Shopmanual 980E5 - Unlocked

CEBM033000
Shop
Manual
980E-5
DUMP TRUCK
SERIAL NUMBERS 980E-5 A50003 and up
ENGINE 18V170
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2018 Komatsu

Printed in U.S.A.
Komatsu America Corp.
November 2018
CEN00042-00
DUMP TRUCK 1SHOP MANUAL
980E
Machine model Serial number

980E-5 A50005 and up
00 Index and foreword

Index
Composition of shop manual ................................................................................................................................ 2
Table of contents................................................................................................................................................... 4
1
CEN00042-00 00 Index and foreword
Composition of shop manual

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
: New module (to be filed additionally) : Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tab No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accordingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs CEBM033000

Index CEN00042-00
Foreword, safety and general information CEN00044-00
01 Specification
Specification and technical data CEN01020-00
10 Structure, function and maintenance standard

Steering circuit CEN10062-01
Hoist circuit CEN10067-00
Brake circuits CEN10068-00
Electrical system, 24 volt CEN10089-00
Cab air conditioning CEN10088-00
Automatic lubrication (auto lube) system CEN10080-00
20 Standard value table

Standard service value table CEN20005-02
30 Testing and adjusting

Steering, brake cooling and hoist hydraulic system CEN30071-01
Brake system CEN30072-03
Accumulators and suspensions CEN30098-02
Electrical systems CEN30104-00
Interface module (IM) CEN30103-00
KOMTRAX Plus II CEN30091-00
Payload meter IV CEN30070-01
Komatsu Wireless Bridge (KWB) CEN30101-00
KomVision CEN30105-00
2
00 Index and foreword CEN00042-00
40 Troubleshooting
Fuse, diode and relay locations CEN40199-00
Troubleshooting by failure code, Part 1 CEN40178-00
Steering system CEN40104-03
50 Disassembly and assembly

Service tools CEN50046-02
Wheels, spindles and rear axle CEN50047-02
Suspensions CEN50049-01
Body and structures CEN50077-00
Operator cab CEN50079-00
Power module CEN50078-00
90 Diagrams and drawings

Hydraulic circuit diagrams CEN90014-00
Electrical circuit diagrams CEN90028-00
3
Table of contents

Index CEN00042-00
Composition of shop manual ....................................................................................................2
Table of contents .......................................................................................................................4
Foreword, safety and general information CEN00044-00
Foreword ...................................................................................................................................4
How to read the shop manual ...................................................................................................5
General safety ...........................................................................................................................7
Precautions before operating the truck ...................................................................................10
Precautions while operating the truck .....................................................................................12
Working near batteries ............................................................................................................15
Precautions before performing service....................................................................................17
Precautions while performing service......................................................................................20
Tires ........................................................................................................................................22
Precautions for performing repairs ..........................................................................................25
Precautions for welding on the truck .......................................................................................26
Capacitor discharge system ....................................................................................................27
Actions taken to meet exhaust gas regulations.......................................................................35
Precautions for DEF ................................................................................................................36
Handling electrical equipment and hydraulic components ......................................................39
Standard tightening torques ....................................................................................................47
Conversion tables....................................................................................................................52
01 Specification
Specification and technical data CEN01020-00
Specification drawing.................................................................................................................3
Specifications ............................................................................................................................4
Weight table ..............................................................................................................................6
Fuel, coolant and lubricants ......................................................................................................7
10 Structure, function and maintenance standard

Steering circuit CEN10062-02
Steering circuit operation...........................................................................................................2
Steering circuit components ......................................................................................................7
Steering/brake pump operation .................................................................................................9
Flow amplifier operation ..........................................................................................................12
Hoist circuit operation................................................................................................................3
Hoist circuit components ...........................................................................................................4
Hoist pilot valve operation .........................................................................................................8
Brake circuits CEN10068-00
General information...................................................................................................................3
Service brake circuit operation ..................................................................................................4
4
Secondary braking .................................................................................................................... 6

Automatic brake application (Auto apply).................................................................................. 6
Parking brake circuit operation.................................................................................................. 7
Wheel brake lock circuit operation ............................................................................................ 8
Brake warning circuit operation................................................................................................. 8
Brake assembly wear data ...................................................................................................... 10
Electrical system, 24V CEN10089-00
Battery supply system ............................................................................................................... 3
Isolation box .............................................................................................................................. 4
Engine starting system with prelube ......................................................................................... 5
Auxiliary control cabinet components........................................................................................ 7
Body-up switch.......................................................................................................................... 9
Hoist limit switch...................................................................................................................... 10
General information................................................................................................................... 2
Principles of refrigeration .......................................................................................................... 3
Air conditioning system components......................................................................................... 5
Air conditioning system electrical circuit.................................................................................... 9
System operation ...................................................................................................................... 3

Standard value table CEN20005-02
Standard value table for truck ................................................................................................... 3

Steering, hoist, brake cooling and auxiliary hydraulic system CEN30071-03
Hydraulic system bleeddown procedure ................................................................................... 3
General information on system checkout.................................................................................. 5
Hydraulic system checkout procedures .................................................................................... 6
Hydraulic system checkout data sheet.................................................................................... 16
Toe-in adjustment.................................................................................................................... 19
Hoist cylinder leakage test ...................................................................................................... 20
Steering cylinder leakage test .................................................................................................20
General information on system checkout.................................................................................. 3
Brake system checkout procedures .......................................................................................... 3
Brake system checkout data sheet ......................................................................................... 14
Brake piston leakage test........................................................................................................ 22
Brake seal pressure test ......................................................................................................... 22
Oil separator seal pressure test .............................................................................................. 22
Wet disc brake bleeding procedure......................................................................................... 23
Parking brake bleeding procedure .......................................................................................... 24
Service brake disc wear inspection......................................................................................... 25
Parking brake disc wear inspection......................................................................................... 26
5
Brake valve bench test and adjustment ..................................................................................27

Dual relay valve bench test and adjustment............................................................................30
Accumulators and suspensions CEN30098-03
Accumulator charging and storage............................................................................................2
Bladder accumulator charging procedure .................................................................................3
Bladder accumulator leak testing ..............................................................................................6
Piston accumulator charging procedure....................................................................................7
Piston accumulator storage.....................................................................................................10
Piston accumulator leak testing...............................................................................................10
Checking for improper suspension charge.............................................................................. 11
Suspension oiling and charging procedures ...........................................................................12
Suspension pressure test........................................................................................................21
Electrical systems CEN30104-00
General information on system checkout ..................................................................................3
Truck shutdown procedure ........................................................................................................4
Required software and tools......................................................................................................4
Electrical system checkout procedures .....................................................................................6
Electrical checkout sheet.........................................................................................................10
Interface module (IM) CEN30103-00
Interface module checkout procedures .....................................................................................4
IM checkout sheet .....................................................................................................................8
KOMTRAX Plus II CEN30091-00
Ethernet connection to KOMTRAX Plus II controller.................................................................3
KOMTRAX Plus II configuration ................................................................................................5
GPS connection test..................................................................................................................7
Iridium satellite system opening ................................................................................................9
Data download over ethernet connection for KOMTRAX Plus II initialization ......................... 11
Payload meter IV CEN30070-01
Payload meter IV software and tools.........................................................................................2
Payload meter IV system configuration.....................................................................................2
Payload meter IV software installation ......................................................................................4
Payload meter IV checkout procedure ......................................................................................5
PLM IV system checkout data sheet .........................................................................................9
Komatsu wireless bridge (KWB) CEN30101-00
General information...................................................................................................................2
Configuring the Bullet wireless radio .........................................................................................3
Installing the Bullet wireless radio .............................................................................................6
Configuring the NanoStation access point ................................................................................7
Testing the connection.............................................................................................................10
Changing a service computer’s IP address............................................................................. 11
Requirements ............................................................................................................................2
Initial setup ................................................................................................................................2
6
KomVision checkout data sheet ................................................................................................ 9

Calibration sheets ................................................................................................................... 14
Camera calibration procedures ............................................................................................... 21
Radar setting procedure.......................................................................................................... 31
Service tools and equipment..................................................................................................... 4
Detecting leaks.......................................................................................................................... 7
System performance test .......................................................................................................... 8
Checking system oil .................................................................................................................. 9
System flushing....................................................................................................................... 10
Installing the manifold gauge set............................................................................................. 11
Recovering and recycling refrigerant ...................................................................................... 12
Evacuating the air conditioning system................................................................................... 14
Charging the air conditioning system ...................................................................................... 15
Priming the system.................................................................................................................... 3
Checkout procedure.................................................................................................................. 4
Adjusting the lubrication cycle timing ........................................................................................ 5
40 Troubleshooting
Fuse, diode and relay locations CEN40199-00
Vehicle Electrical Center (VEC-89) ........................................................................................... 2
Rear Terminal Mini-fuse and Relay (RTMR3) ........................................................................... 9
Rear Terminal Mini-fuse and Relay (RTMR4) ......................................................................... 10
Circuit breakers ....................................................................................................................... 10
Troubleshooting by fault code, Part 1 CEN40178-00
Fault Code A001: Left front suspension pressure sensor signal high ....................................... 4
Fault Code A002: Left front suspension pressure sensor signal low ........................................ 6
Fault Code A003: Right front suspension pressure sensor signal high .................................... 8
Fault Code A004: Right front suspension pressure sensor signal low .................................... 10
Fault Code A005: Left rear suspension pressure sensor signal high...................................... 12
Fault Code A006: Left rear suspension pressure sensor signal low ....................................... 14
Fault Code A007: Right rear suspension pressure sensor signal high ................................... 16
Fault Code A008: Right rear suspension pressure sensor signal low..................................... 18
Fault Code A011: Payload meter speed sensor signal has failed ...........................................20
Fault Code A013: Body up switch has failed........................................................................... 22
Fault Code A014: Payload meter checksum computation has failed ...................................... 24
Fault Code A016: A payload meter write to flash memory has failed ..................................... 25
Fault Code A017: A payload memory flash memory read has failed ...................................... 26
Fault Code A018: Right rear flat suspension cylinder warning ............................................... 28
Fault Code A019: Left rear flat suspension cylinder warning .................................................. 30
Fault Code A022: Carryback load excessive .......................................................................... 32
7
Fault Code A101: High pressure detected across a hydraulic pump filter ..............................34
Fault Code A103: Hydraulic Oil Temp - Tank Sensor Low ......................................................36
Fault Code A104: Hydraulic Oil Temp - Tank Sensor High......................................................37
Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level .......38
Fault Code A109: GE has generated a propel system reduced level signal ...........................40
Fault Code A111: Low steering pressure warning ...................................................................42
Fault Code A115: Low steering precharge pressure detected ................................................44
Fault Code A117: Low brake accumulator pressure warning ..................................................46
Fault Code A118: Brake pressure is low while in brake lock ...................................................48
Fault Code A123: GE has generated a reduced retarding caution .........................................50
Fault Code A124: GE has generated a no propel / no retard or system not running input .....52
Fault Code A125: GE has generated a no propel warning......................................................56
Fault Code A126: Oil level in the hydraulic tank is low............................................................58
Fault Code A127: IM-furnished +5 volt output for sensors is low ............................................59
Fault Code A128: IM-furnished +5 volt output for sensors is high ..........................................60
Fault Code A139: Low fuel warning ........................................................................................62
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm
to advance level 1 for cooling of hydraulic oil............................................................................4
Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm
to advance level 2 for cooling of hydraulic oil............................................................................6
Fault Code A152: Starter failure ................................................................................................8
Fault Code A153: Battery voltage is low with the truck in operation .......................................10
Fault Code A154: Battery charging voltage is excessive ........................................................14
Fault Code A155: Battery charging voltage is low...................................................................16
Fault Code A158: Fuel level sensor is open or shorted high, indicating
a false low fuel level ................................................................................................................18
Fault Code A166: Left rear hydraulic oil temperature sensor is low ........................................20
Fault Code A167: Right rear hydraulic oil temperature sensor is low .....................................22
Fault Code A168: Left front hydraulic oil temperature sensor is low .......................................24
Fault Code A169: Right front hydraulic oil temperature sensor is low.....................................26
Fault Code A170: Left rear hydraulic oil temperature sensor is high ......................................28
Fault Code A172: Left front hydraulic oil temperature sensor is high......................................30
Fault Code A173: Right front hydraulic oil temperature sensor is high ...................................31
Fault Code A184: The J1939 data link is not connected.........................................................32
Fault Code A190: The auto lube control has detected an incomplete lube cycle....................34
Fault Code A193: Hydraulic Tank Oil Temperature is high......................................................37
Fault Code A194: Left front hydraulic oil temperature is high .................................................38
Fault Code A195: Right front hydraulic oil temperature is high ...............................................40
Fault Code A196: Left rear hydraulic oil temperature is high ..................................................42
Fault Code A197: Right rear hydraulic oil temperature is high................................................44
Fault Code A198: Hoist Pressure 1 Sensor is high .................................................................46
Fault Code A199: Hoist Pressure 2 Sensor is high .................................................................47
Fault Code A200: Steering Pressure Sensor High ..................................................................48
Fault Code A201: Brake Pressure Sensor High......................................................................49
Fault Code A202: Hoist Pressure 1 Sensor Low.....................................................................50
8
Fault Code A203: Hoist Pressure 2 Sensor Low..................................................................... 52

Fault Code A204: Steering Pressure Sensor Low................................................................... 54
Fault Code A205: Brake Pressure Sensor Low ...................................................................... 56
Fault Code A206: Ambient Temperature Sensor High ............................................................ 58
Fault Code A207: Ambient Temperature Sensor Low............................................................. 59
Fault Code A213: The parking brake should have applied but is detected as
not having applied ................................................................................................................... 60
Fault Code A214: The parking brake should have released but is detected as
not having released................................................................................................................. 64
Fault Code A215: Brake auto apply valve circuit is defective ................................................. 70
Fault Code A216: An open or short to ground has been detected in the park brake
command valve circuit............................................................................................................. 74
Fault Code A223: Excessive engine cranking has occurred or a jump start
has been attempted ................................................................................................................ 78
Fault Code A230: Park brake has been requested while truck still moving ............................ 82
Fault Code A231: The body is up while traveling or intending to travel .................................. 86
Fault Code A233: Drive system CAN/RPC Control Link not connected ................................. 90
Fault Code A235: Steering accumulator is in the process of being bled down ....................... 94
Fault Code A236: The steering accumulator has not properly bled after 90 seconds ............ 98
Fault Code A237: The CAN/RPC connection to the Display is open .................................... 101
Fault Code A240: The keyswitch input to the Interface Module is open ............................... 102
Fault Code A242: The fuel gauge within the display panel is defective ................................ 103
Fault Code A243: The engine coolant temp gauge within the display panel
is defective ............................................................................................................................ 104
Fault Code A244: Drive system temperature gauge within the dash display panel
is defective ............................................................................................................................ 105
Fault Code A245: The hydraulic oil temp gauge within the display panel is defective .......... 106
Fault Code A246: PLM reports truck overload ...................................................................... 107
Fault Code A247: Low steering pressure warning .................................................................... 4
Fault Code A248: Status module within the dash display panel is defective............................. 6
Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted ........... 8
Fault Code A250: Battery voltage is low with the truck parked ............................................... 10
Fault Code A251: Sonalert used with the dash display (driven by IM) is open or
shorted to ground .................................................................................................................... 14
Fault Code A252: Start enable output circuit is either open or shorted to ground................... 16
Fault Code A253: Steering bleed circuit is not open while running ......................................... 18
Fault Code A256: Red warning lamp in the dash display (driven by IM) is open .................... 20
Fault Code A257: Payload CAN/RPC is not connected.......................................................... 22
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective ................ 24
Fault Code A260: Parking brake failure .................................................................................. 26
Fault Code A261: Low brake accumulator pressure warning ................................................. 30
Fault Code A262: Steering bleed valve circuit open during shutdown .................................... 32
Fault Code A264: Parking brake relay circuit is defective ....................................................... 36
Fault Code A265: Service brake failure .................................................................................. 38
Fault Code A266: Shift lever was not in park while attempting to crank engine...................... 40
9
Fault Code A267: Parking brake was not set while attempting to crank engine .....................42
Fault Code A268: Secondary engine shutdown while cranking ..............................................44
Fault Code A270: Brake lock switch power supply is not on when required ...........................46
Fault Code A272: Brake lock switch power supply is not off when required ...........................50
Fault Code A272: Brake lock switch power supply is not off when required ...........................50
Fault Code A273: A fault has been detected in the hoist or steering pump filter
pressure switch circuit .............................................................................................................54
Fault Code A274: A brake setting fault has been detected .....................................................56
Fault Code A275: A starter has been detected as engaged without a cranking attempt ........58
Fault Code A277: Parking brake applied while loading...........................................................60
Fault Code A278: Service brake applied while loading ...........................................................62
Fault Code A279: Low Steering Pressure Switch bad.............................................................64
Fault Code A280: Steering accumulator bleed down switch is defective ................................66
Fault Code A281: Brake lock degrade switch is defective ......................................................68
Fault Code A282: The number of excessive cranking counts and jump starts
without the engine running has reached 7 ..............................................................................70
Fault Code A283: An engine shutdown delay was aborted because the parking brake
was not set ..............................................................................................................................74
Fault Code A284: An engine shutdown delay was aborted because the secondary
shutdown switch was operated ...............................................................................................78
Fault Code A285: The parking brake was not set when the keyswitch was turned off............80
Fault Code A286: A fault was detected in the shutdown delay relay circuit ............................82
Fault Code A292: The shutdown delay relay has remained on after the latched
key switch circuit is off .............................................................................................................84
Fault Code A303: Shift lever is defective ..................................................................................4
Fault Code A304: Auto lube grease level fault ..........................................................................6
Fault Code A307: Both GE inverters are disabled ....................................................................7
Fault Code A309: No brakes applied when expected ...............................................................8
Fault Code A310: Low fuel warning ........................................................................................12
Fault Code A311: Brake lock switch is on when it should not be ............................................14
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings...........18
Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings...........20
Fault Code A315: DCDC converter 12 volt circuit is low .........................................................22
Fault Code A316: Starter engagement has been attempted with engine running...................24
Fault Code A317: Operation of brake auto apply circuit without a detected response............28
Fault Code A318: Unexpected power loss to interface module ..............................................32
Fault Code A328: Drive system not powered up.....................................................................33
Fault Code A332: Seat belt not buckled..................................................................................34
Fault Code A333: The hydraulic ladder controller has declared a ladder fault........................38
Fault Code A334: Selector switch not in park when propel was either not ready or at rest ....40
Fault Code A337: Engine Air Filter Circuit Fault......................................................................42
Fault Code A338: Engine Air Filter Fault.................................................................................44
Fault Code A339: The diesel exhaust fluid level gauge within the display panel
is defective ..............................................................................................................................46
Fault Code A340: The shifter controller has declared a fault ..................................................48
10
Fault Code A341: The shifter control circuit is defective ......................................................... 50

Fault Code A342: The Accessory Pump Filter Switch has actuated ....................................... 52
Fault Code A343: Truck speed is limited by GE...................................................................... 54
Fault Code A344: GE has posted a No Retarding fault .......................................................... 55
Fault Code A345: Engine speed limited by GE....................................................................... 56
Fault Code A346: Delayed Shut Down by GE ........................................................................ 57
Fault Code A347: Operator Override of GE is active .............................................................. 58
Fault Code A348: GE has disabled load box operation .......................................................... 59
Fault Code A349: GE has limited load box operation ............................................................. 60
Fault Code A350: Overload on output 1B ............................................................................... 62
Fault Code A351: Overload on output 1E ............................................................................... 64
Fault Code A352: Overload on output 1H ............................................................................... 66
Fault Code A353: Overload on output 1J................................................................................ 68
Fault Code A354: Overload on output 1K ............................................................................... 70
Fault Code A355: Overload on output 1L................................................................................ 71
Fault Code A356: Overload on output 1M............................................................................... 72
Fault Code A357: Overload on output 1N ............................................................................... 74
Fault Code A358: Overload on output 1P ............................................................................... 76
Fault Code A359: Overload on output 1R ............................................................................... 78
Fault Code A360: Overload on output 1S ............................................................................... 80
Fault Code A361: Overload on output 1T ............................................................................... 82
Fault Code A362: Overload on output 1U ............................................................................... 84
Fault Code A363: Overload on output 1X ............................................................................... 85
Fault Code A364: Overload on output 1Y ............................................................................... 86
Fault Code A365: Overload on output 1Z ............................................................................... 87
Fault Code A366: Axle box cooling fault ................................................................................. 88
Fault Code A400: Tire 1 (Front Left) High Pressure RED Fault ................................................ 4
Fault Code A401: Tire 1 (Front Left) High Pressure AMBER Fault........................................... 5
Fault Code A402: Tire 1 (Front Left) Low Pressure RED Fault................................................. 6
Fault Code A403: Tire 1 (Front Left) Low Pressure AMBER Fault............................................ 7
Fault Code A404: Tire 1 (Front Left) No Data / Sensor Failure / Not Connected Fault ............. 8
Fault Code A405: Tire 1 (Front Left) High Temperature RED Fault .......................................... 9
Fault Code A406: Tire 1 (Front Left) High Temperature AMBER Fault ................................... 10
Fault Code A407: Tire 1 (Front Left) Bad Value Sensor Error / Not Connected Fault............. 11
Fault Code A408: Tire 2 (Front Right) High Pressure RED Fault............................................ 12
Fault Code A409: Tire 2 (Front Right) High Pressure AMBER Fault ...................................... 13
Fault Code A410: Tire 2 (Front Right) Low Pressure RED Fault ............................................ 14
Fault Code A411: Tire 2 (Front Right) Low Pressure AMBER Fault ....................................... 15
Fault Code A412: Tire 2 (Front Right) No Data / Sensor Failure / Not Connected Fault ........ 16
Fault Code A413: Tire 2 (Front Right) High Temperature RED Fault...................................... 17
Fault Code A414: Tire 2 (Front Right) High Temperature AMBER Fault................................. 18
Fault Code A415: Tire 2 (Front Right) Bad Value Sensor Error / Not Connected Fault .......... 19
Fault Code A416: Tire 3 (Rear Left Outboard) High Pressure RED Fault............................... 20
Fault Code A417: Tire 3 (Rear Left Outboard) High Pressure AMBER Fault ......................... 21
Fault Code A418: Tire 3 (Rear Left Outboard) Low Pressure RED Fault ............................... 22
11
Fault Code A419: Tire 3 (Rear Left Outboard) Low Pressure AMBER Fault ..........................23
Fault Code A420: Tire 3 (Rear Left Outboard) No Data / Sensor Failure /
Not Connected Fault ...............................................................................................................24
Fault Code A421: Tire 3 (Rear Left Outboard) High Temperature RED Fault .........................25
Fault Code A422: Tire 3 (Rear Left Outboard) High Temperature AMBER Fault....................26
Fault Code A423: Tire 3 (Rear Left Outboard) Bad Value Sensor Error /
Fault Code A424: Tire 4 (Rear Left Inboard) High Pressure RED Fault..................................28
Fault Code A425: Tire 4 (Rear Left Inboard) High Pressure AMBER Fault ............................29
Fault Code A426: Tire 4 (Rear Left Inboard) Low Pressure RED Fault ..................................30
Fault Code A427: Tire 4 (Rear Left Inboard) Low Pressure AMBER Fault .............................31
Fault Code A428: Tire 4 (Rear Left Inboard) No Data / Sensor Failure /
Fault Code A429: Tire 4 (Rear Left Inboard) High Temperature RED Fault............................33
Fault Code A430: Tire 4 (Rear Left Inboard) High Temperature AMBER Fault.......................34
Fault Code A431: Tire 4 (Rear Left Inboard) Bad Value Sensor Error /
Fault Code A432: Tire 5 (Rear Right Inboard) High Pressure RED Fault ...............................36
Fault Code A433: Tire 5 (Rear Right Inboard) High Pressure AMBER Fault ..........................37
Fault Code A434: Tire 5 (Rear Right Inboard) Low Pressure RED Fault ................................38
Fault Code A435: Tire 5 (Rear Right Inboard) Low Pressure AMBER Fault...........................39
Fault Code A436: Tire 5 (Rear Right Inboard) No Data / Sensor Failure /
Fault Code A437: Tire 5 (Rear Right Inboard) High Temperature RED Fault .........................41
Fault Code A438: Tire 5 (Rear Right Inboard) High Temperature AMBER Fault ....................42
Fault Code A439: Tire 5 (Rear Right Inboard) Bad Value Sensor Error /
Fault Code A440: Tire 6 (Rear Right Outboard) High Pressure RED Fault ............................44
Fault Code A441: Tire 6 (Rear Right Outboard) High Pressure AMBER Fault .......................45
Fault Code A442: Tire 6 (Rear Right Outboard) Low Pressure RED Fault .............................46
Fault Code A443: Tire 6 (Rear Right Outboard) Low Pressure AMBER Fault ........................47
Fault Code A444: Tire 6 (Rear Right Outboard) No Data / Sensor Failure /
Fault Code A445: Tire 6 (Rear Right Outboard) High Temperature RED Fault.......................49
Fault Code A446: Tire 6 (Rear Right Outboard) High Temperature AMBER Fault .................50
Fault Code A447: Tire 6 (Rear Right Outboard) Bad Value Sensor Error /
Steering circuit troubleshooting chart ........................................................................................2
Steering circuit troubleshooting guidelines ................................................................................4
Basic hydraulic system checks..................................................................................................5
System leakage check ..............................................................................................................6
Steering pump troubleshooting guide........................................................................................8
Pump pressure control checks ................................................................................................ 11
KomVision fault codes...............................................................................................................3
12

Service tools CEN50046-02
Special tool group...................................................................................................................... 3
Additional service tools ............................................................................................................. 3
KomVision calibration tools ....................................................................................................... 4
Locally made tools .................................................................................................................... 4
Wheels, spindles and rear axle CEN50047-02
General precautions for tires and rims ...................................................................................... 3
Rim components ....................................................................................................................... 4
Wheel stud maintenance........................................................................................................... 5
Removal and installation of front wheel .................................................................................... 6
Removal and installation of rear wheel ..................................................................................... 8
Rim and tire service ................................................................................................................ 11
Removal and installation of front wheel hub and spindle ........................................................25
Disassembly and assembly of front wheel hub and spindle.................................................... 32
Hub floating ring seal assembly and installation ..................................................................... 49
Removal and installation of rear axle ...................................................................................... 56
Removal and installation of anti-sway bar............................................................................... 59
Removal and installation of pivot pin....................................................................................... 62
Pivot eye and bearing service ................................................................................................. 64
Removal and installation of wheel motor ................................................................................ 66
Removal and installation of rear brake assembly ................................................................... 73
Removal and installation of brake valve.................................................................................... 3
Disassembly and assembly of brake valve ............................................................................... 5
Removal and installation of dual relay valve ............................................................................. 8
Removal and installation of brake manifold ............................................................................ 10
Disassembly and assembly of brake manifold ........................................................................ 11
Removal and installation of piston brake accumulator ............................................................ 13
Disassembly and assembly of piston brake accumulator ....................................................... 15
Disassembly and assembly of front wheel brake .................................................................... 19
Disassembly and assembly of rear wheel brake..................................................................... 25
Brake floating ring seal assembly and installation .................................................................. 33
Removal and installation of parking brake .............................................................................. 40
Disassembly and assembly of parking brake .......................................................................... 42
Removal and installation of steering control unit....................................................................... 3
Disassembly and assembly of steering control unit .................................................................. 5
Removal and installation of steering column........................................................................... 10
Removal and installation of steering wheel ............................................................................. 12
Removal and installation of bleeddown manifold .................................................................... 13
Removal and installation of flow amplifier ............................................................................... 15
Removal and installation of steering cylinders and tie rod ...................................................... 16
Disassembly and assembly of steering cylinders.................................................................... 18
Removal and installation of steering/brake pump ................................................................... 21
13
Removal and installation of piston steering accumulator ........................................................23

Disassembly and assembly of piston steering accumulator....................................................25
Suspensions CEN50049-01
Removal and installation of front suspension............................................................................3
Disassembly and assembly of front suspension ..................................................................... 11
Removal and installation of rear suspension...........................................................................16
Disassembly and assembly of rear suspension ......................................................................20
Removal and installation of hoist pump.....................................................................................3
Disassembly and assembly of hoist pump ................................................................................8
Removal and installation of hoist valve ...................................................................................17
Disassembly and assembly of hoist valve...............................................................................19
Overcenter manifold service....................................................................................................27
Removal and installation of hoist pilot valve............................................................................28
Disassembly and assembly of hoist pilot valve .......................................................................30
Removal and installation of hoist cylinders .............................................................................32
Disassembly and assembly of hoist cylinders .........................................................................35
Body and structures CEN50077-00
Removal and installation of dump body ....................................................................................3
Removal and installation of body pads......................................................................................6
Removal and installation of diagonal ladder/hood and grille assembly .....................................8
Removal and installation of RH deck ......................................................................................10
Removal and installation of LH deck .......................................................................................12
Removal and installation of fuel tank (with DEF tank) .............................................................14
Removal and installation of fuel gauge sender .......................................................................16
Removal and installation of hydraulic tank ..............................................................................17
Removal and installation of hydraulic tank strainers ...............................................................19
Operator cab CEN50079-00
Removal and installation of operator cab ..................................................................................3
Removal and installation of cab door ........................................................................................6
Disassembly and assembly of cab door....................................................................................8
Adjustment of cab door ...........................................................................................................16
Removal and installation of side window glass .......................................................................18
Removal and installation of windshield and rear window glass...............................................21
Removal and installation of windshield wiper components .....................................................22
Removal and installation of cab seats .....................................................................................24
Removal and installation of seat belts .....................................................................................25
Replacement of air conditioning system components ...............................................................3
Power module CEN50078-00
Removal and installation of power module................................................................................3
Removal and installation of alternator .....................................................................................15
Removal and installation of radiator ........................................................................................27
Repairing the radiator..............................................................................................................33
Removal and installation of engine .........................................................................................36
14

Hydraulic circuit diagrams CEN90014-00
Steering, hoist and brake cooling hydraulic circuit schematic .............................. 58B-60-21400
Brake hydraulic circuit schematic......................................................................... 58B-33-00030
Auxiliary system hydraulic circuit schematic ........................................................ 58E-60-01680
Electrical circuit diagrams CEN90028-00
Electrical circuit diagram ...................................................................................... 58B-06-02390
15
980E Dump truck

Form No. CEN00042-00
16
CEN00044-00
980E

980E-5 A50005 and up

Foreword, safety and general information
Foreword............................................................................................................................................................... 4
How to read the shop manual ............................................................................................................................... 5
General safety....................................................................................................................................................... 7
Precautions before operating the truck ............................................................................................................... 10
Precautions while operating the truck ................................................................................................................. 12
Working near batteries ........................................................................................................................................ 15
Precautions before performing service ............................................................................................................... 17
Precautions while performing service ................................................................................................................. 20
Tires .................................................................................................................................................................... 22
Precautions for performing repairs...................................................................................................................... 25
Precautions for welding on the truck................................................................................................................... 26
Capacitor discharge system................................................................................................................................ 27
Actions taken to meet exhaust gas regulations .................................................................................................. 35
Precautions for DEF............................................................................................................................................ 36
Handling electrical equipment and hydraulic components .................................................................................. 39
Standard tightening torques ................................................................................................................................ 47
Conversion tables ............................................................................................................................................... 52
1
This material is proprietary to Komatsu America

Corp (KAC), and is not to be reproduced, used, or
disclosed except in accordance with written autho-
rization from KAC.
It is the policy of the Company to improve products
whenever it is possible and practical to do so. The
Company reserves the right to make changes or
add improvements at any time without incurring
any obligation to install such changes on products
sold previously.
Because of continuous research and development,
periodic revisions may be made to this publication.
Customers should contact their local Komatsu dis-
tributor for information on the latest revision.
Unsafe use of this machine may cause serious injury or death. Operators and maintenance person-
nel must read and understand this manual before operating or maintaining this machine.
This manual should be kept in or near the machine for reference, and periodically reviewed by all
personnel who will come into contact with it.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust, some of its constituents, and certain vehicle components contain or emit
chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
CALIFORNIA
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
Mercury and mercury compounds are known to the State of California to cause developmental prob-
lems. This machine may be equipped with optional HID lamps which contain mercury. There is no
risk of exposure unless the lamps are broken. However, the lamps must be reused, recycled or prop-
erly disposed of in accordance with Local, State and Federal Laws at the end of their useful lives.
2
NON-OEM PARTS IN CRITICAL SYSTEMS
For safety reasons, Komatsu America Corp. strongly recommends against the use
of non-OEM replacement parts in critical systems of all Komatsu equipment. Critical
systems include but are not limited to steering, braking and operator safety sys-
tems.
Replacement parts manufactured and supplied by unauthorized sources may not be

designed, manufactured or assembled to Komatsu's design specifications; accord-
ingly, use of such parts may compromise the safe operation of Komatsu products
and place the operator and others in danger should the part fail.
Komatsu is also aware of repair companies that will rework or modify an OEM part
for reuse in critical systems. Komatsu does not generally authorize such repairs or
modifications for the same reasons as noted above.
Use of non-OEM parts places full responsibility for the safe performance of the
Komatsu product on the supplier and user. Komatsu will not in any case accept
responsibility for the failure or performance of non-OEM parts in its products,
including any damages or personal injury resulting from such use.
3
Foreword A product identification plate is located on the frame

in front of the right side front wheel. It designates the
This manual is written for use by the operator and/or
Truck Model Number, Product Identification Number
the service technician. It is designed to help these
(vehicle serial number), and Maximum GVW (Gross
persons to become fully knowledgeable of the truck
Vehicle Weight) rating.
and all of its systems in order to keep it operating
safely and efficiently. All operators and maintenance The KOMATSU truck model designation consists of
personnel should read and understand the three numbers and one letter (i.e. 960E).
information in this manual before operating the truck The three numbers represent the basic truck
or performing maintenance and/or operational model.
checks on the truck. All safety notices, warnings, and
The letter “E” designates an Electrical wheel
cautions should be understood and followed when
motor drive system.
operating the truck or performing repairs on the truck.
The Product Identification Number (vehicle serial
The first section covers component descriptions,
number) contains information which identifies several
truck specifications and safe work practices, as well
characteristics of this unit. For a more detailed
as other general information. The major portion of the
explanation, refer to the Operation and Maintenance
manual pertains to disassembly, service and
Manual.
reassembly. Each major serviceable area is dealt
with individually. For example, the disassembly, The Gross Vehicle Weight (GVW) is what determines
service and reassembly of the radiator group is the load on the drive train, frame, tires, and other
discussed as a unit. The same is true of the engine components. The vehicle design and application
and engine accessories, and so on through the entire guidelines are sensitive to the maximum GVW.
mechanical detail of the truck. Disassembly should GVW is total weight: empty vehicle weight + fuel &
be carried only as far as necessary to accomplish lubricants + payload.
needed repairs.
To determine the allowable payload, fill all lubricants
The illustrations used in this manual are typical of the to the proper level and fill the fuel tank of an empty
component shown and may not be an exact truck (which includes all accessories, body liners,
reproduction of what is found on the truck. tailgates, etc.), and then weigh the truck. Record this
value and subtract it from the GVW. The result is the
This manual shows dimensioning of U.S. standard
allowable payload.
and metric (SI) units throughout. All references to
“right,” “left,” “front,” or “rear” are made with respect to NOTE: Accumulations of mud, frozen material, etc,
the operator's normal seated position unless become part of the GVW and reduces the allowable
specifically stated otherwise. payload. To maximize payload and to keep from
When assembly instructions are provided without exceeding the maximum GVW rating, these
references to specific torque values, standard torque accumulations should be removed as often as
values should be used. Standard torque values are practical.
shown in torque charts later in this section. Specific Exceeding the allowable payload will reduce the
torques, when provided in the text, are in bold face expected life of truck components.
type, such as 135 N·m (100 ft lb). All torque
specifications have ±10% tolerance unless otherwise
specified.
4
How to read the shop manual

• Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
• Materials and specifications are subject to change without notice.
• Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It serves
not only to give an understanding of the structure, but also serves as reference material for trouble-
shooting. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table

This section explains the standard values for new machine and judgment criteria for testing, adjusting,
and troubleshooting. This standard value table is used to check the standard values in testing and
adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgment criteria for testing and adjusting are
explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided
by failure modes.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and weight
of components are also explained.
90. Diagrams and drawings

This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-
to-date information before you start any work.
5
Symbols
This “ALERT” symbol is used with the signal words,

“DANGER”, “WARNING”, and “CAUTION” in this
manual to alert the reader to hazards arising from
improper operating and maintenance practices.
“DANGER” identifies a specific potential hazard WHICH WILL

RESULT IN EITHER INJURY OR DEATH if proper precautions
are not taken.
“WARNING” identifies a specific potential hazard WHICH MAY

RESULT IN EITHER INJURY OR DEATH if proper precautions
are not taken.
“CAUTION” is used for general reminders of proper safety

practices OR to direct the reader’s attention to avoid unsafe
or improper practices which may result in damage to the
equipment.
6
General safety Fire extinguisher and first aid kit

Safety records from most organizations will show that • Make sure that fire extinguishers are accessible
the greatest percentage of accidents are caused by and proper usage techniques are known.
unsafe acts performed by people. The remainder are • Provide a first aid kit at the storage point.
caused by unsafe mechanical or physical conditions.
Report all unsafe conditions to the proper authority. • Know what to do in the event of a fire.
The following safety rules are provided as a guide for • Keep the phone numbers of persons you should
the operator. However, local conditions and contact in case of an emergency on hand.
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 Clothing and personal items

• Only trained and authorized personnel may • Avoid loose clothing, jewelry, and loose long hair.
operate and maintain the truck. They can catch on controls or in moving parts and
• Follow all safety rules, precautions and cause serious injury or death. Also, never wear
instructions when operating or performing oily clothes as they are flammable.
maintenance on the truck. • Wear a hard hat, safety glasses, safety shoes,
• When working with another operator or a person mask and gloves when operating or maintaining a
on work site traffic duty, make sure that all truck. Always wear safety goggles, hard hat and
personnel understand all hand signals that are to heavy gloves if your job involves scattering metal
be used. chips or minute materials, particularly when
driving pins with a hammer or when cleaning air
cleaner elements with compressed air. Also,
ensure that the work area is free from other
Safety features personnel during such tasks.
• Make sure that all guards and covers are in their
proper position. Have any damaged guards and
covers repaired.
• Learn the proper use of safety features such as
safety locks, safety pins, and seat belts. Use
these safety features properly.
• Never remove any safety features. Always keep
them in good operating condition.
• Improper use of safety features could result in
serious bodily injury or death.
• Check the seat belt fabric, buckle and hardware
for damage or wear. Replace any worn or
damaged parts immediately.
• The seat belts must be replaced 5 years after
seat belt manufacture, or after every 3 years of
use, whichever comes first.
7
Leaving the operator seat Fire prevention for fuel and oil
When preparing to leave the operator's seat, do not • Fuel, oil, and antifreeze can be ignited by a flame.
touch any control lever that is not locked. To prevent Fuel is extremely flammable and can be
accidental operations from occurring, always perform hazardous. Keep flames away from flammable
the following: fluids.
• Move the directional control lever to PARK. Do • Keep oil and fuel in a designated location and do
not use the wheel brake lock when the engine not allow unauthorized persons to enter.
will be turned off. • When refueling, stop the engine and do not
• Lower the dump body to the frame. smoke.
• Stop the engine. When exiting the truck, always • Refueling and oiling should be done in well
lock compartments and take the keys with you. If ventilated areas.
the truck should suddenly move or move in an • Tighten all fuel and oil tank caps securely.
unexpected way, this may result in serious bodily
injury or death.
Mounting and dismounting

• Use the handrails and steps when getting on or
off the truck.
• Never jump on or off the truck. Never climb on or
off a truck while it is moving.
• When climbing on or off a truck, face the truck
and use the hand-hold and steps.
• Never hold any control levers when getting on or
off a truck.
• Always maintain three-point contact with the
hand-holds and steps to ensure that you support
yourself.
• When bringing tools into the operator's
compartment, always pass them by hand or pull
them up by rope.
• If there is any oil, grease, or mud on the hand-
holds or steps, wipe them clean immediately.
Always keep these components clean. Repair
any damage and tighten any loose bolts.
8
Precautions with high temperature fluids Prevention of injury by work equipment

Immediately after truck operation, engine coolant, Never enter or put your hand, arm or any other part of
engine oil, and hydraulic oil are at high temperatures your body between movable parts such as the dump
and are pressurized. If the cap is removed, the fluids body, chassis or cylinders. If the work equipment is
are drained, the filters are replaced, etc., there is operated, clearances will change and may lead to
danger of serious burns. Allow heat and pressure to serious bodily injury or death.
dissipate before performing such tasks and follow
proper procedures as outlined in the service manual.
Unauthorized modification
Any modification made to this vehicle without
authorization from Komatsu America Corp. can
possibly create hazards.
Before making any modification, consult the
authorized regional Komatsu America Corp.
distributor. Komatsu will not be responsible for any
injury or damage caused by any unauthorized
To prevent hot coolant from spraying: modification.
1. Stop the engine.
2. Wait for the coolant temperature to decrease.
Precautions when using ROPS
3. Depress the pressure release button on the cap
to vent cooling system pressure. The ROPS is intended to protect the operator if the
truck should roll over. It is designed not only to
4. Turn the radiator cap slowly to release the support the load of the truck, but also to absorb the
pressure before removing. energy of the impact.
To prevent hot engine oil spray: • The Rollover Protection Structure (ROPS) must
1. Stop the engine. be properly installed before the truck is operated.
2. Wait for the oil temperature to cool down. • ROPS installed on equipment manufactured and
designed by Komatsu America Corp. fulfills all of
3. Turn the cap slowly to release the pressure the regulations and standards for all countries. If
before removing the cap. it is modified or repaired without authorization
from Komatsu, or if it is damaged when the truck
rolls over, the strength of the structure will be
compromised and will not be able to fulfill its
Asbestos dust hazard prevention intended purpose. Optimum strength of the
Asbestos dust is hazardous to your health when structure can only be achieved if it is repaired or
inhaled. If you handle materials containing asbestos modified as specified by Komatsu.
fibers, follow the guidelines below: • When modifying or repairing the ROPS, always
consult your nearest Komatsu distributor.
• Never use compressed air for cleaning.
• Even with the ROPS installed, the operator must
• Use water for cleaning to control dust.
always use the seat belt when operating the
• Operate the truck or perform tasks with the wind truck.
to your back whenever possible.
• Use an approved respirator when necessary.
9
Precautions for attachments Precautions before operating the truck

• When installing and using optional equipment, Safety is thinking ahead. Prevention is the best safety
read the instruction manual for the attachment program. Prevent a potential accident by knowing the
and the information related to attachments in this employer's safety requirements and all necessary job
manual. site regulations. In addition, know the proper use and
• Do not use attachments that are not authorized care of all the safety equipment on the truck. Only
by Komatsu America Corp. or the authorized qualified operators or technicians should attempt to
regional Komatsu distributor. Use of unauthorized operate or maintain a Komatsu machine.
attachments could create a safety problem and
adversely affect the proper operation and useful Safe practices start before the operator gets to the
life of the truck. equipment.
• Any injuries, accidents, and product failures Safety at the worksite
resulting from the use of unauthorized
attachments will not be the responsibility of • When walking to and from a truck, maintain a
Komatsu America Corp. or the authorized safe distance from all machines even when the
regional Komatsu distributor. operator is visible.
• Before starting the engine, thoroughly check the
area for any unusual conditions that could be
Precautions for starting the truck dangerous.
Start the engine from the operator seat only. Never • Examine the road surface at the job site and
attempt to start the engine by shorting across the determine the best and safest method of
cranking motor terminals. This may cause a fire, operation.
serious injury or death to anyone in truck’s path. • Choose an area where the ground is as
horizontal and firm as possible before performing
the operation.
• If you need to operate on or near a public road,
protect pedestrians and cars by designating a
person for work site traffic duty or by installing
fences around the work site.
• The operator must personally check the work
area, the roads to be used, and the existence of
obstacles before starting operations.
• Always determine the travel roads at the work site
and maintain them so that it is always safe for the
machines to travel.
• If travel through wet areas is necessary, check
the depth and flow of water before crossing the
shallow parts. Never drive through water that
exceeds the permissible water depth.
10
Fire prevention Mirrors, windows and lights

• Remove wood chips, leaves, paper, and other • Remove any dirt from the surface of the
flammable items that have accumulated in the windshield, cab windows, mirrors and lights.
engine compartment. Failure to do so could result Good visibility may prevent an accident.
in a fire.
• Adjust the rear view mirror to a position where the
• Check the fuel, lubrication, and hydraulic systems operator can see best from the operator's seat. If
for leaks. Repair any leaks. Clean any excess oil, any glass or light is broken, replace it with a new
fuel or other flammable fluids, and dispose of part.
them properly.
• Make sure that the headlights, work lights, and
• Make sure that a fire extinguisher is present and taillights are in proper working order. Make sure
in proper working condition. that the truck is equipped with the proper work
lamps that are needed for the operating
• Do not operate the truck near open flames. conditions.
In operator cab (before starting the engine)

• Do not leave tools or spare parts lying around. Do
not allow trash to accumulate in the cab of the
truck. Keep all unauthorized reading material out
of the truck cab.
• Keep the cab floor, controls, steps and handrails
free of oil, grease, snow and excess dirt.
Ventilation in enclosed areas
• Read and understand the contents of this
If it is necessary to start the engine within an enclosed manual. Pay special attention to the sections
area, provide adequate ventilation. Inhaling exhaust pertaining to safety and operating instructions.
fumes from the engine can kill. 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.
• Make sure that the steering wheel, horn, controls
and pedals are free of any oil, grease or mud.
• Check the operation of the windshield wiper,
condition of wiper blades, and the washer fluid
reservoir level.
Preparing for operation • Be familiar with all steering and brake system
controls, warning devices, road speeds and
• Always mount and dismount while facing the loading capabilities before operating the truck.
truck. Never attempt to mount or dismount the
truck while it is in motion. Always use handrails Seat Belts
and ladders when mounting or dismounting the
truck. • On both driver and passenger seats, check the
seat belt fabric, buckle, all belt retractors and
• Check the deck areas for debris, loose hardware hardware for damage or wear. Replace any worn
and tools. Check for people and objects that or damaged parts immediately.
might be in the area.
• Even if there are no signs of damage, replace
• Become familiar with and use all protective both driver and passenger seat belts 5 years after
equipment devices on the truck and ensure that seat belt manufacture, or every 3 years after start
these items (anti-skid material, grab bars, seat of use, whichever comes first. The passenger
belts, etc.) are securely in place. 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.
11
Precautions while operating the truck

When starting the engine
• Never attempt to start the engine by shorting
across cranking motor terminals. This may cause
a fire, or serious injury or death to anyone in The tire and rim assembly may explode if
truck’s path. subjected to excessive heat. Personnel should
move to a remote or protected location if sensing
• Never start the engine if a warning tag has been excessively hot brakes, smelling burning rubber
attached to the controls.
or observing evidence of fire near the tire and
• When starting the engine, sound the horn as an wheel area.
alert.
If the truck must be approached to extinguish a
• Start and operate the truck only while seated in fire, those personnel should do so only while
the operator’s seat. facing the tread area of the tire (front or back)
• Do not allow any unauthorized persons in the unless protected by using large heavy equipment
operator's compartment or any other place on the as a shield. Stay at least 15 m (50 ft) from the
truck. tread of the tire.
General truck operation In the event of fire in the tire and wheel area
(including brake fires), stay away from the truck
• Wear the seat belt at all times. for at least 8 hours or until the tire and wheel are
• Only authorized persons are allowed to ride in the cool.
truck. Riders must be in the cab and belted in the • Keep serviceable fire fighting equipment on hand.
passenger seat. Report empty extinguishers for replacement or
• Do not allow anyone to ride on the decks or steps refilling.
of the truck. • Always place the directional control lever in the
• Do not allow anyone to get on or off the truck PARK position when the truck is parked and
while it is in motion. unattended. Do not leave the truck unattended
while the engine is running.
• Do not move the truck in or out of a building
without a signal person present. NOTE: DO NOT use wheel brake lock when parking
the truck.
• Know and obey the hand signal communications
between operator and spotter. When other • Park the truck a safe distance away from other
machines and personnel are present, the vehicles as determined by the supervisor.
operator should move in and out of buildings,
• Stay alert at all times! In the event of an
loading areas, and through traffic under the
emergency, be prepared to react quickly and
direction of a signal person. Courtesy at all times
avoid accidents. If an emergency arises, know
is a safety precaution.
where to get prompt assistance.
• Immediately report any adverse conditions at the
haul road, pit or dump area that may cause an
operating hazard.
Ensuring good visibility
• Check for flat tires periodically during a shift. If the
truck has been operating on a “flat”, do not park • When working in dark places, install work lamps
the truck inside a building until the tire cools. If the and head lamps. Set up extra lighting in the work
tire must be changed, do not stand in front of the area if necessary.
rim and locking ring when inflating a tire mounted • Discontinue operations if visibility is poor, such as
on the truck. Observers should not be permitted in mist, snow, or rain. Wait for the weather to
in the area and should be kept away from the side improve to allow the operation to be performed
of such tires. safely.
12
Traveling Traveling on slopes

• When traveling on rough ground, travel at low • Traveling on slopes could result in the truck
speeds. When changing direction, avoid turning tipping over or slipping.
suddenly.
• Do not change direction on slopes. To ensure
• Lower the dump body and set the dump lever to safety, drive to level ground before turning.
the FLOAT position before traveling.
• Do not travel up and down on grass, fallen
• If the engine stops while the truck is in motion, leaves, or wet steel plates. These materials may
secondary steering and braking enable the truck make the truck slip on even the slightest slope.
to be steered and stopped. A fixed amount of Avoid traveling sideways, and always keep travel
reserve oil provides temporary steering and speed low.
braking to briefly allow the truck to travel to a safe
• When traveling downhill, use the retarder to
area. Apply the brakes immediately and stop the
reduce speed. Do not turn the steering wheel
truck as quickly and safely as possible off of the
suddenly. Do not use the foot brake except in an
haul road, if possible.
emergency.
• If the engine should stop on a slope, apply the
service brakes fully and stop the truck. Move the
Traveling in reverse
directional control lever to PARK after the truck
Before operating the truck: has stopped.
• Sound the horn to warn people in the area. Make
sure that the back-up horn also works properly.
Operating on snow or ice
• Check for personnel near the truck. Be
particularly careful to check behind the truck. • When working on snowy or icy roads, there is
danger that the truck may slip to the side on even
• When necessary, designate a person to watch the slightest slope. Always travel slowly and
the area near the truck and signal the operator. avoid sudden starting, turning, or stopping in
This is particularly necessary when traveling in these conditions.
reverse.
• Be extremely careful when clearing snow. The
• When operating in areas that may be hazardous road shoulder and other objects are buried in the
or have poor visibility, designate a person to snow and cannot be seen.
direct work site traffic.
• Do not allow any one to enter the line of travel of
the truck. This rule must be strictly observed even Avoid damage to dump body
with machines equipped with a back-up horn or
rear view mirror. Always be extremely cautious when working in
tunnels, on bridges, under electric cables, or when
entering a parking place or any other place where
there are height limits. The dump body must be
completely lowered before driving the truck.
13
Driving near high voltage cables Working on loose ground

Driving near high voltage cables can cause electric • Avoid operating the truck near cliffs, overhangs
shock. Always maintain safe distances between the and deep ditches. If these areas collapse, the
truck and the high voltage cable as listed below. truck could fall or tip over and result in serious
Voltage Minimum Safety Distance injury or death. Remember that ground surfaces
in these areas may be weakened after heavy rain
6.6 kV 3m 10 ft. or blasting.
33.0 kV 4m 14 ft.
• Freshly laid soil and the soil near ditches is loose.
66.0 kV 5m 17 ft. It can collapse under the weight or vibration of the
154.0 kV 8m 27 ft. truck. Avoid these areas whenever possible.
275.0 kV 10 m 33 ft. Parking the truck
• Choose a flat, level surface to park the truck. If
The following actions are effective in preventing
the truck has to be parked on a slope, put blocks
accidents while working near high voltages: behind all the wheels to prevent truck movement.
• Wear shoes with rubber or leather soles. • Do not activate the wheel brake lock when the
• Use a signalman to give warning if the truck parking brake is activated. Bleed down of
approaches an electric cable. hydraulic pressure may occur, causing the truck
to roll away.
• If the work equipment touches an electric cable,
the operator should not leave the cab. • When parking on public roads, provide fences
and signs, such as flags or lights, on the truck to
• When performing operations near high voltage warn pedestrians and other vehicles. Make sure
cables, do not allow anyone to approach the that the truck, flags or lights do not obstruct traffic.
truck.
• Lower the dump body fully, move the directional
• Check with the electrical maintenance control lever to PARK, stop the engine and lock
department about the voltage of the cables before everything. Always take the key with you.
starting operations.
Towing
When dumping
Improper towing methods may lead to serious
• Before starting the dumping operation, make sure personal injury and/or damage. For towing methods,
that there are no persons or objects behind the refer to the Operation & Maintenance Manual.
truck.
• Use a towing device with ample strength for the
• Stop the truck in the desired location. Check
weight of this truck.
again for persons or objects behind the truck.
Give the determined signal, then slowly operate • Towing vehicle must have adequate pulling and
the dump body. If necessary, use blocks for the braking capacity to both move and stop the towed
wheels or position a flagman. truck under all conditions, including towing on a
grade.
• When dumping on slopes, truck stability is poor
and there is danger of tipping over. Always use • Inspect towing components, such as tow bars
extreme care when performing such operations. and couplings, for any signs of damage. Never
use damaged or worn components to tow a
• Never travel with the dump body raised.
disabled vehicle.
When loading • Keep a safe distance from the trucks and towing
apparatus while towing a vehicle.
• Make sure that the surrounding area is safe. Stop
the truck in the correct loading position, then load • When connecting a truck that is to be towed, do
the body uniformly. not allow anyone to go between the tow vehicle
and the disabled vehicle.
• Do not leave the operator seat during the loading
operation. • Set the coupling of the truck being towed in a
straight line with the towing portion of the tow
truck, and secure it in position.
14
Working near batteries • Batteries generate hydrogen gas. Hydrogen gas

is very explosive and can easily be ignited with a
Battery hazard prevention small spark or flame.
• Battery electrolyte contains sulfuric acid, which • Before working with batteries, stop the engine
can quickly burn the skin and eat holes in and turn the key switch to the OFF position.
clothing. If you spill acid on yourself, immediately • Avoid short-circuiting the battery terminals
flush the area with water.
through accidental contact with metallic objects,
• Battery acid can cause blindness if splashed into such as tools, across the terminals.
your eyes. If acid gets into your eyes, flush them • When removing or installing batteries, check
immediately with large quantities of water and
which is the positive (+) terminal and the negative
see a doctor at once. (-) terminal.
• If you accidentally drink acid, drink a large • Tighten battery caps securely.
quantity of water, milk, beaten eggs or vegetable
oil. Call a doctor or poison prevention center • Tighten the battery terminals securely. Loose
immediately. terminals can generate sparks and lead to an
explosion.
• Always wear safety glasses or goggles when
working with batteries.
15
Starting with jumper cables • If any tool touches between the positive (+)
terminal and the chassis, it will cause sparks.
• Always wear safety glasses or goggles when Always use caution when using tools near the
starting the machine with jumper cables. battery.
• While jump starting with another machine, DO
NOT allow the two machines to touch.
• Ensure the parking brake is applied on both Jump starting with receptacles
machines. • Always wear safety glasses or goggles when
• Ensure the size of the jumper cables and clips are starting the machine with jumper cables.
suitable for the battery size. Inspect the cables • While jump starting with another machine, DO
and clips for any damage or corrosion. NOT allow the two machines to touch.
• Ensure the key switch and both battery • Ensure the parking brake is applied on both
disconnect switches on the disabled machine are machines.
in the OFF position.
• Inspect the cables and connectors for any
• Connect the batteries in parallel: positive to damage or corrosion.
positive and negative to negative.
• Ensure the key switch and both battery
• Connect the positive (24VDC +) cable from the disconnect switches on the disabled machine are
good machine to the (24VDC +) on the disabled in the OFF position.
machine first.
• Connect the jumper cable to the receptacle on
• Then connect the ground cable on the good the good machine to the receptacle on the
machine to the frame of the disabled machine, as disabled machine.
far away as possible from the batteries. This will
prevent a spark from possibly starting a battery • Allow time for the batteries to charge.
fire.
NOTE: The batteries will charge even with the battery
• Allow time for the batteries to charge. disconnect switches are in the OFF position.
NOTE: The batteries will charge even with the battery • If starting with a jumper cable, perform the
disconnect switches are in the OFF position. operation with two people. One person in the cab
of the disabled machine, the other person
• If starting with a jumper cable, perform the working with the jumper cables.
operation with two people. One person in the cab
of the disabled machine, the other person • If the batteries are low, DO NOT attempt starting
working with the jumper cables. the machine with only one set of jumper cables
installed. Install the second set of jumper cables
• If the batteries are low, DO NOT attempt starting in the same way as already described.
the machine with only one set of jumper cables
installed. Install the second set of jumper cables • Turn the battery disconnect switches to the ON
in the same way as already described. position and attempt starting.
• Turn the battery disconnect switches to the ON • For jumper cable removal, disconnect the cables
position and attempt starting. from each machine.
• For jumper cable removal, disconnect the ground If any tool touches between the positive (+) terminal
or negative (-) cable first, then the (24VDC +) and the chassis, it will cause sparks. Always use
cable last. caution when using tools near the battery.
INCORRECT
16
Precautions before performing service Proper tools
Warning tag Only use tools that are suited to the task. Using
damaged, low quality, faulty or makeshift tools could
Starting the engine or operating the controls while cause personal injury.
other personnel are performing maintenance on the
truck can lead to serious injury and/or death. Always
attach the warning tag to the control lever in the
operator cab to alert others that you are working on
the truck. Attach additional warning tags around the
truck as necessary.
These tags are available from your Komatsu
distributor. Warning tag part number: 09963-A1640
Use of Tie-Off Anchor During Maintenance and
Repair
While working at heights
during assembly, mainte-
nance or repair of the
haul truck, workers
should wear an appropri-
ate fall protection har-
ness and attach it to a
tie-off anchor or tie-off
point.
Komatsu anchor (58B-98-75190) is available for use
with fall protection harnesses. Carefully read and
understand the harness maker’s instructions before
using any fall protection harness.
NOTE: The anchor must not be used for lifting.
Stopping the engine
• Before performing inspections or maintenance,
stop the truck on firm flat ground, lower the dump
body, move the directional control lever to PARK,
and stop the engine.
• If the engine must be run during service, such as
when cleaning the radiator, the directional control
lever must be in PARK. Always perform this work
with two people. One person must sit in the
operator's seat to stop the engine if necessary.
During these situations, never move any controls
that are not related to the task at hand.
• When servicing the truck, do not to touch any
moving parts. Never wear loose clothing or
jewelry.
• Put wheel blocks under the wheels to prevent
truck movement.
• When performing service with the dump body
raised, place the dump lever in the HOLD position
and apply the lock (if equipped). Install the body-
up safety sling securely.
17
Securing the dump body
To avoid serious personal injury or death, the

body retention sling must be installed whenever
personnel are required to perform maintenance
on the truck while the dump body in the raised
position.
The Komatsu body-up safety sling can only be
used with a Komatsu body. Non-OEM body may
not accommodate the Komatsu body-up safety
sling. The end user must ensure that a proper
cable/sling is used.
1. To hold the dump body in the up position, raise
the body to its maximum height.
2. Install two shackles (2, Figure 00-1) and body
retention sling (3) between rear body ear (1)
and the axle housing.
3. Secure the shackle pins with cotter pins.
4. Move the hoist lever to the FLOAT position to FIGURE 00-1. BODY RETENTION SLING
slowly lower the body until the cable is INSTALLATION
supporting the full weight of the body. Then 1. Rear Body Ear 3. Body Retention
move the hoist lever to the HOLD position. 2. Shackle & Pin Sling
5. After service work is completed, return the sling
to the stored position.
18
Jack point locations Proper jack point locations must be used. The jacks
at locations (3, Figure 00-2) must be located on the
When a truck is being stored for any period of time or
frame rails.
being secured for maintenance work, portable jack
stands or permanent jack stands may be used. If a tow bumper reinforcement group is installed, it is
acceptable to place jack stands under tow hooks at
The jack stands must be adequately rated for the size
locations (4). However, do not position jacks outside
of the truck. Ensure that the jack stands are on a
of the tow hooks.
solid and level surface.
4 4
3 3
2 2
1 1
85201
FIGURE 00-2. JACK POINT LOCATIONS

(Bottom View)
1. Under Rear Suspensions 4. Under Tow Hooks
2. Under Front Suspensions (if equipped)
3. Under Torque Tube
19
Precautions while performing service Working under the truck

NOTE: Only authorized personnel should service and • Always lower all movable work equipment to the
repair the truck. ground or to their lowest position before
performing service or repairs under the truck.
Keep the truck clean • Always block the tires of the truck securely.
• Spilled oil, grease, scattered tools, etc, can cause • Never work under the truck if the truck is poorly
you to slip or trip. Always keep your truck clean supported.
and tidy.
• If water gets into the electrical system, there is
danger that the truck may move unexpectedly
and/or damage to components may occur. Do not
use water or steam to clean any sensors,
connectors or the inside of the operator's
compartment.
• Use extreme care when washing the electrical
control cabinet. Do not allow water to enter the Rotating fan and belts
control cabinet around the doors or vents. Do not Stay away from all rotating parts such as the radiator
allow any water to enter the cooling air inlet duct fan and fan belts. Serious bodily injury may result
above the electrical control cabinet. If water from direct or indirect contact with rotating parts and
enters the control cabinet through any opening or
flying objects.
crevice, major damage to the electrical
components is possible.
• Never spray water into the rear wheel electric
motor covers. Damage to the wheel motor
armatures may occur.
• Do not spray water into the retarding grids.
Excess water in the retarding grids can cause a
ground fault, which will prevent propulsion.
Adding fuel or oil

• Spilled fuel and oil may cause slipping. Always
clean up spills immediately.
• Always add fuel and oil in a well-ventilated area.
• When refueling, stop the engine and do not
smoke.
• Tighten the cap of the fuel and oil fillers securely.
• Never use fuel to wash parts.
Attachments
Use of lighting
Place attachments that have been removed from the
truck in a safe place and manner to prevent them When checking fuel, oil, coolant or battery electrolyte,
from falling. always use lighting with anti-explosion specifications.
If such lighting equipment is not used, there is danger
of an explosion.
20
Radiator coolant level Handling high pressure hoses

