 3

P264

P15

-

LRBPS

TB36-B1

-

J13

44-006

-

J04

LAMP SERVICE BRAKE OP-CAB

SBL

48-007

-

P541

LAMP DECK LADDER LIGHT #1

RDLLT

63H-000

MOTOR WINDSHIELD WIPER

P07

RELAY WIPER MOTOR HIGH

P08

71F-003

TB35

TB35-S4

INTERFACE MODULE

IM2

33PRR-000 33PRR-001 -

J15

-

J702

39FD-001 TB36 39FD-003 -

P13

SENSOR PAYLOAD PRESSURE LEFT F...

P151

44D-000

VEC-89

VEC89-P1

TB35

TB35-H1

48-009

-

P11

-

J541

63H1-000

SWITCH COMBO

P121

RELAY WIPER MOTOR HIGH

P08

71F-004

-

P16

SWITCH BODY-UP PROXIMITY

BUSW

P15

-

RRBPS

P264

INCLINOMETER

P246

44D-001

TB35

TB35-H2

-

J16

48-010

-

P541

LAMP DECK LIGHT #2

RDLT

63L-000

RELAY WIPER MOTOR LOW

P09

MOTOR WINDSHIELD WIPER

P07

71GE-000

GE CONTROL INTERFACE

P305

TB24

TB24-G3

33RF-000

-

P13

SENSOR RIGHT FRONT WHEEL SPEED

P501

39FE-000 PAY LOAD METER 3 39FG-000 PAY LOAD METER 3

P264

INCLINOMETER

P246

44D-002

TB35

TB35-H4

-

P04

48-011

-

P12

-

J540

63L1-000

D15

D15

JB4H

JB4H

71GE-001

TB24

TB24-G2

VEC-91

VEC91-P10

33RF-001

-

J13

TB33

TB33-L2

39G-000

VEC-90

VEC90-P2

TB34

TB34-T1

44D-003

-

P16

TB60

TB60-E1

48-012

-

P540

LAMP DIAGONAL LADDER LIGHT #1

LDLLT

63L1-001

RELAY WIPER MOTOR LOW

P09

JB4H

JB4H

71GE-002

INTERFACE MODULE

IM3

TB24

TB24-G1

33RF-002

GE CONTROL INTERFACE

P301

TB33

TB33-L1

39G-001

TB34

TB34-T2

PAY LOAD METER 3

P264

44D-004

-

J04

LAMP RETARD OP-CAP

DRL

48-013

-

P12

-

J540

63L1-002

TIMER WASHER DELAY (WADT)

WADT-1

JB4H

JB4H

71GG-000

SWITCH PROPEL LOCKOUT (PLOS)

PLOS-F1

-

J537

33RF-003

TB33

TB33-L4

-

P56

39H-000

SWITCH BRAKE LOCK

P39

-

J03

44D-005

TB60

TB60-E2

LAMP RETARD LEFT REAR

LRL

48-014

-

P540

-

P544

63L1-003

TIMER WIPER DELAY

P10

JB4H

JB4H

71GG-001

-

P537

-

P12

33RR-000

-

J02

SWITCH RETARD SPEED CONTROL (R...

RSCS_1-2

39H-001

-

P03

TB23

TB23-A2

44D-006

TB60

TB60-E4

LAMP RETARD RIGHT REAR

RRL

48-015

-

P14

-

P565

63L2-000

SWITCH COMBO

P121

D15

D15

71GG-002

-

J12

TB25

TB25-K1

33RR-001

SWITCH RETARD SPEED CONTROL (R...

RSCS_1-4

39H-002

-

J702

TB23

TB23-A1

44R-000

TB35

TB35-F2

GE CONTROL INTERFACE

P303

48-016

-

J565

SP150

-

63P-000

MOTOR WINDSHIELD WIPER

P07

SWITCH COMBO

P121

71GG-003

TB25

TB25-K2

GE CONTROL INTERFACE

P303

33RR-002

SWITCH RETARD SPEED CONTROL (R... RSCS_1-2 P02 -

TB31

TB31-F2

J702

TB22

TB22-X2

44R-001

TB35

TB35-F4

INTERFACE MODULE

IM3

48-017

SP150

-

SWITCH COMBO

P121

TIMER WIPER DELAY

P10

71GH-000

SWITCH PROPEL LOCKOUT (PLOS)

PLOS-B1

-

J537

GE CONTROL INTERFACE

P303

TB31

TB31-F1

TB22-X1

PAY LOAD METER 3

P264

44R-003

TB35

TB35-F3

VEC-89

VEC89-P11

48-018

63W-000

JB4C

JB4C

-

J03

71GH-001

-

P537

-

P12

33RS-000

RETARD SPEED CONTROL

RSP

SWITCH RETARD SPEED CONTROL (R...

RSCS_1-1

P39

-

J03

44R-004

SWITCH SERVICE BRAKE PSI

SBPS

-

J240

48-019

LAMP DECK LIGHT #1 (OPT LOCATI...

LDLT

63W-001

SWITCH COMBO

P121

JB4C

JB4C

71GH-002

-

J12

TB25

TB25-L1

33SBA-000 TB25 33SBA-001 TB25

TB25-W1

GE CONTROL INTERFACE

P305

39HA-000 SWITCH BRAKE LOCK 39HA-001 -

LAMP CONTROL CABINET WORK LIGH... CDL2 J544 -

LAMP CONTROL CABINET WORK LIGH... CDL1 SP150

63T1-000

33RR-003

39H1-000 39H1-001 TB22

P03

TB23

TB23-V2

44R-005

-

P240

TB35

TB35-F1

48A-000

SWITCH CAB LADDER LIGHT

P24

-

J03

63W-002

JB4C

JB4C

TIMER WASHER DELAY (WADT)

WADT-6

71GH-003

TB25

TB25-L2

GE CONTROL INTERFACE

P303

TB25-W2

-

P03

HFSW1

SWITCH HYDRAULIC FILTER #2

HFSW2

45L-000

SWITCH COMBO

P121

TB10

TB10-J1

48A-001

-

P03

TB34

TB34-J1

63W-003

-

P03

MOTOR WINDSHIELD WASHER

WW+

71H-000

GE CONTROL INTERFACE

P304

TB21

TB21-R1

33SBA-002 33SBA-003 SWITCH BRAKE TEST

J03

SWITCH BRAKE TEST

P37

39HP-000 SWITCH HYDRAULIC FILTER #1 39SP-000 SWITCH HYDRAULIC FILTER #2

HFSW2

SWITCH STEERING FILTER #1

SFSW

45L-001

TB10

TB10-J1

-

J03

48A-002

TB34

TB34-J2

-

J12

65-000

VEC-91

VEC91-P12

TB24

TB24-D1

71H-001

TB21

TB21-R2

-

P02

P37

SWITCH BRAKE TEST

P37

41H-000

SWITCH COMBO

P121

TB10

TB10-K1

45L-002

D4

D4

TB10

TB10-J1

48A-003

-

P12

-

J535

65-001

ENTERTAINMENT RADIO

P737

-

J211

71H-002

-

J02

ALTERNATOR PROPULSION DRIVE

ALT1

33SP-000

INTERFACE MODULE

IM3

TB30

TB30-T1

41H-001

-

P03

TB34

TB34-B1

45L-003

-

P03

TB22

TB22-P1

48A-004

TB34

TB34-J2

-

J11

65-002

-

P04

TB24

TB24-D2

71J-000

SWITCH BODYUP OVERRIDE / RESET... ORS_1-3 T19 GE CONTROL CABINET

33SP-001

TB30

TB30-T1

-

J14

41H-002

TB34

TB34-B2

RELAY HI-BEAM HEADLIGHT (HBHR)

HBHR-86

45L-004

TB22

TB22-P2

VEC-89

VEC89-P12

48A-005

-

P11

-

J534

65-003

-

P211

-

J04

71LS-000

TB23

TB23-M1

VEC-89

VEC89-P4

33SP-002

-

P14

SENSOR STEERING PRESSURE

SPS

41H-004

TB10

TB10-K1

-

J03

45L-005

TB10

TB10-J3

-

P651

48A-006

SWITCH CAB LADDER LIGHT

P24

SWITCH CAB LADDER LIGHT

P24

65A-000

VEC-91

VEC91-P12

TB24

TB24-F1

71LS-001

TB23

TB23-M2

-

P01

33T-000

-

J240

SWITCH SERVICE BRAKE DEGRADE P...

BDS

41H-006

TB10

TB10-K3

ACTIA DASH DISPLAY

P902

45L-006

-

J651

CAMERA CONTROLLER (OPT)

P652

48A-007

SWITCH LEFT LADDER LIGHT GND L...

LLSW-2

-

P535

65A-001

ENTERTAINMENT RADIO

P737

-

J211

71LS-002

TB10

TB10-C1

-

J01

33T-001

TB32

TB32-F2

-

P240

HBHR-88a

TB34

TB34-F1

45LA-000

CAMERA CONTROLLER (OPT)

P652

-

P650

48A-008

SWITCH RIGHT LADDER LIGHT GND ...

RLSW-2

-

P534

65A-002

ENTERTAINMENT RADIO

P737

ENTERTAINMENT RADIO

P737

71LS-003

TB10

TB10-C2

SWITCH FOG LAMP (OPT)

P22

33T-002

TB32

TB32-F1

INTERFACE MODULE

IM2

41HB-000 RELAY HI-BEAM HEADLIGHT (HBHR) 41HB-001 -

J12

TB34

TB34-F2

45LL-000

VEC-89

VEC89-P12

TB35

TB35-J1

48B-000

SWITCH CAB LADDER LIGHT

P24

-

J03

65A-003

TB24

TB24-F2

-

P04

71LS-004

SWITCH FOG LAMP (OPT)

P22

SWITCH FOG LAMP (OPT)

P22

34AT-000

SENSOR DUCT AIR TEMPERATURE

ATS

-

P14

J12

TB34

TB34-F2

45LL-001

TB35

TB35-J2

-

J12

48B-001

-

P03

TB34

TB34-K1

65A-004

-

J04

-

P211

71LS-005

TB10

TB10-C3

SWITCH DISPLAY MODE #2

P20

34AT-001

-

J14

TB30

TB30-J2

41HB-002 41HB-003 -

J11

TB34

TB34-F4

45LL-002

-

P12

-

J540

48B-002

TB34

TB34-K2

-

J12

65C-000

SWITCH A/C RECIEVER DRYER T2

RECDR

A/C COMPRESSOR CLUTCH T2

P803

71LS-006

SWITCH DISPLAY MODE #2

P20

SWITCH DISPLAY MODE #2

P20

34AT-002

TB30

TB30-J1

INTERFACE MODULE

IM3

J11

TB34

TB34-F4

45LL-003

-

P540

-

P503

48B-003

-

P12

-

J535

65C-003

SWITCH A/C RECIEVER DRYER T1

RECDR-T1

A/C COMPRESSOR CLUTCH T1

P803-

71LS-007

SWITCH DISPLAY MODE #2

P20

SWITCH DISPLAY MODE #1

P21

34BT1-000 TB30 34BT1-001 TB30

TB30-G2

-

J14

41HB-004 41HB-005 -

J542

-

P12

45LL-004

-

J503

SP144

-

48B-004

TB34

TB34-K2

-

J11

65S-000

VEC-91

VEC91-P12

TB27

TB27-M2

71LS-008

SWITCH DISPLAY MODE #1

P21

SWITCH DISPLAY MODE #1

P21

TB30-G1

INTERFACE MODULE

IM3

HMLHB

-

P542

45LL-005

ACTIA DASH DISPLAY

P902

-

J01

48B-005

-

P11

-

J534

65S-001

TB27

TB27-M1

-

P808

71LS-009

TB10

TB10-C4

SWITCH CAMERA (OPT)

P31

34BT2-000 TB30 34BT2-001 TB30

TB30-H2

-

J14

41HB-006 LAMP HIGH MOUNT LEFT HI-BEAM 41HB-007 -

J542

-

P12

45LL-006

-

P01

TB35

TB35-J3

48B-006

SWITCH CAB LADDER LIGHT

P24

SWITCH CAB LADDER LIGHT

P24

65S-002

ENGINE QSK60 INTERFACE TIER II

P805

-

J808

71LS-010

SWITCH CAMERA (OPT)

P31

SWITCH CAMERA (OPT)

P31

TB30-H1

INTERFACE MODULE

IM3

LMLHB

-

P542

45LL-007

TB35

TB35-J2

-

J14

48B-007

SWITCH LEFT LADDER LIGHT GND L...

LLSW-3

-

P535

65S-003

-

J808-

ENGINE QSK60 INTERFACE TIER I

P805-

71LS-011

TB10

TB10-C2

SWITCH ROTATING BEACON (OPT)

P32

34BT3-000 34BT3-001 TB30

J14

TB30

TB30-C2

41HB-008 LAMP LOW MOUNT LEFT HI-BEAM 41HB-009 -

J543

-

P11

45LL-008

TB35

TB35-J4

-

J16

48B-008

SWITCH RIGHT LADDER LIGHT GND ...

RLSW-3

-

P534

65SR-000

VEC-91

VEC91-P12

VEC RTMR1

RTMR1-C1

71LS-012

SWITCH ROTATING BEACON (OPT)

P32

SWITCH ROTATING BEACON (OPT)

P32

TB30-C1

INTERFACE MODULE

IM3

HMRHB

-

P543

45LL-009

SP144

-

LAMP MARKER/TURN LEFT SIDE DEC...

LCL1

48C-000

TB34

TB34-L1

RELAY ACCESS LADDER LIGHT (ALL...

ALLR-86

65SS-000

VEC RTMR1

RTMR1-B2

-

J11

71LS-013

SWITCH HEATED MIRROR (OPT)

P33

SWITCH ROTATING BEACON (OPT)

P32

34BT4-000 SENSOR HYDRAULIC TANK TEMP 34BT4-001 -

P711

-

P14

41HB-010 LAMP HIGH MOUNT RIGHT HI-BEAM 41HB-011 -

J543

-

P11

45LL-010

SP144

-

LAMP MARKER/TURN LEFT FRT DECK

LCL2

48C-001

-

J12

TB34

TB34-L1

65SS-001

-

P11

-

J543

71LS-014

SWITCH HEATED MIRROR (OPT)

P33

SWITCH HEATED MIRROR (OPT)

P33

J14

TB30

TB30-A2

-

P543

45LL-011

-

P14

-

P732

48C-002

TB34

TB34-L1

-

J11

65SS-002

-

P543

-

P520

71LS-015

SWITCH HEATED MIRROR (OPT)

P33

SWITCH HEATED MIRROR (OPT)

P33

34BT4-002 TB30 34LL-001 INTERFACE MODULE

TB30-A1

INTERFACE MODULE

IM3

-

J12

45LL-012

-

P16

TB60

TB60-A1

48C-003

-

J534

-

P11

65SS-003

-

J520-

SOLENOID ENGINE SHUTTER (OPT)

ESSOL

71P-000

VEC-89

VEC89-P2

TB23

TB23-J4

IM2

-

J14

45LL-013

TB60

TB60-A2

-

J54

48C-004

-

J535

-

P12

65T-000

VEC RTMR1

RTMR1-A1

TB30

TB30-X2

71P-001

TB23

TB23-J3

-

P02

P14

SENSOR HYDRAULIC TANK LEVEL

P712

45LL-014

-

P54

SP175

-

48C-007

SWITCH LEFT LADDER LIGHT GND L...

LLSW-1

-

P535

65T-001

SWITCH A/C RECIEVER DRYER T2

RECDR

-

J801

71P-002

SWITCH DATA STORE (DSSW)

DSSW-C

JB4B

JB4B

TB26-D1

INTERFACE MODULE

IM3

34LL-002

-

34TW-000 TB26 34TW-001 TB26

LMRHB 41HB-012 LAMP LOW MOUNT RIGHT HI-BEAM 41HM-000 RELAY HEADLIGHT HIGH MOUNT (HH... HHMR-(30) J11 41HM-001 41HM-002 41HM-003 LAMP HIGH MOUNT LEFT LOW-BEAM

P12

RELAY HEADLIGHT HIGH MOUNT (HH... HHMR-(30) J542 -

HMLLB

-

P542

45LL-015

LAMP BODY LEFT SIDE MARKER

LSCL1

SP175

-

48C-008

SWITCH RIGHT LADDER LIGHT GND ...

RLSW-1

-

P534

65T-002

-

P801

TB30

TB30-X1

71P-003

JB4B

JB4B

J543

-

P11

45LL-016

SP175

-

LAMP BODY LEFT REAR MARKER

LSCL2

48F-000

SWITCH FOG LAMP (OPT)

P22

-

J03

65T-003

TB30

TB30-X4

-

P03

71P-004

JB4B

JB4B

SWITCH BODYUP OVERRIDE / RESET... ORS_1-4 SWITCH RETARD SPEED CONTROL (R... RSCS_2-2

HMRLB

-

P543

45LR-002

D4

D4

SWITCH HAZARD LIGHTS

P36

48F-001

-

P03

TB34

TB34-E1

65T-004

-

J03

-

P140

71P-005

TB23

TB23-J2

-

J16

TB34

TB34-E2

VEC-89

VEC89-P1

65T-005

-

J801-

SWITCH A/C RECIEVER DRYER T1

RECDR-T1

71P-006

-

J02

JB4B

JB4B

TB26-D2

GE CONTROL INTERFACE

P304

35L2-000

PAY LOAD METER 3

P264

TB36

TB36-L1

41HM-004 41HM-005 LAMP HIGH MOUNT RIGHT LOW-BEAM

35L2-001

-

J362

TB36

TB36-L2

41L-000

SWITCH HEADLIGHTS

P25

TB10

TB10-L1

45LR-007

SWITCH HAZARD LIGHTS

P36

SWITCH HAZARD LIGHTS

P36

48F-002

35L2-002

TB36

TB36-L4

-

P02

41L-001

TB10

TB10-L1

SWITCH COMBO

P121

45R-000

SWITCH COMBO

P121

TB10

TB10-M1

VEC89-P1

TB34

TB34-D1

67C-000

VEC-91

VEC91-P9

TB24

TB24-V1

71P-007

TB23

TB23-J1

-

P03

35L2-003

-

J02

-

DIAG7

41L-002

TB10

TB10-L1

-

J03

45R-001

TB10

TB10-M1

-

J03

48LF-000 VEC-89 48LF-001 TB34

TB34-D2

-

J11

67C-001

TB24

TB24-V2

-

P03

71P-008

-

J03

SWITCH DC POWER OFF - REST SWI...

P35

35L3-000

PAY LOAD METER 3

P264

TB36

TB36-M1

41L-004

TB34

TB34-C1

-

P03

45R-002

SWITCH HAZARD LIGHTS

P36

TB10

TB10-M1

TB34-D2

-

J12

67C-002

TB24

TB24-V4

-

P03

71P-009

SWITCH GRID DRY

P34

SWITCH DC POWER OFF - REST SWI...

P35

35L3-001

-

J362

TB36

TB36-M2

41L-005

TB34

TB34-C2

45R-003

-

P03

TB22

TB22-R1

P11

-

J543

67C-003

-

J03

12VDC POWER PORT #1

PWR1-1

71P-010

-

P16

SP180

-

35L3-002

TB36

TB36-M4

-

P02

41L-006

RELAY HEADLIGHT LOW MOUNT (HLM... HLMR-(+)

RELAY HEADLIGHT LOW MOUNT (HLM... HLMR-(+) RELAY HEADLIGHT HIGH MOUNT (HH... HHMR-(+)

48LF-002 TB34 48LF-003 -

45R-004

TB22

TB22-R2

VEC-89

VEC89-P12

48LF-004 -

P12

-

J542

67C-004

-

J03

12VDC POWER PORT #2

PWR2-1

71P-011

SP180

-

TB61

TB61-H1

58E-06-02000-00 NOV 11 ELECTRICAL SCHEMATIC 830E-1AC A40851 & UP Sheet 17 of 20

WIRE TABLE WIRE LIST NAME

WIRE LIST CONN TO BUSW

NAME 77DN-000

DEVICE FROM -

P703

77DN-001

TB29

WIRE LIST

71P-012

DEVICE FROM SP180

71P-013

TB61

71P-014

J703

77DN-003

GE CONTROL INTERFACE

PLON

77DP-000

-

P15

71PS-001

SWITCH TRACTION MOTOR PRESSURE... BPSW-COM LAMP LED PROPEL LOCKOUT ON PLOS-B2 SWITCH PROPEL LOCKOUT (PLOS) RELAY 1 PROPEL LOCKOUT PLOS-B2 SWITCH PROPEL LOCKOUT (PLOS)

CONN FROM DEVICE TO CONN TO SENSOR LEFT REAR WHEEL SPEED P720 P15 TB29-F2 J15 TB29 P301 TB29-F1

PLREL

77DP-001

TB29

TB29-D2

SENSOR LEFT REAR WHEEL SPEED P720 J15

71SR-000

SHIFTER CURRENT LIMIT RESISTOR

P250

SHIFTER DIRECTION SELECTOR

P108

77DP-003

GE CONTROL INTERFACE

P301

TB29

71SS-000

VEC-89

VEC89-P4

TB23

TB23-T2

77G-000

-

P15

71SS-001

TB23

TB23-T1

-

P02

77G-001

-

J15

SENSOR LEFT REAR WHEEL SPEED P720 TB29-B2 TB29

71SS-002

-

J02

SHIFTER CURRENT LIMIT RESISTOR

P250

77G-003

GE CONTROL INTERFACE

P301

TB29

TB29-B1

71VHM-000 TB28 71VHM-001 TB28

TB28-B2

VEC-90

VEC90-P1

77P-002

VEC-89

VEC89-P2

TB29

TB29-A2

TB28-B1

-

P04

77P-003

GE CONTROL INTERFACE

P301

TB29

TB29-A1

71VHM-002 71VHM-003 KOMTRAX PLUS MODULE

J04

SP187

-

77Y-000

GE CONTROL INTERFACE

P305

TB33

TB33-E1

P1

SP187

-

77Z-000

GE CONTROL INTERFACE

P305

TB33

TB33-F1

71VHM-004 SP187 71VHM-005 SP187

-

KOMTRAX PLUS MODULE

P1

79A-000

VEC-89

VEC89-P11

-

J16

-

-

P653

79A-001

TB60

TB60-G1

-

P16

71PS-000

CONN FROM DEVICE TO SWITCH BODY-UP PROXIMITY TB61-H2

CONTINUED FROM DIAGRAM 16 & 17

TB29-D1

NAME

DEVICE FROM 90TCT-001 90TCT-002 -

CONN FROM DEVICE TO TB25 P02 J02

90VHG-000 KOMTRAX PLUS MODULE 90VHG-001 -

P4A

90VHG-002 SP193 90VHG-003 -

WIRE LIST CONN TO TB25-R2

NAME 714G-003

DEVICE FROM GE CONTROL INTERFACE

DIAG3

714P-001

VEC-91

CONN FROM DEVICE TO TB29 P301 TB29 VEC91-P2

SP193

-

714P-003

GE CONTROL INTERFACE

P301

DIAG6

SP193

-

714Y-000

GE CONTROL INTERFACE

-

-

J04

714Z-000

GE CONTROL INTERFACE

P04

TB29

TB29-T1

900-000

90VHG-004 TB29 90VHR-000 KOMTRAX PLUS MODULE

TB29-T2

-

VHMS

900-001

ENGINE QSK60 INTERFACE TIER I P806P808 -

P4A

SP192

-

900-002

TB28

90VHR-001 90VHR-002 SP192

DIAG6

SP192

-

900-003

-

-

-

J04

90VHR-003 90VHR-004 TB29

P04

TB29

TB29-V1

900CG-000 KOMTRAX PLUS MODULE 900CR-000 KOMTRAX PLUS MODULE

TB29-V2

-

VHMS

90VHT-000 KOMTRAX PLUS MODULE 90VHT-001 -

P4A

SP191

-

DIAG6

SP191

-

P4B 900CT-000 KOMTRAX PLUS MODULE ENGINE QSK60 INTERFACE TIER I P806901-000 P808 901-001

90VHT-002 SP191 90VHT-003 -

-

-

J04

901-002

TB28

P04

TB29

TB29-W1

901-003

TB29-W2

-

VHMS

NAME

TB29-H2

LR(+)-001

CONN FROM DEVICE TO CONN TO P210 ENTERTAINMENT RADIO P737 ENTERTAINMENT LEFT REAR SPEAKE... LRSPK J210 -

TB29

TB29-H1

LR(-)-000

-

P210

ENTERTAINMENT RADIO

P305

TB33

TB33-D1

LR(-)-001

-

J210

ENTERTAINMENT LEFT REAR SPEAKE... LRSPK

P305

TB33

TB33-C1

RF(+)-000

-

J211

ENTERTAINMENT RADIO

-

J808-

RF(+)-001

-

P211

ENTERTAINMENT RIGHT FRT SPEAKE... RFSPK

TB28

TB28-T1

RF(-)-000

-

J211

ENTERTAINMENT RADIO

TB28-T2

-

P02

RF(-)-001

-

P211

ENTERTAINMENT RIGHT FRT SPEAKE... RFSPK

J02

-

DIAG4

RR(+)-000

ENTERTAINMENT RADIO P737

P4B

ORBCOMM MODULE (OPT)

CNA

RR(+)-001

-

J210

ENTERTAINMENT RIGHT REAR SPEAK... RRSPK

P4B

ORBCOMM MODULE (OPT)

CNA

RR(-)-000

-

P210

ENTERTAINMENT RADIO

ORBCOMM MODULE (OPT)

CNA

RR(-)-001

-

J210

ENTERTAINMENT RIGHT REAR SPEAK... RRSPK

-

J808-

SE1-000

KOMTRAX PLUS MODULE P3A

-

P6A

TB28

TB28-V1

SE2-000

KOMTRAX PLUS MODULE P3A

-

P6A

TB28-V2

-

P02

SE3-000

KOMTRAX PLUS MODULE P3A

-

P6A

-

J02

-

DIAG4

SE4-000

KOMTRAX PLUS MODULE P3A

-

P6A

916M-000

-

J808-

ENGINE QSK60 INTERFACE TIER I

P806-

SE5-000

KOMTRAX PLUS MODULE P3A

-

P6A

LR(+)-000

DEVICE FROM

-

P737 P737 P737 P210 P737

72-000

SHIFTER DIRECTION SELECTOR

P108

-

J02

79A-002

TB60

TB60-G2

HORN BACKUP RIGHT

LRBH-(+)

72-001

-

P02

TB21

TB21-N2

79A-003

TB60

TB60-G2

HORN BACKUP LEFT

RRBH-(+)

72-002

VEC-90

VEC90-P1

TB21

TB21-N3

79B-000

-

J02

SP159

-

90VHT-004 TB29 ENGINE QSK60 INTERFACE TIER II 419I-000

P806

-

J808

916M-001

TB27

TB27-V2

GE CONTROL INTERFACE

P302

SE6-000

KOMTRAX PLUS MODULE P3A

SP730

-

72-003

TB21

TB21-N1

-

J701

79B-001

-

P02

TB21

TB21-L2

419I-001

TB27

TB27-F2

GE CONTROL INTERFACE

P302

916M-002

-

P808

TB27

TB27-V1

SE7-000

SP730

-

KOMTRAX PLUS MODULE

P3A

72A-000

GE CONTROL INTERFACE

P304

TB21

TB21-E1

79B-002

VEC-90

VEC90-P1

TB21

TB21-L3

419I-003

-

P808

TB27

TB27-F1

916M-003

-

J808

SE8-000

SP730

-

KOMTRAX PLUS MODULE

P3A

72AF-000

-

J701

GE CONTROL INTERFACE

P304

79B-003

TB21

TB21-L1

-

J701

419I-004

ENGINE QSK60 INTERFACE TIER I

P806-

-

J808-

924-000

ENGINE QSK60 INTERFACE TIER II P806 ENGINE QSK60 INTERFACE TIER II P805

SWITCH COOLANT LEVEL TIER 2

P802

SE9-000

SP730

-

-

P6A

72AT-000

INTERFACE MODULE

TB27-F4

R4

R4

924-001

P802-

SHIELD

TB36

TB36-J4

SP743

-

J02

925-000

ENGINE QSK60 INTERFACE TIER I P806ENGINE QSK60 INTERFACE TIER II P805

SWITCH COOLANT LEVEL TIER 1

-

SWITCH COOLANT LEVEL TIER 2

P802

SHIELD-001

SP737

-

TB30

TB30-B4

TB27

TB27-R1

925-001

ENGINE QSK60 INTERFACE TIER I P806ENGINE QSK60 INTERFACE TIER II P805

SWITCH COOLANT LEVEL TIER 1

P802-

SHIELD-205

SP767

-

-

P15

SWITCH COOLANT LEVEL TIER 2

P802

SHIELD-205A SP768

-

SENSOR LEFT REAR WHEEL SPEED

P720

SWITCH COOLANT LEVEL TIER 1

P802-

SHIELD-209A SP770

-

SENSOR RIGHT REAR WHEEL SPEED

P721

-

J808-

SHIELD-213

SP765

-

-

J15

IM2

TB33

TB33-A2

79B-004

SP159

-

SHIFTER DIRECTION SELECTOR

P108

419I-005

TB27

72AUT-000 TB21 72CPU-000 TB24

TB21-H1

GE CONTROL INTERFACE

P303

79B-005

SP159

-

-

P651

439-000

TB24-W1

-

P808

79B-006

CAMERA CONTROLLER (OPT)

P652

-

J651

439-001

SWITCH CAB SECONDARY ENGINE SH... ESS_1-4 P02 -

72CPU-001 TB24 72CPU-002 ENGINE QSK60 INTERFACE TIER I

TB24-W2

GE CONTROL INTERFACE

P302

79BA-000

GE CONTROL INTERFACE

P304

TB23

TB23-X1

439-002

TB27

TB27-R2

GE CONTROL INTERFACE

P302

926-000

P806-

-

J808-

79BA-001

-

J701

TB23

TB23-X1

439-003

TB27

TB27-R3

-

P808

926-001

72FC-000

CAMERA CONTROLLER (OPT)

P652

-

P650

79BA-002

TB23

TB23-X2

VEC-89

VEC89-P11

439-004

ENGINE QSK60 INTERFACE TIER II

P804

-

J808

927-000

ENGINE QSK60 INTERFACE TIER I P805ENGINE QSK60 INTERFACE TIER I P804-

72FD-000

TB29

TB29-R1

VEC-90

VEC90-P9

79C-001

-

J651

CAMERA CONTROLLER (OPT)

P652

439-005

TB27

TB27-R4

INTERFACE MODULE

IM3

927-001

-

P808

TB31

TB31-A1

SHIELD-217

SP766

-

-

J15

72FD-001

GE CONTROL INTERFACE

P302

TB29

TB29-R2

79R-000

CAMERA CONTROLLER (OPT)

P652

-

P650

439-006

-

J808-

ENGINE QSK60 INTERFACE TIER I

P806-

927-002

TB31

TB31-A2

-

P02

SHIELD-223

SP741

-

GE CONTROL INTERFACE

P301

VEC90-P12

TB24

TB24-M1

79RC-000

SWITCH CAMERA (OPT)

P31

-

P651

509-000

ENGINE QSK60 INTERFACE TIER II

P806

-

J808

927-003

-

J02

-

DIAG2

SHIELD-277

GE CONTROL INTERFACE P301

SP742

-

TB24-M2

INTERFACE MODULE

IM2

79RD-000

TB29

TB29-S1

VEC-90

VEC90-P9

509-001

ENGINE QSK60 INTERFACE TIER II

P806

-

J808

928-000

-

J808-

SHLD-647

SP774

-

-

J240

TB31

TB31-B1

SHLD-648

-

P240

SP775

-

72FNR-000 VEC-90 72FNR-001 TB24 72GD-000

TB23

TB23-S1

GE CONTROL INTERFACE

P305

79RD-001

GE CONTROL INTERFACE

P302

TB29

TB29-S2

509-002

-

P808

TB27

TB27-S1

928-001

ENGINE QSK60 INTERFACE TIER I P804P808 -

72GD-001

-

P03

TB23

TB23-S2

79W-000

TB26

TB26-C1

INTERFACE MODULE

IM2

509-003

-

P808

TB27

TB27-S3

928-002

TB31

TB31-B2

-

P02

SHLD-834

INTERFACE MODULE

IM1

SP198

-

72GD-002

-

J03

SWITCH GRID DRY

P34

79W-001

TB26

TB26-C2

GE CONTROL INTERFACE

P304

509-004

TB27

TB27-S2

GE CONTROL INTERFACE

P302

928-003

-

J02

-

DIAG2

SHLD_209

SP769

-

-

P15

72GD-003

SWITCH GRID DRY

P34

SWITCH GRID DRY

P34

85-000

TB28

TB28-C2

VEC-91

VEC91-P4

509-005

ENGINE QSK60 INTERFACE TIER I

P806-

-

J808-

929-000

-

J808-

SHLD_731

SP773

-

TB30

TB30-B4

72IP-000

PAY LOAD METER 3

P264

TB21

TB21-C1

85-001

TB28

TB28-C1

-

P04

509-006

TB27

TB27-S4

R3

R3

929-001

ENGINE QSK60 INTERFACE TIER I P804P808 -

TB31

TB31-C1

SPR1-000

-

P03

-

SPR_5

72IP-001

TB21

TB21-C2

GE CONTROL INTERFACE

P304

85-002

-

J04

JB6E

JB6E

509-007

ENGINE QSK60 INTERFACE TIER I

P805-

-

J808-

929-002

TB31

TB31-C2

-

P02

SPR1-001

-

J03

-

SPR_13

72LP-000

TB26

TB26-J1

INTERFACE MODULE

IM3

85-003

JB6E

JB6E

KOMTRAX PLUS MODULE

P1

510E-000

VEC-90

VEC90-P3

TB25

TB25-N1

929-003

-

J02

-

DIAG2

SPR2-000

-

P03

-

SPR_6

72LP-001

TB26

TB26-J2

GE CONTROL INTERFACE

P304

85-004

JB6E

JB6E

KOMTRAX PLUS MODULE

P1

510E-001

TB25

TB25-N2

GE CONTROL INTERFACE

P304

930-001

SWITCH COOLANT LEVEL TIER 1

P802-

SPR2-001

-

J03

-

SPR_14

IM2

TB33

TB33-B2

85-005

JB6E

JB6E

ORBCOMM MODULE (OPT)

CNA

510E2-000

GE CONTROL INTERFACE

P303

TB21

TB21-A1

-

J808

SPR3-000

-

P03

-

SPR_7

CAN TEE J1939 # 1

P301B

SPR3-001

-

J03

-

SPR_15

-

J808-

SPR4-000

-

P03

-

SPR_8

72MAN-000 INTERFACE MODULE SHIFTER DIRECTION SELECTOR 72N-000

P108

-

J02

85-006

JB6E

JB6E

ORBCOMM MODULE (OPT)

CNA

510E2-001

INTERFACE MODULE

IM3

TB21

TB21-A2

72N-001

-

P02

TB21

TB21-M2

85-007

JB6E

JB6E

ORBCOMM MODULE (OPT)

CNA

510E2-002

-

P830

-

P12

72N-002

VEC-90

VEC90-P1

TB21

TB21-M1

86-500

-

J712

TB-HTST

TB-HTST-F4

510E2-003

TB21

TB21-A4

-

J12

72NR-000

VEC-90

VEC90-P4

TB22

TB22-K1

86-501

HEATER COOLANT LH

-

TB-HTST

TB-HTST-G1

525-000

-

J01

ACCELERATOR PEDAL

P236

72NR-001

TB22

TB22-K2

GE CONTROL INTERFACE

P304

86-502

HEATER COOLANT RH

-

TB-HTST-G2

525-001

TB31

TB31-T2

-

P01

VEC90-P4

INTERFACE MODULE

IM2

86-503

TB-HTST

-

525-002

-

J701

TB31

TB31-T1

EOH1

525A-000

GE CONTROL INTERFACE

P304

SP738

-

EOH2

525A-001

SP738

-

-

J701

VEC90-P4

TB22

TB22-J1

86-504

SP703

TB-HTST TB-HTST-G3 SP703 HEATER ENGINE OIL LH

72PR-001

TB22

TB22-J2

GE CONTROL INTERFACE

P304

86-505

SP703

-

72RQ-000

-

J537

D70

D70

86-506

TB-HTST

528A-000

ENGINE QSK60 INTERFACE TIER I

P806-

-

J808-

-

P537

-

P12

86-507

SP707

TB-HTST-H1 -

CON1

72RQ-001

CON2

528A-001

ENGINE QSK60 INTERFACE TIER II

P806

-

J808

72RQ-002

-

J12

TB23

TB23-K4

86-508

SP707

-

HEATER HYDRAULIC OIL #1

HOHTR1

TB27-P2

GE CONTROL INTERFACE

P302

72RQ-003

TB23

TB23-K1

GE CONTROL INTERFACE

P304

86-509

SP707

-

HEATER HYDRAULIC OIL #2

HOHTR2

531SC-000 TB27 531SC-001 R5

R5

TB27

TB27-P1

72RQ-004

TB23

TB23-K2

-

P03

86-510

-

CON3

TB-HTST

TB-HTST-H2

556-000

GE CONTROL INTERFACE

P302

TB27

TB27-T2

72RQ-005

-

J03

D71

D71

86-511

-

CON4

556-001

R50

R50

TB27

TB27-T3

72RR-000

D71

D71

SWITCH DC POWER OFF - REST SWI...

P35

86A-000

THERMOSTAT OIL RESERVE TANK ECHTR1 P31 SWITCH CAMERA (OPT)

-

P651

556-002

-

P808

TB27

TB27-T1

72RR-001

SWITCH DC POWER OFF - REST SWI...

P35

SWITCH DC POWER OFF - REST SWI...

P35

86A-001

SWITCH CAMERA (OPT)

P31

SWITCH CAMERA (OPT)

P31

556-003

ENGINE QSK60 INTERFACE TIER I

P805-

-

J808-

72RRQ-000 RELAY 1 PROPEL LOCKOUT 72RRQ-001 RELAY 1 PROPEL LOCKOUT

PLREL

86A-002

SP702

-

-

J651

556A-001

-

P808

R50

R50

PLREL

LAMP LED PROPEL LOCKOUT LOCKED... PLLO D70 D70

86A-003

CAMERA CONTROLLER (OPT)

P652

SP702

-

556A-002

ENGINE QSK60 INTERFACE TIER II

P806

-

J808

72SBT-000 TB25 72SBT-001 TB25

TB25-X1

GE CONTROL INTERFACE

P305

86A-004

-

P650

SP702

-

712-000

RELAY KEY SWITCH (KSWPR)

KSWPR-30

TB24

TB24-J1

TB25-X2

-

P03

87-000

VEC-89

VEC89-P4

TB21

TB21-J2

712-001

GE CONTROL INTERFACE

P305

TB24

TB24-J2

72SBT-002 SWITCH BRAKE TEST 72T-000

P37

-

J03

87-001

TB21

TB21-J1

INTERFACE MODULE

IM3

712-003

TB24

TB24-K2

VEC-89

VEC89-S5A

J02

SHIFTER DIRECTION SELECTOR

P108

87-002

R15

R15

TB21

TB21-J3

712-004

TB24

TB24-K4

VEC-91

VEC91-S8A

72NR1-000 VEC-90 72PR-000 VEC-90

HEATER ENGINE OIL RH

72T-001

TB21

TB21-P2

-

P02

87-500

-

J712

TB-HTST

TB-HTST-K4

712-005

TB24

TB24-K3

12V POWER RELAY (12VPR)

12VPR-(+)

73DS-000

GE CONTROL INTERFACE

P304

TB21

TB21-S1

87-501

HEATER COOLANT LH

-

TB-HTST

TB-HTST-J1

712-006

TB24

TB24-J4

R21

R21

73DS-001

TB21

TB21-S2

-

P02

87-502

HEATER COOLANT RH

-

TB-HTST

TB-HTST-J2

712-007

TB24

TB24-J4

R20

R20

73DS-002

-

J02

SWITCH DATA STORE (DSSW)

DSSW-NO

87-503

THERMOSTAT ENGINE OIL

EOTS

TB-HTST

TB-HTST-J3

712A-000

VEC-91

VEC91-P9

73DS-003

TB21

TB21-S4

-

P04

87-506

-

CON1

TB-HTST

TB-HTST-K1

VEC90-P12

73DS-005

KOMTRAX PLUS MODULE

P3B

-

J04

87-507

THERMOSTAT HYDRAULIC OIL

HOSTAT

-

CON2

712BL-000 VEC-90 712BL-001 TB23

SWITCH AUX BOX DOME LIGHT (DLS... DLS-2 TB23-L1 TB23

TB23-L2

INTERFACE MODULE

IM3

73LS-000

VEC-91

VEC91-P1

TB21

TB21-F1

87-510

-

CON3

TB-HTST

TB-HTST-K2

TB23-L4

-

P03

73LS-001

TB21

TB21-F2

GE CONTROL INTERFACE

P304

87-511

HEATER OIL RESERVE TANK

ECHTR2

-

CON4

712BL-002 TB23 712BL-003 SWITCH BRAKE LOCK

P39

-

J03

73LS-002

TB21

TB21-F3

R20

R20

90-500

SP704

-

THERMOSTAT ENGINE OIL

EOTS

VEC89-P4

TB24

TB24-C1

TB34-W1

PAY LOAD METER 3

P264

90-501

HEATER ENGINE OIL LH

EOH1

SP704

-

712DS-000 VEC-89 712DS-001 TB24

TB24-C2

-

P02

TB34-W2

VEC-91

VEC91-P1

90-502

SP704

-

HEATER ENGINE OIL RH

EOH2

712DS-002 712DS-003 JB4E

J02

JB4E

JB4E

JB4E

-

J228

712DS-004 JB4E 712G-000 VEC-91

JB4E

-

J229

VEC91-P9

TB23

TB23-H2

73LSL-000 TB34 73LSL-001 TB34 73MS-000

VEC-91

VEC91-P1

TB21

TB21-G1

90-503

SP708

-

THERMOSTAT HYDRAULIC OIL

HOSTAT

73MS-001

TB21

TB21-G2

GE CONTROL INTERFACE

P304

90-506

HEATER HYDRAULIC OIL #1

HOHTR1

SP708

-

73MS-002

TB21

TB21-G3

R21

R21

90-507

SP708

-

HEATER HYDRAULIC OIL #2

HOHTR2

73MSL-000 TB34 73MSL-001 TB34

TB34-X1

PAY LOAD METER 3

P264

90-510

HEATER OIL RESERVE TANK

ECHTR2

712G-001

TB23

TB23-H4

-

P04

TB34-X2

VEC-91

VEC91-P1

90CAG-000 GE CONTROL INTERFACE 90CAG-001 -

P303

THERMOSTAT OIL RESERVE TANK ECHTR1 TB25-G1 TB25

712G-002

-

P01

TB23

TB23-H1

P02

TB25

TB25-G2

712G-003

TB10

TB10-F2

-

J01

90CAG-002 90CAR-000 GE CONTROL INTERFACE

J02

-

DIAG1

712G-004

ACTIA DASH DISPLAY

P902

TB10

TB10-F1

P303

TB25

TB25-E1

712G-005

D9

D9

-

J04

90CAR-001 90CAR-002 -

P02

TB25

TB25-E2

712H-001

-

P16

TB60

TB60-K1

J02

-

DIAG1

712H-002

TB60

TB60-K2

SWITCH HOIST LIMIT

HLS

90CAT-000 GE CONTROL INTERFACE 90CAT-001 -

P303

TB25

TB25-F1

712H-003

VEC-91

VEC91-P10

TB23

TB23-W1

P02

TB25

TB25-F2

712H-004

-

J16

TB23

TB23-W1

J02

-

DIAG1

RELAY KEY SWITCH (KSWPR)

KSWPR-(+)

GE CONTROL INTERFACE

P303

712IM-000 VEC-90 712K-000 SWITCH KEY (KEYSW)

VEC90-P1

TB25-A1

KEYSW-BR

-

J03

73S-000

VEC-90

VEC90-P3

TB32

TB32-M1

73S-001

TB32

TB32-M1

INTERFACE MODULE

IM2

73S-002

-

P240

TB32

TB32-M2

73S-003

-

J240

SWITCH PARK BRAKE RELEASE PRES...

PBRPS

74D-000

GE CONTROL CABINET

T20

ALTERNATOR PROPULSION DRIVE

ALT2

74DS-000

KOMTRAX PLUS MODULE

P1

-

J04

74DS-001

-

P04

TB25

TB25-M2

74DS-002

TB25

TB25-M1

INTERFACE MODULE

IM2

74N-000

-

J01

RETARD CONTROL PEDAL

P235

90CAT-002 90DIG-000 TB25

74N-001

TB31

TB31-R2

-

P01

90DIG-001

TB25

TB25-A2

-

P02

712K-001

-

P03

TB23

TB23-N1

74N-002

-

J701

TB31

TB31-R1

90DIG-002

-

J02

GE DID PANEL

DID

712K-002

TB23

TB23-N2

VEC-90

VEC90-P1

74NA-000

GE CONTROL INTERFACE

P302

SP739

-

90DIR-000

GE CONTROL INTERFACE

P303

TB25

TB25-B1

712K-003

TB23

TB23-N4

INTERFACE MODULE

IM2

74NA-001

SP739

-

-

J701

90DIR-001

-

P02

TB25

TB25-B2

712K-004

SWITCH KEY (KEYSW)

KEYSW-BR

SWITCH MANUAL BACKUP LIGHT

P23

74X-001

TB33

TB33-T2

SENSOR GE ALTERNATOR SPEED

-

90DIR-002

-

J02

GE DID PANEL

DID

712L-000

SP100

-

74X-002

GE CONTROL INTERFACE

P301

TB33

TB33-T1

90DIT-000

GE CONTROL INTERFACE

P303

TB25

TB25-C1

712L-001

SWITCH AUX BOX DOME LIGHT (DLS... DLS-3 SP100

DL1

DL1

74Z-001

TB33

TB33-W2

SENSOR GE ALTERNATOR SPEED

-

90DIT-001

TB25

TB25-C2

-

P02

712L-002

SP100

-

DL2

DL2

74Z-002

GE CONTROL INTERFACE

P301

TB33

TB33-W1

90DIT-002

-

J02

GE DID PANEL

DID

712L-003

SP100

-

DL3

DL3

74ZA-000

GE CONTROL INTERFACE

P301

TB21

TB21-D1

90ER1-000

KOMTRAX PLUS MODULE

P5

-

P653

712L-004

SP102

-

DL4

DL4

74ZA-001

TB21

TB21-D2

VEC-89

VEC89-P1

90ER2-000

KOMTRAX PLUS MODULE

P5

-

P653

712L-005

SP102

-

DL5

DL5

74ZA-002

TB21

TB21-D4

INTERFACE MODULE

IM3

90ET1-000

KOMTRAX PLUS MODULE

P5

-

P653

712L-006

SP102

-

DL6

DL6

75-GP-000

TB26

TB26-F1

INTERFACE MODULE

IM2

90ET2-000

KOMTRAX PLUS MODULE

P5

-

P653

712M-000

VEC-90

VEC90-P1

INTERFACE MODULE

IM1

75-GP-001

TB26

TB26-F2

GE CONTROL INTERFACE

P304

IM2

TB28

TB28-P1

TB32

-

J703

J372

TB28

TB28-P1

P02

75A2-000

SWITCH TRACTION MOTOR PRESSURE... BPSW-NC TB35-V1 TB35

712MM-000 VEC-90 712MM-001 -

VEC90-P4

75A1-000

90IMG-000 INTERFACE MODULE 90IMG-001 -

GE CONTROL INTERFACE

P301

TB28-P4

-

P02

TB35

-

J16

J02

-

DIAG5

712MM-002 712MM-003 SP157

J02

75A2-001

90IMG-002 TB28 90IMG-003 -

75A2-002

SWITCH TRACTION MOTOR PRESSURE... BPSW-NO P16 -

-

J703

TB28

TB28-N1

TB61

TB61-J1

90IMR-000 INTERFACE MODULE 90IMR-001 -

IM2

75A2-003

J372

TB28

TB28-N1

712MM-004 VEC-89 712P-000

75A2-004

TB61

TB61-J2

-

P703

TB28-N4

-

P02

712P-001

75LE-000

TB26

TB26-G1

INTERFACE MODULE

IM2

90IMR-002 TB28 90IMR-003 -

J02

-

DIAG5

75LE-001

TB26

TB26-G2

GE CONTROL INTERFACE

P304

90IMT-000

INTERFACE MODULE

IM2

TB28

75NP-000

TB26

TB26-E1

INTERFACE MODULE

IM2

90IMT-001

-

J372

75NP-001

TB26

TB26-E2

GE CONTROL INTERFACE

P304

90IMT-002

TB28

TB28-M4

76LR-000

TB26

TB26-H1

INTERFACE MODULE

IM2

90IMT-003

-

76LR-001

TB26

TB26-H2

GE CONTROL INTERFACE

P304

77-000

TB26

TB26-K2

GE CONTROL INTERFACE

P303

77-001

TB26

TB26-K1

INTERFACE MODULE

IM1

77-002

TB26

TB26-K4

-

P02

77-003

PAY LOAD METER 3

P264

TB26

TB26-K3

77-005

-

J02

-

P651

77-006

CAMERA CONTROLLER (OPT)

P652

-

J651

77A-000

TB26

TB26-L2

GE CONTROL INTERFACE

P303

77A-001

TB26

TB26-L1

INTERFACE MODULE

IM1

77A-002

TB26

TB26-L4

-

P02

77A-003

PAY LOAD METER 3

P264

TB26

TB26-L3

77A-005

-

J02

-

P651

77A-006

CAMERA CONTROLLER (OPT)

P652

-

J651

77B-000

-

P15

SENSOR LEFT REAR WHEEL SPEED

P720

77B-001

TB29

TB29-E2

-

J15

77B-003

GE CONTROL INTERFACE

P301

TB29

TB29-E1

77C-000

-

P15

SENSOR LEFT REAR WHEEL SPEED

P720

77C-001

TB29

TB29-C2

-

77C-003

GE CONTROL INTERFACE

P301

TB29

TB35-V2

ENGINE QSK60 INTERFACE TIER I P805939GE-000 ENGINE QSK60 INTERFACE TIER II P820 P808 939GE-001 939GE-002 ENGINE QSK60 INTERFACE TIER I P820939GE-003 CAN TEE J1939 # 1 939GE-004 CAN TEE J1939 # 5