If it is necessary to add coolant to the radiator, stop • Do not bend high pressure hoses or hit them with
the engine and allow the engine and radiator to cool hard objects. Do not use any bent or cracked
down before adding the coolant. Depress the piping, tubes or hoses. They may burst during
pressure release button on the cap to vent cooling use.
system pressure. Slowly loosen the cap to relieve any • Always repair any loose or broken hoses. If fuel
remaining pressure. or oil leaks, it may result in a fire.
Precautions when performing maintenance near

high temperature or high pressure
Immediately after stopping operation, engine coolant
and operating oils are at high temperature and under
high pressure. If the cap is removed, the oil or water
is drained, or the filters are replaced under these
conditions, it may result in burns or other injury. Wait
for the temperature to cool and pressure to subside
Precautions with the battery before performing the inspection and/or maintenance
When repairing the electrical system or performing as outlined in the shop manual.
electrical welding, remove the negative (-) terminal of
the battery to stop the flow of current.
Waste materials
• Never dump oil into a sewer system, river, etc.
• Always put oil drained from your truck in
Precautions with high pressure oil appropriate containers. Never drain oil directly
• Work equipment circuits are always under onto the ground.
pressure. Do not add oil, drain oil or perform • Obey appropriate laws and regulations when
maintenance or inspections before completely disposing of harmful objects such as oil, fuel,
releasing the internal pressure. coolant, solvent, filters and batteries.
• Small, high-pressure pin hole leaks are extremely • The machine may be equipped with optional high
dangerous. A jet of high-pressure oil can pierce intensity discharge lamps which contain mercury.
the skin and eyes. Always wear safety glasses These lamps must be reused, recycled or
and thick gloves. Use a piece of cardboard or a properly disposed of in accordance with
sheet of wood to check for oil leakage. applicable local, state and federal laws.
• If you are hit by a jet of high-pressure oil, consult
a doctor immediately for medical attention.
21
Tires
Inspection
The truck tires must be inspected and tire pressure
must be checked with an accurate pressure gauge
before each work shift and during tire rotations. Tire When inflating and deflating tires, always use a
pressure will vary according to manufacturer and safety cage. Never inflate a tire until the lock ring
local working conditions. Consult the tire manufac- is securely in place. DO NOT stand in front of or
turer for recommended tire pressure. over the lock ring during inflation procedures.
Never over inflate a tire. Refer to tire manufac-
Ensure that the valve caps are securely applied to turer’s recommendations.
the valve stems. The caps protect the valves from dirt
build up and damage. DO NOT bleed air from tires
that are hot due to truck operation. Under such cir-
cumstances, it is normal for pressure to increase in
the tire due to expansion.
A bent or damaged rim which does not support the
bead properly may cause abnormal strain on the tire,
resulting in tire damage. If a tire becomes deeply cut,
it must be removed and repaired. Neglected cuts
cause many tire problems. Water, sand, dirt and
other foreign materials can get into the tire through a
FIGURE 00-3. SAFETY CAGE 84825
cut, eventually causing tread or ply separation.
Rim components that are deformed, bent, cracked,
worn, corroded, or damaged must be clearly labeled
to indicate their condition before they are discarded.
Maintenance
Rim and tire maintenance can be hazardous unless the Always keep personnel away from a wheel and
correct procedures are followed by trained personnel. tire assembly when it is being removed, installed,
Tires that are improperly maintained or under/over- deflated or inflated. Personnel must always be
inflated can overheat and burst due to excessive pres- outside the range of the “hazardous trajectory”.
sure. Improper inflation can also result in cuts in the tire Exercise extreme caution as the trajectory may
caused by sharp stones. Both of these conditions can widen.
lead to tire damage, serious personal injury, or even
death. To safely maintain a tire:
Hazardous
• Before a tire is removed from a truck, the valve Trajectory
core must be partially removed to allow deflation.
Then the tire/rim assembly can be removed.
• After the tire/rim assembly is installed on the
truck, inflate the tires to their specified pressure.
Abnormal heat is generated, particularly when the
inflation pressure is too low.
NOTE: Any tire inflation pressures and permissible
speeds given in this manual are general values. The
actual values may differ, depending on the type of tire
and the specific operating conditions. For details,
consult the tire manufacturer. Hazardous
Ensure that appropriate personal protective equip- Trajectory
84860
ment is worn when servicing tires and rims.
FIGURE 00-4. HAZARDOUS TRAJECTORY
22
Storage
Tires must be stored indoors, if possible, in a cool,
dry, dark, draft-free location. If stored outdoors, cover
tires with a tarpaulin to keep out dirt, water and other
DO NOT weld or apply heat on the rim assembly foreign materials. Erect a fence around the tires and
with the tire mounted on the rim. Remaining put up “No Entry” signs and other warning signs that
gases inside the tire may ignite causing explo- even young children can understand. Long exposure
sion of tire and rim. to the sun will cause ozone cracks. Avoid contact with
oil, grease and other petroleum products.
If a brake or wheel motor has experienced a fire,
Tires must be stored vertically. Stand the tire on level
DO NOT go near the tire until the tire has cooled.
ground and block it securely so that it cannot roll or
fall over. If tires must be laid on their sides for a short
period, avoid distortion by stacking no more than
When the tires become overheated, a flammable gas
three tires on top of one another.
is produced inside the tire which can ignite. It is par-
ticularly dangerous if the tires become overheated If the tire falls over, flee the area quickly. The tires for
while the tires are pressurized. If the gas generated dump trucks are extremely heavy, and the impact
inside the tire ignites, the internal pressure will sud- from a significant fall could lead to an explosive sepa-
denly rise, and the tire will explode, resulting in dan- ration of rim components. Never attempt to hold or
ger and/or death to personnel in the area. Explosions support the tire. Attempting to hold or support a tire
differ from punctures or tire bursts because the may lead to serious injury.
destructive force of the explosion is extremely large.
Therefore, the following operations are strictly prohib-
ited when the tire is pressurized:
• Welding the rim
• Welding near the wheel or tire.
• Smoking or creating open
flames
Mounted tires stored as spares must be inflated to

minimum inflation pressure necessary to keep the tire
beads properly seated. Maximum inflation pressure
of the stored tire should never exceed 15% of the
tire’s normal cold inflation pressure.
Before storing used tires, clean the tires thoroughly
and inspect for damage. Repair as necessary. When
a truck is placed in storage, it must be blocked up to
remove the weight from the tires. If a stored truck
cannot be blocked up, check the air pressure of the
tires and inspect the tires twice a month for proper
inflation pressure.
23
Handling
Ensure that the tire handling equipment is capa-

ble of lifting and maneuvering the load.
Due to the size and weight of the tire and rim assem-
blies, special handling equipment, such as a modified
fork lift called a “tire handler”, as shown in Figure 00-
6, is desirable. Consult local tire vendors for sources
of equipment designed especially to remove, repair,
and install large off-highway truck tires.
Handling of tires and rims must only be done by per-
sonnel who have received training and accreditation
based on instruction from a qualified work supervisor.
There are several types of tools that are used for tire
and rim handling. Ensure that the personnel have a
proper understanding of how to use the tools prop-
erly.
When moving tires and rims, be careful to avoid acci-
dental drops or falls that could injure others in the
vicinity.
Regarding dual tire assemblies: DO NOT operate
FIGURE 00-6. TYPICAL TIRE HANDLER
the truck with a single tire on a dual tire assembly.
The load capacity of the tire and rim will be drastically
reduced and may result in damage.
24
Precautions for performing repairs Engine shutdown procedure after AC drive

system failure
NOTE: Only qualified maintenance personnel who
understand the systems being repaired should If the AC drive system is operating normally when the
attempt repairs. Only a qualified operator should engine is shut down, the system should be safe to
move the truck under its own power in the repair service. However, in the event of a drive system
facility or during road testing after repairs are failure, performing the following procedure before any
complete. maintenance activities will ensure that no hazardous
voltages are present in the AC drive system.
• Many components on the Komatsu truck are
large and heavy. Ensure that lifting equipment 1. Before shutting down the engine, verify the
(hoists, slings, chains, and lifting eyes) are of status of all the drive system warning lights. Use
adequate capacity to handle the load. the lamp test switch to verify that all lamps are
• Do not work under a suspended load. Do not functioning properly.
work under a raised body unless body retention If any of the red drive system warning lights
sling, props or pins are in place to hold the body remain on, do not attempt to open any cabinets,
in the raised position. disconnect any cables, or reach inside the
• Do not repair the truck while the engine is retarding grid cabinet without a trained drive
running, except when adjustments can only be system technician present, even if the engine is
made under such conditions. Keep a safe off. Only qualified personnel, specifically trained
distance from moving parts. for servicing the AC drive system, should
• When servicing any air conditioning system with perform this service.
refrigerant, wear a face shield and cold resistant 2. If all red drive system warning lights are off,
gloves for protection against freezing. Follow all follow the normal engine shutdown procedure in
current regulations for handling and recycling the Operation & Maintenance Manual.
refrigerants. Refer to Testing and adjusting
section Cab air conditioning. 3. After the engine has been stopped for at least
five minutes, inspect the link voltage lights on
• Follow package directions carefully when using
the exterior of the main control cabinet and the
cleaning solvents.
DID panel on the rear wall of the operator cab.
• If an auxiliary battery assist is needed, refer to
"Starting with jumper cables" or "Jump starting a. If all lights are off, it is safe to work on the
with receptacles" earlier in this section. retarding grids, wheel motors, alternator and
related power cables. Proceed to Step 5.
• If the truck must be towed, use a rigid tow bar.
Check the truck frame for a decal recommending b. If any red lights continue to be illuminated
special towing precautions. Also refer to the after following the above procedure, a fault
towing instructions in the Operation & has occurred. Leave all cabinet doors in
Maintenance Manual. place. Do not touch the retarding grid ele-
• Relieve hydraulic pressure before disconnecting ments. Do not disconnect any power cables
any lines or hoses. Hydraulic oil escaping under or use them as hand or foot holds. Notify
pressure can have sufficient force to enter a your Komatsu service representative immedi-
person's body by penetrating the skin, resulting in ately.
serious injury and possibly death. 4. Locate the generator field contactor (GF) switch
• After adjustments or repairs, replace all shields, in the access panel on the left side of the main
screens and clamps. 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 its
former position.
5. Leave the drive system in the rest mode until
the truck is to be moved.
25
Precautions for welding on the truck • Do not weld on the rear of the control cabinet!
The metal panels on the back of the cabinet are
NOTE: Before welding or repairing an AC drive truck, part of capacitors and cannot be heated.
notify a Komatsu service representative. Only
qualified personnel, specifically trained for servicing • Do not weld on the retarding grid exhaust
the AC drive system, should perform this service. louvers! They are made of stainless steel. Some
power cable panels throughout the truck are also
If it is necessary to perform welding on the truck made of aluminum or stainless steel. They must
without the field engineer present, the following be repaired with the same material or the power
procedures and precautions must be followed to cables may be damaged.
ensure that the truck is safe for maintenance • Power cables must be cleated in wood or other
personnel to work on and to reduce the chance for non-ferrous materials. Do not repair cable cleats
damage to equipment. by encircling the power cables with metal clamps
or hardware. Always inspect power cable
• Before opening any cabinets or touching a
insulation before servicing the cables and
retarding grid element or a power cable, the
returning the truck to service. Discard cables with
engine must be shutdown and any red drive
broken insulation.
system warning lights must not be illuminated.
• Power cables and wiring harnesses should be
• Always disconnect the positive and negative
protected from weld spatter and heat.
battery cables of the truck before doing any
welding on the unit. Failure to do so may • Always fasten the welding machine ground (-)
seriously damage the battery and electrical lead to the piece being welded. The grounding
equipment. Disconnect the battery charging clamp must be attached as near as possible to
alternator lead wire and isolate the electronic the weld area.
control components before making welding
repairs. (It is not necessary to disconnect or • Always avoid laying welding cables over or near
remove any control circuit cards on electric drive the vehicle electrical harnesses. Welding voltage
dump trucks or any of the AID circuit control could be induced into the electrical harness and
cards.) cause damage to components.
• Always fasten the welding machine ground (-) • Before doing any welding on the truck,
lead to the piece being welded. The grounding disconnect the battery charging alternator lead
clamp must be attached as near as possible to wire and isolate electronic control components.
the weld area. Never allow welding current to • Also, always disconnect the negative and positive
pass through ball bearings, roller bearings, battery cables of the vehicle. Failure to do so may
suspensions or hydraulic cylinders. Always avoid seriously damage the battery and electrical
laying welding cables over or near the vehicle equipment.
electrical harnesses. Welding voltage could be
induced into the electrical harness and possibly • Never allow welding current to pass through ball
cause damage to components. bearings, roller bearings, suspensions or
hydraulic cylinders.
• Drain, clean, and ventilate fuel tanks and
hydraulic tanks before making any welding
repairs on the tanks.
• Before welding on the truck, disconnect all
electrical harnesses from the modules and
controllers inside the auxiliary control cabinet
behind the operator cab.
26
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 sys-
tem 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.
Because a danger can still exist with the capacitor
charge lights off, it is necessary to adhere to the fol-
lowing instructions before touching or servicing drive
system components. Only authorized service person-
nel are allowed to service the drive system.
Refer to the shop manual for rules when servicing the
drive system. Adhere to the proper procedures for
disabling the drive system.
Necessary tools
• 2000VDC meter kit (58B-06-00800)
(Includes the parts for the volt meter assembly in FIGURE 00-7. VOLT METER ASSEMBLY
Figure 00-7, the grounding sticks in Figure 00-8
and high voltage gloves)
• Additional Personal Protective Equipment (PPE)

for working with 2000VDC meter, including safety
shoes and safety glasses
• Multimeter for ground resistance measurement
FIGURE 00-8. GROUNDING STICKS
27
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,
Hazardous voltages are present in this equip-
and safety glasses must be worn.
ment. Avoid touching any energized equipment
Safety cautions and warnings appear throughout the when the door to the low voltage area is open.
instructions. WARNING indicates the potential for
personal injury and CAUTION indicates the potential Failure to do so may result in personal injury and
for equipment damage. Read the following warnings equipment damage.
prior to working on this drive system.
Hazardous voltages are present in this

equipment. Ensure that the Control Power Switch Hazardous voltages may be present in this equip-
(CPS) is in the OFF position and that the ment even if the engine and capacitor charge
Generator Field Contactor (GFCO) switch is in the lights are off.
CUTOUT position before attempting any work on
the drive system components. Check that Use measurement and protective equipment
Capacitor Charge Lights (CCL’s) are not rated for 2000 VDC minimum to verify that no
illuminated. voltage is present before touching any terminal.
Use measurement and protective equipment
Verify functionality of the measurement equip-
rated for 2000 VDC minimum to verify that no
ment using site-approved procedures both
voltage is present before touching any terminal.
before and after performing control group mea-
Verify functionality of the measurement surements.
equipment using site-approved procedures both
before and after performing control group Failure to observe these precautions may result
measurements. in death or serious personal injury.
Failure to observe these precautions may result
in death or serious personal injury.
Verify that the Capacitor Charge Light (CCL) Voltages in excess of 1500 VDC may be present.
above the high voltage contactor area is not Any measurement and/or protective equipment
illuminated before opening the doors to the high used must be rated at 2000 VDC minimum.
voltage area or the high voltage contactor area.
Use measurement and protective equipment Verify functionality of the measurement equip-
rated for 2000 VDC minimum to verify that no ment using site-approved procedures both
voltage is present before touching any terminal. before and after performing control group mea-
surements.
Verify functionality of the measurement
equipment using site-approved procedures both Failure to observe these precautions may result
before and after performing control group in death or serious personal injury.
measurements.
28
Manual DC link capacitor discharge procedure

Follow any and all local and site specific procedures
and requirements for working on off-highway mining
equipment.
1. Verify that the engine is off and the parking

brake is on.
2. Verify that the generator field contactor (GF) FIGURE 00-9. INFORMATION DISPLAY PANEL
switch (2, Figure 00-9) in the low voltage area of
the control cabinet is in the CUTOUT position. 1. Control Power Switch 3. Capacitor Charge
2. GF Cutout Switch Light
3. Move the control power switch (1) to the ON
position for a minimum of 30 seconds. Then,
turn the control power switch to the OFF posi-
tion.
(With control power on, an RP contactor closes
In most control cabinets, RP2 is the normal discharge
and discharges the DC link through the retard-
path. In groups containing an RP3 contactor, RP2
ing grids in less than 10 seconds.)
and RP3 are alternated as the normal discharge
path. Refer to Figure 00-10.
FIGURE 00-10. DISCHARGE PATHS
29
4. 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 00-11. Verify functionality of the measurement equip-
surements.

Hazardous voltages may be present in this equip- in death or serious personal injury.
ment even if the engine and capacitor charge
lights are off.
5. Use volt meter tester (58B-06-00770) to test the
volt meter for proper operation. Voltage should
Use measurement and protective equipment read 100 VDC. If the voltmeter fails the test,
rated for 2000 VDC minimum to verify that no repair or replace the volt meter. Do not proceed
voltage is present before touching any terminal. unless the volt meter is functioning properly.
FIGURE 00-11. CAPACITOR CHARGE LIGHTS

1. Exterior Capacitor Charge Light (CCL2) 3. Information Display Panel
2. Interior Capacitor Charge Light (CCL1) 4. DC Link Capacitors
30
Failure of the discharge system 1. Open the high voltage area doors.
If the capacitor charge lights remain illuminated, a 2. Use a suitable high voltage meter (rated for at
failure of the normal (fast) capacitor discharge sys- least 2000 VDC) and suitable protective equip-
tem (RP discharge path) has likely occurred. The ment that are included in 2000VDC meter kit
slow discharge resistors that are hard wired across (58B-06-00800) to measure the voltage across
the DC link should then discharge the capacitors. The each of the DC link capacitors. Place one meter
slow discharge resistors will discharge the DC link to lead on the positive (+) capacitor terminal, and
less than 1 VDC in under 7.5 minutes. If after 7.5 min- the other meter lead on the negative (-) capaci-
utes, the capacitor charge lights are still illuminated, it tor terminal, and observe the voltage. See
must be assumed that the automatic discharge sys- Figure 00-12 and Figure 00-13. If the voltage is
tem is not working and that high voltage is present in less than 1.0 V the capacitor is sufficiently dis-
the high voltage area. charged. 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 capacitors”.
FIGURE 00-12. DC METER ON CAPACITOR
FIGURE 00-13. CAPACITOR TERMINAL POLARITY
31
Manual discharge of capacitors

If the voltage is greater than 1V on any of the capaci-
tors, the capacitor must be manually discharged. Use
a suitable capacitor discharge device, such as the
grounding sticks included in 2000VDC meter kit Hazardous voltages are present in this equip-
(58B-06-00800), to discharge the capacitors where ment. Avoid touching any energized equipment
needed per the following instructions: when the door to the low voltage area is open.
Failure to do so may result in personal injury and
1. With the control cabinet high voltage compart-
equipment damage.
ment doors closed, connect the grounding stick
pair ground lead to ground. The most conve- 3. Discharge the relevant capacitors. Open the
nient location is the middle top bolt that attaches door(s) and place one grounding stick on one of
the door center post to the control cabinet the positive (+) capacitor terminals and the other
frame. on the diagonally located negative (-) terminal.
Refer to Figure 00-13 and Figure 00-15.
2. Verify the ground connection and grounding
Attempt to minimize the time between applica-
stick resistance levels. Measure the resistance
tion of the positive stick and the negative stick
between each individual grounding stick tip to
so that the current flow will be positive to nega-
either the GND1 or GND2 ground block in the
tive rather than either to ground. Leave sticks in
low voltage compartment of the control cabinet
place until capacitors are discharged. Refer to
using a multimeter (Figure 00-14). Ensure that
Figure 00-15.
the resistance is within the manufacturer’s spec-
ifications for the ground sticks. If the readings NOTE: On the capacitors located behind the door
are not within specifications, repair or replace post, it is difficult to access diagonal terminals on the
the grounding sticks. Do not proceed any further same capacitor. If using adjacent terminals, use care
until the grounding sticks are within specifica- to keep the tips separated while discharging or else
tions. use a positive terminal on one capacitor and negative
terminal of the adjacent capacitor on the same bus
For the grounding sticks included in 2000VDC
bar.
meter kit (58B-06-00800), the valid range is 80
to 125 ohms per stick. For the grounding sticks, the discharge times from
2000 volts are:
• 15 seconds (maximum) for 2 capacitors
• 75 seconds (maximum) for 10 capacitors
FIGURE 00-14. GROUNDING STICK LEAD CONNECTION AND CHECK
32
4. 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
Voltages in excess of 1500 VDC may be present. low voltage compartment of the control cabinet
Any measurement and/or protective equipment using a multimeter (Figure 00-14). Ensure that
used must be rated at 2000 VDC minimum. the resistance is within the manufacturer’s spec-
ifications for the ground sticks.
ment using site-approved procedures both For the grounding sticks included in 2000VDC
before and after performing control group mea- meter kit (58B-06-00800), the valid range is 80
surements. to 125 ohms per stick.
5. Re-test for voltage on all capacitors as
Failure to observe these precautions may result described in “Manual discharge of capacitors”.
in death or serious personal injury. The discharge procedure must be repeated on
all capacitors that indicated 1 VDC or higher.
6. After it is confirmed that all capacitors are fully
discharged, proceed to “Short isolated capacitor
terminals”.
FIGURE 00-15. APPLICATION OF GROUNDING STICKS TO

CAPACITOR TERMINALS
33
Short isolated capacitor terminals Any capacitor that is isolated from the DC link and
confirmed discharged must have its terminals electri-
cally shorted together to prevent static charge build
up. Use bare wire to jumper all four terminals on the
capacitor. See Figure 00-16. Proceed to troubleshoot
and repair the control group to restore it to original
Hazardous voltages may be present in this equip- functionality.
ment 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.

surements.

FIGURE 00-16. JUMPER ALL TERMINALS ON

ISOLATED CAPACITOR
34
Actions taken to meet exhaust gas About DEF

regulations DEF is necessary for the urea SCR system. DEF is a
This machine conforms to either regulation of Tier4 colorless transparent 32.5% aqueous urea solution.
Final (North America) or Stage IV (Europe). Urea as main constituent is a material which is used
for cosmetics, medical and pharmaceutical products,
This machine is equipped with the following two
and fertilizer, etc.
exhaust gas treatment systems:
If you add any additional additive agents or water to
• Komatsu Diesel Particulate Filter (hereafter
KDPF): A device which captures soot in the DEF and use it, the devices will not function properly,
exhaust gas to purify exhaust gas. This process and conformance to the exhaust gas regulations will
performs the combustion of soot referred to as be lost. In addition, it will cause failure of the
"regeneration". machine.
• Urea SCR system: A device which decomposes • In Europe, use AdBlue®.
the toxic nitrogen oxides (NOx) mixed in the
• In North America, use DEF (Diesel Exhaust Fluid)
exhaust gas into harmless nitrogen and water.
which is certified by API (American Petroleum
Spraying aqueous urea solution into the exhaust
Institute).
gas produces a reaction between the nitrogen
oxides and ammonia generated from the urea
The certified DEF has the API DEF Certification
solution and decomposes the nitrogen oxides into
Mark shown as follows. Look for the API DEF
nitrogen and water.
Certification Mark when purchasing DEF. API
Either AdBlue® or DEF may be used as the aqueous Diesel Exhaust Fluid Certification Mark is the
urea solution for the SCR system. trademark of API (American Petroleum Institute).
AdBlue® is a registered trade-mark of VDA (Verband
der Automobilindustrie e.V.: Automobile Association
of Germany).
DEF is the abbreviation for Diesel Exhaust Fluid.
Commercial DEF that is API approved and meets all
the requirements defined in ISO 22241-1.
This solution will be represented as DEF throughout
this manual.
35
Precautions for DEF Precautions for fire hazard and leakage
General character and precautions for handling AdBlue/DEF is non-flammable. However, in the case
of a fire it may generate an ammonia gas.
DEF is a colorless transparent 32.5% aqueous urea
solution. Urea as main constituent is a material which If AdBlue/DEF is spilled, immediately wipe and wash
is used for cosmetics, medical and pharmaceutical the area with water. If spilled AdBlue/DEF is left
products, and fertilizer, etc. The following situations unattended and the area is not wiped and cleaned,
require immediate action: toxic gas or corrosive substance may be produced by
chemical reactions.
• If it gets on your skin, it may cause inflammation.
Immediately take the contaminated clothes or Other precautions
shoes off and wash it off with water. In addition,
use a soap to wash it off thoroughly. If your skin When disposing of AdBlue/DEF, treat it as an
becomes irritated or begins to hurt, immediately industrial waste. Obey appropriate laws and
consult a doctor for treatment. regulations when disposing of harmful objects.
• Do not induce vomiting if swallowed. If Never use an iron or aluminum container when
swallowed, thoroughly rinse mouth with water disposing AdBlue/DEF fluid because toxic gas may
and consult a doctor for treatment. develop and a chemical reaction may corrode the
• Avoid contact with the eyes. If there is contact, container. Use a container made of resin (PP, PE) or
flush with clean water for several minutes and stainless steel when handling the fluid waste of
consult a doctor for treatment. AdBlue/DEF.
• Wear protective eyeglasses when exposed to Do not touch any fluid discharged from urea SCR.
DEF to protect from solution splashing in your This fluid becomes acid by the influence of sulfur in
eyes. Wear rubber gloves when you perform work the fuel or built-in oxidation catalyzer. If it gets on
handling DEF to avoid skin contact. your skin, thoroughly wash it off with water.
Precautions for adding Never relocate or modify the exhaust gas after-
treatment device. The harmful gas may be exhausted
Do not put fluid other than DEF into DEF tank. If
and can cause serious damage to the environment. It
diesel fuel or gasoline is added into the tank, it can
may be a violation of laws as well.
cause a fire. Some fluids or agents added can create
and emit a toxic gas.
When opening the cap of DEF tank of the machine,
the ammonia vapor may escape. Keep your face
away from the filler port during opening or refilling.
Precautions for storing

If the temperature of AdBlue/DEF becomes high,
harmful ammonia gas may be generated. Completely
seal up its container for storage. When opening the
container, perform it where there is good ventilation.
For storage, see "Store AdBlue/DEF".
Store AdBlue/DEF avoiding direct sunlight. Always
use the original container at the time of purchase. Do
not exchange the container of AdBlue/DEF with
another one. If AdBlue/DEF is stored in an iron or
aluminum container, toxic gas may develop and a
chemical reaction may corrode the container.
36
Store AdBlue/DEF Handling AdBlue/DEF in cold weather

• If the temperature of AdBlue/DEF becomes high, • At temperatures of –11 °C (12 °F) or below,
harmful ammonia gas may be generated. AdBlue/DEF may freeze and expand to break the
Completely seal up its container for storage. Only devices and parts in the tank. The parts inside the
open containers in a well-ventilated area. tank may be affected. Add AdBlue/DEF to the
specified amount for cold weather (below the
• Do not store AdBlue/DEF in direct sunlight. level of when AdBlue/DEF may freeze).
Always use the original container at the time of
purchase. Do not exchange the container of • In cold weather, keep AdBlue/DEF or the
AdBlue/DEF with another one. If AdBlue/DEF is machine with AdBlue/DEF indoors where the
stored in an iron or aluminum container, toxic gas temperature is higher than –11 °C (12 °F) to
may develop and a chemical reaction may prevent AdBlue/DEF in the tank from freezing.
corrode the container.
• AdBlue/DEF freezes at –11 °C (12 °F). The
recommended temperature for storage is -5 °C
(23 °F) or above.
The relation between the upper limit of storage
temperature and the storage period of AdBlue/DEF is
shown in the table below. Do not store AdBlue/DEF in
temperatures above 35 °C (95 °F).
Temperature of storage area Storage period

Max.10 °C (50 °F) Up to 36 months
37
38
Handling electrical equipment and

hydraulic components
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried
out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it provides information on handling electrical equipment and handling hydrau-
lic equipment (particularly gear oil and hydraulic oil).
Points to remember when handling electrical equipment

1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

• Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not prop-
erly inserted into the female connector, or
because one or both of the connectors is
deformed or the position is not correctly aligned,
or because there is corrosion or oxidization of
the contact surfaces. The corroded or oxidized
contact surfaces may become shiny again (and
contact may become normal) by connecting and
disconnecting the connector about 10 times.
• Defective crimping or soldering of connectors

The pins of the male and female connectors are
in contact at the crimped terminal or soldered
portion, but if there is excessive force brought to
bear on the wiring, the plating at the joint will
peel and cause improper connection or break-
age.
39
• Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a heavy
object hits the wiring, the crimping of the con-
nector may separate, or the soldering may be
damaged, or the wiring may be broken.
• High-pressure water entering connector

The connector is designed to make it difficult for
water to enter (drip-proof structure), but if high-
pressure water is sprayed directly on the con-
nector, water may enter the connector, depend-
ing on the direction of the water jet. Accordingly,
take care not to splash water over the connec-
tor. The connector is designed to prevent water
from entering, but at the same time, if water
does enter, it is difficult for it to be drained.
Therefore, if water should get into the connec-
tor, the pins will be short-circuited by the water,
so if any water gets in, immediately dry the con-
nector or take other appropriate action before
passing electricity through it.
• Oil or dirt stuck to connector

If oil or grease are stuck to the connector and an
oil film is formed on the mating surface between
the male and female pins, the oil will not let the
electricity pass, so there will be defective con-
tact. If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry with
compressed air and spray it with a contact
restorer.
• When wiping the mating portion of the
connector, be careful not to use excessive
force or deform the pins.
• If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before clean-
ing with compressed air.
40
3. Removing, installing, and drying connectors

and wiring harnesses
• Disconnecting connectors
a. When disconnecting the connectors, hold the
connectors. For connectors held by a screw,
loosen the screw fully, then hold the male
and female connectors in each hand and pull
apart. For connectors which have a lock
stopper, press down the stopper with your
thumb and pull the connectors apart. Never
pull with one hand.
b. Both of the connector and clip have stoppers,

which are engaged with each other when the
connector is installed.
When removing a connector from a clip, pull the

connector in a parallel direction to the clip for
removing stoppers. If the connector is twisted
up and down or to the left or right, the housing
may break.
c. After removing any connector, cover it with a

vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion. If
the machine is left disassembled for a long
time, it is particularly easy for improper con-
tact to occur, so always cover the connector.
41
• Connecting connectors
a. Check that there is no oil, dirt, or water stuck
to the connector pins (mating portion). Check
that there is no deformation, defective con-
tact, corrosion, or damage to the connector
pins. Check that there is no damage or
breakage to the outside of the connector.
• If there is any oil, water, or dirt stuck to the
connector, wipe it off with a dry cloth. If
any water has got inside the connector,
warm the inside of the wiring with a dryer,
but be careful not to make it too hot as
this will cause short circuits.
• If there is any damage or breakage,
replace the connector.
b. Fix the connector securely. Align the position
of the connector correctly, and then insert it
securely. For connectors with the lock stop-
per, push in the connector until the stopper
clicks into position.
• Correct any protrusion of the boot and
any misalignment of the wiring harness.
• For connectors fitted with boots, correct
any protrusion of the boot. In addition, if
the wiring harness is misaligned, or the
clamp is out of position, adjust it to its cor-
rect position.
• If the connector cannot be corrected eas-
ily, remove the clamp and adjust the posi-
tion.
• If the connector clamp has been
removed, be sure to return it to its original
position. Check also that there are no
loose clamps.
42
• Heavy duty wire connector (DT 8-pole, 12-pole)

a. For disconnection, press both sides of locks
(a) and (b) while pulling out female connector
(2).
b. For connection, push in female connector (2)
horizontally until the lock clicks.
Since locks (a) and (b) may not be set com-
pletely, push in female connector (2) while mov-
ing it up and down until the locks are set
normally.
• Right half of figure: Lock (a) is pulled
down (not set completely) and lock (b) is
set completely. 1. Male connector a. Lock
2. Female connector b. Lock
• Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high pressure
water or steam directly on the wiring harness. If
water gets directly on the connector, perform the
following procedure.
a. Disconnect the connector and wipe off the
water with a dry cloth. If the connector is
blown dry with compressed air, there is the
risk that oil in the air may cause defective
contact, so remove all oil and water from the
compressed air before blowing with air.
b. If water gets inside the connector, use a
dryer to dry the inside of the connector. Hot
air from the dryer can be used, but regulate
the time that the hot air is used in order not to
make the connector or related parts too hot,
as this will cause deformation or damage to
the connector.
c. After drying, leave the wiring harness discon-
nected and carry out a continuity test to
check for any short circuits between pins
caused by water.
d. After completely drying the connector, blow it
with contact restorer and reassemble.
43
4. Handling controllers
The controllers contain a microcomputer and
electronic control circuits. These control all of
the electronic circuits on the machine, so be
extremely careful when handling the controllers.
• Do not place objects on top of the controllers.
• Cover the controller connectors with tape or a
vinyl bag. Never touch the connector contacts
with your hand.
• During rainy weather, do not leave a controller
in a place where it is exposed to rain.
• Do not place a controller on oil, water, or soil, or
in any hot place, even for a short time. Place it
on a suitable dry stand.
• When carrying out arc welding on the body,
disconnect all wiring harness connectors that
are connected to the controllers. Fit an arc
welding ground close to the welding point.
5. When troubleshooting electric circuits

1) Always turn the power OFF before discon-
necting or connecting any connectors.
2) Before troubleshooting, ensure that all the
related connectors are properly inserted.
Disconnect and connect the related connec-
tors several times to check.
3) Always connect any disconnected the con-
nectors before proceeding to the next step.
If the power is turned ON while the connec-
tors are still disconnected, unnecessary
fault codes will be generated.
4) When troubleshooting circuits (measuring
the voltage, resistance, continuity, or cur-
rent), move the related wiring and connec-
tors several times and check that there is no
change in the reading of the tester. If there
is any change, there is probably defective
contact in that circuit.
44
Points to remember when handling hydraulic

equipment
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to check the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and maintenance of hydraulic equip-
ment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this. Do not simply drain oil out onto
the ground, but collect it and ask the customer
to dispose of it, or take it back with you for dis-
posal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
45
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
from the hydraulic tank. If any old oil is left, the
contaminants and sludge in it will mix with the
new oil and will shorten the life of the hydraulic
oil.
6. Flushing operations
After disassembly and assembly, or changing
the oil, use flushing oil to remove the contami-
nants, sludge, and old oil from the hydraulic cir-
cuit. Normally, flushing is carried out twice:
primary flushing is carried out with flushing oil,
and secondary flushing is carried out with the
specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine particles (about 3 microns)
that the filter built in the hydraulic equipment
cannot remove, so it is an extremely effective
device.
46
Standard tightening torques If special friction-reducing lubricants are used with

the standard torque values listed in this chapter,
This manual provides dual dimensioning for many
excessive stress and possible breakage of the
specifications. Metric units are specified first, with
fasteners may result.
U.S. standard units in parentheses. When torque
values are not specified in the assembly instructions When the torque tables specify “lubricated threads”
contained in this manual, use the standard torque for the standard torque values listed, these standard
value for the hardware being used. Standard value torque values are to be used with simple lithium base
torque tables are contained in this chapter for metric chassis grease (multi-purpose EP NLGI) or a rust
and SAE hardware. preventive grease (see below) on the threads and
seats unless specified otherwise.
This truck is assembled with both metric and SAE
(U.S.) hardware. Reference the correct table when NOTE: Ensure that the threads of fasteners and
determining the proper torque value. tapped holes are free of burrs and other
imperfections before assembling.
Suggested sources for rust preventive grease

NOTE: This list represents the current engineering
approved sources for use in Komatsu manufacture. It
References throughout the manual to standard
is not exclusive. Other products may meet the same
torques or other standard values will be to one of
specifications of this list.
the following tables. Do not use standard values
to replace specific torque values in assembly • American Anti-Rust Grease #3-X from Standard
instructions. Oil Company (also American Oil Co.)
• Gulf NoRust #3 from Gulf Oil Company.
For values not shown in any of the charts or tables,
standard conversion factors for most commonly used • Mobilarma 355, Product No. 66705 from Mobil Oil
measurements are provided in the following tables. Corporation.
• Rust Ban 326 from Humble Oil Company.
• Rustolene B Grease from Sinclair Oil Co.
Effect of special lubricants on fasteners and • Rust Preventive Grease - Code 312 from the
standard torque values Southwest Grease and Oil Company.
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.
47
SAE grade 5 and grade 8 hex head capscrew and In the following table under “Capscrew Size”, the first
nut assemblies number represents the shank diameter (in.). The
second number represents threads per inch.
The following specifications apply to required
assembly torques for all grade 5 and grade 8 Example: 7/16 - 20
capscrews.
7/16 = shank diameter (7/16 inch [0.438 inch])
NOTE: Capscrew threads and seats shall be lubri- 20 = threads per inch
cated when assembled. Unless instructions specifi-
cally recommend otherwise, these standard torque
values are to be used with simple lithium base chas-
sis grease (multi-purpose EP NLGI) or an approved
rust preventive grease on the threads.
NOTE: Torques are calculated to give a clamping
force of approximately 75% of proof load. The maxi-
mum torque tolerance shall be within ±10% of the
torque value shown.
Table 3: Standard tightening torques for

SAE hex head capscrew and nut assembly with lubricated threads
Torque - Torque - Torque - Torque -

Thread Grade 5 Grade 8 Thread Grade 5 Grade 8
Size Size
ft lb kg·m N·m ft lb kg·m N·m ft lb kg·m N·m ft lb kg·m N·m
1/4-20 7 0.97 9.5 10 1.38 13.6 3/4-16 235 32.5 319 335 46.3 454
1/4-28 8 1.11 10.8 11 1.52 14.9 7/8-9 350 48.4 475 500 69.2 678
5/16-18 15 2.07 20.3 21 2.90 28 7/8-14 375 51.9 508 530 73.3 719
5/16-24 16 2.21 22 22 3.04 30 1.0-8 525 72.6 712 750 103.7 1017
3/8-16 25 3.46 34 35 4.84 47 1.0-12 560 77.4 759 790 109.3 1071
3/8-24 30 4.15 41 40 5.5 54 1.0-14 570 78.8 773 800 110.6 1085
7/16-14 40 5.5 54 58 8.0 79 1 1/8-7 650 89.9 881 1050 145 1424
7/16-20 45 6.2 61 62 8.57 84 1 1/8-12 700 96.8 949 1140 158 1546
1/2-13 65 9 88 90 12.4 122 1 1/4-7 910 125.9 1234 1480 205 2007
1/2-20 70 9.7 95 95 13.1 129 1 1/4-12 975 134.8 1322 1580 219 2142
9/16-12 90 12.4 122 125 17.3 169 1 3/8-6 1200 166 1627 1940 268 2630
9/16-18 95 13.1 129 135 18.7 183 1 3/8-12 1310 181 1776 2120 293 2874
5/8-11 125 17.3 169 175 24.2 237 1 1/2-6 1580 219 2142 2560 354 3471
5/8-18 135 18.7 183 190 26.2 258 1 1/2-12 1700 235 2305 2770 383 3756
3/4-10 220 30.4 298 310 42.8 420
1 ft lb = 0.138 kgm = 1.356 Nm
48
SAE grade 9 capscrews Class 10.9 capscrews and class 10 nuts

The following specifications apply to required The following specifications apply to required
tightening torques for SAE hex head and 12-point, assembly torques for all metric class 10.9 finished
grade 9 (170,000 psi minimum tensile) capscrews. hexagon head capscrews and class 10 nuts.
NOTE: Capscrew threads and seats shall be lubri- DO NOT lubricate capscrew threads and seats during
cated when assembled. Unless instructions specifi- assembly. These specifications are based on the
cally recommend otherwise, these standard torque following hardware:
values are to be used with simple lithium base chas-
• All capscrews
sis grease (multi-purpose EP NLGI) or an approved
rust preventive grease on the threads. • All nuts
NOTE: Torques are calculated to give a clamping • All hardened washers being phosphate and oil
force of approximately 75% of proof load. The maxi- coated
mum torque tolerance shall be within ±10% of the NOTE: If zinc-plated hardware is used, each piece
torque value shown. must be lubricated with simple lithium base chassis
Example: 1/2 - 13 grease (multi-purpose EP NLGI) or an approved rust
preventive grease to achieve the same clamping
1/2 = shank diameter (1/2 inch [0.500 inch]) forces provided below.
13 = threads per inch NOTE: Torques are calculated to give a clamping
force of approximately 75% of proof load. The
Table 4: Standard tightening torques for SAE
maximum torque tolerance shall be within ±10% of
hex head and 12-point, grade 9 capscrews
the torque value shown.
Capscrew Torque Torque Torque In the following table under “Capscrew Size”, the first
size* N·m ft lb kg·m number represents the shank diameter (mm). The
1/4 - 20 12 16 1.7 second number represents thread pitch in
millimeters.
5/16 - 18 24 33 3.3
Example: M20 x 2.25
3/8 - 16 42 57 5.8
M20 = shank diameter (20 mm)
7/16 - 14 70 95 9.7
2.25 = thread pitch in millimeters
1/2 - 13 105 142 14.5
Table 5: Standard tightening torques for
9/16 - 12 150 203 20.7
metric class 10.9 capscrews and class 10 nuts
5/8 - 11 205 278 28.3
Capscrew Torque Torque Torque
3/4 - 10 360 488 49.7 size* N·m ft lb kg·m
7/8 - 9 575 780 79.4 M6 x1 12 9 1.22
1-8 860 1166 119 M8 x 1.25 30 22 3.06
1 - 12 915 1240 126 M10 x 1.5 55 40 5.61
1 1/8 - 7 1230 1670 170 M12 x 1.75 95 70 9.69
1 1/8 - 12 1330 1800 184 M14 x 2 155 114 15.81
1 1/4 - 7 1715 2325 237 M16 x 2 240 177 24.48
1 1/4 - 12 1840 2495 254 M20 x 2.25 465 343 47.43
1 3/8 - 6 2270 3080 313 M24 x 3 800 590 81.6
1 3/8 - 12 2475 3355 342 M30 x 3.5 1600 1180 163.2
1 1/2 - 6 2980 4040 411 M36 x 4 2750 2028 280.5
1 1/2 - 12 3225 4375 445
49
Standard tightening torques for fittings
Table 7: Torques for O-ring boss fittings
Tube
Table 6: Torques for JIC 37° swivel nuts Size Threads Torque Torque
size
(with or without O-ring seals) code UNF-2B ft lb N·m
(O.D.)
Tube –2 0.125 0.312–24 4±2 6±3
Size Threads Torque Torque
size
code UNF-2B ft lb N·m –3 0.188 0.375–24 5±2 7±3
(O.D.)
–2 0.125 0.312–24 4±1 5±1 –4 0.250 0.438–20 8±3 11 ± 4
–3 0.188 0.375–24 8±3 11 ± 4 –5 0.312 0.500–20 10 ± 3 13 ± 4
–4 0.250 0.438–20 12 ± 3 16 ± 4 –6 0.375 0.562–18 13 ± 3 18 ± 4
–5 0.312 0.500–20 15 ± 3 20 ± 4 –8 0.500 0.750–16 24 ± 5 33 ± 7
–6 0.375 0.562–18 18 ± 5 24 ± 7 – 10 0.625 0.875–14 32 ± 5 43 ± 7
–8 0.500 0.750–16 30 ± 5 41 ± 7 – 12 0.750 1.062–12 48 ± 5 65 ± 7
– 10 0.625 0.875–14 40 ± 5 54 ± 7 – 14 0.875 1.188–12 54 ± 5 73 ± 7
– 12 0.750 1.062–12 55 ± 5 74 ± 7 – 16 1.000 1.312–12 72 ± 5 98 ± 7
– 14 0.875 1.188–12 65 ± 5 88 ± 7 – 20 1.250 1.625–12 80 ± 5 108 ± 7
– 16 1.000 1.312–12 80 ± 5 108 ± 7 – 24 1.500 1.875–12 80 ± 5 108 ± 7
– 20 1.250 1.625–12 100 ± 10 136 ± 14 – 32 2.000 2.500–12 96 ± 10 130 ± 14
– 24 1.500 1.875–12 120 ± 10 162 ± 14
– 32 2.000 2.500–12 230 ± 20 311 ± 27
50
Table 8: Torques for O-ring face seal fittings
Tube
Size Threads Torque Torque
size
code UNF-2B ft lb N·m
(O.D.)
–4 0.250 0.438–20 11 ± 1 15 ± 1
–6 0.375 0.562–18 18 ± 2 24 ± 3
–8 0.500 0.750–16 35 ± 4 47 ± 5
– 10 0.625 0.875–14 51 ± 5 70 ± 8
– 12 0.750 1.062–12 71 ± 7 96 ± 9
– 16 1.000 1.312–12 98 ± 6 133 ± 8
– 20 1.250 1.625–12 132 ± 7 179 ± 9
– 24 1.500 1.875–12 165 ± 15 224 ± 20
Table 9: Torques for pipe thread fittings
Torque with Torque with Torque without Torque without

Size Pipe thread
sealant sealant sealant sealant
code size
ft lb N·m ft lb N·m
–2 0.125–27 15 ± 3 20 ± 4 20 ± 5 27 ± 7
–4 0.250–18 20 ± 5 27 ± 7 25 ± 5 34 ± 7
–6 0.375–18 25 ± 5 34 ± 7 35 ± 5 47 ± 7
–8 0.500–14 35 ± 5 47 ± 7 45 ± 5 61 ± 7
– 12 0.750–14 45 ± 5 61 ± 7 55 ± 5 74 ± 7
– 16 1.000-11.50 55 ± 5 74 ± 7 65 ± 5 88 ± 7
– 20 1.250–11.50 70 ± 5 95 ± 7 80 ± 5 108 ± 7
– 24 1.500–11.50 80 ± 5 108 ± 7 95 ± 10 129 ± 14
– 32 2.000–11.50 95 ± 10 129 ± 14 120 ± 10 162 ± 14
51
Conversion tables
Common conversion multipliers
Table 10: English to metric Table 11: Metric to English

Multiply Multiply
From To From To
by by
inch (in.) millimeter (mm) 25.40 millimeter (mm) inch (in.) 0.0394
inch (in.) centimeter (cm) 2.54 centimeter (cm) inch (in.) 0.3937
foot (ft) meter (m) 0.3048 meter (m) foot (ft) 3.2808
yard (yd) meter (m) 0.914 meter (m) yard (yd) 1.0936
mile (mi) kilometer (km) 1.61 kilometer (km) mile (mi) 0.6210
square centimeter square centimeter
square inch (in.2) 6.45 square inch (in.2) 0.1550
(cm2) (cm2)
square centimeter square centimeter
square foot (ft2) 929 square foot (ft2) 0.001
(cm2) (cm2)
cubic centimeter cubic centimeter
cubic inch (in.3) 16.39 cubic inch (in.3) 0.061
(cm3) (cm3)
cubic inch (in.3) liter (l) 0.016 liter (l) cubic inch (in.3) 61.02
cubic foot (ft3) cubic meter (m3) 0.028 cubic meter (m3) cubic foot (ft3) 35.314
3
cubic foot (ft ) liter (l) 28.317 liter (l) cubic foot (ft3) 0.0353
ounce (oz) gram (g) 28.350 gram (g) ounce (oz) 0.0353
fluid ounce (fl oz) milliliter (ml) 29.573 milliliter (ml) fluid ounce (fl oz) 0.0338
pound (lb) - mass kilogram (kg) 0.454 kilogram (kg) pound (lb) - mass 2.2046
pound (lb) - force Newton (N) 4.448 Newton (N) pound (lb) - force 0.2248
inch pound (in lb) Newton meter (N·m) 0.113 Newton meter (N·m) inch pound (in lb) 8.85
foot pound (ft lb) Newton meter (N·m) 1.356 Newton meter (N·m) foot pound (ft lb) 0.7376
foot pound (ft lb) kilogram meter (kgm) 0.138 kilogram meter (kgm) foot pound (ft lb) 7.2329
pounds/square inch pounds/square inch
kilopascal (kPa) 6.895 kilopascal (kPa) 0.1450
(psi) (psi)
pounds/square inch pounds/square inch
megapascal (MPa) 0.007 megapascal (MPa) 145.038
(psi) (psi)
pounds/square inch kilograms/square kilograms/square pounds/square inch
0.0704 14.2231
(psi) centimeter (kg/cm2) centimeter (kg/cm2) (psi)
short ton kilogram (kg) 907.2 kilogram (kg) short ton 0.0011
short ton metric ton 0.0907 metric ton short ton 1.1023
quart (qt) liter (l) 0.946 liter (l) quart (qt) 1.0567
U.S gallon (gal) liter (l) 3.785 liter (l) U.S gallon (gal) 0.2642
horsepower (HP) kilowatt (kw) 0.745 kilowatt (kw) horsepower (HP) 1.3410
52
Table 12: Metric to metric
Multiply
From To
by
Newton meter (N·m) kilogram meter (kgm) 0.102
kilogram meter (kgm) Newton meter (N·m) 9.807
kilograms/square
kilopascal (kPa) 98.068
centimeter (kg/cm2)
kilograms/square
kilopascal (kPa) 0.01
centimeter (kg/cm2)
53
Temperature conversion table

When converting from Fahrenheit (°F) to Centigrade (°C), consider the center (boldface) column to be a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
When converting from Centigrade (°C) to Fahrenheit (°F), consider the center (boldface) column to be a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
54
NOTES
55
980E Dump truck

56
CEN01020-00
980E

980E-5 A50005 and up
01 Specification
Specification and technical data
Specification drawing ............................................................................................................................................ 3
Specifications ........................................................................................................................................................ 4
Weight table .......................................................................................................................................................... 6
Fuel, coolant and lubricants .................................................................................................................................. 7
1
CEN01020-00 01 Specification
NOTES
2
01 Specification CEN01020-00
Specification drawing
10.0 m 32’10”
15.0 m
49’3”
1.8 m 5’10”
5.8 m 19’
9.1 m 29’10”
13.90 m 45’7”
7.09 m
23’3”
8.0 m
26’4”
4.53 m
14’10”
2.17 m
7’1”
1.22 m 1.65 m
4’0” 5’5”
4.60 m 15’1” 6.65 m 21’10” 4.47 m 14’8” 6.5 m 21’4”

8.0 m 26’4”
15.72 m 51’7”
9.6 m 31’6”
86991
3
Specifications
Specification Value
Empty 265 125 kg (584,500 lb)
Nominal load 362 874 kg (800,000 lb)
Gross total 627 999 kg (1,384,500 lb)
Weight
front 123 569 kg (272,423 lb)

distribution
Empty
Weight
rear 141 556 kg (312,077 lb)

front 206 396 kg (455,025 lb)
Loaded
rear 421 603 kg (929,475 lb)
Struck 191 m3 (250 yd3)
Dump body capacity
Performance
Heaped (2:1) 250 m3 (327 yd3)

Max. travel speed 64.4 kph (40 mph)
Gradeability 23.7% at stall
Min. turning diameter 32 m (105 ft)
Dumping angle 45°
Overall length 15.72 m (51 ft 7 in)
Dimensions
Overall width 9.6 m (31 ft 6 in)

Overall height 8 m (26 ft 4 in)
Wheel base 9.1 m (29 ft 10 in)
Ground clearance (empty) 1.22 m (4 ft)
Model KOMATSU SSDA18V170
4-cycle, water-cooled, direct injection,
Type
with turbocharger, aftercooler and intercooler
No. of cylinders - Bore x stroke 18 - 170 mm x 190 mm (6.7 in. x 7.5 in.)
Piston displacement 78 L (20.6 gal)
Engine
Rated output 2 611 kW (3,500 hp) at 1,800 rpm

Max. torque 13 771 N·m (10,157 ft lb)
Min. fuel consumption 0.330 lb/hp-hr
Cranking motor 24V, 7.5 kW X 2 units
Battery charging alternator 24V, 275A X 2 units
Batteries 12V, 1400 CCA, 8D type X 4 units
Motorized wheels AC induction traction motors
AC Drive System
Standard gear ratio 35.02:1
Continuous dynamic retarding 4 476 kW (6,000 hp)
4
Steering Specification Value

System
Type Fully hydraulic
Front axle Sliding pillar

Suspension
Suspension method
Rear axle Hydro-pneumatic
Size 59/80 R63

Min. tire pressure 600 kPa (87 psi)
Tires
Front wheel 116 mm (4.6 in.)

Tread (standard tire)
Rear wheel 116 mm (4.6 in.)
Service brakes (front and rear) Multiple wet disc
System
Brake
Parking brake Multiple dry disc
Type Pressure compensated piston pump

Steering/brake pump Delivery
Hydraulic
246 liters/min (65 gpm)

pumps
at 1900 rpm
Type Tandem gear pump
Hoist/brake cooling
pump Delivery
931 liters/min (246 gpm)
at 1900 rpm
Hydraulic systems
Type 3-stage piston

1st stage - 384.2 mm x 945.9 mm
(15.13 in x 37.24 in)
Hoist cylinder 2nd stage - 320.7 mm x 945.9 mm
Bore x stroke
Cylinders
(12.63 in x 37.24 in)

3rd stage - 257.1 mm x 945.9 mm
(10.12 in x 37.24 in)
Piston, double acting
Type
with accumulator assist
Steering cylinder
190.5 mm x 665.7 mm
Bore x stroke
(7.50 in x 26.21 in)
5
Weight table
NOTE: This weight table is a guide for use when transporting or handling a component.
Component Approximate Weight
Power module (with sub-frame and grille) 22 000 kg (48,500 lb)
Engine assembly (with oil) 12 338 kg (27,200 lb)
Radiator assembly 2 450 kg (5,400 lb)
Main traction alternator 4 900 kg (10,800 lb)
Fuel tank assembly (with DEF tank) 2 325 kg (5,125 lb)
Hydraulic tank assembly 635 kg (1,400 lb)
Front suspension cylinder assembly (with oil) 4 363 kg (9,619 lb)
Rear suspension cylinder assembly (with oil) 1 015 kg (2,238 lb)
Hoist cylinder assembly 1 175 kg (2,590 lb)
Steering cylinder assembly 260 kg (573 lb)
Tie rod 383 kg (845 lb)
Bleeddown manifold 170 kg (375 lb)
Pump/hoist valve module (without driveshaft) 765 kg (1,686 lb)
Hoist pump 136 kg (300 lb)
Steering/brake pump 102 kg (225 lb)
Hoist valve 189 kg (417 lb)
Overcenter valve manifold 94 kg (207 lb)
Spindle, hub and brake assembly 6 681 kg (14,728 lb)
Front spindle and hub 3 957 kg (8,724 lb)
Steering arm 352 kg (776 lb)
Front brake assembly 1 687 kg (3,719 lb)
Anti-sway bar 160 kg (353 lb)
Axle housing 7 750 kg (17,100 lb)
Wheel motor assembly 24 000 kg (52,900 lb)
Electric wheel motor 6 135 (13,520 lb)
Transmission/rear brake assembly 17 465 kg (38,500 lb)
Parking brake 173 kg (381 lb)
Final frame structure 31 978 kg (70,500 lb)
Battery box assembly 467 kg (1,030 lb)
Alternator blower air duct 205 kg (452 lb)
Wheel motor blower air duct 315 kg (695 lb)
Cab assembly 2 415 kg (5,325 lb)
Hydraulic brake cabinet 186 kg (410 lb)
Main electrical control cabinet 3 176 kg (7,000 lb)
Auxiliary control cabinet 450 kg (990 lb)
Retarding grid 2 600 kg (5,735 lb)
Right deck 1 065 kg (2,348 lb)
Left deck 895 kg (1,974 lb)
Center deck 280 kg (617 lb)
6
Fuel, coolant and lubricants

Reservoir Fluid type Recommended fluids Service Capacity
See engine manufacturer’s 371 L (98 gal)
Engine crankcase Engine oil
service manual. including oil filters
Hydraulic tank Hydraulic oil C-4 type (SAE 10W) 1 325 L (350 gal)
Front suspension 148.4 L (39.2 gal)

Suspension oil with See "Suspension cylinder oil and
friction modifier nitrogen specifications".
Rear suspension 61.7 L (16.3 gal)
Grease fittings Multi-purpose extreme

NLGI No. 2 41 kg (90 lb)
Auto lube tank pressure grease
Heavy duty synthetic See drive system manufacturer’s 98 L (26 gal)
Wheel motor
gear oil service manual. per wheel motor
See engine manufacturer’s
Cooling system Coolant 799 L (211 gal)
service manual.
Fuel tank Diesel fuel 4 542 L (1,200 gal)
service manual.
DEF tank Diesel exhaust fluid 348 L (92 gal)
service manual.
7
Suspension cylinder oil and nitrogen specifications
HYDRAIR® II oil specifications

Ambient Temperature
Part No. Approved Sources
Range
Mobilfluid 424 Sunfleet TH Universal Tractor Fluid
VJ3911 Mobil DTE 15M Chevron Tractor Hydraulic Fluid
(need to add Texaco TDH Oil Conoco Power Tran III Fluid Petro
6% of AK3761) AMOCO ULTIMATE Motor Oil Canada Duratran Fluid
-34.5°C & above 5W-30 Shell Canada Donax TDL
(-30°F & above) AK4063 Suspension Oil (premixed with 5 gallon container
AK4064 6% Friction Modifier) 55 gallon container
Petro Canada Super Arctic
VJ5925 Emery 2811, SG-CD,
Motor Oil, 0W-30
(need to add 5W-30
Conoco High Performance
6% of AK3761) Mobil Delvac I, 5W-40
Synthetic Motor Oil, 5W-30
-48.5°C & above
AK4065 Suspension Oil (premixed with 5 gallon container
(-55°F & above)
AK4066 6% Friction Modifier) 55 gallon container
NOTE: VJ3911 and VJ5925 oils are not compatible and must not be mixed in a suspension.VJ3911 and
VJ5925 oils are supplied in 5 gallon (19 Liter) cans.
Friction modifier mixing instructions

Friction modifier
(94% suspension oil, 6% friction modifier)
Part number Amount of suspension oil Amount of friction modifier to add
AK3761 1 gallon of suspension oil add 7.7 oz.

(5 Gallon container of 5 gallons of suspension oil add 38.4 oz.
100% Friction Modifier) 55 gallons of suspension oil add 3.3 gal.
Nitrogen gas (N2) specifications

Property Value
Nitrogen gas used in HYDRAIR® II Nitrogen 99.9% Minimum

Suspension Cylinders must meet or Water 32 PPM Maximum
exceed CGA specification G-10.1 for Dew Point -55°C (-68°F) Maximum
Type 1, Grade F Nitrogen Gas
Oxygen 0.1% Maximum
8
NOTES
9
980E Dump truck

10
CEN10062-02
980E

980E-4 A40003 and up
980E-5 A50005 and up
10 Structure and functions

Steering circuit
Steering circuit operation ...................................................................................................................................... 2
Steering circuit components.................................................................................................................................. 7
Steering/brake pump operation............................................................................................................................. 9
Flow amplifier operation...................................................................................................................................... 12
1
CEN10062-02 10 Structure and functions
Steering circuit operation Two nitrogen precharged steering accumulators (3,

Steering/brake pump (8, Figure 10-1) supplies oil to Figure 10-1) are mounted on the left frame rail behind
bleeddown manifold (5) after passing through high the front tire. They provide an oil supply that is
pressure filter (9). This oil supply is then distributed to sufficient to allow the operator to steer the truck off
the various circuits. the haul road and park in a safe area if a loss of
steering circuit oil occurs. Steering accumulator
The bleeddown manifold performs many functions, bleeddown solenoid (2, Figure 10-3) is electrically
including distribution of the steering circuit oil supply activated to bleed the pressurized hydraulic oil from
to steering accumulators (3), flow amplifier (4) and inside the accumulators back to the hydraulic tank
steering cylinders (1). Oil is also provided to the whenever the key switch is turned to the OFF
brake circuit and the auxiliary system manifold. position. Approximately 90 seconds is required for
NOTE: The hoist pilot circuit passes through the the accumulator to bleed down fully.
bleeddown manifold, but is not supplied by the The bleeddown manifold and steering accumulators
steering/brake pump. It is supplied by the hoist pump. supply oil to flow amplifier (4, Figure 10-1). The flow
Oil pressure from the bleeddown manifold is routed amplifier directs oil flow to the appropriate ports on
back to the steering/brake pump and sensed by the steering cylinders as determined by inputs from
“ACC” port (7, Figure 10-6) on the unloader valve the steering control unit (as the operator steers the
located on the steering/brake pump. The unloader truck).
valve regulates the system pressure between 22 065 Oil entering the steering control unit is blocked until
kPa (3,200 psi) and 24 130 kPa (3,500 psi). Steering the steering wheel is turned in a desired direction.
system pressure switch (10, Figure 10-3) on the The steering control unit then directs oil to the flow
bleeddown manifold activates a warning if the amplifier, which in turn provides a high volume of oil
steering system pressure drops below 15 858 kPa to steering cylinders (1, Figure 10-1). Hydraulic oil at
(2,300 psi). Pressure switch (1, Figure 10-3) confirms the opposite ends of the steering cylinders flows back
that hydraulic pressure is fully relieved at the through the flow amplifier and bleeddown manifold to
completion of the bleeddown cycle. hydraulic tank (6).
Auxiliary system pressure switch (18, Figure 10-3) Oil flow to the brake apply circuit flows through a
controls a solenoid valve in the auxiliary system check valve, preventing loss of oil in the brake circuit
manifold. When the steering system pressure is if a loss of oil occurs in the steering circuit. Refer to
above 18,960 kPa (2,750 psi), the switch sends a Section 10, Structure and functions, Brake circuit for
signal current to the solenoid valve to open. When more information.
the steering system pressure drops below 17,580
kPa (2,550 psi), the signal current is removed,
causing the solenoid valve to close, and all steering/ NOTE: Refer to Section 90, Diagrams and drawings,
brake pump supply returns to the steering and brake Steering, hoist and brake cooling hydraulic
circuits. circuit schematic for more details on the hydraulic
circuit operation.
2
10 Structure and functions CEN10062-02
5
2
8 86994
FIGURE 10-1. STEERING CIRCUIT COMPONENTS - TYPICAL

1. Steering Cylinders 6. Hydraulic Tank
2. Steering Cylinder Manifold 7. Steering/Brake Pump
3. Steering Accumulators (Piston Type) 8. High Pressure Filter
4. Flow Amplifier 9. Hoist Pump
5. Steering Bleeddown Manifold
3
5
6
8
3 4
10 11 12
7
9
1
13
16
15 14
86244
FIGURE 10-2. BLEEDDOWN MANIFOLD PIPING

1. Supply To Flow Amplifier 9. Supply From Pump
2. Return From Flow Amplifier 10. Return From Hoist Pilot Valve
3. To Front Steering Accumulator 11. Hoist Pilot Valve, Power Down
4. To Rear Steering Accumulator 12. Hoist Pilot Valve, Power Up
5. Supply Port (Quick Disconnect) 13. Feedback Pressure to Unloader Valve
6. Return Port (Quick Disconnect) 14. To Hoist Valve, Power Up
7. To Auxiliary Hydraulic System 15. To Hoist Valve, Power Down
8. Return to Tank 16. To Brake System
4
5
6
2
15
3 4
18
10
8
17
16
14
13 12 11
9 86243
FIGURE 10-3. BLEEDDOWN MANIFOLD COMPONENTS

1. Steering Bleeddown Pressure Switch 10. Steering System Pressure Switch
2. Steering Accumulator Bleeddown Solenoid 11. Test Port (TP2)
3. Relief Valve - 4 100 kPa (600 psi) 12. Check Valve
4. Relief Valve - 27 500 kPa (4,000 psi) 13. Check Valve
5. Pilot Operated Check Valve 14. Check Valve
6. Hoist Up Limit Solenoid 15. Test Port (TP3)
7. Pilot Operated Check Valve 16. Check Valve
8. Inlet Check Valve 17. Check Valve
9. KOMTRAX Plus Steering Pressure Sensor 18. Auxiliary System Pressure Switch
5
18 11 19 20 10 21 22 23 12 24 39 25 15
8 1
TP2 TP4 TP3

9
TP1
26
38
16
4 13
37
27
36
17 14
TP9
6 2
35 28
TP10
TP8 TP7 TP6 TP5
7 34 33 32 34 31 3 5 29 87540
FIGURE 10-4. BLEEDDOWN MANIFOLD SCHEMATIC

1. Pressure Switch (Bleeddown) 21. Pantograph (plugged)
2. Steering Accumulator Bleeddown Solenoid 22. Radiator Shutters (plugged)
3. Relief Valve - 4 100 kPa (600 psi) 23. Spare Pressure (plugged)
4. Relief Valve - 27 500 kPa (4,000 psi) 24. Brake Circuit Supply
5. Pilot Operated Check Valve 25. Steering Accumulator (ACC2)
6. Hoist Up Limit Solenoid 26. Supply to Flow Amplifier
7. Pilot Operated Check Valve 27. Supply Port (Quick Disconnect)
8. Inlet Check Valve 28. Return From Flow Amplifier
9. Komtrax Steering Pressure Sensor (TP1) 29. Return Port (Quick Disconnect)
10. Steering System Pressure Switch 30. Spare Return (plugged)
11. Test Port (TP2) 31. Lube (plugged)
12. Check Valve 32. Hoist Pilot Return
13. Check Valve 33. Hoist Pilot Power Down
14. Check Valve 34. Hoist Pilot Power Up
15. Test Port (TP3) 35. Tank Return
16. Check Valve 36. Hoist Power Up
17. Check Valve 37. Hoist Power Down
18. Steering Accumulator (ACC1) 38. Inlet (from Steering/Brake Pump)
19. APU (to Auxiliary System Manifold) 39. Spare Brake (plugged)
20. Pressure Feedback (to Steering/Brake Pump)
6
Steering circuit components Steering accumulators
Steering control unit Two piston type steering accumulators (3, Figure 10-
1) are mounted on the left side of the truck. Each
Steering control unit (1, Figure 10-5) is mounted accumulator has a capacity of 62 liters (16.5 gallons),
inside the cab and is directly coupled to the lower end and each is precharged to 9 650 kPa (1,400 psi) with
of the steering column. The steering control unit pure dry nitrogen.
incorporates a rotary meter which ensures that the oil
volume supplied to the steering cylinders is Oil entering the accumulators compresses the piston
proportional to the rotation of the steering wheel. The against the nitrogen. The nitrogen pressure increases
steering control unit is a closed circuit system. directly with steering circuit pressure. When steering
circuit pressure reaches 24 305 kPa (3,525 psi), the
Operation of the steering control unit is both manual unloader valve will unload the pump. The
and hydraulic in effect. This component incorporates accumulators will contain a quantity of oil, under
a hydraulic control valve. Steering effort applied to pressure and held by check valves in the bleeddown
the steering wheel by the operator actuates the valve, manifold, that will be available for steering the truck.
which in turn directs hydraulic oil through flow When system pressure drops to 22 065 kPa (3,200
amplifier valve (2) to the steering cylinders to provide psi), the pump output will again increase to refill the
the operator with power steering. accumulators and increase the steering system
pressure. The accumulators also provide oil for a
limited period of time to be used in case the steering/
1 brake pump becomes inoperative.
2 A pressure switch located in the top of each

T accumulator monitors the precharge pressure when
L LS the key switch is turned ON before the engine is
P
R started. If the nitrogen pressure drops below 7 600
kPa (1,100 psi), a warning is activated. A latching
LS
circuit prevents the warning from turning off when the
T engine is started and steering system pressure
L
compresses the remaining nitrogen in the
L P accumulator.
R 86257
FIGURE 10-5. STEERING CONTROL UNIT / Do not operate the truck with a precharge
FLOW AMPLIFIER VALVE CIRCUIT pressure of less than 7 600 kPa (1,100 psi) in the
1. Steering Control Unit “T”: Tank Port accumulator. Low nitrogen pressure may not
2. Flow Amplifier Valve “L”: Left Steer Port provide an adequate supply of steering system
“P”: Pressure Supply Port oil in some emergency conditions.
“R”: Right Steer Port
“LS”: Load Sense Port If the low precharge warning remains active, wait
approximately three minutes after the steering
accumulators are completely depressurized to
High pressure filter check the accumulator precharge pressure and
High pressure filter (9, Figure 10-1), located on the recharge the accumulator, if necessary.
back of the fuel tank, filters oil for the steering and
brake apply circuits.
If the filter element becomes restricted, a warning is
activated at 241 kPa (35 psi) differential. Oil will start
to bypass the element when the pressure differential
exceeds 345 kPa (50 psi).
7
Bleeddown manifold Quick disconnect ports

Bleeddown manifold (5, Figure 10-1) is located on the Two quick disconnect ports on the bleeddown
outside of the left frame rail just behind the manifold allow service personnel to connect an
accumulators. external hydraulic supply to allow operation of the
The bleeddown manifold receives oil from the truck steering and service brakes if the steering/
steering/brake pump through a high pressure filter brake pump or engine is not operational.
and directs oil to the steering accumulators, flow The external supply is connected to port (5, Figure
amplifier, brake apply circuit, and the auxiliary 10-2) and the return is connected to port (6) on top of
system. The manifold also provides hoist circuit the bleeddown manifold. This feature should only be
control when the body is raised. used for an emergency to allow operation of the truck
to return to the shop for service or to move the truck
Relief valve (4, Figure 10-3) limits the hydraulic
out of haul road traffic.
supply pressure to the steering and brake circuits to
27 500 kPa (4,000 psi). Relief valve (3) provides
Flow amplifier
maximum pressure protection of 4 100 kPa (600 psi)
for the oil returning to the hydraulic tank. Flow amplifier (4, Figure 10-1), located on the left
frame rail in front of the accumulators, provides the
NOTE: The relief valves, steering accumulator steering circuit with the high volume of oil required for
bleeddown solenoid, and hoist up limit solenoid are the steering cylinders.
factory preset and cannot be individually rebuilt.
The flow amplifier uses the amount of flow from the
Steering accumulator bleeddown solenoid steering control unit to determine a proportional
amount of flow to send from the bleeddown manifold
Each time the key switch is turned OFF with the truck
to the steering cylinders.
stopped, steering accumulator bleeddown solenoid
(2, Figure 10-3) is energized. When the solenoid is
energized, all hydraulic steering pressure (including
the accumulators) is bled back to the hydraulic tank.
Brake pressure, however, will not bleeddown due to
internal check valves in the brake manifold and
bleeddown manifold.
After approximately 90 seconds, the solenoid will de-
energize to close the return port to the hydraulic tank.
By this time, all the oil in the accumulators should be
returned to the hydraulic tank. At startup, the steering
circuit and brake circuit will be charged. Steering
system pressure switch (10, Figure 10-3) will activate
a low steering pressure warning until steering
pressure reaches 15 858 kPa (2,300 psi).
If steering pressure falls below 15 858 kPa (2,300
psi) during operation, the low steering pressure
warning will be activated until pressure returns to
normal.
8
Steering/brake pump operation