P303B

CAN TEE J1939 # 2

P304B

SPR4-001

-

J03

-

SPR_16

P305B

-

P02

SPR5-000

-

P03

-

SPR_9

939GE-005 939GE-006 CAN TEE J1939 # 3

J02

CAN TEE J1939 # 3

P307B

SPR5-001

-

J03

-

SPR_17

P308B

CAN TEE J1939 # 4

P310B

SPR6-000

-

P03

-

SPR_10

939GE-007 CAN TEE J1939 # 3 939GE-008 INTERFACE MODULE

P309D

-

DIAG4

SPR6-001

-

J03

-

SPR_18

IM1

CAN TEE J1939 # 2

P306D

SPR7-000

-

P04

-

SPR_11

939GE-009 PAY LOAD METER 3 939GE-010 KOMTRAX PLUS MODULE

P264

CAN TEE J1939 # 1

P302D

SPR7-001

-

J04

-

SPR_19

P4A

CAN TEE J1939 # 4

P311D

SPR8-000

-

P04

-

SPR_12

939GE-011 CAN TEE J1939 # 2 939GE-012 CAN TEE J1939 # 5

P315B

CAN TEE J1939 # 5

P316B

SPR8-001

-

J04

-

SPR_20

P317D

-

P318D

939GP-000 CAN TEE RPC # 1 939GP-001 ACTIA DASH DISPLAY

P203B

CAN TEE RPC # 2

P204B

P903

CAN TEE RPC # 4

P212D

939GP-002 CAN TEE RPC # 6 939GP-003 -

P205B

-

P01

J01

CAN TEE RPC # 3

P207B

939GP-004 CAN TEE RPC # 3 939GP-005 CAN TEE RPC # 4

P208B

CAN TEE RPC # 4

P210B

P211B

CAN TEE RPC # 5

P213B

939GP-006 939GP-007 PAY LOAD METER 3

MM/RPC

CAN TEE RPC # 3

P209D

P264

CAN TEE RPC # 1

P202D

939GP-008 INTERFACE MODULE 939GP-009 CAN TEE RPC # 6

IM1

CAN TEE RPC # 2

P206D

P218D

-

P219D

939GP-010 KOMTRAX PLUS MODULE 939GP-012 CAN TEE RPC # 2

P4A

CAN TEE RPC # 5

P214D

P215B

CAN TEE RPC # 6

P216B

-

J808

CAN TEE J1939 # 1

P301B

-

J808-

939YE-000 ENGINE QSK60 INTERFACE TIER II P820 P808 939YE-001 939YE-002 ENGINE QSK60 INTERFACE TIER I P820939YE-003 CAN TEE J1939 # 1 939YE-004 CAN TEE J1939 # 5

P303B

CAN TEE J1939 # 2

P304B

P305B

-

P02

939YE-005 939YE-006 CAN TEE J1939 # 3

J02

CAN TEE J1939 # 3

P307B

P308B

CAN TEE J1939 # 4

P310B

939YE-007 CAN TEE J1939 # 3 939YE-008 INTERFACE MODULE

P309D

-

DIAG4

IM1

CAN TEE J1939 # 2

P306D

939YE-009 PAY LOAD METER 3 939YE-010 KOMTRAX PLUS MODULE

P264

CAN TEE J1939 # 1

P302D

P4A

CAN TEE J1939 # 4

P311D

939YE-011 CAN TEE J1939 # 2 939YE-012 CAN TEE J1939 # 5

P315B

CAN TEE J1939 # 5

P316B

P317D

-

P318D

939YP-000 CAN TEE RPC # 1 939YP-001 ACTIA DASH DISPLAY

P203B

CAN TEE RPC # 2

P204B

P903

CAN TEE RPC # 4

P212D

939YP-002 CAN TEE RPC # 6 939YP-003 -

P205B

-

P01

J01

CAN TEE RPC # 3

P207B

939YP-004 CAN TEE RPC # 3 939YP-005 CAN TEE RPC # 4

P208B

CAN TEE RPC # 4

P210B

P211B

CAN TEE RPC # 5

P213B

939YP-006 939YP-007 PAY LOAD METER 3

MM/RPC

CAN TEE RPC # 3

P209D

P264

CAN TEE RPC # 1

P202D

939YP-008 INTERFACE MODULE 939YP-009 CAN TEE RPC # 6

IM1

CAN TEE RPC # 2

P206D

P218D

-

P219D

939YP-010 KOMTRAX PLUS MODULE 939YP-012 CAN TEE RPC # 2

P4A

CAN TEE RPC # 5

P214D

P215B

CAN TEE RPC # 6

P216B

952M/0-001 TB27 952M/0-002 -

TB27-W2

GE CONTROL INTERFACE

P302

P808

TB27

TB27-W1

-

J808

BUSS BAR BAT(-)

BAT(-)-4

952M/0-003 ENGINE QSK60 INTERFACE TIER II P806 BAT1(-) BAT(-)-000 BATT1 BAT(-)-1 BAT(-)-001 BUSS BAR BAT(-)

CONTINUED ON DIAGRAM 19

WIRE LIST CONN TO TB29-J1

BATT3

BAT3(-)

BAT(-)-002 BUSS BAR BAT(-) BAT(-)-003 BUSS BAR BAT(-)

BAT(-)-6

BUSS BAR BAT-

DISC(-)-1

BAT(-)-5

BUSS BAR BAT-

DISC(-)-2

BAT(-)-004 BUSS BAR BATBAT(-)-010 ENGINE JUMP START1

DISC(-)-6 -

LAMP LED MASTER DISCONNECT OPE... MLLO BAT(-)-2 BUSS BAR BAT(-)

-

BUSS BAR BAT(-)

BAT(-)-3

TB32-R1

BAT(-)-020 ENGINE JUMP START2 J1

P701

-

P701

TB32

TB32-R2

J2

-

P701

-

P701

SP157

-

J3

-

P701

-

P701

-

-

MM/RPC

J4

-

P701

-

P701

MM/RPC

SP157

-

J5

-

P701

-

P701

VEC89-P4

TB35

TB35-D1

J6

-

P701

-

P701

TB35

TB35-D2

-

P03

J7

-

P702

-

P702

712P-002

-

J03

SWITCH BRAKE TEST

P37

J8

-

P702

-

P702

TB28-M1

712P-003

SWITCH BRAKE TEST

P37

SWITCH BRAKE TEST

P37

J9

-

P702

-

P702

TB28

TB28-M1

712PL-000

VEC-90

VEC90-P4

TB34

TB34-V1

J10

SWITCH FOG LAMP (OPT)

P22

SWITCH FOG LAMP (OPT)

P22

-

P02

712PL-001

TB34

TB34-V2

PAY LOAD METER 3

P264

J11

SWITCH FOG LAMP (OPT)

P22

SWITCH FOG LAMP (OPT)

P22

J02

-

DIAG5

712SL-000

VEC-90

VEC90-P3

TB36

TB36-P1

J12

SWITCH BRAKE LOCK

P39

SWITCH BRAKE LOCK

P39

90MMG-000 GE CONTROL INTERFACE 90MMG-001 -

P303

TB36

TB36-H1

712SL-001

SCORE BOARD LEFT (OPT)

CNLIN

TB36

TB36-P2

J13

SWITCH BRAKE TEST

P37

SWITCH BRAKE TEST

P37

P02

TB36

TB36-H2

712SL-002

SCORE BOARD RIGHT (OPT)

CNRIN

SCORE BOARD LEFT (OPT)

CNLO

J14

KOMTRAX PLUS MODULE

P2B

KOMTRAX PLUS MODULE

P2B

90MMG-002 90MMG-003 TB36

J02

-

DIAG8

712T-000

VEC-91

VEC91-P11

TB23

TB23-R2

J15

SWITCH CAMERA (OPT)

P31

SWITCH CAMERA (OPT)

P31

TB36-H4

INTERFACE MODULE

IM2

712T-001

TB23

TB23-R1

-

P03

J16

SWITCH ROTATING BEACON (OPT)

P32

90MMR-000 GE CONTROL INTERFACE 90MMR-001 -

P303

TB36

TB36-G1

712T-002

-

J03

SWITCH COMBO

P121

J17

SWITCH ROTATING BEACON (OPT) P32 SWITCH ROTATING BEACON (OPT) P32

SWITCH ROTATING BEACON (OPT)

P32

P02

TB36

TB36-G2

714A-000

-

P15

SENSOR RIGHT REAR WHEEL SPEED

P721

J18

SWITCH HEATED MIRROR (OPT)

P33

SWITCH HEATED MIRROR (OPT)

P33

90MMR-002 90MMR-003 TB36

J02

-

DIAG8

714A-001

TB29

TB29-K2

-

J15

J19

SWITCH HEATED MIRROR (OPT)

P33

SWITCH HEATED MIRROR (OPT)

P33

TB36-G4

INTERFACE MODULE

IM2

714A-003

GE CONTROL INTERFACE

P301

TB29

TB29-K1

J20

SWITCH GRID DRY

P34

SWITCH GRID DRY

P34

90MMT-000 GE CONTROL INTERFACE 90MMT-001 -

P303

TB36

TB36-F1

714B-000

-

P15

SENSOR RIGHT REAR WHEEL SPEED

P721

J21

SWITCH HAZARD LIGHTS

P36

SWITCH HAZARD LIGHTS

P36

P02

TB36

TB36-F2

714B-001

TB29

TB29-M2

-

J15

J22

SWITCH MANUAL BACKUP LIGHT

P23

90MMT-002 90MMT-003 TB36

J02

-

DIAG8

714B-003

GE CONTROL INTERFACE

P301

TB29

TB29-M1

J23

SWITCH MANUAL BACKUP LIGHT P23 J6 -

-

J6

TB36-F4

INTERFACE MODULE

IM2

P15

SENSOR RIGHT REAR WHEEL SPEED

P721

J24

-

J6

-

J6

90TCG-000 GE CONTROL INTERFACE 90TCG-001 -

P303

TB25

TB25-S1

714DN-000 714DN-001 TB29

TB29-N2

-

J15

J25

-

J6

-

J6

P02

TB25

TB25-S2

P301

TB29

TB29-N1

J26

-

J6

-

J6

90TCG-002 90TCR-000 GE CONTROL INTERFACE

J02

-

DIAG3

714DN-003 GE CONTROL INTERFACE 714DP-001 TB29

TB29-L2

-

J15

J30

-

J830

-

J830

P303

TB25

TB25-P1

P301

TB29

TB29-L1

LF(+)-000

ENTERTAINMENT RADIO

P737

-

J211

P02

TB25

TB25-P2

P15

SENSOR RIGHT REAR WHEEL SPEED

P721

LF(+)-001

-

P211

ENTERTAINMENT LEFT FRT SPEAKER

LFSPK

J15

90TCR-001 90TCR-002 -

714DP-003 GE CONTROL INTERFACE 714DP000 -

J02

-

DIAG3

714G-000

-

P15

SENSOR RIGHT REAR WHEEL SPEED

P721

LF(-)-000

ENTERTAINMENT RADIO

P737

-

J211

TB29-C1

90TCT-000 GE CONTROL INTERFACE

P303

TB25

TB25-R1

714G-001

TB29

TB29-J2

-

J15

LF(-)-001

-

P211

ENTERTAINMENT LEFT FRT SPEAKER

LFSPK

DEVICE TABLE DEVICE 12VDC CONVERTER (12VCN)

SHORT DESCRIPTION DIAGRAM ZONE Diagram5 D9 Diagram5 E5 -

12VDC POWER PORT #1

-

Diagram5

O11

12VDC POWER PORT #2

-

Diagram5

O11

24VDC ALTERNATOR

-

Diagram3

K7

24VDC AUXBOX BUSS

-

Diagram5

A5

24VDC AUXBOX BUSS

-

Diagram5

A5

24VDC AUXBOX BUSS

-

Diagram5

A5

24VDC AUXBOX BUSS

-

Diagram5

A5

24VDC AUXBOX BUSS

-

Diagram5

B5

24VDC AUXBOX BUSS

-

Diagram5

B5

24VDC AUXBOX BUSS

-

Diagram5

B5

A/C COMPRESSOR CLUTCH T2

-

Diagram6

L5

A/C COMPRESSOR CLUTCH T1

-

Diagram7

L5

ACCELERATOR PEDAL

-

Diagram10 N11

ACTIA DASH DISPLAY

-

Diagram8

H8

ACTIA DISPLAY PANEL DIMMER

-

Diagram8

J12

ACTIA STATUS PANEL

-

Diagram8

ALTERNATOR PROPULSION DRIVE

-

ANTENNA KWB MODULE (OPT)

-

D1 Diagram15 O12 Diagram12 J21

ANTENNA ORBCOMM SATELLITE / GPS (OP... BATT1

Diagram12 H21 Diagram3 D2

12V POWER RELAY (12VPR)

BATT2

-

Diagram3

D3

BATT3

-

Diagram3

E2

BATT4

-

Diagram3

E3

BUSS BAR 0

-

Diagram3

G15

BUSS BAR 11

-

Diagram3

E15

BUSS BAR 11L

-

Diagram9

L5

BUSS BAR 11ST

-

Diagram3

F15

BUSS BAR 24VDC BATT BOX

-

Diagram3

E6

BUSS BAR BAT(-)

-

Diagram3

F4

BUSS BAR BAT-

-

Diagram3

CAMERA CONTROLLER (OPT)

-

CAN TEE J1939 # 1

-

CAN TEE J1939 # 2

-

CAN TEE J1939 # 3

-

CAN TEE J1939 # 4

-

CAN TEE J1939 # 5

-

CAN TEE RPC # 1

-

CAN TEE RPC # 2

-

CAN TEE RPC # 3

-

CAN TEE RPC # 4

-

CAN TEE RPC # 5

-

CAN TEE RPC # 6

-

Diagram15 E18 Diagram15 E8

CB60

-

Diagram5

D1

-

D2

-

D6 Diagram11 L16 Diagram6 H14

D3

-

Diagram7

M20

D4

-

Diagram9

K6

D9

-

Diagram8

D12

D10

-

Diagram8

D15

-

D26

-

D13 Diagram11 N3 Diagram13 C11

D70

-

Diagram3

D71

-

D87

-

C19 Diagram12 M7 Diagram3 N13

DL1

-

Diagram5

C21

DL2

-

Diagram5

D21

DL3

-

Diagram5

D21

DL4

-

Diagram5

E21

DL5

-

Diagram5

E21

DL6

-

Diagram5

F21

ENGINE JUMP START1

-

Diagram3

D6

ENGINE JUMP START2

-

Diagram3

D7

ENGINE OIL RESERVE SYSTEM (OPT)

-

Diagram6

N14

ENGINE PRELUBE HIGH VOLUME PUMP

-

Diagram3

O14

ENGINE QSK60 INTERFACE TIER I

-

Diagram7

I2

ENGINE QSK60 INTERFACE TIER II

-

Diagram6

I2

ENTERTAINMENT LEFT FRT SPEAKER

-

Diagram5

M16

ENTERTAINMENT LEFT REAR SPEAKER

-

Diagram5

N16

ENTERTAINMENT RADIO

-

Diagram5

N20

ENTERTAINMENT RIGHT FRT SPEAKER

-

Diagram5

M16

ENTERTAINMENT RIGHT REAR SPEAKER

-

Diagram5

O16

FUSE LINK1 (150A)

-

Diagram3

O10

FUSE LINK2 (150A)

-

Diagram3

GB LEFT DECK

-

GB1 - REAR AXLE

-

GB1 - REAR AXLE

-

GB1 - REAR AXLE

-

GB1 - REAR AXLE

-

GB1 - REAR AXLE

-

GB1 - REAR AXLE

-

GB1 - REAR AXLE

-

GB1 - REAR AXLE

-

GB3 ENG GND BLOCK

-

Diagram11 M15 Diagram3 O15

GB3 ENG GND BLOCK

-

Diagram3

O15

GB3 ENG GND BLOCK

-

Diagram6

K4

GB3 ENG GND BLOCK

-

Diagram7

K5

GB8 BRAKE CABINET

-

Diagram4

H22

GB8 BRAKE CABINET

-

Diagram7

GB8 BRAKE CABINET

-

GB8 BRAKE CABINET

-

L21 Diagram11 O11 Diagram13 F16

GB10 FRT CAB GND

-

Diagram7

J15

GB10 FRT CAB GND

-

Diagram8

B8

GB10 FRT CAB GND

-

Diagram8

G9

GB10 FRT CAB GND

-

Diagram8

K13

GB10 FRT CAB GND

-

Diagram9

GB10 FRT CAB GND

-

GB10 FRT CAB GND

-

GB10 FRT CAB GND

-

GB10 FRT CAB GND

-

Diagram15 I2 Diagram15 M21

GB12 REAR CAB

-

Diagram5

M11

GB12 REAR CAB

-

Diagram5

M11

GB12 REAR CAB

-

Diagram5

M11

GB12 REAR CAB

-

Diagram7

GB12 REAR CAB

-

GB12 REAR CAB

-

GB12 REAR CAB

-

GB12 REAR CAB

-

GB12 REAR CAB

-

GB12 REAR CAB

-

GB12 REAR CAB

-

GB31-A AUXBOX GND BLCK

-

Diagram15 G14 Diagram5 E7

GB31-A AUXBOX GND BLCK

-

Diagram5

E7

GB31-A AUXBOX GND BLCK

-

Diagram5

E7

GB31-A AUXBOX GND BLCK

-

Diagram5

E18

GB31-A AUXBOX GND BLCK

-

Diagram5

H3

GB31-A AUXBOX GND BLCK

-

Diagram5

I3

GB31-A AUXBOX GND BLCK

-

Diagram5

I7

GB31-A AUXBOX GND BLCK

-

Diagram5

J7

GB31-A AUXBOX GND BLCK

-

Diagram5

J11

GB31-A AUXBOX GND BLCK

-

Diagram5

M7

GB31-A AUXBOX GND BLCK

-

Diagram5

M7

GB31-A AUXBOX GND BLCK

-

Diagram7

O10

GB31-A AUXBOX GND BLCK

-

Diagram9

GB31-A AUXBOX GND BLCK

-

GB31-A AUXBOX GND BLCK

-

G15 Diagram15 K7 Diagram15 B4 Diagram15 B7 Diagram15 B15 Diagram15 B18 Diagram15 B10 Diagram15 E2 Diagram15 E5 Diagram15 E13 Diagram15 E16

O10 Diagram14 I18 Diagram11 B19 Diagram11 B19 Diagram11 B19 Diagram11 D19 Diagram11 I13 Diagram11 I13 Diagram11 M15

B5 Diagram12 L6 Diagram14 D1

C14 Diagram10 I16 Diagram10 I16 Diagram10 K7 Diagram10 K16 Diagram11 N6 Diagram15 D16

E13 Diagram12 A4 Diagram14 E7

58E-06-02000-00 NOV 11 ELECTRICAL SCHEMATIC 830E-1AC A40851 & UP Sheet 18 of 20

DEVICE TABLE DEVICE TABLE DEVICE

DEVICE TABLE

GB31-A AUXBOX GND BLCK

SHORT DESCRIPTION DIAGRAM ZONE Diagram15 I14 -

GB31-B AUXBOX GND BLCK

-

Diagram4

GB31-B AUXBOX GND BLCK

-

Diagram5

GB31-B AUXBOX GND BLCK

-

GB31-B AUXBOX GND BLCK

DEVICE

DEVICE TABLE

M0TOR STARTER 1 (STRT1)

SHORT DESCRIPTION DIAGRAM ZONE Diagram3 K10 -

H18

MIRROR HEATED LEFT DECK (OPT)

-

H7

MIRROR HEATED RIGHT DECK (OPT)

-

Diagram5

H7

MOTOR LEFT WINDOW

-

Diagram5

I3

GB31-B AUXBOX GND BLCK

-

Diagram5

GB31-B AUXBOX GND BLCK

-

GB31-B AUXBOX GND BLCK

DEVICE

CONTINUED FROM DIAGRAM 18

DEVICE TABLE

DEVICE TABLE

DEVICE TABLE

DEVICE TABLE

DEVICE TABLE

DEVICE TABLE

DEVICE SHORT DESCRIPTION DIAGRAM ZONE Diagram15 N2 TB-HTST -

DEVICE SHORT DESCRIPTION DIAGRAM ZONE Diagram4 E12 TB23

DEVICE SHORT DESCRIPTION DIAGRAM ZONE Diagram8 B15 TB26

DEVICE SHORT DESCRIPTION DIAGRAM ZONE Diagram13 H12 TB28

DEVICE SHORT DESCRIPTION DIAGRAM ZONE Diagram10 O7 TB31

DEVICE SHORT DESCRIPTION DIAGRAM ZONE Diagram9 K14 TB35

SP175

SHORT DESCRIPTION DIAGRAM ZONE Diagram11 J17 -

Diagram14 C14

SP176

-

Diagram11 J17

TB-HTST -

Diagram15 N2

TB23

-

Diagram7

E13

TB26

-

Diagram8

C15

TB28

-

Diagram13 H12

TB31

-

Diagram10 O7

TB35

-

Diagram14 B14

SP177

-

Diagram11 J18

TB-HTST -

Diagram15 N2

TB23

-

Diagram7

E13

TB26

-

Diagram8

C15

TB28

-

Diagram13 H12

TB31

-

Diagram10 O7

TB35

-

-

Diagram10 I21

SP180

-

Diagram12 F7

TB-HTST -

Diagram15 N2

TB23

-

Diagram7

E19

TB26

-

Diagram8

D15

TB28

-

Diagram13 H12

TB31

-

Diagram10 P7

TB35

MOTOR RIGHT WINDOW

-

Diagram10 K21

SP181

-

Diagram12 H4

TB-HTST -

Diagram15 O2

TB23

-

Diagram7

E20

TB26

-

Diagram8

D15

TB28

-

Diagram13 H12

TB31

-

Diagram10 P7

J3

MOTOR STARTER 2 (STRT2)

-

Diagram3

K12

SP182

-

Diagram12 H4

TB-HTST -

Diagram15 O2

TB23

-

Diagram7

J13

TB26

-

Diagram9

F14

TB28

-

Diagram13 H12

TB31

-

Diagram10 P7

Diagram6

B8

MOTOR WHEEL DRIVE # 1

-

Diagram15 N12

SP183

-

Diagram13 C10

TB-HTST -

Diagram15 O2

TB23

-

Diagram7

J13

TB26

-

Diagram9

F14

TB28

-

Diagram13 I5

TB32

-

Diagram4

-

Diagram6

B8

MOTOR WHEEL DRIVE # 2

-

Diagram15 O12

SP184

-

Diagram13 C12

TB-HTST -

Diagram15 O2

TB23

-

Diagram7

J13

TB26

-

Diagram9

F14

TB28

-

Diagram14 A6

TB32

-

GB31-B AUXBOX GND BLCK

-

Diagram6

B8

MOTOR WINDSHIELD WASHER

-

Diagram11 N8

SP185

-

Diagram13 E17

TB-HTST -

Diagram15 O2

TB23

-

Diagram7

K12

TB26

-

Diagram12 A5

TB28

-

Diagram14 A6

TB32

GB31-B AUXBOX GND BLCK

-

Diagram6

F8

MOTOR WINDSHIELD WIPER

-

Diagram11 O8

SP187

-

Diagram12 H16

TB-HTST -

Diagram15 O2

TB23

-

Diagram7

K12

TB26

-

Diagram12 A5

TB29

-

Diagram6

F18

GB31-B AUXBOX GND BLCK

-

Diagram6

M9

ORBCOMM MODULE (OPT)

-

Diagram12 J20

SP191

-

Diagram12 D16

TB-HTST -

Diagram15 P2

TB23

-

Diagram7

N12

TB26

-

Diagram12 A5

TB29

-

Diagram6

GB31-B AUXBOX GND BLCK

-

Diagram8

K9

PAY LOAD METER 3

-

Diagram14 O9

SP192

-

Diagram12 E16

TB10

-

Diagram8

E9

TB23

-

Diagram7

N12

TB26

-

Diagram12 A5

TB29

-

GB31-B AUXBOX GND BLCK

-

Diagram12 N4

R3

-

Diagram6

F12

SP193

-

Diagram12 E16

TB10

-

Diagram8

E9

TB23

-

Diagram7

N12

TB26

-

Diagram12 A6

TB29

GB31-B AUXBOX GND BLCK

-

Diagram13 A10

R4

-

Diagram6

F12

SP194

-

Diagram12 E16

TB10

-

Diagram8

I12

TB23

-

Diagram8

F12

TB26

-

Diagram12 A6

GB31-B AUXBOX GND BLCK

-

Diagram13 H14

R5

-

Diagram6

F17

SP195

-

Diagram14 G20

TB10

-

Diagram8

I16

TB23

-

Diagram8

F12

TB26

-

GB31-B AUXBOX GND BLCK

-

R15

-

-

-

Diagram8

I16

TB23

-

Diagram8

F12

TB26

-

R16

-

SP198

-

Diagram14 H20 Diagram13 I10

TB10

-

Diagram13 D12 Diagram8 E12

SP196

GB31-B AUXBOX GND BLCK

Diagram14 J7 Diagram14 K16

TB10

-

Diagram8

J9

TB23

-

Diagram8

G12

TB26

-

GB70 FRAME GND

-

Diagram3

I10

R17

-

SP701

-

-

Diagram8

J9

TB23

-

Diagram8

G12

TB26

-

-

Diagram3

I10

R18

-

SP702

-

Diagram15 I7 Diagram15 I7

TB10

GB70 FRAME GND

Diagram12 G7 Diagram7 I15

TB10

-

Diagram8

J9

TB23

-

Diagram9

C8

TB26

-

GB70 FRAME GND

-

Diagram3

I10

R19

-

SP703

-

-

Diagram8

J9

TB23

-

Diagram9

C8

TB26

-

-

R20

-

SP704

-

TB10

-

Diagram8

J9

TB23

-

Diagram9

K2

TB26

-

GE CONTROL INTERFACE

-

Diagram15 O9 Diagram4 D21

Diagram15 N5 Diagram15 N5

TB10

GE CONTROL CABINET

Diagram13 B12 Diagram14 L20

R21

-

SP705

-

-

Diagram8

J9

TB23

-

Diagram9

K2

TB26

-

-

Diagram5

D2

R23

-

SP706

-

Diagram15 N5 Diagram15 N4

TB10

GE CONTROL INTERFACE

Diagram14 L20 Diagram12 A7

TB10

-

Diagram9

C4

TB23

-

TB26

-

GE CONTROL INTERFACE

-

Diagram6

G20

R27

-

Diagram8

SP707

-

TB10

-

Diagram9

C4

TB23

-

TB26

-

GE CONTROL INTERFACE

-

Diagram7

F15

R30

-

SP708

-

TB10

-

Diagram9

C4

TB23

-

-

-

R34

-

SP709

-

-

Diagram9

C4

TB23

-

TB26

-

-

R44

-

Diagram5

C9

SP723

-

Diagram15 P5 Diagram8 E14

TB10

GE CONTROL INTERFACE

Diagram10 P2 Diagram12 O3

Diagram10 H9 Diagram10 H9

TB26

GE CONTROL INTERFACE

Diagram13 M14 Diagram12 B7

Diagram15 O5 Diagram15 O5

Diagram10 H9 Diagram10 H9

TB10

-

Diagram9

J5

TB23

-

TB26

-

GE CONTROL INTERFACE

-

R50

-

Diagram6

E9

SP728

-

-

Diagram9

J5

TB23

-

TB26

-

-

R51

-

Diagram6

C9

SP729

-

Diagram10 A8 Diagram10 C8

TB10

GE DID PANEL

Diagram14 M20 Diagram12 I9

Diagram10 M16 Diagram12 M4

TB10

-

Diagram9

J5

TB23

-

TB26

-

HEATER COOLANT LH

-

RELAY 1 PROPEL LOCKOUT

-

Diagram3

D16

SP730

-

-

Diagram9

J5

TB23

-

TB26

-

-

RELAY ACCESS LADDER LIGHT (ALLR)