The steering/brake pump is mounted on the rear of
the hoist pump. The driveshaft mates with an 1
internally splined coupling inside the hoist pump
when the pump is bolted in place.
The steering/brake pump is piston-type pump with an
unloader valve. The pump-mounted unloader valve
maintains system pressure between 22 065 kPa
(3,200 psi) and 24 305 kPa (3,525 psi).
Oil flow from the pump is routed through a high
pressure filter, then to the bleeddown manifold,
where the flow is directed to the steering circuit and
to the brake apply circuit components located in the
hydraulic brake cabinet.
3 4 2
High altitude operation
Stroke adjuster (9, Figure 10-6) is set at the factory to
provide maximum pump flow so adjustment is not
normally required. If the truck is operated at high 5
altitude locations of 3 050 meters (10,000 feet) or
more above sea level, it may be necessary to
readjust the stroke control to reduce pump flow to
prevent pump cavitation under certain conditions. If
the truck is operating at high altitude and problems 10
occur, consult your Komatsu service representative
for adjustment procedures.
6
9 8 7 86808
FIGURE 10-6. PUMP ASSEMBLY

1. Outlet (to Filter) 6. GPA Test Port
2. GP4 Test Port 7. GP2 Test Port
3. ACC Port 8. Unloader Adjuster
4. Case Drain 9. Stroke Adjuster
5. Inlet (from Tank) 10. Driveshaft
9
FIGURE 10-7. STEERING PUMP PRESSURE CONTROL SCHEMATIC

1. 4-Way Valve 4. Case Drain 6. GP4 Port
2. Unloader Control Block 5. GP2 Port 7. GPA Test Port
3. “ACC” Port
Neutral position
Neutral position (Figure 10-8) results when control
piston (1) centers swashblock (4). The swashblock
angle is zero and the swashblock face is parallel to
the splined housing face. Therefore, no inward or
outward motion of pistons (3) exists as the piston
shoes rotate around the swashblock face. The lack of
inward and outward motion results in no fluid being
displaced from the piston bores to the crescents in
the valve plate and, subsequently, no delivery from
pump ports.
FIGURE 10-8. PUMP IN NEUTRAL POSITION

1. Control Piston 3. Piston
2. Splined Housing 4. Swashblock
10
Full pump volume Half pump volume

Control piston (1, Figure 10-9) controls the angle of The position of control piston (1, Figure 10-10) is
swashblock (4). When the control piston moves to the near the center of its travel. Swashblock (4) is not
full right position, the pump is at maximum pumping angled as steeply as before. Therefore, the pistons
capacity. have a shorter stroke. As the piston stroke gets
The driveshaft turns splined housing (2), which shorter, the pump output also decreases.
contains pistons (3). When the housing is rotated, the
pistons move in and out of their bores and the piston
shoes “ride” against the angled swashblock.
As the cylinder rotates, the individual piston bores are
connected alternately to the left (port “A”) and right
(port “B”) crescent shaped ports in the valve plate.
While connected to left side (suction) port “A”, each
piston moves outward, drawing oil from port “A” into
the piston bore until its outermost stoke is reached.
At that point, the piston bore passes from the left
crescent port to the right crescent port.
While rotating across the right side crescent, each
piston moves downward on the angled swashblock
face. Thus, each piston is forced inward. Each piston
displaces fluid through the right side crescent to port
“B” until its innermost stroke is reached. At that point, FIGURE 10-10. HALF PUMP VOLUME
the piston bore again passes from the right to the left 1. Control Piston 3. Piston
side crescent and the operating cycle is repeated. 2. Splined Housing 4. Swashblock
FIGURE 10-9. FULL PUMP VOLUME

1. Control Piston 3. Piston
2. Splined Housing 4. Swashblock
11
Flow amplifier operation

No steer
Refer to Figure 10-11.
High pressure oil from the steering pump and
steering accumulators is available through the
bleeddown manifold to the “HP” port on the flow
amplifier.
Upon entering the priority valve, the oil goes past the
spool to the closed amplifier valve and also out port
“P” through a hose to port “P” on the steering control
unit. In the steering control unit, the oil goes to a
closed area in the control.
As pressure builds up in these two areas, oil passes
through orifices in the end of the priority valve and
builds pressure on the end of the valve and port PP.
When pressure reaches approximately 1 600 kPa
(232 psi), the spool moves, compressing its spring
and closing off oil supply through area “A”, resulting
in high pressure at “PP” but only 1 600 kPa (232 psi)
at the amplifier spool and steering control unit.
12
FIGURE 10-11. FLOW AMPLIFIER - NO STEER
13
Steering left This combined oil going to the center area “Q” of the
Refer to Figure 10-12. directional valve passes out port “CL” of the flow
amplifier and travels to the steering cylinders to steer
When the operator turns the steering wheel to the the front wheels to the left. As the cylinders move, oil
left, the steering control unit is opened to allow oil is forced to return out the opposite ends, enter port
coming in port “P” to pass to the gerotor section of “CR” of the flow amplifier, pass through the
the control unit to turn the rotor. Oil in the other side directional valve to area “M”, pass through return
of the gerotor flows through other passages in the check valve “N”, and exit port “HT” to the hydraulic
control unit valve and out steering control unit port reservoir.
“L”. This oil enters port “L” of the flow amplifier and
goes to a closed area “B” in the directional valve. At the steering control unit, when the operator turned
the steering wheel, supply oil from port “P” was also
As pressure in area “B” builds, it also passes into the delivered through the control unit valve to port “LS”.
spool through orifice “C” to the spring area on the end This oil enters the flow amplifier through its “LS” port
of the directional valve. The pressure then moves the and builds pressure in the spring area of the priority
spool compressing the springs on the opposite end. valve. This additional force on the spring end of the
This movement allows the oil entering area “B” to priority valve causes area “A” to open and allow the
pass through the directional valve to area “D” of the necessary flow and pressure to pass through the flow
amplifier valve, through holes in sleeve “E” to a amplifier to operate the steering cylinders.
passage between sleeve “E” and valve “F”, and
through hole “G” in sleeve “E”, where it initially is The flow amplifier includes a relief valve in the priority
blocked by the valve body. valve spring area that is used to control maximum
steering working pressure to 20 685 kPa (3,000 psi),
As pressure builds up in this area, oil also flows from even though supply pressure coming in to port “HP”
area “D”, around the outside of sleeve “E”, around pin is higher. When 20 685 kPa (3,000 psi) is obtained,
“H”, through orifice “J” to build pressure on the end of the relief valve prevents the “LS” pressure from
the amplifier valve, and opens hole “G” just enough to increasing, thereby allowing the priority valve to
allow the flow of oil coming from the steering control compress the spring enough to close off area “A”.
unit to pass to the control area of the directional
valve.
At the same time, the movement of sleeve “E”
opened the holes near the spring end to allow the oil
from the priority valve to flow into the center of sleeve
“E”.
This oil now inside sleeve “E” pushes valve “F”
against its spring to give the oil access to a series of
holes “K” that are in the same plane as hole “G”. The
passage of oil through holes “K” past the valve body
is metered by holes “K” being opened the same
proportion as hole “G”. The number of holes “K” (7) in
sleeve “E” determine the amount of additional oil that
is added to the steering control unit oil passing
through hole “G”.
14
86868
FIGURE 10-12. FLOW AMPLIFIER - STEERING LEFT
15
Steering right
There are only a few differences between steering
left and steering right. When the operator turns the
steering wheel right, oil is supplied out ports “R” and
“LS” of the steering control unit.
The oil enters the flow amplifier assembly at port “R”
and shifts the directional valve the opposite direction.
The oil flows through the amplifier valve in exactly the
same way. The combined oil from the amplifier valve
passes through the center area “Q” of the directional
valve to port “CR”, where it goes to the opposite ends
of the steering cylinders to turn the wheels to the
right.
The returning oil comes back through port “CL” to go
to the tank. The “LS” oil operates exactly the same as
steering left.
16
86867
FIGURE 10-13. FLOW AMPLIFIER - STEERING RIGHT
17
No steer, external shock load

When the operator is not turning the steering wheel,
the steering control unit valve supply is closed. The
directional valve remains centered by its springs,
thus closing the passages to ports “CL” and “CR”.
This creates a hydraulic lock on the steering cylinders
to prevent their movement.
If the tires hit an obstruction that causes a large
shock load, forcing the wheels to the left, increased
pressure will occur in the ends of the cylinders
connected to port “CR”. The shock and suction relief
valve inside the flow amplifier at port “CR” will open at
its adjusted setting of 24 000 kPa (3,480 psi) and
allow oil to escape from the pressurized ends of the
cylinders, preventing a higher pressure.
As the cylinders are allowed to move, the other ends
will have less than atmospheric pressure on port
“CL”. This low pressure permits oil that is escaping
through the “CR” port relief valve to flow through the
check valve portion of the shock and suction relief
valve connected to port “CL”. The oil then flows to the
low pressure ends of the cylinders to keep the
cylinders full of oil and prevent cavitation. A shock
load in the opposite direction merely reverses the
above procedure.
18
86869
FIGURE 10-14. FLOW AMPLIFIER - NO STEER, EXTERNAL SHOCK LOAD
19
980E Dump truck

20
CEN10067-00
980E

980E-4 A40003 and up
980E-5 A50005 and up

Hoist circuit
Hoist circuit operation ........................................................................................................................................... 3
Hoist circuit components ....................................................................................................................................... 4
Hoist pilot valve operation..................................................................................................................................... 8
1
NOTES
2
Hoist circuit operation The hoist valve directs oil to hoist cylinders (10) for
raising and lowering of the dump body. Hoist valve
Hydraulic oil is supplied by a hydraulic tank (1, Figure
functions are controlled by the operator through the
10-1) located on the left frame rail. Hydraulic oil is
hoist control lever that is connected to hoist pilot
routed to hoist pump (2). A second pump, coupled to
valve (4) located in the hydraulic brake cabinet. Hoist
the rear of the hoist pump, supplies oil for the
limit solenoid (5), located in the bleeddown manifold,
steering and brake systems. The pumps are driven
shifts the hoist valve out of POWER UP before the
by an accessory drive at the end of the traction
hoist cylinders extend to their maximum physical
alternator.
limit.
Hoist pump output is directed to a pair of high
When the hoist valve is in the HOLD or FLOAT
pressure filters (3) mounted on the back of the fuel
position, hoist circuit oil flows to the front and rear
tank. Hydraulic oil from the hoist filters is directed to
service brakes, cooling the wet disc brakes during
hoist valve (7), which is mounted above the pumps.
truck operation.
FIGURE 10-1. HOIST CIRCUIT SCHEMATIC

1. Hydraulic Tank 6. Pilot Operated Check Valve 11. Quick Disconnect
2. Hoist Pump 7. Hoist Valve 12. Overcenter Manifold
3. High Pressure Filter 8. Brake Cooling Oil Supply (Front) 13. Check Valve
4. Hoist Pilot Valve 9. Brake Cooling Oil Supply (Rear) 14. Counterbalance Valve
5. Hoist Limit Solenoid 10. Hoist Cylinder 15. Bleeddown Manifold
3
Hoist circuit components A smaller piston type, pressure compensated pump,

rated at 250 l/m (66 gpm) at 1,900 rpm, is coupled to
Hydraulic tank the hoist pump. It supplies oil to the steering system
The hydraulic tank supplies hydraulic oil for the hoist, and brake apply system.
steering and brake circuits. The hydraulic tank is Hoist pressure is limited to 18 960 kPa (2,750 psi) by
located on the left frame rail in front of the rear internal relief valves located in the hoist control valve
wheels. Type C-4 hydraulic oil is recommended for inlet sections.
use in the hydraulic system. Oil used in the hoist
circuit flows through 100 mesh wire suction strainers High pressure filters
to the inlet hoses of the pump. Air drawn into the tank
Hoist pump output oil is directed to the high pressure
during operation is filtered by air filters located on the
filters mounted on the inboard side of the fuel tank.
top of the hydraulic tank. The oil level can be checked
The filter assemblies are equipped with a bypass
visually at sight glasses located on the face of the
valve which permits oil flow if the filter element
hydraulic tank.
becomes excessively restricted. Flow restriction
Hoist pump through the filter element is sensed by an indicator
switch which will activate a warning in the cab to
Hoist pump (6, Figure 10-2) is a tandem, gear type indicate that filter service is required when the
pump driven by a driveshaft on the end of the traction restriction reaches approximately 241 kPa (35 psi).
alternator. The pump has a total output of 931 L/m Actual filter bypass will start to occur when the filter
(246 gpm) at 1,900 rpm and 18 960 kPa (2,750 psi). element restriction reaches approximately 345 kPa
1
2 3
6 86246
FIGURE 10-2. PUMP MODULE

1. Hoist Valve 4. Quick Disconnects
2. Counterbalance Valve 5. Steering/Brake Pump
3. Overcenter Valve 6. Hoist Pump
4
Hoist valve Inlet sections

Hoist valve (1, Figure 10-2) is mounted on a modular Each of the front and rear inlet sections of the hoist
assembly containing the hoist valve, overcenter valve contains of the following components:
manifold, and both hydraulic pumps. This assembly is • Flow control valve and main relief valve
bolted to brackets attached to the frame rails behind
the main alternator. The hoist valve is a split spool • Secondary low pressure relief valve
design. The term “split spool” describes the spool • Anti-void check valve
section of the valve.
• Load check valve
The hoist valve precisely follows the differential The flow control portion of the flow control and main
pressure input signals generated by the hoist pilot relief valves allow pump flow to be diverted to the
valve when the operator moves the hoist control lever service brake cooling circuit unless the body is being
while raising and lowering the dump body. raised or lowered. The relief portion of this valve is
direct-acting and has the capacity to limit the
maximum working pressure at full pump flow.
The secondary low pressure relief valve is located
between the low pressure core and the outlet to the
brake cooling circuit. It provides pressure relief if
pressure spikes occur in the low pressure passage
area.
The load check allows free flow from the inlet to the
high pressure core and prevents flow from the high
pressure core to the inlet.
The anti-void check valve allows free flow from the
low pressure core to the high pressure core and
prevents flow from the high pressure core to the low
pressure core.
Tank ports (front) spool section

The primary low pressure valves are located in the
front spool section of the hoist valve. These valves
maintain back pressure on the low pressure passage
FIGURE 10-3. HOIST VALVE and direct the hoist cylinder return oil back to the
hydraulic tank.
1. Inlet Section 4. Inlet Section
2. Work Ports Spool 5. Inlet Port
Section 6. Outlet Port
3. Tank Ports Spool 7. Spool Section Cover
Section 8. Separator Plate
5
Work ports (rear) spool section Hoist pilot valve

The rear spool section of the hoist valve consists of Hoist pilot valve (1, Figure 10-4) is mounted in the
the following components: hydraulic brake cabinet behind the operator cab. The
hoist pilot valve spool is spring centered to the
• Pilot ports
neutral position and is controlled directly by the
• Main spools operator through a lever mounted on the console
• Work ports between the operator and passenger seat. A cable
connects the cab mounted lever to the hoist pilot
• Check poppets valve in the hydraulic components cabinet.
The pilot ports are located in the spool section cover. When the operator moves the hoist control lever, the
These ports provide connections for a pilot line to the pilot valve spool moves and directs pilot flow to the
hoist pilot valve. Each work port has a corresponding appropriate pilot port on the hoist valve. The pilot flow
pilot port. causes the main spool to direct oil flow to the hoist
The work ports provide for a line connection between cylinders.
the spool section and the hoist cylinders. One main The hoist pilot valve is equipped with a one-way load
spool for each work port is spring biased on both check valve which allows free flow from the center
ends. This blocks the work port from the high and low passage to bridge core and prevents reverse flow.
pressure cores when there is no flow through the The valve also contains power down relief valve (2),
spool cross-holes. which limits the power down pressure to 10 400 kPa
When there is flow through the pilot ports to the (1,500 psi).
spools, a positive differential pressure occurs at the
top of the spool, overcomes the bottom spring bias
and causes the spool to shift, connecting the work
port to the high pressure core.
When there is flow from the main valve work port to
the pilot port through the cross-holes, a positive
differential pressure at the bottom of the spool
occurs, overcoming the top spring bias and the spool
will shift to connect the work port to the low pressure
core.
The check poppets located in the spool section
permit free flow from the work port to the pilot port
and restrict flow from the pilot port to the work port.
These check poppets control spool response and
spool movements during void conditions.
FIGURE 10-4. HOIST PILOT VALVE

1. Hoist Pilot Valve 4. To Hoist Valve
2. Power Down Relief (Rod End)
Valve 5. To Hoist Valve
3. Supply Port (Base End)
6. Return to Tank
6
NOTE: The pilot valve/hoist valve hydraulic circuit is

routed through the bleeddown manifold located on
the left frame rail. The hoist limit solenoid and pilot
operated check valve described below are contained
in the manifold. Refer to Structure, functions and
maintenance standard section Steering circuit for
more information about the bleeddown manifold.
1
Hoist limit solenoid
Hoist limit solenoid (5, Figure 10-5), located in the 2
bleeddown manifold, is used in the hydraulic circuit to
prevent maximum hoist cylinder extension.
The 3-way valve solenoid valve is controlled by a
proximity switch (hoist limit switch) located near the
body pivot and the right rear suspension upper
mount.
When the body is nearly fully raised, the body
activates the magnetic proximity switch, signaling the 86247
solenoid to open the “raise” pilot line to the tank, and
FIGURE 10-5. BLEEDDOWN MANIFOLD
close the “raise” pilot line to the hoist valve, thus
stopping further oil flow to the hoist cylinders. 1. Hoist Limit Solenoid 2. Pilot operated
check valve
Pilot operated check valve
Pilot operated check valve (6, Figure 10-5), located in
the bleeddown manifold, is opened by power down
pilot pressure to allow oil in the raise port to bypass
Overcenter manifold
the hoist limit solenoid for initial power down
operation while the solenoid is activated by the hoist Overcenter manifold (3, Figure 10-2) contains
limit switch. counterbalance valve (2), which controls the pressure
of the cushion of oil in the annulus area of the hoist
cylinder when the body approaches the maximum
dump angle. The counterbalance valve limits the
maximum pressure buildup by relieving pressure in
excess of 20 400 kPa (3,000 psi), preventing possible
seal damage.
Quick disconnect fittings (4) allow dumping of the
load in a disabled truck by connecting jumper hoses
to the hydraulic system of an operational truck.
7
Hoist pilot valve operation Float position with body down

Refer to Figure 10-6 through Figure 10-10 for oil flow Refer to Figure 10-6.
paths during the following hoist circuit conditions:
Figure 10-6 shows the position of the hoist pilot valve
• Float (with body down) when the truck body is resting on the frame.
• Power up However, the hoist valve internal valves and spools
will be in the position shown in Figure 10-8.
• Hold
Oil from the hoist pump enters the inlet sections of
• Power down the hoist valve in supply port (11), passes through
• Float load check valve (18), and stops at closed high
pressure passage (19) at rod end spool (7) and head
end spool (8).
Pressure builds to approximately 414 kPa (60 psi) on
the pilot of flow control valve (2), causing the valve to
compress the spring and open, which allows the oil to
flow through brake cooling circuit port (23) to the
service brakes for brake disc cooling and eventually
back to the tank. Between brake cooling circuit port
(23) and the brakes or heat exchanger, the cooling
supply tee’s to orificed regulator valves. If supply
pressure attempts to increase above 240 kPa (35
psi), the regulator valve opens and dumps to the
hydraulic tank.
Oil also flows out of pilot supply port (12) of the hoist
valve to pilot supply port (12) of the hoist pilot valve,
through the hoist pilot valve spool, and out through
tank return port (10) to the hydraulic tank. This oil
flow is limited by orifices in the inlet sections of the
hoist valve and, therefore, has no pressure buildup.
8
84748
FIGURE 10-6. FLOAT POSITION (BODY DOWN)

1. Hoist Relief Valve (2,750 psi) 9. Head End Work Port 17. Anti-Void Check Valve
2. Flow Control Valve 10. Tank Return Port 18. Load Check Valve
3. Secondary Low Pressure 11. Supply Port 19. High Pressure Passage
Valve (250 psi) 12. Pilot Supply Port 20. Low Pressure Passage
4. Counterbalance Valve 13. Hoist Limit Solenoid 21. Pilot Operated Check Valve
5. Rod End Work Port 14. Raise Pilot Port 22. Primary Low Pressure Relief
6. Hoist Cylinders 15. Down Pilot Port Valve (26 psi)
7. Rod End Spool 16. Power Down Relief Valve 23. Brake Cooling Circuit Port
8. Head End Spool (1,500 psi) 24. Overcenter Manifold
9
Power up operation No pressure is present on the top of rod end spool

(7). Cylinder return pressure passes through the
Figure 10-7.
check-poppet in the bottom of rod end spool (7) to
The hoist pilot valve spool is moved to the power up build pressure under the spool, which moves the
position when the operator moves the lever rearward spool upward, thus compressing the top spring. This
in the cab. The pilot supply oil coming in pilot supply movement allows the returning cylinder oil to flow into
port (12) of the hoist pilot valve is prevented from low pressure passage (20) to primary low pressure
returning to the hydraulic tank. Instead, the oil is relief valve (22). Approximately 179 kPa (26 psi)
directed out raise pilot port (14), through hoist limit causes this relief valve to open, allowing the oil to
solenoid (13) in the bleeddown manifold, and into flow through tank return port (10) to the hydraulic
raise pilot port (14) of the hoist valve. tank.
From there it goes to the top of head end spool (8) If the load passing over the tail of the body during
and builds pressure on the end of the spool, causing dumping causes the body to raise faster than the oil
the spool to move down and compress the bottom is being supplied by the pump, the return oil from the
spring, thus connecting high pressure passage (19) annulus area of hoist cylinders (6) that is passing
to head end work port (9). Working oil flow in the high through the counterbalance valve in overcenter
pressure passage is now allowed to flow through manifold (24) controls how fast the hoist cylinders
head end spool (8) and out head end work port (9) to can extend due to the external force of the load. The
extend hoist cylinders (6). speed is controlled by counterbalance valve.
Even though a small amount of oil flows through the During the normal raise process, the raise pilot
check poppet in the top of head end spool (8), pressure supplied to the counterbalance valve will
pressure at raise pilot ports (14) increases to slightly open the cylinder return ports fully whenever the
higher pressure than the required hoist cylinder raise pressure is above 4 600 kPa (666 psi). As the
pressure. As a result, the pressure in pilot supply load shifts toward the tail of the body, the raise
ports (12) also increases, causing back pressure to pressure decreases. As it drops below 4 600 kPa
occur in the spring area of flow control valve (2). This (666 psi), the counterbalance valve starts restricting
overcomes the pilot pressure on the other end of the oil flow, causing a back pressure to the annulus area.
flow control valve, causing it to close and direct the If the raise pressure were to drop to 0, return
incoming pump oil through head end spool (8) and to pressure would increase to 20 400 kPa (3,000 psi)
hoist cylinders (6) to extend them. At this time, oil maximum.
flow to the brake cooling circuit is stopped.
When the operator releases the hoist control lever,
If, at any time, the resistance to the flow of the pump the valves change to the HOLD position. If the body
oil coming into the inlet section causes the pressure rises to the position that activates the hoist limit
to increase to 18 960 kPa (2,750 psi), the pilot switch, located above the right rear suspension,
pressure against hoist relief valve (1) causes it to before the operator releases the lever, hoist limit
open and allow oil to flow through brake cooling solenoid (13) is energized. The solenoid valve closes
circuit port (23) and to return to the hydraulic tank. raise pilot port (14) on the hoist and releases the
hoist pilot valve raise pilot pressure at port (14) to the
As the hoist cylinders extend, oil in the annulus area
tank, allowing head end spool (8) to center and shut
of all three stages must exit sequentially from the
off the supply of oil to the hoist cylinders. This
cylinders. Initially, rod end spool (7) ports are closed.
prevents maximum extension of the hoist cylinders.
As the returning oil entering rod end work port (5)
builds low pressure, it flows through the check-
poppet in the top of the spool, through down pilot
ports (15), through the pilot valve spool, through tank
return port (10) of the pilot valve, to the bleeddown
manifold and to the hydraulic tank.
10
84236
FIGURE 10-7. POWER UP POSITION

11
Hold operation
The pilot valve spool is positioned to allow the pilot
supply oil entering pilot supply port (12) to return to
the hydraulic tank through head end work port (10).
Pilot supply pressure in pilot supply ports (12) then
decreases to no pressure, allowing flow control valve
(2) to open and route the incoming pump oil through
brake cooling circuit port (23) and back to the
hydraulic tank.
Both raise pilot port (14) and down pilot port (15) in
the pilot valve are closed by the pilot valve spool. In
this condition, pressure is equalized on each end of
each rod end spool (7) and head end spool (8),
allowing the springs to center the spools and close all
ports to trap the oil in hoist cylinders (6) and hold the
body in its current position.
12
84237
FIGURE 10-8. HOLD POSITION

13
Power down operation

When the operator moves the hoist control lever to
lower the body, the hoist pilot valve is positioned to
direct the oil in pilot supply ports (12) through down
pilot ports (15) to the top of rod end spool (7).
Pilot pressure increases to move the spool down,
compressing the bottom spring. Movement of the
spool connects high pressure passage (19) to the rod
end (annulus area) of the hoist cylinders. At the same
time, flow control valve (2) is forced to close as pilot
pressure increases, thus directing the incoming pump
oil to the hoist cylinders through rod end spool (7)
and the check valve in the overcenter manifold rather
than back to the hydraulic tank. Oil flow to the brake
cooling circuit ceases when the flow control valve
closes.
If the body is at the maximum up position, the hoist
limit switch has the hoist up limit solenoid activated,
therefore closing raise pilot port (14) on the hoist
valve. Power down pilot pressure in ports (15)
pushes open pilot operated check valve (21), located
in the bleeddown manifold, so the pilot pressure in
ports (14) is open to the tank through the pilot valve
spool.
As oil attempts to return from the head end of the
hoist cylinders, it initially encounters closed head end
spool (8). Pressure increases on the bottom end of
the spool, causing it to move upward. This allows the
returning oil to enter low pressure passage (20), build
up 179 kPa (26 psi) to open primary low pressure
relief valve (22) and exit the hoist valve through tank
return port (10) to the hydraulic tank.
As the dump body descends and the hoist limit
solenoid is no longer activated, pilot operated check
valve (21) is no longer necessary.
14
84238
FIGURE 10-9. POWER DOWN POSITION

15
Float operation
When the operator releases the hoist control lever as
the body travels down, the hoist pilot valve spool
returns to the FLOAT position. In this position, all
ports (10), (12), (14), and (15) are common with each
other. Therefore, the pilot supply oil is returning to the
hydraulic tank with no pressure buildup, thus allowing
flow control valve (2) to remain open to allow the
pump oil to flow through brake cooling circuit port
(23) and eventually return to the hydraulic tank.
With no blockage of either raise pilot port (14) or
down pilot port (15) in the pilot valve, there is no
pressure on the top of either main spool. The oil
returning from the head end of hoist cylinders (6)
builds pressure on the bottom of head end spool (8)
exactly like in POWER DOWN, allowing the returning
oil to transfer to low pressure passage (20). The back
pressure in the low pressure passage, created by
primary low pressure relief valve (22), causes
pressure under rod end spool (7) and moves the
spool upward. This connects the low pressure
passage to the rod end of the hoist cylinders.
The 179 kPa (26 psi) in low pressure passage (20)
causes oil to flow to the rod end of hoist cylinders (6)
to keep them full of oil as they retract. When the body
reaches the frame and there is no more oil flow from
the cylinders, the main spools center themselves and
close the cylinder ports and the high and low
pressure passages.
16
84235
FIGURE 10-10. FLOAT POSITION

17
980E Dump truck
18
CEN10068-00
980E

980E-4 A40003 and up
980E-5 A50005 and up

Brake circuits
General information .............................................................................................................................................. 3
Service brake circuit operation.............................................................................................................................. 4
Secondary braking ................................................................................................................................................ 6
Automatic brake application (Auto apply) ............................................................................................................. 6
Parking brake circuit operation ............................................................................................................................. 7
Wheel brake lock circuit operation ........................................................................................................................ 8
Brake warning circuit operation............................................................................................................................. 8
Brake assembly wear data.................................................................................................................................. 10
1
NOTES
2
General information The brake system consists of several major valve

components:
The truck is equipped with an all-hydraulic actuated
wet disc service brake system. The brake system • The dual circuit brake valve is attached to service
utilizes Type C-4 hydraulic oil provided by the brake/ brake/retarder pedal (1, Figure 10-1) in the
steering pump from the main hydraulic tank for brake operator cab.
application. Brake disc cooling during truck operation
• The two piston type accumulators are mounted
is provided by the hoist pump through the hoist valve.
on the frame rail behind the right front tire. See
A disc type parking brake, located in the rear axle
Figure 10-2.
housing, is attached to each wheel motor. The
fundamental function of the brake system is to • The brake manifold, the dual relay valve for the
provide an operator with the necessary control for front brakes, and the electrical components are
stopping the truck in either a slow modulating fashion located in the hydraulic brake cabinet behind the
or in as short a distance as reasonably possible. cab. See Figure 10-3.
Outlined below are the functions that Komatsu • The dual relay valve for the rear brakes is located
recommends for safe truck operation: on the left side of the rear axle housing. See
Figure 10-6.
• Warn the operator as soon as practical of a
serious or potentially serious loss of brake Brake manifold (1, Figure 10-3) contains dual circuit
pressure so that proper action can be taken to isolation check valves, brake accumulator bleeddown
stop the truck before the secondary system is valves, and valves for the brake lock, parking brake
exhausted of its power. and automatic apply functions. All of these
components are screw-in cartridge type valves.
• Provide secondary brake circuits so that any
single failure leaves the truck with sufficient There are two independent means of brake actuation
stopping power. provided for the operator: the service brake/retarder
pedal and the wheel brake lock switch. Additionally,
• Automatically apply the service brakes if low
the brakes will apply automatically if the brake
pressure warnings are ignored and pressures
system supply pressure drops below a
continue to decrease.
predetermined value.
• Provide a wheel brake lock to relieve the operator
NOTE: The following brake circuit descriptions
from holding the brake pedal while at the dump or
should be used in conjunction with the hydraulic
shovel.
brake system schematic located in the Diagrams and
• Provide a spring-applied, hydraulically released drawings section.
parking brake for holding (not stopping) the truck
during periods other than loading or dumping.
• The brake system should be easy to diagnose
and service.
3
Service brake circuit operation Brake accumulators have two functions: storing
energy for reserve braking in the event of a failure
This portion of the system provides the operator with
and providing rapid oil flow for good brake response.
the precise control that is necessary to modulate
(feather) brake pressure to slowly stop the truck or Depressing the brake pedal also actuates stop light
develop full brake effort to stop as quickly as pressure switch (4, Figure 10-3), which in turn
possible. The heart of this circuit is the foot-operated, activates the brake light on top of the cab, the stop/
dual circuit brake valve. This valve enables the tail lights on the rear axle housing and the propulsion
operator to control the relatively high pressure energy interlock.
within the brake accumulators directed to the brakes.
There are two valves in the dual circuit brake valve.
One supplies pressure to dual relay valve (3, Figure
10-3) in the hydraulic brake cabinet to provide apply
pressure for the front brakes. The other supplies
pressure to a dual relay valve located in the rear axle
housing to provide apply pressure for the rear brakes.
As service brake/retarder pedal (1, Figure 10-1) is
depressed, each valve within the dual circuit brake 2 1
valve simultaneously delivers fluid from its respective
accumulator to the dual relay valves, which deliver
fluid to the wheel brakes at a pressure proportional to
both pedal position and force. The farther the pedal is
depressed, the higher the brake force, which gives FRO
the operator a very positive feel of control. NT
2
1
86249
FIGURE 10-2. BRAKE ACCUMULATORS

1. Front Brake Accumulator
86231
2. Rear Brake Accumulator
FIGURE 10-1. OPERATOR CAB PEDALS
1. Service Brake/Retarder Pedal
2. Accelerator Pedal NOTE: For an internal view of the brake valve, refer
to Figure 10-7.
4
4
5
DETAIL A
1 A
2
86250
FIGURE 10-3. HYDRAULIC BRAKE CABINET - BRAKE CIRCUIT COMPONENTS

1. Brake Manifold 4. Stop Light Pressure Switch
2. Brake Lock Shuttle Valve 5. Brake Lock Degradation Switch
3. Dual Relay Valve (Front Brakes)
5
Secondary braking Automatic brake application (Auto apply)

The purpose of the secondary braking system is to Auto apply is a non-operator controlled feature of the
stop the truck in the event of any single brake system service brake system that hydraulically applies the
failure. If any single service brake system were to fail, service brakes by using the brake treadle valve. This
the truck can be safely stopped by using the feature uses auto apply sequence valve (2, Figure
remaining functioning portions of the service brake 10-4) located in the brake manifold, which senses the
system and retarder. lowest brake accumulator pressure. This valve will
automatically shift if the low brake system pressure
This is accomplished by dividing the service brake
warning has been activated at 12 750 kPa (1,850 psi)
system into two separate circuits, each with its own
and the brake system pressure drops below 11 400
isolation check valve and accumulator. The check
kPa (1,650 psi). When the valve shifts, hydraulic
valves are used to isolate each circuit from each
pressure will be applied to an internal piston that is
other. Each check valve allows each circuit to retain
incorporated into the brake treadle valve. This
pressurized oil and energy in case the other circuit
pressure moves the piston to depress the treadle
experiences a failure or a failure occurs in the supply
valve which, in turn, applies pressure to the dual
of pressurized oil from the steering system.
relay valves and applies all of the service brakes.
The accumulators of each brake circuit are located
after the check valves and perform two functions:
• Provides a source of pressurized oil and rapid 8 7
flow for good brake application response.
• Provides a stored energy that can be used for
secondary braking.
The pressure of both brake circuits is monitored by
low brake pressure switch (8, Figure 10-4). If the
pressure in one circuit falls below 12 750 kPa (1,850
psi), the low brake pressure warning will be activated.
When this warning is activated, a message will be
displayed and an alarm will sound to inform the
operator that the truck must be stopped by using the 6
secondary brake system as soon as practical. The
operator will stop the truck using the normal brake 1 2 3 4 5 86251
system controls (brake treadle valve). If the brake
FIGURE 10-4. BRAKE MANIFOLD
treadle valve is nonfunctional, the brake lock and the
retarder would be used to stop the truck. 1. Rear Brake Accumulator Bleeddown Valve
2. Automatic Apply Sequence Valve
Sensing the lower brake accumulator circuit pressure
3. Front Brake Accumulator Bleeddown Valve
ensures two to four full brake applications after the
4. Parking Brake Solenoid Valve
low brake pressure warning activates and before
5. Brake Lock Solenoid Valve
auto apply activates. This allows the operator the
6. Pressure Reducing Valve
opportunity to safely stop the truck after the warning
7. Parking Brake Pressure Switch
occurs.
8. Low Brake Pressure Switch
6
Parking brake circuit operation If a loss of supply pressure occurs with the directional
control lever in F, R, or N, the parking brake solenoid
Parking brakes (1, Figure 10-5) are spring applied
will still be energized. The supply circuit that lost
and hydraulically released. Whenever the parking
pressure is still open to the parking brake pistons. To
brake solenoid is de-energized, the spring in the
prevent parking brake pressure oil from returning to
solenoid valve will shift the spool, diverting oil
the supply circuit, a check valve in the parking brake
pressure from the parking brakes to direct the oil
circuit traps the oil, holding the parking brake in the
back to the hydraulic tank.
released position.
Normal operation (key switch ON, engine on) NOTE: Normal internal leakage in the parking brake
• Directional control lever in PARK solenoid may allow leakage of the trapped oil to
Brake lock solenoid (5, Figure 10-4) is energized, return to tank and eventually allow parking brake
causing the rear service brakes to apply. After application.
one second, parking brake solenoid (4) is de- If 24 volt power to the parking brake solenoid is
energized. The oil pressure in the parking brake interrupted, the parking brake will apply at any truck
lines returns to tank and the springs in the parking speed. The spring in the solenoid will cause it to shift,
brake apply the brake. Parking brake pressure opening a path for the oil pressure in the parking
switch (7) closes, completing a path to ground brake line to return to tank, and the springs in the
and illuminating the parking brake indicator light parking brake will apply the brake. Parking brake
on the dash panel. After a 1/2 second, the brake pressure switch (7) will close, completing a path to
lock solenoid is de-energized, causing the rear ground, illuminating the parking brake indicator light
service brakes to release. on the dash panel and interrupting propulsion.
• Directional control lever in F, R, or N
The parking brake solenoid is energized. The oil
flow is routed from parking brake solenoid valve 1
(4) to the parking brake pistons for release. The
parking brake circuit is protected against
accidental application by monitoring a wheel
motor speed sensor to determine the truck
ground speed. The parking brake will not apply
until the truck is virtually stopped. This eliminates
parking brake damage and will extend brake
adjustment intervals. If the key switch is turned
OFF, the parking brake will not apply until the
truck speed is less than 0.5 kph (1/3 mph).
2
86253
FIGURE 10-5. PARKING BRAKE LOCATION

1. Parking Brake
2. Wheel Motor
7
Wheel brake lock circuit operation Brake warning circuit operation

The primary function of the wheel brake lock is to The brake warning circuit will activate a low brake
provide a means for the operator to hold the truck pressure warning message, a red warning light and
while at the shovel or dump. The brake lock only an audible alarm in the operator cab to alert the
applies the rear service brakes. It may also provide operator to low brake pressures. Several electrical
a secondary means of stopping the truck in the event sensors, a relay and delay timer are used to detect
of a brake valve malfunction. brake system problems.
During normal operations, the wheel brake lock will • Brake warning relay
function only when: When the wheel brake lock switch is ON, the
brake warning relay is energized and switches
• the control power is ON,
the electrical connection from the terminal to
• the key switch is ON, brake lock degradation switch (5, Figure 10-3).
When the wheel brake lock switch is OFF, the
• and the parking brake is not activated (directional
relay is de-energized and switches the
control lever is not in PARK).
connection from the brake lock degradation
If the wheel brake lock is applied while the truck is switch to the terminal.
moving, the brake lock function will remain applied
• System supply pressure switch
after the truck is stopped regardless of the conditions
The system supply pressure switch is located on
stated above (except the control power must be ON
the pump pressure sensing manifold. When
for the wheel brake lock to function). The operator
system supply pressure drops below 15 800 kPa
must deactivate the wheel brake lock.
(2,300 psi), the low brake pressure warning will
When the wheel brake lock switch on the dash panel activate.
is activated, brake lock solenoid valve (5, Figure 10-
• Low brake pressure switch
4) and pressure reducing valve (6) will apply
Low brake pressure switch (8, Figure 10-4) is
unmodulated pressure oil at 13 800 kPa (2,000 psi)
located on the brake manifold in the hydraulic
to fully actuate the rear brakes. Shuttle valve (2,
brake cabinet. When the brake accumulator with
Figure 10-3) in the rear brake line provides the
the lower pressure falls below 12 700 kPa (1,850
independence from the brake valve for brake
psi), the low brake pressure warning will activate.
application.
• Brake lock degradation switch
Brake lock degradation switch (5, Figure 10-3) is
located on a junction manifold in the hydraulic
brake cabinet. When the wheel brake lock switch
1 is ON, brake lock solenoid (5, Figure 10-4) and
the brake warning relay are energized. The brake
warning relay switches the electrical connection
from the terminal to the brake lock degradation
switch. If the brake lock apply pressure is less
than 6 900 kPa (1,000 psi), a path to ground will
be completed and the low brake pressure
warning will activate.
86252
FIGURE 10-6. REAR AXLE

1. Dual Relay Valve (Rear Brakes)
8
FIGURE 10-7. BRAKE VALVE
1. Actuator Cap
2. Adjustment Collar
3. Nut
4. Actuator Plunger
5. Wiper Seal
6. Poly-Pak Seal Assembly
7. Glyde Ring Assembly
8. Regulator Springs (B1)
9. Plunger Return Spring
10. Spring Seat
11. Spool Return Spring (B1)
12. Regulator Sleeve (B1)
13. Regulator Spool (B1)
14. Reaction Plunger (B1)
15. Base Plate
16. Reaction Plunger (B2)
17. Regulator Sleeve (B2)
18. Regulator Spool (B2)
19. Spool Return Spring (B2)
20. Regulator Springs (B2)
21. Staging Seat
A. Adjustment Collar Maximum

Pressure Contact Area
B. Automatic Apply Piston Area
C. PX Port
D. Tank Port
E. Reactionary Pressure Area
F. Brake Apply Port
G. Orifice
H. Supply Port
Note:
B1 - Rear Brakes
B2 - Front Brakes
9
Brake assembly wear data
Criteria
No. Check item Maximum Remedy
New
wear
3.70 mm 3.40 mm
Overall thickness
(0.15 in.) (0.13 in.)
0.50 mm 0.70 mm Replace separator
1 Check separator plates Flatness
(0.020 in.) (0.027 in.) plate
< 10% of
Scoring -
surface area
7.70 mm 6.88 mm
Overall thickness
(0.30 in.) (0.27 in.)
0.45 mm 0.70 mm
Flatness
(0.018 in.) (0.03 in.)
Disc to disc wear < 0.164 mm
-
variation (0.0065 in.)
2 Check friction discs Replace friction disc
Friction material 1.10 mm 0.69 mm
depth (each side) (0.043 in.) (0.027 in.)
Friction material < 10% of
-
loss surface area
Friction material
- -
flakes off easily
6.9 mm 5.9 mm
3 Check damper Overall thickness Replace damper
(0.27 in.) (0.23 in.)
Check assembled thickness
• 10 separator plates 135.50 mm 123.48 mm Replace brake
4 Overall thickness
• 11 friction discs (5.335 in.) (4.861 in.) assembly
• 2 dampers
10
NOTES
11
980E Dump truck

12
CEN10089-00
980E

980E-5 A50005 and up

Electrical system, 24 volt
Battery supply system........................................................................................................................................... 3
Isolation box.......................................................................................................................................................... 4
Engine starting system with prelube ..................................................................................................................... 5
Auxiliary control cabinet components ................................................................................................................... 7
Body-up switch...................................................................................................................................................... 9
Hoist limit switch ................................................................................................................................................. 10
1
NOTES
2
Battery supply system 24VDC auxiliary battery receptacles
Batteries Two auxiliary battery receptacles (5) are provided to

attach battery charger leads for charging the
The truck uses a 24VDC electrical system to supply batteries. These receptacles can also be used for
power for the engine starting circuits and most non- connecting external batteries to aid engine starting
propulsion related electrical components. The 24VDC during cold weather.
electrical circuit is supplied by four heavy duty, type
8D, 12-volt storage batteries (1, Figure 10-1) located When external batteries are used, they should be of
in the battery box on the platform in front of the the same type (8D) as the batteries that are installed
radiator. The batteries are of the lead-acid type, each on the truck. Two pairs of batteries should be used.
containing six 2-volt cells. Each pair should be connected in series to provide
24VDC, with one pair connected to each receptacle.
While the engine is off, power is supplied by the
batteries. During engine cranking, power is supplied
by the batteries. When the engine is running,
however, power is supplied by a high capacity
alternator that is driven by the engine.
During operation, the batteries function as an
electrochemical device that converts chemical energy
into the electrical energy that is required for operating
the accessories when the engine is off.
1 1 1 1 2 3
5
86760
FIGURE 10-1. BATTERY BOX COMPONENTS
1. Batteries 4. Fuses (battery charging alternator and

2. 24VDC Bus Bar auxiliary control cabinet)
3. Negative Bus Bar 5. Auxiliary Battery Receptacles
3
Isolation box Propel lockout lever
Ground level shutdown switch Propel lockout lever (5) provides a convenient
method for disconnecting the drive system while the
Ground level shutdown switch (1, Figure 10-2) is a engine is in operation. This ensures that the truck will
push-pull type switch located on top of the isolation remain stationary without the need to check the
box. This switch provides a means to shut off the generator field contact (GF) switch in the main control
truck in an emergency. Push the button inward to cabinet. When the propel lockout lever is in the OFF
stop the engine and disable keyswitch power. position, the drive system is locked out and the truck
will not propel. When the propel lockout lever is in the
Battery disconnect switches ON position, the drive system is active and the truck
The battery disconnect switches provide a can be driven.
convenient method of disconnecting the truck’s
batteries from the 24V electrical circuits without System busy light
having to remove any battery cables. If green LED light (6) is illuminated, do not turn off
When starter disconnect switch (4) is in the OFF master disconnect switch (3). 24V electrical system
position, only the cranking motor battery circuit is components are still in operation.
open, preventing engine startup while still allowing
LED lights
battery power to the 24VDC control system circuits.
When master disconnect switch (3) is in the OFF LED lights (7) provide a positive, visual indicator
position, the entire 24VDC system circuit is when a switch is in the ON position. LED lights (8)
disconnected. provide a positive, visual indicator when a switch is in
the OFF position.
NOTE: Both switches are shown in the OFF position
in Figure 10-2.
1 7
8 7
8 8
2 5
3 6 4 86262
FIGURE 10-2. ISOLATION BOX COMPONENTS

1. Ground Level Shutdown Switch 4. Starter Disconnect Switch 7. LED Lights (on)
2. Access Ladder Light Switch 5. Propel Lockout Lever 8. LED Lights (off)
3. Master Disconnect Switch 6. System Busy Light
4
Engine starting system with prelube

The Komatsu SDA18V170 engine includes an engine
prelubrication system designed to reduce wear due
1
to dry starts.
The prelube system automatically, safely and quickly
fills the engine oil filters and all oil passages prior to
cranking at each engine startup. The system also
prevents startup if no oil is present in the engine.
NOTE: There will be a short but noticeable delay
2
between the time that the key switch is moved to the
START position and the time that the cranking motors
actuate.
Prelube operation
The prelube system is activated when the operator
3
turns the key switch and holds it in the START
position. This allows the current to flow to prelube
solenoid (3, Figure 10-3). When this prelube solenoid
is activated, current flows through the fusible link to
the prelube motor, driving prelube pump (1), but does
not allow the cranking motors to engage the cranking
motor pinion gears at this time. The prelube pump
supplies oil from the engine oil pan to fill the engine
85377
oil filters and oil passages prior to cranking.
FIGURE 10-3. ENGINE PRELUBE SYSTEM
When the pressure in the engine cam oil rifle reaches
62 kPa (9 psi), the engine prelube oil pressure switch 1. Engine Prelube Pump 3. Engine Prelube
and dedicated lube pressure switch supply signal 2. Engine Prelube Relay Solenoid
current to the engine start relays. When the engine
start relays are activated, current is provided to the
solenoids of both cranking motors (1, Figure 10-4).
The cranking motors will then be activated and the
pinion gears will be engaged into the flywheel ring
gear. Normal cranking will now occur with sufficient
lubrication to protect the engine bearings and other
components.
NOTE: The oil supply line has 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 oil pan
after the engine is started. Check valve leakage back
to the prelube pump will cause extensive damage to
the pump.
5
Cranking operation
After the operator turns the key switch and holds it in
the START position and the engine prelube system
fills the engine oil filters and all oil passages, the
engine start relays provide current to the solenoids of
both cranking motors (1, Figure 10-4).
When the solenoid coils are energized, the plunger is
pulled in, moving the cranking motor drive assembly
forward in the nose housing to engage the engine
flywheel ring gear. The main solenoid contacts also
close to provide current to the motor armature and
cranking takes place.
When the engine starts, an overrunning clutch in the
cranking motor drive assembly protects the armature
from excessive speed until the key switch is released.
When the key switch is released, a return spring
causes the drive pinion to disengage.
After the engine is running, the dedicated lube
pressure switch senses the engine oil pressure and
opens the electrical circuit to prevent actuation of the
cranking motor(s) after the engine has started.
FIGURE 10-4. ENGINE STARTING SYSTEM
1. Cranking Motors 2. Engine Prelube

Pump
6
Auxiliary control cabinet components

The auxiliary control cabinet houses various
components for the 24VDC circuits and terminal
strips that connect truck wiring harnesses with the
main control cabinet and cab. Refer to the electrical
schematics in the Drawings and diagrams section for
additional information.
4
24VDC to 12VDC converter
24VDC to 12VDC converter (7, Figure 10-5) is used
to convert the 24 volt battery system voltage to 12
volts for various truck components such as the radio, 3
power windows, 12V auxiliary power receptacles in
the cab, ethernet switch (4), KomVision radars and
optional wireless access.
The converter output circuits are protected by 50 amp
circuit breaker (2).
Interface module (IM)

Interface module (3, Figure 10-5) collects data from
various sensors and sends this information to the
KOMTRAX Plus controller through the main wiring
harness.
1
NOTE: New IM controllers come unprogrammed and
must have the correct software installed in order to
function. Refer to Testing and adjusting section 2
Interface module (IM) for the correct software
87541
installation procedures.
FIGURE 10-5. AUXILIARY CONTROL CABINET
24VDC COMPONENTS - RH WALL
1. 24VDC to 12 VDC Converter
2. Circuit Breaker (50 amp)
3. Interface Module (IM)
4. Ethernet Switch
7
VEC blocks
VEC blocks (1), (2), (3) and (4, Figure 10-7) contain
replaceable relays, diodes and fuses that are
mounted on a plug-in connector for easy
replacement. The diodes are used to control the flow 2 1
of current in a circuit as required. The fuses protect
various circuits on the truck. Spare fuses are
provided in the VEC blocks. The relays switch on/off
circuits that require control logic.
Refer to Troubleshooting section Fuse and circuit
breaker locations for a list of diode, fuse and relay 4 3
functions.
NOTE: Before replacing a fuse, determine the cause
of failure. Repair as necessary. Always replace a fuse
with one of the same specified amperage. Never
replace with one of greater amperage.
5
Light timers
Timer (5) will turn off the engine service lights after 7
two hours of operation. 6
Timer (6) will turn off the pump module service lights
after two hours of operation. 8
Relays
Relays (7) are used to switch heavy loads on various 9
electrical circuits. These relays are rated at 24V, 75
amps. 87542
• Key Switch Power FIGURE 10-7. AUXILIARY CONTROL CABINET

24VDC COMPONENTS - LH WALL
• 12V Power
1. VEC Block 89
• Horn
2. VEC Block 90
• Rear Backup Light 3. VEC Block 91
• Key Control Power 4. VEC Block 92
5. Engine Service Light Timer
• Ladder/Deck Light 6. Pump Module Light Timer
• High Beam Headlights 7. Relays
8. Ground Terminals
• High Mounted Low Beam Headlights 9. 24VDC Power Terminals
• Low Mounted Low Beam Headlights
Ground terminals
Ground terminals (8) provide a ground location for
many circuits and are a convenient test point during
troubleshooting procedures.
24VDC power terminals

24VDC power terminals (8) distribute 24VDC battery
voltage and are a convenient test point for measuring
battery voltage during troubleshooting procedures.
8
Body-up switch
Body-up switch (1, Figure 10-6) is located inside the
right frame rail near the front of the body. It must be
adjusted to specifications to ensure that the proper
electrical signal is obtained when the body is raised
or lowered. 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.
When the body is resting on the frame, magnet
assembly (3) on bracket (4) causes the electrical
contacts in the magnetically-operated switch to close.
When the body is raised, the bracket and magnet
assembly move away from the switch, opening the
contacts. The electrical signal is sent to the control
system and the body-up relay.
The switch must be properly adjusted at all times.
Improper adjustment or loose mounting capscrews
may cause false signals or damage to the switch
assembly.
FIGURE 10-6. BODY-UP SWITCH
1. Body Up Switch 3. Magnet Assembly
Dimension "A"................................ 45 mm (1.77 in.) 2. Switch Mounting Bracket 4. Bracket
Dimension "B"............................. 32.3 mm (1.27 in.)
9
Hoist limit switch

Hoist limit switch (1, Figure 10-7) is located inside the
right frame rail above the rear suspension, near the
body pivot pin. The hoist limit switch is designed to
stop the hoist cylinders before they reach full
extension, preventing possible damage to the dump
body or hoist cylinders.
When the hoist cylinders are approximately 152 mm
(6 in.) from maximum stroke and the body pivots on
the pins, magnet assembly (3) on bracket (4) moves
close enough to magnetically-operated hoist limit
switch (1) to close the electrical contacts. When the
contacts close, an electrical signal is sent to the hoist
limit solenoid valve to prevent further oil flow to the
hoist cylinders.
Dimension "A"................................ 45 mm (1.77 in.)

Dimension "B"............................. 83.1 mm (3.27 in.) FIGURE 10-7. HOIST LIMIT SWITCH
1. Hoist Limit Switch 3. Magnet Assembly

2. Switch Mounting Plate 4. Actuator Arm
10
NOTES
11
980E Dump truck

12
CEN10088-00
830E
930E
980E

830E-5 A50005 and up
930E-5 A40004 and up
980E-5 A50005 and up

Cab air conditioning
Principles of refrigeration ...................................................................................................................................... 3
Air conditioning system components .................................................................................................................... 5
Air conditioning system electrical circuit ............................................................................................................... 9
1
General information Air conditioning for off-highway vehicles
Environmental impact of air conditioning Mining and construction vehicles have unique
characteristics of vibration, shock-loading, operator
Environmental studies have indicated a weakening of changes, and climate conditions that present different
the earth’s protective Ozone (O3) layer in the outer design and installation challenges for air conditioning
stratosphere. Chloro-flouro-carbon compounds systems. Off-highway equipment, in general, is
(CFC’s), such as R-12 refrigerant (Freon), commonly unique enough that normal automotive or highway
used in mobile equipment air conditioning systems, truck engineering is not sufficient to provide the
have been identified as a possible contributing factor reliability to endure the various work cycles
of the Ozone depletion. encountered.
Consequently, legislative bodies in more than 130 The cab tightness, insulation, and isolation from heat
countries have mandated that the production and sources is very important to the efficiency of the
distribution of R-12 refrigerant be discontinued after system. It is advisable to close all vents, even the
1995. Therefore, a more “environmentally-friendly” intakes of pressurization systems, when there are
hydro-flouro-carbon. high humidity conditions.
(HFC) refrigerant, commonly identified as HFC-134a The general cleanliness of the system and
or R-134a, is being used in most current mobile air components is important. Dust and dirt collected in
conditioning systems. Additionally, the practice of the condenser, evaporator, and air filters decreases
releasing either refrigerant to the atmosphere during the system's cooling capacity.
the charging/recharging procedure is prohibited.
The compressor, condenser, evaporator units, hoses
These restrictions require the use of equipment and and fittings must be installed clean and tight and be
procedures which are significantly different from capable of withstanding the strain and abuse they are
those traditionally used in air conditioning service subjected to on off-highway vehicles.
techniques. The use of new equipment and
Equipment downtime costs are high enough to
techniques allows for complete recovery of
encourage service areas to perform preventive
refrigerants, which will not only help to protect the
maintenance at regular intervals on vehicle air
environment, but through the “recycling” of the
conditioning systems (cleaning, checking belt
refrigerant will preserve the physical supply, and help
tightness, and checking operation of electrical
to reduce the cost of the refrigerant.
components).
2
Principles of refrigeration • Reversing the process, when heat is removed

from water vapor, it will return to the liquid state.
A brief review of the principles of air conditioning is Heat from air moves to a cooler object. Usually
necessary to relate the function of the components, the moisture in the cooled air will condense on
the technique of troubleshooting, and the corrective the cooler object.
action necessary to put the air conditioning unit into
top operating efficiency. • Refrigerant - Only R-134a should be used in the
new mobile systems which are designed for this
Too frequently, the operator and the service refrigerant.
technician overlook the primary fact that no air
conditioning system will function properly unless it is The refrigeration cycle
operated within a completely controlled cab In an air conditioning system, the refrigerant is
environment. The circulation of air must be a directed circulated under pressure through the five major
flow. The cab must be sealed against seepage of components in a closed circuit. At these points in the
ambient air. The cab interior must be kept free of dust system, the refrigerant undergoes predetermined
and dirt which, if picked up in the air system, will clog pressure and temperature changes.
the intake side of the evaporator coil.
The compressor (refrigerant pump) takes in low
Air conditioning pressure heat laden refrigerant gas through the
suction valve (low side), and as its name indicates,
Air conditioning is a form of environmental control. As pressurizes the heat laden refrigerant and forces it
applied to the cab, it refers to the control of through the discharge valve (high side) on to the
temperature, humidity, cleanliness, and circulation of condenser.
air. In the broad sense, a heating unit is as much an
air conditioner as is a cooling unit. The term “air Ambient air, passing through the condenser removes
conditioner” is commonly used to identify an air heat from the circulating refrigerant resulting in the
cooling unit. To be consistent with common usage, conversion of the refrigerant from gas to liquid.
the term “air conditioner” will refer to the cooling unit The liquid refrigerant moves on to the receiver drier
utilizing the principles of refrigeration, sometimes where impurities are filtered out, and moisture
referred to as the evaporator unit. removed. This component also serves as the
temporary storage unit for some liquid refrigerant.
Refrigeration - the act of cooling
The liquid refrigerant, still under high pressure, then
• There is no process for producing cold; there is
only heat removal. flows to the expansion valve. This valve meters the
amount of refrigerant entering the evaporator. As the
• Heat always travels toward cooler temperatures. refrigerant passes through the valve, it becomes a
This principle is the basis for the operation of a low temperature, low pressure liquid and saturated
cooling unit. As long as one object has a vapor. This causes the refrigerant to become cold.
temperature lower than another, this heat transfer
will occur. The remaining low pressure liquid immediately starts
• Temperature is the measurement of the intensity to boil and vaporize as it approaches the evaporator,
of heat in degrees. The most common measuring adding to the cooling. The hot, humid air of the cab is
device is the thermometer. pulled through the evaporator by the evaporator
blower. Since the refrigerant is colder than the air, it
• All liquids have a point at which they will turn to absorbs the heat from the air producing cool air
vapor. Water boiling is the most common
which is pushed back into the cab. The moisture in
example of heating until vapor is formed. Boiling
is a rapid form of evaporation. Steam is a great the air condenses upon movement into the
deal hotter than boiling water. The water will not evaporator and drops into the drain pan from which it
increase in temperature once brought to a boil. drains out of the cab.
The heat energy is used in the vaporization Refrigerant leaving the evaporator enters the
process. The boiling point of a liquid is directly
accumulator. The accumulator functions as a sump
affected by pressure. By changing pressure, we
can control the boiling point and temperature at for liquid refrigerant in the system. Because of its
which a vapor will condense. When a liquid is design, the accumulator only allows vaporized
heated and vaporizes, the gas will absorb heat refrigerant to return to the compressor, preventing
without changing pressure. compressor slugging from occurring.
3
Desiccant is located at the bottom of the This simplified explanation of the principles of
accumulators to remove moisture that is trapped in refrigeration does not call attention to the fine points
the system. of refrigeration technology. Some of these will be
covered in the following discussions of the
The cycle is completed when the heated low
components, controls, and techniques involved in
pressure gas is again drawn into the compressor
preparing the unit for efficient operation.
through the suction side.
FIGURE 10-1. BASIC AIR CONDITIONING SYSTEM

1. Blower Switch 7. Evaporator 13. Magnetic Clutch
2. Thermostatic Switch 8. Expansion Valve 14. Compressor Drive Pulley
3. Battery Supply 9. Suction Line 15. Receiver-Drier
4. Circuit Breaker 10. Test Gauges & Manifold 16. Discharge Line
5. Blower 11. Compressor 17. Condenser
6. Temperature Sensor 12. Refrigerant Container 18. Accumulator
4
Air conditioning system components

NOTE: Figure 10-3 illustrates both the heater system
and air conditioning system parts contained in the
cab mounted enclosure.
ECU module
ECU module (1, Figure 10-3) controls the damper
doors, A/C compressor clutch, temperature control
switch, water (heater) valve and the actuator motors.
Fan motor and speed control

Fan speed is controlled by interface panel (1, Figure
10-3) in the operator cab.
If blower assembly (5) 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. If voltage is present, the blower 1
assembly is probably defective and should be 86986
removed and replaced. FIGURE 10-2. CAB AIR FILTER LOCATION
Cab air filter 1. Cab Air Filter

Recirculation air filter (6, Figure 10-3) and cab air
filter (1, Figure 10-2) need periodic cleaning to
prevent restrictions in air circulation. Restricted filters Actuators
will decrease the performance of the heater and air
Two rotary actuators (4, Figure 10-3) are installed on
conditioner. The recommended interval for cleaning
the ductwork and are used to actuate the damper
and inspection is 250 hours, but in extremely dusty
doors for the following:
conditions the filters may need daily service and
inspection, especially the outer panel filter on the cab • Defroster outlet
shell. The filter elements should be cleaned with
• Bi-level or floor outlets
water and dried in a dust free environment before re-
installation. Replace the filter element every 2,000 A failure to switch one of the above modes of
hours, or sooner if inspection indicates a clogged or operation may be caused by a faulty actuator.
damaged filter. Visually inspect the damper doors and the linkage for
the function being diagnosed. Ensure that the
Heater core
damper door is not binding or obstructed, preventing
Heater core (6, Figure 10-3) receives engine coolant movement from one mode to the other. Verify that
through water valve (2) when heating is selected. If 24VDC is present at the actuator when the fan speed
the temperature is set for cooling, coolant flow should switches on interface panel (1, Figure 10-3) are
be blocked. cycled through the various positions of operation.
If the interface panel and water valve appear to be If the correct voltages are present during operation of
working properly, yet no heat is apparent in the the switches, disconnect the actuator from the
heater core, the core may be restricted. Remove and damper door and verify that actuator force is
clean or replace the core. comparable to a known (new) actuator. If it is not,
install a new actuator.
5
6 8 9
7
1 2 3
86987
FIGURE 10-3. HEATER/AIR CONDITIONER ASSEMBLY

1. Interface Panel 6. Heater Core
2. Water Valve & Actuator 7. Evaporator Core
3. Expansion Valve 8. Recirculation Filter
4. Damper Doors & Actuators 9. ECU Module
5. Blower Assembly
Compressor (refrigerant pump) To create high pressure concentration, the

compressor draws in refrigerant from the evaporator
Compressor (11, Figure 10-1) is where the low
through the suction valve and, during compression
pressure side of the system changes to high
strokes, forces it out through the discharge valve to
pressure. It concentrates the refrigerant returning
the condenser. The pressure from the compressor
from the evaporator (low side), creating high
action moves the refrigerant through the condenser,
pressure and a temperature much higher than the
receiver-drier and connecting hoses to the expansion
outside air temperature. The high temperature
valve.
differential between the refrigerant and the outside air
is necessary to aid rapid heat flow in the condenser The compressor is driven by the engine through a
from the hot refrigerant gas to much cooler outside drive belt driving an electrically operated clutch
air. mounted on the compressor drive shaft.
6
Service valves Receiver-drier

Quick-connect hose end fittings with integral service Receiver-drier (15, Figure 10-1) is an important part
valves attach to system service ports for servicing the of the air conditioning system. The drier receives the
unit. A manifold gauge set is connected into the liquid refrigerant from the condenser and removes
system at the service valve ports and all procedures, any moisture and foreign matter present which may
such as discharging, evacuating and charging the have entered the system. The receiver section of the
system, are performed through the service valves. tank is designed to store extra refrigerant until it is
needed by the evaporator. The storage of this
Condenser refrigerant is temporary and is dependent on the
Condenser (17, Figure 10-1) receives the high demand of the expansion valve.
pressure, high-temperature refrigerant vapor from the A desiccant is a solid substance capable of removing
compressor and condenses it to high pressure, hot moisture from gas, liquid or solid. It is held in place
liquid. within the receiver between two screens, which also
It is designed to allow heat movement from the hot act as strainers.
refrigerant vapor to the cooler outside air. The cooling The receiver-drier is also equipped with a sight glass
of the refrigerant changes the vapor to liquid. Heat and a moisture indicator. The sight glass can give a
exchange is accomplished using cooler air flowing good indication of the charge of the system. If the
through the condenser. Condenser cooling is sight glass is not clear, the system is low on
achieved by air flowing from the radiator fan along refrigerant.
with ram air provided by vehicle movement. The
radiator fan moves more than 50% of condenser air The moisture indicator is a device to notify service
flow unless travel speed is at least 40 kph (25 mph). personnel that the drier is full of moisture and must
be replaced. The indicator is blue when the
Ram air condensers depend upon the vehicle component is free from moisture. When the indicator
movement to force a large volume of air past the fins turns beige or tan, the drier must be replaced.
and tubes of the condenser. The condenser is usually
located in front of the radiator or on the roof of the
truck.
Accumulator
Condensing of the refrigerant is the change of state
Accumulator (18, Figure 10-1) receives vaporized
of the refrigerant from a vapor to a liquid. The action
refrigerant from the evaporator, moisture and/or any
is affected by the pressure of the refrigerant in the
residual liquid refrigerant is collected at the bottom of
coil and air flow through the condenser. Condensing
the component. The moisture is absorbed by the
pressure in an air conditioning system is the
desiccant where it is safely isolated from the rest of
controlled pressure of the refrigerant which affects
the system.
the temperature at which it condenses to liquid,
giving off large quantities of heat in the process. The The storage of the liquid refrigerant is temporary.
condensing point is sufficiently high to create a wide When the liquid vaporizes into a gas it will be pulled
temperature differential between the hot refrigerant from the bottom of the accumulator into the
vapor and the air passing over the condenser fins compressor. This process not only allows the
and tubes. This difference permits rapid heat transfer accumulator to act as a storage device, but also
from the refrigerant to ambient air. protects the compressor from liquid slugging.
The low side service port is also located on the
accumulator.
7
Expansion valve Evaporator core

Expansion valve (2, Figure 10-3) controls the amount Evaporator core (7, Figure 10-3) cools and
of refrigerant entering the evaporator core. Both dehumidifies the air before it enters the cab. Cooling
internally and externally equalized valves are used. a large area requires that large volumes of air be
passed through the evaporator coil for heat
The expansion valve is located near the inlet of the
exchange. Therefore, a blower becomes a vital part
evaporator and provides the functions of throttling,
of the evaporator assembly. It not only draws heat
modulating, and controlling the liquid refrigerant to
laden air into the evaporator, but also forces this air
the evaporator coil.
over the evaporator fins and coils where the heat is
The refrigerant flows through a restriction creating a surrendered to the refrigerant. The blower forces the
pressure drop across the valve. Since the expansion cooled air out of the evaporator into the cab.
valve also separates the high side of the system from
Heat exchange, as explained under condenser
the low side, the state of the refrigerant entering the
operation, depends upon a temperature differential of
valve is warm to hot high pressure liquid; exiting it is
the air and the refrigerant. The greater the
low pressure liquid and gas. The change to low
temperature differential, the greater will be the
pressure allows the flowing refrigerant to immediately
amount of heat exchanged between the air and the
begin changing to gas as it moves toward the
refrigerant. A high heat load condition, as is generally
evaporator. This produces the desired cooling effect.
encountered when the air conditioning system is
The amount of refrigerant metered into the turned on, will allow rapid heat transfer between the
evaporator varies with different heat loads. The valve air and the cooler refrigerant.
modulates from wide open to the nearly closed
The change of state of the refrigerant in and going
position, seeking a point between for proper metering
through the evaporator coil is as important as that of
of the refrigerant.
the air flow over the coil.
As the load increases, the valve responds by opening
All or most of the liquid that did not change to vapor in
wider to allow more refrigerant to pass into the
the expansion valve or connecting tubes boils
evaporator. As the load decreases, the valve reacts
(expands) and vaporizes immediately in the
and allows less refrigerant into the evaporator. It is
evaporator, becoming very cold. As the process of
this controlling action that provides the proper
heat loss from the air to the evaporator coil surface is
pressure and temperature control in the evaporator.
taking place, any moisture (humidity) in the air
This system uses an internally equalized, block type condenses on the cool outside surface of the
expansion valve. With this type valve, the refrigerant evaporator coil and is drained off as water.
leaving the evaporator coil is also directed back
At atmospheric pressure, refrigerant boils at a point
through the valve so the temperature of the
lower than water freezes. Therefore, the temperature
refrigerant is monitored internally rather than by a
in the evaporator must be controlled so that the water
remote sensing bulb. The expansion valve is
collecting on the coil surface does not freeze on and
controlled by both the temperature of the power
between the fins and restrict air flow. The evaporator
element bulb and the pressure of the liquid in the
temperature is controlled through pressure inside the
evaporator.
evaporator, and temperature and pressure at the
NOTE: It is important that the sensing bulb, if outlet of the evaporator.
present, is tight against the output line and protected
from ambient temperatures with insulation tape.
8
Air conditioning system electrical circuit Compressor clutch

The air conditioner's electrical circuit is fed from an An electromagnetic clutch is used in conjunction with
accessory circuit and is fused with a 30-ampere the thermostat to disengage the compressor when it
circuit breaker. is not needed, such as when a defrost cycle is
indicated in the evaporator, or when the system or
The interface panel in the operator cab provides a
blower is turned off.
range of blower speeds and temperature settings.
When the ON switch is pressed, current is available The stationary field clutch is the most desirable type
at the compressor clutch. Once the blower is turned since it has fewer parts to wear. The field is mounted
on, fan speeds may be changed without affecting the to the compressor by mechanical means depending
thermostat sensing level. on the type field and compressor. The rotor is held on
the armature by a bearing and snap rings. The
The thermostat reacts to changing temperatures
armature is mounted on the compressor body.
which cause electrical contacts to open and close.
The thermostat has a capillary tube extended into the When no current is fed to the field, there is no
evaporator coil to sense temperature. magnetic force applied to the clutch and the rotor is
free to rotate on the armature, which remains
When the contacts are closed, current flows to the
stationary on the crankshaft.
clutch field and energizes the clutch, causing the
swash plate inside the compressor to turn which When the thermostat or switch is closed, current is
starts the refrigeration cycle. When the temperature fed to the field. This sets up a magnetic force
of the evaporator coil drops to a predetermined point, between the field and armature, pulling it into the
the contacts open and the clutch disengages. rotor. When the armature becomes engaged with the
rotor, the complete unit rotates while the field remains
When the clutch is disengaged, the blower remains at
stationary. This causes the compressor crankshaft to
the set speed. After the evaporator temperature rises
turn, starting the refrigeration cycle.
about twelve degrees above the cutout point, the
contacts in the thermostat close and the refrigeration When the switch or thermostat is opened, current is
cycle resumes. cut off. The armature snaps back out and stops while
the rotor continues to turn. Pumping action of the
Thermostat compressor is stopped until current is again applied
An electromagnetic clutch is used on the compressor to the field. In addition, safety switches in the
to provide a means of constant temperature control of compressor clutch electrical circuit control clutch
the cab. The clutch is controlled by a thermostat in operation, disengaging the clutch if system pressures
the evaporator which is set initially by the driver to a are abnormal.
predetermined point. Evaporator temperature is then
maintained by the cycling action of the clutch.
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.
9
Trinary™ switch • Fan Clutch - The mid-range function actuates the

engine fan clutch, if installed.
This switch is mounted on the receiver-drier and has
three functions (as implied by the name): • High Pressure - This switch opens and
disengages the compressor clutch if system
1. Disengage the compressor clutch when system pressure rises above the 2 068 - 2 413 kPa (300 -
pressure is too high. 350 psi) range. After system pressure drops to
2. Disengage the compressor clutch when system 1 448 - 1 724 kPa (210 - 250 psi), the switch
pressure is too low. contacts will close and the clutch will engage.
3. Engage and disengage the radiator fan drive The switch functions will automatically reset when
clutch during normal variation of system system pressure returns to normal.
pressure.
OPENS CLOSES
The Trinary™ switch performs three distinct functions Low 103 - 207 kPa 276 kPa
to monitor and control refrigerant pressure in the Pressure (15 - 30 psi) (40 psi)
system. This switch is installed on the receiver-drier. descending rising pressure
The switch functions are: pressure
Terminals 1 and 2 are connected internally through High 2 068 - 2 413 kPa 1 448 - 1 724 kPa
two, normally closed pressure switches in series, the Pressure (300 - 350 psi) (210 - 250 psi)
low pressure switch and the high pressure switch.
241 - 414 kPa 1 379 - 1 586 kPa
Fan (35 - 60 psi) (200 - 230 psi)
Clutch below closing rising pressure
pressure
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 138 kPa (20
psi) higher. This factor should be observed when
Terminals 3 and 4 are connected internally through a checking for proper operation of the switch.
normally open switch that is used to control the clutch
that drives the radiator fan. This switch closes and
NOTE: One other pressure controlling device is
causes the cooling fan clutch to engage when system
installed within the compressor. A mechanical relief
pressure rises to 1 379 - 1 586 kPa (200 - 230 psi).
valve is located on the back of the compressor. The
When pressure falls to 965 - 1 344 kPa (140 - 195
relief valve will open at 3 447 - 3 792 kPa (500 - 550
psi), the switch contacts open, and the cooling fan
psi). The purpose of this valve is to protect the
clutch disengages.
compressor in the event that pressure should be
• Low Pressure - This switch opens and allowed to rise to that level. Damage to the
disengages the compressor clutch if system compressor will occur if pressure exceeds 3 792 kPa
pressure drops into the 103 - 207 kPa (15 - 30 (550 psi).
psi) range. When pressure rises above 276 kPa
(40 psi), the switch contacts close, and the clutch
engages the compressor. Since temperature has
NOTE: During installation, tighten the switch to 9 N•m
a direct effect on pressure, if the ambient
temperature is too cold, system pressure will drop (7 ft lb) or 1/8 of a turn after hand tightening.
below the low range, and the pressure switch will
disengage the clutch.
10
NOTES
11
830E Dump truck

930E Dump truck
980E Dump truck
12
CEN10080-00
830E
930E
980E

830E-5 A50005 and up
930E-5 A40004 and up
980E-5 A50005 and up

Automatic lubrication (auto lube) system
System operation .................................................................................................................................................. 3
1
General information
The automatic lubrication (auto lube) system is a
5 6 7
pressurized lubricant delivery system which delivers
a controlled amount of lubricant to designated lube
points such as:
• steering cylinder pins
• tie rod pins 4 8
• body pivot pin
• hoist cylinder pins 9
• rear suspension pins
• sway bar pins
10
The system is controlled by logic in the interface
module (IM), which signals a solenoid valve to 3
operate a hydraulic motor powered grease pump.
The solenoid valve is equipped with a manual
override switch that, when actuated, activates the 2
pump when power is not being supplied to the motor.
Hydraulic oil for pump operation is supplied through
the auxiliary hydraulic system. Grease pump (5, 1 87506
Figure 10-1) is driven by the rotary motion of
FIGURE 30-1. AUTO LUBE PUMP AND
hydraulic motor (9), which is then converted to
RESERVOIR COMPONENTS
reciprocating motion through an eccentric crank
mechanism. The pump is a positive displacement, 1. Reservoir 6. Hydraulic Oil Supply
double-acting type as grease output occurs on both 2. Main Grease Supply 7. Pump Control
the up and the down stroke. Line Manifold
3. Relief Valve 8. Hydraulic Oil Return
Integrated pump control manifold (7) is incorporated
4. Vent Valve 9. Hydraulic Motor
with the motor to control input flow and pressure.
5. Grease Pump 10. Grease Filter
Relief valve (3) in vent valve (4) protects the pump
from high pressures. The relief valve is set at 27 580
kPa (4,000 psi). A pressure gauge can be installed in
the plugged port on top of the manifold to check the
hydraulic oil pressure to the inlet of the hydraulic
motor. Normal stall pressure is 2 415 - 2 585 kPa
(350 - 375 psi).
When the grease supply is replenished through the
service center, the grease passes through grease
filter (10) to remove contaminants before it flows into
reservoir (1). A bypass indicator on the filter alerts
service personnel when the filter requires
replacement.
2
System operation
During truck operation, the lubrication cycle logic in 3 4
the interface module (IM) will energize the system at
a preset time interval. The IM provides a path to
ground to energize solenoid valve (3, Figure 10-2),
allowing hydraulic oil from the auxiliary hydraulic
system to flow to hydraulic motor (1) and initiate a 5
pumping cycle. The hydraulic oil is directed through
pressure reducing valve (2) and flow control valve (5)
located in pump control manifold (4) before entering
the hydraulic motor. The high hydraulic oil pressure
from the auxiliary hydraulic system is reduced to a
2
suitable operating pressure by the pressure reducing
valve. The flow control valve controls the amount of
oil flow to the hydraulic motor.
NOTE: The flow control valve has been factory
adjusted and the setting should not be disturbed.
With oil flowing into the hydraulic motor, the grease
pump will operate, pumping grease from the reservoir
to the injectors, through a check valve, and to vent
valve (4, Figure 10-1). With the vent valve closed, the 1
pump continues to operate until maximum grease 87507
pressure is achieved. During this period, the injectors FIGURE 30-2. HYDRAULIC MOTOR AND
will meter the appropriate amount of grease to each MANIFOLD COMPONENTS
lubrication point.
1. Hydraulic Motor
2. Pressure Reducing Valve
3. Solenoid Valve with Manual Override Switch
4. Pump Control Manifold
5. Flow Control Valve
3
NOTE: Each injector services only one lube point. In

case of pump malfunction, each injector is equipped
with a covered grease zerk (4, Figure 10-3) to allow
the use of external lubricating equipment.
When grease pressure reaches the setting of
pressure switch (6, Figure 10-3) on the rear axle
housing, the switch contacts will close, sending a
signal to the IM that the pressure setting has been 5
reached. This removes power from the hydraulic
motor, which stops pump operation. The IM will
complete a 120 second ON cycle. 3 4
After the hydraulic motor stops, hydraulic pressure in
the pump control manifold drops and the vent valve
will open, releasing the grease pressure in the lines 3
to injector banks (1). When this occurs, the injectors
are then able to recharge for the next lubrication
cycle. The system will remain at rest until the IM
initiates the next lubrication cycle.
During the normal lubrication cycle, if grease
pressure fails to reach 13 790 kPa (2,000 psi) at
pressure switch (6), fault code A190 - Auto Lube 2 1
Fault will be logged.
FRONT INJECTORS
2 1 REAR INJECTORS 87508
FIGURE 30-3. GREASE INJECTORS

1. Injector Bank 4. Injector Grease Zerk
2. Main Supply Line 5. Injector
3. Secondary Supply Line 6. Pressure Switch
4
NOTES
5
830E Dump truck

930E Dump truck
980E Dump truck
6
CEN20005-02
980E

980E-4 A40003 and up
980E-5 A50005 and up

Standard value table
Standard value table for truck ............................................................................................................................... 3
1
CEN20005-02 20 Standard value table
NOTES
2
20 Standard value table CEN20005-02
Standard value table for truck
980E-4
Truck model
980E-5
Measurement
Check item Unit Standard value
conditions
• Flat dry road surface
0% grade 64
• Engine coolant
(empty) temperature within (40)
Travel speed
operating range
Maximum speed in 12% grade • Travel resistance: 2.0% kph
28.2
forward gear uphill (mph)
• Standard tires (17.5)
(empty)
12% grade
10.8
uphill
(6.7)
(loaded)
• Engine coolant
temperature within
operating range 980E-4 1,900
Rated
Engine speed
980E-5 1,800
rpm
Idle 750
Max. overspeed 2,030
Stationary steering • Flat dry road surface

91 ± 2.0
effort
Operating
• Steering wheel speed: (20.45 ± 0.45)

force
(If stationary steering is 30 rpm N

impossible, measure (lb)
Max. 115
steering effort at low • Engine low idle
(25.8)
speed.)
Steering wheel
• Engine stopped
Dimension
• Dimension on periphery of
Play grip Degrees 5
• Until front wheel starts
moving
• Lock to lock
Number of
rotations
Number of
Rotation range 4.5 ± 0.5
rotations
3
980E-4
Truck model
980E-5
Measurement
conditions
• Point at • Starting to 29.3 + 13.0/-0
Operating 150 mm depress N (6.6 + 2.9/-0)
force (6 in.) from (lb)
• Full 58.7 + 0/-13.3
fulcrum of
Accelerator pedal pedal (13.2 + 0/-3.0)
• Starting to mm 45 ± 5
Stroke depress
(in.) (1.8 ± 0.2)
to Full
• Retarding 44.5 ± 4.0
Operating N (10.0 ± 0.9)
force • Braking (lb) 300.5 ± 189.5
Brake pedal (67.55 ± 42.6)
• Retarding 17.5 ± 1.0
Stroke Degrees
• Braking 17.5 ± 1.0
Operating • Measuring point: N Max. 29.4
Directional control force Center of grip (lb) (Max. 6.61)
lever
Operating force and stroke
mm 24.5 ± 2
Stroke
(in.) (0.96 ± 0.08)
• Measuring • Initial Max. 35.3
Float to point: (Max. 7.94)
Raise Center of
• Full Max. 24.5
grip
(Max. 5.51)
Must return smoothly when
Raise to
engine speed is at high
Hold
idle.
• Initial Max. 35.3
Operating Hold to N (Max. 7.94)
force Raise • Full (lb) Max. 24.5
Hoist lever
(Max. 5.51)
• Initial Max. 35.3
Hold to (Max. 7.94)
Lower • Full Max. 24.5
(Max. 5.51)
Must return smoothly when
Lower to
engine speed is at high
Float
idle.
Raise to • Measuring point:
Hold Center of grip mm 44.8 ± 1.9
Stroke
Hold to (in.) (1.76 ± 0.08
Lower
4
980E-4
Truck model
980E-5
Measurement
conditions
• Flat dry road surface 228.6 ± 10
Standard
(9.0 ± 0.8)
Dimension
Installed Front • Body unloaded

Suspension cylinder
length mm Oil 165.1 ± 10

(exposed (in.) Sands (6.5 ± 0.8)
rod) 212.3 ± 10
Rear
(8.36 ± 0.4)
3 047
Pressure
Nitrogen Front
kPa (442)
gas
(psi) 1 455
pressure Rear
(211)
Accumulator
Front and • Atmospheric temperature):

Pressure
Nitrogen rear service 21 °C (70 °F)

kPa 9 653 ± 70
gas brakes (psi) {1,400 ± 10}
pressure
Steering
• With maximum allowed
Stop slope angle
payload (120%)
• Machine can hold on
Braking capacity specified grade % Max. 15
Parking brake
• Engine running
Oil pressure
kPa 22 753 ± 1 378

Release pressure
(psi) (3,300 ± 200)
Operating • At full stroke

Service brakes
Oil pressure
pressure
Front and
kPa 16 545 ± 517
rear service • Charge accumulator and
Brake oil operate brake first time (psi) (2,400 ± 75)
brakes
pressure
• At full stroke
Air pressure
• Machine unloaded
kPa 600 + 100/-0
Tire
59/80 R63
(psi) (87 + 14/-0)
5
980E-4
Truck model
980E-5
Measurement
conditions
At rated • Oil temperature:
20 600 ± 500
speed 50 – 80 °C
(122 – 176 °F) (2,987 ± 72)
(1,900 rpm)
Steering
valve
Relief oil
pressure At low idle
(750 rpm) 18 600 ± 500
[Reference (2,697 ± 72)
value]
Cut-in pressure • Oil temperature: 24 300
Counterbalance Steering pump
(unload) 45 – 55 °C (3525)
unloader
(113 – 131 °F)

Oil pressure
Cut-out pressure • High idle 22 240 ± 172

(reload) kPa (3,225 ± 25)
(psi)
• Oil temperature:
50 – 80 °C
(122 – 176 °F)
valve
20 685 ± 690
• Engine speed: (3,000 ± 100)
1,900 rpm (rated speed)
Relief pressure
Hoist valve
18 960 ± 690
(2,750 ± 100)
Empty • Oil temperature: 24 ± 2

50 – 80 °C
Lifting (122 – 176 °F)
speed Loaded 26 ± 2
• Engine speed:
Body
Time
1,900 rpm (rated speed) seconds

Power • Oil temperature:
13 ± 1
Lowering down 50 – 80 °C
speed (122 – 176 °F)
Float 16 ± 2
• Engine speed: 780 rpm
6
NOTES
7
980E Dump truck

8
CEN30071-03
980E

980E-4 A40003 and up
980E-5 A50005 and up

Steering, hoist, brake cooling and auxiliary
hydraulic system
Hydraulic system bleeddown procedure ............................................................................................................... 3
General information on system checkout.............................................................................................................. 5
Hydraulic system checkout procedures ................................................................................................................ 6
Hydraulic system checkout data sheet ............................................................................................................... 16
Toe-in adjustment................................................................................................................................................ 19
Hoist cylinder leakage test .................................................................................................................................. 20
Steering cylinder leakage test ............................................................................................................................. 20
1
CEN30071-03 30 Testing and adjusting
NOTES
2
30 Testing and adjusting CEN30071-03
Hydraulic system bleeddown procedure 7. Turn both brake accumulator bleed valves (1,
Figure 30-1) clockwise to bleed down the brake
accumulators.
8. Depress the brake pedal. The service brakes
should not apply and the service brake status
indicator should not illuminate.
Hydraulic oil escaping under pressure can have
sufficient force to enter a person's body by
penetrating the skin and cause serious injury,
and possibly death, if proper medical treatment is
not received immediately.
Relieve pressure before disconnecting any
hydraulic lines. Tighten all connections securely
before applying pressure.
Ensure that all pressure is removed from the

steering, brake and auxiliary hydraulic circuits before
opening any hydraulic connection or performing any
service work.
1. Park the truck on solid, level ground.
2. Place the hoist lever into the FLOAT position
and verify that the dump body is resting on the FIGURE 30-1. BRAKE MANIFOLD
frame.
1. Brake Accumulator Bleed Valves
2. Brake Manifold
9. Install 35 000 kPa (5,000 psi) pressure gauges

The steering accumulator bleeddown solenoid is
in test ports "BR" (1, Figure 30-2) and "BF" (2)
energized by the interface module (IM) after the
on the junction manifold to the right of the brake
truck is stopped, the key switch is OFF, and the
manifold. With the brake pedal depressed, the
engine is not running. The solenoid will remain
pressure at each test port should be at 103 kPa
energized until the IM is shut down.
(15 psi) or less after the brake system has been
bled down.
Do not engage the battery disconnect switch or
remove battery power from the truck in any
manner during the steering accumulator
bleeddown process. Steering pressure may 2 1
remain in the system, creating a personal injury
risk when hydraulic lines are opened.
3. Stop the engine by turning the key switch to the
OFF position. Wait for two minutes for the
steering accumulators to bleed down
completely.
4. Chock the rear tires.
86260
5. Ensure that all personnel and equipment are FIGURE 30-2. JUNCTION MANIFOLD
clear of the tires.
1. Test Port "BR"
6. Turn the steering wheel back and forth until it 2. Test Port "BF"
can no longer be turned by hand.
3
10. Open bleed valve (2, Figure 30-3) on auxiliary 11. To verify that the auxiliary accumulator is bled
hydraulic manifold (3) to bleed down auxiliary down, press override switch (3, Figure 30-4) on
accumulator (1). automatic lubrication pump (1). The automatic
lubrication pump will not operate if the auxiliary
accumulator is bled down.
1 2
1
3
3
2
86183
FIGURE 30-4. AUTOMATIC LUBRICATION

SYSTEM
86259 1. Automatic Lubrication 3. Override Switch
FIGURE 30-3. AUXILIARY HYDRAULIC MANIFOLD Pump 4. Hydraulic Motor
1. Auxiliary Accumulator 2. Manifold
2. Accumulator Bleed Valve
3. Auxiliary Hydraulic Manifold
12. Install a 35 000 kPa (5,000 psi) pressure gauge
in test port "GA" on the auxiliary hydraulic
manifold (3, Figure 30-3). The pressure should
be at 103 kPa (15 psi) or less after the auxiliary
hydraulic system has been bled down.
13. Install a 35 000 kPa (5,000 psi) pressure gauge
in test port "TP3" on the steering bleeddown
manifold. The pressure should be at 103 kPa
(15 psi) or less after the steering system has
been bled down.
14. After the service work is completed, tighten all
hydraulic connections and close all bleed
valves.
4
General information on system checkout NOTE: Excessive internal leakage within the brake
circuit may contribute to problems within the steering
The hydraulic system checkout procedures are
circuit. Ensure that brake circuit leakage is not
intended to help the technician diagnose problems in
excessive before troubleshooting the steering circuit.
the steering and hoist circuits. The technician should
read the checkout procedures to become familiar The steering circuit hydraulic pressure is supplied
with the procedures and all the warnings and from the steering/brake pump and steering
cautions before performing any steps. The checkout accumulators. Some steering system problems, such
procedures begin by checking the basic system as spongy or slow steering or abnormal operation of
before checking individual components. the low steering pressure warning, can sometimes be
traced to internal leakage of steering components. If
A data sheet is included in this section to record the
internal leakage is suspected, perform the steering
test information obtained during the hydraulic system
component leakage tests outlined in this section.
checkout procedure. The data sheet is designed to
be printed or copied, then used during the checkout The steering circuit can be isolated from the brake
procedure. circuit by first releasing all steering system pressure,
then releasing all pressure from the brake
accumulators and removing the brake system supply
hose from the bottom of the bleeddown manifold.
Plug the hose and cap the fitting at the bleeddown
manifold to prevent high pressure leakage.
The hydraulic system checkout procedures must
be performed before a truck is put back into
operation after any hydraulic system service has
been performed.
If the steering pump has just been installed, it is

NOTE: The interface module (IM) checkout essential that the pump case is full of oil before
procedure must be successfully completed and starting the engine.
engine startup must be possible before beginning the
checkout procedures.
5
Hydraulic system checkout procedures 2. Install 35 000 kPa (5,000 psi) calibrated
pressure gauges at the following locations:
Required equipment
a. steering pump test port "GPA"
• Steering, hoist and brake cooling hydraulic circuit
schematic b. bleeddown manifold test port "TP3"
• Service computer with Interface Module Realtime c. bleeddown manifold test port "TP2"
Data Monitor software d. both steering cylinder manifold test ports
• Five 35 000 kPa (5,000 psi) calibrated pressure 3. Install 24 000 kPa (3,500 psi) calibrated
gauges pressure gauges at the following locations:
• Three 24 000 kPa (3,500 psi) calibrated pressure a. both hoist filter test ports
gauges
b. overcenter manifold test port "TPD"
• Two 690 kPa (100 psi) calibrated pressure
gauges
• A graduated container marked to measure liquid Also, install 690 kPa (100 psi) calibrated pres-
volume in cubic inches or milliliters sure gauges at the following locations:
Preliminary steps a. front brake cooling test port on the hoist

valve outlet
1. The steering accumulators, brake accumulators
and auxiliary system accumulator must have the b. rear brake cooling test port on the brake
correct precharge and must be at normal cooling/hoist return manifold
operating temperature. Refer to Testing and
adjusting section Accumulators and
suspensions for the accumulator charging Hydraulic system flushing procedure
procedures.
4. Install a jumper hose between the "QD Supply"
* Record on Data Sheet and "QD Return" ports on the bleeddown
NOTE: For best performance, charge the manifold. The hose must be rated for at least
accumulators in the ambient conditions in which the 24 000 kPa (3,500 psi) in case the steering
machine will be operating. system becomes fully pressurized. However,
the pressure during the flushing procedure
should be less than 3 500 kPa (500 psi).
5. Use two flushing blocks (PC3074) to join the
piston end and rod end hoist cylinder hoses if
not already assembled.
6
6. An optional hose/needle assembly for manually c. Connect one end of the hose/needle valve
bleeding down the steering accumulators can assembly to the #10 SAE boss port.
be used. This hose/needle valve assembly is
d. Remove the plug in brake manifold port "T3"
only for convenience and is not required. It
(2, Figure 30-6). This port will return oil that is
provides a way to manually bleed down both
bled from the steering accumulators to the
steering accumulators any time during the
hydraulic tank.
checkout procedure.
The assembly will consist of two 1/4” diameter
hoses connected to a needle valve. The hose
material can be 1/4” diameter SAE 100R2,
which has 35 000 kPa (5000 psi) rating. The
needle valve will allow simple opening/closing
and must be rated for 27 500 kPa (4,000 psi) or
above. The length of the hoses is not critical and
can be selected to provide the best accessibility
to the needle valve. Connect the opposite ends
of the hose/needle valve assembly as follows.
a. Ensure that both steering accumulators and
both brake accumulators are bled down.
1
b. Remove the plug from #10 SAE boss port (1,
Figure 30-5) located near bleeddown 84723
manifold port "TP3" (2). This port has the
same pressure as the steering supply port FIGURE 30-6. BRAKE MANIFOLD
and ACC2 port and will allow both steering
1. Port T3
accumulators to bleed down when the needle
valve is opened.
e. Connect hose/needle valve assembly to port

"T3".
1
f. Retain the plugs that were removed from the
manifolds for replacement when the hose/
needle valve assembly is removed.
NOTE: Use of optional bleeddown hose/needle valve
assembly does not substitute for the use of jumper
hose installed in step 4.
2
This hose/valve assembly cannot be connected

or disconnected if the steering accumulators are
pressurized.
84722 The hose/needle valve assembly must be removed

FIGURE 30-5. BLEEDDOWN MANIFOLD when the checkout procedure is completed. The
original plugs must be installed in the manifold ports
1. #10 SAE Boss Port and tightened to the proper torque.
2. Port "TP3"
7
7. If brakes are not installed, connect brake 15. It may be necessary at any time during this
cooling supply and return hoses together for this checkout procedure to stop the engine and
entire checkout procedure. Service brake and allow the steering accumulators to bleed down.
parking brake hoses must be fitted with steel Steering pressure at bleeddown manifold test
plugs rated for 27 500 kPa (4000 psi) or higher port "TP3" will be 103 kPa (15 psi) or less after a
during this checkout procedure. successful bleed down. The pressure gauge
8. Disconnect or disable all auxiliary hydraulic installed in bleeddown manifold port "TP3" will
systems (auto lube, retractable ladder, radiator show the steering accumulator pressure.
shutters, etc) that may be present on the truck. Refer to step 6 if an optional manual method of
9. Fill the steering pump case through case drain bleeding down the steering accumulators is
port with clean hydraulic oil. desired when performing this checkout proce-
dure.
An alternate method to filling the pump case
with oil is by leaving case drain hose connected
and removing small SEA #6 plug marked "PRG"
near the case drain port on top of the pump.
This will vent air from the pump case if the
hydraulic tank is filled with oil. Install and tighten If the warning indicator is illuminated, the buzzer
the plug when oil appears. is sounding and the steering pressure status
NOTE: Filling the pump case with oil does not indicator is flashing, do not attempt to remove
eliminate the need for bleeding air from the pump any hydraulic hose, fitting, plug, switch, etc.
suction line as described in step 11. Both must be Hydraulic pressure may be trapped.
done.
If fault code A236 is shown on the message
10. Fully open all pump suction line shutoff valves, if display, the steering accumulators did not
equipped. Valves are fully open when the properly bleed down.
handle is in line with the hose.
Locate and correct any steering accumulator
bleeddown problem before proceeding.
16. Turn the key switch to ON but do not start the

engine. Verify that the low steering accumulator
Serious pump damage will occur if any shutoff precharge warning (fault A115) is not displayed.
valve is not fully open when the engine is started. If the warning is displayed, correct the problem
before starting engine.
11. Fill hydraulic tank with hydraulic oil to upper * Record on Data Sheet
sight glass.
NOTE: The brake accumulators and the auxiliary
12. Bleed the air from all pump suction lines by system accumulator do not have pressure switches
loosening each suction hose at the pump inlet. to warn for low precharge, but they must be
Ensure that the O-ring does not fall out of the precharged to 9 653 kPa (1,400 psi) before starting
groove. When oil appears, retighten the the engine. Do not start the engine without ensuring
capscrews. that all accumulators are precharged to 9 653 kPa
(1,400 psi).
NOTE: Bleeding the piston pump suction line does
not eliminate the need for filling the piston pump case
with oil as described in step 9. Both must be done.
13. Check that the oil level in the hydraulic tank is
still visible in the upper sight glass. Add oil if
necessary.
14. Place the hoist lever in the FLOAT position.
8
Start the engine and operate at low idle for no 18. If all pump pressures and brake cooling oil
more than 30 seconds. At low idle with 21°C supply pressures are as stated in steps 16 and
(70° F) oil, pressure at the hoist filters should be 17, increase engine to 1500 rpm and flush the
approximately 552 kPa (80 psi). Pressure at system for 20 minutes. During this time, move
steering pump test port "GPA" should be the hoist lever to POWER UP for 30 seconds.
approximately 689 kPa (100 psi). Pressure at Then move the hoist lever to POWER DOWN
the front and rear brake cooling test ports for 30 seconds. Continue to monitor the brake
should be approximately 172 kPa (25 psi) or cooling oil supply pressures. The oil supply
less. pressure should be 345 kPa (50 psi) or less
when the hoist lever is in HOLD or FLOAT and
drop to 0 kPa (0 psi) when the hoist lever is in
POWER UP or POWER DOWN.
Cycle the hoist lever as stated above five times.
Do not operate at low idle for more than 30
seconds. Steering pump pressure at test port
"GPA" needs to be at or above 1 724 kPa (250 psi) 19. After flushing is complete, stop the engine and
during the flushing process to provide adequate allow steering accumulators to completely
pump internal lubrication. Steering pump damage discharge. Remove the special flushing
will result if pressure is below 1 724 kPa (250 psi). plumbing. If the optional steering accumulator
This also applies to steps 17-20. hose/needle valve assembly was installed in
step 6, leave it installed. Reconnect all original
NOTE: Do not turn the steering wheel until step 21. plumbing. Check that oil is visible in upper sight
Do not apply the brakes at any time during this glass on hydraulic tank. Add oil if necessary.
checkout procedure. NOTE: If the brakes are not installed, leave the brake
17. With engine at a speed that is fast enough to cooling supply and return hoses connected together
provide at least 1 724 kPa (250 psi) at steering during this entire checkout procedure.
pump test port "GPA", move the hoist lever to
the POWER UP or POWER DOWN position.
The front and rear brake cooling oil supply NOTE: Step 20 cannot be combined with the flushing
pressures should be 0 kPa (0 psi) when the procedure in steps 16-18. This flushing procedure
hoist lever is in POWER UP or POWER DOWN, must be performed after step 19 is completed.
This confirms that the hoist valve is functioning
NOTE: Do not steer or apply the brakes at any time
properly.
during step 20.
If the pressures do not drop to 0 kPa (0 psi), the 20. Flush the accumulators by starting the engine
hoist valve may be plumbed incorrectly. Stop the and operating until the accumulator pressure is
checkout procedure and check all plumbing, approximately 24 300 kPa (3,525 psi) when the
including all pilot lines. If there is a plumbing unloader valve shifts and unloads the steering
error, repeat this step again. If no plumbing error pump. If the pressure will not reach 24 300 kPa
was found or if the pressures still do not drop to (3,525 psi), refer to the pump adjustment
0 kPa (0 psi), replace the hoist valve and repeat procedure in step 26.
this step again.
9
If the pressure reaches 24 300 kPa (3,525 psi): Flow amplifier adjustment
a. The first time through this step: 22. In preparation for the steering shock valve
checkout, adjust the unloader valve on the
• Stop engine by leaving the key switch ON
steering pump by turning the unloader valve
and pulling up the engine shutdown switch
on the center console. Confirm that adjustment screw clockwise until a minimum
steering accumulator bleed down does not reload pressure of 25 325 ± 172 kPa (3675 ± 25
occur and that no bleeddown faults are psi) is measured at bleeddown manifold port
generated. "TP2". The unload pressure will be
* Record on Data Sheet approximately 27 400 kPa (3975 psi).
• Turn the key switch OFF and confirm that Turn the steering wheel to verify that at least
steering accumulator bleed down begins. 25 150 kPa (3650 psi) is maintained. This is
Confirm that bleed down is completed acceptable pump performance for this part of
normally within 90 seconds and that fault the checkout procedure.
A236 “Steering Bleed Fault” is not active.
NOTE: The pump adjustment in this step is to be
Steering pressure at bleeddown manifold
test port "TP3" will be 103 kPa (15 psi) or used only for checking the steering shock valves. It is
less after a successful bleed down. not intended for normal truck operation. Refer to step
26 when adjusting the pump for normal truck
* Record on Data Sheet
operation.
Continue to step 20c.
23. Before checking the steering shock valves, raise
b. For the second and all other times through the steering relief valve pressure setting.
step 20, turn the key switch OFF and allow Remove the external access plug on the flow
the steering accumulators to bleed down. amplifier, then turn the internal adjustment
The steering pressure at bleeddown manifold screw clockwise to gently bottom out the relief
test port "TP3" will be 103 kPa (15 psi) or valve.
less after a successful bleed down.
24. To check the steering shock valve pressure
* Record on Data Sheet settings, turn the steering wheel away from the
c. Open the brake accumulator bleed valves on cylinder stops, then turn the steering wheel fully
the brake manifold and allow the brake into a stop and continue to turn the steering
accumulators to fully bleed down. Open the wheel. One gauge on the steering cylinder
bleed valve on the auxiliary hydraulic manifold should read 24 000 ± 1000 kPa (3480
manifold to bleed down the auxiliary ± 145 psi).
accumulator. Close the bleed valves. Turn the steering wheel into opposite stop. The
d. Perform step 20 five times. other gauge on the steering cylinder manifold
should read 24 000 ± 1000 kPa (3480 ± 145
psi).
21. After flushing all of the accumulators, the * Record on Data Sheet
steering system must be flushed. Start the
engine. Allow the accumulators to fully charge 25. After checking the steering shock valve
and the steering pump to unload. Turn the pressure settings, lower the steering relief valve
steering wheel fully to the left and right at least pressure setting to 20 685 -207/+827 kPa (3000
10 times. Stop the engine and allow the steering -30/+120 psi). Turn the steering wheel fully to
accumulators to bleed down completely. Add oil the left or right into a stop, then adjust the
to the hydraulic tank if necessary. steering pressure at the flow amplifier while
slowly turning the steering wheel into the stop.
When the appropriate gauge at the steering
cylinder manifold reads the correct pressure,
replace the external access plug on the flow
amplifier. Tighten the plug to the proper torque.
10
Steering pump unloader valve adjustment Auxiliary accumulator pressure verification

26. The steering pump unloader valve should 27. The auxiliary accumulator supply valve closes
unload the pump at a nominal pressure of when the steering system supply pressure falls
24 300 kPa (3,525 psi) and reload the below the minimum required for proper system
accumulators when the pressure at bleeddown operation. Oil that is consumed by any auxiliary
manifold port "TP2" falls to 22 240 ± 172 kPa systems is not replaced below this pressure.
(3225 ± 25 psi). The reload pressure is the The supply valve closing pressure is the critical
critical pressure to obtain. pressure to verify. Maximum auxiliary pressure
is equal to the steering pump unload pressure
If the pump operates as described, proceed to
and is not independently adjustable.
the end of this step to record pressures. If not,
adjust the unloader valve as follows: The auxiliary accumulator supply valve is
a. Install a calibrated multiple range pressure located on the auxiliary hydraulic manifold. It is
gauge capable of 35 000 kPa (5,000 psi) at controlled by a non-adjustable pressure switch
steering pump test port "GPA". in the steering bleeddown manifold. Verify the
auxiliary accumulator supply valve closing pres-
b. Install a calibrated pressure gauge capable sure as follows:
of 35 000 kPa (5,000 psi) in bleeddown
manifold test port "TP2". a. Install calibrated 35 000 kPa (5,000 psi)
pressure gauges in auxiliary hydraulic
c. Fully open all pump suction shutoff valves. manifold test ports “GA” and "GP1".
d. Remove the unloader valve adjuster cap and NOTE: Test port “GP1" is connected directly to
completely back out the adjustment screw. steering bleeddown manifold test port "TP2". For the
e. Start the engine and allow the steering pump sake of convenience, "GP1" pressure readings may
to unload. When unloaded, the pressure at be used instead of "TP2" pressure readings.
steering pump test port "GPA" will be 1 380 - b. Start the engine and allow the steering pump
2 760 kPa (200 - 400 psi). to unload. Continue to operate the engine at
f. Adjust the unloader valve to reload the low idle for at least three minutes to allow the
accumulators when the pressure at accumulator temperatures to stabilize. The
bleeddown manifold test port "TP2" falls to pressures at steering bleeddown manifold
19 133 ± 172 kPa (2,775 ± 25 psi). The test ports "TP2" and "TP3" and auxiliary
unload pressure will be approximately hydraulic manifold test port “GA” should be at
21 200 kPa (3,075 psi), but the reload least 22 065 kPa (3,200 psi).
pressure is the critical pressure to obtain. c. To prevent the accumulators from bleeding
NOTE: If adjusting after step 20, do not turn the down, leave the key switch ON and pull up
steering wheel to make the accumulator pressure fall. the engine shutdown switch on the center
The bleed valves on the brake manifold can be console to stop the engine.
opened partially to slowly bleed down the steering d. Slowly open the bleed valve on the auxiliary
accumulator pressure to allow the pump to cycle hydraulic manifold.
every 20-30 seconds while adjusting the unloader
valve. e. Observe the pressure at steering bleeddown
manifold test port "TP2" at which the supply
g. Tighten the adjustment cap and verify that valve closes and the pressure at auxiliary
the pressures remain as adjusted. If the hydraulic manifold test port “GA” falls below
reload pressure is 22 065 - 22 400 kPa the pressure at "TP2". The supply valve
(3,200 - 3,250 psi) as the pump is cycling, the should close at a falling pressure of 17 580
pump is properly adjusted. Close the bleed +690/-345 kPa (2550 +100/-50 psi). If
valves. outside this range, correct the problem and
* Record on Data Sheet return to step 27b.
h. If the pump is being adjusted from step 20, * Record on Data Sheet
return to step 20 now and flush the
accumulators without turning the steering
wheel.
11
f. With the auxiliary accumulator bleed valve c. Measure the leakage from the flow amplifier
open, verify that the pressures at test ports and the steering control unit.
"TP2" and "TP3" remain above 16 550 kPa
• Leakage from the flow amplifier should not
(2400 psi) for at least five minutes after the
exceed 820 mL (50 in.3) per minute. If
auxiliary accumulator is bled down to 103
leakage is excessive, replace the flow
kPa (15 psi) or less. If either of the steering amplifier.
accumulator pressures at test port "TP2" or
"TP3" falls or the pressure at auxiliary • Leakage from the steering control unit
hydraulic manifold test port “GA” rises, should not exceed 164 mL (10 in.3) per
correct the problem and return to step 27b. minute. If leakage is excessive, replace the
steering control unit.
g. Close the bleed valve on the auxiliary
hydraulic manifold. NOTE: Step 31 may be skipped if no excessive
leakage in the steering bleeddown manifold is
System diagnostics suspected.
28. Start the engine to charge the steering 31. To check for leakage in the steering bleeddown
accumulators to at least 22 065 kPa (3200 psi). manifold:
To prevent the accumulators from bleeding a. Disconnect the flow amplifier return hose at
down, leave the key switch ON and pull up the the steering bleeddown manifold and plug
engine shutdown switch on the center console the fitting on the manifold. Disconnect the
to stop the engine. steering control unit return hose at the flow
29. Set the wheel speed on the DID panel to 1.0 amplifier and plug the port. Disconnect the
kPa. Slowly open the brake accumulator bleed tank return hose at the steering bleeddown
valve on the brake manifold. Observe the manifold.
pressure at steering bleeddown manifold test
port "TP2" when the buzzer sounds and low
steering pressure fault code A247 appears on
the dash panel message display. The fault
should occur at a falling pressure of 15 860 ± The hydraulic tank oil level is above the level of
420 kPa (2300 ± 61 psi). If outside this range, the tank return line. It is necessary to draw a
correct the problem. vacuum on the hydraulic tank to prevent a large
amount of oil from draining from the tank with the
return line disconnected from the bleeddown
NOTE: Step 30 may be skipped if no excessive manifold.
leakage in the steering system is suspected.
b. Disconnect the hoist pilot valve return hose
30. To check for leakage in the steering system: at the steering bleeddown manifold and plug
a. Disconnect the flow amplifier return hose at the port. Connect the tank return hose to the
the steering bleeddown manifold and plug hoist pilot valve return hose, or plug the tank
the fitting on the manifold. Disconnect the return hose and vent the hoist pilot valve
steering control unit return hose at the flow return hose to the tank. Do not plug the
amplifier and plug the port. hoist pilot valve return hose.
b. Start the engine. Allow the steering

accumulators to fully charge and the steering
pump to unload. Do not turn the steering
wheel while the return hoses are
disconnected.
12
e. Wait 20 minutes, then record each

accumulator pressure again. Note any
changes.
• Each pressure gauge at brake manifold
In the next step, DO NOT use the key switch to ports "AF3" and "AR3" must be less than
shut off the engine. If the key switch is turned 2 275 kPa (330 psi). This is a loss of 6 900
OFF, all accumulator oil will be discharged kPa (1,000 psi) per hour.
through the open port on the bleeddown • The pressure gauge at auxiliary hydraulic
manifold. If the hose/needle valve assembly was manifold test port “GA” must be less than
installed in step 6, use this method to bleed down 207 kPa (30 psi). This is a loss of 690 kPa
the steering accumulators after leakage is (100 psi) per hour.
measured. If not, the same hose/needle valve * Record on Data Sheet
assembly can be made and connected between
bleeddown manifold test port "TP3" and the f. Remove the pressure gauges from ports
hydraulic tank fill tube. Both steering "AF3", "AR3" and "GA".
accumulators will be bled down when test port 34. Disconnect and cap the four hoses from the
"TP3" is opened to the tank. hoist cylinders.
c. Start the engine and allow the steering pump 35. Start the engine and raise the engine speed to
to unload. Measure the leakage from the tank high idle. Move the hoist lever to POWER UP.
return port in the steering bleeddown The pressure gauges at the hoist filters should
manifold. Leakage from the tank return port read 18 960 ± 690 kPa (2 750 ± 100 psi) at high
should not exceed 541 mL (33 in.3) per idle.
minute. * Record on Data Sheet
* Record on Data Sheet 36. Move the hoist lever to POWER DOWN. The
32. Reconnect all hoses to the steering bleeddown pressure gauge at overcenter manifold test port
manifold. "TPD" should read 10 340 ± 515 kPa (1 500 ±
75 psi) at high idle.
NOTE: Step 33 may be skipped if no excessive
leakage in the brake system or auxiliary hydraulic * Record on Data Sheet
system is suspected. 37. Move the hoist lever to FLOAT to reduce the
33. To check for leakage in the brake system and pressure in the hoist cylinder hoses. Turn the
auxiliary hydraulic system: key switch OFF to stop the engine. Vent the
residual hoist cylinder hose pressure and
a. Install pressure gauges at brake manifold remove the caps from the hoses. Reconnect the
ports "AF3" and "AR3" and at auxiliary four hoses to the hoist cylinder.
hydraulic manifold test port “GA”.
b. Start the engine and allow the steering pump
to unload. Continue to operate the engine at
low idle for at least three minutes to allow the
accumulator temperatures to stabilize. Do
not operate the service brakes during this
step.
c. With the steering accumulators charged to at
least 22 065 kPa (3,200 psi), turn the key
switch OFF and wait two minutes for the
steering accumulators to bleed down.
d. The pressure gauges at brake manifold ports
"AF3" and "AR3" and at auxiliary hydraulic
manifold test port “GA” should remain above
20 685 kPa (3,000 psi).
13
Hoist counterbalance valve adjustment • If the pressure is below 20 685 kPa (3,000
psi), increase the engine speed by
NOTE: Skip step 38 if the dump body is not installed. approximately 300 rpm and repeat step
* Record on Data Sheet 38e. Continue testing the pressure setting
at increasing 300 rpm intervals until high
38. To adjust the hoist counterbalance valve on the idle is reached.
overcenter manifold, the dump body must be
empty and the hoist cylinder hoses must be The counterbalance valve pressure must be
connected to the hoist valve. 20 685 kPa (3,000 psi) when the hoist lever is in
POWER UP, the engine is at high idle and the
a. Move the hoist lever to the FLOAT position hoist cylinder is in the third stage.
and lower the body to the frame, or secure
the raised body with the proper body • If the pressure is correct, repeat step 38a,
retention cable or sling. Stop the engine. then go to step 38i.
b. Loosen the locknut on the needle valve • If the pressure does not reach 20 685 kPa
adjustment stem, then turn the adjustment (3,000 psi), step 38a, then go to step 38f.
stem inward. This will block the hoist cylinder f. Loosen the locknut on the counterbalance
head pressure from the counterbalance valve adjustment stem. Turn the adjustment
valve pilot. step fully clockwise to lower the pressure as
much as possible.
c. Remove the plug from the "PILOT VENT"
port on the overcenter manifold. This will NOTE: If the dump body is secured in the raised
vent the counterbalance valve pilot to position, remove the body retention cable or sling.
atmosphere.
g. Start the engine and operate at high idle.
NOTE: Do not allow dirt or debris to enter the open Move the hoist lever to POWER UP until the
pilot vent port. A clean SAE # 4, 1/4" hydraulic hose hoist cylinders are in the third stage. Adjust
can be installed in the port and pointed downward to the counterbalance valve adjustment stem
help prevent entry of contaminants. as needed to obtain a reading of 20 685 kPa
(3,000 psi) at overcenter manifold test port
d. Install a calibrated pressure gauge at
"TR".
overcenter manifold test port "TR". The
gauge will measure hoist cylinder rod end NOTE: Turning the adjustment stem clockwise
pressure, which is the pressure controlled by decreases the pressure. Turning the adjustment stem
the counterbalance valve. counterclockwise increases the pressure. The entire
range of the adjustment stem is three turns.
NOTE: If adjustment of the counterbalance valve is
anticipated, skip verification step 38e and proceed to * Record on Data Sheet
step 38f. h. Repeat step 38a.
NOTE: If the dump body is secured in the raised i. Install the plug in the "PILOT VENT" port on
position, remove the body retention cable or sling. the overcenter manifold and tighten it to the
e. Start the engine and operate at low idle. proper torque.
Move the hoist lever to POWER UP until the j. Turn the needle valve adjustment stem fully
hoist cylinders are in the third stage and outward, then tighten the locknut. This
observe the pressure gauge at overcenter needle valve must be fully open for normal
manifold test port "TR". hoist operation.
• If the pressure is 20 685 kPa (3,000 psi) or k. Remove the pressure gauge from overcenter
higher, stop raising the dump body manifold test port "TR".
immediately. The pressure setting is too
high and must be lowered. Repeat step
38a, then go to step 38f.
14
Final steps Oil cleanliness check

39. Reconnect or enable any auxiliary hydraulic 43. Before the truck can be put into service, the
systems on the truck (auto lube, hydraulic cleanliness of the hydraulic oil must be checked.
ladder, radiator shutters, etc). Use the quick disconnect coupling at either hoist
40. Perform the individual checkout procedures for filter test port to attach a hose and obtain an oil
any auxiliary hydraulic systems. sample. Do not use the steering filter test
port. Do not use a hose that has been
41. If the optional hose/needle valve assembly was previously used for system flushing.
installed in steps 6 or 31, bleed down all of the
a. The hydraulic system checkout procedure
accumulators, then remove the hose/needle
must be completed before taking an oil
valve assembly and any associated fittings.
sample.
Install the port plugs and tighten them to the
proper torques. b. Start the engine and operate at high idle for
42. Remove all pressure gauges that were installed at least ten minutes. Do not operate the
during the checkout procedure. steering, hoist, brakes or any other hydraulic
function during the oil sampling procedure.
c. Take particle count readings for at least 20
minutes without changing the engine speed.
d. When the particle count level is at or below
ISO 21/18/15 standard and is showing a
trend of improving cleanliness or at least
maintaining the ISO 21/18/15 standard, the
hydraulic oil meets the acceptable criteria for
cleanliness.
e. If the particle count level of the ISO 21/18/15
standard is not achieved within 20 minutes,
continue operating the engine at high idle
until the conditions in step 43d are achieved.
44. Replace all hydraulic filter elements before the
truck is put into service. Note the service hour
meter reading.
15
Hydraulic system checkout data sheet

** Acceptable values of each measurement are shown in (parenthesis).
Machine Model ___________ Unit Number ____________ Serial Number _____________

1e. Steering and brake accumulator precharge pressures:
Front steering accumulator, ACC1 (1400 ± 10 psi at 70º F) ___________ at _______
Rear steering accumulator, ACC2 (1400 ± 10 psi at 70º F) ___________ at _______
Front brake accumulator, AF1 (1400 ± 10 psi at 70º F) ___________ at _______
Rear brake accumulator, AR1 (1400 ± 10 psi at 70º F) ___________ at _______
16. Was low steering accumulator precharge warning A115 displayed before start-up? (circle one)
(No) YES NO
20. Pressure at bleeddown manifold test port TP3:

a.) Does bleed down occur when stopping with engine shutdown switch? (circle one)
(No) YES NO
Pressure at port “TP3” (approximately 3075 psi) ___________
Faults (none) ___________
Pressure at port TP3 and faults after each bleeddown cycle:
1st Bleeddown cycle
Pressure after bleeddown (15 psi or less) ___________
2nd Bleeddown cycle
3rd Bleeddown cycle
4th Bleeddown cycle
5th Bleeddown cycle
24. Flow amplifier shock valve pressures:

Left shock valve pressure (3480 ± 145 psi) ___________
Right shock valve pressure (3480 ± 145 psi) ___________
16
25. Flow amplifier relief valve pressure: (3000 -30/+120 psi) ___________
26g. Steering pump reload pressure: (3225 ± 25 psi) ___________

Steering pump unload pressure: (3525 psi nominal) ___________
27e. Auxiliary accumulator supply valve closing pressure: (2550 +110/-50 psi) ___________
27f. 5 minutes after auxiliary accumulator bleeddown:

Front steering accumulator pressure, TP2 (> 2400 psi) ___________
Rear steering accumulator pressure, TP3 (> 2400 psi) ___________
Auxiliary accumulator pressure, GA (15 psi or less) ___________
29. Pressure when low steering pressure fault A247 occurs: (3000 ± 61 psi) ___________
30. Was steering system leakage checked? (circle one) (Yes) YES NO
Flow amplifier leakage (< 50 in.3/ min.)___________

Steering control unit leakage (< 10 in.3/ min.)___________
31. Was steering bleeddown manifold leakage checked? (circle one) (Yes) YES NO
Steering bleeddown manifold leakage (< 33 in.3/ min.)___________
33d. After steering accumulator bleeddown:

Front brake accumulator pressure, AF3 (> 3000 psi) ___________
Rear brake accumulator pressure, AR3 (> 3000 psi) ___________
Auxiliary accumulator pressure, GA (> 3000 psi) ___________
33e. 20 minutes after steering accumulator bleeddown:
Front brake accumulator pressure, AF3 (< 330 psi below 33d) ___________
Rear brake accumulator pressure, AR3 (< 330 psi below 33d) ___________
Auxiliary accumulator pressure, GA (< 10 psi below 33d) ___________
35. POWER UP pressure at hoist filter: (2750 ± 100 psi) ___________
36. POWER DOWN pressure at overcenter manifold, TPD: (1500 ± 75 psi) ___________
17
38. Was dump body installed? (circle one) (Yes) YES NO
If dump body is installed, what is the final pressure of the counterbalance valve at
overcenter manifold port TR with hoist cylinders at third stage
(3000 ± 100 psi) ___________
43. Hydraulic fluid cleanliness level after 10 minutes at high idle:

(ISO 21/18/15 or lower)___________
Particle counter printout attached to these sheets? (circle one) (Yes) YES NO
44. Service meter reading (SMR) when filter elements were replaced:
Brake filter (hours) ___________
Front hoist filter (hours) ___________
Rear hoist filter (hours) ___________
Steering filter (hours) ___________
Name of Technician or Inspector Performing Checkout: _________________________
Badge number: ________________________
Date & shift completed: __________________
18
Toe-in adjustment
NOTE: Before returning the truck to operation, the
1 3 2 5 3 4
steering system must first be centered in the straight
ahead position.
1. Check the toe-in by measuring the distance
between the centers of the front tires. Measure
on the horizontal centerline at the front and rear
of the tires. Refer to Figure 30-7.
Radial tires should have equal measurements
(zero toe-in).
84515
FIGURE 30-8. TIE ROD ASSEMBLY

1. Threaded Rod End 4. Locknut
2. Capscrew 5. Clamps
3. Hardened Flat Washer
2. Loosen locknuts (4, Figure 30-8). Rotate the tie

rod as necessary to obtain the correct toe-in
setting. The tie rod length when installed is
3 683 ± 10mm (145.0 ± 0.4 in.).
3. When this adjustment is complete, hold the
head of each capscrew (2) with a wrench and
use a torque wrench to tighten each locknut to
1017 ± 102 N·m (750 ± 75 ft lb).
4. Reapply torque to each locknut (4) until the
specified torque is maintained.
FIGURE 30-7. MEASURING TOE-IN
19
Hoist cylinder leakage test Steering cylinder leakage test

After the hoist cylinder is assembled, perform the After the steering cylinder is assembled, perform the
following tests to verify that performance is within following tests to verify that performance is within
acceptable limits. acceptable limits.
1. With the rod fully extended, piston leakage must 1. Piston leakage must not exceed 2.5 cm3/min.
not exceed 164 cm3/min. (10 in3/min.) at 17 237 (0.15 in3/min.) at 20 700 kPa (3,000 psi) port to
kPa (2,500 psi), port to port. port.
2. With the rod fully retracted, piston leakage must 2. Rod seal leakage must not exceed one drop of
not exceed 328 cm3/min. (20 in3/min.) at 17 237 oil in eight cycles of operation.
kPa (2,500 psi), port to port.
3. Piston break-away force must not exceed 690
3. Rod seal leakage must not exceed one drop of
kPa (100 psi).
oil in eight cycles of operation.
20
NOTES
21
980E Dump truck

22
CEN30072-03
980E

980E-4 A40003 and up
980E-5 A50005 and up

Brake system
Brake system checkout procedures...................................................................................................................... 3
Brake system checkout data sheet ..................................................................................................................... 14
Brake piston leakage test.................................................................................................................................... 22
Brake seal pressure test ..................................................................................................................................... 22
Oil separator seal pressure test .......................................................................................................................... 22
Wet disc brake bleeding procedure .................................................................................................................... 23
Parking brake bleeding procedure ...................................................................................................................... 24
Service brake disc wear inspection..................................................................................................................... 25
Parking brake disc wear inspection .................................................................................................................... 26
Brake valve bench test and adjustment .............................................................................................................. 27
Dual relay valve bench test and adjustment ....................................................................................................... 30
1
NOTES
2
General information on system checkout Brake system checkout procedures

The brake system checkout procedures are intended
to help the technician diagnose problems in the brake
circuits. The technician should read the entire
checkout procedure to become familiar with the
procedures and all the warnings and cautions before
The steering system supplies the brake system
performing any steps. The checkout procedures
with operating pressure. Therefor, the steering
begin by checking the basic system before checking
system must be checked for proper operation
individual components.
before checking the brake systems. Successfully
A data sheet is included in this section to record the complete the hydraulic system checkout
test information obtained during the brake system procedure before performing the brake system
checkout procedure. The data sheet is designed to checkout procedures.
be copied and used during the checkout procedure.
This section outlines a procedure to test the
functionality of the entire brake system. Pressure
specifications and other criteria that must be
duplicated for the braking system to be considered
ready for daily operations are provided.
Hydraulic oil escaping under pressure can have The steering circuit can be isolated from the brake
sufficient force to enter a person's body by circuit by first releasing all steering system pressure,
penetrating the skin and cause serious injury, then releasing all pressure from the brake
and possibly death, if proper medical treatment accumulators and removing the brake system supply
by a physician familiar with this type of injury is hose from the bottom of the bleeddown manifold.
not received immediately. Plug the hose and cap the fitting at the bleeddown
Relieve pressure before disconnecting any manifold to prevent high pressure leakage.
Required equipment
• Brake hydraulic circuit schematic
• Service computer with Interface Module Realtime
NOTE: The interface module (IM) checkout Data Monitor software
procedure must be successfully completed and
engine startup must be possible before beginning the • Accumulator charging kit (EB1759 or equivalent)
checkout procedures. with gauges and dry nitrogen
• Four 24 100 kPa (3,500 psi) pressure gauges
• Clear plastic hose and bucket for brake bleeding
NOTE: If the brakes are not assembled on the truck,
brake simulators will be required.
3
3 8
9
7 4
DETAIL A DETAIL B
6 5
A
B
86261
FIGURE 30-1. HYDRAULIC BRAKE CABINET - TEST PORTS AND VALVES

1. Low Accumulator Pressure Test Port "LAP1" 6. Parking Brake Solenoid Valve "SV2"
2. Parking Brake Release Pressure Test Port "PK3" 7. Auto Apply Sequence Valve "PS1"
3. Brake Lock Apply Pressure Test Port "PP3" 8. Front Brake Pressure Test Port "BF"
4. Pressure Reducing Valve "PR" 9. Rear Brake Pressure Test Port "BR"
5. Brake Lock Solenoid Valve "SV1"
4
Initial system setup 6. Slowly depress the brake pedal. Rear brake
pressure "BR" should begin to rise before front
NOTE: Configure the DID panel to metric units. The
brake pressure "BF". Verify that the rear brake
truck must remain in PARK and at zero ground speed
pressure is 310 - 1415 kPa (45 - 205 psi) when
unless otherwise noted.
the front brake pressure begins to rise.
NOTE: Securely block the tires to prevent the truck * Record on Data Sheet
from rolling away.
7. Slowly depress the brake pedal. Force feedback
1. Install 35 000 kPa (5,000 psi) calibrated of the pedal on your foot should be smooth with
pressure gauges at the following locations: no abnormal noise or mechanical roughness.
a. junction manifold test port "BR" Verify that the stop lights illuminate when rear
brake pressure "BR" is 517 ± 34 kPa (75 ± 5
b. junction manifold test port "BF"
psi).
c. brake manifold test port "LAP1"
2. The steering accumulators, brake accumulators
8. Quickly and completely depress the brake
and auxiliary system accumulator must have the
pedal. Verify that rear brake pressure "BR" and
correct precharge and must be at normal
front brake pressure "BF" are both 17 235 ± 517
operating temperature. Refer to Testing and
kPa (2,500 ± 75 psi) within one second after the
brake is applied:
suspensions for the accumulator charging
procedures. Both pressures must remain above their
* Record on Data Sheet minimum values for a minimum of 20 seconds
while the pedal is fully applied.
NOTE: For best performance, charge the
accumulators in the ambient conditions in which the
machine will be operating. Brake lock / secondary braking checkout
3. Close the brake accumulator bleed valves and 9. Disconnect the lead wire from the brake lock
the auxiliary accumulator bleed valve. solenoid valve (5, Figure 30-1) on the brake
4. Start the engine. Observe the rising brake manifold in the hydraulic brake cabinet.
pressures at test ports "BR" and "BF" as the 10. Move the directional control lever to NEUTRAL.
system charges. The brake pressures should
begin to fall when the auto apply valve releases. 11. Press the brake lock switch. The brake lock will
The auto apply valves should release the front not apply if the engine is not operating. Fault
and rear brakes when the pressure at test port code A118 will become active.
"LAP1" is 11 375 -515/+2 585 kPa (1,650 -75/ Depress the brake pedal until fault code A118 is
+375 psi). cleared, then very slowly release the pedal until
* Record on Data Sheet fault code A118 is active again. Verify that the
rear brake pressure "BR" drops to 6 895 ± 172
5. Partially depress the brake pedal to bleed air
kPa (1,000 ± 25 psi) when the fault reoccurs.
from each brake. Move the directional control
lever to NEUTRAL to bleed air from the parking * Record on Data Sheet
brakes. Then move the directional control lever NOTE: There is a three second delay between the
to PARK. time that the brake lock degradation switch senses
the pressure and fault code A118 occurs. Fault code
A265 will also become active during this step.
5
12. Connect the lead wire to brake lock solenoid Parking brake checkout
valve (6).
14. Move the pressure gauge from test port "PP3" to
13. Cycle the brake lock switch several times to parking brake release pressure "PK3" test port
ensure crisp application and release of oil (2, Figure 30-1). Start the engine.
pressure and proper function of the status light.
a. Move the directional control lever to PARK,
Check the pressure readings at pressure test then back to NEUTRAL. The parking brake
ports (BR) and (PP3). Verify that the rear brake status light should illuminate, then go out.
pressure "BR" and the pressure at "PP3" are Verify that parking brake release pressure at
both 13 790 ± 690 kPa (2,000 ± 100 psi) when test port "PK3" is 22 753 ± 1378 kPa (3,300 ±
the brake lock is applied. Fault code A118 200 psi).
should also not be displayed. * Record on Data Sheet
* Record on Data Sheet b. Move the directional control lever to PARK.
If the brake lock does not function correctly, Verify that the parking brake apply pressure
ensure that all brake lock circuit plumbing is at test port "PK3" is 0 kPa (0 psi).
correct. * Record on Data Sheet
If the plumbing is correct, allow the steering If the parking brake does not function correctly,
accumulators to fully charge, then disconnect ensure that all parking brake circuit plumbing is
wire 52B to the brake lock solenoid at TB32-J. correct.
Apply 24V to the disconnected wire 52B. Verify
that the pressure reading at pressure test port If the plumbing is correct, allow the steering
"PP3" is 13 790 ± 690 kPa (2,000 ± 100 psi). accumulators to fully charge, then disconnect
Ignore any resulting brake lock faults. wire 52CS to the parking brake solenoid at
TB32-K. Ground the disconnected wire 52CS.
a. If the pressure is out of range, adjust Verify that the pressure reading at pressure test
pressure reducing valve (4, Figure 30-1) as port "PK3" is 22 753 ± 1 378 kPa (3,300 ± 200
required. psi). Ignore any resulting parking brake faults.
b. If the pressure reducing valve cannot be a. If the pressure is out of range and the
adjusted to achieve the correct pressure, steering pump has a pressure compensator,
replace the pressure reducing valve. verify that the pressure compensator
c. If the brake lock solenoid cannot be adjustment screw is properly adjusted.
energized, verify that the wiring to the b. If parking brake solenoid cannot be
solenoid is correct. If it is correct, then energized, verify that the wiring to the
replace the solenoid. solenoid is correct. If it is correct, then
d. If the brake lock valve will not operate, replace the solenoid.
replace the valve. c. If parking brake solenoid valve (6, Figure 30-
e. Connect wire 52B to TB32-J and repeat step 1) will not operate, replace the valve.
13. d. Connect wire 52CS to TB32-K and repeat
step 14.
15. Cycle the parking brake several times by
moving the directional control lever between
NEUTRAL and PARK to ensure crisp
application and release of oil pressure and
proper function of the status light.
6
Service brake checkout