-

Diagram9

F12

SP732

-

Diagram12 F15 Diagram9 L6

TB10

HEATER COOLANT RH

Diagram15 L5 Diagram15 L5

Diagram12 M4 Diagram12 M4

TB10

-

Diagram9

L5

TB23

-

TB26

-

HEATER ENGINE OIL LH

-

RELAY BACKUP LIGHT (BULR)

-

-

-

Diagram9

L5

TB23

-

TB26

-

RELAY ENG STARTER 1 (ESREL1)

-

SP738

-

Diagram13 H5 Diagram10 N4

TB10

-

Diagram11 D9 Diagram3 F6

SP737

HEATER ENGINE OIL RH

Diagram15 N7 Diagram15 N7

Diagram12 N4 Diagram12 N4

TB10

-

Diagram9

L5

TB23

-

TB26

-

HEATER HYDRAULIC OIL #1

-

RELAY ENG STARTER 2 (ESREL2)

-

Diagram3

F7

SP739

-

-

Diagram9

L5

TB23

-

TB26

-

-

RELAY ENGINE PRELUBE

-

Diagram3

N9

SP740

-

Diagram10 O4 Diagram10 P4

TB10

HEATER HYDRAULIC OIL #2

Diagram15 P7 Diagram15 P7

Diagram14 C7 Diagram14 C7

TB10

-

TB23

-

-

-

RELAY ENGINE PRELUBE MAG SWITCH (PL... -

Diagram3

O12

SP741

-

-

TB23

-

TB26

-

-

RELAY HEADLIGHT HIGH MOUNT (HHMR)

-

Diagram8

O7

SP742

-

Diagram10 G3 Diagram10 E3

TB10

HORN BACKUP LEFT

Diagram15 M7 Diagram11 C17

Diagram14 F13 Diagram14 G14

TB26

HEATER OIL RESERVE TANK

Diagram11 L5 Diagram11 L5

TB21

-

Diagram5

M8

TB23

-

TB26

-

HORN BACKUP RIGHT

-

RELAY HEADLIGHT LOW MOUNT (HLMR)

-

Diagram8

N7

SP743

-

-

Diagram5

M8

TB24

-

TB26

-

-

RELAY HI-BEAM HEADLIGHT (HBHR)

-

Diagram8

L7

SP744

-

Diagram14 N9 Diagram14 L9

TB21

HORN FRONT VEHICLE

Diagram11 C17 Diagram11 L18

Diagram14 H13 Diagram4 D7

TB21

-

Diagram5

M8

TB24

-

Diagram4

D7

TB26

-

INCLINOMETER

-

RELAY HYDRAULIC LADDER PK STATUS (O... -

-

-

Diagram7

G13

TB24

-

Diagram5

A11

TB26

-

RELAY KEY / GE CNTRL PWR (KCNPR)

-

SP766

-

Diagram10 G9 Diagram10 E9

TB21

-

Diagram15 N19 Diagram5 C9

SP765

INTERFACE MODULE

Diagram14 O7 Diagram4 L7

TB21

-

Diagram7

G13

TB24

-

Diagram5

A11

TB26

-

INTERFACE MODULE

-

Diagram5

B2

RELAY KEY SWITCH (KSWPR)

-

Diagram4

F8

SP767

-

TB21

-

Diagram7

G13

TB24

-

Diagram5

A11

TB26

-

INTERFACE MODULE

-

Diagram7

J20

RELAY MASTER DISCONNECT

-

Diagram3

G16

SP768

-

Diagram10 E10 Diagram10 E11

TB21

-

Diagram7

G13

TB24

-

Diagram5

A11

TB26 M5 -

INTERFACE MODULE

-

Diagram8

G17

RELAY STARTER LOCKOUT

-

Diagram3

E16

SP769

-

TB21

-

Diagram7

G13

TB24

-

Diagram5

B11

TB27

INTERFACE MODULE

-

RELAY VEHICLE HORN POWER (HPR)

-

-

TB21

-

Diagram7

G13

TB24

-

Diagram5

B11

-

RELAY WIPER MOTOR HIGH

-

Diagram11 L11 Diagram11 P6

SP770

INTERFACE MODULE

Diagram11 I6 Diagram13 P7

Diagram10 G10 Diagram10 G11

SP773

-

TB21

-

Diagram7

G13

TB24

-

Diagram5

JB1

-

Diagram3

E19

RELAY WIPER MOTOR LOW

-

SP774

-

TB21

-

Diagram7

G13

TB24

-

JB4A

-

Diagram6

H12

RETARD CONTROL LEVER (OPT)

-

Diagram11 O6 Diagram10 P11

Diagram13 I5 Diagram13 K2

SP775

-

TB21

-

Diagram7

G13

TB24

JB4B

-

RETARD CONTROL PEDAL

-

-

TB21

-

Diagram7

G13

-

RETARD SPEED CONTROL

-

Diagram10 O11 Diagram10 L11

SP777

JB4C

Diagram10 I10 Diagram11 M2

Diagram13 K4 Diagram6 M13

SP778

-

TB21

-

Diagram7

JB4D

-

Diagram8

SCORE BOARD LEFT (OPT)

-

SP779

-

TB21

-

JB4E

-

Diagram7

SCORE BOARD RIGHT (OPT)

-

SP782

-

-

SENSOR BRAKE PRESSURE

-

SP783

-

TB21

JB6A

-

SENSOR DUCT AIR TEMPERATURE

-

Diagram13 K1 Diagram13 L17

Diagram10 K20 Diagram10 K19

TB21

JB4H

A15 Diagram11 O3 Diagram10 J19

Diagram14 J17 Diagram14 J14

Diagram10 I20 Diagram10 J20

SP785

-

JB6B

-

Diagram7

F17

SENSOR FUEL LEVEL

-

SP786

-

JB6C

-

Diagram7

D12

SENSOR GE ALTERNATOR SPEED

-

Diagram13 D16 Diagram10 H6

Diagram13 M14 Diagram13 O14

STARTER DISCONNECT (DISC+)

-

Diagram3

JB6E

-

SENSOR HOIST PRESSURE #1

-

-

-

SENSOR HOIST PRESSURE #2

-

Diagram13 H1 Diagram13 I1

SWITCH A/C RECIEVER DRYER T1

JB6G

Diagram12 H20 Diagram11 L2

SWITCH A/C RECIEVER DRYER T2

JB8A

-

SENSOR HYDRAULIC TANK LEVEL

-

JB41

-

Diagram12 I18 Diagram6 G4

SENSOR HYDRAULIC TANK TEMP

-

Diagram13 I16 Diagram13 J17

JB41-

-

Diagram7

SENSOR LEFT FRONT WHEEL SPEED

-

KOMATSU WIRELESS BRIDGE (OPT) KWB

-

SENSOR LEFT REAR WHEEL SPEED

-

KOMTRAX PLUS MODULE

-

Diagram12 K20 Diagram12 L14

SENSOR PAYLOAD PRESSURE LEFT FRONT

-

L BAR-1

-

Diagram4

J12

SENSOR PAYLOAD PRESSURE LEFT REAR

-

L BAR-2

-

Diagram5

B11

SENSOR PAYLOAD PRESSURE RIGHT FRONT -

L BAR-3

-

SENSOR PAYLOAD PRESSURE RIGHT REAR

-

L BAR-4

-

Diagram11 M12 Diagram6 D8

SENSOR RIGHT FRONT WHEEL SPEED

-

L BAR-5

-

SENSOR RIGHT REAR WHEEL SPEED

-

L BAR-6

-

Diagram10 L4 Diagram10 M5

SENSOR STEERING PRESSURE

-

L BAR-7

-

SHIFTER CURRENT LIMIT RESISTOR

L BAR-8

-

Diagram13 J11 Diagram12 A5

LAMP AMBER PAYLOAD LEFT

-

LAMP AMBER PAYLOAD RIGHT

-

LAMP BACKUP LIGHT LEFT DECK (OPT)

-

LAMP BACKUP LIGHT RIGHT DECK (OPT)

-

LAMP BACKUP REAR LEFT

-

LAMP BACKUP REAR RIGHT

-

LAMP BODY LEFT REAR MARKER

-

LAMP BODY LEFT SIDE MARKER

-

LAMP BODY RIGHT REAR MARKER

-

LAMP BODY RIGHT SIDE MARKER LAMP CAB DOME

DEVICE TABLE DEVICE

SHORT DESCRIPTION DIAGRAM ZONE Diagram12 F9

TB61

-

Diagram10 E17

TB61

-

Diagram14 N4

Diagram10 E17

TB61

-

Diagram14 N4

-

Diagram10 F17

TB61

-

Diagram14 N4

TB35

-

Diagram10 O14

TB61

-

Diagram14 N4

TB35

-

Diagram10 O14

TB61

-

Diagram14 N4

H18

TB35

-

Diagram11 C12

TB61

-

Diagram14 N4

Diagram4

H18

TB35

-

Diagram11 C12

TB61

-

Diagram14 N4

-

Diagram4

H18

TB35

-

Diagram11 D12

TB61

-

Diagram14 N4

TB32

-

Diagram4

J12

TB35

-

Diagram11 H9

TERM#1

-

Diagram15 B18

F18

TB32

-

Diagram4

J12

TB35

-

Diagram11 H9

TERM#2

-

Diagram15 E2

Diagram6

G18

TB32

-

Diagram4

J12

TB35

-

Diagram11 H10

TERM#3

-

Diagram15 E18

-

Diagram6

G18

TB32

-

Diagram4

J12

TB35

-

Diagram11 H10

THERMOSTAT ENGINE OIL

-

Diagram15 N5

TB29

-

Diagram10 D4

TB32

-

Diagram4

J12

TB35

-

Diagram11 H10

THERMOSTAT HYDRAULIC OIL

-

Diagram15 O6

Diagram12 A6

TB29

-

Diagram10 D4

TB32

-

Diagram4

J12

TB35

-

Diagram11 H10

THERMOSTAT OIL RESERVE TANK

-

Diagram15 L7

Diagram12 A6 Diagram12 B5

TB29

-

TB32

-

Diagram7

I13

TB35

-

-

Diagram10 D14

-

TB32

-

Diagram7

I13

TB35

-

Diagram11 M12 Diagram11 M12

TIMER (1HR) ENGINE SERVICE LAMP (ES...

TB29

Diagram10 D4 Diagram10 D4

TIMER (1HR) HYDRAULIC PUMP MOD (HP... -

Diagram10 C16

Diagram12 B5 Diagram12 B5

TB29

-

TB32

-

Diagram7

I13

TB35

-

-

Diagram11 O16

-

TB32

-

Diagram7

J13

TB35

-

Diagram11 M12 Diagram11 M12

TIMER REAR SERVICE LAMP (PLT)

TB29

Diagram10 E4 Diagram10 E4

TIMER WASHER DELAY (WADT)

-

Diagram11 M8

Diagram12 B5 Diagram12 B6

TB29

-

TB32

-

Diagram7

L15

TB35

-

-

Diagram11 M5

-

TB32

-

Diagram7

L15

TB35

-

Diagram11 M13 Diagram11 M13

TIMER WIPER DELAY

TB29

Diagram10 E4 Diagram10 E4

VEC RTMR1

-

Diagram7

L12

Diagram12 B6 Diagram12 B6

TB29

-

TB32

-

Diagram7

M11

TB35

-

-

Diagram7

O7

-

TB32

-

TB35

-

VEC-89

-

Diagram5

C14

Diagram12 B6 Diagram12 C5

TB29

-

TB32

-

TB35

-

-

Diagram7

A10

-

TB32

-

TB35

-

VEC-89

-

Diagram7

E18

Diagram12 C5 Diagram12 C6

TB29

-

TB32

-

TB35

-

-

Diagram8

I5

-

TB32

-

TB35

-

VEC-89

-

Diagram8

L6

Diagram12 C6 Diagram12 D5

TB29

-

TB32

-

TB35

-

-

Diagram8

N5

-

TB32

-

TB35

-

VEC-89

-

Diagram8

O5

Diagram12 D6 Diagram12 D7

TB29

-

TB32

-

TB35

-

-

Diagram9

B10

-

TB32

-

TB35

-

VEC-89

-

Diagram9

C10

Diagram12 D7 Diagram12 E7

TB29

-

TB32

-

TB35

-

-

Diagram9

G11

-

TB32

-

TB35

-

VEC-89

-

Diagram9

I9

Diagram12 E7 Diagram12 E7

TB29

-

TB32

-

TB35

-

-

Diagram9

K9

-

TB32

-

TB35

-

VEC-89

-

Diagram10 D6

Diagram12 E7 Diagram12 E7

TB29

-

TB32

-

TB35

-

-

Diagram10 H10

-

TB32

-

TB35

-

VEC-89

-

Diagram11 D5

Diagram12 E7 Diagram12 E7

TB29

-

TB32

-

TB35

-

-

Diagram11 D7

-

TB32

-

TB35

-

VEC-89

-

Diagram11 G6

Diagram12 E7 Diagram12 E7

TB29

-

TB33

-

TB35

-

-

Diagram11 H6

-

TB33

-

TB36

-

VEC-89

-

Diagram12 P2

Diagram12 E7 Diagram12 E7

TB29

-

TB33

-

TB36

-

-

Diagram13 B15

-

TB33

-

TB36

-

VEC-89

-

Diagram13 C15

-

Diagram4

C20

TB29

-

TB33

-

TB36

-

-

Diagram13 C16

-

Diagram4

C20

TB29

-

TB33

-

TB36

-

VEC-89

-

Diagram13 N10

B11

TB27

-

Diagram4

C20

TB29

-

TB33

-

TB36

-

-

Diagram14 B3

B11

TB27

-

Diagram4

C20

TB29

-

TB33

-

TB36

-

VEC-90

-

Diagram4

B7

-

Diagram5

C5

TB27

-

Diagram6

A10

TB29

-

TB33

-

TB36

-

-

Diagram4

D9

-

Diagram5

C5

TB27

-

Diagram6

A10

TB29

-

TB33

-

TB36

-

VEC-90

-

Diagram5

D14

H13

TB24

-

Diagram5

C5

TB27

-

Diagram6

A10

TB29

-

TB33

-

TB36

-

-

Diagram7

L7

I17

TB24

-

Diagram5

C11

TB27

-

Diagram6

B10

TB29 X5 -

TB33

-

TB36

-

VEC-90

-

Diagram12 C7

-

Diagram7

I17

TB24

-

Diagram5

C11

TB27

-

Diagram6

B10

TB30

-

Diagram6

K9

TB33

-

Diagram10 C4 Diagram10 C4

Diagram12 L5 Diagram12 L5

VEC-90

Diagram7

Diagram12 F19 Diagram12 F19

Diagram10 B4 Diagram10 C4

Diagram12 L5 Diagram12 L5

VEC-90

TB24

Diagram12 F19 Diagram12 F19

Diagram10 B4 Diagram10 B4

Diagram12 K5 Diagram12 L5

VEC-89

Diagram5

Diagram12 F19 Diagram12 F19

Diagram10 B4 Diagram10 B4

Diagram12 K5 Diagram12 K5

VEC-89

TB27

Diagram12 E19 Diagram12 E19

Diagram10 B4 Diagram10 B4

Diagram12 K5 Diagram12 K5

VEC-89

TB29

Diagram12 E19 Diagram12 E19

Diagram10 A4 Diagram10 B4

Diagram13 M12 Diagram12 K5

VEC-89

TB29

Diagram10 G4 Diagram10 G4

Diagram15 J15 Diagram10 A4

Diagram13 M12 Diagram13 M12

VEC-89

TB29

Diagram10 G4 Diagram10 G4

Diagram15 I15 Diagram15 J14

Diagram13 L11 Diagram13 M12

VEC-89

TB29

Diagram10 G4 Diagram10 G4

Diagram15 I14 Diagram15 I15

Diagram13 L11 Diagram13 L11

VEC-89

TB29

Diagram10 F4 Diagram10 F4

Diagram15 G9 Diagram15 I14

Diagram13 D11 Diagram13 D11

VEC-89

TB29

Diagram10 F4 Diagram10 F4

Diagram15 G9 Diagram15 G9

Diagram12 P4 Diagram13 D10

VEC-89

TB29

Diagram10 F4 Diagram10 F4

Diagram13 G11 Diagram15 G9

Diagram12 G5 Diagram12 P4

VEC-89

TB29

Diagram10 F4 Diagram10 F4

Diagram13 F11 Diagram13 G10

Diagram12 F5 Diagram12 G5

VEC-89

TB29

Diagram10 E4 Diagram10 E4

Diagram13 F10 Diagram13 F11

Diagram12 F4 Diagram12 F5

VEC-89

TB29

Diagram10 E4 Diagram10 E4

Diagram13 B13 Diagram13 F10

Diagram11 M13 Diagram12 F4

VEC RTMR1

TB29

Diagram10 E4 Diagram10 E4

TB36

-

-

Diagram12 G20

Diagram7

I17

TB24

-

Diagram5

C11

TB27

-

Diagram6

B10

TB30

-

Diagram6

K9

TB33

-

TB36

-

VEC-90

-

Diagram14 H9

TB21

-

Diagram7

I17

TB24

-

Diagram5

D8

TB27

-

Diagram6

B10

TB30

-

Diagram6

K9

TB33

-

Diagram10 C4 Diagram10 C4

Diagram14 J13 Diagram14 J13

VEC-90

-

TB36

-

VEC-90

-

Diagram14 I6

TB21

-

TB24

-

Diagram5

D8

TB27

-

Diagram6

B10

TB30

-

-

-

VEC-90

-

Diagram15 G7

-

TB24

-

Diagram5

D8

TB27

-

Diagram6

B10

TB30

-

TB33

-

Diagram10 C4 Diagram10 C4

TB36

TB21

Diagram13 B10 Diagram13 B11

TB33

F15

Diagram10 A4 Diagram10 J4

Diagram14 J13 Diagram14 J13

TB36

-

VEC-91

-

Diagram4

K14

Diagram7

L2

TB21

-

TB24

-

Diagram5

L10

TB27

-

Diagram6

B10

TB30

-

-

-

VEC-91

-

Diagram4

K14

L2

TB21

-

TB24

-

Diagram5

L10

TB27

-

Diagram6

B10

TB30

-

TB33

-

Diagram10 C4 Diagram10 C4

TB36

Diagram6

Diagram13 B11 Diagram13 H5

TB33

-

Diagram10 J4 Diagram10 J4

Diagram14 J13 Diagram14 J13

TB36

-

VEC-91

-

Diagram4

L14

SWITCH ACCUMULATOR PRESSURE #1 (ACC...

-

TB21

-

-

Diagram5

L10

TB27

-

Diagram6

B10

TB30

-

-

-

VEC-91

-

Diagram5

C6

-

TB24

-

Diagram5

L10

TB27

-

Diagram6

B10

TB30

-

TB33

-

Diagram10 C4 Diagram10 H4

TB36

TB21

Diagram13 H5 Diagram13 H5

TB33

-

Diagram10 J4 Diagram10 J4

TB24

SWITCH ACCUMULATOR PRESSURE #2 (ACC...

Diagram13 M2 Diagram13 M2

Diagram14 J13 Diagram14 J13

TB36

-

VEC-91

-

Diagram5

C17

Diagram10 D12 Diagram10 E12

SWITCH AUTOLUBE LEVEL (OPT)

-

TB21

-

-

Diagram5

O6

TB27

-

Diagram6

C8

TB30

-

-

-

VEC-91

-

Diagram5

F14

-

TB24

-

Diagram5

O7

TB27

-

Diagram6

C8

TB30

-

TB33

-

Diagram10 H4 Diagram10 H4

TB36

TB21

Diagram13 I5 Diagram13 J11

TB33

-

Diagram10 K4 Diagram11 H4

TB24

SWITCH AUTOLUBE PRESSURE

Diagram13 O19 Diagram13 L16

Diagram14 K13 Diagram14 L7

TB36

-

VEC-91

-

Diagram5

L4

Diagram14 M3 Diagram14 N2

SWITCH AUX BOX DOME LIGHT (DLS)

-

Diagram5

TB21

-

TB24

-

Diagram5

O7

TB27

-

Diagram6

C8

TB30

-

-

-

VEC-91

-

Diagram5

M5

TB21

-

TB24

-

Diagram6

G9

TB27

-

Diagram6

D8

TB30

-

TB33

-

TB36

-

-

Diagram5

M5

SWITCH BODYUP OVERRIDE / RESET (ORS...

-

TB21

-

TB24

-

Diagram6

G10

TB27

-

Diagram6

D8

TB30

-

-

-

VEC-91

-

Diagram5

O5

Diagram7

TB21

-

TB24

-

Diagram7

A12

TB27

-

Diagram6

D8

TB30

-

TB33

-

Diagram10 H4 Diagram10 H4

TB36

-

Diagram13 J11 Diagram13 J11

TB33

SWITCH BRAKE LOCK

Diagram12 E4 Diagram12 E4

Diagram14 L7 Diagram14 L8

VEC-91

Diagram14 L3 Diagram14 N2

Diagram12 F7 Diagram10 J7

Diagram10 H4 Diagram10 H4

TB36

-

Diagram13 J11 Diagram13 J11

TB33

SWITCH BODY-UP PROXIMITY

Diagram11 H4 Diagram11 H4

Diagram14 L7 Diagram14 L7

TB36

-

VEC-91

-

Diagram6

A12

Diagram10 B12 Diagram10 G12

SWITCH BRAKE TEST

-

TB21

-

-

Diagram7

A12

TB27

-

Diagram6

D8

TB30

-

-

-

VEC-91

-

Diagram6

B12

-

TB24

-

Diagram7

F13

TB27

-

Diagram6

D8

TB30

-

TB33

-

Diagram10 I4 Diagram10 I4

TB36

TB21

Diagram13 J11 Diagram13 J11

TB33

-

Diagram12 E4 Diagram12 G5

TB24

SWITCH CAB LADDER LIGHT

Diagram12 P9 Diagram9 G3

Diagram14 L8 Diagram14 L8

TB36

-

VEC-91

-

Diagram6

B12

SWITCH CAB SECONDARY ENGINE SHUTDOW... -

Diagram4

TB21

-

-

Diagram7

F13

TB27

-

Diagram6

D8

TB30

-

-

-

VEC-91

-

Diagram6

B12

TB21

-

TB24

-

Diagram7

F13

TB27

-

Diagram6

D8

TB30

-

TB33

-

TB36

-

-

Diagram6

B12

-

Diagram7

G18

SWITCH COMBO

-

TB21

-

TB24

-

Diagram7

H13

TB27

-

Diagram6

D8

TB30

-

-

-

VEC-91

-

Diagram6

C12

-

SWITCH COMBO

-

Diagram9

TB21

-

TB24

-

Diagram7

H13

TB27

-

Diagram6

D10

TB30

-

TB33

-

TB36

-

-

Diagram6

J9

-

SWITCH COMBO

-

TB21

-

-

Diagram7

H13

TB27

-

Diagram6

D11

TB30

-

-

-

VEC-91

-

Diagram6

L10

Diagram7

O15

SWITCH COOLANT LEVEL TIER 1

-

TB21

-

TB24

-

Diagram7

J16

TB27

-

Diagram6

E10

TB30

-

TB34

-

Diagram13 P5 Diagram4 B5

TB36

-

Diagram13 K11 Diagram13 K11

TB33

SOLENOID ENGINE SHUTTER (OPT)

Diagram12 G5 Diagram12 H5

TB24

Diagram11 F4 Diagram11 E4

Diagram11 N2 Diagram7 C5

Diagram14 M14 Diagram14 M14

VEC-91

SOLENOID BRAKE LOCK

Diagram13 N19 Diagram7 L20

Diagram10 I4 Diagram13 P5

TB36

SOLENOID AUTO LUBE

Diagram13 J11 Diagram13 J11

TB33

Diagram14 H19 Diagram14 G19

Diagram12 G5 Diagram12 G5

Diagram14 M8 Diagram14 M14

VEC-91

SHIFTER DIRECTION SELECTOR

Diagram15 I3 Diagram8 I14

Diagram10 I4 Diagram10 I4

TB36

-

Diagram13 J11 Diagram13 J11

TB33

SWITCH CAMERA (OPT)

Diagram12 G5 Diagram12 G5

TB24

-

Diagram13 H1 Diagram7 G20

Diagram14 L8 Diagram14 M7

TB36

-

VEC-91

-

Diagram6

L10

SOLENOID ETHER START (OPT)

-

Diagram7

P14

SWITCH COOLANT LEVEL TIER 2

-

Diagram6

C5

TB21

-

TB24

-

Diagram7

J16

TB27

-

Diagram6

E10

TB30

-

-

Diagram4

B5

TB36

-

VEC-91

-

Diagram8

G15

SOLENOID HOIST LIMIT

-

SWITCH DATA STORE (DSSW)

-

-

TB24

-

-

Diagram6

E10

TB30

-

TB34

-

Diagram8

E16

TB36

-

-

Diagram8

G15

-

TB21

-

TB24

-

TB27

-

Diagram6

E10

TB30

-

-

Diagram8

E16

TB36

-

VEC-91

-

Diagram9

K3

SOLENOID STEERING BLEED DOWN

-

SWITCH DISPLAY MODE #1

-

Diagram8

D10

TB21

-

TB24

-

-

Diagram6

E10

TB30

-

TB34

-

Diagram8

J5

TB36

-

-

Diagram9

K3

SWITCH DISPLAY MODE #2

-

Diagram8

B10

TB21

-

TB24

-

TB27

-

Diagram6

E11

TB30

-

-

Diagram8

J6

TB36

-

VEC-91

-

Diagram10 A5

SP08

-

Diagram5

H8

SWITCH DRIVERS SEAT BELT

-

TB21

-

TB24

-

-

Diagram6

E11

TB30

-

TB34

-

Diagram8

K5

TB36

-

-

Diagram10 C5

-

Diagram5

H8

SWITCH ENGINE OIL RESERVE PRESS T1 ...

-

TB21

-

TB24

-

TB27

-

Diagram6

E11

TB30

-

-

Diagram8

K5

TB36

-

VEC-91

-

Diagram10 D14

Diagram9

M7

SP10

-

Diagram5

I8

SWITCH ENGINE OIL RESERVE PRESS T2 ...

-

Diagram6

M3

TB21

-

TB24

-

TB27

-

Diagram6

E11

TB30

-

TB34

-

Diagram8

L5

TB36

-

-

Diagram10 F6

Diagram9

G20

SP11

-

Diagram5

J8

SWITCH ENGINE PRELUBE OIL PRESS (PL...

-

Diagram3

M9

TB21

-

TB24

-

TB27

-

Diagram6

E11

TB30

-

-

Diagram8

L5

TB36

-

VEC-91

-

Diagram10 H15

Diagram9

G20

SP12

-

Diagram5

H4

SWITCH ENGINE RUN OIL PRESSURE T1 (...

-

Diagram7

M2

TB21

-

TB24

-

TB27

-

Diagram6

E11

TB30

-

TB34

-

Diagram8

L9

TB36

-

-

Diagram10 L15

-

Diagram9

D20

SP13

-

Diagram5

I4

SWITCH ENGINE RUN OIL PRESSURE T2 (...

-

Diagram6

M1

TB21

-

TB25

-

TB27

-

Diagram6

F10

TB31

-

Diagram6

F8

TB34

-

Diagram8

L9

TB36

-

VEC-91

-

Diagram10 M15

LAMP DECK LIGHT #1 (OPT LOCATION)

-

Diagram9

F21

SP14

-

Diagram5

I4

SWITCH FOG LAMP (OPT)

-

Diagram9

B4

TB21

-

Diagram14 L19 Diagram14 M18

Diagram14 N14 Diagram14 N14

VEC-91

LAMP DECK LADDER LIGHT #1

Diagram13 I12 Diagram4 B15

Diagram13 L11 Diagram13 L11

TB34

LAMP CONTROL CABINET WORK LIGHT #2 -

Diagram14 L18 Diagram14 L18

Diagram14 N14 Diagram14 N14

VEC-91

LAMP CONTROL CABINET WORK LIGHT #1 -

Diagram11 K4 Diagram13 I11

Diagram13 K11 Diagram13 L11

TB34

-

Diagram14 K18 Diagram14 K19

Diagram14 N14 Diagram14 N14

VEC-91

SP09

Diagram10 K14 Diagram11 K4

TB27

-

Diagram13 A14 Diagram7 M3

Diagram13 K11 Diagram13 K11

TB34

Diagram11 H19 Diagram11 G19

Diagram13 D13 Diagram14 K18

Diagram14 N14 Diagram14 N14

VEC-91

-

Diagram10 I14 Diagram10 K14

TB27

SONALERT (SONA)

Diagram13 C11 Diagram8 E13

Diagram13 K11 Diagram13 K11

TB34

Diagram11 J19 Diagram11 I19

Diagram13 D13 Diagram13 D13

Diagram14 N8 Diagram14 N8

VEC-91

SWITCH DC POWER OFF - REST SWITCH

Diagram10 D16 Diagram10 I14

TB27

-

Diagram10 J8 Diagram12 M8

TB21

SOLENOID PARK BRAKE

Diagram10 O18 Diagram6 H14

Diagram13 K11 Diagram13 K11

TB34

Diagram11 E17 Diagram11 D17

Diagram12 H5 Diagram12 H5

Diagram14 N7 Diagram14 N7

TB25

-

Diagram4

B15

TB27

-

Diagram6

F10

TB31

-

Diagram6

H9

TB34

-

Diagram8

L9

TB36

-

VEC-91

-

Diagram11 K3

LAMP DECK LIGHT #2

-

Diagram9

E20

SP15

-

Diagram5

J4

SWITCH GRID DRY

-

TB21

-

-

Diagram4

B15

TB27

-

Diagram6

F11

TB31

-

Diagram6

H9

TB34

-

Diagram9

B8

TB36

-

VEC-91

-

Diagram11 M11

-

Diagram9

E21

SP100

-

Diagram5

D19

SWITCH HAZARD LIGHTS

-

TB22

-

Diagram14 M18 Diagram4 D14

TB25

LAMP DIAGONAL LADDER LIGHT #1

Diagram12 N8 Diagram9 M7

Diagram14 N14 Diagram14 N14

TB25

-

Diagram4

B15

TB27

-

Diagram6

F11

TB31

-

Diagram6

I9

TB34

-

Diagram9

B8

TB36-J5 -

VEC-91

-

Diagram12 G20

LAMP GREEN PAYLOAD LEFT

-

SP102

-

Diagram5

E19

SWITCH HEADLIGHTS

-

Diagram8

TB22

-

Diagram4

D14

TB25

-

Diagram4

C19

TB27

-

Diagram6

F11

TB31

-

Diagram6

I9

TB34

-

Diagram9

B14

TB36-K5 -

VEC-91

-

Diagram14 L15

LAMP GREEN PAYLOAD RIGHT

-

Diagram14 I19 Diagram14 G19

Diagram12 L5 Diagram14 N14

SP103

-

Diagram5

E19

SWITCH HEATED MIRROR (OPT)

-

TB22

-

Diagram4

F13

TB25

-

Diagram4

C20

TB27

-

Diagram6

F14

TB31

-

Diagram6

I9

TB34

-

Diagram9

B14

TB60

-

-

Diagram15 F7

-

SP104

-

Diagram5

C19

SWITCH HOIST LIMIT

-

TB22

-

Diagram4

F13

TB25

-

Diagram7

F9

TB27

-

Diagram6

F14

TB31

-

Diagram6

I9

TB34

-

Diagram9

F5

TB60

-

LAMP HIGH MOUNT LEFT HI-BEAM

-

Diagram11 D17 Diagram8 L15

Diagram10 N17 Diagram10 N17

VEC-91

LAMP HID BACKUP BERM AXLE (OPT)

Diagram14 B3 Diagram10 N19

SP106

-

Diagram4

B5

SWITCH HORN BUTTON

-

-

Diagram4

F13

TB25

-

Diagram7

F9

TB27

-

Diagram6

F14

TB31

-

Diagram6

I9

TB34

-

Diagram9

F5

TB60

-

-

Diagram8

P15

SP107

-

Diagram3

N11

SWITCH HYDRAULIC FILTER #1

-

Diagram11 K16 Diagram13 E13

TB22

LAMP HIGH MOUNT LEFT LOW-BEAM

TB22

-

Diagram5

M6

TB25

-

Diagram7

F9

TB27

-

Diagram6

F14

TB31

-

Diagram6

I9

TB34

-

Diagram9

F6

TB60

-

LAMP HIGH MOUNT RIGHT HI-BEAM

-

Diagram8

M15

SP108

-

Diagram3

M11

SWITCH HYDRAULIC FILTER #2

-

-

Diagram5

M7

TB25

-

Diagram7

-

Diagram6

F18

TB31

-

-

Diagram9

F6

TB60

-

P15

SP112

-

Diagram6

A3

SWITCH HYDRAULIC LAMP

-

TB22

-

Diagram5

M7

TB25

-

TB27

-

Diagram6

F19

TB31

-

Diagram10 K4 Diagram10 K4

TB34

Diagram8

TB34

-

Diagram9

F11

TB60

-

LAMP HYDRAULIC CABINET #1

-

SP113

-

Diagram6

A4

SWITCH HYDRAULIC PUMP MOD LAMP (OPT...

-

-

Diagram5

M7

TB25

-

TB27

-

Diagram6

G8

TB31

-

-

-

-

Diagram6

B5

SWITCH KEY (KEYSW)

-

TB22

-

Diagram5

M7

TB25

-

TB28

-

Diagram4

K9

TB31

-

TB34

-

TB60

-

LAMP HYDRAULIC PUMP MOD (OPT)

-

Diagram10 C20 Diagram3 G19

SP115

-

Diagram6

B4

SWITCH LEFT ENGINE SERVICE LAMP (LE...

-

TB22

-

Diagram6

J10

TB25

-

TB28

-

Diagram4

K9

TB31

-

-

-

Diagram6

B5

SWITCH LEFT GROUND LEVEL SHUTDOWN (...

-

TB22

-

Diagram6

J10

TB25

-

TB28

-

Diagram4

K9

TB31

-

TB34

-

TB60

-

Diagram6

SWITCH LEFT LADDER LIGHT GND LVL (L...

-

Diagram9

TB22

-

Diagram7

N10

TB25

-

TB28

-

Diagram4

K9

TB31

-

-

-

TB22

-

Diagram7

N10

TB25

-

TB28

-

Diagram4

K12

TB31

-

TB34

-

TB60

-

TB22

-

Diagram8

I6

TB25

-

Diagram12 I5 Diagram12 I5

Diagram14 G8 Diagram14 G8

TB60

-

Diagram10 L4 Diagram10 L4

TB34

SWITCH LEFT WINDOW

E6 Diagram10 J18 Diagram13 F14

Diagram12 I5 Diagram12 I5

Diagram14 G8 Diagram14 G8

TB60

-

Diagram10 K4 Diagram10 K4

TB34

SP116

Diagram10 E15 Diagram4 C1

Diagram12 I5 Diagram12 I5

Diagram13 N11 Diagram13 N11

TB60

SP114

Diagram10 K4 Diagram10 K4

TB34

-

Diagram10 C20 Diagram4 E9

TB22

LAMP HYDRAULIC CABINET #2

Diagram11 O13 Diagram11 P13

F9 Diagram12 H5 Diagram12 H5

TB27

-

Diagram13 E14 Diagram11 N11

TB22

LAMP HIGH MOUNT RIGHT LOW-BEAM

TB28

-

Diagram4

K12

TB31

-

-

-

Diagram8

I7

TB25

-

TB28

-

Diagram5

D3

TB31

-

TB34

-

TB60

-

TB22

-

Diagram9

J8

TB25

-

Diagram12 I5 Diagram12 I5

Diagram14 G8 Diagram14 G8

TB60

-

Diagram10 L4 Diagram10 L4

TB34

TB22

TB28

-

Diagram5

D3

TB31

-

-

-

-

Diagram9

J8

TB25

-

TB28

-

Diagram5

D3

TB31

-

TB34

-

TB60

-

H20 Diagram13 F14 Diagram3 C17

TB22

-

Diagram9

J8

TB25

-

Diagram12 J5 Diagram12 J5

Diagram14 I7 Diagram14 I8

TB60

TB22

Diagram10 L4 Diagram10 L4

TB34

G15

TB28

-

Diagram6

I9

TB31

-

-

-

Diagram9

J8

TB25

-

TB28

-

Diagram6

I9

TB31

-

TB34

-

TB60

-

TB22

-

Diagram9

L1

TB25

-

Diagram12 J5 Diagram12 J5

Diagram14 K13 Diagram14 K13

TB60

-

Diagram10 L4 Diagram10 L4

TB34

TB22

TB28

-

Diagram6

I9

TB31

-

-

-

-

Diagram9

L1

TB25

-

TB28

-

Diagram6

I9

TB31

-

TB34

-

TB60

-

TB22

-

Diagram9

TB25

-

TB28

-

Diagram6

I9

TB31

-

-

Diagram6

G19

TB60

-

TB22

-

TB25

-

TB28

-

Diagram6

I9

TB31

-

TB35

-

Diagram6

G19

TB60

-

TB22

-

TB25

-

Diagram12 J5 Diagram12 J5

Diagram10 M5 Diagram10 M5

TB35

Diagram10 E22 Diagram4 E2

L1 Diagram11 B5 Diagram11 B5

Diagram12 J5 Diagram12 J5

Diagram14 L13 Diagram14 L13

TB60

TB22

Diagram10 L4 Diagram10 M5

TB34

Diagram11 N18 Diagram10 K10

TB28

-

Diagram6

K9

TB31

-

-

Diagram6

G19

TB60

-

-

Diagram11 K13 Diagram11 K13

TB25

-

TB28

-

Diagram6

K9

TB31

-

TB35

-

Diagram6

G19

TB60

-

TB25

-

Diagram12 J5 Diagram12 J5

Diagram10 M5 Diagram10 M5

TB35

TB22

TB28

-

Diagram6

M10

TB31

-

-

Diagram8

F16

TB60

-

TB25

-

TB28

-

Diagram6

M10

TB31

-

TB35

-

Diagram8

F16

TB60

-

TB25

-

Diagram12 J5 Diagram12 J5

Diagram10 M5 Diagram10 M5

TB35

Diagram12 C5 Diagram12 C5

TB28

-

Diagram6

M10

TB31

-

-

Diagram8

G12

TB61

-

TB25

-

TB28

-

Diagram6

M10

TB31

-

TB35

-

Diagram8

G12

TB61

-

TB25

-

Diagram12 K5 Diagram12 K5

Diagram10 M5 Diagram10 M5

TB35

Diagram12 C6 Diagram12 C6

TB28

-

Diagram6

-

-

Diagram9

I14

TB61

-

-

TB28

-

TB31

-

TB35

-

Diagram9

I14

TB61

-

TB25

-

Diagram12 O4 Diagram12 O4

Diagram10 M5 Diagram10 N7

TB35

TB25

TB28

-

M10 Diagram12 G18 Diagram12 G18

TB31

Diagram12 H5 Diagram12 H5

TB31

-

-

Diagram9

I14

TB61

-

TB25

-

TB28

-

-

TB35

-

Diagram9

K14

TB61

-

-

TB28

-

Diagram12 G18 Diagram12 G18

TB31

TB25

Diagram12 O4 Diagram12 O4

Diagram10 N7 Diagram10 N7

TB35

Diagram12 H5 Diagram14 D6

TB31

-

-

Diagram9

K14

TB61

-

TB25

-

TB28

-

-

TB35

-

Diagram9

K14

TB61

-

-

TB28

-

Diagram13 A10 Diagram13 A11

TB31

TB25

Diagram13 F6 Diagram13 F6

Diagram10 N7 Diagram10 O7

TB35

Diagram14 D7 Diagram14 D7

TB31

-

-

Diagram9

K14

TB61

-

-

Diagram8

B15

TB28

-

TB31

-

TB35

-

Diagram9

K14

TB61

-

TB26

-

Diagram8

B15

TB28

-

Diagram13 G12 Diagram13 G12

Diagram10 O7 Diagram10 O7

TB35

TB26

TB31

-

-

Diagram9

K14

TB61

-

-

Diagram8

B15

TB28

-

Diagram13 H12

TB31

-

Diagram10 O7 Diagram10 O7

TB35

TB26

TB35

-

Diagram9

K14

TB61

-

LAMP LED MASTER DISCONNECT CLOSED -

E10

G4

J10

D18

K17

D17

J2

I9

-

Diagram3

H19

SP117

-

LAMP LED PROPEL LOCKOUT LOCKED OUT -

Diagram3

E19

SP135

-

LAMP LED PROPEL LOCKOUT ON

-

Diagram3

D19

SP138

-

B5 Diagram10 I16 Diagram10 K16

SWITCH LOW BRAKE ACCUM PRESSURE

-

LAMP LED STARTER LOCKOUT CLOSED

-

Diagram3

G19

SP142

-

Diagram9

J19

SWITCH LOW STEERING PRESSURE

-

LAMP LED STARTER LOCKOUT OPEN

-

Diagram3

F19

SP143

-

Diagram9

I19

SWITCH MANUAL BACKUP LIGHT

-

Diagram13 N2 Diagram11 C9

LAMP LEFT FOG

-

Diagram9

C21

SP144

-

Diagram9

I20

SWITCH MASTER GROUND DISCONNECT (DI...

-

Diagram3

LAMP LEFT LOWER ENGINE SERVICE

-

-

Diagram9

K20

SWITCH PARK BRAKE RELEASE PRESSURE

-

Diagram4

-

Diagram10 G13 Diagram10 F13

SP145

LAMP LEFT UPPER ENGINE SERVICE

SP146

-

Diagram9

K19

SWITCH PARK BRAKE SET

-

LAMP LOW MOUNT LEFT HI-BEAM

-

Diagram8

L15

SP147

-

Diagram9

L19

SWITCH PROPEL LOCKOUT (PLOS)

-

LAMP LOW MOUNT LEFT LOW-BEAM

-

Diagram8

N15

SP148

-

Diagram9

M17

SWITCH REAR SERVICE LAMP (PLS)

-

LAMP LOW MOUNT RIGHT HI-BEAM

-

Diagram8

N15

SP149

-

Diagram9

M17

SWITCH RETARD SPEED CONTROL (RSCS)

-

LAMP LOW MOUNT RIGHT LOW-BEAM

-

Diagram8

O15

SP150

-

Diagram9

G19

SWITCH RIGHT ENGINE SERVICE LAMP (R...

-

LAMP MARKER/TURN LEFT FRT DECK

-

Diagram9

J21

SP151

-

Diagram9

G19

SWITCH RIGHT GROUND LEVEL SHUTDOWN ... -

LAMP MARKER/TURN LEFT SIDE DECK

-

Diagram9

I21

SP155

-

Diagram5

M11

SWITCH RIGHT LADDER LIGHT GND LVL (...

-

Diagram9

LAMP MARKER/TURN RIGHT FRT DECK

-

Diagram9

K21

SP156

-

Diagram5

-

-

Diagram9

L21

SP157

-

SWITCH ROTATING BEACON (OPT)

-

Diagram10 K18 Diagram14 E3

TB22

-

TB22

-

LAMP REAR SERVICE

-

SP159

-

SWITCH SERVICE BRAKE DEGRADE PRESSU...

-

-

-

SP160

-

Diagram7

SWITCH SERVICE BRAKE PSI

-

Diagram13 G14 Diagram6 G14

TB22

LAMP RED PAYLOAD LEFT

Diagram11 O14 Diagram14 H19

M11 Diagram15 G15 Diagram7 G17

SWITCH RIGHT WINDOW

LAMP MARKER/TURN RIGHT SIDE DECK

TB22

-

LAMP RED PAYLOAD RIGHT

-

-

Diagram6

-

-

-

SWITCH STEERING FILTER #1

-

Diagram13 O2 Diagram13 E16

TB22

SP165

TB22

-

LAMP RETARD OP-CAP

-

SP166

-

SWITCH TRACTION MOTOR PRESSURE (BPS...

-

-

-

SP167

-

TB-HTST

-

TB22

-

LAMP RIGHT FOG

-

Diagram9

SP168

-

TB-HTST

-

-

-

SP169

-

TB-HTST

-

TB22

-

LAMP RIGHT UPPER ENGINE SERVICE

-

SP171

-

Diagram11 N15 Diagram11 O11

Diagram15 M2 Diagram15 M2

TB22

LAMP RIGHT LOWER ENGINE SERVICE

B21 Diagram10 G21 Diagram10 F21

Diagram11 L16 Diagram11 L16

Diagram12 E8 Diagram15 L2

TB22

LAMP RETARD RIGHT REAR

Diagram11 J12 Diagram11 I16

H15 Diagram10 G22 Diagram10 C21

SWITCH STEERING BLEED PRESSURE

-

Diagram14 F19 Diagram11 H16

SP161

LAMP RETARD LEFT REAR

TB-HTST

-

-

-

SP172

-

-

TB22

-

-

SP173

-

Diagram11 G18 Diagram11 G17

TB-HTST

LAMP STOP/TAIL LEFT

Diagram11 I12 Diagram11 E17

Diagram15 M2 Diagram15 M2

TB22

LAMP SERVICE BRAKE OP-CAB

TB-HTST

-

TB23

-

LAMP STOP/TAIL RIGHT

-

Diagram11 F17

SP174

-

Diagram11 H17

TB-HTST

-

Diagram15 M2 Diagram15 N2

Diagram14 D7 Diagram4 E12

TB23

-

Diagram4

LAMP LED MASTER DISCONNECT OPEN

L18

H6

E12

Diagram10 N18 Diagram10 N18 Diagram11 C15 Diagram11 C15 Diagram11 C15 Diagram11 C15 Diagram11 D15 Diagram11 D15 Diagram11 G12 Diagram11 G12 Diagram11 G13 Diagram11 G13 Diagram11 H12 Diagram11 H12 Diagram11 H13 Diagram11 H13 Diagram11 H13 Diagram11 H13 Diagram11 M15 Diagram11 M15 Diagram13 L15 Diagram13 L15 Diagram13 L15 Diagram13 L15 Diagram11 B15 Diagram11 B15 Diagram11 B15 Diagram11 B15 Diagram11 B15 Diagram11 B15 Diagram11 F13 Diagram11 F13 Diagram11 F13 Diagram12 F9 Diagram12 F9 Diagram12 F9

58E-06-02000-00 NOV 11 ELECTRICAL SCHEMATIC 830E-1AC A40851 & UP Sheet 19 of 20

CONNECTOR TABLE CONNECTOR TABLE

CONNECTOR DIAGRAM

ZONE

12VCN-12VA Diagram5 D5 12VCN-12VB Diagram5 D5 12VCN-24VA Diagram5 D5 12VCN-GND Diagram5 D5 12VPR-(+)

Diagram5 D9

12VPR-30

Diagram5 D10

12VPR-(-)

12VPR-87

24VDC-A1 24VDC-A2 24VDC-A3 24VDC-A4 24VDC-B1 24VDC-B2 24VDC-B4 ACCBD ACCBD

ACCP1-C

ACCP1-NO ACCP2-C

ACCP2-NO ACPSW ACPSW AHS

ALLR-85 ALLR-86 ALLR-88

ALLR-88A ALLSW ALLSW

ALT (+) ALT (-) ALT1 ALT2

ALT_SEN ATFS

ATFS_CP ATS

BAT(-)-1 BAT(-)-2 BAT(-)-3 BAT(-)-4 BAT(-)-5 BAT(-)-6 BAT1(+) BAT1(-)

BAT2(+) BAT2(-)

BAT3(+) BAT3(-)

BAT4(+) BAT4(-) BDS BDS BLS BLS

BPS

BPSW-COM BPSW-NC

BPSW-NO BULR-(+) BULR-(-) BULR-30 BULR-87

BUS24V-1 BUS24V-2 BUS24V-3 BUS24V-4 BUS24V-5

BUS24V-6 BUS24V-7 BUS24V-8 BUS24V-9

BUS24V-10 BUS24V-11 BUSW BUSW

CB60-1 CB60-2 CDL

CDL1 CDL1 CDL2 CDL2 CNA

CNLIN CNLO

CNRIN CON1 CON2 CON3 CON4 D1 D1 D2 D2 D3 D3 D4 D4 D9 D9

D10 D10 D15 D15 D26 D26 D70 D70 D71 D71 D87 D87

DIAG1 DIAG2 DIAG3 DIAG4 DIAG5 DIAG6 DIAG7 DIAG8 DID

DISC(-)-1 DISC(-)-2 DISC(-)-3 DISC(-)-4 DISC(-)-5

DISC(-)-6 DISC(-)-7

Diagram5 D10 Diagram5 D9 Diagram5 A5 Diagram5 A5 Diagram5 A5 Diagram5 A5 Diagram5 B5 Diagram5 B5 Diagram5 B5