16. Move the directional control lever to PARK and
turn off the brake lock.
17. Move both brake pressure gauges to left rear
brake pressure "LBP" test port (2, Figure 30-2)
and right rear brake pressure "RBP" test port (1)
on the manifold on the left side of the rear axle
housing.
Quickly and completely depress the brake
pedal. Verify that left rear brake pressure "LBP"
and right rear brake pressure "RBP" are both
16 545 ± 517 kPa (2,400 ± 75 psi). within one
second after the brake is applied:
Both pressures must remain above their
minimum values for a minimum of 20 seconds.
* Record on Data Sheet FIGURE 30-2. REAR BRAKE PRESSURE
TEST PORTS
18. Release the brake pedal. Verify that both rear
brake pressures "LBP" and "RBP" return to 0 1. Right Rear Brake Pressure "RBP" Test Port
kPa (0 psi) within two seconds. There should be 2. Left Rear Brake Pressure "LBP" Test Port
no residual pressure trapped in the brakes.
19. Move both rear brake pressure gauges to front
brake pressure test ports "LFBP" and "RFBP"
(1, Figure 30-3) on the front brake backplates.
NOTE: These test ports are not stamped on the
spindle.
Quickly and completely depress the brake
pedal. Verify left front brake pressures "LFBP"
and "RFBP" are both 16 545 ± 517 kPa (2,400 ±
75 psi) within one second after the brake is
applied:
Both pressures must remain above their
minimum values for a minimum of 20 seconds. FIGURE 30-3. FRONT BRAKES
* Record on Data Sheet 1. Test Port - "LFBP" and "RFBP"
20. Release the brake pedal. Verify that both front 2. Bleed Port
brake pressures "LFBP" and "RFBP" return to 0
kPa (0 psi) within two seconds. There should be
no residual pressure trapped in the brakes.
7
Low brake accumulator pressure and auto apply NOTE: The brake warning system will activate when
checkout the lower pressure in either brake accumulator falls
21. Move both front brake pressure gauges back to below 12 755 ± 360 kPa (1,850 ± 52 psi). The auto
pressure test ports "BF" and "BR" in the apply sequence valve will apply the service brakes if
hydraulic brake cabinet. Start the engine and the pressure of either brake accumulator drops below
allow the low brake accumulator pressure 11 375 ± 517 kPa (1,650 ± 75 psi).
"LAP1" to increase to 22 065 kPa (3,200 psi). 27. While the front brake accumulator bleed valve is
22. Move the directional control lever to NEUTRAL. still open, allow low accumulator pressure
Turn the key switch OFF and allow 90 seconds "LAP1" to continue to drop. Front brake
for the steering accumulators to bleed down pressures "BF" and "BR" will begin to rise when
completely. the auto apply sequence valve (7, Figure 30-1)
is activated at 11 375 ± 517 kPa (1,650 ± 75
23. Turn the key switch ON, but do not start the psi).
engine. Wait for two minutes, then check the low
accumulator pressure reading at low Front brake pressures "BF" and "BR" should be
accumulator pressure "LAP1" test port (1, at 0 kPa (0 psi) when the auto apply sequence
Figure 30-1). If the pressure is below 14 480 valve is activated.
kPa (2,100 psi), there is excessive leakage in * Record on Data Sheet
the system. The source of the leakage must be
28. Observe the final pressures at "LAP1", "BF" and
identified and repaired.
"BR" while auto apply is active.
• "LAP1" should be 11 375 ± 517 kPa (1,650
24. Start the engine and allow the low brake ± 75 psi).
accumulator pressure "LAP1" to increase to
• "BF" should be 9 825 kPa (1,425 psi) or
22 065 kPa (3,200 psi) or above. Then, turn the
higher.
key switch OFF and allow 90 seconds for the
steering accumulators to bleed down • "BR" should be 16 545 ± 517 kPa (2,400 ±
completely. 75 psi).
25. Turn the key switch ON, but do not start the * Record on Data Sheet
engine. Move the directional control lever to NOTE: The auto apply sequence valve will need an
NEUTRAL. Provide a speed signal of 3 kph adjustment if it does not activate at 11 375 ± 517 kPa
from the DID panel on the rear wall of the (1,650 ± 75 psi). After adjusting the valve, repeat
operator cab. Fault code A260 will occur after steps 21-28.
the speed signal is generated.
29. Close the front brake accumulator bleed valve.
26. Slowly open front brake accumulator bleed Provide a speed signal of 0 kph from the DID
valve (9) a small amount while observing the panel on the rear wall of the operator cab. Fault
decreasing pressure at the low accumulator code A260 will be cleared.
pressure "LAP1" test port. Low brake pressure
Move the directional control lever to PARK. Start
fault A261 should occur when the pressure
the engine and allow low brake accumulator
drops to 12 755 ± 360 kPa (1,850 ± 52 psi) and
pressure "LAP1" to increase to 22 065 kPa
the brake pressure switch in port "LAP2" is
(3,200 psi) or above.
activated.
30. Turn the key switch OFF and allow 90 seconds
Front brake pressures "BF" and "BR" should be
for the steering accumulators to bleed down
at 0 kPa (0 psi) when fault code A261 appears.
completely.
Fault code A260 should also occur.
* Record on Data Sheet Turn the key switch ON, but do not start the
engine. Move the directional control lever to
NEUTRAL. Provide a speed signal of 3 kph
from the DID panel on the rear wall of the
operator cab. Fault code A260 will occur after
the speed signal is generated.
8
31. Slowly open rear brake accumulator bleed valve Brake reapplications
(7) a small amount while observing the
35. Start the engine and allow low brake
decreasing pressure at low accumulator
accumulator pressure "LAP1" to increase to
pressure "LAP1" test port (15). Low brake
22 065 kPa (3,200 psi) or above.
pressure fault A261 should occur when the
pressure drops to within 690 kPa (100 psi) of 36. Pull up on the engine shutdown switch on the
the observed pressure in step 26. center console to shut off the engine. Do not
turn the key switch OFF. The accumulators
Front brake pressures "BF" and "BR" should be must not be allowed to bleed down.
at 0 kPa (0 psi) when fault code A261 appears.
Move the directional control lever to NEUTRAL.
Provide a speed signal of 3 kph from the DID
32. While the rear brake accumulator bleed valve is panel on the rear wall of the operator cab.
still open, allow low accumulator pressure
37. While observing the pressure gauges, make
"LAP1" to continue to drop. Front brake
repeated, slow brake applications until fault
pressures "BF" and "BR" will begin to rise when
code A261 appears. Fault code A261 must not
the auto apply sequence valve is activated
occur before the sixth pedal application. Auto
within 690 kPa (100 psi) of the observed
apply must not occur until after fault code A261
pressure in step 27.
occurs.
Front brake pressures "BF" and "BR" should be * Record on Data Sheet
at 0 kPa (0 psi) when the auto apply sequence
valve is activated. Fault code A260 should also 38. Remove the speed signal from the DID panel.
occur. Set the speed signal to 0 kph.
33. Observe the final pressures at "LAP1", "BF" and
"BR" while auto apply is active.
• "LAP1" should be 11 375 ± 517 kPa (1,650
± 75 psi).
• "BF" should be 16 545 ± 517 kPa (2,400 ±
75 psi).
• "BR" should be 9 825 kPa (1,425 psi) or
higher.
34. Close the rear brake accumulator bleed valve.
panel on the rear wall of the operator cab. Fault
code A260 will be cleared.
9
Parking brake control logic checkout b. Start the engine. Ensure that low brake
accumulator pressure "LAP1" is 21 718 kPa
39. Do not activate the brake lock switch. Keep the
(3,100 psi) or higher, then move the
speed signal from the DID panel at 0 kph. If any
directional control lever to NEUTRAL.
of the following steps are not successfully
completed, find and correct the problem.
Pull up on the engine shutdown switch on the
NOTE: The parking brake will not apply if the truck center console to shut off the engine. Do not
speed is above 0.8 kph (0.5 mph). If the parking turn the key switch OFF. The accumulators
brake is selected and the truck speed is less than 0.8 must not be allowed to bleed down. Verify
kph (0.5 mph), the following sequence will occur: proper operation of the parking brake and
• From 0 - 1 second, brake lock is applied, parking status light. No faults should be generated.
brake is released. Record the highest pressure observed at
ports "PK3", "PP3", "BF" and "BR" during the
• From 1 - 1.5 seconds, brake lock is applied, 1.5 seconds of the parking brake application
parking brake is applied. sequence.
• After 1.5 seconds, brake lock is released, parking
• The pressure at test port "PK3" should be
brake is applied.
22 753 ± 1 378 kPa (3,300 ± 200 psi), then
This sequence uses the service brakes to completely fall to 0 kPa (0 psi).
stop the truck before allowing the parking brake to • The pressure at test port "PP3" should rise
apply. from 0 kph (0 psi) to 13 790 ± 690 kPa
a. Start the engine. Ensure that the low brake (2,000 ± 100 psi), then fall to 0 kPa (0 psi).
accumulator pressure "LAP1" is 21 718 kPa • Front brake pressure "BF" should remain at
(3,100 psi) or higher, then move the 0 kPa (0 psi).
directional control lever to NEUTRAL.
• Rear brake pressure "BR" should rise from
0 kph (0 psi) to 13 790 ± 690 kPa (2,000 ±
Move the directional control lever to PARK 100 psi), then fall to 0 kPa (0 psi).
and verify proper operation of the parking
brake and status light. No faults should be
generated. Record the highest pressure c. Start the engine. Ensure that low brake
observed at ports "PK3", "PP3", "BF" and accumulator pressure "LAP1" is 21 718 kPa
"BR" during the 1.5 seconds of the parking (3,100 psi) or higher and the directional
brake application sequence. control lever is in PARK., then turn the key
switch to OFF. Verify that the parking brake
remains applied. Record the highest
22 753 ± 1 378 kPa (3,300 ± 200 psi), then
fall to 0 kPa (0 psi). pressure observed at ports "PK3", "PP3",
"BF" and "BR" when the key switch is turned
• The pressure at test port "PP3" should rise to OFF. All of the pressure readings should
from 0 kph (0 psi) to 13 790 ± 690 kPa be 0 kPa (0 psi).
(2,000 ± 100 psi), then fall to 0 kPa (0 psi).
• Front brake pressure "BF" should remain at
0 kPa (0 psi).
• Rear brake pressure "BR" should rise from
0 kph (0 psi) to 13 790 ± 690 kPa (2,000 ±
100 psi), then fall to 0 kPa (0 psi).
10
d. Start the engine. Ensure that low brake Brake lock control logic checkout
accumulator pressure (LAP1) is 21 718 kPa
40. Remove the speed signal from the DID panel.
(3,100 psi) or higher, then move the
Keep the speed signal at 0 kph. If any of the
directional control lever to NEUTRAL and
following steps are not successfully completed,
turn the key switch to OFF. Verify that the
find and correct the problem.
parking brake applies. Record the highest
pressure observed at ports "PK3", "PP3", a. With the engine running, low brake
"BF" and "BR" during the 1.5 seconds of the accumulator pressure "LAP1" at 21 718 kPa
parking brake application sequence. (3,100 psi) or higher, and the directional
control lever to NEUTRAL, turn the brake
• The pressure at test port "PK3" should be lock switch ON and OFF. Verify proper
22 753 ± 1 378 kPa (3,300 ± 200 psi), then
operation of the brake lock and status light.
fall to 0 kPa (0 psi).
No faults should be generated. Record the
• The pressures at pressure test ports "PP3", highest pressure observed at ports "PK3",
"BF" and "BR" should read 0 kPa (0 psi). "PP3", "BF" and "BR" when the brake lock is
* Record on Data Sheet ON.
NOTE: With the key switch OFF, brake lock • The pressure at test port "PK3" should be
sequencing with the parking brake will not occur. 22 753 ± 1 378 kPa (3,300 ± 200 psi).
e. Start the engine. Ensure that low brake • The pressure at test port "PP3" should rise
accumulator pressure (LAP1) is 21 718 kPa to 13 790 ± 690 kPa (2,000 ± 100 psi), then
(3,100 psi) or higher, then move the fall to 0 kPa (0 psi).
directional control lever to NEUTRAL. • Front brake pressure "BF" should be 0 kPa
(0 psi).
Place a jumper wire between circuit 36 and
• Rear brake pressure "BR" should rise to
ground. Pull up on the engine shutdown 13 790 ± 690 kPa (2,000 ± 100 psi), then
switch on the center console to shut off the fall to 0 kPa (0 psi).
engine. Do not turn the key switch OFF.
Provide a speed signal of 1 kph from the DID b. With the engine running, low brake
panel on the rear wall of the operator cab. accumulator pressure "LAP1" at 21 718 kPa
Attempt to move the directional control lever (3,100 psi) or higher, and the directional
to PARK. Verify that the parking brake does control lever to PARK, attempt to turn the
not apply and fault code A230 is activated. brake lock switch ON. Verify that the brake
Record the highest pressure observed at lock does not apply, the status light does not
ports "PK3", "PP3", "BF" and "BR". illuminate, and fault codes A272 and A274
are not activated. Record the highest
pressure observed at ports "PK3", "PP3",
22 753 ± 1 378 kPa (3,300 ± 200 psi), then
fall to 0 kPa (0 psi). "BF" and "BR". All of the pressures should be
0 kPa (0 psi).
• The pressures at pressure test ports "PP3",
"BF" and "BR" should read 0 kPa (0 psi). * Record on Data Sheet
11
c. With the engine running, low brake e. With the engine running, low brake
accumulator pressure "LAP1" at 21 718 kPa accumulator pressure "LAP1" at 21 718 kPa
(3,100 psi) or higher, directional control lever (3,100 psi) or higher, directional control lever
to NEUTRAL, and brake lock switch ON, in PARK, and brake lock switch OFF, turn the
move the directional control lever to PARK. key switch OFF and attempt to turn on the
Verify that the parking brake applies, the brake lock switch during the timed engine
brake lock releases and the status lights shutdown sequence. Verify that the brake
operate properly. Record the highest lock does not apply and the status light does
pressure observed at ports "PK3", "PP3", not illuminate. Record the highest pressure
"BF" and "BR". observed at ports "PK3", "PP3", "BF" and
"BR". All of the pressures should be 0 kPa (0
psi).
22 753 ± 1 378 kPa (3,300 ± 200 psi), then
fall to 0 kPa (0 psi). * Record on Data Sheet
• The pressure at test port "PP3" should rise NOTE: The brake lock will remain applied if the brake
to 13 790 ± 690 kPa (2,000 ± 100 psi), then lock switch is turned ON when a truck speed above
fall to 0 kPa (0 psi). 0.8 kph (0.5 mph) is detected. The switch must be
• Front brake pressure "BF" should be 0 kPa turned OFF to release the brake lock.
(0 psi). f. With the engine running and low brake
• Rear brake pressure "BR" should rise to accumulator pressure "LAP1" at 21 718 kPa
13 790 ± 690 kPa (2,000 ± 100 psi), then (3,100 psi) or higher, move the directional
fall to 0 kPa (0 psi). control lever to NEUTRAL.
In the wPTU software, set the "FWD True"
d. With the engine running, low brake
output to ON. Pull up on the engine
accumulator pressure "LAP1" at 21 718 kPa
shutdown switch on the center console to
(3,100 psi) or higher, directional control lever
shut off the engine. Do not turn the key
to NEUTRAL, and brake lock switch ON, pull
switch OFF.
up on the engine shutdown switch on the
center console to shut off the engine. Do not
turn the key switch OFF.
panel on the rear wall of the operator cab.
Place a jumper wire between circuit 36 and
Verify that the parking brake applies, the
ground. Turn the brake lock switch ON. Verify
brake lock releases and the status lights
proper operation of the brake lock and status
operate properly. Record the highest
light. No faults should be generated. Record
pressure observed at ports "PK3", "PP3",
the highest pressure observed at ports
"BF" and "BR".
"PK3", "PP3", "BF" and "BR".
22 753 ± 1 378 kPa (3,300 ± 200 psi), then
22 753 ± 1 378 kPa (3,300 ± 200 psi).
• The pressure at test port "PP3" should be
• The pressure at test port "PP3" should rise
13 790 ± 690 kPa (2,000 ± 100 psi).
to 13 790 ± 690 kPa (2,000 ± 100 psi), then
fall to 0 kPa (0 psi). • Front brake pressure "BF" should be 0 kPa
(0 psi).
• Front brake pressure "BF" should be 0 kPa
(0 psi). • Rear brake pressure "BR" should be 13 790
± 690 kPa (2,000 ± 100 psi).
• Rear brake pressure "BR" should rise to
13 790 ± 690 kPa (2,000 ± 100 psi), then * Record on Data Sheet
Remove the jumper wire between circuit 36
* Record on Data Sheet and ground. Reset the speed signal to 0 kph
from the DID panel on the rear wall of the
operator cab. In the wPTU software, set the
"FWD True" output to OFF.
12
g. Verify that the brake lock remains applied Move the directional control lever to PARK.
while the truck is moving. With the engine Reset the speed signal to 0 kph. Fault codes
running and low brake accumulator pressure A272 and A274 should be activated when
"LAP1" at 21 718 kPa (3,100 psi) or higher, the speed signal is at 0 kph. Confirm that
move the directional control lever to brake lock is still activated. Record the
NEUTRAL. highest pressure observed at ports "PK3",
"PP3", "BF" and "BR"
In the wPTU software, set the "FWD True"
• The pressure at test port "PK3" should be 0
output to ON. Pull up on the engine
kPa (0 psi).
shutdown switch on the center console to
shut off the engine. Do not turn the key • The pressure at test port "PP3" should be
switch OFF. 13 790 ± 690 kPa (2,000 ± 100 psi).
Provide a speed signal of 1 kph from the DID (0 psi).
panel on the rear wall of the operator cab.
• Rear brake pressure "BR" should be 13 790
Place a jumper wire between circuit 36 and ± 690 kPa (2,000 ± 100 psi).
ground. Turn the brake lock switch ON.
Confirm that brake lock is activated. Record * Record on Data Sheet
the highest pressure observed at ports In the wPTU software, set the "FWD True"
"PK3", "PP3", "BF" and "BR". output to OFF. Turn the brake lock switch
• The pressure at test port "PK3" should be OFF. Confirm that brake lock is deactivated.
22 753 ± 1 378 kPa (3,300 ± 200 psi). Record the highest pressure observed at
ports "PK3", "PP3", "BF" and "BR". All of the
• The pressure at test port "PP3" should be pressures should be 0 kPa (0 psi).
13 790 ± 690 kPa (2,000 ± 100 psi).
(0 psi). 41. Remove the jumper wire between circuit 36 and
ground. Remove the pressure gauges.
• Rear brake pressure "BR" should be 13 790
± 690 kPa (2,000 ± 100 psi).
13
Brake system checkout data sheet

** Acceptable values of each measurement are shown in (parenthesis).
Machine Model ___________ Unit Number ____________ Serial Number _____________
ACCUMULATOR PRECHARGE
Step 2b ____________ (1,400 psi) Front brake accumulator precharge pressure
____________ (1,400 psi) Rear brake accumulator precharge pressure
INITIAL SYSTEM SETUP
Step 4 ____________ (1,650 -75/+375 psi) Brake accumulator pressure "LAP1" when
auto apply releases
Step 6 ____________ (1,650 -75/+375 psi) Rear brake pressure "BR" when front brake
pressure "BF" begins to rise
____________ (0-5 psi) Front brake pressure "BF" when front brake pressure "BR"
begins to rise
Step 7 _____________ (75 ± 5 psi) Rear brake pressure "BR" when brake lights activate
Step 8 _____________ (2500 ± 75 psi) Front brake pressure "BF" 1 second after pedal applied
_____________ (2500 ± 75 psi) Rear brake pressure "BR" 1 second after pedal applied
_____________ (2500 ± 75 psi) Front brake pressure "BF" 20 seconds after pedal applied
_____________ (2500 ± 75 psi) Rear brake pressure "BR" 20 seconds after pedal applied
BRAKE LOCK / SECONDARY BRAKE CHECKOUT
Step 11 ____________ (1,000 ± 25 psi) Rear brake pressure "BR" when brake degradation
fault A118 occurs
Step 13 ____________ (2,000 ± 100 psi) Rear brake pressure "BR" when brake lock is applied
____________ (2,000 ± 100 psi) Brake lock pressure "PP3" when brake lock is applied
14
PARKING BRAKE CHECKOUT
Step 14a ___________ (3,300 ± 200 psi) Parking brake release pressure "PK3"
Step 14b ___________ (0 psi) Parking brake apply pressure "PK3"
SERVICE BRAKE CHECKOUT
Step 17 ____________ (2400 ± 75 psi) Left rear brake pressure "LBP" 1 second after
pedal applied
____________ (2400 ± 75 psi) Right rear brake pressure "RBP" 1 second after
pedal applied
____________ (2400 ± 75 psi) Left rear brake pressure "LBP" 20 seconds after
pedal applied
____________ (2400 ± 75 psi) Right rear brake pressure "RBP" 20 seconds after
pedal applied
Step 18 ____________ (0 psi) Left rear brake pressure "LBP" when pedal is released
____________ (0 psi) Right rear brake pressure "RBP" when pedal is released
Step 19 ____________ (2400 ± 75 psi) Left front brake pressure "LFBP" 1 second after
pedal applied
____________ (2400 ± 75 psi) Right front brake pressure "RFBP" 1 second after
pedal applied
____________ (2400 ± 75 psi) Left front brake pressure "LFBP" 20 seconds after
pedal applied
____________ (2400 ± 75 psi) Right front brake pressure "RFBP" 20 seconds after
pedal applied
Step 20 ____________ (0 psi) Left front brake pressure "LFBP" when pedal is released
____________ (0 psi) Right front brake pressure "RFBP" when pedal is released
15
LOW BRAKE ACCUMULATOR PRESSURE AND AUTO APPLY CHECKOUT
Step 23 ____________ (above 2100 psi) Low brake accumulator pressure "LAP1" after 2 minutes
Step 26 ____________ (1,850 ± 52 psi) Low brake accumulator pressure "LAP1" when
low brake pressure fault A261 occurs
____________ (0 psi) Front brake pressure "BF" when low brake pressure
fault A261 occurs
____________ (0 psi) Rear brake pressure "BR" when low brake pressure
fault A261 occurs
____________ (yes) Is fault A260 displayed?
Step 27 ____________ (1,650 ± 75 psi) Low brake accumulator pressure "LAP1" when front brake
pressure "BF" begins to rise
____________ (0 psi) Front brake pressure "BF" when front brake pressure "BF"
begins to rise
____________ (0 psi) Rear brake pressure "BR" when front brake pressure "BF"
begins to rise
auto brake apply completes
____________ (1425 psi or above) Front brake pressure "BF" when auto brake apply
completes
____________ (2,400 ± 75 psi) Rear brake pressure "BR" when auto brake apply
completes
low brake pressure fault A261 occurs
____________ (0 psi) Front brake pressure "BF" when low brake pressure
fault A261 occurs
____________ (0 psi) Rear brake pressure "BR" when low brake pressure
fault A261 occurs
16
rear brake pressure "BR" begins to rise
____________ (0 psi) Front brake pressure "BF" when rear brake pressure "BR"
begins to rise
____________ (0 psi) Rear brake pressure "BR" when rear brake pressure "BR"
begins to rise
____________ (yes) Is fault A260 displayed?
auto brake apply completes
____________ (2,400 ± 75 psi) Front brake pressure "BF" when auto brake apply
completes
____________ (1425 psi or above) Rear brake pressure "BR" when auto brake apply
completes
BRAKE REAPPLICATIONS
Step 37 ____________ (6 or more) Number of brake applications before fault A261 occurs
PARKING BRAKE CONTROL LOGIC CHECKOUT
Step 39a - Maximum pressures during 1.5 second parking brake application sequence
__________ (3,300 ± 200 psi) Parking brake pressure "PK3"
__________ (2,000 ± 100 psi) Brake lock pressure "PP3"
__________ (0 psi) Front brake pressure "BF"
__________ (2,000 ± 100 psi) Rear brake pressure "BR"
Step 39a - Pressures at completion of parking brake application sequence
__________ (0 psi) Parking brake pressure "PK3"
__________ (0 psi) Brake lock pressure "PP3"
__________ (0 psi) Rear brake pressure "BR"
17
Step 39b - Maximum pressures during 1.5 second parking brake application sequence
Step 39b - Pressures at completion of parking brake application sequence
Step 39c - Maximum pressures
Step 39d - Maximum pressures during 1.5 second parking brake application sequence
Step 39d - Pressures at completion of parking brake application sequence
18
Step 39e - Pressures at completion of parking brake application sequence
__________ (yes) Is fault A230 displayed?
BRAKE LOCK CONTROL LOGIC CHECKOUT
Step 40a - Maximum pressures with brake lock ON
Step 40a - Pressures at completion with brake lock OFF
Step 40b - Maximum pressures
__________ (no) Is fault A272 displayed?
__________ (no) Is fault A274 displayed?
19
Step 40c - Maximum pressures with parking brake applied / brake lock released
Step 40c - Pressures at completion with parking brake applied / brake lock released
Step 40d - Maximum pressures with engine shutdown switch engaged
Step 40d - Pressures at completion with engine shutdown switch engaged
Step 40e - Maximum pressures during timed engine shutdown sequence
20
Step 40f - Pressures at completion with 1 kph speed signal
Step 40g - Pressures at completion with 1 kph speed signal
Step 40g - Pressures at completion with 0 kph speed signal
Step 40g - Pressures at completion with brake lock OFF
Name of Technician or Inspector Performing Checkout ________________________________
DATE_____________________________
21
Brake piston leakage test Oil separator seal pressure test

1. Remove the dust cap on test port (1, Figure 30- Check the integrity of the duo cone seal after
4) on the brake backplate. installing the wheel hub/brake assembly on the
2. Remove the capnut on bleed port (2). Attach a spindle. The wheel hub must be facing upward.
hydraulic pressure test device to the fitting. 1. Remove fill plug (1, Figure 30-5). Fill the wheel
3. Slowly apply pressure to bleed air from the hub cavity with approximately 11.5 L (3 gal) of
piston cavity. TO-50 oil.
4. Cycle the piston to full stroke ten times by

applying 2 070 kPa (300 psi) of hydraulic
pressure at bleed port (2). Observe the piston
for leakage. 1
5. Minor oil seepage (non-measurable) is
permissible. If the leakage is greater,
disassemble the piston assembly and determine
the cause.
86564
FIGURE 30-4. FRONT BRAKES FIGURE 30-5. WHEEL HUB
1. Test Port - "LFBP" and "RFBP" 1. Fill Plug

2. Bleed Port
2. Connect a hose to the fill port in the hub cover

plate. Ensure that all other ports are plugged.
3. Pressurize the hub cavity to a maximum of 103
kPa (15 psi).
Brake seal pressure test
Check the integrity of the duo cone seal before
installing the brakes on the truck.
1. Cap the cooling oil ports and pressurize the
brake to a maximum of 103 kPa (15 psi). Do not overpressurize the cavity. Excessive
2. Close off the air supply and monitor the interior pressure may cause damage to the seals.
brake pressure for 15 minutes. 4. Close off the air supply and monitor the hub
3. If the air pressure decreases rapidly, a cavity pressure for 15 minutes.
displaced or damaged brake seal is indicated. a. If there is no pressure drop, the integrity of
Disassemble the brake and reinstall or replace the seals is verified.
the duo cone seal.
b. If the pressure drops at all, a displaced or
damaged seal is indicated. Disassemble the
hub and reinstall or replace the duo cone
seal.
22
Wet disc brake bleeding procedure Front wheel brakes:

NOTE: Rear wheel brakes must be bled before rear NOTE: The front wheel brakes are equipped with a
tire installation. diagnostic coupler on the brake backplate. A hose
1. Make sure that the hydraulic brake supply with a mating fitting can be attached to direct the oil
(steering circuit) is operating properly. into a container during the bleeding process.
2. If necessary, charge the brake accumulators. 8. Attach a hose to the diagnostic coupler at test
Refer to Refer to Testing and adjusting section port (1, Figure 30-6) on the brake backplate
Accumulators and suspensions for the (brake apply pressure circuit).
accumulator charging procedure. 9. Slowly depress the brake pedal until the service
3. Make sure that the bleed down valves on the brake is partially applied.
brake manifold are closed. 10. After the oil stream is clear of air, remove the
4. Check the hydraulic tank oil level and fill if hose from the coupler. Release the brake pedal.
necessary. 11. Repeat Steps 8 - 10 for the other front wheel
5. With the wheels securely blocked, start the brake.
engine and allow the accumulators to fill. 12. Shut off the engine and allow 90 seconds for the
6. Slowly depress the brake pedal until the service steering accumulators to depressurize
brake is partially applied. completely. Check the hydraulic tank oil level.
Rear wheel brakes:

7. Slowly open the O-ring plug located next to the
cooling oil port and brake apply port on the
brake backplate. Close the plug after the oil runs
clear and free of bubbles. Repeat for the other
rear wheel brake.
NOTE: The other cooling line has a single hex plug
located adjacent. DO NOT use this plug for bleeding
brake.
FIGURE 30-6. FRONT BRAKES
1. Test Port
2. Bleed Port
23
Parking brake bleeding procedure 5. Open the rear axle housing hatch.
1. Securely block the wheels to prevent the truck 6. Start the engine and allow the steering system
from rolling away. to fully charge (pump unloads). Then move the
2. Open bleed down valves (1, Figure 30-7) on directional control lever to NEUTRAL to
brake manifold (2) to depressurize the brake disengage the parking brake.
accumulators. 7. Connect a clear plastic hose to the bleeder
3. To verify that the brake accumulators are valve at the top of the parking brake. Place the
depressurized, turn the key switch ON, but do other end of hose into a container.
not start the engine. Press the brake lock switch 8. Slowly open the bleeder valve and allow
and apply the service brake pedal. The service hydraulic oil to run until it is clear and free of
brake light should not come on. bubbles. Close the bleeder valve securely.
4. Close bleed down valves (1). 9. Repeat Steps 7 and 8 for the other parking
brake.
10. Shut off the engine. Remove the bleed
equipment and close the rear axle housing
hatch.
FIGURE
30-7.
BRAKE
MANIFOLD
1. Brake Accumulator Bleed Down Valves
2. Brake Manifold
84513
FIGURE 30-8. PARKING BRAKE

BLEEDING/FLUSHING PROCEDURE
1. Bleeder Valve
24
Service brake disc wear inspection NOTE: The front brake assemblies have diagnostic
coupler (2) installed for measuring brake apply
Check brake disc wear by using two front brake wear
pressure. The rear brake assemblies do not have a
indicators (EM1275) and two rear brake wear
diagnostic coupler installed on the brake backplate,
indicators (EM3708) that are included in the tool
but instead have a plug installed. Do not attempt to
group that is shipped with the truck. Refer to Figure
install the brake wear indicator in these ports.
30-10.
5. Start the engine. Allow the steering system
NOTE: The brake wear indicator is inserted in a port
pressure to stabilize and the brake
which is open to cooling oil. Removal of the
accumulators to fill.
inspection port plug to insert the brake wear indicator
will cause the loss of some of this oil. Advance 6. While fully applying the service brake pedal,
planning will help to minimize oil loss. check the wear on each brake disc as follows:
The brake wear indicators may be permanently a. Remove cover (1, Figure 30-10) from the
installed in the brake ports if desired. If all of the brake wear indicator.
brake assemblies are equipped with brake wear b. Push pin (8) inward until it stops against the
indicators, future checks will not require installation brake piston.
and removal.
c. Measure the distance from indicator pin end
1. Place the directional control lever in PARK and face (2) to housing face (3).
turn the rest switch ON. Turn the key switch
OFF to turn off the engine and wait 90 seconds  If indicator pin end face (2) is even with
to allow the steering accumulators to housing face (3) or below, disc pack is worn to
the maximum safe wear limits. The brakes
depressurize completely. Block the truck
should be scheduled for rebuild.
wheels.
 If indicator pin end face (2) extends beyond
2. Open bleed down valves (1, Figure 30-7) to housing face (3), brake disc wear is still within
depressurize the brake accumulators. Close the allowable limits.
bleed down valves after the pressure is
completely released. d. Pull pin (8) outward until it stops against tool
housing (6). Install cover (1).
3. Thoroughly clean the brake assemblies,
especially the area surrounding cooling oil lines.
4. Remove the plug from port (1, Figure 30-9).
Quickly insert the brake wear indicator and
tighten it securely. Repeat this step for each
brake assembly.
2 1
FIGURE 30-10. BRAKE WEAR INDICATOR

1. Cover 5. O-Ring
2. Indicator Pin End Face 6. Housing
86565
3. Housing Face 7. O-Ring
4. O-Ring 8. Indicator Pin
FIGURE 30-9. BRAKE WEAR INDICATOR
INSTALLATION
1. Brake Wear Indicator Installation Port
2. Diagnostic Coupler
25
7. Release the brakes. Turn off the engine and Parking brake disc wear inspection
wait 90 seconds to allow the steering
Measure the amount of disc wear on both parking
accumulators to depressurize completely.
brake assemblies as follows:
8. Open bleed down valves (1, Figure 30-7) to
1. Insert a depth micrometer through each piston
depressurize the brake accumulators. Close the
position hole (1, Figure 30-11) and record the
bleed down valves after the pressure is
dimensions.
completely released.
2. Add the three measurements and divide the
9. If not permanently installing the brake wear
total by 3 to determine the average.
indicators, remove the brake wear indicators
and reinstall the plug in each port. If the resulting average of the three
measurements is greater than 24 mm (0.969
NOTE: Checking the brake disc wear in all the brake
in.), the parking brake assembly must be
assemblies is recommended. Disc wear in one brake
removed and rebuilt.
assembly may be different from another due to
dissimilar operation of parts and/or haul profiles
which require repeated braking while steering in one
direction only. 1
10. Service the hydraulic tank as required.
11. If brake repairs are necessary, refer to
Disassembly and assembly section Brake
system.
NOTE: If any leakage is observed around the brake
wear indicator, replace O-rings (4, 5, and 7).
86381

1. Piston Position Holes
26
Brake valve bench test and adjustment

The following parts and test equipment will be • Hose fittings for valve ports:
required to completely bench test and adjust the Port PX . . . . . . . . . . . . . . . . . 7/16 in., # 4 SAE
brake valve. Ports P1, P2, B1 and B2 . . . . . . 3/4 in., #8 SAE
Port T . . . . . . . . . . . . . . . . 1 1/16 in., #12 SAE
• Three 20 680 kPa (3,000 psi) pressure gauges
• Ohmmeter or continuity tester
• Hydraulic pressure supply, regulated to 18 960
kPa (2,750 psi)
NOTE: It is possible to check the pressures with the
• Hydraulic test stand brake valve installed and connected to the vehicle.
Remove the brake pedal assembly and actuator cap
and boot assembly to adjust individual brake circuit
pressures.
FIGURE 30-12. TEST BENCH SETUP
1. Motor 5. Needle Valve 9. Simulated Brake Volume

2. Pump 6. Brake Valve 10. Rear Brake Pressure Gauge
3. System Pressure Gauge 7. Front Brake Pressure Gauge 11. Relief Valve
4. Needle Valve 8. Shutoff Valves
27
Test setup procedure Brake valve output pressure adjustment

1. Position the valve in the fixture to allow plungers 1. Install the pedal pivot shaft in the actuator base
to be activated by hand using a lever. Refer to by itself without installing the pedal assembly.
Figure 30-12. 2. By placing a screwdriver or pry bar under the
2. Attach the pilot input supply pressure to the pilot pivot pin and on top of the threaded plunger
port labeled “PX” on the rear of the valve. assembly, each circuit can be actuated
3. Attach the main supply input pressure to the O- individually. Refer to Figure 30-12.
ring ports on the rear of the valve labeled “P1” 3. Gradually apply pressure on each circuit one at
and “P2”. a time to check for leaks around the plunger.
4. Attach the tank return line to the O-ring port Make sure that the adjustment collar is screwed
labeled “T” on the rear of the valve. all the way down on the threads.
5. Attach the regulated output ports “B1” and “B2” 4. “B1” Adjustment: Adjust the adjustment collar
to the test lines. Pressure monitoring devices in up (counterclockwise), starting with one-turn
these two lines must be capable of 20 680 kPa increments until the output pressure at port “B1”
(3,000 psi). Connect all ports according to the is 17 235 ± 517 kPa (2,500 ± 75 psi) with the
diagram shown in Figure 30-12. All ports must adjustment collar contacting the actuator base
be used and connected. (fully actuated). Fine adjustment will require
turning the collar only in 1/8 turn increments.
5. “B2” Adjustment: Adjust the adjustment collar
up (counterclockwise), starting with one-turn
increments until the output pressure at port “B2”
is 17 235 ± 517 kPa (2,500 ± 75 psi) with the
All ports must be used. Relieve pressure before adjustment collar contacting the actuator base
disconnecting hydraulic and other lines. Tighten (fully actuated). Fine adjustment will require
all connections before applying pressure. turning the collar only in 1/8 turn increments.
Avoid spillage and contamination! Avoid contact 6. Tighten the set screws in the adjustment collars
with hot oil if the machine has been operating. to 3 - 4 N·m (25 - 30 in lb). The entire plunger
The oil will be at very high pressure. may have to be rotated to get to the set screws.
Hydraulic fluid escaping under pressure can have 7. Check the pressures again after tightening the
sufficient force to enter a person's body by set screws. If the pressures have moved out of
penetrating the skin and cause serious injury and specified range, loosen the appropriate set
possibly death if proper medical treatment by a screw and re-adjust.
physician familiar with this injury is not received 8. Cycle each circuit 50 times using pilot apply.
immediately. This is done by closing needle valve (5, Figure
30-12) and opening needle valve (4). Read the
• Start the hydraulic pump and regulate output pressure on gauges (7) and (10). Close valve
pressure to 18 960 kPa (2,750 psi) at pressure (4) and open valve (5). The pressure gauges
gauge (3). Pressure gauges (7) and (10) should should read zero.
read zero. 9. Recheck the pressures after cycling. If they
• Pilot supply circuit pressure must also be 18 960 have changed, re-adjust the pressures.
kPa (2,750 psi).
• Return line pressure during this test is not to
exceed 34 kPa (5 psi).
• Test the valve with ISO 32 grade hydraulic oil at
49 ± 3 °C (120 ± 10 °F).
28
Final test and adjustment 7. Adjust the set screw until it is just touching the
1. The brake pedal actuator must be installed on cap.
the brake valve body before the final test and 8. Continue turning the set screw until the
adjustment. Refer to "Disassembly and pressure begins to rise on one of the brake
assembly of brake valve" in Disassembly and apply pressure gauges.
assembly section Brake system. 9. Back off the set screw by 1/8 turn.
NOTE: The final test and adjustment procedure can 10. Tighten the jam nut and remove the shim that
also be performed with the brake valve installed in was inserted previously.
the truck. Install the gauges at the “B1” and “B2”
11. Fully stroke the brake pedal actuator to verify
diagnostic test connectors in the brake cabinet.
that the output pressures at port “B1” and “B2”
2. Reinstall the brake valve with the actuator pedal are within specifications.
attached on the test stand.
NOTE: If the pedal is adjusted properly, the spring
3. With the test stand pump adjusted for 18 960 and spring pivots will not interfere with pedal travel.
kPa (2,750 psi) or with the engine running and
the brake system supply pressure at or above 12. If the pressures are not within specifications, re-
18 960 kPa (2,750 psi), depress the pedal as adjust the set screw. If the pressure is within
quickly as possible. The pressure on the output specifications, apply a few drops of Loctite to
circuits must reach at least 17 235 ± 517 kPa the jam nut.
(2,500 ± 75 psi) at port “B1” and port “B2” within 13. Check for internal leakage at port “T”. Leakage
one second. Measurement of time begins the must be less than 100 cc/minute with the valve
moment force is applied to move the pedal. in the released position and system pressure
4. With “B1” and “B2” plugged into a strip chart supplied to the “P1” and “P2” inlet ports.
recorder (if available), check the modulation by 14. “T” port leakage must be less than 250 cc/
slowly applying pressure until the maximum minute with valve pilot pressure or manually
pressure is reached. Make sure that the applied.
pressure increase is smooth and no sticking of
the spools is observed. Fully depress the pedal.
The pressures must remain within specification
at “B1” and “B2” for 20 seconds.
5. Adjust the set screw until it is not touching the
actuator cap. Apply Loctite® 242 to the
adjustment screw before setting the deadband.
6. Set the deadband by placing a 0.254 mm (0.010
in.) thick shim at location (9) between the pedal
structure and the return stop boss on the pivot
structure.
29
Dual relay valve bench test and adjustment • Hose fittings for valve ports:
Port PX . . . . . . . . . . . . . . . . . 7/16 in., # 4 SAE
The following parts and test equipment will be Ports B1 and B2 . . . . . . . . . . . . 3/4 in., #8 SAE
required to completely bench test the dual relay Port T. . . . . . . . . . . . . . . . . 1 1/16 in., #12 SAE
valve.
• Ohmmeter or continuity tester
• Four 20 680 kPa (3,000 psi) pressure gauges
NOTE: It is possible to check the pressures with the
• Hydraulic pressure supply, regulated to 18 960 dual relay valve installed on the truck by using the
kPa (2,750 psi) brake treadle valve to modulate pilot pressure and
• Hydraulic test stand monitoring brake apply pressure in the appropriate
brake apply pressure lines.
FIGURE 30-13. DUAL RELAY VALVE BENCH TEST SETUP
1. Motor 6. Needle Valve 10. RH Brake Apply Pressure

2. Pump (Pressure Bleed to Tank) Gauge
3. Main Pressure Gauge 7. Pilot Pressure Gauge 11. Needle Valve
4. Pressure Regulator 8. Dual Relay Valve 12. Needle Valve
(Pilot Pressure) 9. LH Brake Apply Pressure 13. Shutoff Valves
5. Needle Valve Gauge 14. Simulated Brake Volume
(Pilot Pressure Release) 15. Relief Valve
30
Test setup procedure Relay valve output pressure adjustment

1. Position the valve on the test stand as shown in 1. With the pump operating and supply pressure
Figure 30-13. and pilot pressure adjusted as described earlier
2. Attach the pilot input supply line to the port inspect the valve for leakage.
labeled “PX” on the side of the valve. 2. With 17 235 kPa (2,500 psi) of pilot pressure
3. Attach the main supply input pressure line to the applied, verify that pressure gauges (9) and (10)
port on the front of the valve labeled “P”. read 17 235 ± 517 kPa (2,500 ± 75 psi).
4. Attach the tank return line to the port labeled 3. Close pilot supply needle valve (5) and open
“T”. pilot pressure release needle valve (6) to bleed
5. Attach the regulated output ports “B1” and “B2” pressure back to the reservoir. Pilot pressure
to the test lines. Pressure monitoring devices in gauge (7) and regulated output pressure
these two lines must be capable of 20 680 kPa gauges (9) and (10) should drop to zero.
(3,000 psi). Connect all ports according to the 4. Repeat Steps 2 and 3 approximately 50 times
diagram shown in Figure 30-13. All ports must to cycle the valve from minimum to maximum
be used and connected. apply pressure.
5. Verify that the output pressure remains within
specifications. If not, the valve must be rebuilt.
6. While observing pilot pressure gauge (7) and
regulated output pressure gauges (9) and (10),
All ports must be used. Relieve pressure before apply pilot pressure slowly and steadily until
disconnecting hydraulic and other lines. Tighten 17 235 kPa (2,500 psi) maximum pilot pressure
all connections before applying pressure. is obtained.
Avoid spillage and contamination! Avoid contact Pilot pressure and regulated output pressure
with hot oil if the machine has been operating. must track within 345 kPa (50 psi) after the pilot
The oil will be at very high pressure. pressure reaches 690 kPa (100 psi).
Hydraulic fluid escaping under pressure can have 7. Reduce pilot pressure to zero. Apply 17 235
sufficient force to enter a person's body by kPa (2,500 psi) of pilot pressure as quickly as
penetrating the skin and cause serious injury and possible. Regulated output pressure must
possibly death if proper medical treatment by a increase to 17 235 ± 517 kPa (2,500 ± 75 psi)
physician familiar with this injury is not received within one second after pressure is applied to
immediately. the pilot line.
8. Check for internal valve leakage from port “T”
6. Start the hydraulic pump and regulate output with full supply pressure (port “P”) applied.
pressure at 18 960 kPa (2,750 psi) at pressure
 With pilot pressure released, leakage must
gauge (3). Pressure gauges (9) and (10) should
not exceed 100 cc/minute.
read zero.
 With 17 235 kPa (2,500 psi) of pilot
7. Adjust pressure regulator (4) to set pilot supply
pressure applied, leakage must not exceed
pressure to 17 235 kPa (2,500 psi) on gauge
150 cc/minute.
(7).
8. Return line pressure during this test is not to
exceed zero.
9. Test the valve with ISO 32 grade hydraulic oil at
49 ± 3 °C (120 ± 10 °F).
31
980E Dump truck

32
CEN30098-03
DUMP TRUCK
830E
930E
980E

830E-5 A50005 and up
930E-5 A40004 and up
980E-5 A50005 and up

Accumulators and suspensions
Accumulator charging and storage ....................................................................................................................... 2
Bladder accumulator charging procedure ............................................................................................................. 3
Bladder accumulator leak testing.......................................................................................................................... 6
Piston accumulator charging procedure ............................................................................................................... 7
Piston accumulator storage ................................................................................................................................ 10
Piston accumulator leak testing .......................................................................................................................... 10
Checking for improper suspension charge ..........................................................................................................11
Suspension oiling and charging procedures ....................................................................................................... 12
Suspension pressure test ................................................................................................................................... 21
1
Accumulator charging and storage Temperature during precharge

Temperature variation can affect the precharge
pressure of an accumulator. As the temperature
increases, the precharge pressure increases.
Conversely, decreasing temperature will decrease
the precharge pressure. To ensure the accuracy of
Always consider any accumulator to contain
the accumulator precharge pressure, the
pressure until proven otherwise.
temperature variation must be accounted for.
A temperature variation factor is determined by the
Pure dry nitrogen is the only gas approved for
ambient temperature encountered at the time when
use in the accumulator. The accidental charging
charging the accumulator on a truck that has been
of oxygen or any other gas in this compartment
shut down for one hour. Refer to Table 1 for charging
may cause an explosion. Ensure that pure dry
pressures in different ambient operating conditions
nitrogen gas is being used to charge the
that the truck is currently exposed to DURING the
accumulator.
charging procedure.
Before charging or discharging nitrogen gas in For example, assuming that the ambient temperature
the accumulator, ensure that the warning labels is 10 °C (50 °F), charge the accumulator to 9 294 kPa
are observed and the instructions regarding the (1,348 psi).
charging valve are carefully read and understood.
Table 1: Relationship Between Precharge

NOTE: If one accumulator is low on nitrogen, check Pressure and Ambient Temperature
and charge both accumulators at the same time. Ambient Charging Pressure
Correct precharge pressure is the most important Temperature ± 70 kPa (10 psi)
factor in prolonging accumulator life.
-23°C (-10°F) and below 8 232 kPa (1,194 psi)
-17°C (0°F) 8 412 kPa (1,220 psi)

NOTE: Use only nitrogen that meets or exceeds CGA
(Compressed Gas Association) specification G-10.1 -12°C (10°F) 8 584 kPa (1,245 psi)
for type 1, grade F. The nitrogen should be 99.9%
pure. Use only nitrogen cylinders with standard CGA -7°C (20°F) 8 763 kPa (1,271 psi)
number 580 connections with the appropriate high -1°C (30°F) 8 943 kPa (1,297 psi)
pressure regulator.
4°C (40°F) 9 122 kPa (1,323 psi)
10°C (50°F) 9 294 kPa (1,348 psi)

NOTE: For best performance, charge the
accumulators in the temperature conditions in which 16°C (60°F) 9 473 kPa (1,374 psi)
the truck is expected to operate. During the
21°C (70°F) 9 653 kPa (1,400 psi)
precharge, allow the temperature of the nitrogen gas
to come into equilibrium with the ambient 27°C (80°F) 9 832 kPa (1,426 psi)
temperature.
32°C (90°F) 10 011 kPa (1,452 psi)
38°C (100°F) 10 184 kPa (1,477 psi)
43°C (110°F) 10 363 kPa (1,503 psi)
49°C (120°F) 10 542 kPa (1,529 psi)
NOTE: A precharge pressure below 8 232 kPa (1,194

psi) is not recommended because of low precharge
pressure warnings. The low accumulator precharge
warning switch activates at 7 584 ± 310 kPa (1,100 ±
45 psi).
2
Bladder accumulator charging procedure 4. Remove protective cap (1, Figure 30-1) from the
charging valve (2).
Only precharge accumulators to 9653 kPa (1400

psi) while installed on the truck. Never handle an
accumulator with lifting equipment if the nitrogen
precharge pressure is over 827 kPa (120 psi).
Always set the precharge to 690 - 827 kPa (100 -
120 psi) before removing or installing the
accumulators.
Ensure that the nitrogen supply is shut off before

attaching the charging manifold to the nitrogen
container.

sufficient force to enter a person's body by FIGURE 30-1. GAS VALVE COMPONENTS -
penetrating the skin and cause serious injury, BLADDER ACCUMULATOR
and possibly death, if proper medical treatment is 1. Protective Cap 2. Charging Valve
hydraulic lines. Tighten all connections securely 5. Close inlet valve (4, Figure 30-2) on control
before applying pressure. manifold (6).
1. Refer to the "Hydraulic system bleeddown 6. Connect the nitrogen charging kit to nitrogen
procedure" in Testing and adjusting section container (8). Open the valve on the container.
Steering, hoist, brake cooling and auxiliary 7. Turn the “T” handle (1) on charging valve
hydraulic system. adapter (2) all the way out (counterclockwise).
2. Close all accumulator bleed valves. 8. Close the bleed valve at the bottom of the
3. Remove the bleed plug in the port valve at the accumulator.
bottom of each accumulator to vent residual 9. Attach the charging valve adapter (2) to the
pressure. charging valve on the accumulator. Ensure the
hose does not loop or twist. Tighten the swivel
NOTE: If a new or rebuilt accumulator (or any bladder
nut on the charging valve adapter finger-tight.
accumulator with all nitrogen discharged) is being
precharged while installed on the truck and 10. Turn the “T” handle on charging valve adapter
connected to the hydraulic system, the oil side of the (2) clockwise to open the accumulator gas
accumulator must be vented to allow proper bladder valve. Do not turn the “T” handle all the way
expansion. Trapped air or oil on the hydraulic side of down as it will damage the valve core.
the bladder will prevent the proper precharge 11. Set the regulator (5) for 172 kPa (25 psi), then
pressure to be obtained for safe operation. slightly open inlet valve (4) on control manifold
(6) to slowly fill the accumulator.
3
14. Turn the “T” handle (1) on the charging valve

adapters all the way out (counterclockwise) to
close the accumulator gas valve.
15. Hold the gas valve on the accumulator
If the precharge is not added slowly, the bladder stationary. Loosen the swivel nut on the
may suffer permanent damage. A “starburst” charging valve adapter to remove the nitrogen
rupture in the lower end of the bladder is a charging kit.
characteristic failure caused by charging too
quickly. 16. Use a common leak reactant to check for
nitrogen leaks.
12. When 172 kPa (25 psi) of precharge pressure is
obtained, close the nitrogen container valve. Set 17. Install protective cap (1, Figure 30-1) on the gas
the regulator (5) for the charging pressure valve.
based on the current ambient temperature. 18. Operate the truck and check the steering
Refer to Table 1. Then, slowly open the nitrogen operation.
container valve again and fill the accumulator.
The proper fill time for the bladder accumulator
is approximately three minutes.
13. After the accumulator is charged to the desired
pressure, shut off the charging kit and wait 15
minutes to allow the gas temperature to
stabilize. If the desired pressure is maintained,
proceed to step 19. If the desired pressure is
exceeded:
a. close the nitrogen container valve, inlet valve
(4) and both outlet valves (3).
b. Disconnect the hose that connects the
manifold (6) to regulator valve (5).
NOTE: A small blast of pressure will escape.
c. Open inlet valve (4) then slowly open each
outlet valve (3) independently until the
correct precharge pressure is obtained in
each accumulator. HYDRAIR
FIGURE
30-2. ®
CHARGING
KIT
NOTE: The arrangement of parts may vary from

the illustration depending on the kit part number.
1. “T” Handle Valve
Do not reduce pressure by depressing the valve
2. Charging Valve Adapter
core with a foreign object. High pressure may
3. Manifold Outlet Valves (from gauge)
rupture the rubber valve seat.
4. Inlet Valve (from regulator)
5. Regulator Valve (Nitrogen Pressure)
6. Manifold
7. Charging Pressure Gauge
8. Dry Nitrogen Gas Container
4
Precharge maintenance Bladder accumulator storage procedure
If the low accumulator precharge warning is

active when the key switch is turned ON, do not Always store bladder accumulators with 690 - 827
attempt to start the engine. Permanent bladder kPa (100 - 120 psi) nitrogen precharge pressure.
damage may result. Check the steering This amount of pressure fully expands the
accumulator precharge pressure and adjust it if bladder and holds oil against the inner walls for
necessary. lubrication and rust prevention. Do not exceed
827 kPa (120 psi). Storing accumulators with too
1. When starting the truck, turn the key switch to much pressure is not safe due to possible
the ON position and wait to confirm that the low leakage.
accumulator precharge warning does not stay
active after the system check is complete. If the Only precharge accumulators to 9 653 kPa (1,400
warning stays active, do not operate the truck. psi) while installed on the truck. Never handle an
Notify maintenance personnel. accumulator with lifting equipment if the
2. Check the accumulator precharge pressure precharge pressure is over 827 kPa (120 psi).
every 500 hours. If the precharge pressure is Always set the precharge to 690 - 827 kPa (100 -
too low, the bladder will be crushed into the top 120 psi) before removing or installing the
of the shell by hydraulic system pressure and accumulators.
can extrude into the gas stem and become
1. If the accumulator was just rebuilt, ensure that
punctured. This condition is known as "pick out".
there is approximately 2 liters (64 oz.) of clean
One such cycle is sufficient to destroy a bladder.
C-4 hydraulic oil inside the accumulator before
3. Check all sealing areas on the nitrogen side of adding a precharge pressure of 690 kPa (100
the accumulator (charging valve, pressure psi).
switch, manifold, etc) during every precharge 2. Store bladder accumulators with a precharge
maintenance interval to ensure that the seals do pressure of 690 - 827 kPa (100 - 120 psi).
not leak. Replace all faulty or leaking seals,
3. Cover the hydraulic port with a plastic plug to
valves, etc. Failure to repair leaking nitrogen
prevent contamination. Do not use a screw-in
seals may result in a failed accumulator bladder
type plug.
or low performance from the accumulator.
4. Store the accumulator in an upright position.
NOTE: If the precharge pressure continues to decline
frequently between precharge maintenance intervals,
and if all nitrogen sealing areas are free of leaks, then
Bladder storage
the accumulator bladder most likely has a small hole
in it and must be replaced. The shelf life of bladders under normal storage
4. Check all heat shields and exhaust blankets, as conditions is one year. Normal storage conditions
provided, during every precharge maintenance consist of the bladder being heat sealed in a black
interval to ensure that they are in place and plastic bag and placed in a cool dry place away from
good condition. the sun, ultraviolet and fluorescent lights, and
electrical equipment. Direct sunlight or fluorescent
NOTE: If the truck is equipped with cold weather
light can cause the bladder to weather check and dry
bladder accumulators, the precharge pressure must
rot, which will appear on the bladder surface as
be checked every 100 hours because the nitrogen
cracks.
permeates this bladder material at a much greater
rate than the standard bladder material.
5
Installing a bladder accumulator from storage Bladder accumulator leak testing

Refer to "Bladder accumulator charging procedure" Leak testing entails checking for internal and external
to install the nitrogen charging kit on the accumulator leaks at high pressure. A source of 24 130 kPa
and to check the precharge pressure. (3,500 psi) hydraulic pressure and nitrogen
precharge pressure of 9 653 kPa (1,400 psi) will be
• If the precharge pressure is between 172 kPa (25
required. A small water tank is necessary for a
psi) and 690 kPa (100 psi), set the regulator to
portion of the test.
690 kPa (100 psi) and slowly charge the
accumulator to 690 kPa (100 psi). Disconnect the 1. Remove protective cap (1, Figure 30-1) from the
nitrogen charging kit from the accumulator and gas valve.
install the accumulator on the truck. Charge the 2. Close inlet valve (4, Figure 30-2) on control
accumulator to the correct operating precharge manifold (6).
pressure. Refer to Table 1. 3. Connect the nitrogen charging kit to nitrogen
• If the precharge pressure is less than 172 kPa container (8). Open the valve on the container.
(25 psi), slowly drain off all of the precharge 4. Turn the “T” handle on charging valve adapter
pressure and use the following procedure: (2) all the way out (counterclockwise).
1. Remove the nitrogen charging kit from the 5. Close the bleed valve at the bottom of the
accumulator. accumulator.
2. Lay the accumulator on a suitable work bench 6. Attach the charging valve adapter (2) to the
so the valve port at the bottom of the charging valve on the accumulator. Ensure the
accumulator is higher than the top end of the hose does not loop or twist. Tighten the swivel
accumulator. Remove the protective cap from nut on the charging valve adapter finger-tight.
the valve port. 7. Turn the “T” handle on charging valve adapter
3. Pour approximately 2 liters (64 oz.) of clean C-4 (2) clockwise to open the accumulator gas
hydraulic oil into the accumulator through the valve. Do not turn the “T” handle all the way
valve port. Allow time for the oil to run down the down as it will damage the valve core.
inside of the accumulator to reach the other 8. Set the regulator (5) for 690 kPa (100 psi), then
end. slightly open inlet valve (4) on control manifold
4. Lay the accumulator flat on the work bench (or (6) to slowly fill the accumulator. After 690 kPa
floor) and slowly roll the accumulator two (100 psi) is obtained, the charging rate can be
complete revolutions. This will thoroughly coat increased until the accumulator is fully charged
the accumulator walls with a film of oil that is to 9 653 kPa (1,400 psi).
necessary for bladder lubrication during the 10. Close inlet valve (4) on control manifold (6) then
charging procedure. turn the “T” handle on charging valve adapter
5. Stand the accumulator upright. Charge the (2) fully counterclockwise to close the
accumulator to 690 kPa (100 psi). Refer to accumulator gas valve.
"Bladder accumulator charging procedure" for
11. Submerge the accumulator assembly under
the proper charging procedure.
water and observe it for 20 minutes. No leakage
6. Remove the nitrogen charging kit. Install the (oil or bubbles) is permitted from the gas valve
protective cap on the valve port. at the top or the valve port at the bottom. If
7. Install the accumulator on the truck. leakage is present, proceed to Step 16.
8. Charge the accumulator to the correct operating 12. Hold the gas valve on the accumulator
precharge pressure listed in Table 1. Refer to stationary. Loosen the swivel nut on the
"Bladder accumulator charging procedure" for charging valve adapter to remove the nitrogen
the proper charging procedure. charging kit.
13. Install protective cap (1, Figure 30-1) on the gas
valve.
6
14. Ensure that the bleed valve at the bottom of the

accumulator is closed. Connect a hydraulic
power supply to the valve port at the bottom of
the accumulator.
15. Pressurize the accumulator with oil to 24 130 Hydraulic oil escaping under pressure can have
kPa (3,500 psi). This may take 6 to 8 gallons of sufficient force to enter a person's body by
oil. No external oil leakage is permitted. penetrating the skin and cause serious injury,
16. Slowly relieve oil pressure and remove the
hydraulic power supply. Install the protective
cap on the valve port to prevent contamination. Relieve pressure before disconnecting any
17. Install the nitrogen charging kit. hydraulic lines. Tighten all connections securely
• If any gas or oil leakage was present, discharge
1. Refer to the "Hydraulic system bleeddown
all nitrogen gas from the accumulator. Repair the
procedure" in Testing and adjusting section
accumulator as necessary.
• If there were no leaks, adjust the precharge hydraulic system.
pressure to 690 - 827 kPa (100 - 120 psi). 2. Close all accumulator bleed valves.
18. Verify that all warning and caution labels are 3. Remove valve cover (1, Figure 30-3) and
attached and legible. Install new labels as spacer (2).
required.
1
Piston accumulator charging procedure
2 4
Only precharge accumulators that are installed
on the truck. Never use lifting equipment to
handle an accumulator that has a nitrogen 3
precharge of more than 172 kPa (25 psi). Always
set the precharge to 172 kPa (25 psi) or less for
storage purposes and before removing or
installing accumulators.
Ensure that the nitrogen supply is shut off before

attaching the charging manifold to the nitrogen
container.
NOTE: In piston-type accumulators, an increase in

precharge pressure (after allowing for any 84476
appreciable temperature variation) indicates a
gradual leakage of fluid into the gas side. Conversely, FIGURE 30-3. TOP OF PISTON ACCUMULATOR
a decrease in precharge pressure is indicative of 1. Valve Cover 3. Charging Valve
nitrogen gas leakage into the fluid side. 2. Spacer 4. Switch Cover
7
NOTE: If a loss in nitrogen pressure is the reason for

recharging, inspect the charging valve and
accumulator for damage. Replace or repair items, as
necessary, before continuing the charging procedure.
7. Hold the gas valve stationary at valve body (3,
Nitrogen pressure may be present in the Figure 30-4) with one wrench, then loosen
accumulator. Only turn the swivel nut (small hex swivel nut (2) with a second wrench. This will
nut) during the next step. Turning the entire valve open the gas valve.
body may result in the valve assembly being
forced out of the accumulator by the nitrogen NOTE: Three turns will fully open the valve.
pressure inside. Wear a protective face mask 8. Disconnect the hose that connects manifold (6,
when discharging nitrogen gas. Figure 30-5) to regulator valve (5).
4. Turn “T” handle (1, Figure 30-5) on the charging NOTE: A small blast of pressure may escape.
valve adapter all the way out
(counterclockwise). 9. Open the inlet valve (4) then slowly open the
outlet valve (3) connected to the accumulator
5. Attach the charging valve adapter (2) to the until any stored pressure in the accumulator is
charging valve on the accumulator. Ensure the relieved.
hose does not loop or twist. Tighten the swivel
nut on the charging valve adapter finger-tight. 10. Close inlet valve (4) and outlet valves (3) then
reconnect the hose that connects manifold (6) to
6. Close inlet valve (4) and outlet valves (3) on
regulator valve (5).
control manifold (6).
11. Connect the nitrogen charging kit to nitrogen
container (8). Open the valve on the container.
1 12. Open outlet valve (3) connected to the
accumulator.
13. To prevent damage to the piston, first provide a
precharge to the accumulator by setting the
2 regulator (5) for 172 kPa (25 psi) then slightly
open inlet valve (4) until the precharge pressure
is reached.
14. Set the regulator (5) for the charging pressure
3 based on the current ambient temperature from
Table 1, then slightly open inlet valve (4) to
slowly fill the accumulator.
84483
NOTE: If a loss in nitrogen pressure occurred during
FIGURE 30-4. PISTON ACCUMULATOR operation, oil may still be present in the accumulator
CHARGING VALVE below the piston. This oil can be bled off during the
nitrogen charging procedure by turning the steering
wheel back and forth until resistance prevents the
1. Valve Cap 3. Valve Body steering wheel from turning.
2. Swivel Nut (Large Hex Nut)
(Small Hex Nut)
8
15. After the accumulator is charged to the desired

pressure, shut off the charging kit and wait 15
minutes to allow the gas temperature to
stabilize. If the desired pressure is maintained,
proceed to step 16. If the desired pressure is
exceeded:
a. Close the nitrogen container valve, inlet
valve (4) and both outlet valves (3).
b. Disconnect the hose that connects manifold
(6) to regulator valve (5).
NOTE: A small blast of pressure will escape.
c. Open the inlet valve (4) then slowly open
each outlet valve (3) independently until the
correct precharge pressure is obtained in
each accumulator.
®
HYDRAIR
FIGURE
30-5.
CHARGING
KIT
Do not reduce pressure by depressing the valve NOTE: The arrangement of parts may vary from
core with a foreign object. High pressure may the illustration depending on the kit part number.
rupture the rubber valve seat.
1. “T” Handle Valve
16. Tighten swivel nut (2, Figure 30-4) to 6-11 N·m 2. Charging Valve Adapter
(5-8 ft lb). 3. Manifold Outlet Valves (from gauge)
17. Use a common leak reactant to check for 4. Inlet Valve (from regulator)
nitrogen leaks. 5. Regulator Valve (Nitrogen Pressure)
6. Manifold
18. Install charging valve cap (1) finger tight. 7. Charging Pressure Gauge
19. Install valve cover (1, Figure 30-3) and tighten 8. Dry Nitrogen Gas Container
capscrews to 34 N·m (25 ft lb).
20. Operate the truck and check the steering
operation.
9
Piston accumulator storage Piston accumulator leak testing

It will be necessary to check for internal and external
leaks at high pressure. A source of 24 132 kPa
(3,500 psi) hydraulic pressure and nitrogen pressure
of 9 653 kPa (1,400 psi) will be required. A small
water tank with the necessary safety guards will be
When storing a piston accumulator, do not necessary for a portion of the test.
exceed the recommended storage pressure of
172 kPa (25 psi) or less. Sudden loss of the
accumulator pressure can result in a projectile
hazard that can cause serious injury or death.
Do not stand near the accumulator during test
Only precharge the accumulators to operating procedure. A box enclosure made of heavy steel
pressure while installed on the truck. DO NOT plate is recommended to contain the accumulator
handle an accumulator with a nitrogen precharge during oil pressurization test.
greater than 172 kPa (25 psi).
1. Ensure there is no pressure in either end of the
accumulator.
Apply a small nitrogen precharge of 172 kPa (25 psi)
or less to prevent seal compression and corrosion 2. Fill each end of the accumulator with
due to condensation. approximately 22.7 L (6 gal) of clean type C-4
hydraulic oil. Install an adapter on the oil end to
Store the accumulator in the upright position in a cool connect to a hydraulic power source. Plug the
dry place away from the sun. The ideal temperature remaining ports.
for storage is 21°C (70°F).
a. Apply 24 132 kPa (3,500 psi) of oil pressure.
Cover the oil port at the bottom of the accumulator
b. Verify that no external leakage exists.
with a plastic plug (without threads) to prevent con-
tamination. DO NOT install a threaded plug in the c. Verify that no structural damage exists.
oil port. 3. Release the pressure and remove the oil side
fitting.
4. Drain all the hydraulic oil from both ends of the
accumulator. Leave the oil port open.
5. Slowly pressurize the gas end of the accumula-
tor with approximately 690 kPa (100 psi) of
nitrogen to move the piston to the bottom of the
housing.
6. Submerge the oil end of the accumulator in the
water tank.
7. Apply 9 653 kPa (1,400 psi) of nitrogen pres-
sure to the gas end and observe for 20 minutes.
No leakage (oil or bubbles) is permitted.
8. Release the nitrogen pressure and remove the
accumulator from the water tank.
9. Drain all remaining oil from the accumulator.
10. If the accumulator is to be placed in storage,
add 1.5 L (3 pints) of clean type C-4 hydraulic oil
in the gas side of the accumulator and 0.5 L
(1 pint) in the oil side. Plug all open ports.
11. Verify that all warning and caution labels are
attached and legible. Install new labels as
required.
10
Checking for improper suspension charge Dirt ring heights should be similar across a typical
fleet of the same truck model. A benchmark dirt ring
During periodic maintenance inspections, check the
height should be established for the truck fleet to help
dirt ring on the exposed portion of each suspension
determine suspect suspension cylinders.
piston. See Figure 30-6. The dirt rings of the front
suspensions should be approximately the same NOTE: Checking and/or adjusting the suspension
height as each other, and the dirt rings of the rear charging pressures during periodic maintenance
suspensions should be approximately the same inspections is not recommended. The oiling and
height as each other. Dirt rings that are at charging procedures must be performed on flat
significantly different heights may indicate an ground and under specific controlled conditions.
improperly charged suspension cylinder.
CLEANED BY
WIPER SEAL CLEANED BY
WIPER SEAL
DIRT RING
DIRT RING
FRONT SUSPENSION
REAR SUSPENSION
73536
FIGURE 30-6. DIRT RING ON SUSPENSION PISTON
11
Suspension oiling and charging For best results, suspensions should be charged in
procedures pairs (front suspensions together and rear
suspensions together). If rear suspensions are to be
charged, the front suspensions should be charged
first. If the truck lifts off of support blocks before
charging is complete, stop charging. If both front and
rear suspensions are serviced, DO NOT remove the
All HYDRAIR® II suspensions are charged with front suspension support blocks until after the rear
compressed nitrogen gas with sufficient pressure suspensions have been completely serviced.
to cause injury and/or damage if improperly
Anytime the suspensions are charged, the calibration
handled. Follow safety instructions, cautions,
of the payload meter (PLM) system is affected. To
and warnings provided in the following
ensure accurate payload records, perform a "Clean
procedures to prevent accidents during oiling
Truck Tare" before returning the truck to operation.
and charging.
Refer to the payload meter information in the
These procedures cover the suspension oiling and operation and maintenance manual.
charging of Hydrair® II suspensions on Komatsu
electric drive dump trucks. Suspensions that have
been properly charged will provide improved handling Required equipment
and ride characteristics while also extending the life
of the truck frame and improving tire wear. • Hydrair® charging kit (see Figure 30-7)
Inflation pressures and exposed piston lengths are • Jacks and/or overhead crane
calculated for a normal truck gross vehicle weight • Support blocks for oiling
(GVW). Additions to truck weight, such as body
liners, tailgates, water tanks, etc, should be • Support blocks for charging
considered part of the payload. Keeping the truck • Hydrair® oil (see Specifications Chart)
GVW within the specification shown on the grade/
speed chart in the operator cab will extend the • Friction modifier (see Specifications Chart)
service life of the truck main frame and allow the • Dry nitrogen (see Specifications Chart)
suspensions to produce a comfortable ride.
12
Installing the charging kit

1. Assemble the charging kit as shown in Figure
30-7.
2. Remove the protective covers and charging
valve caps from the suspensions.
3. Turn "T" handle valves (1, Figure 30-7) of
adapters (2) completely counterclockwise.
4. Ensure that outlet valves (3) and inlet valve (4)
are closed (turned completely clockwise).
5. Attach charging valve adapters (2) to each
suspension charging valve stem.
6. Turn the swivel nut (small hex) on the charging
valve three full turns counterclockwise to unseat
the valve.
7. Turn "T" handle valves (1) clockwise. This will
depress the core of the charging valve and open
the gas chamber of the suspension.
8. Open both outlet valves (3).
FIGURE 30-7. HYDRAIR® CHARGING KIT
NOTE: By selective opening and closing of outlet
valves (3) and inlet valve (4), suspensions may be 1. “T” Handle Valve
charged separately or together. 2. Charging Valve Adapter
3. Manifold Outlet Valves (from gauge)
4. Inlet Valve (from regulator)
Removing the charging kit 5. Regulator Valve (Nitrogen Pressure)
6. Manifold
1. Close both outlet valves (3, Figure 30-7). 7. Charging Pressure Gauge (Suspensions)
2. Turn "T" handle valves (1) counterclockwise to 8. Dry Nitrogen Gas Container
release the charging valve cores.
3. Tighten the swivel nut (small hex) on the NOTE: The arrangement of parts may vary from
charging valve. If a new charging valve is being the illustration.
used, tighten the swivel nut to 15 N·m (11 ft lb),
then loosen and retighten the swivel nut to 15
N·m (11 ft lb). Loosen the swivel nut again and
retighten to 6 N·m (50 in lb).
4. Remove charging valve adapters (2) from the
charging valves.
5. Install the charging valve caps and protective
covers on both suspensions.
13
Support blocks for oiling and charging Exposed piston rod extensions are specified for both
dimensions oil level and nitrogen charging for Hydrair II
suspensions. These dimensions are listed in Table 2
Before starting the oiling and charging procedures,
and Table 3. At the front suspension, measure from
support blocks must be fabricated to maintain the
the face of the cylinder gland to the machined surface
correct exposed piston rod extensions. Different
on the spindle. At the rear suspension, measure from
support blocks are required for oiling and for charging
the face of the cylinder gland to the piston flange.
because the oiling and charging heights are different.
See Figure 30-8.
See Table 2 for the front suspension dimensions. See
Table 3 for the rear suspension dimensions. Support blocks may be fabricated in various forms.
Mild steel materials are recommended. Square stock
NOTE: Nitrogen charging support blocks for the rear
or pipe segments at least 25 mm (1 in.) may be used.
suspension are not necessary. However, oiling blocks
The blocks must be capable of supporting the weight
are necessary to properly set the oiling height.
of the truck during oiling and charging procedures
while avoiding contact with plated surfaces and seals
on the suspension. Refer to Figure 30-9 for front
suspension support block placement and Figure 30-
11 for rear suspension support block placement.
CHARGING
HEIGHT CHARGING
HEIGHT
FRONT SUSPENSION REAR SUSPENSION 73538
FIGURE 30-8. MEASURING THE CHARGING HEIGHT
14
Front suspensions
NOTE: The dump body must be empty and resting on
the truck frame before performing the following
procedures.
1. Park the truck on a hard, level surface. Place
the directional control lever in PARK.
2. Place wheel chocks in front of and behind both
sets of rear tires to prevent roll away.
NOTE: Do not place wheel chocks around the front
tires. The front tires will roll forward and backward a
small amount as the suspension travels up and down
during the suspension charging process. SUPPORT SUPPORT
BLOCK BLOCK
3. Throughly clean the charging valve area on top
of each front suspension. Remove the
protective covers from the charging valves.
73537
When support blocks are in place, they must be FIGURE 30-9. FRONT SUSPENSION
secured with a strap or by other means to avoid
accidental discharge. An unsecured support
block could fly loose as weight is applied,
presenting the possibility of serious injury to
nearby personnel and/or damage to the
equipment. Overhead clearance may be reduced
rapidly and suddenly when nitrogen pressure is
released.
4. Position and secure the oiling support blocks

180 degrees apart as shown in Figure 30-9.
When nitrogen pressure is released, the
suspensions will lower and rest on the blocks.
NOTE: Ensure that the blocks do not mar or scratch
the plated surfaces of the pistons or damage wiper
seals in the lower bearing retainer. Support blocks
must seat on the spindle and the cylinder housing,
not on the capscrew heads.
15
6. Remove the top fill plug next to the charging

valve.
7. Fill the suspension cylinder with a clean
suspension oil mixture (with 6% friction
modifier) until the oil is even with the top of the
Wear a face mask or goggles. Ensure that only
fill plug hole.
the swivel nut turns. Turning the entire charging
valve body may result in the valve assembly NOTE: As an alternative method, the suspension can
being ejected from the suspension by the gas be pressure filled from the rod drain port at the
pressure inside. bottom of the cylinder. This would eliminate the 15
5. Discharge the nitrogen pressure from the minute wait in the following step.
suspension as follows: 8. Allow the suspension to settle for at least 15
minutes. Add more suspension oil mixture if
a. Remove valve cap (1, Figure 30-10) from the
necessary.
charging valve on top of the front suspen-
sion. 9. Install a new o-ring on the fill plug and install the
fill plug.
b. Connect the nitrogen charging kit to the
charging valve. Refer to "Installing the 10. Connect the nitrogen charging kit to the
charging kit". charging valve. Refer to "Installing the charging
kit".
c. Turn swivel nut (2) counterclockwise three
full turns to unseat the valve seal. Do not 11. Charge the suspensions with nitrogen gas to a
turn the swivel nut more than three turns. charging height of approximately 280 mm (11
Do not turn charging valve body (3). in.) in order to accommodate the charging
support blocks. Close inlet valve (4, Figure 30-
d. As the nitrogen pressure is released, the 7).
suspension should lower slowly and seat sol-
idly on the support blocks. Remove the nitro- 12. Remove the oiling support blocks from the
gen charging kit. Refer to "Removing the suspensions and install the charging support
charging kit". blocks. Secure the blocks to prevent accidental
dislodging.
NOTE: Use caution to prevent damage to plated
1 cylinder surfaces and oil seals when installing the
support blocks.
13. Remove the center hose from the charging
valve manifold.
2
14. Slowly release nitrogen gas until the pressure
drops below the estimated charging pressure
listed in Table 2, then close the valve.
3 15. Install the center hose to manifold (6).
84483
FIGURE 30-10. CHARGING VALVE

1. Valve Cap 3. Valve Body
(Small Hex Nut)
16
16. Charge the suspensions to the charging height 17. Close inlet valve (4). Leave outlet valves (3)
listed in Table 2. open for five minutes to allow the pressures in
the suspensions to equalize.
The charging pressure is provided only as a
starting point for obtaining the correct charging 18. Close outlet valves (3). Remove the charging kit
height. The pressure may be adjusted as neces- components. Refer to “Removing the Charging
sary to maintain the proper charging height Kit”.
listed in Table 2. Do not use an overcharge of 19. If the charging valve is being reused, tighten
nitrogen to lift the suspensions off the support swivel nut (2, Figure 5) to 6-11 N·m (5-8 ft lb).
blocks. Install the valve cap finger-tight.
NOTE: There is no specific charging pressure that If a new charging valve is being used, tighten
must be maintained. The required pressure for swivel nut (2) to 15 N·m (11 ft lb), then loosen
maintaining the charging height will depend upon the and tighten the swivel nut to 15 N·m (11 ft lb).
weight of the dump body. Loosen the swivel nut again and tighten to 6-11
N·m (5-8 ft lb). Install the valve cap finger-tight.
Table 2: Front Suspension Dimensions (Empty) 20. Install the protective guard over the charging
Oiling Charging valve.
Charging Height
Height Pressure NOTE: If the rear suspensions are to be serviced at
830E-5 this time, leave the charging support blocks in place
25.4 mm 228.6 mm * 2 696 kPa on the front suspensions until after the rear
(1.00 in.) (9.00 in.) (391 psi) suspensions are completely serviced.
930E-5
25.4 mm 228.6 mm * 2 930 kPa
(1.00 in.) (9.00 in.) (425 psi)
980E-5
228.6 mm
Standard
25.4 mm (9.0 in.) *3 047 kPa
(1.0 in.) 165.1 mm (442 psi)
Oil Sands
(6.5 in.)
* Charging pressures are for reference only and may vary
depending upon the weight of the dump body. The charging
pressure is provided only as a starting point for obtaining the
correct charging height, which is the critical measurement for a
properly charged suspension. The pressure may be adjusted
as necessary to maintain the proper charging height.
17
Rear suspensions
NOTE: The dump body must be empty and resting on
the truck frame before performing the following
procedures.
1. Park the truck on a hard, level surface. Place
the directional control lever in PARK.
2. Place wheel chocks in front of and behind both
sets of rear tires to prevent roll away.
NOTE: Do not place wheel chocks around the front
tires. The front tires will roll forward and backward a
small amount as the suspension travels up and down
during the suspension charging process.
3. Throughly clean the charging valve area on top
of each front suspension. Remove the
protective covers from the charging valves.
When support blocks are in place, they must be FIGURE 30-11. SUPPORT BLOCK
secured with a strap or by other means to avoid INSTALLATION
accidental discharge. An unsecured support 1. Main Frame 3. Rear Axle Housing
block could fly loose as weight is applied, 2. Support Block
presenting the possibility of serious injury to
nearby personnel and/or damage to the
equipment. Overhead clearance may be reduced
rapidly and suddenly when nitrogen pressure is
released.
4. Position and secure oiling support blocks (2,

Figure 30-11) in place so the blocks are seated
between main frame (1) and rear axle housing
(3). A block should be used on both the left and
right sides of the truck.
18
NOTE: A plastic tube can be used to help bleed off

trapped air inside the piston.
6. Remove vent plug (1, Figure 30-13), pressure
sensor (2) and charging valve (3).
Wear a face mask or goggles. Ensure that only 7. Use one of the open ports to fill the suspension
the swivel nut turns. Turning the entire charging cylinder with a clean suspension oil mixture
valve body may result in the valve assembly (with 6% friction modifier) until oil weeps from
being ejected from the suspension by the gas the open ports. Use drip pans and clean all
pressure inside. spillage from the outside of the suspension.
5. Discharge the nitrogen pressure from the NOTE: As an alternative method, the suspension can
suspension as follows: be pressure filled from the rod drain port at the
bottom of the cylinder. This would eliminate the 15
minute wait in the following step.
charging valve on top of the front suspen-
sion. 8. Allow the suspension to settle for at least 15
minutes. Add more suspension oil mixture if
b. Connect the nitrogen charging kit to the necessary.
charging valve. Refer to "Installing the
charging kit". 9. Install vent plug (1) and pressure sensor (2) into
the suspension cylinder.
c. Turn swivel nut (2) counterclockwise three
full turns to unseat the valve seal. Do not 10. Install a new O-ring onto charging valve (3) and
turn the swivel nut more than three turns. install it into the suspension cylinder.
Do not turn charging valve body (3).
d. As the nitrogen pressure is released, the
suspension should lower slowly and seat sol-
idly on the support blocks. Remove the nitro-
gen charging kit. Refer to "Removing the
charging kit". 1
1 3
2 73539
FIGURE 30-13. REAR SUPENSION PORTS

3
1. Vent Plug 3. Charging Valve
2. Pressure Sensor
84483
FIGURE 30-12. CHARGING VALVE

(Small Hex Nut)
19
11. Connect the nitrogen charging kit to the 14. Close inlet valve (4). Leave outlet valves (3)
charging valve. Refer to "Installing the charging open for five minutes to allow the pressures in
kit". the suspensions to equalize.
12. Charge the suspensions with nitrogen gas to a 15. Ensure that both of the rear suspension
charging height of approximately 305 mm (12 cylinders are extended the same distance ± 10
in.). Close inlet valve (4, Figure 30-7). mm (0.39 in.). If the difference in the extension
from side to side exceeds this amount, check
the front suspensions for equal extension.
Adjust the front suspensions as necessary.
NOTE: A low left front suspension will cause the right
rear suspension to be high. A low right front
Be aware that the truck may lower suddenly when
suspension will cause the left rear suspension to be
releasing nitrogen gas from the suspensions.
high.
13. Slowly release nitrogen gas until the charging
16. Close outlet valves (3). Remove the charging kit
heights of both rear suspensions match the
components. Refer to "Removing the charging
charging height listed in Table 3.
kit".
The charging pressure is provided only as a
17. If the charging valve is being reused, tighten
starting point for obtaining the correct charging
swivel nut (2, Figure 30-12) to 6-11 N·m (5-8 ft
height. The pressure may be adjusted as neces-
lb). Install the valve cap finger-tight.
sary to maintain the proper charging height
listed in Table 3. If a new charging valve is being used, tighten
swivel nut (2) to 15 N·m (11 ft lb), then loosen
NOTE: There is no specific charging pressure that
and tighten the swivel nut to 15 N·m (11 ft lb).
must be maintained. The required pressure for
Loosen the swivel nut again and tighten to 6-11
maintaining the charging height will depend upon the
N·m (5-8 ft lb). Install the valve cap finger-tight.
weight of the dump body.
18. Install the protective guard over the charging
valve.
Table 3: Rear Suspension Dimensions (Empty)
19. If the front suspensions were serviced, remove
Charging the charging support blocks from the front
Oiling Height Charging Height
Pressure suspensions. Floor jacks or an overhead crane
830E-5 may be necessary to raise the truck if the blocks
54.2 mm 270.1 mm * 1 186 kPa have become jammed in place.
(2.13 in.) (10.63 in.) (172 psi) 20. Remove the oiling support blocks from the rear
930E-5 axle housing.
54.2 mm 219.3 mm * 1 296 kPa
(2.1 in.) (8.6 in.) (188 psi)
980E-5
47.2 mm 212.3 mm *1 455 kPa
(1.86 in.) (8.36 in.) (211 psi)
* Charging pressures are for reference only and may vary
depending upon the weight of the dump body. The charging
pressure is provided only as a starting point for obtaining the
correct charging height, which is the critical measurement for a
properly charged suspension. The pressure may be adjusted
as necessary to maintain the proper charging height.
20
Suspension pressure test 4. Pressurize the suspension with air or nitrogen to

7 585 ± 1 380 kPa (1,100 ± 200 psi).
The suspension assembly should be tested for
leakage after rebuild procedures are completed. If 5. Maintain pressure for a minimum of 20 minutes
leakage occurs, the cause of the leakage must be and check for bubbles at the following locations:
identified, and repaired before the suspension is • Housing bearing/housing joint
installed on the truck.
• Piston/piston seal area
• Charging valve and plugs
6. After the test is complete, remove the assembly
from the water tank and release the air or
nitrogen pressure. Do not remove the charging
The entire suspension assembly must be placed valve from the suspension.
in a containment device that will keep the
suspension piston in the retracted position and 7. Remove the suspension from the containment
prevent it from extending during pressurization. device.
Ensure the containment device is capable of 8. Coat any exposed, unpainted areas with rust
withstanding the applied force. preventive grease.
1. Collapse the suspension until the piston is fully 9. Store the suspension in a collapsed position to
retracted in the housing. protect the piston chrome surface until it is
installed on a truck.
2. Ensure the charging valve and all plugs are
installed. Attach the pressurization line to the
charging valve.
3. Place the suspension assembly in a
containment device and submerge the entire
assembly in the water tank.
21
830E Dump truck

930E Dump truck
980E Dump truck
22
CEN30104-00
980E

980E-5 A50005 and up

Electrical systems
Truck shutdown procedure.................................................................................................................................... 4
Required software and tools ................................................................................................................................. 4
Electrical system checkout procedures................................................................................................................. 6
Electrical checkout sheet .................................................................................................................................... 10
1
NOTES
2
General information on system checkout

The electrical system checkout procedures are
intended to help the technician diagnose problems in
the 24V control and lighting systems. The technician
should read the checkout procedures to become DANGEROUS VOLTAGE LEVELS ARE PRESENT
familiar with the procedures and all the warnings and WHEN THE TRUCK IS RUNNING AND CONTINUE
cautions before performing any steps. The checkout TO EXIST AFTER SHUTDOWN IF THE REQUIRED
procedures begin by checking the basic system SHUTDOWN PROCEDURES ARE NOT
before checking individual components. FOLLOWED.
A data sheet is included in this section to record the Before attempting repairs or working near drive
test information obtained during the electrical system system components, the following precautions
checkout procedure. The data sheet is designed to and truck shutdown procedure must be followed:
be printed or copied, then used during the checkout
procedure. • DO NOT step on or use any power cable as a
hand hold when the engine is running.
• NEVER open any electrical control cabinet
covers or touch the retarding grid elements.
Additional drive system safety checks must
be performed by a technician trained to
service the system before working on drive
This checkout procedure must be performed by
system components.
qualified, trained personnel that have knowledge
of the operation of the truck and the stored • ALL removal, repairs and installation of drive
energy systems. Personnel must observe all system electrical components, and cables
established precautions where the checkout must be performed by an electrical
procedure is being performed. All potentially maintenance technician properly trained to
service the drive system.
stored energy within the truck must be released
before performing any troubleshooting. • IN THE EVENT OF A DRIVE SYSTEM
MALFUNCTION, a qualified technician must
inspect the truck and verify the drive system
does not have dangerous voltage levels
present before repairs are started.
• THE DC LINK VOLTAGE LIGHTS MUST NOT
BE ILLUMINATED WHEN TEST OR REPAIRS
ARE INITIATED. It requires approximately five
minutes after the truck is shut down before
the DC link voltage has dissipated.
Power cables must be cleated in wood or other

non-ferrous materials. Do not repair cable cleats
by encircling the power cables with metal clamps
or hardware. Always inspect power cable
insulation prior to servicing the cables. Replace
cables that have broken insulation.
3
Truck shutdown procedure

Energizing the drive system is not dependent on the
position of the directional control lever or actuation of
the accelerator pedal. If generator field contactor
(GF) switch (2, Figure 30-1) is in the NORMAL (ON) Certain drive system failures can result in a
position and the engine is running, the drive system condition where one or more capacitors can
link is "hot" with dangerous voltage. remain in a charged state even though the DC
Normal operation of the drive system at shutdown link voltage lights are off.
should leave the system safe to operate. In the event
of a system failure, performing the following Because a danger can still exist when the DC link
procedure will ensure that hazardous voltages are voltage lights are off, it is necessary to manually
not present in the drive system. discharge the capacitors before touching or
servicing drive system components. Only
1. Before shutting down the engine, verify the authorized service personnel are allowed to
status of the drive system warning lights in the service the drive system.
cab. If any of the drive system warning lights are
illuminated, do not attempt to open any Refer to the GE shop manual for safety rules and
cabinets, disconnect any cables, or reach inside procedures regarding the servicing of the drive
the retarding grid. system. Adhere to the proper procedures for
2. If all drive system warning lights are off, move disabling, checking and discharging the drive
the directional control lever to PARK and turn system.
the key switch OFF to shut down the engine.
3. Chock the tires to prevent possible roll away.
4. After the engine has been off for at least five
minutes, verify that capacitor charge lights (3) Required software and tools
and (4) on the front of the main control cabinet Several tools are required for the electrical system
are off. This indicates that the DC link voltage checkout procedures.
has been discharged to less than 50 VDC.
• Electrical system schematic
5. To ensure that the DC link will not be re- • Service computer (1 GHz processor, 512 MB
energized, move generator field contactor (GF)
RAM minimum) with Windows® operating system
switch (2, Figure 30-1) to the CUTOUT (OFF) (XP or later)
position.
• RS232 serial cable (one male DB9 connector,
6. At the battery isolation station, move both the one female connector)
starter disconnect switch and the main battery
disconnect switch to the OFF position. • Ethernet cable
• WebPTU software from GE
• GE drive system electrical schematic
• GE Vehicle Test Instructions (VTI)
• Megger - 0- 1500 volt (0-2000 Mega ohms)
• Several jumper wires
• Multimeter (1,000V)
4
1 2
4 3
87521
FIGURE 30-1. MAIN CONTROL CABINET

1. Control Power Switch 3. Capacitor Charge Light (DC Link Voltage)
2. Generator Field Contactor (GF) Switch 4. Capacitor Charge Light (DC Link Voltage)
5
Electrical system checkout procedures Voltage checks
Visual inspection 1. Verify that the key switch is in the OFF position.
1. Verify that all electrical connections for the 2. Ensure that the generator field contactor (GF)
power cables and wiring harnesses are securely switch is in the CUTOUT (OFF) position.
connected. 3. Verify that the 21PT circuit wires which connect
to both engine starter relays are disconnected
2. At the battery isolation station, verify that both and insulated to prevent engine cranking.
the starter disconnect switch and the main
battery disconnect switch are in the OFF 4. Ensure that the engine shutdown switch in the
position. Also check that the battery cables are operator cab is pushed down and the ground
connected correctly. level shutdown switch is pulled out.
3. Check that all fluids are at the correct levels. 5. To provide 24VDC, reconnect both of the short
jumper battery cables which connect the
4. Ensure that DC link voltage is drained before positive (+) and ground between the two
performing these checks. batteries.
6. Check battery voltage to ground (circuit 11)
Resistance checks
inside the battery box. A battery charger may
1. Remove both of the short jumper battery cables need to be installed if battery voltage is low.
which connect the positive (+) and ground
between the two batteries that make up 24VDC. 7. At the battery isolation station, turn the main
battery disconnect switch ON but leave the
2. Verify that the 21PT circuit wires which connect starter disconnect switch OFF.
to both engine starter relays are disconnected
and insulated to prevent engine cranking. 8. Check battery voltage to ground (circuit 11) in
3. Turn the key switch to OFF. Ensure that all the auxiliary control cabinet on the 24VDC buss.
switches in the operator cab are OFF. 9. In the auxiliary control cabinet, check the
4. In the auxiliary control cabinet, use a multimeter circuits in the following table for the appropriate
to check the resistance from ground buss circuit battery voltage to ground.
0 to the points in the following table.
All points should measure resistance values Circuit Connection Voltage
from a few ohms to infinity. Stop and
troubleshoot any direct shorts (0 ohms) to 11B1 TB24 12VDC
ground. Restore all connections when done. 11A TB35-A 24VDC
11E1 TB27-A 24VDC

Circuit Connection
11E2 TB27-B 24VDC
11 24VDC buss
11E3 TB27-C 24VDC
12V VEC91-S7
11E4 TB27-D 24VDC
71CK TB24-N
11L TB22-C 24VDC
10V TB31-N
11SL TB24-A 24VDC
+15VDI TB21-T
39G TB34-T 24VDC
-15VDI TB21-V
11LL relay HLMR-88 24VDC
5VDI TB21-W
11LR relay HHMR-88 24VDC
5VIM TB30-L
11HL relay HBHR-88 24VDC
24VIM TB32-H
47B relay BULR-88 24VDC
18VIM TB30-W
85 TB28-C 24VDC
6
10. Turn the key switch to the ON position. Truck function checks
11. In the auxiliary control cabinet, check the circuits If any of the following truck functions fail to operate,
in the following table for the appropriate battery shut down the truck and release all stored energy.
voltage to ground. Use the electrical wiring diagram to troubleshoot the
circuits within the associated truck function that failed
to operate.
Circuit Connection Voltage
1. Turn the key switch to the OFF position.
11D TB22-A 24VDC
a. Verify cab dome light functionality by turning
712 TB24-K 24VDC the dome light switch ON and OFF.
71CK TB24-N 24VDC b. Check the front horn for proper operation.
c. Turn the ladder light switches ON and OFF
71LS TB23-M 24VDC
(inside the operator cab and at ground level
71VHM TB28-B 24VDC near the diagonal ladder entrance). The two
platform lights, diagonal ladder light and deck
24VIM TB32-H 24VDC light should illuminate.
5VIM TB30-K 5VDC d. Press the hazard light switch to verify that the
front and rear hazard lights flash.
12V VEC91-S7 12VDC
e. Verify functionality of the dome lights in the
18VIM TB30-W 18VDC
hydraulic brake cabinet.
f. In the battery isolation station, verify that the
indicator lights for each of the disconnect
12. In the main control cabinet, move control power switches function properly when the
switch (2, Figure 30-1) to the ON position. disconnect switches are turned ON and OFF.
13. Verify that the LED power indicators are g. On both sides of the truck, turn the engine
illuminated on the face of Invertex II control service light switches ON and OFF to verify
panel. functionality of the engine service lights.
14. Check the circuits in the following table for the
2. Turn the key switch to the ON position.
appropriate battery voltage to ground.
a. Verify that the switch indicators for the mode
switches 1 and 2, manual backup switch, grid
Circuit Connection Voltage dry switch, and heated mirror switch are
illuminated. If equipped, the fog light switch,
71GE TB24-G 24VDC rotating beacon switch, and camera select
10V TB31-N 10 - 12VDC switch should also be illuminated.
b. Turn the headlight switch to the clearance
15SRW TB33-M 15VDC
light position (middle position). Verify that the
15SLW TB33-S 15VDC front left/right clearance lights, rear tail lights,
instrument panel lights, directional control
77P TB29-A 15VDC lever, engine shutdown switch and body
714P TB29-H 15VDC override/reset switch are illuminated. Verify
that the instrument panel light dimmer can
15VDI TB21-T 15VDC adjust the back light on the electronic display
panel brightness.
-15VDI TB21-V -15VDC
5VDI TB21-W 5VDC
7
c. With the headlight switch in the OFF position o. Start the engine. Verify operation of the
and the directional control lever in the PARK heating and air conditioning system by
position, the bottom green indicator in the turning the AC and heater selector switch.
headlight switch, ladder light switch, and Check all blower speed positions.
hazard light switch should illuminate.
p. Verify functionality of the dome lights in the
d. Move the headlight switch to the headlight auxiliary control cabinet.
position (top position). Both sets of low beam
q. If equipped, verify functionality of the
headlights should be on. Pull the multi-
hydraulic pump module access light by
function switch lever on the steering column
operating the switch located on the air duct
to the high beam position. The low beam
behind the cab.
headlights should remain on and the high
beam headlights should turn on. The high r. Turn the key switch to the OFF position to
beam indicator on the instrument panel stop the engine.
should be illuminated.
e. Verify operation of the fog lights by turning
the fog light switch ON and OFF. Interface module (IM) checks
f. Actuate the window switches to verify 1. Turn the key switch to the ON position.
operation of the operator side and passenger 2. Connect the service computer to the IM
side windows. diagnostic port (IM DIAG) in the cab or in the
g. Move the directional control lever to the auxiliary control cabinet. Verify that the latest
REVERSE position. The backup alarms and software configuration has been loaded into the
the backup lights should turn on. Move the interface module. Upload the latest software if
directional control lever to the NEUTRAL or necessary.
FORWARD position. The backup alarms and
3. Review the IM system error code report and
backup lights should turn off.
resolve all reported faults.
h. Press the manual backup light switch to
4. Complete the IM checkout procedure. Refer to
verify the functionality of the rear backup
Testing and adjusting section Interface Module
lights and deck mounted backup lights.
(IM).
i. Move the multi-function switch lever on the
steering column up and down. Verify that the
clearance lights on the decks, dump body,
KOMTRAX Plus II checks
and the turn signal indicators on the
instrument panel flash to indicate the proper 1. Turn the key switch to the ON position.
direction.
2. Complete the KOMTRAX Plus II setup
j. Turn the multi-function switch on the steering procedure. Refer to Testing and adjusting
column to verify operation of the windshield section KOMTRAX Plus II.
wipers in the low, high, and intermittent
speeds.
k. Press the windshield washer button on the Payload meter (PLM) checks
end of the multi-function switch lever to verify
1. Turn the key switch to the ON position.
that the washer pump runs and the wipers
operate monetarily. 2. Connect the service computer to the PC LAN
ethernet diagnostic port (PC) in the cab. Verify
l. If equipped, verify that both the left side and
that the latest software configuration has been
right side heated mirrors function when the
loaded into the payload meter controller. Upload
heated mirror switch is turned ON.
the latest software if necessary.
m.Verify operation of the cab radio. Check the
functionality of both front and rear speakers. 3. Complete the PLM checkout procedure. Refer
to Testing and adjusting section Payload meter
n. Check the functionality of the operator seat IV.
and passenger seat switches.
8
Drive system checks 3. Use the GE WebPTU software to check the

following drive system analog inputs and
1. Use the Vehicle Test Instructions (VTI) in the GE
outputs.
service manual to verify functionality of the drive
system.
2. Use the GE WebPTU software to check the Function Criteria
following drive system digital inputs and outputs.
Power Supply Operating value verified
Operating range verified and

Retard Pedal
Function Criteria calibrated
KEYSW Engine start switch ON/OFF Operating range verified and

Accelerator Pedal
calibrated
Output for GE control power (71GE)
CPSFB
ON/OFF 10V
Potentiometer Operating value verified
Parking brake applied pressure switch Reference
PKBP
ON/OFF
Speed Control Operating range verified and
BRAKON Service brake applied pressure switch Switch calibrated
WHEELOCK Brake lock switch ON/OFF
BRAKTSREQ Pre-shift brake test switch ON/OFF

Engine delayed shutdown Smart Timer check
AXLEP Axle blower pressure switch ON/OFF
1. Install a multimeter to monitor the voltage on
Control cabinet blower pressure circuit 21NSL (TB27-E) to ground.
CNTRLP
switch (RPM 950- 1150)
2. Start the engine and operate at an
RSC Retard speed control switch ON/OFF approximately 1500 rpm. After the engine
coolant temperature rises to 82 °C (180 °F),
SPINDIS Slip-Slide feature disabled
circuit 21NSL voltage will rise from 0 to 24VDC.
FORREQ Directional control lever - FORWARD
3. Lower the engine speed to low idle for
REVREQ Directional control lever - REVERSE approximately one minute, then turn the key
switch to the OFF position. The engine should
Body up override / rest reset switch continue to operate at low idle for approximately
REST-DO
ON/OFF
three minutes or less and then shut down.
DATST Data store switch ON/OFF
GFNCO Control cabinet GF switch ON/OFF

Body hoist limit switch check
PROPLO Propel lockout switches ON/OFF
1. Turn the key switch ON.
Optional hydraulic access ladder
OEMACCIN 2. Place a piece of metal in front of the body up
down limit switch
switch located at the rear of the truck.
ENGSTRREQ Engine starter request key switch start
3. In the hydraulic brake cabinet, measure the
ENGKILL Engine shutdown switches ON/OFF voltage circuit 53H to ground at TB35-N. There
should be battery voltage at TB35-N.
BODYDWN Body up proximity switch ON/OFF
4. Remove the piece of metal from the body up
WARMUP Grid dry/engine warm switch ON/OFF switch. There should be 0V when the piece of
metal is removed.
FULPAYLD Full payload signal (RPC CAN)
OVERPAYLD Overload payload signal (RPC CAN)
ENGWARN Engine warning signal (J1939 CAN)
9
Electrical checkout sheet
ELECTRICAL CHECKOUT SHEET
Result
Function Description Comments
(OK/Fail)
RESISTANCE CHECKS
VOLTAGE CHECKS
TRUCK FUNCTION CHECKS
Cab Dome Light
Forward Horn
Ladder Lights
Hazard Lights
Brake Cabinet Dome Lights
Disconnect Switch Lights
Engine Service Lights
Cab Switch Indicators
Clearance Lights
Cab Switch Green Indicators
Headlights
Fog Lights
Cab Side Windows
Backup Alarms and Lights
Manual Backup Lights
Turn Signal Lights
Windshield Wipers
Windshield Washer Pump
Heated Mirrors (if equipped)
Cab Radio
Cab Seats
HVAC System
Auxiliary Control Cabinet Dome Lights
Hydraulic Pump Access Light (if equipped)
10
Result
(OK/Fail)
IM CHECKOUT
KOMTRAX PLUS II SETUP
PLM CHECKOUT
VTI CHECKOUT
KEYSW
CPSFB
PKBP
BRAKON
WHEELOCK
BRAKTSREQ
AXLEP
CNTRLP
RSC
SPINDIS
FORREQ
REVREQ
REST-DO
DATST
GFNCO
PROPLO
OEMACCIN
ENGSTRREQ
ENGKILL
BODYDWN
WARMUP
FULPAYLD
OVERPAYLD
ENGWARN
Power Supply
11
Result
(OK/Fail)
Retard Pedal
Accelerator Pedal
10V Potentiometer Reference
Speed Control Switch
SMART TIMER CHECK
BODY HOIST LIMIT SWITCH CHECK
Truck S/N: _____________________
Completed By: ______________________________________________
Date: _____________________
12
NOTES
13
980E Dump truck

14
CEN30103-00
980E

980E-5 A50005 and up

Interface module (IM)
Interface module checkout procedures................................................................................................................. 4
IM checkout sheet................................................................................................................................................. 8
1
NOTES
2
Required software and tools

Several software programs and tools are required for
interface module (IM) checkout procedures.
• Electrical system schematic
• Service computer (1 GHz processor, 512 MB
(XP or later)
• RS232 serial cable (one male DB9 connector,
one female connector)
• WebPTU software from GE
• Interface Module Realtime Data Monitor software
• Application code
• Flashburn program
• Jumper wire 77 mm (3 in.) or longer
• Voltmeter
• Resistor (300 to 332 ohm)
• 3/8 in. nut driver
• Connector back probes
• Small flat head screw driver (to push the release FIGURE 30-1. INTERFACE MODULE
buttons when removing a wire from a terminal CONNECTIONS
board)
1. IM Controller 3. Connector IM2
2. Connector IM1 4. Connector IM3
The Interface Module Realtime Data Monitor
software is used to display the data going into and
out of the interface module.
The application code is truck specific software that is
installed into the IM controller. The Flashburn
software is used to install the application code.
NOTE: The data files, application code and

Flashburn software are only required if the interface
module is being replaced. New IM controllers come
unprogrammed and must have the correct software
installed in order to function.
NOTE: Be aware that the software and data files are
updated periodically. Check with the local Komatsu
distributor for the latest software versions.
3
Interface module checkout procedures 5. Park Brake Request (IM3-V) - Short engine oil
pressure switch wire circuit 36 on TB28-A to
Initial startup ground. Move lever from NEUTRAL to PARK
NOTE: The interface module must be powered up to and confirm state change (1 to 0). Remove
communicate with the service computer. ground from TB28-A.
6. GE Batt + (IM3-M) - Confirm that state is 1.
1. Turn the key switch to the ON position but do
not start the engine. 7. Starter Motor 1 Energized (IM3-R) -
Disconnect wire 11SM1 from cranking motor to
2. Connect the RS232 serial cable from the serial TB28-F at TB28-F. Momentarily short TB28-F to
port on the service computer to the IM 24V and confirm state change (0 to 1).
Diagnostic connector in the cab or auxiliary Reconnect wire.
control cabinet.
8. Starter Motor 2 Energized (IM3-S) -
3. Double click the shortcut to IM Realtime Monitor Disconnect wire 11SM2 from cranking motor to
on the desktop of the service computer. TB28-G at TB28-G. Momentarily short TB28-G
to 24V and confirm state change (0 to 1).
4. On the menu, click on Select Serial Port to
Reconnect wire.
select the serial port that is being used. Then
click on Start/Stop to view the data. 9. Crank Sense (IM3-U) - Open starter disconnect
switch so that there is no battery voltage to the
5. Confirm that there are no fault codes associated starters. Momentarily short TB28-J to 24V and
with the interface module. If any faults are confirm state change (0 to 1). After removing
found, these circuits must be analyzed to 24V short from TB28-J, close starter disconnect
determine the cause of the fault. Repair the switch.
circuits or, if required, replace the interface
module. 10. Selector Switch [Park] (IM3-T) - Move lever to
PARK and confirm state (1), then move lever to
NEUTRAL and confirm state (0). Return lever to
PARK.
Checking digital inputs to the IM
11. Selector Switch [FNR] (IM2-N) - Move lever to
Use the IM Realtime Data Monitor software to PARK and confirm state (0), then move lever to
confirm the functionality of all IM inputs. The key NEUTRAL, FORWARD and REVERSE.
switch must be ON for all checks. Confirm state (1) for each position. Return lever
1. Hydraulic Tank Level (IM2-k) - Disconnect to PARK.
connector CN712 at hydraulic tank level sensor. 12. Steering Bleed Pressure Switch (IM2-Z) -
Short pin C to ground momentarily and confirm Disconnect connector SABS at the steering
state change (1 to 0). Reconnect CN712. bleed pressure switch and confirm state change
2. Low Steering Precharge (IM2-W) - This step (0 to 1). Reconnect switch.
requires properly precharged steering 13. Brake Lock Switch Power Supply (IM3-L) -
accumulators. Disconnect one of the low Ensure that lever is in PARK. Use GE WebPTU
accumulator precharge switches momentarily software to turn on FWD True output signal.
and confirm state change (0 to 1). Reconnect Confirm state change (0 to 1). Leave GE FWD
switch. True signal on until completion of step 20.
3. Pump Filter Switches (IM2-Y) - Disconnect
14. Brake Lock (IM2-i) - Actuate brake lock switch
connector CN730 at steering filter pressure
and confirm state change (0 to 1). Turn off GE
switch momentarily and confirm state change (0
FWD True signal. Confirm input state remains at
to 1). Reconnect CN730.
1. Turn off brake lock switch. Confirm input state
4. Park Brake Released (IM2-M) - Short wire returns to 0. (The Brake Lock Switch Power
73S1 to ground at TB32-M momentarily and Supply test, item 13, must be completed before
confirm state change (1 to 0). this test can be successfully completed.) Turn
off GE FWD True signal.
4
15. Service Brake Set Switch (IM3-C) - Short wire 28. Brake Accumulator Pressure switch (IM2-U) -
44R at TB35-F to 24 volts momentarily and Short wire 33BP to ground at TB32-E
confirm state change (0 to 1). momentarily and confirm state change (1 to 0).
16. Engine Shutdown Delay (IM3-F) - Disconnect 29. Brake Lock Degradation Switch (IM2-V) -
wire 21NSL from the engine ECM at TB27-E. Short wire 33T to ground at TB32-F
Leave wire 21NSL to IM connected at TB27-E. momentarily and confirm state change (1 to 0).
Momentarily short TB27-E to 24V and confirm
30. Key Switch Direct (IM2-P) - Confirm that state
state change (0 to 1). Reconnect wire.
is 1. Turn key switch OFF for one second, then
17. Secondary Engine Shutdown Switch (IM3-E) back ON. Confirm state changes to 0, then back
- Actuate secondary engine shutdown switch to 1.
and confirm state change (1 to 0).
31. Auto Lube Level (IM3-W) - Disconnect
18. Key switch (IM3-G) - Confirm that state is 1. connector CN511 at auto lube low level switch.
19. Mode Switch 1 (IM3-H) - Actuate "left arrow” Short pin C to ground momentarily and confirm
LCD screen navigation switch and confirm state state change (1 to 0). Reconnect connector
change (1 to 0). CN511.
20. Mode Switch 2 (IM3-J) - Actuate "OK” LCD 32. Auto Lube Pressure Switch (IM3-Y) - Short
screen navigation switch and confirm state wire 68P to ground at rear axle auto lube
change (1 to 0). pressure switch connector momentarily and
confirm state change (1 to 0).
21. Mode Switch 3 (IM3-K) - Actuate "down arrow”
LCD screen navigation switch and confirm state 33. Body Up Switch (IM2-R) - If dump body is not
change (1 to 0). installed, place a washer on body proximity
sensor, confirm state change, then remove
22. Mode Switch 4 (IM2-q) - Actuate "up arrow” washer and confirm state change again.
LCD screen navigation switch and confirm state
change (1 to 0). If dump body is installed, ensure that dump
body is lowered all the way to the frame.
23. Crank Request (IM2-j) - Open starter Disconnect wire 71F at TB35-S and confirm
disconnect switch so that there is no battery state change (1 to 0). Reconnect wire 71F.
voltage to the starters. Momentarily turn key
switch to the START position and confirm state 34. Dynamic Retard (IM3-Z) - Momentarily short
change (0 to 1). wire 74ZA to ground at TB21-D and confirm
state change (1 to 0).
24. Park Brake Set (IM2-f) - Momentarily
disconnect park brake pressure switch 35. No Propel/Retard (GE CPU Running) (IM2-n) -
(identified by circuit 33) and confirm state Confirm that state is 0. Turn keyswitch OFF and
change (0 to 1). confirm that state changes to 1. Turn keyswitch
back ON and confirm that state changes to 0
25. Seat Belt Switch (IM2-g) - Buckle seat belt, once VID panel is booted back up (may take up
then unbuckle seat belt and confirm state to 45 seconds).
change (0 to 1).
36. Engine Air Filter (IM2-X) - Disconnect air
26. Snapshot In-Progress (IM2-L) - Actuate data restriction switch 2 (located on top of engine air
store switch. Confirm state change (1 to 0). intake pipe) and confirm state change (0 to 1).
27. Low Steering Pressure Switch 1 (IM2-S) - Use Reconnect switch.
back probe to short wire 33F to ground at 37. Shifter Fault (IM2-m) - Disconnect wire 72IM
connector CN14, pin 6 momentarily and confirm from TB26-C and confirm state change (0 to 1).
state change (1 to 0). Remove back probe. Reconnect wire 72IM.
5
Checking analog inputs to the IM 9. Right Front Brake Oil Temp [°C] (IM3-r) -
Disconnect right front brake oil temperature
Use the IM Realtime Data Monitor software to
sensor and confirm fault A169, Hydraulic Oil
confirm that the analog inputs are in the correct range
Temp - Right Front Sensor Low, is active.
of values. The key switch must be ON for all checks.
Reconnect sensor.
1. Truck Speed [kph] (IM1-g,h) - Use the VID
10. Left Front Brake Oil Temp [°C] (IM3-t) -
panel to simulate vehicle speed. Confirm that
Disconnect left front brake oil temperature
reported speed matches vehicle speed set
using VID panel +/- 2 kph.
Temp - Left Front Sensor Low, is active.
2. Steering Pressure [kPa] (IM3-d) - Disconnect Reconnect sensor.
steering pressure sensor (identified by circuit
33SP) and confirm that fault A204, Steering 11. Hoist Pressure 2 [kPa] (IM3-q) - Short wire
Pressure Sensor Low, is active. Reconnect 33HP2 to ground at TB28-K momentarily.
sensor. Confirm fault A203, Hoist Pressure 2 Sensor
Low, is active.
3. Ambient Air Temp [°C] (IM3-e) - Confirm that
reported temperature matches ambient 12. Hoist Pressure 1 [kPa] (IM3-s) - Short wire
temperature within 3 °C. 33HP1 to ground at TB30-N momentarily.
4. Fuel Level [%] (IM3-g) - Confirm that reported Confirm fault A202, Hoist Pressure 1 Sensor
level matches actual fuel level in tank +/- 5%. Low, is active.
5. 12V Converter [V] (IM3-h) - Confirm reported 13. Battery Voltage 24V [V] (IMint) - Confirm that
voltage is 13.5V +/- 0.5V. (24V battery voltage reported voltage is +/- 1 volt of actual measured
must be greater than 18 volts.) battery voltage.
6. Brake Pressure [kPa] (IM3-p) - Disconnect
service brake pressure sensor located in brake
cabinet (identified by circuit 33BPS) and confirm Checking serial communication to the IM
that fault A205, Brake Pressure Sensor Low, is Proper operation of the serial communication
active. Reconnect sensor. interfaces to the interface module is assured if faults
7. Right Rear Brake Oil Temp [°C] (IM3-m) - A184, A233, A237 and A257 are not active.
Disconnect right rear brake oil temperature
Temp - Right Rear Sensor Low, is active.
Reconnect sensor.
8. Left Rear Brake Oil Temp [°C] (IM3-i) -
Disconnect left rear brake oil temperature
Temp - Left Rear Sensor Low, is active.
Reconnect sensor.
6
Checking outputs from the IM 3. IM On Signal (IM1-K) - Turn key switch ON and
confirm voltage on circuit 11ONS at TB35-T is
NOTE: Before performing the next steps, the key
approximately 0 volts.
switch must be turned off for at least seven minutes
to allow the IM to completely shutdown. Confirm that 4. Red Warn (IM1-G), Sonalert (IM1-M) -
the IM has shutdown by verifying that the green LED Disconnect the IM from the CAN/RPC network
on the IM controller has stopped flashing. While by unplugging its T-connection to the network.
performing the following IM output checks, ensure Confirm the following on the dash panel:
that no output short circuit fault codes are reported by a. All status panel indicators flash on/off.
the IM Realtime Data Monitor software.
b. The red warning indicator flashes on/off.
1. Park Brake Solenoid (IM1-E), Brake Auto
Apply (IM1-R) - Short engine oil pressure c. Two separate audible alarms can be heard
switch wire circuit 36 to ground on TB28-A. Turn sounding on/off.
key switch ON and move lever to NEUTRAL. d. A loss of communications message is
Confirm that park brake solenoid is energized displayed on the speedometer.
by verifying that coil is magnetized. Use VID
e. The needles in all of the gauges are moving
panel to set truck speed above 1 kph. Move
through their entire range of motion.
lever to PARK. Confirm that park brake solenoid
remains energized. Reconnect the IM to the CAN/RPC network.
Reduce truck speed to 0 kph. Confirm that 5. Steering Bleeddown Solenoid (IM1-P) -
brake lock solenoid energizes, then park brake Confirm steering bleeddown solenoid is de-
solenoid de-energizes after one second, then energized. Turn key switch OFF and confirm
brake lock solenoid de-energizes after half a that steering bleeddown solenoid is energized
second. Remove ground from TB28-A. by verifying that coil is magnetized.
2. Start Enable (IM1-B) - Disconnect all circuit
21PL wires from prelube timer. Move lever to
PARK and confirm that circuit 21PS on TB28-H
is 24 volts while cranking. Move lever to
NEUTRAL and confirm that circuit 21PS on
TB28-H is 0 volts while cranking. Reconnect all
circuit 21PL wires to prelube timer.
7
IM checkout sheet
TABLE 1. INTERFACE MODULE (IM) CHECKOUT SHEET
Expected Result
Result (OK/Fail)
DIGITAL INPUT CHECKS
1 - Hydraulic Tank Level 1 to 0
2 - Low Steering Precharge 0 to 1
3 - Pump Filter Switches 1 to 0
4 - Park Brake Released 1 to 0
5 - Park Brake Request 1 to 0
6 - GE Batt + 1
7 - Starter Motor 1 Energized 0 to 1
8 - Starter Motor 2 Energized 0 to 1
9 - Crank Sense 0 to 1
10 - Selector Switch [PARK] 1 to 0
11 - Selector Switch [FNR] PARK=0
F/N/R=1
12 - Steering Bleed Pressure 0 to 1
13 - Brake Lock Switch Power 0 to 1

Supply
14 - Brake Lock 0 to 1
15 - Service Brake Set 0 to 1
16 - Engine Shutdown Delay 0 to 1
17 - Secondary Engine Shutdown 1 to 0
18 - Keyswitch 1
19 - Mode Switch 1 1 to 0
23 - Crank Request 0 to 1
24 - Park Brake Set 0 to 1
25 - Seat Belt Switch 0 to 1
8
TABLE 1. (Continued)INTERFACE MODULE (IM) CHECKOUT SHEET
Expected Result
Result (OK/Fail)
26 - Snapshot In-Progress 1 to 0
27 - Low Steering Pressure Switch 1 to 0
28 - Brake Accum Pressure Switch 1 to 0
29 - Brake Lock Degradation Switch 1 to 0
30 - Keyswitch Direct 1 to 0 to 1
31 - Auto Lube Level Switch 1 to 0
32 - Auto Lube Pressure Switch 1 to 0
33 - Body Up Switch without body =

0 to 1 to 0
with body =
1 to 0
34 - Dynamic Retard 1 to 0
35 - No Propel/Retard 0 to 1 to 0
(GE CPU Running)
36 - Engine Air Filter 0 to 1
37 - Shifter Fault 0 to 1
ANALOG INPUT CHECKS
1 - Truck Speed set speed

+/- 2 kph
2 - Steering Pressure fault A204
3 - Ambient Air Temp ambient temp

+/- 3°C
4 - Fuel Level tank level

+/- 5%
5 - Converter Voltage (12V) 13.5 +/- 0.5V
6 - Brake Pressure fault A205
7 - Right Rear Brake Oil Temp fault A167
8 - Left Rear Brake Oil Temp fault A166
9 - Right Front Brake Oil Temp fault A169
10 - Left Front Brake Oil Temp fault A168
9
TABLE 1. (Continued)INTERFACE MODULE (IM) CHECKOUT SHEET
Expected Result
Result (OK/Fail)
11 - Hoist Pressure 2 fault A203
12 - Hoist Pressure 1 fault A202
13 - Battery Voltage 24V measured

battery voltage
+/- 1V
SERIAL COMMUNICATION INTERFACE CHECKS
CAN/J1939 no faults
Drive System CAN/RPC A184, A233,
Display CAN/RPC A237, A257
Payload CAN/RPC
OUTPUT CHECKS
1a - Park Brake Solenoid energized/

de-energized
1b - Brake Lock Solenoid energized/

de-energized
in park brake
setting
sequence
2 - Start Enable 24 V, 0 V
3 - IM On Signal 0V
4 - Dash Panel/Sonalarm items function

as described
5 - Steering Bleed Solenoid de-energized/

energized
IM Software Version: _____________________
Truck S/N: _____________________
Completed By: ______________________________________________
Date: _____________________
10
NOTES
11
980E Dump truck

12
CEN30091-00
830E
930E
980E

830E-5 A50005 and up
930E-5 A40004 and up
980E-5 A50005 and up

KOMTRAX Plus II
Ethernet connection to KOMTRAX Plus II controller ............................................................................................ 3
KOMTRAX Plus II configuration............................................................................................................................ 5
GPS connection test ............................................................................................................................................. 7
Iridium satellite system opening............................................................................................................................ 9
Data download over ethernet connection for KOMTRAX Plus II initialization ......................................................11
1
NOTES
2
Required software and tools Ethernet connection to KOMTRAX Plus II

Several software programs and tools are required for
controller
KOMTRAX Plus II setup procedures. The following procedure must be completed each
time the KOMTRAX Plus PC Tool software is used to
setup, administrate, or download a KOMTRAX Plus II
controller.
(XP or later)
• Ethernet cable 1. Open the Network and Sharing center, disable
windows firewall or have add a permanent
• KOMTRAX Plus PC Tool software exception for all KOMTRAX Plus II PC Tool
• If Windows® XP or Vista is being used, .Net software.
Framework software must also be installed in 2. Disconnect the service computer from all other
order to use KOMTRAX Plus PC Tool software. network connections including Wi-Fi.
3. Turn the keyswitch ON. Wait approximately
NOTE: Be aware that the software and data files are three minutes for the KOMTRAX Plus II
updated periodically. Check with the local Komatsu controller to boot.
distributor for the latest software versions. 4. Connect one end of the ethernet cable to the
service computer and the other to the PC
Ethernet port located on the back wall of the
If the truck is equipped with the Komatsu Wireless cab.
Bridge (KWB) for wireless connectivity rather than
the Iridium satellite system, refer to Testing and KOMTRAX Plus II uses DHCP so the service
adjusting section Komatsu Wireless Bridge (KWB). computer is automatically assigned an IP
Prior steps are a prerequisite to wireless setup. address.
86947
FIGURE 30-1. NETWORK AND SHARING CENTER
3
5. Optional: Open a command prompt to ping If the ping is unsuccessful, troubleshoot the
192.168.3.20. A successful ping verifies that the ethernet connection.
service computer can communicate with the
KOMTRAX Plus II controller. Continue with the
setup or administration.
86948
FIGURE 30-2. COMMAND PROMPT
4
KOMTRAX Plus II configuration 4. Click KOMTRAX Plus Configuration on the

Destination Configuration menu.
The following procedure must be completed when
the truck is checked out at the mine site. The purpose
is to populate site specific information.
1. Turn the keyswitch ON. Wait approximately
three minutes for the KOMTRAX Plus II
controller to boot.
2. Open the KOMTRAX Plus Initial Configuration
Tool.
3. Click Destination Configuration on the main
menu.
86950
FIGURE 30-4. DESTINATION CONFIGURATION

MENU
5. After clicking KOMTRAX Plus Configuration, a

dialog box will open as the tool searches for
KOMTRAX Plus controllers on the local area
network. When complete, the available
86949
controllers will be shown.
FIGURE 30-3. MAIN MENU
86951
FIGURE 30-5. SCANNING KOMTRAX PLUS

CONTROLLERS DIALOG BOX
5
6. Double click the target controller. The 8. Select the Unit Number tab and enter the
KOMTRAX Plus configuration page will open. If truck’s unit number. (This is the customer
no controller is found, refer to the topic assigned designation for the truck.)
"Ethernet connection to KOMTRAX Plus II
controller".
86954
FIGURE 30-8. UNIT NUMBER TAB

86952
FIGURE 30-6. DISCOVERED KOMTRAX PLUS

CONTROLLERS WINDOW
9. Click Apply. A status window will be displayed.
Changes will take approximately three minutes.
7. Select the Calendar tab.
a. Set the time zone.
b. Select the Daylight Saving Time check box
if currently being observed.
86955
FIGURE 30-9. KOMTRAX PLUS CONFIGURATION

STATUS WINDOW
86953
FIGURE 30-7. CALENDAR TAB
6
10. Click Next to review the changes. GPS connection test

11. Click Back to complete mine site portion of the The following procedure must be completed outside
initial configuration. with an unobstructed view of the sky. The purpose is
to verify that the GPS system is functioning properly.
1. Park the truck away from buildings and any
objects that obstruct a clear view of the sky.
Turn the keyswitch ON. Wait approximately five
minutes for the KOMTRAX Plus II system to
acquire signals from the GPS satellites.
2. Establish an ethernet connection between the
service computer and the KOMTRAX Plus II
controller.
Tool.
menu.
86956
FIGURE 30-10. CONFIGURATION WINDOW
86949
7
5. Click GPS Test on the Destination 7. Double click the target controller. The GPS test
Configuration menu. screen will open. If no controller is found, refer
to the topic "Ethernet connection to KOMTRAX
Plus II controller".
86950
86952
MENU FIGURE 30-14. DISCOVERED KOMTRAX PLUS
CONTROLLERS WINDOW
6. After clicking GPS Test, a dialog box will open

as the tool searches for KOMTRAX Plus II
controllers on the local area network. When
complete, the available controllers will be
shown.
86951
FIGURE 30-13. SCANNING KOMTRAX PLUS

CONTROLLERS DIALOG BOX
8
8. The window below is an example of Iridium satellite system opening

successfully receiving a GPS signal.
The following procedure must be completed outside
with an unobstructed view of the sky. The purpose is
to verify that the Iridium system is functioning
properly and to establish communication.
NOTE: Do not perform this procedure if the truck is
not equipped with the Iridium satellite system.
1. Verify that an Iridium modem is installed.
2. Park the truck away from buildings and any
objects that obstruct a clear view of the sky.
Turn the keyswitch ON. Wait approximately five
minutes for the KOMTRAX Plus II system to
acquire signals from the GPS satellites and the
Iridium satellites.
controller.
86957 Tool.
FIGURE 30-15. GPS INFORMATION WINDOW -
SUCCESSFUL
menu.
The window below is an example of a failed

attempt at receiving a GPS signal.
In the event of a failure, click Back, check the
connections and the antenna, then retest. If
successful, click Back to complete the test.
86949
86958
FIGURE 30-16. GPS INFORMATION WINDOW -

FAILED
9
6. Click KOMTRAX Configuration on the 9. A status window will appear. It may take 5 to 10
Destination Configuration menu. minutes to complete. Any failure must be
investigated and corrected before proceeding to
the next step.
86950

MENU 86960
FIGURE 30-20. OPENING INSPECTION STATUS

WINDOW
7. Select the Opening tab.

8. Verify that the with KOMTRAX Modem radio 10. Click OK. Return to the Opening tab. Click Start
button is selected, then click Start. for the opening procedure.
86959 86961
FIGURE 30-19. OPENING TAB FIGURE 30-21. OPENING TAB
10
11. The Datum and Time Zone menu will appear. Data download over ethernet connection
Make changes if needed, then click Start. for KOMTRAX Plus II initialization
Downloading data from the KOMTRAX Plus II
controller immediately after setup can help identify
configuration problems and is required for
initialization.
controller.
2. Open the Data Collection Tool.
The software will automatically download the
data if more than 12 hours has passed since the
previous download. Click the Download button
to force a download if necessary.
3. Click View Files for a link to the location where
the downloaded data is stored.
86962
FIGURE 30-22. DATUM AND TIME ZONE MENU
12. A status window will appear. Click OK to

complete the Iridium satellite system setup.
86963
FIGURE 30-23. KOMTRAX OPENING STATUS

WINDOW
11
4. Open the Data Conversion Tool. 6. Select binary files from the target machine.
They will have the *.K extension.
5. Select the folder that contains data from the
download tool. The "Plus_Binary" folder 7. Click Convert. A success dialog box will
contains the files to be converted. appear. Click OK.
86964
FIGURE 30-24. SELECT BINARY FILES
12
8. Click View Files. Data is organized by truck 10. Send the binary file (*.K) from step 6 to
model, truck serial number and date. komtrax@komatsuna.com to complete the
KOMTRAX Plus II initialization process.
9. After conversion, the files are ready for analysis.
Use the files in the "Rate_Calendar_Alignment"
folder for human readable date and time
stamps.
86965
FIGURE 30-25. CONVERTED BINARY FILES
13
830E Dump truck

930E Dump truck
980E Dump truck
14
CEN30070-01
730E
830E
930E
980E
730E-8 A40015 and up
830E-5 A50005 and up
930E-5 A40004 and up
980E-4 A40003 and up
980E-4AT A40083 and up
980E-5 A50005 and up

Payload meter IV
Payload meter IV software and tools .................................................................................................................... 2
Payload meter IV system configuration ................................................................................................................ 2
Payload meter IV software installation .................................................................................................................. 4
Payload meter IV checkout procedure.................................................................................................................. 5
PLM IV system checkout data sheet..................................................................................................................... 9
1
Payload meter IV software and tools Payload meter IV system configuration

Several software programs and tools are required for Connecting to the payload meter IV web server
Payload Meter IV (PLM IV) setup and checkout
procedures. The PLM IV web server allows users to download
data and configure the payload meter system. PLM
• PLM IV application code IV can be connected to a service PC via a Cat5e
• Service PC with Windows® operating system cable connection from RJ45 ethernet port (3,
(200 MHz processor, 64 MB RAM minimum) Figure 30-1) on the payload meter communication
board, or it can be connected to a wireless radio on
• Cat5e ethernet cable the truck if a wireless connection is desired.
• USB drive with 1 - 4GB of memory
Once connected, use a web browser such as Internet
• Four 3 kohm, 1W resistors (58B-06-03100) Explorer® or Google Chrome™ to access the web
• Voltmeter server.
NOTE: Be aware that the software and data files are NOTE: The service PC static IP address must be
updated periodically. Download the latest versions configured within the same network range as the
from the Komatsu extranet at: payload meter.
https://www.komatsuamerica.net/northamerica Configuring a static IP address

For a wired or wireless connection, a static IP
address of the service PC is required to allow
connectivity. Refer to Figure 30-2.
1. Right click on the Wired Connection icon in the
bottom right corner of the window.
2. Click on “Open Network and Sharing Center.”
3. In the Network and Sharing Center window,
click on “Change adapter settings” on the left
hand bar.
4. Right click on the computer's Wired Connection
Device. If using wireless access, right click on
the Wireless Connection Device.
5. Click on "Properties".
6. Click on "Internet Protocol Version 4 (TCP/
IPv4)" to highlight the option.
7. Click on "Properties."
8. Select "Use the following IP address:".
9. Fill in the following IP Settings:
• Set the service PC’s IP address within the same
IP address range of the PLM IV controller. The
default factory programmed static IP address of
the PLM IV controller is 192.168.3.128.
For example, set the IP address of the service

PC to 192.168.3.123. The last three numbers
can be any number between 1 and 254 except
for 128 since that number is already assigned to
FIGURE 30-1. PLM IV CONTROLLER the PLM IV controller.
1. USB 2.0 Ports 3. RJ45 Ethernet Port • Subnet Mask: 255.255.255.0
2. Status Window 10. Click "OK."
11. Click "OK."
2
NOTE: To return the service PC’s network card to

normal operation, follow steps 1 - 7, but in step 8
select “Obtain an IP address automatically.”
FIGURE 30-2. PLM IV STATIC IP ADDRESS CONFIGURATION
3
Payload meter IV software installation

1. Insert a blank USB drive into the service PC.
Format the USB drive to FAT32 by right-clicking
on the correct drive letter and selecting
"Format".
2. Copy the truck application software to the USB
drive.
3. Remove the USB drive, then insert the USB
drive into either USB 2.0 port (1, Figure 30-1) on
the PLM IV controller.
4. Turn the truck’s engine start switch to ON.
5. Ensure that the service PC is set up to
communicate with the PLM IV controller. If not,
refer to "Payload meter IV system
configuration".
6. On the home page, click on the "Program Flash"
link. See Figure 30-3.
7. On the next web page, click on "Program Now"
to begin installing the truck application code.
This may take 20-25 minutes to complete. Do
not turn off 24V truck power during this
process.
The completion percentage will be shown and FIGURE 30-3. PLM IV HOME PAGE
periodically updated on the web page as the
installation progresses.
8. When the "Reboot PLM IV" message appears,
turn the engine start switch to OFF, wait for ten
seconds, then turn the switch ON again. The
software installation is complete.
4
Payload meter IV checkout procedure 7. Log on to the PLM IV home page. Refer to
1. Ensure that the PLM IV software is up-to-date. Figure 30-3.
2. Install one resistor (58B-06-03100) in place of NOTE: After turning the engine start switch to ON,
each of the suspension pressure sensors. The wait for five minutes before connecting to the PLM IV
resistors will provide a test load between circuit dynamic web browser.
39F and each of the sensor circuits 39FA, 39FB, 8. Click on the "System Configurations" link. There
39FC and 39FD. are eight parameters that can be set from this
3. In the auxiliary control cabinet, use a voltmeter web page. There is no need to reboot the
to check the PLM IV controller input voltage payload meter after updating any of these
between circuit 39G and 0 (ground). This should parameters. Refer to Figure 30-5.
be 24VDC supplied by the batteries. NOTE: Some of the parameters require a password
* Record on Data Sheet to change. The password for all parameters except
4. Turn the engine start switch to ON. the Payload Gain is Kac2300. This password is case
sensitive. The password for the Payload Gain
5. In the auxiliary control cabinet, use a voltmeter parameter is not included in this document.
to check the PLM IV sensor supply voltage
between circuit 39F and 0 (ground). This should • Truck Model: There are many different truck
be 18 ± 1VDC. models available for selection. The correct truck
model must be selected for the payload meter to
* Record on Data Sheet accurately estimate payloads.
6. Use a Cat5e ethernet cable to connect the • PLM IV Mounting Orientation: It is important to
service PC to RJ45 ethernet port (3, Figure 30- configure the payload meter according to its
1) on the PLM IV controller. mounted position in the auxiliary control cabinet.
Refer to Figure 30-4 to identify which wall the
payload meter is mounted on in the auxiliary
control cabinet.
FIGURE 30-4. PLM IV CONTROLLER MOUNTING ORIENTATION

1. Position (1) - Right Tire 3. Position (3) - Truck Forward
2. Position (2) - Truck Rear 4. Position (4) - Left Tire
5
FIGURE 30-5. PLM IV SYSTEM CONFIGURATIONS PAGE
6
• Display Units: This parameter can be set to 11. Return to the PLM IV home page. Click on the
display measurements in metric tons, short tons "Truck Data Configuration" link to set the
or long tons. following parameters:
• Pressure Sensor Units (Real Time Data): • Frame Serial Number: This is located on a
Select kg/cm2 or psi for the values displayed on plate that is mounted to the truck frame. This
the Real Time Data web page only. field will hold up to 20 alpha-numeric characters.
• Date and Time: If the truck is equipped with • Customer Unit: This is number assigned by
KOMTRAX Plus, this parameter of the will be most mining operations to each truck in its fleet.
automatically updated when the truck is This field will hold up to 20 alpha-numeric
powered up. If not, the date and time must be characters.
set. This parameter will be lost after
approximately 30 days without truck power up. • Distributor: This is the name and/or number
assigned to the distributor that installed the
• Payload Load Light Test: Proceed to step 10 payload meter system. This will be used for
to perform this test. warranty claims. This field will hold up to 20
• Payload Gain Factor: The default parameter is alpha-numeric characters.
100%, but it is adjustable between 90% and • Customer: This is the name and/or number
110%. It is recommended that this parameter assigned to the customer or mine site where the
not be changed. A change in this value will truck is in service. This will be used for warranty
affect all payload calculations, which may cause claims. This field will hold up to 20 alpha-
errors. numeric characters.
• Truck Tare Reset: This function forces the Enter the password Kac2300 and click on the
payload meter to reset the truck tare to its "Save Truck Data" button to save these parame-
default value. Do not use this function unless ters. This password is case sensitive.
the payload meter state machine is locked up or
has calculated an unusually low tare value. 12. Check the PLM IV software version on the
Check the system for a Sensor Low Pressure "Truck Data Configuration" page.
alarm. * Record on Data Sheet
10. To test the functionality of the payload meter
lamps and wiring, turn on the brake lock. Click
on the check box next to the light(s) to be
tested. The lights can be set ON/OFF for five
minutes from this web page. After five minutes,
the lights will return to their default states.
Test the following combinations and confirm
proper light function:
• Green ON, Amber OFF, Red OFF
• Green OFF, Amber ON, Red OFF
• Green OFF, Amber OFF, Red ON
• Green OFF, Amber OFF, Red OFF
FIGURE 30-6. TRUCK DATA CONFIGURATION