Diagram13 C11 Diagram13 C12 Diagram13 M3 Diagram13 M2 Diagram13 M3 Diagram13 M2 Diagram13 N2 Diagram13 N2

Diagram11 L18

Diagram9 F13 Diagram9 F12 Diagram9 F12 Diagram9 F13

Diagram13 O19 Diagram13 O19 Diagram3 K7 Diagram3 K7

Diagram15 O12 Diagram15 O12 Diagram3 K7

Diagram15 K16 Diagram15 K16 Diagram13 L16 Diagram3 F4 Diagram3 F5 Diagram3 F5 Diagram3 F4 Diagram3 F4 Diagram3 F5

Diagram3 D2 Diagram3 D2 Diagram3 D4 Diagram3 D3 Diagram3 E2 Diagram3 E2 Diagram3 E4 Diagram3 E3

Diagram13 G14 Diagram13 G14 Diagram7 L20 Diagram7 L20 Diagram13 K1 Diagram12 E8 Diagram12 E9 Diagram12 E9

Diagram11 D9 Diagram11 D9 Diagram11 D9 Diagram11 D9 Diagram3 E6 Diagram3 E6 Diagram3 E6 Diagram3 E6 Diagram3 E6 Diagram3 E6 Diagram3 E6 Diagram3 E6 Diagram3 E6 Diagram3 E6 Diagram3 E6 Diagram12 F7 Diagram12 F8

Diagram5 D7 Diagram5 D6

Diagram9 M7

Diagram9 G20 Diagram9 G21 Diagram9 G20 Diagram9 G21 Diagram12 J20 Diagram14 J17 Diagram14 J17 Diagram14 J14 Diagram15 P4 Diagram15 P4

Diagram15 M5 Diagram15 M5

Diagram11 L16 Diagram11 L17

Diagram6 H14 Diagram6 H14

Diagram7 M20

CONNECTOR TABLE

CONNECTOR DIAGRAM

Diagram5 C21

DL3

Diagram5 D21

DL2 DL4 DL5 DL6

DLS-2 DLS-3 DRL

DSSW-C

DSSW-NO ECHTR1 ECHTR2 EOH1 EOH2

EOPSW-1 EOPSW-2 EOPSW1 EOPSW2 EOTS

ESDS -1 ESDS-2

ESDSR-1 ESDSR-2 ESLT-3

ESLT-C

ESLT-NO ESOL ESOL

ESREL1-85 ESREL1-86 ESREL1-88

Diagram8 D13 Diagram11 N3 Diagram11 N3

Diagram13 C11 Diagram13 C12 Diagram3 C18 Diagram3 C19 Diagram12 M7 Diagram12 M7

Diagram3 N13 Diagram3 N13 Diagram12 J9

Diagram6 I13 Diagram12 J9

Diagram15 D17 Diagram13 H17 Diagram12 E18

Diagram14 O19 Diagram12 K9

Diagram3 F15

Diagram3 G15

Diagram10 J9 Diagram10 J8

Diagram15 L7

Diagram15 M7 Diagram15 N7 Diagram15 N7

Diagram6 M1 Diagram6 M2 Diagram7 M2 Diagram7 M2 Diagram15 N5 Diagram4 C1 Diagram4 C2 Diagram4 E1 Diagram4 E2

Diagram10 D14 Diagram10 D14 Diagram10 D14 Diagram7 P14 Diagram7 P14 Diagram3 F7 Diagram3 F6 Diagram3 F6

Diagram3 F7

Diagram4 C17

ESSOL

Diagram7 O15

ESS-B ESSOL

ESS_1-3 ESS_1-4 ETHER1 ETHER2

ETHER2FLS

FUS-1 FUS-2

GB1-A1 GB1-A2 GB1-A3

GB1-A4 GB1-B1 GB1-B2 GB1-B3 GB1-B4

GB3-A1 GB3-A3 GB3-B1 GB3-B3 GB8-1 GB8-2 GB8-3 GB8-4

GB10-A3 GB10-A4 GB10-B2 GB10-B4

GB10-C1 GB10-C3

GB10-D2 GB10-D3 GB10-D4 GB12-A1 GB12-A2 GB12-B1 GB12-B2

GB12-C2 GB12-C3 GB12-C4

GB12-D1 GB12-D2 GB12-D3 GB12-D4 GB31-D3

GB31A-A1 GB31A-A2 GB31A-A3 GB31A-A4 GB31A-B1

GB31A-B2

GB31A-B3

GB31A-B4

GB31A-C1 GB31A-C2 GB31A-C3

GB31A-D1

GB31A-D3

GB31A-D4 GB31B-A1

GB31B-A2

GB31B-A3

GB31B-A4 GB31B-B1 GB31B-B2 GB31B-B3 GB31B-B4

GB31B-C1

GB31B-C2

GB31B-C3

GB31B-C4

GB31B-D1 GB31B-D2 GB31B-D4 GB70-A1 GB70-A2 GB70-B2 GND

HBHR-85

HBHR-88a

Diagram3 G15

Diagram11 J12

ESS-A

Diagram3 G15 Diagram3 G15

Diagram5 D18

ESREL2-88a Diagram3 F7

HBHR-86

Diagram3 G15

Diagram5 D17

Diagram3 F7

Diagram12 I9

Diagram3 F15

Diagram5 F21

ESREL2-88

ESREL2-86

GB31A-D2

Diagram8 D13

Diagram5 E21

Diagram3 F7

Diagram9 K6

Diagram8 D13

Diagram5 E21

ESREL2-85

GB31A-C4

Diagram8 D12

Diagram5 D21

ESREL1-88a Diagram3 F7

Diagram7 M20 Diagram9 K6

ZONE

DL1

HBHR-88 HFSW1 HFSW1 HFSW2 HFSW2

HHMR-(+)

Diagram4 C17

Diagram7 O16 Diagram4 C17 Diagram4 C17 Diagram7 P12 Diagram7 P12 Diagram7 P13

Diagram13 D16

Diagram3 O10 Diagram3 O10 Diagram11 B19 Diagram11 B19 Diagram11 B19 Diagram11 I13

Diagram11 D19

Diagram11 M15 Diagram11 I13

Diagram11 M15 Diagram7 K5 Diagram6 K4

Diagram3 O15 Diagram3 O15 Diagram4 H22 Diagram13 F16 Diagram7 L21

Diagram11 O11 Diagram9 B5

Diagram7 J15

Diagram8 K13 Diagram8 B8 Diagram12 L6

Diagram15 M21 Diagram14 D1 Diagram8 G9 Diagram15 I2

Diagram5 M11 Diagram5 M11 Diagram5 M11 Diagram15 G14 Diagram10 K16 Diagram11 N6

Diagram15 D16 Diagram10 I16 Diagram10 I16

Diagram7 C14 Diagram10 K7 Diagram6 F8

Diagram5 E7 Diagram5 I3

Diagram5 E7

Diagram9 E13 Diagram5 E7 Diagram5 J3

Diagram5 E18 Diagram14 E7

Diagram5 M7 Diagram5 H3

Diagram5 J11 Diagram5 M7

Diagram7 O10 Diagram5 I3

Diagram15 I14 Diagram12 A4

Diagram6 M9 Diagram5 I7

Diagram14 J8

Diagram13 A10 Diagram8 K9 Diagram5 J7

Diagram12 N4 Diagram6 B8 Diagram6 B8

Diagram5 H7

Diagram14 K16

Diagram13 H14 Diagram6 B8

Diagram5 H7

Diagram4 H18 Diagram3 I9

Diagram3 I10 Diagram3 I10 Diagram14 I18 Diagram8 K8 Diagram8 K7 Diagram8 L7 Diagram8 L8

Diagram13 E13 Diagram13 E13 Diagram13 E14 Diagram13 E15 Diagram8 O7

CONNECTOR TABLE

CONNECTOR DIAGRAM HHMR-(-)

ZONE

Diagram8 O7

HHMR-(30) Diagram8 O7 HHMR-(87) Diagram8 O7 HIDBL

Diagram11 D17

HL1

Diagram11 O13

HIDBL_CP HL2

HLMR-(+) HLMR-(-)

HLMR-(30) HLMR-(87) HLS HLS

HLSW-1 HLSW-2 HMLHB HMLLB

HMRHB HMRLB

HOHTR1 HOHTR2 HOSTAT HPLT-3

HPLT-C

HPLT-NO HPML HPML

HPMS-1 HPMS-3

HPR-(+) HPR-(-) HPR-30 HPR-87 HPS1 HPS2 HS

IM1 IM1 IM1 IM1 IM1 IM1 IM1 IM1 IM1 IM1 IM1 IM2 IM2 IM2 IM2 IM2 IM2 IM2 IM2 IM2 IM2 IM2 IM3 IM3 IM3 IM3 IM3 IM3 IM3 IM3 IM3 IM3 IM3 IM3 IM3 IM3

IPT1AX2 IPT1AX3 IPT1BX2 IPT1BX3

IPT1CX2 IPT1CX3 IPT2AX2 IPT2AX3 IPT2BX2 IPT2BX3

IPT2CX2 IPT2CX3 J01 J01 J01 J01 J01 J02 J02 J02 J02 J02 J02 J02 J02 J02 J02 J02 J02 J02 J02 J02 J02 J02 J02 J03 J03 J03 J03 J03 J03 J03 J03 J03 J03 J03 J03 J03 J03 J03 J03 J03 J03 J03 J03 J03 J03 J03

Diagram11 D17 Diagram11 P13 Diagram8 N7 Diagram8 N7 Diagram8 N7 Diagram8 N7

Diagram10 N19 Diagram10 N19 Diagram11 N12 Diagram11 N11 Diagram8 L15

Diagram8 P15

Diagram8 M15 Diagram8 P15 Diagram15 P7 Diagram15 P7

Diagram15 O6

Diagram10 C16 Diagram10 C16 Diagram10 C16 Diagram10 C20 Diagram10 C21 Diagram10 C20 Diagram10 C21 Diagram11 K11 Diagram11 K12 Diagram11 L12 Diagram11 L11 Diagram13 H1 Diagram13 I1

Diagram10 O18 Diagram4 I7

Diagram4 K7 Diagram4 L7

Diagram7 I20

Diagram7 J20

Diagram8 G17 Diagram13 A7 Diagram13 B9 Diagram13 E7 Diagram13 I9

Diagram13 M9 Diagram4 H7 Diagram4 J7

Diagram7 J20 Diagram7 J20

Diagram8 D17 Diagram13 A9

Diagram13 C7

Diagram13 G7

Diagram13 H9 Diagram13 I9

Diagram13 P7

Diagram4 H7 Diagram4 H7 Diagram4 K7 Diagram5 B3

Diagram7 H20 Diagram7 J20

Diagram8 C17 Diagram11 I6

Diagram13 D7 Diagram13 D9 Diagram13 I7

Diagram13 L9 Diagram13 L9

Diagram13 O9

Diagram15 M9 Diagram15 M9 Diagram15 N9 Diagram15 N9 Diagram15 N9 Diagram15 N9 Diagram15 N9 Diagram15 N9

Diagram15 O9 Diagram15 O9 Diagram15 O9 Diagram15 O9

Diagram8 D13 Diagram8 G10 Diagram9 C7 Diagram10 P9

Diagram15 E11

Diagram4 C19

Diagram4 D16 Diagram6 I11

Diagram7 A13 Diagram7 E21

Diagram7 G16 Diagram8 J7

Diagram10 H8 Diagram10 L6

Diagram12 D5 Diagram12 I7

Diagram12 K7

Diagram13 A12

Diagram13 H14

Diagram14 O17 Diagram15 B13

Diagram15 D15 Diagram15 G11 Diagram4 E7

Diagram4 E11 Diagram5 N9

Diagram5 O9

Diagram6 K12 Diagram7 K16 Diagram7 K19 Diagram8 I8

Diagram8 J19 Diagram8 L3

Diagram9 B6 Diagram9 F4 Diagram9 J1 Diagram9 J6

Diagram9 L3

Diagram10 K15 Diagram11 B7

Diagram11 K15 Diagram11 L6

Diagram11 N7 Diagram12 P6

Diagram14 A5

Diagram14 D5

CONNECTOR TABLE

CONNECTOR DIAGRAM

ZONE

J03

Diagram15 M17

J04

Diagram8 E15

J04 J04 J04 J04 J04 J04 J04 J04 J6

J11 J11 J11 J11 J11 J11 J11 J11 J11 J11 J11 J11 J11 J11 J11 J11 J11 J11 J11 J12 J12 J12 J12 J12 J12 J12 J12 J12 J12 J12 J12 J12 J12 J12 J12 J12 J12 J12 J12 J12 J12 J12 J12 J13 J13 J13 J14 J14 J14 J14 J14 J14 J14 J14 J14 J15 J15 J16 J16 J16 J16 J16 J16 J16 J16 J16 J16 J16 J16 J16 J54 J55

J56_CP J57_CP

J170_CP J180_CP J190 J210 J211 J228 J229 J240 J240 J240 J240 J240 J240 J240

J262_CP J362 J372 J502 J502 J502 J502 J502 J502 J503 J503 J503 J503 J503 J503 J503

J504_CP J505

J505_CP J506 J511 J520

J520J533

J533_CP J534 J535 J536

J536_CP J537 J540

Diagram5 L12

Diagram8 K19 Diagram9 M4

Diagram11 J11

Diagram12 F17

Diagram12 G17 Diagram13 F4

Diagram14 E9

Diagram12 F16 Diagram4 E4

Diagram6 P12

Diagram7 O11 Diagram8 N12

Diagram8 O11 Diagram8 P11

Diagram9 B17 Diagram9 E16 Diagram9 G7

Diagram9 G10 Diagram9 L16

Diagram10 E19

Diagram10 G18 Diagram11 E8

Diagram13 O16 Diagram14 B9

Diagram14 D9

Diagram14 G15

Diagram15 H16 Diagram3 I4

Diagram4 B3

Diagram4 C4

Diagram6 N12 Diagram7 P8

Diagram8 L12

Diagram8 N11 Diagram8 P11

Diagram9 C17 Diagram9 F7

Diagram9 F10 Diagram9 F16 Diagram9 J16

Diagram10 D15 Diagram10 E18

Diagram10 G16 Diagram11 F8

Diagram11 L13

Diagram13 N16 Diagram14 C9

Diagram14 D9

Diagram14 I15 Diagram15 I16

Diagram15 N15

Diagram10 D10 Diagram13 M5 Diagram14 M5

Diagram9 G16 Diagram9 K17

Diagram10 C17 Diagram13 C9

Diagram13 C13 Diagram13 H3

Diagram13 L14 Diagram13 O5

Diagram15 K14 Diagram10 G9

Diagram15 K15

Diagram9 M16 Diagram10 N16

Diagram11 D14 Diagram11 H11 Diagram11 H11

Diagram11 M14 Diagram12 F6

Diagram13 D13 Diagram13 E11 Diagram13 J3

Diagram13 L13 Diagram14 N6

Diagram15 J17 Diagram11 J16

Diagram11 H16 Diagram10 A9

Diagram10 C9

Diagram6 O13 Diagram6 P14 Diagram6 P14

Diagram5 N18

Diagram5 M18 Diagram7 B12

Diagram7 C12

Diagram4 H19 Diagram6 H16 Diagram7 L17

Diagram10 O16 Diagram11 N10 Diagram13 G12 Diagram13 K3

Diagram15 N17 Diagram14 N17 Diagram13 I15

Diagram9 L18 Diagram11 E5

Diagram14 B11

Diagram14 D11 Diagram14 G18

Diagram15 H19 Diagram9 J18 Diagram11 F5

Diagram11 L15

Diagram14 C11

Diagram14 D11 Diagram14 I18 Diagram15 I19

Diagram6 N13 Diagram6 N14 Diagram6 N14

Diagram6 M14 Diagram13 O17 Diagram7 O14 Diagram7 O14 Diagram4 E3 Diagram4 E3

Diagram9 H7 Diagram9 E7

Diagram4 C3 Diagram4 C3

Diagram3 C20 Diagram9 F18

CONNECTOR TABLE

CONNECTOR DIAGRAM

ZONE

J540

Diagram9 J17

J540

Diagram10 E16

J540 J540 J540 J540 J540 J540 J540 J540 J541 J541 J541 J541 J541 J541 J541 J541 J541 J542 J542 J542 J542 J542 J543 J543 J543 J543 J543 J544

J544_CP J546_CP J547_CP J548_CP J549_CP J563

J563_CP J565 J601 J602 J651

J651_CP J653_CP J701 J701 J701 J701 J702 J702 J702 J702 J703 J704 J712 J730 J730

J731_CP J732_CP J801 J801

J801J801J808

J808J815

J815J830 JB1

JB4A JB4B

JB4C

JB4D JB4E

JB4H JB6A JB6B

JB6C JB6E

JB6G JB8A JB41

JB41-

Diagram10 D16 Diagram10 G14 Diagram11 F7

Diagram11 L14

Diagram14 C10

Diagram14 D10 Diagram14 I16 Diagram15 I17

Diagram9 E18 Diagram9 L17

Diagram10 E20

Diagram10 G20 Diagram11 E7

Diagram14 B10

Diagram14 D10 Diagram14 G16

Diagram15 H17 Diagram7 P10 Diagram8 L13

Diagram8 N13 Diagram8 P13

Diagram9 C19

Diagram7 O12 Diagram8 N13

Diagram8 O13 Diagram8 P13

Diagram9 B19 Diagram9 F20 Diagram9 F19

Diagram14 B12

Diagram14 C12

Diagram14 D13 Diagram14 D13 Diagram10 C19 Diagram10 C19

Diagram9 G18

Diagram5 M12 Diagram5 N12 Diagram15 K5 Diagram15 K5

Diagram12 K19 Diagram7 E11 Diagram10 N5

Diagram10 O5 Diagram10 P5

Diagram4 D13 Diagram7 N11 Diagram13 E10

Diagram15 K12 Diagram12 E10

Diagram11 M17 Diagram15 O1

Diagram13 D14 Diagram13 E12

Diagram9 M18 Diagram9 K18

Diagram3 M15 Diagram6 M6 Diagram7 M6 Diagram7 O5 Diagram6 I6 Diagram7 I6

Diagram3 M13 Diagram7 P3

Diagram15 O16 Diagram3 E18

Diagram6 H12 Diagram10 I10 Diagram11 M2

Diagram8 E10

Diagram7 A15 Diagram11 O3

Diagram10 J19

Diagram7 F17

Diagram7 D12 Diagram12 H20 Diagram11 L2

Diagram12 I18 Diagram6 G4 Diagram7 G4

KCNPR-(+) Diagram5 C9 KCNPR-(-)

Diagram5 C10

KCNPR-87

Diagram5 C9

KCNPR-30 KEYSW-B

KEYSW-BR KEYSW-C

Diagram5 C10 Diagram4 E8 Diagram4 E9 Diagram4 E9

KSWPR-(+) Diagram4 F8 KSWPR-(-)

Diagram4 F8

KSWPR-87

Diagram4 F8

KSWPR-30 L547 LBPS LBPS

LBUL LBUL

LCL1 LCL1 LCL2 LCL2

LDLLT LDLLT LDLT LDLT

LDML

LDML_CP LESLS-1 LESLS-2 LESLS-3 LFLT

LFSPK LLESL LLESL LLPS LLPS

LLSOL LLSOL

LLSW-1 LLSW-2 LLSW-3 LMLHB LMLLB

LMRHB LMRLB LP

LPLA LPLA

LPLG

Diagram4 F8 Diagram14 C13 Diagram13 F14 Diagram13 F14 Diagram11 F4 Diagram11 F4

Diagram9 I21 Diagram9 I21

Diagram9 J21 Diagram9 J21

Diagram9 E21 Diagram9 E21 Diagram9 F21 Diagram9 F21 Diagram15 I20 Diagram15 I20

Diagram10 E15 Diagram10 E15 Diagram10 E15

Diagram9 C21

Diagram5 M16 Diagram10 G13 Diagram10 G13 Diagram13 L16 Diagram13 L16

Diagram13 N19 Diagram13 N19 Diagram9 E6 Diagram9 E6 Diagram9 E6

Diagram8 L15

Diagram8 N15 Diagram8 N15

Diagram8 O15 Diagram6 I4

Diagram14 H18 Diagram14 H19 Diagram14 I18

CONNECTOR TABLE

CONNECTOR DIAGRAM

ZONE

LPLG

Diagram14 I19

LPLR

Diagram14 H19

LPLR

LRBH-(+) LRBH-(-) LRBL LRBL

LRBPS

LRBPS_CP LRL LRL

LRSPK LRSTL LRSTL

LSCL1 LSCL1 LSCL2 LSCL2 LUESL LUESL

M1-TA1 M1-TA2 M1-TB1 M1-TB2

M1-TC1 M1-TC2 M2-TA1 M2-TA2 M2-TB1 M2-TB2

M2-TC1 M2-TC2

MIRROR1 MIRROR2 MLLO

MLLON MLREL MLREL

MM/RPC ORPS-1 ORPS-2 ORPS1 ORPS2

ORS-A ORS-B

ORS_1-3 ORS_1-4 P01 P01 P01 P01 P1 P1

P01 P02 P02 P02 P02 P02 P02 P02 P02 P02 P02 P02 P02 P02 P02 P02 P02 P02 P02

P2A P2B

P03 P03 P03 P03 P03 P03 P03 P03 P03 P03 P03 P03 P03 P03 P03 P03 P03 P03 P03 P03 P03 P03 P03 P03

P3A P3B

P04 P04 P04 P04 P04 P04 P04 P04 P04

P4A P4B P5

P6A P07 P07 P08 P08 P09 P09 P10 P11 P11 P11 P11 P11 P11 P11 P11 P11 P11

Diagram14 H18 Diagram11 C17 Diagram11 C17 Diagram11 E17 Diagram11 E17

Diagram15 K17 Diagram15 K18

Diagram11 H16 Diagram11 H17

Diagram5 N16 Diagram11 E17 Diagram11 E18 Diagram11 I19 Diagram11 I19

Diagram11 J19 Diagram11 J19

Diagram10 F13 Diagram10 F13

Diagram15 M12 Diagram15 M12 Diagram15 N12 Diagram15 N12 Diagram15 N12 Diagram15 N12 Diagram15 N12 Diagram15 N12

Diagram15 O12 Diagram15 O12 Diagram15 O12 Diagram15 O12 Diagram14 B14

Diagram14 C14

Diagram3 H19 Diagram3 G19 Diagram3 G16 Diagram3 G17 Diagram15 G16 Diagram6 M3 Diagram6 M3 Diagram7 M3 Diagram7 M4 Diagram10 I7 Diagram10 I8 Diagram10 I7 Diagram10 I8

Diagram8 D13 Diagram8 G10 Diagram9 C7 Diagram10 P9

Diagram12 I14

Diagram12 L14

Diagram15 E11

Diagram4 C19

Diagram4 D16 Diagram6 I11

Diagram7 A13 Diagram7 E21

Diagram7 G16 Diagram8 J7

Diagram10 H8 Diagram10 L6

Diagram12 D5 Diagram12 I7

Diagram12 K7

Diagram13 A12

Diagram13 H14

Diagram14 O17 Diagram15 B13

Diagram15 D15 Diagram15 G11 Diagram12 I14

Diagram12 K14 Diagram4 E7

Diagram4 E11 Diagram5 N9

Diagram5 O9

Diagram6 K12 Diagram7 K16 Diagram7 K19 Diagram8 I8

Diagram8 J19 Diagram8 L3

Diagram9 B6 Diagram9 F4 Diagram9 J1 Diagram9 J6

Diagram9 L3

Diagram10 K15 Diagram11 B7

Diagram11 K15 Diagram11 L6

Diagram11 N7 Diagram12 P5

Diagram14 A5

Diagram14 D5

Diagram15 M17 Diagram12 F14 Diagram12 L14 Diagram5 L12

Diagram8 E15

Diagram8 K19 Diagram9 M4

Diagram11 J11

Diagram12 F17

Diagram12 G17 Diagram13 F4

Diagram14 E9

Diagram12 E14 Diagram12 J14

Diagram12 K14 Diagram12 F16 Diagram11 O8 Diagram11 O8 Diagram11 P6 Diagram11 P6

Diagram11 O6 Diagram11 O6

Diagram11 M5 Diagram4 E4

Diagram6 P12

Diagram7 O11 Diagram8 N12

Diagram8 O12 Diagram8 P12

Diagram9 B17 Diagram9 E16 Diagram9 G7 Diagram9 G9

CONNECTOR TABLE

CONNECTOR DIAGRAM

ZONE

P11

Diagram9 L16

P11

Diagram10 G18

P11 P11 P11 P11 P11 P11 P11 P12 P12 P12 P12 P12 P12 P12 P12 P12 P12 P12 P12 P12 P12 P12 P12 P12 P12 P12 P12 P12 P12 P12 P12 P13 P13 P13 P14 P14 P14 P14 P14 P14 P14 P14 P14 P15 P15 P16 P16 P16 P16 P16 P16 P16 P16 P16 P16 P16 P16 P16 P18 P20 P20 P21 P21 P22 P22 P23 P23 P24 P24 P25 P25 P31 P31 P32 P32 P33 P33 P34 P34 P35 P35 P36 P36 P37 P37 P39 P39 P54 P55 P56 P57