PAGE
7
13. Return to the PLM IV home page. Click on the

"View Real Time Data" link to check the current
status of various PLM IV inputs and outputs.
a. The sprung weight shown includes the
weight of the truck. With the load provided by
the resistors installed in step 2, the nominal
value should be 113 metric tons (125 short
tons).
b. Confirm that all suspension pressures are
within the acceptable range. The nominal
values should be 25.6 ± 6.4 kg/cm2 (364 ± 91
psi).
* Record on Data Sheet FIGURE 30-7. TRUCK DATA CONFIGURATION
PAGE
c. Check the inclinometer reading. Calibrate if
necessary.
14. Remove the resistor from the left rear
d. To confirm that the body up input is function- suspension pressure sensor. Wait for at least
ing properly, place a steel washer on the one minute.
body up switch. The reading in the Real Time
Data window should be "OFF". When the 15. Remove the resistor from the left rear
washer is removed, the reading should be suspension pressure sensor. Wait for at least
"ON". one minute.
* Record on Data Sheet 16. Remove the resistor from the right rear
suspension pressure sensor. Wait for at least
e. To confirm that the brake lock input is func- one minute.
tioning properly, activate the brake lock
switch. The reading in the Real Time Data 17. Remove the resistor from the right front
window should be "ON". When the switch is suspension pressure sensor. Wait for at least
deactivated, the reading should be "OFF". one minute.
* Record on Data Sheet 18. On the PLM IV home page, click on the "View
alarms" link to view the list of alarms.
f. Ensure that the brake lock is OFF. Use the
VID panel on the rear wall of the operator cab All active alarms will be saved within five sec-
to provide a speed signal of 40 kph (25 mph). onds. Confirm that the four alarms occurred in
Confirm that the speed value is displayed on the order in which the resistors were removed:
the speedometer and on the Real Time Data • Left front suspension low
window.
• Left rear suspension low
• Right rear suspension low
• Right front suspension low
19. Turn the engine start switch to OFF. Close all
windows on the service PC, then disconnect the
service PC from the PLM IV controller.
8
PLM IV system checkout data sheet
Machine Model___________ Unit Number ___________ Serial Number_____________
Step 3 - PLM IV controller input voltage 24VDC? ____________________
Step 5 - Pressure sensor supply voltage 18 ± 1VDC? ____________________
Step 10 - Green light functions properly? ____________________
Amber light functions properly? ____________________
Red light functions properly? ____________________
Step 12 - PLM IV software version ____________________
Step 13b - Left front suspension pressure ____________________
Right front suspension pressure ____________________
Left rear suspension pressure ____________________
Right rear suspension pressure ____________________
Step 13c - Inclinometer reading ____________________
Step 13d - Body up input functions properly? ____________________
Step 13e - Brake lock input functions properly? ____________________
Step 13f - Speed input functions properly? ____________________
Name of Technician or Inspector Performing Checkout: _________________________
Badge number: ________________________
Date & shift completed: __________________
9
730E Dump truck

830E Dump truck
930E Dump truck
980E Dump truck
10
CEN30101-00
830E
930E
980E

830E-5 A50005 and up
930E-5 A40004 and up
980E-5 A50005 and up

Komatsu wireless bridge (KWB)
Configuring the Bullet wireless radio..................................................................................................................... 3
Installing the Bullet wireless radio ......................................................................................................................... 6
Configuring the NanoStation access point ............................................................................................................ 7
Testing the connection ........................................................................................................................................ 10
Changing a service computer’s IP address .........................................................................................................11
1
General information Required software and tools

Komatsu wireless bridge (KWB) is a system that uses Several software programs and tools are required for
commercially available wireless technology to allow KWB setup and checkout procedures.
communication that normally requires a wired
connection and a technician on board the truck.
Communication requires an access point (often (XP or later)
located in a service truck or at the fueling area) and • Bullet Titanium wireless radio (purchased locally)
haul trucks equipped with a Bullet wireless radio. A
service computer with the KOMTRAX Plus PC Tools • NanoStation M2 access point (purchased locally)
software that is connected to the access point can • Two ethernet cables
automatically collect KOMTRAX Plus downloads
when the haul truck comes into range. If setup in a • Latest KWB configuration file
fueling area, downloads can be collected
automatically each time a truck stops for fuel.
NOTE: Trucks are not equipped with wireless radios
The KOMTRAX Plus PC Tools also provide links to or access points from the factory. The wireless radios
devices on the truck’s local area network (LAN), such are governed by regulatory agencies. The only way
as payload meter and the drive system realtime data to ensure that proper approvals are granted is to
screens. Haul cycle records can also be downloaded order locally so that the certifications are applied
from the payload meter website. when imported. Each Bullet wireless radio and
access point must be ordered from a local Ubiquiti
networks distributor.
NOTE: NanoStation M2 devices act as access points
for each network. One NanoStation M2 is required for
each network.
The referenced wireless devices are high power

(1W) RF transmitters in the 2.4GHz band. Before
installing these devices, verify the local
regulatory restrictions regarding the uses of such
devices. Do not use these devices if use is
restricted at your location.
The configuration file contains the settings required

to configure the Bullet wireless radio for
communication with the 0002KPLUS wireless
network. The file is generic so it can be used on each
radio with no specific changes per truck. For
convenience, 002KPLUS is the same wireless
network used by other Tier 4 Komatsu equipment
such as loaders and mechanical drive trucks.
NOTE: Be aware that the KWB configuration files are
updated periodically. Check with the local Komatsu
distributor for the latest version to download to the
service computer.
2
Configuring the Bullet wireless radio 4. Change the service computer’s wired LAN
1. Download the KWB configuration files (.zip file) settings to the following:
and the latest WiFi setup instructions from the IP address: 192.168.1.100
Komatsu extranet to the service computer.
Extract the files onto the service computer. Net mask: 255.255.0.0
2. Connect POE adapter (2, Figure 30-1) to Bullet 5. Open an internet browser (Google Chrome™ is
wireless radio (1) by using a CAT 5E network recommended), type 192.168.1.20 into the
cable. Ensure that the cable is in the POE port address bar, then press the Enter key.
as shown. 6. Proceed to the website regardless of any
3. Connect POE adapter (2) to service computer security messages.
(3) by using another CAT 5E network cable.
Ensure that the cable is in the LAN port as
shown.
1 2 3
86981
FIGURE 30-1. KWB POE ADAPTER CONNECTIONS

1. Bullet Wireless Radio 3. Service Computer
2. Power over Ethernet (POE) Adapter
3
7. Login using the following default settings: 11. Click Change, then click Apply on the blue
ribbon that appears toward the top of the
• Username: ubnt
screen. Record the password in a safe place.
• Password: ubnt
12. Under the Configuration Management
8. Click the SYSTEM tab. See Figure 30-2. heading, click Choose File. Select the Bullet
9. Set the time zone. wireless radio configuration file that was
10. Click the magnifying glass icon next to the downloaded from the extranet.
administrator user name. Enter the default 13. Click Upload, then click Apply on the blue
password and choose a new password. ribbon that appears toward the top of the
screen.
86977
FIGURE 30-2. FIRMWARE UPDATE SCREEN
4
14. Wait approximately 30 seconds, then the click Network Mode: Bridge
MAIN tab. Verify that the information matches
Wireless Mode: Station
the fields in Figure 30-3. If not, a problem has
occurred. Repeat steps 12 and 13. SSID: 0002KPLUS
NOTE: This check only works when the wireless Security: WPA2-AES
radio is not within range of a powered 0002Kplus
access point. If the access point cannot be powered
off, skip step 14.
86978
FIGURE 30-3. STATUS SCREEN
5
Installing the Bullet wireless radio 3. Install rubber washer (4, Figure 30-5) on cable
gland body (3) if not already installed.
Trucks equipped with the KWB have the required
cables and hardware already installed. Mount the 4. Slide compression nut (1) and cable gland body
Bullet wireless radio to the antenna station on the (3) over the ethernet cable. Ensure that the
front handrail on the left side of the truck. parts are correctly oriented.
1. Install Bullet wireless radio (4, Figure 30-4) on 5. Connect the ethernet cable to the Bullet
antenna station (2). wireless radio.
2. Install the bolted half of Hydra-zorb clamp (3) 6. Thread the cable gland body into the Bullet
around the Bullet wireless radio and tighten the wireless radio. Tighten the gland body by hand.
capscrews to standard torque. NOTE: Be careful not to twist the ethernet cable or
connector when installing the cable gland body.
7. Split compression seal (2) at the precut location
1 and slide it over the ethernet cable. Push the
compression seal into the back side of cable
gland body (3).
2
8. Thread compression nut (1) onto the cable
gland body. Tighten the nut to compress the
seal and waterproof the connection.
NOTE: Failure to complete the previous steps
correctly may leave the Bullet wireless radio
unprotected from water ingress, which could result in
failure of the wireless radio.
9. Install KWB antenna (1, Figure 30-4) on top of
3 the Bullet wireless radio.
4
DETAIL A 5
5
A 4
3
2
1
86979 86980
FIGURE 30-4. BULLET WIRELESS RADIO FIGURE 30-5. BULLET WIRELESS RADIO
INSTALLATION INSTALLATION
1. KWB Antenna 4. Bullet Wireless Radio 1. Compression Nut 4. Rubber Washer

2. Antenna Station 5. Ethernet Cable 2. Compression Seal 5. Bullet Wireless Radio
3. Hydra-Zorb Clamp 3. Cable Gland Body
6
Configuring the NanoStation access point 3. Change the service computer’s wired LAN
settings to the following:
NOTE: Each mine site will require at least one
access point because the KWB operates in IP address: 192.168.1.100
infrastructure wireless mode.
Net mask: 255.255.0.0
1. Connect POE adapter (2, Figure 30-1) to 4. Open an internet browser (Google Chrome™ is
NanoStation access point (1) by using a CAT 5E recommended), type 192.168.1.20 into the
network cable. Ensure that the cable is in the address bar, then press the Enter key.
POE port as shown.
5. Proceed to the website regardless of any
2. Connect POE adapter (2) to service computer security messages.
(3) by using another CAT 5E network cable.
Ensure that the cable is in the LAN port as
shown.
1 2 3
86982
FIGURE 30-6. KWB POE ADAPTER CONNECTIONS

1. NanoStation Access Point 3. Service Computer
2. Power over Ethernet (POE) Adapter
7
6. Login using the following default settings: 10. Click Change, then click Apply on the blue
ribbon that appears toward the top of the
• Username: ubnt
screen. Record the password in a safe place.
• Password: ubnt
11. Under the Configuration Management
7. Click the SYSTEM tab. See Figure 30-2. heading, click Choose File. Select the
8. Set the time zone. NanoStation access point configuration file that
9. Click the magnifying glass icon next to the was downloaded from the extranet.
administrator user name. Enter the default 12. Click Upload, then click Apply on the blue
password and choose a new password. ribbon that appears toward the top of the
screen.
86977
FIGURE 30-7. FIRMWARE UPDATE SCREEN
8
13. Wait approximately 30 seconds, then the click Network Mode: Router
MAIN tab. Verify that the information matches
Wireless Mode: Access Point
the fields in Figure 30-3. If not, a problem has
occurred. Repeat steps 11 and 12. SSID: 0002KPLUS
NOTE: This check only works when the wireless Security: WPA2-AES
radio is not within range of a powered 0002Kplus
access point. If the access point cannot be powered
off, skip step 14.
86983
FIGURE 30-8. STATUS SCREEN
9
Testing the connection 4. Click on a truck to see links to the devices

1. Power up the NanoStation access point. connected to the onboard local area network
Connect the service computer to the (LAN).
0002KPLUS wireless network.
2. Ensure that a haul truck equipped with KWB
and KOMTRAX Plus II is nearby. Open the Data
Collection PC Tool.
The Data Collection PC Tool will automatically
discover the truck and download data if more
than 12 hours has passed since the previous
download. Clicking on Download will force a
download immediately.
3. Open the Komtrax Plus Discovery Tool. All
trucks within wireless range will be displayed in
the Discovered Komtrax Plus Machines
window.
86985
FIGURE 30-10. KOMTRAX PLUS DISCOVERY

TOOL WINDOW
86984
FIGURE 30-9. KOMTRAX PLUS DISCOVERY

TOOL WINDOW
10
Changing a service computer’s IP address 4. For automatic IP settings, go to the General tab
(see Figure 30-12):
NOTE: The following instructions are for the
Microsoft® Windows 7® operating system. a. Select the Obtain an IP address
automatically radio button.
1. Click Start > Control Panel. Open the Network
and Sharing Center. b. Select the Obtain DNS server address
automatically radio button.
• If settings are displayed by icons, click “Network
and Sharing Center”. c. Click the "OK" button.
• If settings are displayed by category, click “View d. Click the "OK/Close" button.
network status and tasks”.
2. Click “Change Adapter settings” in the left hand

pane. Right click on the adapter that needs to
be configured, then click “Properties”.
• For WIRELESS connections, use "Wireless
Network Connection".
• For WIRED LAN connections, use "Local Area
Connection".
3. Select “Internet Protocol Version 4 (TCP/IPV4)”.

Click “Properties”. See Figure 30-11.
FIGURE 30-12. AUTOMATIC IP ADDRESS

CONFIGURATION SCREEN
86349
FIGURE 30-11. CONNECTION PROPERTIES

SCREEN
11
830E Dump truck

930E Dump truck
980E Dump truck
12
CEN30105-00
830E
930E
980E

830E-5 A50005 and up
930E-5 A40004 and up
980E-5 A50005 and up

KomVision
Requirements........................................................................................................................................................ 2
Initial setup............................................................................................................................................................ 2
KomVision checkout data sheet............................................................................................................................ 9
Calibration sheets ............................................................................................................................................... 14
Camera calibration procedures........................................................................................................................... 21
Radar setting procedure ..................................................................................................................................... 31
1
Requirements The truck must be empty, operable and located in a

level area with adequate space for Forward and
The testing and adjusting procedures that are
Reverse movements of up to 16 kph (10 mph).
required depends upon the situation. Refer to Table 1
to determine the necessary testing and adjusting The calibration sheet layout uses approximately 18 x
procedures for each situation. 25 m (59 X 82 ft) of area with the truck in the interior
of the area. If the calibration sheet is required, the
recommended area is approximately 30 x 35 m (98 X
115 ft).
Table 1: TESTING AND ADJUSTING REQUIREMENTS

Main 6 Camera 1 Camera Radar
Situation
Settings Calibration Calibration Setting
System installation (initial setup) • • •
Controllers are exchanged • • •
After pushing and initializing DEFAULT on a • • •
maintenance screen
Vehicle dimensions are changed by •
attachment exchange
Cameras are exchanged • •
Camera mount is fixed or exchanged • •
Radars are exchanged •
Radar mount is fixed or exchanged •
Initial setup
NOTE: A data sheet is included in this section to
record the setup information obtained during the
initial setup procedure. The data sheet is designed to
be copied and used during the checkout procedure.
1. Turn the key switch to the RUN position, but do
not start the engine at this time. Verify that the
KomVision screen displays the logo
immediately (see Figure 30-1).
2. System boot up should occur quickly. Record
the number of seconds it takes the screen to
change from the logo screen to the system 87529
running screen. The green standby indicator FIGURE 30-1. STARUP LOGO SCREEN
should also be blinking.
NOTE: The illumination of the green standby
indicator is dim and may be difficult to see when
bright ambient conditions exist. Use a hand to shade
the indicator if needed.
2
3. Enable the maintenance mode by pushing the

following three buttons simultaneously for three
seconds (see Figure 30-2):
Monitor Display Mode button

Guide Line Display button
Lower Body Display button
4. The password entry screen will be displayed.

Enter 6 4 9 1 to gain entry to the maintenance
mode (see Figure 30-3).
• Use the up arrow to increase the number.
• Use the down arrow to decrease the number.
• Use the diagonal down right arrow to tab to 87530
the next field.
• Use the alarm cancel button to finalize the FIGURE 30-2. ENTERING MAINTENANCE MODE
selected numbers (to click the OK button on
the screen).
87531
FIGURE 30-3. PASSWORD SCREEN
3
5. The program software part number and the 6. Use the diagonal down right arrow to tab the red
application version number appear at the top of highlight box to the MAIN SETTING button on
the main menu (see Figure 30-4). the screen, then press the alarm cancel button.
* Record on Data Sheet This will enable the main setting input screen.
87532
FIGURE 30-4. MAIN MENU SCREEN
4
7. Set the truck type to the proper Machine Code Default values for the selected truck type will be
(see Figure 30-5). seeded, and some values can be stored, as
a. Use the diagonal down right arrow to move appropriate, for a standard truck after the SAVE
the cursor to each data entry field. button is selected.
b. Press the alarm cancel button to change the Confirm that the correct machine type is stored
data in the selected field. by selecting the BACK button, which returns to
the Main Menu screen. Select the MAIN
c. Use the up arrow and down arrow to move SETTING button again and confirm that the
the cursor selection within each field’s drop- machine code matches the desired truck type.
down menu.
d. Press the alarm cancel button to finalize the
8. Record the remaining data inputs from the main
data selection.
setting screen.
87533
FIGURE 30-5. MAIN SETTING SCREEN
5
9. Return to the Main Menu, then select the Confirm that the correct values are stored by
CAMERA SETTING button on the screen. The selecting the BACK button, which returns to the
All Camera Position screen will appear (see Main Menu screen. Select the CAMERA
Figure 30-6). Adjust the values, as needed. SETTING button again and confirm the stored
values.
10. Record the values, the select the SAVE button
to store the data.
87534
FIGURE 30-6. CAMERA SETTING SCREEN
11. Return to the Main Menu, then select the 12. Record the values, then select the SAVE button
RADAR SETTING button on the screen. Record to store the data.
the values from each of the three tabs: Area, * Record on Data Sheet
Threshold, All Radar Position (see Figure 30-7
through Figure 30-9). Adjust the values, as Confirm that the correct values are stored by
needed. selecting the BACK button, which returns to the
Main Menu screen. Select the RADAR
SETTING button again and confirm the stored
values.
6
87535
FIGURE 30-7. RADAR SETTING SCREEN - AREA TAB
87536
FIGURE 30-8. RADAR SETTING SCREEN - THRESHOLD TAB
87537
FIGURE 30-9. RADAR SETTING SCREEN - ALL RADAR POSITION TAB
7
13. Perform the camera calibration procedure. This 19. Verify that body rear hide, grid line display, and
requires the calibration sheets to be laid out display mode buttons function properly. Also
accordingly around the machine on level verify that the brightness buttons for the monitor
ground. are functional.
The quickest calibration technique is automatic * Record on Data Sheet
6 camera calibration which, if successful, will 20. Verify that the display changes to the rear
complete automatically in several minutes. camera view when the directional control lever
However, the automatic calibration is very is moved to REVERSE.
sensitive to lighting conditions and
surroundings. This may require that only
manual 6 camera calibration is possible. 21. Place a target in the target zone of the truck.
Verify that the alarm sounds when the target is
Manual calibration may take an hour or more if
found only when the directional control lever is
technicians are not very familiar with the actual
moved to FORWARD or REVERSE. The alarm
key pressing and entry of the calibration screen
should stop when the directional control lever is
points that are outlined the manual calibration
moved to NEUTRAL or PARK.
procedure.
Refer to the topics "Calibration sheets" and
"Camera calibration procedures" for the 22. Operate truck in FORWARD. Verify that standby
necessary information. mode activates at a speed above the preset
forward low-high speed that was recorded in
step 8. (The default speed is 15 kph, but it may
14. After calibration is complete, the runtime screen be set to a different speed.) Also verify that the
should appear without any faults present. screen returns to active mode when nearly
Troubleshoot and correct any faults that exist stopped.
before continuing. * Record on Data Sheet
15. Verify that all buttons are lighted green when not 23. Operate truck in REVERSE. Verify that standby
depressed. mode activates at a speed above the preset
* Record on Data Sheet reverse low-high speed that was recorded in
16. Verify that all buttons are lighted amber when step 8. (The default speed is 15 kph, but it may
depressed. be set to a different speed.) Also verify that the
screen returns to active mode when nearly
* Record on Data Sheet stopped.
17. Verify that the radar is functioning properly by * Record on Data Sheet
having a person walk around the truck on the
inside edge of the calibration tarps 24. Verify that no active faults exist (red icons on the
[approximately 1 m (3 ft) from the truck]. screen or audible alarm sounding). Clear the
fault log.
While the person walks around the truck,
confirm that the located target circle tracks
properly and is consistent with the location of 25. Perform the KomVision start-up inspection.
the person. Also, verify that a smooth transition Refer to the Operation and Maintenance
occurs in the bird’s eye view. Manual for your truck.
* Record on Data Sheet * Record on Data Sheet
18. Verify camera selection by pressing each arrow
key which should, in turn, display the respective
camera for that sector of the truck.
8
KomVision checkout data sheet
Machine Model___________ Unit Number ___________ Serial Number_____________
Step 1 - Screen displays logo immediately? yes no
Step 2 - Standby indicator blinking during boot up? yes no
Number of seconds before logo screen changes to system running screen? _______________
Step 5 - Program part number _______________
Application version number _______________
Step 7 - Machine Code setting _______________
Step 8 - Data inputs:
Offset _______________
Body width _______________
Forward option _______________
Rear wheel to end _______________
Diagonal ladder LH RH
Forward (Low-High) speed _______________
Reverse (Low-High) speed _______________
Hysteresis _______________
Image Magnification - Bird’s Eye View _______________
Radarless option yes no
9
Step 10 - Camera Setting values:
Camera 1 Offset X _______________ Camera 4 Offset X _______________
Camera 1 Offset Y _______________ Camera 4 Offset Y _______________
Camera 1 Offset Z _______________ Camera 4 Offset Z _______________
Camera 1 Roll _______________ Camera 4 Roll _______________
Camera 1 Pitch _______________ Camera 4 Pitch _______________
Camera 1 Yaw _______________ Camera 4 Yaw _______________
10
Step 12 - Radar Setting values:
Area Tab
Outside Front _______________
Outside Side _______________
Threshold Tab
Radar 1 _______________
Radar 2 _______________
Radar 3 _______________
Radar 4 _______________
Radar 5 _______________
Radar 6 _______________
Radar 7 _______________
Radar 8 _______________
All Radar Position Tab
Radar 1 Offset X _______________ Radar 2 Offset X _______________
Radar 1 Offset Y _______________ Radar 2 Offset Y _______________
Radar 1 Offset Z _______________ Radar 2 Offset Z _______________
Radar 1 Roll _______________ Radar 2 Roll _______________
Radar 1 Pitch _______________ Radar 2 Pitch _______________
Radar 1 Yaw _______________ Radar 2 Yaw _______________
11
Step 13 - Auto calibration successful? yes no
Manual calibration successful? yes no N/A
12
Step 15 - Green button lighting when not depressed? yes no
Step 16 - Amber button lighting when depressed? yes no
Step 17 - Radar target follows person correctly? yes no
Smooth transition in bird’s eye view? yes no
Step 18 - Camera selection is functional for all 6 cameras? yes no
If "no", which cameras are malfunctioning? 1 2 3 4 5 6
Step 19 - Display buttons are functioning properly?
Monitor Display Mode button yes no
Guide Line Display button yes no
Lower Body Display button yes no
Bright button yes no
Dim button yes no
Step 20 - Rear camera view in REVERSE? yes no
Step 21 - Alarm sounds when target found in FORWARD or REVERSE? yes no
Alarm stops when in NEUTRAL or PARK? yes no
Step 22 - Speed at which screen enters standby mode in FORWARD _______________
Screen returns to active mode when nearly stopped? yes no
Step 23 - Speed at which screen enters standby mode in REVERSE _______________
Screen returns to active mode when nearly stopped? yes no
Step 24 - Active faults? yes no
Fault log cleared? yes no
Step 25 - Pre-shift inspection completed? yes no
13
Calibration sheets Although a default value is set for each camera

parameter, the actual camera installation position and
Layout and assemblage angle will be in error. Therefore, if a bird's eye view is
For the KomVision® camera system to combine a constructed using the default values, it will create an
bird's eye view from each image of the six cameras, image which has a gap on the boundary between
the installation position and the parameter of an each camera (see Figure 30-11).
angle of each camera are needed. To acquire each
camera parameter, it is necessary to perform the 6
camera calibration, which requires the use of the 1 2
calibration sheets.
85236
FIGURE 30-11. BEFORE AND AFTER CALIBRATION
1. Before Calibration 2. After Calibration
85235 Ensure that the site where calibration will occur is

FIGURE 30-10. TOP CALIBRATION SHEET level, clear of all obstacles, and has a minimum of 30
x 35 m (98 X 115 ft) of space.
Place the calibration sheet bundles in a centralized

location of the calibration site.
14
There are four calibration sheets. Each of the

calibration sheets are defined as follows.
1. Front calibration sheet
2. Right calibration sheet
3. Rear calibration sheet Ensure that the calibration sheets are laid out in
the same position as shown in Figure 30-12 so
4. Left calibration sheet
that the red markers are in the correct locations.
18 m
(19.5 yd)
5m
(5.5 yd)
VEHICLE VEHICLE
LEFT RIGHT
VEHICLE FRONT
15 m
(16.5 yd)
4 2
4m
(4.5 yd)
VEHICLE VEHICLE
FRONT REAR
18 m
(19.5 yd)
5m
(5.5 yd)
VEHICLE VEHICLE
RIGHT LEFT
VEHICLE REAR
85237
FIGURE 30-12. CALIBRATION SHEET DIMENSIONS
15
1
TOP
10 m
(11 yd)
4 2
15 m
(16.5 yd)
3
1m
(1 yd)
1m
(1 yd)
600 mm 600 mm
(24 in) (24 in)
600 mm 600 mm
(24 in) (24 in)
85238
FIGURE 30-13. CALIBRATION SHEET LAYOUT
16
Unfolding a calibration sheet
1 2
3 4
5 6
7 8
9 10
11
85239
17
Folding a calibration sheet
1 2
3 4
5 6
7 8
9 10
85240
18
Placement of calibration sheets The front calibration sheet is constructed so that the
side of the front calibration sheet may pass along “a”
Both ends of the truck’s front lower platform are
and “b”, and the center of the front calibration sheet
defined as base points “a” and “b.” The measured
may be set to “c.”
mid-point of “a” and “b” is “c” (see Figure 30-14).
After the front calibration sheet is in place, use stakes
to secure the four corners to the ground.
a c b
b c a
Base Points
85241
FIGURE 30-14. FRONT CALIBRATION SHEET BASE POINTS
19
The left calibration sheet and the right calibration Temporarily place the rear calibration sheet so that it
sheet are constructed to be perpendicular to the front is adjacent to the back end of left calibration sheet
calibration sheet. and the back end of the right calibration sheet (similar
to the front calibration sheet).
After each calibration sheet is in place, use stakes to
secure the two corners of side which contacts the The central line of truck is measured from the body
front calibration sheet to the ground. frame. The position of the rear calibration sheet must
be adjusted so that the center of rear calibration
sheet is aligned with the central line of truck.
Make adjustments so that the grid lines of the rear
calibration sheet and the grid lines of the left and right
calibration sheets are in alignment. After the
calibration sheets are in place and correctly adjusted,
1
use stakes to secure the remaining corners to the
ground.
2 3
85242
FIGURE 30-15. LEFT AND RIGHT CALIBRATION
SHEET LAYOUT
20
Camera calibration procedures 4. When the "Initial 6 Camera Calibration" screen

is displayed, select AUTOMATIC. A 6 camera
Automatic 6 camera calibration calibration screen will appear.
An automatic 6 camera calibration is completed by
performing an image recognition of the grid line of
each camera image, then extracting the coordinates
of the marker points automatically.
Ensure that the calibration sheets are free from

objects or debris. An object may generate
inaccurate image recognition. Furthermore, an
object may create harsh contrasts that may
disrupt the grid pattern as seen by the cameras
which will generate inaccurate image recognition.
85246
If a harsh contrast cannot be removed, it may be FIGURE 30-17. INITAIL 6 CAMERA CALIBRATION
necessary to carry out the manual 6 camera
calibration.
The detection work of camera markers is done
1. Simultaneously push the Monitor Display Mode by image recognition. When image recognition
Switch, Guide Line Display Switch, and Lower is normal, a “Result Bird's Eye View Dialog”
Body Display Switch for three seconds or more. screen is displayed (see Figure 30-18).
The password screen will appear.
2. Enter a password to move to the maintenance
screen.
3. Select 6 CAMERA CALIBRATION.
85247
FIGURE 30-18. INITAIL 6 CAMERA CALIBRATION
85245
FIGURE 30-16. 6 CAMERA CALIBRATION
21
5. Check the Result Window at the lower right side 6. When attempting manual marker selection,
of the 6 camera calibration screen. there are four markers that must be selected per
camera. Choose each marker manually
• If the Result Window states “Calculation
according to the following steps.
Completed Successfully”, select NEXT in
the “Result Bird's Eye View Dialog” screen a. Determine the position (near a marker) to
and proceed to step 7. select by using the "Whole" picture window
• If the Result Window states “Calculation (2nd Tab area). See Figure 30-21.
Completed, But Large Error - x.x pixels”, b. After determining the position, move the
select MANUAL in the “Result Bird's Eye View cursor to the “Magnifying-power change Bar”
Dialog” screen and select a marker according
(4th Tab area) and enlarge the “Expansion”
to step 6.
picture window (3rd Tab area).
• If the Result Window states “CAM1
Calculation Failed. Recheck Marker c. Move the cursor to the “Expansion” picture
Positions”, select a marker according to step window (3rd Tab area) and determine the
6. center of the marker.
d. When the center of the marker is determined,
a “Marker Dialog” screen will be displayed.
See Figure 30-20. Use the cursor to select
the marker name, then select OK. After
registration is complete, the marker changes
to green.
85248
FIGURE 30-19. DISPLAYED 6 CAMERA
CALIBRATION
85250
FIGURE 30-20. MARKER DIALOG SCREEN
22
1st Tab area
4th
Tab area
2nd Tab area 3rd Tab area
5th Tab area
85249
85251
FIGURE 30-21. TAB AREA LOCATIONS
FIGURE 30-22. RESULT BIRD’S EYE VIEW
DIALOG SCREEN
e. Select the CALC button (5th Tab area) after

determining the markers of all the registration 9. Select OK to close the “Result Bird's Eye View
positions. Dialog.” Select the EXIT button (5th Tab area) of
f. When the “Result Bird's Eye View Dialog” the 6 Camera Calibration screen.
screen appears, it will either be successful or 10. The "End Dialog" screen will appear.
require further attention.
• To save the calibration results, select END
• If the Result Window states “Calculation NEW SETTING. The screen returns to the
Completed Successfully”, select NEXT in maintenance screen.
the “Result Bird's Eye View Dialog” screen
and proceed to step 7. • To perform the 6 camera calibration again,
choose END OLD SETTING.
Completed, But Large Error - x.x pixels”,
select MANUAL in the “Result Bird's Eye
View Dialog” screen and repeat step 6.
7. Repeat step 5 for the remaining cameras. It is
acceptable once “Calculation Completed
Successfully” is displayed in the Result
Window for all six cameras.
8. Check the alignment of the calibration sheets in
the “Result Bird's Eye View Dialog” picture. The
sheets should be finely connected with no
jagged breaks.
85252
FIGURE 30-23. END DIALOG SCREEN
23
85244
FIGURE 30-24. SOFTWARE OPERATION FLOW CHART
24
Manual 6 camera calibration 5. In the Configuration screen for the 6 camera

calibration, choose the number of the calibration
Manual 6 camera calibration is used when the
marker for each camera. See Figure 30-27.
automatic calibration does not complete successfully
or when recommended by service personnel. NOTE: Default value 4 is recommended. The
1. Simultaneously push the Monitor Display Mode calibration sheet corresponds only to 4.
Switch, Guide Line Display Switch, and Lower
Body Display Switch for three seconds or more.
2. Enter a password to move to the maintenance
screen.
3. Select 6 CAMERA CALIBRATION.
85254
FIGURE 30-27. CALIBRATION MARKERS
85245
FIGURE 30-25. 6 CAMERA CALIBRATION
4. When the "Initial 6 Camera Calibration" screen

is displayed, select MANUAL. A 6 camera
calibration screen will appear.
85253
FIGURE 30-26. INITAIL 6 CAMERA CALIBRATION
25
852
85255
852
FIGURE 30-28. CALIBRATION SHEETS
26
6. When attempting manual marker selection,

there are four markers that must be selected per
camera. Choose each marker manually 1st Tab area
according to the following steps.
4th
a. Determine the position (near a marker) to Tab area
select by using the "Whole" picture window
2nd Tab area 3rd Tab area
(2nd Tab area). See Figure 30-30.
b. After determining the position, move the
cursor to the “Magnifying-power change Bar”
5th Tab area
c. Move the cursor to the “Expansion” picture 85249
window (3rd Tab area) and determine the FIGURE 30-30. TAB AREA LOCATIONS
center of the marker.
a “Marker Dialog” screen will be displayed. 7. Select the LEFT or RIGHT image switching
See Figure 30-29. Use the cursor to select button (1st Tab area) and change the selected
the marker name, then select OK. After camera. Repeat step 6 for the remaining
registration is complete, the marker changes cameras.
to green.
8. Select the CALC button (5th Tab area) after
determining the markers of all the registration
positions.
When the “Result Bird's Eye View Dialog”
screen appears, it will either be successful or
and proceed to step 9.
It is acceptable once “Calculation Completed
Window for all six cameras.
85250
27
9. Check the alignment of the calibration sheets in 1 camera calibration

the “Result Bird's Eye View Dialog” picture. The
When exchanging or replacing cameras, perform the
sheets should be finely connected with no
1 camera calibration.
jagged breaks.
NOTE: A single camera can also be calibrated during
the 6 camera calibration process.
NOTE: A marker is an object that can be easily
recognized or detected by each camera. A pylon
(safety cone) may function as a marker.
1. Place four or more markers near the image
boundary of the proofreading camera and
neighboring cameras as shown in Figure 30-33.
In this example, the proofreading camera is the
front camera (CAM1).
85251 target
FIGURE 30-31. RESULT BIRD’S EYE VIEW CAM1
DIALOG SCREEN
Marker
10. Select OK to close the “Result Bird's Eye View
Dialog.” Select the EXIT button (5th Tab area) of
the 6 Camera Calibration screen.
11. The "End Dialog" screen will appear.
• To save the calibration results, select END
NEW SETTING. The screen returns to the
maintenance screen.
• To perform the 6 camera calibration again,
85257
FIGURE 30-33. CAMERA 1 MARKERS
85252
FIGURE 30-32. END DIALOG SCREEN
28
2. Simultaneously push the Monitor Display Mode 6. The TARGET camera image is displayed on the
Switch, Guide Line Display Switch, and Lower 1 camera calibration screen. Set up the markers
Body Display Switch for three seconds or more. for the TARGET camera.
a. Determine the position (near a marker) to
3. Enter a password to move to the maintenance select by using the "Whole" picture window
screen. (2nd Tab area). See Figure 30-37.
4. Select 1 CAMERA CALIBRATION. b. After determining the position, move the
cursor to the “Magnifying-power change Bar”
c. Move the cursor to the “Expansion” picture
window (3rd Tab area) and determine the
center of the marker.
a “Marker Dialog” screen will be displayed.
See Figure 30-36. Use the cursor to select
the marker name, then select OK. After
registration is complete, the marker changes
to green.
85258
FIGURE 30-34. 1 CAMERA CALIBRATION SCREEN
5. In the Configuration screen for 1 camera

calibration, select the proofreading camera and
the number of boundary markers on each side.
NOTE: The recommended value is 2 on the right and
2 on the left (total of four markers that were set out).
85250
85259
FIGURE 30-35. CALIBRATION MARKERS
29
9. Select the EXIT button (5th Tab area) of the 1

Camera Calibration screen.
1st Tab area
10. The "End Dialog" screen will appear.
4th • To save the calibration results, select END
Tab area NEW SETTING. The screen returns to the
2nd Tab area 3rd Tab area maintenance screen.
• To perform the 1 camera calibration again,
5th Tab area

85256
FIGURE 30-37. TAB AREA LOCATIONS
7. Select the LEFT or RIGHT image switching

button (1st Tab area) and change the camera.
Set up a marker for the LEFT camera and the
RIGHT camera using the same procedure as
step 6.
8. Select the CALC button (5th Tab area) after
determining the markers of all the registration
positions.
85252
When the “Result Bird's Eye View Dialog” FIGURE 30-38. END DIALOG SCREEN
screen appears, it will either be successful or
and proceed to step 9.
It is acceptable once “Calculation Completed
Window for the TARGET camera.
30
Radar setting procedure 1. Place a mini pylon in the areas indicated in

Figure 30-39.
2. Simultaneously push the Monitor Display Mode
Switch, Guide Line Display Switch, and Lower
Body Display Switch for three seconds or more.
When setting the radars, do not place any items 3. Enter a password to move to the maintenance
other than the specified items within 10 m (33 ft) screen.
of the truck. The radar adjustment cannot be
properly achieved.
10m Mini Pylon

(approximately 40cm
or 16in)
6.6m
When carring out the radar setting,

do not place any items other than
the thing specified in this area.
10m
10m
2.5m
2.5m
6.6m
Critical Zone
10m
85260
FIGURE 30-39. RADAR ZONE
31
4. Select the RADAR DETAIL button. 6. Take note of the OBJECT NO column, then
select the BACK button. In the maintenance
screen, select RADAR SETTING.
85261
FIGURE 30-40. RADAR DETAIL SCREEN
85263
FIGURE 30-42. RADAR DETAIL SCREEN
5. Select RADAR ON.
• If no OBJECT is displayed, adjustments are a. When the RADAR SETTING screen is
not necessary. Proceed to step 7. displayed, select the Threshold tab.
• If an OBJECT is displayed, adjustment is b. Increase the number of the RADAR POWER
required. Proceed to step 6. SETTING of the radar that corresponds to
the OBJECT NO from the previous screen,
then select SAVE.
Example: OBJECT NO 102 = RADAR2
CHANGE RADAR2 POWER SETTING 26 to 28
85262
FIGURE 30-41. INTEGRATION SCREEN
85264
FIGURE 30-43. THRESHOLD SCREEN
c. To verify whether the OBJECT is still

displayed, repeat steps 4 and 5. Continue
adjusting the RADAR POWER SETTING
until the OBJECT is no longer displayed.
Then proceed to step 7.
32
7. Select RADAR SETTING in the maintenance 8. Radar setting is complete. Select the BACK
screen. In the Area tab, select the SET button. button to return to the maintenance screen.
If a radar is attached to the truck in a different

position at the user's order, select the
AllRadarPosition tab of the RADAR SETTING
screen and input the values of for that radar’s
MOUNTING POSITION and MOUNTING ANGLE.
85265
FIGURE 30-44. AREA SCREEN
a. Select YES in the "Set Radar setting?"

screen.
85268
FIGURE 30-47. ALLRARDARPOSITION SCREEN
85265
FIGURE 30-45. RARDAR SCREEN
b. When SET is successful, select OK when the

"Success" window appears.
85265
FIGURE 30-46. RARDAR SCREEN
33
830E Dump truck

930E Dump truck
980E Dump truck
34
CEN30029-01
730E 960E
830E 980E
860E
930E
730E-8 A40004 and up 960E-2 A30027 and up
830E-5 A50005 and up 960E-2K A50011 and up
860E-1K A30031 and up 960E-2KT A50028 and up
860E-1KT A30031 and up 980E-4 A40003 and up
930E-5 A40004 and up 980E-4AT A40083 and up
960E-1K A50009 - A50010 980E-5 A50005 and up

Service tools and equipment................................................................................................................................. 4
Detecting leaks ..................................................................................................................................................... 7
System performance test ...................................................................................................................................... 8
Checking system oil .............................................................................................................................................. 9
System flushing................................................................................................................................................... 10
Installing the manifold gauge set .........................................................................................................................11
Recovering and recycling refrigerant .................................................................................................................. 12
Evacuating the air conditioning system............................................................................................................... 14
Charging the air conditioning system.................................................................................................................. 15
1
NOTES
2
General information
Servicing an air conditioning system really means
closely monitoring refrigerant flow. For this reason,
the following procedures deal extensively with the
proper use, handling, care and safety factors Federal regulations prohibit venting R-12 and R-
involved in the R-134a refrigerant quality and quantity 134a refrigerant into the atmosphere. An SAE and
in an air conditioning system. UL approved recovery/recycle station must be
used to recover refrigerant from the A/C system.
Because the refrigerant in an air conditioning system Refrigerant is stored in a container on the unit for
must remain pressurized and sealed within the unit to recycling, reclaiming, or transporting. In addition,
function properly, safety is a major consideration technicians servicing A/C systems must be
when anything causes this pressurized, sealed certified they have been properly trained to
condition to change. The following warnings are service the system.
provided here to alert service personnel to their
importance before learning the correct procedures. Although accidental release of refrigerant is a
Read, remember, and observe each warning before remote possibility when proper procedures are
beginning actual system servicing. followed, the following warnings must be
observed when servicing A/C systems:
NOTE: If the mine operates a fleet with some trucks
using R-12 and others using R-134a refrigerant, it is • Provide appropriate protection for your eyes
(goggles or face shield) when working around
essential that servicing tools that come into contact
refrigerant.
with the refrigerant (gauge sets, charging equipment,
recycle/recovery equipment etc.) be dedicated to one • A drop of the liquid refrigerant on your skin
type of refrigerant only in order to prevent cross will produce frostbite. Wear gloves and use
contamination. extreme caution when handling refrigerant.
• If even the slightest trace of refrigerant enters
your eye, flood the eye immediately with cool
water and seek medical attention as soon as
possible.
• Ensure that there is sufficient ventilation
Trucks operating in cold weather climates must whenever refrigerant is being discharged
continue to keep the A/C system charged during from a system. Keep in mind that refrigerant
cold weather months. Keeping the system is heavier than air and will fall to low-lying
charged helps prevent moisture intrusion into areas.
system oil and desiccants. • 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 leave A/C components, hoses, oil, etc,
• Never direct a steam cleaning hose or torch in
exposed to the atmosphere. Always keep sealed
direct contact with components in the air
or plugged until the components are to be conditioning system. Localized heat can raise
installed and the system is ready for evacuation the pressure to a dangerous level.
and charging. PAG oil and receiver-drier
desiccants attract moisture. Leaving system • Do not heat or store refrigerant containers
components open to the atmosphere will allow above 49 °C (120 °F).
moisture to invade the system, resulting in • Do not flush or pressure test the A/C system
component and system failures. using shop air or another compressed air
source. Certain mixtures of air and R-134a
refrigerant are combustible when slightly
To help prevent air, moisture or debris from
pressurized. Shop air supplies also contain
entering an open system, cap or plug open lines, moisture and other contaminants that could
fittings, components and lubricant containers. damage system components.
Keep all connections, caps, and plugs clean.
3
Service tools and equipment

Recovery/recycle station
Whenever refrigerant must be removed from the
system, a dual purpose station (Figure 30-1) Mixing different types of refrigerant will damage
performs both recovery and recycle procedures equipment. Dedicate one recovery/recycle station
which follows the new guidelines for handling used to each type of refrigerant processing to avoid
refrigerant. The recovered refrigerant is recycled to equipment damage. DISPOSAL of the gas
reduce contaminants, and can then be reused in the removed requires laboratory or manufacturing
same machine or fleet. facilities.
To accomplish this, the recovery/recycle station Test equipment is available to confirm whether the
separates the oil from the refrigerant and filters the refrigerant in the system is actually the type intended
refrigerant multiple times to reduce moisture, acidity, for the system and has not been contaminated by a
and particulate matter found in a used refrigerant. mixture of refrigerant types.
NOTE: To be re-sold, the gas must be “reclaimed” Recycling equipment must meet certain standards as
which leaves it as pure as new, but requires published by the Society of Automotive Engineers
equipment normally too expensive for all but the (SAE) and carry a UL approved label. The basic
largest refrigeration shops. principals of operation remain the same for all
Equipment is also available to just remove or extract machines, even if the details of operation differ
the refrigerant. Extraction equipment does not clean somewhat.
the refrigerant; it is used to recover the refrigerant
from an A/C system prior to servicing. Leak detector
The electronic leak detector (Figure 30-2) is very
accurate and safe. It is a small hand-held device with
a flexible probe used to seek refrigerant leaks. A
buzzer, alarm or light will announce the presence of
even the smallest leak.
Some leak detectors are only applicable to one type
of refrigerant. Ensure that the leak detector being
used applies to the refrigerant in the system.
FIGURE 30-1. RECOVERY/RECYCLE STATION

FIGURE 30-2. TYPICAL ELECTRONIC LEAK
DETECTOR
4
Manifold gauge set

A typical manifold gauge set (Figure 30-3) has two
screw type hand valves to control access to the
system, two gauges and three hoses. The gauges
are used to read system pressure or vacuum. The
manifold and hoses are for access to the inside of an
air conditioner, to remove air and moisture, and to put
in, or remove, refrigerant from the system. Shutoff
valves are required within 305 mm (12 in.) of the
hose end(s) to minimize refrigerant loss.
A gauge set for R-134a will have a blue hose with a
black stripe for the low side, a red hose with a black
stripe for the high side, and a yellow hose with a
black stripe for the utility (center) hose. The hoses
use a 1/2 in. ACME female nut on the gauge end.
Special quick disconnect couplings are normally
combined with a shutoff valve on the high and low
side hoses. The free end of the center hose contains
a 1/2 in. ACME female nut and a shutoff device within
305 mm (12 in.) of the hose end. These special FIGURE 30-3. MANIFOLD GAUGE SET
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 R-134a”.
Functions of the manifold gauge set are included in
many of the commercially available recovery or
recovery/recycle stations.
The low pressure gauge registers both vacuum and
pressure. The vacuum side of the scale is calibrated
from 0 to 30 inches of mercury (in. Hg). The pressure
side of the scale is calibrated to 1035 kPa (150 psi).
Never open the hand valve to the high side when

the air conditioning system is operating. High
side pressure, if allowed, may rupture charging
containers and potentially cause personal injury.
The high pressure gauge is used to measure
pressure only on the discharge side of the
compressor. The scale is calibrated to 3450 kPa (500
psi).
5
Service valves Vacuum pump

Because an air conditioning system is a sealed The vacuum pump (Figure 30-5) is used to
system, two service valves are provided on the completely evacuate all of the refrigerant, air, and
compressor to enable diagnostic tests, system moisture from the system by deliberately lowering the
charging or evacuation. Connecting the applicable pressure within the system to the point where water
hoses from the manifold gauge set to the compressor turns to a vapor (boils) and together with all air and
service valves enables each of these to be readily refrigerant is withdrawn (pumped) from the system.
performed.
New and unique service hose fittings (Figure 30-4)
have been specified for R-134a systems. Their
purpose is to avoid accidental cross-mixing of
refrigerants and lubricants with R-12 based systems.
The service ports on the system are quick disconnect
type with no external threads. They do contain a
Schrader type valve. The low side fitting has a
smaller diameter than the high side attachment.
Protective caps are provided for each service valve.
When not being used these caps should be in place
to prevent contamination or damage to the service
valves.
FIGURE 30-5. VACUUM PUMP
FIGURE 30-4. R-134a SERVICE VALVE
1. System Service Port 3. Service Hose

Fitting Connection
2. Quick Connect
6
Detecting leaks Several methods are available for detecting

refrigerant leaks.
Refrigerant leaks are probably the most common
cause of air conditioning problems, resulting from NOTE: The refrigerant is heavier than air and will
improper or no cooling, to major internal component move downward when it leaks. Apply pickup hose or
damage. Leaks most commonly develop in two or test probe on the under-surface of all components to
three places. The first is around the compressor shaft locate leaks.
seal, often accompanied by an indication of fresh
• An electronic leak detector (see Figure 30-2) can
refrigerant oil. If a system is not operated for a while
be used to detect leaks. As the test probe is
(winter months), the shaft seal may dry out and leak moved into an area where traces of refrigerant
slightly. The centrifugal force of the clutch pulley are present, a visual or audible announcement
spinning can also cause the problem. When the indicates a leak. Audible units usually change
system is operated and lubricant wets the seal, the tone or speed as intensity changes.
leak may stop. Such leaks can often be located
• Tracer dyes are available that can be added to
visually or by feeling with your fingers around the
the system as refrigerant is added. The system is
shaft for traces of oil. The R-134a itself is invisible, then operated to thoroughly circulate the dye. As
odorless, and leaves no trace when it leaks, but has a refrigerant escapes, it leaves a trace of the dye at
great affinity for refrigerant oil. the point of leakage, which is then detected using
A second common place for leaks is the nylon and an ultraviolet light (“black light”), revealing a
bright fluorescent glow.
rubber hoses where they are crimped or clamped to
the fittings, or where routing allows abrasion. Other • Soap and water can be mixed together and
threaded joints or areas where gaskets are used applied to system components. Bubbles will
should be visually and physically examined. Moving appear to pinpoint the specific location of leaks.
your fingers along the bottom of the condenser and
evaporator, particularly near the drain hole for the
condensate will quickly indicate the condition of the After determining the location or source of leak(s),
evaporator. Any trace of fresh oil here is a clear repair or replace leaking component(s).
indication of a leak. NOTE: The length of the hose will affect the
Usually, a 50% charged system is enough to find refrigerant capacity. When replacing hoses, always
most leaks. If the system is empty, connect the use the same hose length, if possible.
manifold gauge set to the system and charge at least
1.6 kg (3.5 lbs) of refrigerant into the system.
Before system assembly, check the compressor

oil level and fill to specifications.
Use extreme caution when leak testing a system
while the engine is running. In its natural state,
refrigerant is a harmless, colorless gas. But when
combined with an open flame, it will generate
toxic fumes (phosgene gas) which can cause
serious injuries or death.
7
System performance test

This test is performed to establish the condition of all 8. Feel the hoses and components on the low
components in the system. Observe these conditions side. They should be cool to the touch. Check
during testing: the connections near the expansion valve. The
inlet side should be warm and the outlet side
1. Place a fan in front of the condenser to simulate
should be cold.
normal ram air flow and allow the system to
stabilize. 9. After a minimum of 10 minutes has elapsed and
the system has stabilized, observe the gauge
2. Install a thermometer into the air conditioning
readings. Compare the readings to the
vent closest to the evaporator.
specifications in Table 2.
3. Start the engine and operate at 1000 rpm.
4. Evaluate the readings obtained from the gauges
to see if they match the readings for the ambient NOTE: Pressures may be slightly higher in very
temperature. humid conditions and lower in very dry conditions.
Pressures listed in the table are during compressor
5. Set the air conditioning system at maximum
clutch engagement.
cooling and maximum blower speed operation.
6. Close all windows and doors to the cab.
7. Carefully feel the hoses and components on the 10. Check the cab vents for cool air. Outlet air
high side. All should be warm or hot to the temperature should be approximately 16 - 22 °C
touch. Check the inlet and outlet of receiver- (30 - 40 °F) below ambient air temperature.
drier for even temperatures. If outlet is cooler 11. If pressures and temperatures are not within the
than inlet, a restriction is indicated. specified ranges, the system is not operating
properly. Refer to Troubleshooting section Cab
air conditioning for tips on diagnosing poor
system performance.
Use extreme caution when placing hands on high

side components and hoses. Under most normal
conditions, these items can be extremely hot.
Table 2: NOMINAL R-134a PRESSURE RANGES
Ambient Air Temperature High Side Pressure Low Side Pressure
21 °C (70 °F) 820 - 1 300 kPa (120 - 190 psi) 70 - 138 kPa (10 - 20 psi)
27 °C (80 °F) 950 - 1 450 kPa (140 - 210 psi) 70 - 173 kPa (10 - 25 psi)
32 °C (90 °F) 1 175 - 1 650 kPa (170 - 240 psi) 105 - 210 kPa (15 - 30 psi)
38 °C (100 °F) 1 300 - 1 850 kPa (190 - 270 psi) 105 - 210 kPa (15 - 30 psi)
43 °C (110 °F) 1 450 - 2 075 kPa (210 - 300 psi) 105 - 210 kPa (15 - 30 psi)
NOTE: All pressures in this chart are for reference only. Weight is the only absolute means of determining
proper refrigerant charge.
8
Checking system oil

R-134a air conditioning systems require the use of
Polyalkylene Glycol (PAG) lubricating oil. This is the
only oil recommended for use in this system. The
Komatsu PAG oil (PC2279) is the oil that is furnished The receiver-drier and accumulator must be
in the system on Komatsu trucks equipped with the replaced each time the system is opened.
compressor as shown in Figure 30-6.
1. Remove the compressor from the truck. With
• Avoid skin contact and inhalation of PAG oil, as the compressor positioned horizontally, remove
these are normal precautions with any chemical. the drain plug and capture the oil in a clear
• PAG oil removed from new or old components graduated container. Rock the compressor back
must not be retained for re-use. It must be stored and forth and rotate the shaft to facilitate oil
in a marked container and properly sealed. PAG removal.
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
Under no circumstances should the A/C
atmosphere any longer than necessary. PAG oil
absorbs moisture very rapidly, and therefore, any compressor be stood upright onto the clutch
absorbed moisture could cause damage to an air assembly. Damage to the compressor clutch will
conditioning system. 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 "Evacuating the air conditioning
It is critical to keep the correct amount of system". If no particles are found, proceed to
lubricant in the air conditioning system at all the next step.
times. Failure to do so could result in damage to 3. Add 300 ml (10.1 oz.) of PAG oil to the
the compressor. compressor sump. Add the oil through the drain
port, and install the drain plug. It is important to
Damage to the compressor can be a result from only add the specified amount to ensure optimal
not only a lack of oil, but also too much oil. A lack system performance. Too much oil will result in
of oil will cause excess friction and wear on a reduction in cooling. Too little oil will result in
moving parts. Excessive oil can result in compressor failure.
“slugging” the compressor. This condition
occurs when the compressor attempts to 4. Determine the correct amount of additional oil to
compress liquid oil as opposed to vaporized add to the system by using the Replacing Oil
refrigerant. Since liquid cannot be compressed, table. Add this extra oil to the inlet side of the
damage to internal parts results. receiver drier or to the 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 for initial
lubrication of the A/C components.
EXAMPLE - If only the accumulator and receiver drier
were replaced, then add 120 ml (4 oz.) of PAG oil to
the inlet side of the receiver-drier or to the
accumulator. If the evaporator was also replaced at
this time, then add 150 ml (5 oz.) of PAG oil to the
inlet side of the receiver-drier or to the accumulator.
FIGURE 30-6. COMPRESSOR NOTE: The proper quantity of oil may be injected into
300 ml - (10.1 oz.) PC2279 PAG OIL the system during charging as an alternate method of
adding oil.
9
System flushing
If any contaminants are found in system hoses,
components or oil, the entire system must be flushed.
Major components such as the compressor are
When installing a new compressor, the extremely susceptible to foreign particles and must
compressor must be completely drained of its oil be replaced. If contaminated, the evaporator and
before installation. Add 300 ml (10.1 oz.) of new condenser must also be replaced. The evaporator
PAG oil to the compressor to ensure proper and condenser are multi-pass units, and they can not
system oil level. Failure to adjust the amount of be properly cleaned by flushing.
oil in the compressor will lead to excessive
system oil and poor A/C performance. Also, a
new receiver-drier and accumulator must be
installed and the correct amount of extra oil (per
Table 1) must be added to either one of these
components. Only SAE and/or Mobile Air Conditioning Society
(MACS) approved flushing methods with the
appropriate refrigerants are to be performed
Table 1: Replacing system oil when removing debris from the system. Other
methods may be harmful to the environment, as
Component Oil to add well as air conditioning components.
Condenser 60-90 ml (2-3 ounces) 1. Remove the compressor, receiver-drier,
expansion valve, and accumulator.
Evaporator 30 ml (1 ounce)
2. Inspect all other components such as the
Receiver-Drier 60 ml (2 ounces) condenser, evaporator, hoses and fittings. If any
of these items are damaged or highly
Accumulator 60 ml (2 ounces) contaminated, replace the components.
Compressor 300 ml (10.1 ounces) 3. Flush the remaining hoses with a flushing unit.
Use only R134a as a flushing agent.
Expansion valve Not necessary 4. After flushing, blow out the system with dry shop
Drain and measure the air for 5 to 10 minutes.
Hoses 5. If the expansion valve has been removed of all
amount removed.
foreign contamination, it may be reinstalled back
into the system. If contamination is still present,
5. Connect all hoses and components in the replace the valve.
system. Lubricate O-rings with clean mineral oil 6. Install a new compressor, receiver-drier, and
before assembly. accumulator.
NOTE: Do not use PAG oil to lubricate O-rings or 7. Add oil to the system as outlined in Table 1.
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

air conditioning system".
10
Installing the manifold gauge set

Before attempting to service the air conditioning
system, a visual inspection of both the engine and air 1
conditioning system components is recommended.
Particular attention should be given to the belts,
hoses, tubing and all attaching hardware as well as
the radiator cap, fan clutch, and thermostat. Inspect HIGH
both the condenser and the radiator for any SIDE
obstructions or potential contamination. Minimize all
the possibilities for error or malfunction of
components in the air conditioning system.
Shut off the engine. DO NOT attempt to connect LOW

service equipment when the engine is running. SIDE
1. Make sure that all valves on the manifold are
closed all the way (turn them clockwise).
2. Check the hose connections on the manifold for
tightness. 2
3. Locate the low and high side system service
fittings and remove their protective caps.
4. Connect the two service hoses from the 3
manifold to the correct service valves on the
compressor and accumulator as shown in 86210
Figure 30-7 (high side to compressor discharge FIGURE 30-7. SERVICE HOSE HOOK-UP
valve and low side to accumulator). Do not open
the service valves at this time. Purging air from the service hoses
This gauge hook-up process will be the same, The purpose of this procedure is to remove all the air
regardless of the gauge set being installed. Whether trapped in the hoses prior to actual system testing.
it is a recovery station or individual gauges, the Environmental regulations require that all service
connections are the same. The procedures hoses have a shutoff valve within 12 inches of the
performed next will vary depending what type of service end. These valves are required to ensure
equipment is being used. If a recovery/recycling only a minimal amount of refrigerant is lost to the
station is being used, complete servicing can be atmosphere. R-134a gauge sets have a combination
accomplished. Using only a set of gauges will limit quick disconnect and shutoff valve on the high and
the servicing to only adding refrigerant or observing low sides. The center hose also requires a valve.
pressures.
The initial purging is best accomplished when
connected to recovery or recycle equipment. With the
center hose connected to the recovery station,
service hoses connected to the high and low sides of
the system, we can begin the purging. The manifold
valves and service valves should be closed.
Activating the vacuum pump will now pull any air or
moisture out of the center hose. This will require only
a few minutes of time. The hose is the only area that
is being placed in a vacuum and this will not require a
lengthy process. Closing the valve will then insure the
hose is purged. It is now safe to open the other
manifold valves.
11
Recovering and recycling refrigerant

Recycled refrigerant has been extracted from a
mobile air conditioning system using a recovery unit.
The refrigerant is cleaned by the recovery unit as it
passes through filters located on the unit that meet An unclear sight glass on R-134a systems can
specifications stipulated by Society of Automotive indicate that the system may be low on
Engineers, SAE J2099. The refrigerant that has refrigerant. However, the sight glass should not
passed through the filtering process has only been be used as a gauge for charging the system.
cleaned of contaminants that are associated with Charging the system must be done with a scale
mobile systems. Therefore, recycled refrigerant from to ensure the proper amount of refrigerant has
mobile systems is only acceptable for reuse in mobile been added.
systems.
Two basic, readily available containers are used to
Reclaimed refrigerant has been filtered through a store R-134a: the 14 kg (30 lb) or 28 kg (60 lb) bulk
more thorough filtering process and has been canisters (Figure 30-8). Always read the container
processed to the same standards of purity as virgin label to verify the contents are correct for the system
refrigerant. Because of this, reclaimed refrigerant is being serviced. Note the containers for R-134a are
acceptable for use in all systems, not just mobile. The painted light blue.
reclaiming equipment used for this process is
expensive, and therefore, not common among
normal maintenance shops. Equipment such as this
is more commonly found in air conditioning specialty
shops.
Always use new, recycled, or reclaimed

refrigerant when charging a system. Failure to
adhere to this recommendation may result in
premature wear or damage to air conditioning
system components and poor cooling
performance.
FIGURE 30-8. R-134a CONTAINERS
If not enough refrigerant is charged into the system,
cooling ability will be diminished. If too much 1. 14 kg (30 lb) Canister 2. 28 kg (60 lb) Canister
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.
If an incorrect charge is suspected, recover the
refrigerant from the system, and charge the system
with the correct operating weight of 3.4 kg (7.4 lb).
This is not only the recommended procedure, but it is
also the best way to ensure that the system is
operating with the proper charge and providing
optimum cooling. Using the sight glass to determine
the charge is not an accurate method.
12
Draining oil from previous recovery cycle 7. Continue extraction until a vacuum exists in the
1. Place the power switch and the controller on the A/C system.
recovery unit in the OFF position. 8. If an abnormal amount of time elapses after the
system reaches 0 kPa (0 psi) and does not drop
2. Plug in the recovery station to the correct power
steadily into the vacuum range, close the
source.
manifold valves and check the system pressure.
3. Drain the recovered oil through the valve If it rises to 0 psi and stops, there is a major
marked “oil drain” on the front of the machine. leak.
4. Place the controller knob in the ON position. 9. Check the system pressure after the recovery
The low pressure gauge will show a rise. equipment stops. After five minutes, system
pressure should not rise above 0 kPa (0 psi). If
5. Immediately switch to the OFF position and
the pressure continues to rise, restart and begin
allow the pressure to stabilize. If the pressure
the recovery sequence again. This cycle should
does not rise to 34 - 69 kPa (5 - 10 psi), switch
continue until the system is void of refrigerant.
the controller ON and OFF again.
10. Check the sight glass oil level to determine the
6. When the pressure reaches 34-69 kPa (5-10
amount of oil that needs to be replaced. (The
psi), open the “oil drain” valve, collect the oil in
amount of oil that was lost during the recovery
an appropriate container, and dispose of
cycle must be replaced back into the system).
container as indicated by local, state or federal
regulation. The oil is not reusable due to 11. Mark the cylinder with a “RECOVERED” (red)
contaminants that were absorbed during use. magnetic label to reduce the chance of charging
a system with contaminated refrigerant. Record
Recovery cycle the amount of refrigerant recovered.
1. Ensure that the equipment being used is
Recycling procedure
designed for the refrigerant you intend to
recover. The recovered refrigerant contained in the cylinder
2. Observe the sight glass oil level. Having been must undergo the recycle procedure before it can be
drained, it should be at zero. reused. The recycle or clean mode is a continuous
loop design and cleans the refrigerant rapidly. Follow
3. Check the cylinder refrigerant level before
the equipment manufacturer's instructions for this
beginning recovery to make sure you have
procedure.
enough capacity.
4. Confirm that all shutoff valves are closed before
connecting to the A/C system.
5. Attach the appropriate hoses to the system
being recovered.
6. Start the recovery process by operating the
equipment according to the manufacturer's
instructions.
13
Evacuating the air conditioning system 3. Allow the vacuum pump to run for at least 45
minutes.
Evacuating the complete air conditioning system is
required for all new system installations, when repairs 4. Shut off the vacuum pump and observe the
are made on systems requiring a component gauges. The system should hold the vacuum
replacement (system opened), or when a major loss within 5 cm Hg (2 in. Hg) of the optimal vacuum
of refrigerant has occurred. All these conditions will for five minutes. If the vacuum does not hold,
require that a vacuum be pulled using a vacuum moisture may still be present in the system.
pump that completely removes any moisture from the Repeat the previous step. If the vacuum still
system. Once properly evacuated, the system can be does not hold, a leak may be present in the
recharged again. system. Find the source of the leak, repair, and
evacuate the system again.
Using a pump to create a vacuum in the air
conditioning system effectively vaporizes any NOTE: In some cases, 45 minutes of evacuation may
moisture, allowing the water vapor to be easily drawn not be sufficient to vaporize all of the moisture and
out by the pump. The pump does this by reducing the draw it out of the system. If it has been verified that
point at which water boils (100 °C, 212 °F at sea level no system leaks exist and gauge readings increase
with 14.7 psi). In a vacuum, water will boil at a lower after 45 minutes, extend the evacuation time to
temperature depending upon how much of a vacuum ensure total moisture removal.
is created.
As an example, if the ambient air outside the truck is
24 °C (75 °F) at sea level, by creating a vacuum in 1
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.
Do not attempt to use the air conditioning

VACUUM
compressor as a vacuum pump or the
PUMP
compressor will be damaged.
NOTE: Refer to Table 3 for optimal vacuum
specifications at various altitudes. 2
1. With the manifold gauge set still connected
(after discharging the system), connect the
center hose to the inlet fitting of the vacuum 3
pump as shown in Figure 30-9. Then open both
hand valves to maximum. 86211
2. Open the discharge valve on the vacuum pump FIGURE 30-9. VACUUM PUMP HOOKUP
or remove the dust cap from the discharge
outlet. Turn on the pump and watch the low side
gauge. The pump should pull the system into a
vacuum. If not, the system has a leak. Find the
source of the leak, repair, and attempt to
evacuate the system again.
14
Charging the air conditioning system

Table 3: ALTITUDE VACUUM VARIATIONS The first step in properly charging refrigerant into an
Altitude Above R-134a system is to recover all of the refrigerant from
Optimal Vacuum the system. Then weigh the charging refrigerant on a
Sea Level
scale to ensure that the proper amount is charged
0 m (0 ft) 76.0 cm Hg. (29.92 in. Hg.)
into the system. Most recovery units include a scale
305 m (1,000 ft) 73.5 cm Hg. (28.92 in. Hg.) within the apparatus, making it easy to charge the
610 m (2,000 ft) 70.7 cm Hg. (27.82 in. Hg.) correct amount every time. If equipment such as this
is not available, a common scale can be used to
914 m (3,000 ft) 68.1 cm Hg. (26.82 in. Hg.)
determine the weight of charge. Simply weigh the
1 219 m (4,000 ft) 65.6 cm Hg. (25.82 in. Hg.) charging tank, subtract the weight of the proper
1 524 m (5,000 ft) 63.3 cm Hg. (24.92) in. Hg. charge, and charge the system until the difference is
shown on the scale. On certain types of equipment, it
1 829 m (6,000 ft) 60.8 cm Hg. (23.92 in. Hg.)
is also possible to add any necessary lubricant when
2 134 m (7,000 ft) 58.5 cm Hg. (23.02 in. Hg.) charging the system.
2 438 m (8,000 ft) 56.4 cm Hg. (22.22 in. Hg.) If a scale is not used when charging R-134a into a
2 743 m (9,000 ft) 54.2 cm Hg. (21.32 In. Hg.) system, it is difficult to determine whether the correct
NOTE: The chart indicates the expected gauge charge has been achieved. The sight glass can
readings at altitude to obtain the optimal vacuum. provide some indication, but it is not a reliable tool for
determining the proper charge.
NOTE: Charging is to be performed while the engine
and compressor are operating. Charge the A/C
system through the low side service port. Trucks
equipped with accumulators may charge the
refrigerant as a liquid or as a vapor.
1. Charge the A/C system with 3.4 kg (7.4 lbs) of
R-134a refrigerant.
2. Check the system for leaks. Refer to "Detecting
leaks".
3. If no leaks are found, verify that the system’s
cooling capacity meets requirements. Refer to
"System performance test".
15
730E Dump truck

830E Dump truck
860E Dump truck
930E Dump truck
960E Dump truck
980E Dump truck
16
CEN30089-00
830E
930E
980E

830E-5 A50005 and up
930E-5 A40004 and up
980E-5 A50005 and up

Automatic lubrication (auto lube) system
Priming the system ............................................................................................................................................... 3
Checkout procedure.............................................................................................................................................. 4
Adjusting the lubrication cycle timing .................................................................................................................... 5
1
NOTES
2
Priming the system