P058 P059 P071 P071 P072 P072 P108 P108 P120 P121 P121 P121 P121 P121 P121 P140 P150 P151 P152 P153 P170 P180

P190_CP P202D P203B P204B P205B

P206D P207B P208B

P209D P210

P210B P211

P211B P212 P212

Diagram10 E19 Diagram11 E8

Diagram13 O16 Diagram14 B9

Diagram14 D9

Diagram14 G15

Diagram15 H16 Diagram3 I4

Diagram4 B3

Diagram4 C4

Diagram6 N12 Diagram7 P8

Diagram8 L12

Diagram8 N12 Diagram8 P12

Diagram9 C17 Diagram9 F7 Diagram9 F9

Diagram9 F16 Diagram9 J16

Diagram10 D15 Diagram10 E18

Diagram10 G15 Diagram11 F8

Diagram11 L13

Diagram13 N16 Diagram14 C9

Diagram14 D9

Diagram14 I15 Diagram15 I16

Diagram15 N15

Diagram10 D10 Diagram13 M4 Diagram14 M5

Diagram9 G16 Diagram9 K17

Diagram10 C17 Diagram13 C9

Diagram13 C13 Diagram13 H3

Diagram13 L14 Diagram13 O4

Diagram15 K14 Diagram10 G9

Diagram15 K15

Diagram9 M16 Diagram10 N16

Diagram11 D14 Diagram11 H11 Diagram11 H11

Diagram11 M14 Diagram12 F6

Diagram13 D13 Diagram13 E11 Diagram13 J3

Diagram13 L13 Diagram14 N6

Diagram15 J17 Diagram8 J12

Diagram8 B10 Diagram8 B10

Diagram8 D10 Diagram8 D10 Diagram9 B3 Diagram9 B4

Diagram11 C9 Diagram11 C9

Diagram9 G3 Diagram9 G3 Diagram8 I9

Diagram8 I10 Diagram15 I3 Diagram15 I3

Diagram14 E3 Diagram14 E3

Diagram14 B3 Diagram14 B3

Diagram12 N8 Diagram12 N9

Diagram12 M8 Diagram12 M9 Diagram9 M7 Diagram9 M8 Diagram12 P8 Diagram12 P9

Diagram7 K17 Diagram7 K18 Diagram11 J16

Diagram11 H16 Diagram10 A9

Diagram10 C9

Diagram10 K21 Diagram10 I21

Diagram10 K18 Diagram10 K18 Diagram10 J18 Diagram10 J18

Diagram7 G18 Diagram7 G19 Diagram11 K16 Diagram8 I14 Diagram8 I14 Diagram9 J2 Diagram9 J3

Diagram11 N2 Diagram11 N2

Diagram6 J14 Diagram14 L3

Diagram14 M3 Diagram14 N2 Diagram14 N2

Diagram6 O13 Diagram6 P14 Diagram6 P14 Diagram15 E2 Diagram15 E2 Diagram15 E5 Diagram15 E8 Diagram15 E5

Diagram15 E13 Diagram15 E14 Diagram15 E14

Diagram5 N18 Diagram15 E15

Diagram5 M18 Diagram15 E16

Diagram13 A14 Diagram13 A14

CONNECTOR TABLE

CONNECTOR DIAGRAM

ZONE

P212D

Diagram15 E16

P214D

Diagram15 E19

P213B P215B P216B

P218D P219D P235 P236 P237 P240 P240 P240 P240 P240 P240 P240 P246 P250 P250 P262 P263 P263 P264 P264 P301 P301 P301

P301B P302 P302 P302 P302 P302 P302

P302D P303 P303 P303 P303 P303 P303

P303B P304 P304 P304 P304 P304 P304 P304 P304 P304

P304B P305 P305 P305 P305

P305B

P306D P307B P308B

P309D P310B

P311D P315B P316B

P317D P318D P501 P502 P502 P502 P502 P502 P502 P503 P503 P503 P503 P503 P503 P503 P504

P505P506

P506_CP P507 P511 P520 P533 P534 P535 P536 P537 P540 P540 P540 P540 P540 P540 P540 P540 P540 P540 P540 P541 P541 P541 P541 P541 P541 P541 P541 P541 P542 P542 P542 P542 P542 P543 P543 P543 P543 P543 P544 P546 P547 P548 P549 P563

Diagram15 E18 Diagram15 E5 Diagram15 E8 Diagram15 E8

Diagram15 E10

Diagram10 O11 Diagram10 N11 Diagram10 P11

Diagram4 H19 Diagram6 H16 Diagram7 L17

Diagram10 O16 Diagram11 N10 Diagram13 G12 Diagram13 K3

Diagram14 O7

Diagram7 G20 Diagram7 G21

Diagram15 N17 Diagram15 N18 Diagram15 N19 Diagram14 O9

Diagram14 O11 Diagram10 G2

Diagram10 H2 Diagram12 F3

Diagram15 B4

Diagram4 C21

Diagram6 G20 Diagram10 N2

Diagram10 O2 Diagram12 A3

Diagram12 H3 Diagram15 C4

Diagram4 B21

Diagram6 G20 Diagram10 L2

Diagram10 P2 Diagram12 E3 Diagram12 L3

Diagram15 B4

Diagram4 C21 Diagram5 D3

Diagram7 F15 Diagram10 A2 Diagram10 K2

Diagram10 M2 Diagram12 D3

Diagram12 M3

Diagram14 M20 Diagram15 B7

Diagram4 D21 Diagram5 C3 Diagram10 I2

Diagram12 O3

Diagram15 B10 Diagram15 C7

Diagram15 B15 Diagram15 B16

Diagram15 C16 Diagram15 B18

Diagram15 C18 Diagram15 B7

Diagram15 B10

Diagram15 C10 Diagram15 C12 Diagram10 B11 Diagram9 L18 Diagram11 E6

Diagram14 B11

Diagram14 D11 Diagram14 G17

Diagram15 H19 Diagram9 J18 Diagram11 F6

Diagram11 L15

Diagram14 C11

Diagram14 D11 Diagram14 I17 Diagram15 I19

Diagram6 N13 Diagram6 N14

Diagram6 M14 Diagram6 M14 Diagram10 D11

Diagram13 O17 Diagram7 O14 Diagram4 E3

Diagram9 H7 Diagram9 E7

Diagram4 C3

Diagram3 C20 Diagram9 F18 Diagram9 J17

Diagram10 D17 Diagram10 E16

Diagram10 G14 Diagram11 F7

Diagram11 L14

Diagram14 C10

Diagram14 D10 Diagram14 I16 Diagram15 I17

Diagram9 E18 Diagram9 L17

Diagram10 E21

Diagram10 G20 Diagram11 E7

Diagram14 B10

Diagram14 D10 Diagram14 G16

Diagram15 H17 Diagram7 P10 Diagram8 L13

Diagram8 N13 Diagram8 P13

Diagram9 C19

Diagram7 O12 Diagram8 N13

Diagram8 O13 Diagram8 P13

Diagram9 B19 Diagram9 F19

Diagram14 B12

Diagram14 C12

Diagram14 D13 Diagram14 D13 Diagram10 C19

CONNECTOR TABLE

CONNECTOR DIAGRAM

ZONE

P565

Diagram9 G18

P602_CP

Diagram5 N12

P601_CP P650 P651 P652 P652 P653 P701 P701 P701 P701 P702 P702 P702 P702 P703 P704 P711 P712 P720 P721 P730 P730 P731 P732 P737 P800 P800 P801 P801 P802

P802P803 P803

P803P803P804

P804P805

P805P805P805P805P805P806

P806P806P806P806P806P806P806P808 P815 P820

P820P826 P830 P902 P903

PBPSW PBPSW PBRPS PBRPS PBS PBS PL PL

PLLO

PLMS-(+) PLMS-(-) PLMS-1 PLMS-2 PLON

PLOS-B1 PLOS-B2 PLOS-F1 PLOS-F2

PLPM-(+) PLPM-(-) PLPSW PLPSW PLREL PLREL

PLS-2 PLS-3

PLT-3

PLT-C

PLT-NO

PWR1-1 PWR1-2 PWR2-1 PWR2-2 R3 R3 R4 R4 R5 R5

R15 R15 R16 R16 R17 R17 R18 R18 R19 R19 R20 R20 R21 R21 R23 R23 R27 R27 R30 R30 R34 R34 R44 R44 R50 R50 R51 R51

R546

RBML

Diagram5 M12 Diagram15 K9 Diagram15 K5 Diagram15 K7 Diagram15 K8

Diagram12 K19 Diagram7 E11 Diagram10 N5

Diagram10 O5 Diagram10 P5

Diagram4 D13

Diagram7 M11 Diagram13 E11

Diagram15 K12 Diagram12 E10

Diagram11 M17 Diagram13 J16 Diagram13 I16

Diagram10 E11

Diagram10 G11

Diagram13 D14 Diagram13 E12

Diagram9 M18 Diagram9 K18

Diagram5 N20 Diagram3 N9

Diagram3 N10

Diagram3 M15 Diagram6 M6 Diagram6 C5 Diagram7 C5 Diagram6 L5 Diagram6 L5 Diagram7 L5 Diagram7 L6

Diagram6 B2 Diagram7 I2

Diagram6 D2 Diagram7 A2

Diagram7 C2 Diagram7 C2

Diagram7 D2 Diagram7 G2 Diagram6 G2 Diagram7 A2 Diagram7 B2

Diagram7 C2

Diagram7 D2 Diagram7 F2

Diagram7 G2 Diagram7 I2 Diagram6 I6

Diagram3 M13 Diagram6 H2 Diagram7 H2 Diagram6 I2

Diagram15 O16 Diagram8 F8

Diagram8 H8

Diagram13 F14 Diagram13 F14

Diagram4 H20 Diagram4 H21 Diagram6 H14 Diagram6 H14

Diagram11 O14 Diagram11 O14 Diagram3 E19

Diagram3 O12 Diagram3 O12 Diagram3 O12 Diagram3 O12 Diagram3 D19 Diagram3 C17 Diagram3 C17 Diagram3 C17 Diagram3 C17

Diagram3 O13 Diagram3 O14 Diagram3 M9

Diagram3 M10 Diagram3 D16 Diagram3 D17 Diagram11 N17 Diagram11 N18 Diagram11 N16

Diagram11 O16 Diagram11 O16 Diagram5 O11 Diagram5 O11 Diagram5 O11 Diagram5 O11 Diagram6 F12 Diagram6 F12 Diagram6 F12 Diagram6 F12 Diagram6 F16 Diagram6 F17

Diagram13 D12 Diagram13 D12 Diagram8 E12 Diagram8 E12 Diagram12 G7 Diagram12 G7

Diagram7 I15 Diagram7 I15

Diagram13 B12 Diagram13 B12 Diagram14 L19 Diagram14 L20 Diagram14 L19 Diagram14 L20 Diagram12 A7 Diagram12 A7

Diagram8 J10 Diagram8 J11

Diagram13 M14 Diagram13 M14 Diagram12 B7 Diagram12 B7

Diagram5 C8 Diagram5 C9 Diagram6 E8 Diagram6 E9

Diagram6 C9

Diagram6 C10 Diagram14 B13 Diagram15 J18

CONNECTOR TABLE

CONNECTOR DIAGRAM

ZONE

RBML1

Diagram15 J19

RBML2_CP

Diagram15 J20

RBML2

RBML_CP RBUL RBUL

RCL1 RCL1 RCL2 RCL2

RDLLT RDLLT RDLT RDLT

RDML

RDML_CP RECDR RECDR

RECDR-T1 RECDR-T1 RESLS-1 RESLS-2 RESLS-3 RFLT

RFSPK RLESL RLESL

RLSW-1 RLSW-2 RLSW-3 RPLA RPLA

RPLG RPLG RPLR RPLR

RRBB1 RRBB2

RRBH-(+) RRBH-(-) RRBL RRBL

RRBPS

RRBPS_CP RRL RRL

RRSPK RRSTL RRSTL

RSCL1 RSCL1 RSCL2 RSCL2

RSCS-A RSCS-B

RSCS_1-1 RSCS_1-2 RSCS_1-3 RSCS_1-4 RSCS_2-1 RSCS_2-2 RSP

RTMR1-A1 RTMR1-B2

RTMR1-C1 RTMR1-C2

RTMR1-D1 RTMR1-D2 RTMR1-F1 RTMR1-F2 RUESL RUESL SABS SABS SBL

SBPS SBPS

SDISC-1 SDISC-2 SDISC-3 SDISC-4 SDISC-5 SDISC-6 SDISC-7 SDISC-8 SFSW SFSW SLLO

SLON

SLREL SLREL

SONA(+) SONA(-) SPR_1 SPR_2 SPR_3 SPR_5 SPR_6 SPR_7 SPR_8 SPR_9

SPR_10 SPR_11 SPR_12 SPR_13 SPR_14 SPR_15 SPR_16 SPR_17 SPR_18 SPR_19 SPR_20 SPS

STRT1-1A

STRT1-1C STRT1-2A STRT1-2B STRT1-3

STRT1-4B

Diagram15 J20 Diagram15 J18 Diagram11 E4 Diagram11 E4

Diagram9 K21 Diagram9 K21 Diagram9 L21 Diagram9 L21

Diagram9 D20 Diagram9 D21 Diagram9 E20 Diagram9 E21

Diagram15 H20 Diagram15 H20 Diagram6 L2 Diagram6 L2 Diagram7 L2 Diagram7 L3

Diagram10 E22 Diagram10 E22 Diagram10 E22

Diagram9 B21

Diagram5 M16 Diagram10 G21 Diagram10 G21 Diagram9 H6 Diagram9 H6 Diagram9 H6

Diagram14 G18 Diagram14 G19 Diagram14 G18 Diagram14 G19 Diagram14 F18 Diagram14 F19

Diagram14 E10 Diagram14 E10

Diagram11 C17 Diagram11 C17

Diagram11 D17 Diagram11 D17 Diagram15 J17 Diagram15 J18 Diagram11 I16 Diagram11 I17

Diagram5 O16 Diagram11 F17 Diagram11 F18

Diagram11 G19 Diagram11 G19

Diagram11 H19 Diagram11 H19 Diagram10 J10 Diagram10 J10 Diagram10 J10 Diagram10 J10

Diagram10 K10 Diagram10 K10 Diagram10 K10 Diagram10 K10 Diagram10 L11 Diagram7 O7 Diagram7 O8 Diagram7 O7 Diagram7 O8

Diagram7 L11 Diagram7 L12 Diagram7 L11 Diagram7 L12

Diagram10 F21 Diagram10 F21 Diagram13 O2 Diagram13 O2

Diagram11 I12

Diagram6 G14 Diagram6 G14 Diagram3 E15 Diagram3 E15 Diagram3 F15 Diagram3 F15 Diagram3 F15

Diagram3 E15 Diagram3 E15 Diagram3 F15

Diagram13 E16 Diagram13 E16 Diagram3 F19

Diagram3 G19 Diagram3 E16 Diagram3 E17 Diagram8 E13 Diagram8 E13 Diagram7 M5 Diagram6 M5 Diagram6 M8

Diagram8 I17 Diagram8 I17 Diagram8 I17 Diagram8 I17

Diagram8 J17 Diagram8 J17 Diagram8 J17

Diagram8 K17 Diagram8 I20 Diagram8 I20 Diagram8 I20 Diagram8 I20

Diagram8 J20 Diagram8 J20 Diagram8 J20

Diagram8 K20 Diagram13 H1

Diagram3 K10 Diagram3 K10 Diagram3 K11 Diagram3 K11 Diagram3 K10 Diagram3 K11

STRT1-4B- Diagram7 O1 STRT2-1A

Diagram3 K12

STRT2-2A

Diagram3 K13

STRT2-1B STRT2-2B STRT2-3

STRT2-4A

Diagram3 K12 Diagram3 K13 Diagram3 K12 Diagram3 K12

STRT2-4A- Diagram7 O2 T19 T20

Diagram15 O9 Diagram15 O9

TB-HTST-C1Diagram15 L2

CONNECTOR TABLE

CONNECTOR DIAGRAM

ZONE

TB-HTST-C2Diagram15 M2 TB-HTST-D2Diagram15 M2 TB-HTST-D4Diagram15 M2 TB-HTST-E1 Diagram15 M2 TB-HTST-E2 Diagram15 M2 TB-HTST-F4 Diagram15 N2 TB-HTST-G1Diagram15 N2 TB-HTST-G2Diagram15 N2 TB-HTST-G3Diagram15 N2 TB-HTST-H1Diagram15 N2

TB-HTST-H2Diagram15 O2 TB-HTST-J1 Diagram15 O2 TB-HTST-J2 Diagram15 O2 TB-HTST-J3 Diagram15 O2 TB-HTST-K1Diagram15 O2 TB-HTST-K2Diagram15 P2

TB-HTST-K4Diagram15 O2 TB10-A1

Diagram8 J9

TB10-A4

Diagram8 J9

TB10-A3 TB10-C1 TB10-C2 TB10-C3 TB10-C4

TB10-D2 TB10-D3 TB10-D4 TB10-E1 TB10-E2 TB10-F1 TB10-F2

TB10-G1

TB10-H2 TB10-J1 TB10-J3

TB10-K1 TB10-K3 TB10-L1

TB10-M1

Diagram8 J9 Diagram9 C4 Diagram9 C4 Diagram9 C4 Diagram9 C4 Diagram8 J9 Diagram8 J9 Diagram8 J9

Diagram11 L5 Diagram11 L5

Diagram8 E9 Diagram8 E9 Diagram9 L4 Diagram9 L4 Diagram9 J5 Diagram9 J4

Diagram8 I16 Diagram8 I16 Diagram8 I12 Diagram9 J5

TB10-M3

Diagram9 J4

TB21-A2

Diagram12 E4

TB21-A1 TB21-A4 TB21-B1 TB21-B2 TB21-B3

TB21-C1 TB21-C2

TB21-D1 TB21-D2 TB21-D4 TB21-E1 TB21-F1 TB21-F2 TB21-F3

TB21-G1 TB21-G2 TB21-G3

TB21-H1 TB21-J1 TB21-J2 TB21-J3

TB21-K1 TB21-K2 TB21-L1 TB21-L2 TB21-L3

TB21-M1 TB21-M2 TB21-N1 TB21-N2 TB21-N3 TB21-P2

TB21-R1 TB21-R2 TB21-S1 TB21-S2 TB21-S4

TB21-T1 TB21-T2 TB21-T3 TB21-T4

TB21-V1 TB21-V2

TB21-W1 TB21-W2 TB21-W3 TB21-X1 TB21-X2 TB21-X3 TB21-X4

TB22-A1 TB22-A2 TB22-B1 TB22-B2

TB22-C1 TB22-C2 TB22-C4

TB22-D1 TB22-D2 TB22-D3 TB22-E1 TB22-E2 TB22-E3 TB22-E4 TB22-F1 TB22-F2

TB22-G1 TB22-G2

TB22-H1 TB22-H2 TB22-H4 TB22-J1 TB22-J2

TB22-K1 TB22-K2 TB22-L1 TB22-L2

TB22-P1 TB22-P2

TB22-R1 TB22-R2 TB22-S1 TB22-S2 TB22-S3

TB22-T1 TB22-T2 TB22-X1 TB22-X2

TB23-A1

Diagram12 E4 Diagram12 E4

Diagram5 M8 Diagram5 M8 Diagram5 M8

Diagram14 M18 Diagram14 M18 Diagram11 H4 Diagram11 H4 Diagram11 H4 Diagram10 A4

Diagram14 L18 Diagram14 L19 Diagram14 L18

Diagram14 K18 Diagram14 K19 Diagram14 K18 Diagram10 K4

Diagram13 D13 Diagram13 D13 Diagram13 D13 Diagram7 G13 Diagram7 G13 Diagram7 G13 Diagram7 G13 Diagram7 G13 Diagram7 G13 Diagram7 G13 Diagram7 G13 Diagram7 G13 Diagram7 G13

Diagram7 H13 Diagram10 J4 Diagram10 J4 Diagram10 J4 Diagram10 J4 Diagram10 J4

Diagram12 G5 Diagram12 G5 Diagram12 G5 Diagram12 G5 Diagram12 G5 Diagram12 G5

Diagram12 H5 Diagram12 H5 Diagram12 H5

Diagram7 I17 Diagram7 I17 Diagram7 I17 Diagram7 I17 Diagram8 I6 Diagram8 I7

Diagram11 K13 Diagram11 K14 Diagram9 L1 Diagram9 L1 Diagram9 L1

Diagram5 M7 Diagram5 M8 Diagram5 M8 Diagram14 D6 Diagram14 D7 Diagram14 D7 Diagram14 D7

Diagram5 M6 Diagram5 M7

Diagram6 J10 Diagram6 J11

Diagram4 F13 Diagram4 F13 Diagram4 F13 Diagram12 C6 Diagram12 C5 Diagram12 C6 Diagram12 C5

Diagram4 D14 Diagram4 D14 Diagram9 J7 Diagram9 J8 Diagram9 J7 Diagram9 J8

Diagram12 H5 Diagram12 H5 Diagram12 H5 Diagram11 B5 Diagram11 B5

Diagram7 N10 Diagram7 N10 Diagram7 N12

CONNECTOR TABLE

CONNECTOR DIAGRAM

ZONE

TB23-A2

Diagram7 N13

TB23-B2

Diagram7 K12

TB23-B1

TB23-C1

TB23-D1 TB23-E1 TB23-F1 TB23-F2

TB23-G1 TB23-G2

TB23-H1 TB23-H2 TB23-H4 TB23-J1 TB23-J2 TB23-J3 TB23-J4

TB23-K1 TB23-K2 TB23-K4 TB23-L1 TB23-L2 TB23-L4

TB23-M1 TB23-M2 TB23-N1 TB23-N2 TB23-N4 TB23-R1 TB23-R2 TB23-S1 TB23-S2

TB23-T1 TB23-T2

TB23-V2

TB23-W1 TB23-X1 TB23-X2

TB24-A1 TB24-B1 TB24-B2 TB24-B4

TB24-C1 TB24-C2

TB24-D1 TB24-D2 TB24-E1 TB24-E2 TB24-E4 TB24-F1 TB24-F2

TB24-G1 TB24-G2 TB24-G3

TB24-H1 TB24-H2 TB24-J1 TB24-J2 TB24-J4

TB24-K2 TB24-K3 TB24-K4 TB24-L1 TB24-L3 TB24-L4

TB24-M1 TB24-M2 TB24-N1 TB24-N2 TB24-N4 TB24-R1 TB24-R2

Diagram7 K12 Diagram14 F13

Diagram14 G13

Diagram14 H13 Diagram14 C7 Diagram14 C7

Diagram8 G12 Diagram8 G12 Diagram8 F12 Diagram8 F12 Diagram8 F12 Diagram10 H9 Diagram10 H9 Diagram10 H9 Diagram10 H9

Diagram12 M4 Diagram12 M4 Diagram12 M4

Diagram7 J13 Diagram7 J13 Diagram7 J13 Diagram9 C9 Diagram9 C8

Diagram4 E12 Diagram4 E12 Diagram4 E12 Diagram9 K2 Diagram9 K2

Diagram12 N4 Diagram12 N4

Diagram7 E20 Diagram7 E19

Diagram7 N13

Diagram10 M16 Diagram7 E13 Diagram7 E13

Diagram10 D16 Diagram7 H13 Diagram7 H13 Diagram7 H13 Diagram7 A12 Diagram7 A12 Diagram5 L10 Diagram5 L10

Diagram7 F13 Diagram7 F13 Diagram7 F13 Diagram5 L10 Diagram5 L10 Diagram5 C5 Diagram5 C5 Diagram5 C5

Diagram4 D7 Diagram4 D7

Diagram5 A11 Diagram5 A11 Diagram5 A11 Diagram5 B11 Diagram5 B11 Diagram5 B11 Diagram5 D8 Diagram5 D8 Diagram5 D8

Diagram7 J16 Diagram7 J16

Diagram5 C11 Diagram5 C11 Diagram5 C11 Diagram11 K4 Diagram11 K4

TB24-S1

Diagram10 K14

TB24-T1

Diagram10 I14

TB24-S2

TB24-T2

TB24-V1 TB24-V2 TB24-V4

TB24-W1 TB24-W2 TB24-X1 TB24-X3

TB25-A1 TB25-A2 TB25-B1 TB25-B2

TB25-C1 TB25-C2

TB25-D1 TB25-D2 TB25-E1 TB25-E2 TB25-F1 TB25-F2

TB25-G1 TB25-G2

TB25-H1 TB25-H2 TB25-K1 TB25-K2 TB25-L1 TB25-L2

TB25-M1 TB25-M2 TB25-N1 TB25-N2 TB25-P1 TB25-P2

TB25-R1 TB25-R2 TB25-S1 TB25-S2

TB25-T1 TB25-T2

TB25-V1 TB25-V2 TB25-V3 TB25-V4

TB25-W1 TB25-W2 TB25-X1 TB25-X2

TB26-A1 TB26-A2 TB26-A3 TB26-A4 TB26-B1 TB26-B3 TB26-B4

Diagram10 K14 Diagram10 I14 Diagram5 O6 Diagram5 O7 Diagram5 O7 Diagram6 G9

Diagram6 G10 Diagram13 I12 Diagram13 I11 Diagram12 H5 Diagram12 H5 Diagram12 I5 Diagram12 I5 Diagram12 I5 Diagram12 I5 Diagram12 I5 Diagram12 I5 Diagram12 I5 Diagram12 I5

Diagram12 J5 Diagram12 J5 Diagram12 J5 Diagram12 J5 Diagram12 J5 Diagram12 J5

Diagram4 B15 Diagram4 B15 Diagram4 B15 Diagram4 B15 Diagram13 F6 Diagram13 F6

Diagram4 C19 Diagram4 C20 Diagram12 J5 Diagram12 J5 Diagram12 J5 Diagram12 J5 Diagram12 J5 Diagram12 J5

Diagram12 K5 Diagram12 K5 Diagram7 F9 Diagram7 F9 Diagram7 F9 Diagram7 F9

Diagram12 O4 Diagram12 O4 Diagram12 O4 Diagram12 O4 Diagram12 A6 Diagram12 A5 Diagram12 A6 Diagram12 A5 Diagram12 A6 Diagram12 A6 Diagram12 A5

CONNECTOR TABLE

CONNECTOR DIAGRAM

ZONE

TB26-C1

Diagram12 B6

TB26-D1

Diagram12 D6

TB26-C2

TB26-D2 TB26-E1 TB26-E2 TB26-F1 TB26-F2

TB26-G1 TB26-G2

TB26-H1 TB26-H2 TB26-J1 TB26-J2

TB26-K1 TB26-K2 TB26-K3 TB26-K4 TB26-L1 TB26-L2 TB26-L3 TB26-L4

TB26-M1 TB26-M2 TB26-M3 TB26-M4 TB26-M5 TB26-N1 TB26-N2 TB26-P1 TB26-P2

TB26-R1 TB26-R2 TB26-S1 TB26-S2

TB26-T1 TB26-T2

TB26-V2

TB27-A1 TB27-A2 TB27-A3 TB27-B1 TB27-B2 TB27-B3

TB27-C1 TB27-C2 TB27-C3

TB27-D1 TB27-D2 TB27-E1 TB27-E2 TB27-E4 TB27-F1 TB27-F2 TB27-F4

TB27-G1

TB27-H1 TB27-H2 TB27-J1 TB27-J2 TB27-J3 TB27-J4

TB27-K1 TB27-K3 TB27-L1 TB27-L3

TB27-M1 TB27-M2 TB27-P1 TB27-P2

TB27-R1 TB27-R2 TB27-R3 TB27-R4 TB27-S1 TB27-S2 TB27-S3 TB27-S4

TB27-T1 TB27-T2 TB27-T3

TB27-V1 TB27-V2

TB27-W1 TB27-W2 TB27-W3 TB27-W4 TB27-X1 TB27-X2

TB28-A1 TB28-A2 TB28-B1 TB28-B2

TB28-C1 TB28-C2

TB28-D1 TB28-D2 TB28-E1 TB28-E2 TB28-F1 TB28-F2

TB28-G1 TB28-G2

TB28-H1 TB28-H2 TB28-J1 TB28-J3 TB28-J4

TB28-K1 TB28-L1

TB28-M1 TB28-M4 TB28-N1 TB28-N4 TB28-P1 TB28-P4

TB28-R1 TB28-R2 TB28-R4 TB28-S1 TB28-S2

TB28-T1 TB28-T2

TB28-V1 TB28-V2

TB28-W1 TB28-W2 TB28-X1 TB28-X2

TB29-A1

Diagram12 B5

Diagram12 D5 Diagram12 B6 Diagram12 B5 Diagram12 B6 Diagram12 B5 Diagram12 B6 Diagram12 B5

Diagram12 C6 Diagram12 C5 Diagram12 C6 Diagram12 C5

Diagram12 D7 Diagram12 D7 Diagram12 E7 Diagram12 E7 Diagram12 E7 Diagram12 E7 Diagram12 E7 Diagram12 E7 Diagram12 E7 Diagram12 E7 Diagram12 E7 Diagram12 E7 Diagram12 E7

Diagram8 B15 Diagram8 B15 Diagram8 B15 Diagram8 B15

Diagram8 C15 Diagram8 C15

Diagram8 D15 Diagram8 D15 Diagram9 F14 Diagram9 F14 Diagram9 F14

Diagram6 A10 Diagram6 A10 Diagram6 A10 Diagram6 B10 Diagram6 B10 Diagram6 B10 Diagram6 B10 Diagram6 B10 Diagram6 B10 Diagram6 B10 Diagram6 B10 Diagram6 C8 Diagram6 C8 Diagram6 C8

Diagram6 E10 Diagram6 E11 Diagram6 F11 Diagram6 G8

Diagram6 D8 Diagram6 D8

Diagram6 F14 Diagram6 F14 Diagram6 F14 Diagram6 F14 Diagram6 D8 Diagram6 D8 Diagram6 D8 Diagram6 D8

Diagram6 B10 Diagram6 B10 Diagram6 F18 Diagram6 F19

Diagram4 C20 Diagram4 C20 Diagram4 C20 Diagram4 C20 Diagram6 F10 Diagram6 F11 Diagram6 F10 Diagram6 F11

Diagram6 D10 Diagram6 D11 Diagram6 E10 Diagram6 E10 Diagram6 E11 Diagram6 E10 Diagram6 E11 Diagram6 E11 Diagram6 E11 Diagram6 E10 Diagram6 E11 Diagram6 K9 Diagram6 K9

Diagram12 G18 Diagram12 G18 Diagram12 G18 Diagram12 G18

Diagram6 M10 Diagram6 M10 Diagram6 M10 Diagram6 M10 Diagram4 K9 Diagram4 K9 Diagram4 K9 Diagram4 K9

Diagram4 K12 Diagram4 K12 Diagram5 D3 Diagram5 D3 Diagram5 D4 Diagram13 I5

Diagram6 M10 Diagram13 G12 Diagram13 G13

Diagram13 H12 Diagram13 H13 Diagram13 H12 Diagram13 H13 Diagram13 H12 Diagram13 H13 Diagram13 H13 Diagram6 I9 Diagram6 I9 Diagram6 I9 Diagram6 I9 Diagram6 I9 Diagram6 I9

Diagram14 A6 Diagram14 A6

Diagram13 A10 Diagram13 A11 Diagram10 D4

CONNECTOR TABLE

CONNECTOR DIAGRAM

ZONE

TB29-A2

Diagram10 D4

TB29-B2

Diagram10 D4

TB29-B1

TB29-C1 TB29-C2

TB29-D1 TB29-D2 TB29-E1 TB29-E2 TB29-F1 TB29-F2

TB29-G1 TB29-G2

TB29-H1 TB29-H2 TB29-J1 TB29-J2

TB29-K1 TB29-K2 TB29-L1 TB29-L2

TB29-M1 TB29-M2 TB29-N1 TB29-N2 TB29-P1 TB29-P2

TB29-R1 TB29-R2 TB29-S1 TB29-S2

TB29-T1 TB29-T2

TB29-V1 TB29-V2

TB29-W1 TB29-W2 TB29-X1 TB29-X2 TB29-X4 TB29-X5

TB30-A1 TB30-A2 TB30-B1 TB30-B2 TB30-B3 TB30-B4

TB30-C1 TB30-C2

TB30-D1 TB30-D2 TB30-D4 TB30-G1 TB30-G2

TB30-H1 TB30-H2 TB30-J1 TB30-J2

TB30-K1 TB30-K2 TB30-K3 TB30-K4 TB30-L2 TB30-L4

TB30-M1 TB30-M2 TB30-N1 TB30-T1

TB30-W1 TB30-W4 TB30-X1 TB30-X2

Diagram10 D4 Diagram10 E4 Diagram10 E4 Diagram10 E4 Diagram10 E4 Diagram10 E4 Diagram10 E4 Diagram10 E4 Diagram10 E4 Diagram10 E4 Diagram10 E4 Diagram10 F4 Diagram10 F4 Diagram10 F4 Diagram10 F4 Diagram10 F4 Diagram10 F4 Diagram10 F4 Diagram10 F4

Diagram10 G4 Diagram10 G4 Diagram10 G4 Diagram10 G4 Diagram10 G4 Diagram10 G4

Diagram6 G18 Diagram6 G18 Diagram6 F18 Diagram6 F18 Diagram12 F19 Diagram12 F19

Diagram12 E19 Diagram12 E19 Diagram12 E19 Diagram12 E19 Diagram12 F19 Diagram12 F19 Diagram12 F19 Diagram12 F19 Diagram13 J11 Diagram13 J11

Diagram13 K11 Diagram13 J11

Diagram13 K11 Diagram13 K11 Diagram13 J11 Diagram13 J11

Diagram13 B10 Diagram13 B11 Diagram13 B11

Diagram13 K11 Diagram13 K11 Diagram13 J11 Diagram13 J11

Diagram13 L11 Diagram13 L11 Diagram13 J11 Diagram13 J11

Diagram13 K11 Diagram13 K11 Diagram13 J11

Diagram13 L11

Diagram13 K11 Diagram13 K11 Diagram13 I5

Diagram13 H5 Diagram13 H5 Diagram13 H5 Diagram6 K9 Diagram6 K9

TB30-X4

Diagram6 K9

TB31-A2

Diagram6 H9

TB31-A1 TB31-B1 TB31-B2

TB31-C1 TB31-C2

TB31-D1 TB31-D2 TB31-E1 TB31-E2 TB31-F1 TB31-F2

TB31-G1 TB31-G2 TB31-G3

TB31-H1 TB31-H2 TB31-J1 TB31-J2

TB31-K1 TB31-K2 TB31-L1 TB31-L2 TB31-L3

TB31-M1 TB31-M2 TB31-M4 TB31-N2 TB31-N3 TB31-N4 TB31-P1 TB31-P2

TB31-R1 TB31-R2 TB31-S1 TB31-S2

TB31-T1 TB31-T2

TB31-V1 TB31-V2 TB31-V4

TB31-W1 TB31-W2 TB31-W3 TB31-X1

TB32-A1 TB32-A2 TB32-B1 TB32-B2

TB32-C1 TB32-C2

TB32-D1 TB32-D2 TB32-E1 TB32-E2 TB32-F1 TB32-F2

Diagram6 H9 Diagram6 I9 Diagram6 I9 Diagram6 I9 Diagram6 I9 Diagram6 I9 Diagram6 I9

Diagram10 K4 Diagram10 K4 Diagram10 K4 Diagram10 K4 Diagram10 L4 Diagram10 L4 Diagram10 L4

Diagram10 K4 Diagram10 K4

Diagram10 O7 Diagram10 O7 Diagram10 P7 Diagram10 P7

Diagram10 O7 Diagram10 O7 Diagram10 P7 Diagram10 L4 Diagram10 L4 Diagram10 L4

Diagram10 M6 Diagram10 L4

Diagram10 M6 Diagram10 O7 Diagram10 O7 Diagram10 O7 Diagram10 O7 Diagram10 N7 Diagram10 N7 Diagram10 N7 Diagram10 N7

Diagram10 M5 Diagram10 M6 Diagram10 M6 Diagram10 M5 Diagram10 M6 Diagram10 M5 Diagram6 F8

Diagram15 I14 Diagram15 I15 Diagram15 I14 Diagram15 I15

Diagram15 J14 Diagram15 J15

Diagram13 F10 Diagram13 F11 Diagram13 F10 Diagram13 F11

Diagram13 G10 Diagram13 G11

CONNECTOR TABLE

CONNECTOR DIAGRAM

ZONE

TB32-G1

Diagram4 J12

TB32-H1

Diagram4 J12

TB32-G4

TB32-H2 TB32-J1 TB32-J4

TB32-K1 TB32-K2 TB32-K3 TB32-L2

TB32-M1 TB32-M2 TB32-N2 TB32-P1 TB32-P2

TB32-R1 TB32-R2 TB32-S1

TB32-T1

TB33-A2 TB33-B2

TB33-C1

TB33-D1 TB33-E1 TB33-F1

TB33-G1

TB33-H1 TB33-J1 TB33-J2

TB33-K1 TB33-K2 TB33-K3 TB33-L1 TB33-L2 TB33-L4

TB33-M1 TB33-M2 TB33-N1 TB33-N2 TB33-P1 TB33-P2 TB33-P3

TB33-R1 TB33-R2 TB33-R4 TB33-S1 TB33-S2

TB33-T1 TB33-T2

TB33-V1 TB33-V2

TB33-W1 TB33-W2 TB34-A1 TB34-A2 TB34-B1 TB34-B2

TB34-C1 TB34-C2

TB34-D1 TB34-D2 TB34-E1 TB34-E2 TB34-F1 TB34-F2 TB34-F4 TB34-J1 TB34-J2

TB34-K1 TB34-K2 TB34-L1

TB34-M1 TB34-M2 TB34-N1 TB34-N2 TB34-P1 TB34-P2

TB34-R1 TB34-R2 TB34-S1 TB34-S2

TB34-T1 TB34-T2

TB34-V1 TB34-V2

TB34-W1 TB34-W2 TB34-X1 TB34-X2

TB35-A1 TB35-A2 TB35-B2 TB35-B3 TB35-B4

TB35-C1 TB35-C2 TB35-C4

TB35-D1 TB35-D2 TB35-E1 TB35-E2 TB35-E4 TB35-F1 TB35-F2 TB35-F3 TB35-F4

TB35-G1 TB35-G2 TB35-G4

TB35-H1 TB35-H2 TB35-H4 TB35-J1 TB35-J2 TB35-J3 TB35-J4

TB35-K1 TB35-K2 TB35-K3 TB35-K4 TB35-L1 TB35-L2 TB35-L3

TB35-M1 TB35-M2 TB35-M3 TB35-N1 TB35-N2 TB35-P1 TB35-P2

Diagram4 J12 Diagram4 J12

Diagram7 L15 Diagram7 L15 Diagram7 I13 Diagram7 I13 Diagram7 I13

Diagram13 B13

Diagram4 H18 Diagram4 H18 Diagram4 H18 Diagram15 G9 Diagram15 G9 Diagram15 G9 Diagram15 G9

Diagram7 J13

Diagram7 M11 Diagram13 P5 Diagram13 P5 Diagram10 I4 Diagram10 I4 Diagram10 I4 Diagram10 I4

Diagram10 H4 Diagram10 I4

Diagram10 B4 Diagram10 B4 Diagram10 B4 Diagram10 B4 Diagram10 B4 Diagram10 B4 Diagram10 B4 Diagram10 B4

Diagram10 A4 Diagram10 A4

Diagram10 C4 Diagram10 C4 Diagram10 C4 Diagram10 C4 Diagram10 C4 Diagram10 C4 Diagram10 C4 Diagram10 C4 Diagram10 C4 Diagram10 C4

Diagram10 H4 Diagram10 H4 Diagram10 H4 Diagram10 H4 Diagram10 H4 Diagram10 H4 Diagram8 J5 Diagram8 J6

Diagram8 K5 Diagram8 K5 Diagram8 L5 Diagram8 L5

Diagram9 B14 Diagram9 B14 Diagram9 B8 Diagram9 B9 Diagram8 L9 Diagram8 L9 Diagram8 L9

Diagram9 F5 Diagram9 F6 Diagram9 F5 Diagram9 F6

Diagram9 F11

Diagram13 N11 Diagram13 N11 Diagram8 E16 Diagram8 E16 Diagram14 G8 Diagram14 G8 Diagram14 G8 Diagram14 G8 Diagram14 G8 Diagram14 G8 Diagram4 B5 Diagram4 B5 Diagram14 I7 Diagram14 I8

Diagram14 L13 Diagram14 L13

Diagram14 K13 Diagram14 K13

Diagram11 M12 Diagram11 M13 Diagram11 M13 Diagram11 M12 Diagram11 M13 Diagram13 D10 Diagram13 D11 Diagram13 D11 Diagram12 P4 Diagram12 P4

Diagram9 I14 Diagram9 I14 Diagram9 I14

Diagram6 G18 Diagram6 G19 Diagram6 G18 Diagram6 G19 Diagram11 H9

Diagram11 H10 Diagram11 H10 Diagram11 H9

Diagram11 H10 Diagram11 H10 Diagram9 K14 Diagram9 K14 Diagram9 K14 Diagram9 K14 Diagram9 K14 Diagram9 K14 Diagram9 K14 Diagram9 K14

Diagram11 C12 Diagram11 C13

Diagram11 D12 Diagram10 E17 Diagram10 E17 Diagram10 F17

Diagram10 O14 Diagram10 O14 Diagram8 F16 Diagram8 F16

CONNECTOR TABLE

CONNECTOR DIAGRAM

ZONE

TB35-R1

Diagram13 M11

TB35-R3

Diagram13 M11

TB35-R2 TB35-R4 TB35-S1 TB35-S2 TB35-S3 TB35-S4

TB35-T1 TB35-T2

TB35-V1 TB35-V2

TB35-W1 TB35-W2 TB35-W3 TB36-A1 TB36-A2 TB36-B1 TB36-B2

TB36-C1 TB36-C2 TB36-C3 TB36-C4

TB36-D1 TB36-D2 TB36-E1 TB36-E2 TB36-F1 TB36-F2 TB36-F4

TB36-G1 TB36-G2 TB36-G4

TB36-H1 TB36-H2 TB36-H4 TB36-J1 TB36-J2 TB36-J3 TB36-J4 TB36-J5

TB36-K1 TB36-K2 TB36-K3 TB36-K4 TB36-K5 TB36-L1 TB36-L2 TB36-L4

TB36-M1 TB36-M2 TB36-M4

Diagram13 M12 Diagram13 M12 Diagram12 F5 Diagram12 F5

Diagram12 G5 Diagram12 G5

Diagram8 G12 Diagram8 G12 Diagram12 F4 Diagram12 F4

Diagram13 L11 Diagram13 L11 Diagram13 L11 Diagram14 L7 Diagram14 L8 Diagram14 L7 Diagram14 L8 Diagram14 L7 Diagram14 L8 Diagram14 L7 Diagram14 L8

Diagram14 N7 Diagram14 N8 Diagram14 N7 Diagram14 N8 Diagram12 K5 Diagram12 K5 Diagram12 K5 Diagram12 K5 Diagram12 K5 Diagram12 K5 Diagram12 L5 Diagram12 L5 Diagram12 L5 Diagram12 L5 Diagram12 L5

Diagram14 M7 Diagram14 M8 Diagram12 L5

Diagram14 N14 Diagram14 N15 Diagram14 N14 Diagram14 N14 Diagram14 N15

Diagram14 M14 Diagram14 M15 Diagram14 M15 Diagram14 N14 Diagram14 N15 Diagram14 N15

TB36-N1

Diagram14 N14

TB36-N4

Diagram14 N15

TB36-N2 TB36-P1 TB36-P2

TB36-R1 TB36-R2 TB36-R4 TB36-S1 TB36-S2

TB36-T1 TB36-T2

TB60-A1 TB60-A2 TB60-B1 TB60-B2

TB60-D1 TB60-D2 TB60-D4 TB60-E1 TB60-E2 TB60-E4 TB60-F1 TB60-F2 TB60-F3 TB60-F4

TB60-G1 TB60-G2

TB60-H1 TB60-H2 TB60-J1 TB60-J2

TB60-K1 TB60-K2 TB60-L1 TB60-L2

TB60-M1 TB60-M2 TB61-A1 TB61-A2 TB61-A4 TB61-B1 TB61-B2

TB61-C1

TB61-D1 TB61-D2 TB61-E1 TB61-E2 TB61-F1 TB61-F2

TB61-G1 TB61-G2

TB61-H1 TB61-H2 TB61-J1 TB61-J2

TB61-M1 TB61-M2 TB61-M4

VEC89-P1 VEC89-P1 VEC89-P1 VEC89-P1 VEC89-P1 VEC89-P1 VEC89-P1 VEC89-P2 VEC89-P2 VEC89-P2 VEC89-P2 VEC89-P2 VEC89-P2 VEC89-P2 VEC89-P4 VEC89-P4 VEC89-P4 VEC89-P4 VEC89-P4

Diagram14 N15 Diagram14 J13 Diagram14 J14 Diagram14 J13 Diagram14 J14

Diagram14 K14 Diagram14 J13 Diagram14 J14 Diagram14 J13 Diagram14 J14

Diagram11 G12 Diagram11 G13 Diagram13 L15 Diagram13 L15

Diagram11 H12 Diagram11 H13 Diagram11 H13 Diagram11 H12 Diagram11 H13 Diagram11 H13 Diagram11 C15 Diagram11 C16

Diagram11 D16 Diagram11 D16 Diagram11 C15 Diagram11 C16

Diagram11 G12 Diagram11 G13

Diagram10 N17 Diagram10 N18 Diagram10 N17 Diagram10 N18

Diagram11 M15 Diagram11 M15 Diagram13 L15 Diagram13 L15

Diagram11 B15 Diagram11 B16 Diagram11 B16 Diagram11 B15 Diagram11 B16 Diagram11 B15 Diagram14 N4 Diagram14 N4 Diagram14 N4 Diagram14 N4 Diagram14 N4 Diagram14 N4 Diagram14 N4 Diagram14 N4

CONNECTOR TABLE

CONNECTOR DIAGRAM

ZONE

VEC89-P4

Diagram13 N10

VEC89-P9

Diagram8 N5

VEC89-P4 VEC89-P9 VEC89-P9

Diagram13 N12 Diagram8 O5 Diagram11 D7

VEC89-P11 Diagram9 I9

VEC89-P11 Diagram9 I12 VEC89-P11 Diagram11 D5 VEC89-P11 Diagram11 D8 VEC89-P11 Diagram11 G5 VEC89-P12 Diagram8 L6

VEC89-P12 Diagram9 G11 VEC89-P12 Diagram9 K9

VEC89-P12 Diagram9 K12 VEC89-P12 Diagram11 H8

VEC89-S5A Diagram5 B14 VEC89-S6A Diagram5 B14 VEC89-S7A Diagram5 B14

VEC89-S8A Diagram5 C14 VEC90-P1

Diagram4 D9

VEC90-P1

Diagram7 H10

VEC90-P1 VEC90-P1 VEC90-P2 VEC90-P2 VEC90-P2 VEC90-P2 VEC90-P3 VEC90-P3 VEC90-P3 VEC90-P4 VEC90-P4 VEC90-P4 VEC90-P4 VEC90-P4 VEC90-P9 VEC90-P9 VEC90-P9

Diagram4 D12 Diagram12 G20 Diagram4 B6 Diagram4 B8

Diagram14 H9

Diagram14 H12 Diagram4 B6

Diagram4 C12

Diagram14 G12

Diagram4 D12 Diagram12 C7 Diagram12 C9 Diagram14 I6

Diagram15 G7

Diagram7 G10 Diagram7 K10 Diagram7 L7

VEC90-P11 Diagram7 I10

VEC90-P11 Diagram7 L10 VEC90-P12 Diagram7 J10

VEC90-S7A Diagram5 D14 VEC90-S7B Diagram5 D14 VEC90-S8A Diagram5 C14

VEC90-S8B Diagram5 D14 VEC91-P1

Diagram10 A5

VEC91-P1

Diagram10 C5

VEC91-P1 VEC91-P1 VEC91-P1 VEC91-P1 VEC91-P2 VEC91-P2 VEC91-P2 VEC91-P2 VEC91-P2 VEC91-P2 VEC91-P2 VEC91-P3 VEC91-P3 VEC91-P3 VEC91-P3 VEC91-P4 VEC91-P4 VEC91-P4 VEC91-P4 VEC91-P4 VEC91-P4 VEC91-P4 VEC91-P4 VEC91-P9 VEC91-P9 VEC91-P9 VEC91-P9 VEC91-P9 VEC91-P9

Diagram10 A7

Diagram10 C7

Diagram14 L15 Diagram14 L17

Diagram4 K15

Diagram6 A11 Diagram6 B11 Diagram6 B11 Diagram6 B11

Diagram8 G15 Diagram10 F5

Diagram4 K13 Diagram4 K13 Diagram9 K3 Diagram10 F7

Diagram4 K13 Diagram4 L13 Diagram6 L10 Diagram6 L10

Diagram10 D14

Diagram11 M11 Diagram12 G20 Diagram15 F7

Diagram5 C17 Diagram5 O5 Diagram6 J9

Diagram8 G15

Diagram10 H15 Diagram10 L15

VEC91-P10 Diagram5 C6 VEC91-P10 Diagram5 C7 VEC91-P10 Diagram5 L3

VEC91-P10 Diagram10 M15 VEC91-P10 Diagram11 K3

VEC91-P11 Diagram5 M5 VEC91-P11 Diagram5 M5 VEC91-P11 Diagram5 M6 VEC91-P11 Diagram9 K3 VEC91-P12 Diagram5 L6

VEC91-P12 Diagram6 B11

VEC91-P12 Diagram6 C11 VEC91-P12 Diagram6 C14 VEC91-P12 Diagram6 C14 VEC91-S5A Diagram5 F14

VEC91-S6A Diagram5 E14 VEC91-S6B Diagram5 E14 VEC91-S7A Diagram5 E14 VEC91-S8A Diagram5 E14 VHMS

Diagram12 F21

WADT-2

Diagram11 M8

WADT-1

WADT-4 WADT-6 WIF

WW+ WW-

Diagram11 M8 Diagram11 M8 Diagram11 M8 Diagram6 H4

Diagram11 N8 Diagram11 N8

Diagram12 F9 Diagram12 F9 Diagram12 F9 Diagram12 F9

Diagram11 F13 Diagram11 F13 Diagram11 F13

Diagram9 B10 Diagram9 B13 Diagram11 H5 Diagram11 H8

Diagram13 C15 Diagram14 B3

Diagram14 C6 Diagram8 I5

Diagram10 D6 Diagram10 D7

Diagram10 H10 Diagram13 B15 Diagram13 B17

Diagram13 M12 Diagram7 A10 Diagram7 E18

Diagram9 C10 Diagram12 P2

Diagram13 C16

58E-06-02000-00 NOV 11 ELECTRICAL SCHEMATIC 830E-1AC A40851 & UP Sheet 20 of 20