3 4
Do not connect the electrical harness to the auto

lube pump until the reservoir has been filled and
all air has been purged from the system. Damage
to the auto lube pump may occur if the pump is
operated with insufficient lubrication.
5
The system must be full of grease and free of air to
function properly. If auto lube pump (3, Figure 30-1)
has been replaced, the new pump must be primed.
1. Fill the reservoir with grease, if necessary.
2. Remove the grease discharge hose from the
pump, then connect a short clean temporary
2
hose to route grease back to the reservoir or
into a suitable container.
1
3. Start the engine.
4. Actuate manual override switch (5) to operate
the pump. Watch for grease flow from the
87502
temporary hose.
5. Once full grease flow is achieved, stop the FIGURE 30-1. AUTO LUBE PUMP
pump. Remove the temporary hose and 1. Main Supply Line 4. Plug
reconnect the discharge hose to the system. 2. Vent Valve 5. Manual Override
3. Auto Lube Pump Switch
NOTE: Full grease flow should appear within two
minutes of starting the pump. If it takes longer than
two minutes, check for problems.
If any lubrication lines were opened or replaced, it will
be necessary to prime the system to purge any
entrapped air. Begin with the main supply lines.
1. Fill the reservoir with grease, if necessary.
2. Remove plug (1, Figure 30-2) from the injector
manifold.
NOTE: Always start with the injector manifold that is
closest to the auto lube pump. The last grease line to
be purged should be the main grease line to the rear
axle (longest grease line).
3. Disconnect main supply line (1, Figure 30-1)
from vent valve (2). Connect an external grease
supply to the main supply line.
4. Pump grease into main supply line (1) until
grease appears at the injector manifold plug.
5. Install plug (1, Figure 30-2) in the injector
manifold. Repeat these steps for the remaining
injector groups.
3
After all main supply lines are purged of air, the Checkout procedure
injector circuits must be primed.
To check that the auto lube system is functioning
1. If necessary, disconnect an injector grease line properly:
from the component to which that particular
1. Ensure that the engine is off and all hydraulic
injector supplies grease.
system pressure is bled down.
2. Remove grease zerk cap (2, Figure 30-2) from
2. Remove the injector covers (5, Figure 30-2)
each injector and connect an external grease
from the injectors to allow visual inspection of
supply to injector grease zerk (3).
indicator pins (4) during system operation.
3. Pump grease into the injector until grease
3. Remove plug (4, Figure 30-1) from the top of
appears at the far end of the individual grease
the pump manifold and install a 3 500 kPa (500
line or the joint that is being greased.
psi) hydraulic pressure gauge.
4. Reconnect the injector grease line to the
4. Start the engine. Allow the hydraulic system to
component, then remove the external grease
build pressure.
supply.
5. Actuate manual override switch (5) at the pump.
5. Install the injector grease zerk cap. Repeat
The hydraulic motor and pump should operate.
these steps for the remaining secondary supply
lines 6. Allow the pump to reach stall condition. The
pressure gauge should read 2 415 - 2 585 kPa
After all grease lines are primed, use the manual (350 - 375 psi).
override switch to cycle the auto lube pump a few
7. Observe the movement of indicator pin (4) at
times to lubricate the components. Allow enough time
each injector. With the grease under pressure,
between cycles for the injectors to reset.
the indicator pin should be retracted inside the
injector body.
8. Check for leakage while the system is under
pressure.
5 9. When the system is at 16 200 - 17 250 kPa
(2,350 - 2,500 psi), the pump should shut off
and the pressure in the system should drop to
zero, venting back to the grease reservoir.
4 10. Stop the engine. Allow all hydraulic system
pressure to bleed down.
11. Remove the pressure gauge and install plug (4,
Figure 30-1) in the top of the pump manifold.
2 3 12. Install injector covers (5, Figure 30-2).
13. Repair any leaks that were observed.
1
87503
FIGURE 30-2. AUTO LUBE INJECTORS

1. Plug 4. Indicator Pin
2. Grease Zerk Cover 5. Injector Cover
3. Injector Grease Zerk
4
Adjusting the lubrication cycle timing

The time between lube events is determined by the
setting that is selected through the dash panel
display.
1. Turn the key switch ON to power up the dash
panel.
2. Use the up/down arrow mode switch to scroll to
the "Payload Data" menu item. Press "OK" on FIGURE 30-3. MODE SWITCHES
the other mode switch. Note the current
Operator ID setting.
3. Press "OK", change the Operator ID to 5625, NOTE: Turning the key switch to the ON position will
then press "OK" again. This unlocks the lube not initiate a lube cycle. To initiate a lube cycle while
cycle timing adjustment. the truck is stationary, select Manual Lube on the
4. Press the sideways arrow to return to the main dash display panel, or use the manual override
menu. switch on the auto lube pump. The truck must be
5. Use the up/down arrow mode switch to scroll to moving before the system will initiate lubrication
the "Configure System" menu item. cycles based on the time interval that is selected.
6. Press "OK" on the other mode switch, then
press the arrow to select either 8, 15, 24 or 30
minutes between lube cycles. The default
setting is 15 minutes.
7. Press "OK" to accept the selected interval.
Press the sideways arrow to return to the main
menu.
8. Scroll to the "Payload Data" menu item. Reset
the Operator ID to the value that was noted in
Step 2.
5
830E Dump truck

930E Dump truck
980E Dump truck
6
CEN40199-00
DUMP TRUCK
980E

980E-5 A50005 and up
40 Troubleshooting
Fuse, diode and relay locations
Vehicle Electrical Center (VEC-89) ....................................................................................................................... 2
Rear Terminal Mini-fuse and Relay (RTMR3) ....................................................................................................... 9
Rear Terminal Mini-fuse and Relay (RTMR4) ..................................................................................................... 10
Circuit breakers................................................................................................................................................... 10
1
CEN40199-00 40 Troubleshooting
Vehicle Electrical Center (VEC-89)
84052
FIGURE 3-1. VEC-89
Table 1: VEC - 89
Location Amps Device(s) Protected
F2 25 Back-Up Lamps
F3 15 Back-Up Horn
F4 15 Left Low Beam Headlights
F5 15 Right Low Beam Headlights
F6 25 High Beam Headlights
F8 15 Marker & Tail Lights
F9 10 Brake Light
F10 20 Ladder Lights
F11 15 Turn Signal Hazard
F12 10 Steering Bleed Down
F13 10 Retard Lamps
F20 10 Auto Lube
F42 5 IM & Fuel Sensor
F43 5 Direction Selector Switch
Display Mode Switch, Camera Switch and
F44 5
Switch LED Lights
F45 15 GE Drive Control & Feedback
2
40 Troubleshooting CEN40199-00
Table 1: VEC - 89
F53 20 Heated Mirror
F56 15 Operator Seat
F57 10 Pre-Shift Brake Test
F61 5 Cab Controller Fans
F62 15 Fog Lamp
F63 15 Seat Belt Alarm
F64 5 Headlight Switch
D14 3 Back-Up Diode 1
D15 3 Back-Up Diode 2
R3 Back-Up Horn Relay
R8 Marker & Tail Light Relay
R9 Brake Light Relay
R11 Left Turn Relay
R12 Right Turn Relay
R13 Turn Signal Hazard Flasher Relay
R14 Steering Bleed Down Relay
R15 Retard Lamps Relay
R29 System Busy Relay
R39 Heated Mirror Relay
R40 Fog Lamp Relay
R41 Seat Belt Alarm Relay
3
84053
FIGURE 3-2. VEC-90
Table 2: VEC - 90
F14 5 Payload Lamps
F15 5 Park Brake Status
F17 5 Payload Meter
F18 15 Ground Level Shutdown Switch
F19 10 Park Brake Control
F46 5 Payload Meter Key Switch Power
F47 5 KOMTRAX Plus Key Switch Power
F48 5 Modular Mining Conn Key Switch Power
D1 3 Key Switch Run Diode
D2 3 Shift Selector Reverse Diode
D3 3 Shift Selector Neutral Diode
D4 3 Shift Selector Forward Diode
D5 3 Park Brake Diode
D6 3 Truck Moving Diode
D7 3 Brake Lock Diode
D8 3 Park Brake Latch Diode
D9 3 GE True Forward Signal Diode
4
Table 2: VEC - 90
D10 3 GE True Reverse Signal Diode
D11 3 GE Propel System At Rest Diode
D12 3 GE Propel System Not Ready Diode
D13 3 Forward, Neutral, Reverse Signal Diode
D14 3 Engine Running Diode
R16 Payload Red Lamp Relay
R17 Payload Amber Lamp Relay
R18 Payload Green Lamp Relay
R19 Engine Interlock Relay
R20 Timed Engine Shutdown Relay
R21 Engine Running Relay
R22 Park Brake Request Relay
R23 Park Brake Release Relay
R24 Park Brake Switch Relay
R25 Truck Moving Relay
R26 Park Brake Latch Relay
R27 GE Interface Relay
R28 Park Brake Status Relay
5
84054
FIGURE 3-3. VEC-91
Table 3: VEC - 91
F21 10 Ether Start
F22 20 Operator Cab Communication Radio 12V
F23 10 Entertainment Radio 12V
F24 10 A/C Compressor
F25 10 Shutter Control
F26 15 Electronic Gauge Display Un-switched
F27 10 IM Un-switched # 1
F28 10 IM Un-switched # 2
F29 10 KOMTRAX Plus & Iridium
F30 20 Modular Mining Un-switched
F31 15 Engine Oil Reserve Pump Motor
F32 15 Engine Oil Reserve Controller
F33 15 Vehicle Horn / Service Lamps
F34 15 Engine Service Lamps / Hydraulic Mod Lamp
F35 15 Ladder & Hazard Lamp Control Switch
F36 20 Engine Un-switched Power Fuse #1
6
Table 3: VEC - 91
F40 20 Operator Cab Communication Radio 24V
F41 5 Operator Cab Fire Suppression
F50 10 Windshield Wipers
F51 10 Hoist Limit Switch
F52 5 Turn Signal Switch
F54 5 Electronic Gauge Display Key Switch
F55 5 Aux Box Dome Lamps
F56 20 Electric Window - Left
F58 5 Ladder Switch Control
F59 25 HVAC Control Panel
F60 15 Operator Seat
F62 20 Electric Window - Right
F63 20 Auxiliary Power Port 12V
D13 3 Turn Signal Switch Diode
D14 3 Key Switch Power Diode
D15 3 GE Control Power Diode
R30 Starter Enable Relay
R34 GE Payload 70% Signal Relay
R35 GE Payload 100% Signal Relay
R36 Ether Start Relay
R37 Entertainment Radio Relay
R38 A/C Compressor Relay
R39 Shutter Control Relay
7
87520
FIGURE 3-4. VEC-92
Table 4: VEC - 92
F1 20 Engine NOX Power
F2 20 Engine Child 3
F3 15 KomVision Power
F4 10 VID Panel
F5 15 DEF Supply Pumps
F6 15 NOX Sensors
F7 15 Dosing Modules 1 & 2
F8 20 Oil Reserve Heated Line
F9 15 KomVision Control Key
F10 5 Fan Clutch
F11 20 KomVision Radar
R1 IM System Busy Relay
R2 Shutter Control Relay
R3 Spare
R4 Park Brake Protection Relay
8
Rear Terminal Mini-fuse and Relay

(RTMR3)
58B-65-00001
FIGURE 3-5. RTMR3 VEC BLOCK
Table 5: RTMR3
F1 15 Line Heater DEF Supply/Return LH1/2
F5 15 Line Heater DEF Suction LH9/10/11/12
Line Heater DEF Transfer LH13
F6 15
Line Heater DEF Fast Fill Receiver/Valve
F7 Unused
F8 Unused
F9 Unused
F10 Unused
R1 Dosing Module #1 Heater Relay
9
Rear Terminal Mini-fuse and Relay

(RTMR4)
WB4011
FIGURE 3-6. RTMR4 VEC BLOCK
Table 6: RTMR4
F1 15 DEF Line Heaters Pumps 1 & 2
F2 15 DEF Line Heaters Pumps 3 & 4
R1 DEF Line Heaters Relay
R2 DEF Supply Pump 1 Relay
R6 NOX ECU 1 Relay
R7 NOX ECU 2 Relay
Circuit breakers
Table 7: CIRCUIT BREAKERS

Location Amps Device(s) Protected Circuit
CB60 50 24VDC to 12VDC Converter 11BS
CB1 90 DEF Tank Line Heater 11LH
10
NOTES
11
980E Dump truck

12
CEN40178-00
DUMP TRUCK
830E
930E
980E

830E-5 A50005 and up
930E-5 A40004 and up
980E-5 A50005 and up
40 Troubleshooting
Troubleshooting by fault code, Part 1
Fault Code A001: Left front suspension pressure sensor signal high................................................................... 4
Fault Code A002: Left front suspension pressure sensor signal low .................................................................... 6
Fault Code A003: Right front suspension pressure sensor signal high ................................................................ 8
Fault Code A004: Right front suspension pressure sensor signal low................................................................ 10
Fault Code A005: Left rear suspension pressure sensor signal high ................................................................. 12
Fault Code A006: Left rear suspension pressure sensor signal low ................................................................... 14
Fault Code A007: Right rear suspension pressure sensor signal high ............................................................... 16
Fault Code A008: Right rear suspension pressure sensor signal low ................................................................ 18
Fault Code A011: Payload meter speed sensor signal has failed....................................................................... 20
Fault Code A013: Body up switch has failed ...................................................................................................... 22
Fault Code A014: Payload meter checksum computation has failed.................................................................. 24
Fault Code A016: A payload meter write to flash memory has failed ................................................................. 25
Fault Code A017: A payload memory flash memory read has failed .................................................................. 26
Fault Code A018: Right rear flat suspension cylinder warning ........................................................................... 28
Fault Code A019: Left rear flat suspension cylinder warning.............................................................................. 30
Fault Code A022: Carryback load excessive ...................................................................................................... 32
1
Fault Code A101: High pressure detected across a hydraulic pump filter .......................................................... 34
Fault Code A103: Hydraulic Oil Temp - Tank Sensor Low .................................................................................. 36
Fault Code A104: Hydraulic Oil Temp - Tank Sensor High ................................................................................. 37
Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level ................................... 38
Fault Code A109: GE has generated a propel system reduced level signal....................................................... 40
Fault Code A111: Low steering pressure warning............................................................................................... 42
Fault Code A115: Low steering precharge pressure detected ............................................................................ 44
Fault Code A117: Low brake accumulator pressure warning.............................................................................. 46
Fault Code A118: Brake pressure is low while in brake lock............................................................................... 48
Fault Code A123: GE has generated a reduced retarding caution ..................................................................... 50
Fault Code A124: GE has generated a no propel / no retard or system not running input ................................. 52
Fault Code A125: GE has generated a no propel warning ................................................................................. 56
Fault Code A126: Oil level in the hydraulic tank is low ....................................................................................... 58
Fault Code A127: IM-furnished +5 volt output for sensors is low........................................................................ 59
Fault Code A128: IM-furnished +5 volt output for sensors is high ...................................................................... 60
Fault Code A139: Low fuel warning .................................................................................................................... 62
2
NOTES
3
Fault Code A001: Left front suspension pressure sensor signal high
Operator Action None
Fault Code A001
Description Left front suspension pressure sensor signal is high.
Fault Conditions Sets if pressure signal is out of range high (sensor current over 22 ma).
Resets if reading returns to normal.
Operator Alerting Repair Lamp
System Response Display Operator Action: None
Display Fault Description: PLM LF PRESS SENS HI
Display Fault Code: A001
Resulting Problem(s) Bad payload computation.
Related Information A laptop running “IM Realtime Data Monitor” software may be required to resolve this
fault.
Table
1. This fault is generated by PLM in response to a problem in the sensor circuit. This sensor circuit may have a
related fault that can be used to resolve the problem. Refer to the Troubleshooting Instructions for the active
parameter fault(s).
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data
Monitor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the
malfunction is still unresolved then check each of the parameters in the Table for proper functionality.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Left Front Pressure Sensor current > 22 ma: failed high
Sensor (PLM4 1,40) Sensor current < 2 ma: failed low
Sensor current > 2 ma but < 22 ma: valid readings
Fault(s): A002
4
Related Circuit Diagram

Circuit Description Circuit Reference Machine
Reference
Left Front Pressure Refer to 58E-06-02311, sheet 16, zones M3 through M10 830E
Sensor connection at Refer to 58E-06-02321, sheet 29, zones A5 through A6
PLM Refer to 58F-06-02311, Sheet 16, zones M3 through M10 930E
Refer to 58F-06-10561, Sheet 29, zones A5 through A6
Refer to 58B-06-02390, Sheet 17, zones M3 through M10 980E
Refer to 58B-06-03570, Sheet 31, zones A5 through A6
5
Fault Code A002: Left front suspension pressure sensor signal low
Fault Code A002
Description Left front suspension pressure sensor signal is low.
Fault Conditions Sets if pressure signal is out of range low (sensor current less than 2 ma).
Display Fault Description: PLM LF PRESS SENS LO
fault.
Table
parameter fault(s).
Fault(s): A001
6

Reference
Left Front Pressure Refer to 58E-06-02311, sheet 16, zones M3 through M10 830E
PLM Refer to 58F-06-02311, Sheet 16, zones M3 through M10 930E
7
Fault Code A003: Right front suspension pressure sensor signal high
Fault Code A003
Description Right front suspension pressure sensor signal is high.
Display Fault Description: PLM RF PRESS SENS HI
fault.
Table
parameter fault(s).
Right Front Pressure Sensor current > 22 ma: failed high
Fault(s): A004
8

Reference
Right Front Pressure Refer to 58E-06-02311, sheet 16, zones L3 through L10 830E
PLM Refer to 58F-06-02311, Sheet 16, zones L3 through L10 930E
9
Fault Code A004: Right front suspension pressure sensor signal low
Fault Code A004
Description Right front suspension pressure sensor signal is low.
Display Fault Description: PLM RF PRESS SENS LO
fault.
Table
parameter fault(s).
Fault(s): A003
10

Reference
Right Front Pressure Refer to 58E-06-02311, sheet 16, zones L3 through L10 830E
PLM Refer to 58F-06-02311, Sheet 16, zones L3 through L10 930E
11
Fault Code A005: Left rear suspension pressure sensor signal high
Fault Code A005
Description Left rear suspension pressure sensor signal is high.
Display Fault Description: PLM LR PRESS SENS HI
fault.
Table
parameter fault(s).
Left Rear Pressure Sensor current > 22 ma: failed high
Fault(s): A006
12

Reference
Left Rear Pressure Refer to 58E-06-02311, sheet 16, zones N1 through N10 830E
Sensor connection at Refer to 58E-06-02321, sheet 29, zones A5 through C6
PLM Refer to 58F-06-02311, Sheet 16, zones N1 through N10 930E
Refer to 58F-06-10561, Sheet 29, zones A5 through C6
Refer to 58B-06-02390, Sheet 17, zones N1 through N10 980E
Refer to 58B-06-03570, Sheet 31, zones A5 through C6
13
Fault Code A006: Left rear suspension pressure sensor signal low
Fault Code A006
Description Left rear suspension pressure sensor signal is low.
Display Fault Description: PLM LR PRESS SENS LO
fault.
Table
parameter fault(s).
Fault(s): A005
14

Reference
Left Rear Pressure Refer to 58E-06-02311, sheet 16, zones N1 through N10 830E
15
Fault Code A007: Right rear suspension pressure sensor signal high
Fault Code A007
Description Right rear suspension pressure sensor signal is high.
Display Fault Description: PLM RR PRESS SENS HI
fault.
Table
parameter fault(s).
Right Rear Pressure Sensor current > 22 ma: failed high
Fault(s): A008
16

Reference
Right Rear Pressure Refer to 58E-06-02311, sheet 16, zones N1 through N10 830E
17
Fault Code A008: Right rear suspension pressure sensor signal low
Fault Code A008
Description Right rear suspension pressure sensor signal is low.
Display Fault Description: PLM RR PRESS SENS LO
fault.
Table
parameter fault(s).
Fault(s): A007
18

Reference
Right Rear Pressure Refer to 58E-06-02311, sheet 16, zones N1 through N10 830E
19
Fault Code A011: Payload meter speed sensor signal has failed
Fault Code A011
Description Payload meter speed sensor signal has failed.
Fault Conditions Sets when PLM declares a speed sensor fault.
Resets when PLM resets the speed sensor fault.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: PLM TRK SPD SENSOR
Resulting Problem(s) Payload and haul cycle data is bad.
fault.
Table
1. This fault is produced by PLM in response to a problem in the generation of truck speed by GE or
transmission of the truck speed signal via CAN/RPC to PLM. The CAN circuit may have a related fault that can
be used to resolve the problem. Refer to the Troubleshooting Instructions for the active parameter fault(s).
Payload CAN/RPC Not CAN/RPC working: Truck speed is updated
Connected (PLM4 5, CAN/RPC not working: No truck speed updates
11, 14) Fault(s): A257
Drive System Control CAN/RPC working: Truck speed is updated
Link (CAN/RPC) Not CAN/RPC not working: No truck speed updates
Connected (IM1I,j,k) Fault(s): A233
20

Reference
CAN/RPC connection Refer to 58E-06-02311, sheet 16, zone M13 and sheet 17, zone B9 830E
at PLM4 Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 16, zone M13 and Sheet 17, zone B7 930E
Refer to 58F-06-10561, Sheet 6, zone A2
Refer to 58B-06-02390, Sheet 17, zone M11 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone B2
CAN/RPC connection Refer to 58E-06-02311, sheet 15, zone I12 and sheet 17, zone C6 830E
at IM Refer to 58E-06-02321, sheet 6, zone A2
Refer to 58F-06-02311, Sheet 15, zone I12 and Sheet 17, zone B5 930E
Refer to 58B-06-02390, Sheet 16, zone D6 and Sheet 18, zone B8 980E
Refer to 58B-06-03570, Sheet 6, zone A2
CAN/RPC connection Refer to 58E-06-02311, sheet 17, zone B3 830E
at GE Refer to 58E-06-02321, sheet 6, zone B2
Refer to 58F-06-02311, Sheet 17, zone C4 930E
Refer to 58F-06-10561, Sheet 6, zone B2
Refer to 58B-06-02390, Sheet 18, zone C4 980E
21
Fault Code A013: Body up switch has failed

Fault Code A013
Description Body up switch has failed.
Fault Conditions The switch no longer responds to payload cycles.
System Response Display Fault Description: BODY UP SWITCH FAIL
fault.
Table
1. The primary corrective measure for this fault is to change / correct the body up switch and wiring to PLM. No
other faults are available to troubleshoot this problem.
Body Up Switch Input 0: Body is up
(PLM4 46) 1: Body is down
22

Reference
Body Up Switch Refer to 58E-06-02311, sheet 15, zone K9 830E
connection to PLM Refer to 58E-06-02321, sheet 31, zones D1 through E1
Refer to 58F-06-02311, Sheet 16, zone K9 930E
Refer to 58F-06-10561, Sheet 31, zones D1 through E1
Refer to 58B-06-02390, Sheet 17, zone K9 980E
Refer to 58B-06-03570, Sheet 31, zones D1 through E1
Body Up Switch Refer to 58E-06-02311, sheet 14, zones C3 through C7 830E
connections Refer to 58E-06-02321, sheet 31, zones D1 through E1
Refer to 58F-06-02311, Sheet 14, zones C3 through C7 930E
Refer to 58B-06-02390, Sheet 15, zones C3 through C7 980E
B+ to Body Up Switch Refer to 58E-06-02311, sheet 12, zone I6 830E
Refer to 58E-06-02321, sheet 31, zone D1 and sheet 3, zone D7
Refer to 58F-06-02311, Sheet 12, zone I6 930E
Refer to 58F-06-10561, Sheet 31, zone D1 and Sheet 3, zone D7
Refer to 58B-06-02390, Sheet 13, zone I11 980E
Refer to 58B-06-03570, Sheet 31, zone D1 and Sheet 3, zone D7
23
Fault Code A014: Payload meter checksum computation has failed

Fault Code A014
Description Payload meter checksum computation has failed.
Fault Conditions PLM reports a checksum failure.
System Response Display Fault Description: PLM CHECKSUM FAIL
fault.
Table
1. This fault is totally contained within the payload meter.

Circuit Description Circuit Reference
None None
24
Fault Code A016: A payload meter write to flash memory has failed
Fault Code A016
Description Payload meter reports a failure in write to flash memory.
Fault Conditions PLM reports a checksum failure.
System Response Display Fault Description: PLM FLASH MEM WRITE
fault.
Table

None None
25
Fault Code A017: A payload memory flash memory read has failed
Fault Code A017
Description A payload memory flash memory read has failed.
Fault Conditions Payload meter reports a failure of flash memory read.
System Response Display Fault Description: PLM FLASH MEM READ
fault.
Table

None None
26
NOTES
27
Fault Code A018: Right rear flat suspension cylinder warning

Fault Code A018
Description Right rear flat suspension cylinder warning.
Fault Conditions Sets if PLM detects a flat right rear suspension cylinder.
Resets if condition clears.
Display Fault Description: RR FLAT SUSP CYL FLT
Resulting Problem(s) Potential damage to suspension and frame.
fault.
Table
1. The logic that produces this fault is intended to identify flat suspension cylinders. The primary correction is to
recharge / repair the cylinder. If the cylinder is not defective, use the following procedure to correct PLM.
2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).
This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting
Instructions for the active parameter fault(s).
Sensor (PLM4 4, 40) Sensor current < 2 ma: failed low
Fault(s): A007, A008
28

Reference
PLM Pressure Refer to 58E-06-02311, sheet 16, zones L1 through N9 830E
Sensors Refer to 58E-06-02321, sheet 29, zones A5 through C10
Refer to 58F-06-02311, Sheet 16, zones L1 through N9 930E
Refer to 58B-06-02390, Sheet 17, zones L1 through N9 980E
29
Fault Code A019: Left rear flat suspension cylinder warning

Fault Code A019
Description Left rear flat suspension cylinder warning.
Fault Conditions Sets if PLM detects a flat left rear suspension cylinder.
Display Fault Description: LR FLAT SUSP CYL FLT
Resulting Problem(s) Potential damage to suspension and frame.
fault.
Table
1. The logic that produces this fault is intended to identify flat suspension cylinders. The primary correction is to
recharge / repair the cylinder. If the cylinder is not defective, use the following procedure to correct PLM4.
30

Reference
31
Fault Code A022: Carryback load excessive

Fault Code A022
Description Carryback load excessive.
Fault Conditions Sets if PLM detects excessive load remaining in the bed after dumping is complete.
Operator Alerting Display Operator Action: None
System Response Display Fault Description: None
Display Fault Code: None
Resulting Problem(s) Reduced production.
fault.
Table
1. The logic that produces this fault is intended to identify excessive carryback load. This is a KOMTRAX Plus
recording only. No display announces the fault. If excessive carryback does not exist, troubleshoot the payload
system.
2. This fault's logic contains more than one parameter, each of which may have it's own related fault code(s).
32

Reference
33
Fault Code A101: High pressure detected across a hydraulic pump filter
Operator Action Go To Shop Now
Fault Code A101
Description High pressure detected across a hydraulic pump filter.
Fault Conditions Sets if switch is on, engine is running, and oil temperature is above 50 ºC (122 ºF) for
10 seconds.
Resets if any of this is not true for 10 seconds.
Operator Alerting Sound Buzzer
System Response Flash IM Warning Indicator
Display Operator Action: GO TO SHOP NOW
Display Fault Description: HYD OIL FILT RESTRICT
Resulting Problem(s) Hydraulic oil filters will bypass oil without filtration. Continuing operation may damage
hydraulic system components.
fault.
Table
1. This fault is generated by series input to IM from the hydraulic oil filter switches. Any of the three switches
can open and cause the warning. The normal corrective measure for this fault is to change one or more
hydraulic filters.
Pump Filter Switches 0: No hydraulic filter switches open
(IM2Y) 1: One or more hydraulic filter switches open
Fault(s): A273
Hydraulic Oil 0.016 Volt to 4.89 Volt: Good Readings
Temperature - Tank < 0.016 Volt or > 4.89 Volt: Defective Sensor or Circuit
(IM3m) Fault(s): A104, A014, A193
Engine Speed [RPM] < 300 RPM: engine is not running
(CAN/J1939) (IM1q,r,s) > 300 RPM for 4 seconds: engine is running
Fault(s): A184
Keyswitch (IM3G) 0: keyswitch is off and the truck is not moving and the engine is not running
1: keyswitch is on or the truck is moving (GE power not yet off)
Fault(s): A240
34

Reference
Pump Filter Switch Refer to 58E-06-02311, sheet 15, zones D9 through D22 830E
connection at IM Refer to 58E-06-02321, sheet 31, zones B6 through C8
Refer to 58F-06-02311, Sheet 15, zones D9 through D22 930E
Refer to 58F-06-10561, Sheet 31, zones B6 through C8
Refer to 58B-06-02390, Sheet 16, zones E9 through E22 980E
Refer to 58B-06-03570, Sheet 33, zones B6 through C8
35
Fault Code A103: Hydraulic Oil Temp - Tank Sensor Low

Fault Code A103
Description Hydraulic Oil Temp - Tank Sensor Low
Fault Conditions Sets if temperature reading drops to -62ºC (-80 ºF).016 Volts for 3 seconds.
Resets if temperature reading rises to -59ºC (-74 ºF).032 Volts for 3 seconds.
Operator Alerting No Lamp
System Response Display Fault Description: TNK OIL TEMP SENS LO
Resulting Problem(s) Loss of monitoring of the Hydraulic Tank Temperatures with potential for damage if
temperatures also go high
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the sensor.
(IM3m) Fault(s): A104, A193

Reference
Hydraulic Oil Refer to 58E-06-02311, sheet 15, zones J9 through K21 830E
Temperature Refer to 58E-06-02321, sheet 5, zones D4 through E6
connection to IM
36
Fault Code A104: Hydraulic Oil Temp - Tank Sensor High

Fault Code A104
Description Hydraulic Oil Temp - Tank Sensor High
Fault Conditions Sets if temperature reading rises to 133ºC (271 ºF) 4.89 Volts for 3 seconds.
Resets if temperature reading drops to 107ºC (225 ºF) 4.77 Volts for 3 seconds.
Operator Alerting No Lamp
System Response Display Fault Description: TNK OIL TEMP SENS HI
Resulting Problem(s) Loss of monitoring of the Hydraulic Tank Temperatures with potential for damage if
temperatures also go high
fault.
Table

Reference
connection to IM
37
Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level
Fault Code A105
Description Fuel level sensor is shorted to ground, indicating a false high fuel level.
Fault Conditions Sets if fuel level indication is at 110% for 5 seconds with keyswitch on, and battery
voltage does not drop below 18, with engine speed below 600 rpm.
Resets if fuel level indication is at 104.2% for 3 seconds.
Display Fault Description: FUEL LEVEL SENSOR LO
Resulting Problem(s) False high fuel gauge readings. If ignored, possible shutdown of engine while on the
haul road.
fault.
Table
1. The primary correction for this fault is to correct or change the fuel level sensor and wiring.
Fuel Level Sensor 0.57 to 8.2 Volts: Good Readings at 24 Volt Battery (varies with battery voltage)
(IM3g) < 0.57 or > 8.2 Volts: Defective Sensor or Circuit at 24 Volt Battery (varies with battery
voltage)
Fault(s): A158
Battery Voltage, 24 > 18 Volt: Good Reading
Volt (IM1A) < 18 Volt: Low battery voltage (while cranking) blocks this A105 fault code.
Fault(s): A153, A154, A155, A250
Fault(s): A240
Engine Speed [RPM] < 600 RPM: combined with low voltage means cranking is in process and fault is
(CAN/J1939) (IM1q,r,s) blocked
> 600 RPM: engine is running normally
Fault(s): A184
38

Reference
Keyswitch, OR Refer to 58E-06-02311, sheet 15, zones D10 through D19 830E
connection to IM Refer to 58E-06-02321, sheet 31, zones B8 through B10
Refer to 58F-06-10561, Sheet 31, zones B8 through B10
Refer to 58B-06-02390, Sheet 16, zones D10 through D19 980E
Refer to 58B-06-03570, Sheet 33, zones B9 through B10
Fuel Level Sensor Refer to 58E-06-02311, sheet 15, zones D10 through D22 830E
circuit Refer to 58E-06-02321, sheet 31, zones B8 through B10
Refer to 58B-06-02390, Sheet 16, zones C9 through D22 980E
39
Fault Code A109: GE has generated a propel system reduced level signal
Operator Action Max Speed Limited
Fault Code A109
Description GE has generated a propel system reduced level signal.
Fault Conditions Sets if the GE controller generates a propel system reduced level event.
Operator Alerting Sound Buzzer - single burst
System Response Display Operator Action: MAX SPEED LIMITED
Display Fault Description: REDUCED PROPEL
Resulting Problem(s) Propel system may not permit the truck to remain at full performance. Shutdown of
propel system may occur if severity increases.
fault.
A laptop running GE's PTU software may be required to resolve this fault.
Table
1. This fault is generated by GE placing a message on CAN/RPC
2. It may be necessary to use GE's PTU software to determine the actual cause of the propel system distress
Propel System 0: Fault not present
Reduced Level (CAN/ 1: Fault active
RPC) IM1I, j, k Fault(s): A233
40

Reference
CAN/J1939 connection Refer to 58E-06-02311, sheet 17, zones E1 and sheet 7, zones H2 830E
at Engine through H10
Refer to 58E-06-02321, sheet 6, zone A5
Refer to 58F-06-02311, Sheet 17, zones E1 and Sheet 7, zones H2 930E
through H10
Refer to 58B-06-02390, Sheet 18, zones E1 and Sheet 7, zones H2 980E
through H8
CAN/J1939 connection Refer to 58E-06-02311, sheet 17, zones B5 through B6 and sheet 15, 830E
at IM zones I9 through I12
Refer to 58F-06-02311, Sheet 17, zones B4 through B5 and Sheet 15, 930E
zones J9 through J12
Refer to 58B-06-02390, Sheet 18, zones E4 through E5 and Sheet 16, 980E
zones E6
41
Fault Code A111: Low steering pressure warning

Fault Code A111
Description A111 is a low steering pressure warning for storage by KOMTRAX Plus. It is designed
to filter out some service and operational conditions that would otherwise produce this
warning.
Fault Conditions A111 sets if low steering pressure input to IM remains after 90 seconds of engine
running at 300 rpm or above and is sustained for 30 seconds at speeds of 1200 rpm or
above.
Resulting Problem(s) Truck may not steer properly.
fault.
Table
2. If there are no active parameter fault codes, then based on the truck's setup while this fault is active,
malfunction is still unresolved, then check each of the parameters in the Table for proper functionality.
Low Steering Pressure 0: steering pressure normal
Switch (IM2S) 1: low steering pressure
Fault(s): A279, A115, A253
Engine Speed [RPM] 0: engine is not running
> 300 RPM: engine is running
> 1200 RPM: engine is running fast enough to maintain steering pressure
42

Reference
Low Steering Pressure Refer to 58E-06-02311, sheet 15, zones N2 through N8 830E
Switch connection to Refer to 58E-06-02321, sheet 31, zone C3
IM Refer to 58F-06-02311, Sheet 15, zones N2 through N8 930E
Refer to 58F-06-10561, Sheet 31, zone C3
Refer to 58B-06-03570, Sheet 33, zone C3
through H10
through H8
zones E6
43
Fault Code A115: Low steering precharge pressure detected

Operator Action Stop; Park
Fault Code A115
Description Low steering precharge pressure is detected.
Fault Conditions Sets and latches if low steering precharge switch operates for 2 seconds with
keyswitch on and “Steering Precharge Mask” not on. The “Steering Precharge Mask”
prevents warnings that might occur from the beginning of steering bleed until 5
minutes after bleed is complete or timed out or keyswitch is turned back on.
Resets when steering bleed comes on. Mask prevents new operations for 5 minutes.
System Response Flash IM Warning indicator
Display Operator Action: STOP: PARK
Display Fault Description: LOW STRG PRECHARGE
Resulting Problem(s) Low steering accumulator precharge will reduce the amount of stored energy in the
steering system.
fault.
Table
1. The primary correction for this fault is to adjust the nitrogen charge in the steering accumulators.
Troubleshoot all item(s) related to the parameter(s) which are found to be malfunctioning
Low Steering 0: Normal reading - full precharge pressure
Precharge Pressure 1: Steering precharge pressure is low
Switch (IM2W)
Fault(s): A240
Steering Accum Bled 0: Steering bleed is complete
Pressure Switch 1: Steering bleed is not complete
(IM2Z) Fault(s): A258, A280
44

Reference
Low Steering Refer to 58E-06-02311, sheet 15, zones M2 through M8 830E
Precharge Pressure Refer to 58E-06-02321, sheet 31, zones B3 through C3
Switch to IM Refer to 58F-06-02311, Sheet 15, zones M2 through M8 930E
Steering Accum Bled Refer to 58E-06-02311, sheet 15, zones O2 through O8 830E
Pressure Switch to IM Refer to 58E-06-02321, sheet 31, zones B2 through C2
Refer to 58F-06-02311, Sheet 15, zones O2 through O8 930E
Refer to 58B-06-02390, Sheet 16, zones O2 through O7 980E
45
Fault Code A117: Low brake accumulator pressure warning

Fault Code A117
Description A117 is a low brake accumulator pressure warning for storage by KOMTRAX Plus. It is
designed to filter out some service and operational conditions that would otherwise
produce this warning.
Fault Conditions A117 sets if low brake accumulator pressure input to IM remains after 90 seconds of
engine running at 300 rpm or above.
A117 resets if pressure returns or engine stops running for 1 second.
Resulting Problem(s) Service brake may not stop or hold the truck.
fault.
Table
1. This fault is generated by more than one parameter, but the independent parameters do not have fault codes
for situations that will affect this fault.
Brake Accumulator 0: Brake accumulator pressure normal
Pressure Switch 1: Low brake accumulator pressure
(IM2U)
Engine Speed [RPM] 0: Engine is not running
> 300 RPM: Engine is running
46

Reference
through H10
through H8
zones E6
Brake Accumulator Refer to 58E-06-02311, sheet 15, zones F9 through F16 830E
Pressure Switch to IM Refer to 58E-06-02321, sheet 5, zones E3 through F3
Refer to 58F-06-02311, Sheet 15, zones F9 through F16 930E
Refer to 58F-06-10561, Sheet 5, zones E3 through F3
Refer to 58B-06-02390, Sheet 16, zones F9 through F16 980E
Refer to 58B-06-03570, Sheet 5, zones E3 through F3
47
Fault Code A118: Brake pressure is low while in brake lock

Operator Action Set Park Brake
Fault Code A118
Description Brake pressure is low while in brake lock.
Fault Conditions Sets in response to brake lock switch when park brake is not set and brake lock
degrade on for 3 seconds except when operated by steering bleed circuitry.
Park brake set is defined as closure of the park brake set pressure switch and opening
of the park brake release pressure switch.
Resets if brake lock or brake lock degrade switch are off for 1 second.
Display Operator Action: SET PARK BRAKE
Display Fault Description: SERV BRAKE DEGRADE
fault.
Table
Brake Lock (IM2i) 0: brake lock not on
1: brake lock is on
Fault(s): A272
Brake Lock Degrade 0: brake lock degrade not on
Sw (IM2V) 1: brake lock degrade is on
Fault(s): A281
Park Brake Set input 0: Park Brake is Set
(IM2f) 1: Park Brake is not Set
Fault(s): A213
Park Brake Release 0: Park Brake is Released
input (IM2M) 1: Park Brake is not Released
Fault(s): A214
48

Reference
Service Brake Refer to 58E-06-02311, sheet 15, zones G9 through G16 830E
Degrade Pressure Refer to 58E-06-02321, sheet 5, zones E3 through F3
Switch to IM Refer to 58F-06-02311, Sheet 15, zones G9 through G16 930E
Refer to 58B-06-02390, Sheet 16, zones G9 through G16 980E
Brake Lock Switch Refer to 58E-06-02311, sheet 9, zones N10 through N17 830E
connection to IM Refer to 58E-06-02321, sheet 5, zone D4
Refer to 58F-06-02311, Sheet 9, zones N10 through N17 930E
Refer to 58F-06-10561, Sheet 5, zone D4
Refer to 58B-06-03570, Sheet 5, zone D4
49
Fault Code A123: GE has generated a reduced retarding caution

Operator Action Slow Down Hill
Fault Code A123
Description GE has generated a reduced retarding caution.
Fault Conditions Sets if the GE controller generates a reduced retarding event.
Resets if GE removes the reduced retarding event.
System Response Display Operator Action: SLOW DOWN HILL
Display Fault Description: REDUCED RETARDING
Resulting Problem(s) Retarding will be at somewhat reduced level, but the truck can still be driven.
fault.
Table
Reduced Retarding 0: Fault not present
Input (CAN/RPC) 1: Fault active
(IM1q, r, s) Fault(s): A233
50

Reference
51
Fault Code A124: GE has generated a no propel / no retard or system not running input
Fault Code A124
Description GE has generated a no propel / no retard or system not running input.
Fault Conditions Sets if a No Propel / No Retard input is received from GE on CAN bus or a System
Running input is not received from GE on wire input with Keyswitch, OR on and Park
Brake not Set. Park brake set is defined as closure of the park brake set pressure
switch and opening of the park brake release pressure switch.
Resets when CAN signal is removed or 3 seconds after the System Running signal
appears.
Display Operator Action: STOP; PARK
Display Fault Description: NO PROPEL / RETARD
Resulting Problem(s) The drive system is inoperable in either propel or retard.
fault.
Table
1. This fault is generated by GE placing a No Propel/Retard message on CAN/RPC or by a missing System
Running Wire Input.
2. It may be necessary to use GE's PTU software to determine the actual cause of the propel system distress.
No Propel/Retard 0: fault not present
(CAN/RPC) (IM1i,j,k) 1: fault active
Fault(s): A233
GE System Running 0: system is running
input (IM2n) 1: system not running
Keyswitch, OR input 0: Keyswitch, OR is missing
(IM3G) 1: Keyswitch, OR is active
Fault(s): A240
Park Brake Set input 0: Park Brake is Set
(IM2f) 1: Park Brake is not Set
Fault(s): A213
Park Brake Release 0: Park Brake is Released
input (IM2M) 1: Park Brake is not Released
Fault(s): A214
52

Reference
GE System Running Refer to 58E-06-02311, sheet 7, zones G15 through G18 830E
Refer to 58F-06-02311, Sheet 7, zones G15 through G18 930E
53

Reference
Park Brake Set Refer to 58E-06-02311, sheet 15, zones F10 through F16 830E
Pressure Switch Refer to 58E-06-02321, sheet 5, zone C8
connection to IM Refer to 58F-06-02311, Sheet 15, zone F10 to F16 930E
Refer to 58B-06-02390, Sheet 16, zone F10 to F16 980E
Park Brake Release Refer to 58E-06-02311, sheet 5, zones H3 through H9 830E
Pressure Switch to IM Refer to 58E-06-02321, sheet 5, zone C9
Refer to 58F-06-02311, Sheet 5, zones H5 through H14 930E
Refer to 58B-06-02390, Sheet 5, zones H6 through H20 980E
54
NOTES
55
Fault Code A125: GE has generated a no propel warning

Fault Code A125
Description GE has generated a no propel warning.
Fault Conditions Sets in response to a GE No Propel signal on the CAN/RPC bus. Resets when GE
clears the signal.
Display Operator Action: STOP; PARK
Display Fault Description: NO PROPEL
Resulting Problem(s) The drive system is inoperable in propel.
fault.
Table
No Propel (CAN/RPC) 0: Fault not present
(IM1i,j,k) 1: Fault active
Fault(s): A233
56

Reference
57
Fault Code A126: Oil level in the hydraulic tank is low

Operator Action Stop; Park; Power Down; Check
Fault Code A126
Description Oil level in the hydraulic tank is low.
Fault Conditions Sets if sensor reports oil level to be low.
Resets if oil level is restored or if steering bleed comes on.
Display Operation Action: STOP: PRK: PWR: CHK
Display Fault Description: HYD OIL LEVEL FAULT
Resulting Problem(s) Low hydraulic oil level can cause damage to equipment and failure to operate
properly.Steering and brakes may deteriorate in performance.
fault.
Table
1. This primary correction for this fault is to add oil to the hydraulic system and check for hydraulic leaks.
2. If oil is sufficient, check the sensor and sensor wiring.
3. No additional fault codes are available for this function.
Hydraulic Oil Level 0: Oil level is normal
Sensor (IM1W, IM2k) 1: Oil level is low

Reference
Hydraulic Oil Level Refer to 58E-06-02311, sheet 15, zones J10 through J21 830E
connection to IM Refer to 58E-06-02321, sheet 31, zone C8
Refer to 58F-06-02311, Sheet 15, zones J10 through J21 930E
Refer to 58B-06-02390, Sheet 16, zones I9 through I19 980E
58
Fault Code A127: IM-furnished +5 volt output for sensors is low

Fault Code A127
Description IM-furnished +5 volt output for sensors is low.
Fault Conditions Sets when Sensor +5V Input drops below 4.52 volts for 2 seconds.
Resets when Sensor +5V Input recovers to 4.66 volts for 2 seconds.
System Response Operate IM Warning Indicator
Display Fault Description: TEMP SENSOR +5V LOW
Resulting Problem(s) All 5 temperature sensors using the +5 Volt supply will report low readings. Control of
engine speed and warnings of high oil temperature will be compromised. Equipment
damage may result.
fault.
Table
2. Check external wiring and sensors to determine if problem is outside of IM.
Sensor +5V Analog >4.52 Volts: Normal voltage
Input (IM3j) <4.52 Volts: Low voltage
Sensor +5V Output >4.52 Volts: Normal voltage
(IM3c) <4.52 Volts: Low voltage

Reference
5 Volt Thermal Sensor Refer to 58E-06-02311, sheet 15, zones K10 through K12 830E
Supply Circuit Refer to 58E-06-02321, sheet 18, zone A6 and sheet 31, zone C8
Refer to 58F-06-02311, Sheet 15, zone K10 to K12 930E
Refer to 58F-06-10561, Sheet 18, zone A6 and Sheet 5, zones D7
through E7
Refer to 58B-06-02390, Sheet 16, zone J9 to J10 980E
Refer to 58B-06-03570, Sheet 20, zone A6 and Sheet 5, zones D7
through E7
59
Fault Code A128: IM-furnished +5 volt output for sensors is high

Fault Code A128
Description IM-furnished +5 volt output for sensors is high.
Fault Conditions Sets when Sensor +5V Input rises above 5.51 volts for 2 seconds.
Resets when Sensor +5V Input drops to 5.27 volts for 2 seconds.
Operator Alerting Operate Repair Lamp
System Response Display Fault Description: TEMP SENSOR +5V HI
Resulting Problem(s) All 5 temperature sensors using the +5 Volt supply will report high readings. Control of
engine speed and warnings of high oil temperature will occur at lower than normal
temperatures. False warnings will occur.
fault.
Table
2. Check external wiring and sensors to determine if problem is outside of IM.
Sensor +5V Analog <5.51 Volts: Normal voltage
Input (IM3j) >5.51 Volts: High voltage
Sensor +5V Output <5.51 Volts: Normal voltage
(IM3c) >5.51 Volts: High voltage

Reference
5 Volt Thermal Sensor Refer to 58E-06-02311, sheet 15, zones K10 through K12 830E
Supply Circuit Refer to 58E-06-02321, sheet 18, zone A6 and sheet 31, zone C8
Refer to 58F-06-02311, Sheet 15, zone K10 to K12 930E
Refer to 58F-06-10561, Sheet 18, zones A6 and Sheet 5, zones D7
through E7
Refer to 58B-06-02390, Sheet 16, zone J9 to J10 980E
Refer to 58B-06-03570, Sheet 20, zones A6 and Sheet 5, zones D7
through E7
60
NOTES
61
Fault Code A139: Low fuel warning

Fault Code A139
Description A139 is a low fuel level warning for storage by KOMTRAX Plus and for use by A310.
Fault Conditions Sets after 15 seconds of fuel level readings below 10% of full if the key switch is on,
low voltage due to cranking is not sensed, and the fuel level sensor is not high.
Resets after 1 minute if fuel level recovers to 15% of full.
Resulting Problem(s) Possible running out of fuel on haul road. Possible engine damage.
fault.
Table
1. The primary correction for this fault is to add fuel to the tank.
Fuel Level Sensor 0.57 to 8.2 Volts: Good readings at 24 volt battery (varies with battery voltage)
(IM3g) <0.57 or >8.2 Volts: Defective sensor or circuit at 24 volt battery (varies with battery
voltage)
Battery Voltage, >18 Volt: Good reading
24 Volt (IM1A) <18 Volt: Low battery voltage (while cranking) blocks this A105 fault code.
Fault(s): A240
blocked
> 300 RPM for 4 seconds: engine is running
62

Reference
Battery Supply Voltage Refer to 58E-06-02311, sheet 5, zones L4 through L15 830E
to IM Refer to 58E-06-02321, sheet 18, zones A9 through B9
Refer to 58F-06-02311, Sheet 5, zones L4 through L15 930E
Refer to 58F-06-10561, Sheet 18, zones A9 through B9
Refer to 58B-06-02390, Sheet 5, zones L6 through L14 980E
Refer to 58B-06-03570, Sheet 20, zones A9 through B9
63
830E Dump truck

930E Dump truck
980E Dump truck
64
CEN40179-00
DUMP TRUCK
830E
930E
980E

830E-5 A50005 and up
930E-5 A40004 and up
980E-5 A50005 and up
40 Troubleshooting
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of
hydraulic oil.................................................................................................................................................... 4
Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of
hydraulic oil.................................................................................................................................................... 6
Fault Code A152: Starter failure............................................................................................................................ 8
Fault Code A153: Battery voltage is low with the truck in operation ................................................................... 10
Fault Code A154: Battery charging voltage is excessive .................................................................................... 14
Fault Code A155: Battery charging voltage is low .............................................................................................. 16
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level............................ 18
Fault Code A166: Left rear hydraulic oil temperature sensor is low ................................................................... 20
Fault Code A167: Right rear hydraulic oil temperature sensor is low ................................................................. 22
Fault Code A168: Left front hydraulic oil temperature sensor is low................................................................... 24
Fault Code A169: Right front hydraulic oil temperature sensor is low ................................................................ 26
Fault Code A170: Left rear hydraulic oil temperature sensor is high .................................................................. 28
Fault Code A172: Left front hydraulic oil temperature sensor is high ................................................................. 30
Fault Code A173: Right front hydraulic oil temperature sensor is high ............................................................... 31
1
Fault Code A184: The J1939 data link is not connected..................................................................................... 32

Fault Code A190: The auto lube control has detected an incomplete lube cycle ............................................... 34
Fault Code A193: Hydraulic Tank Oil Temperature is high.................................................................................. 37
Fault Code A194: Left front hydraulic oil temperature is high ............................................................................. 38
Fault Code A195: Right front hydraulic oil temperature is high........................................................................... 40
Fault Code A196: Left rear hydraulic oil temperature is high .............................................................................. 42
Fault Code A197: Right rear hydraulic oil temperature is high............................................................................ 44
Fault Code A198: Hoist Pressure 1 Sensor is high............................................................................................. 46
Fault Code A199: Hoist Pressure 2 Sensor is high............................................................................................. 47
Fault Code A200: Steering Pressure Sensor High.............................................................................................. 48
Fault Code A201: Brake Pressure Sensor High.................................................................................................. 49
Fault Code A202: Hoist Pressure 1 Sensor Low................................................................................................. 50
Fault Code A203: Hoist Pressure 2 Sensor Low................................................................................................. 52
Fault Code A204: Steering Pressure Sensor Low............................................................................................... 54
Fault Code A205: Brake Pressure Sensor Low .................................................................................................. 56
Fault Code A206: Ambient Temperature Sensor High ........................................................................................ 58
Fault Code A207: Ambient Temperature Sensor Low......................................................................................... 59
Fault Code A213: The parking brake should have applied but is detected as not having applied ...................... 60
Fault Code A214: The parking brake should have released but is detected as not having released ................. 64
Fault Code A215: Brake auto apply valve circuit is defective ............................................................................. 70
Fault Code A216: An open or short to ground has been detected in the park brake command valve circuit ..... 74
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted ...................... 78
Fault Code A230: Park brake has been requested while truck still moving ........................................................ 82
Fault Code A231: The body is up while traveling or intending to travel .............................................................. 86
Fault Code A233: Drive system CAN/RPC Control Link not connected ............................................................. 90
Fault Code A235: Steering accumulator is in the process of being bled down ................................................... 94
Fault Code A236: The steering accumulator has not properly bled after 90 seconds ........................................ 98
Fault Code A237: The CAN/RPC connection to the Display is open ................................................................ 101
Fault Code A240: The keyswitch input to the Interface Module is open ........................................................... 102
Fault Code A242: The fuel gauge within the display panel is defective ............................................................ 103
Fault Code A243: The engine coolant temp gauge within the display panel is defective ................................. 104
Fault Code A244: Drive system temperature gauge within the dash display panel is defective ....................... 105
Fault Code A245: The hydraulic oil temp gauge within the display panel is defective ...................................... 106
Fault Code A246: PLM reports truck overload .................................................................................................. 107
2
NOTES
3
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance
level 1 for cooling of hydraulic oil
Fault Code A145
Description Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for
cooling of hydraulic oil.
Fault Conditions Sets (advances engine) after 5 seconds at 105ºC (221ºF) after filtering out data from
sensors failed high.
Resets (returns engine to normal) after 5 seconds at 100ºC (212ºF).
Operator Alerting None. This event is recorded by KOMTRAX Plus only.
System Response
Resulting Problem(s) If this control is non-functional, excessive oil temperatures can cause oil and
equipment damage.
fault.
Table
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volt: Good readings
Left Rear (IM3i) <0.016 Volt or >4.89 Volt: Defective sensor or circuit
Right Rear (IM3m) <0.016 Volt or >4.89 Volt: Defective sensor or circuit
Left Front (IM3t) <0.016 Volt or >4.89 Volt: Defective sensor or circuit
Right Front (IM3r) <0.016 Volt or >4.89 Volt: Defective sensor or circuit
4

Reference
Hydraulic Oil Refer to 58F-06-02311, Sheet 15, zones J9 through L22 930E
Temperature Refer to 58F-06-10561, Sheet 5, zones D4 through E6
connection to IM Refer to 58B-06-02390, Sheet 16, zones J9 through K20 980E
5
Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance
level 2 for cooling of hydraulic oil
Fault Code A146
Description Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for
cooling of hydraulic oil.
Fault Conditions Sets (advances engine) after 5 seconds at 120ºC (248ºF) after filtering out data from
sensors failed high.
Resets (returns engine to normal) after 5 seconds at 108ºC (226ºF).
Operator Alerting None. This event is recorded by KOMTRAX Plus only.
System Response
Resulting Problem(s) If this control is non-functional, excessive oil temperatures can cause oil and
equipment damage.
fault.
Table
Left Rear (IM3i) <0.016 Volt or >4.89 Volt: Defective sensor or circuit
Right Rear (IM3m) <0.016 Volt or >4.89 Volt: Defective sensor or circuit
Left Front (IM3t) <0.016 Volt or >4.89 Volt: Defective sensor or circuit
Right Front (IM3r) <0.016 Volt or >4.89 Volt: Defective sensor or circuit
6

Reference
7
Fault Code A152: Starter failure

Fault Code A152
Description Starter Failure
Fault Conditions Sets if either starter motor is not energized for 2 seconds when cranking is attempted.
Resets only when steering bleed occurs.
Operator Alerting Display: Repair Item
System Response Display Fault Description: STARTER FAILURE
Resulting Problem(s) One good starter may be destroyed or engine may not start at all.
fault.
Table
Starter Motor 1 0: starter motor 1 not energized
Energized (IM3R) 1: starter motor 1 energized
Fault(s): A275
Energized (IM3S) 1: starter motor 2 energized
Fault(s): A275
Crank Sense (IM3U) 0: no cranking in process
1: cranking in process
8

Reference
Starter Motors 1 and 2 Refer to 58E-06-02311, sheet 4, zones K10 through K12 830E
Refer to 58E-06-02321, sheet 4, zones C8 through C9
Refer to 58F-06-02311, Sheet 4, zones K10 through K12 930E
Refer to 58F-06-10561, Sheet 4, zones C8 through C9
Refer to 58B-06-02390, Sheet 4, zones K10 through K12 980E
Refer to 58B-06-03570, Sheet 4, zones C8 through C9
Starter Motor Refer to 58E-06-02311, sheet 5, zones L4 through L7 830E
connections to IM Refer to 58E-06-02321, sheet 4, zones C8 through C9
Crank Sense Refer to 58E-06-02311, sheet 4, zones M9 through N19 and sheet 6, 830E
connection to IM zones B2 through D4
Refer to 58E-06-02321, sheet 4, zones A7 through B7
Refer to 58F-06-02311, Sheet 4, zones M9 through N19 and Sheet 6, 930E
zones B2 through D4
Refer to 58B-06-02390, Sheet 4, zones M9 through N19 and Sheet 6, 980E
zones H2 through H4
9
Fault Code A153: Battery voltage is low with the truck in operation
Fault Code A153
Description Battery voltage is low with the truck in operation.
Fault Conditions Sets if battery voltage with the engine running or truck moving is below 23 volts for 5
seconds. Truck moving sets if truck speed is above 0 or if a bad speed signal fault is
active and the park brake is not set.
Resets if voltage recovers to 25.5 volts
Display Fault Description: BATTERY VOLTS LOW
Resulting Problem(s) Voltage may continue to drop and cause improper operation of the many electrical
controls on the truck.
fault.
10
Table
1. The primary correction for this fault is to charge the batteries.
Battery Voltage, < 23.0 volts: Too low to continue operation.
24 Volt (IM1A) > 23.0 volts: OK to continue operation.
Fault(s): A154, A155, A250
Fault(s): A184
Truck Speed [kph] 0: truck is not moving
(CAN/RPC) (IM1i,j,k) > 0.8 kph (0.5 mph): truck is moving
Fault(s): A233
Park Brake Set (IM2f) 0: parking brake pressure switch indicating low pressure and an applied parking brake
1: parking brake pressure switch indicating higher pressure and an unapplied parking
brake
Fault(s): A213
Park Brake Released 0: parking brake pressure switch indicating high pressure and a released parking
(IM2M) brake
1: parking brake pressure switch indicating low pressure and an applied parking brake
Fault(s): A214
11

Reference
through H10
through H8
zones E6
12

Reference
13
Fault Code A154: Battery charging voltage is excessive

Operator Action Stop; Park; Power Down
Fault Code A154
Description Battery charging voltage is excessive.
Fault Conditions Sets if above 32 volts for 5 seconds.
Resets if below 27.5 volts for 5 seconds.
Display Operator Action: STOP: PARK: PWR 
Display Fault Description: HIGH BATTERY VOLTS
Resulting Problem(s) Sustained excessive charging voltage may burn out electrical and electronic compo-
nents.
fault.
Table
1. The primary correction for this fault is to check / replace the battery charger.
2. This fault's logic contains only one parameter.
Battery Voltage, > 32.0 volts: Too high to continue operation.
24 Volt (IM1A) < 32.0 volts: OK to continue operation.
Fault(s): A153, A155, A250

Reference
14
NOTES
15
Fault Code A155: Battery charging voltage is low

Operator Action Go to shop now
Fault Code A155
Description Battery charging voltage is low.
Fault Conditions Sets if below 24.5 volts for 5 seconds with engine above 1400 rpm.
Resets if above 26.0 volts for 5 seconds or at steering bleed.
Display Fault Description: BATT CHARGING FLT
Resulting Problem(s) If defective battery charging alternators are not replaced, batteries may become
discharged and electrical and electronic equipment will stop working.
fault.
Table
1. The primary correction for this fault is to check / replace the battery charger.
Battery Voltage, < 24.5 volts: Charger must be changed soon.
24 Volt (IM1A) > 26.0 volts: OK to continue operation.
Fault(s): A153, A154, A250
Engine Speed [RPM] < 1400 RPM: engine is not running fast enough for battery charger test.
(CAN/J1939) (IM1q,r,s) > 1400 RPM: engine is running fast enough for battery charger test.
Fault(s): A184
16

Reference
CAN/J1939 connection Refer to 58E-06-02311, sheet 17, zone E1 and sheet 7, zones H2 830E
Refer to 58F-06-02311, Sheet 17, zone E1 and Sheet 7, zones H2 930E
through H10
Refer to 58B-06-02390, Sheet 18, zone E1 and Sheet 7, zones H2 980E
through H8
zones E6
17
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level
Fault Code A158
Description Fuel level sensor is open or shorted high, indicating a false low fuel level.
Fault Conditions Sets if fuel level indication is at -18.5% for 3 seconds, and battery voltage does not
drop below 18, with engine speed below 600 rpm.
Resets if fuel level indication is above -12.5% for 3 seconds.
Display Fault Description: FUEL LEVEL SENSOR HI
Resulting Problem(s) Fuel readings will show an empty tank, whether there is fuel in the tank or not.
fault.
Table
1. The primary correction for this fault is to correct or replace the fuel level sensor or wiring.
Fuel Level Sensor 0.57 to 8.2 Volts: Good Readings at 24 Volt Battery (varies with battery voltage)
(IM3g) < 0.57 or > 8.2 Volts: Defective Sensor or Circuit at 24 Volt Battery (varies with battery
voltage)
Fault(s): A105
Battery Voltage, > 18 Volt: Good Reading
24 Volt (IM1A) < 18 Volt: Low battery voltage (while cranking) blocks this fault code.
Fault(s): A153, A154, A155, A250
Fault(s): A184
18

Reference
through H10
through H8
zones E6
19
Fault Code A166: Left rear hydraulic oil temperature sensor is low
Fault Code A166
Description Left rear hydraulic oil temperature sensor is low.
Fault Conditions Sets if temperature reading drops to -51ºC (-60ºF) [.016 Volt] for 3 seconds or remains
10ºC (18ºF) below ambient temperature for 15 minutes after the engine runs.
Resets if temperature reading rises to -46ºC (-51ºF) [.032 Volt] for 3 seconds and
recovers to within 10ºC (18ºF) of ambient temperature.
System Response Display Fault Description: LR OIL TEMP SENS LO
Resulting Problem(s) Loss of monitoring of the left rear brake temperature begins a compromise of the
brake system temperature monitoring that can only worsen if other sensors are lost.
fault.
Table
Hydraulic Oil Temp - 0.016 Volt to 4.89 Volts: Good readings
Left Rear (IM3i) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A170
Ambient Temperature 0.016 Volt to 4.89 Volts: Good readings
(IM3e) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
20

Reference
Ambient Temperature Refer to 58F-06-02311, Sheet 15, zones L9 through L21 930E
Sensor connection to Refer to 58F-06-10561, Sheet 5, zone D10
IM Refer to 58B-06-02390, Sheet 16, zones L9 through L19 980E
21
Fault Code A167: Right rear hydraulic oil temperature sensor is low
Fault Code A167
Description Right rear hydraulic oil temperature sensor is low.
System Response Display Fault Description: RR OIL TEMP SENS LO
Resulting Problem(s) Loss of monitoring of the right rear brake temperature begins a compromise of the
fault.
Table
Right Rear (IM3m) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A171
Ambient Temperature 0.016 Volt to 4.89 Volts: Good Readings
22

Reference
23
Fault Code A168: Left front hydraulic oil temperature sensor is low
Fault Code A168
Description Left front hydraulic oil temperature sensor is low.
System Response Display Fault Description: LF OIL TEMP SENS LO
Resulting Problem(s) Loss of monitoring of the left front brake temperature begins a compromise of the
fault.
Table
Left Front (IM3t) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A172
24

Reference
25
Fault Code A169: Right front hydraulic oil temperature sensor is low
Fault Code A169
Description Right front hydraulic oil temperature sensor is low.
System Response Display Fault Description: RF OIL TEMP SENS LO
Resulting Problem(s) Loss of monitoring of the right front brake temperature begins a compromise of the
fault.
Table
Right Front (IM3r) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A173
26

Reference
27
Fault Code A170: Left rear hydraulic oil temperature sensor is high
Fault Code A170
Description Left rear hydraulic oil temperature sensor is high.
Fault Conditions Sets if temperature reading rises to 211ºC (412ºF) [4.89 Volts] for 3 seconds.
Resets if temperature reading drops to 188ºC (370ºF) [4.77 Volts] for 3 seconds.
System Response Display Fault Description: LR OIL TEMP SENS HI
Resulting Problem(s) Loss of monitoring of the Left Rear brake temperature begins a compromise of the
fault.
Table
Fault(s): A166

Reference
28
Fault Code A171: Right rear hydraulic oil temperature sensor is high
Fault Code A171
Description Right rear hydraulic oil temperature sensor is high.
System Response Display Fault Description: RR OIL TEMP SENS HI
Resulting Problem(s) Loss of monitoring of the right rear brake temperature begins a compromise of the
Related Information A laptop running "IM Realtime Data Monitor" software may be required to resolve this
fault.
Table
Fault(s): A167

Reference
29
Fault Code A172: Left front hydraulic oil temperature sensor is high
Fault Code A172
Description Left front hydraulic oil temperature sensor is high.
System Response Display Fault Description: LF OIL TEMP SENS HI
Resulting Problem(s) Loss of monitoring of the left front brake temperature begins a compromise of the
fault.
Table
Fault(s): A168

Reference
30
Fault Code A173: Right front hydraulic oil temperature sensor is high
Fault Code A173
Description Right front hydraulic oil temperature sensor is high.
System Response Display Fault Description: RF OIL TEMP SENS HI
Resulting Problem(s) Loss of monitoring of the right front brake temperature begins a compromise of the
Related Information A laptop running "IM Realtime Data Monitor" software may be required to resolve this
fault.
Table
Fault(s): A169

Reference
31
Fault Code A184: The J1939 data link is not connected

Operator Action Stop; Park Power down
Fault Code A184
Description The J1939 data link is not connected.
Fault Conditions Sets if no data is received from the engine for 10 seconds after an initial 11 second
delay at keyswitch ON.
Resets immediately when communication is established.
Display Fault Description: NO ENGINE DATA
Resulting Problem(s) Loss of engine data makes it impossible to operate the truck in a normal manner with-
out risking serious damage to the engine.
fault.
Table
CAN J1939 Data Link No communication for 10 seconds if keyswitch has been on for 11 seconds: J1939 not
(IM1qrs) connected.
Successful read of PGN 61444: J1939 is connected.
1: keyswitch is on or the truck is moving or the engine is running NOTE: for this fault,
the keyswitch function is delayed for 11 seconds internally after initial turn on
Fault(s): A240
32

Reference
through H10
through H8
zones E6
33
Fault Code A190: The auto lube control has detected an incomplete lube cycle
Fault Code A190
Description The auto lube control has detected an incomplete lube cycle.
Fault Conditions Sets if lube cycle is terminated by timeout rather than pressure. Lubrication occurs
with steering pressure up, truck moving, and drive control power on.
Resets when a lube cycle is properly terminated by pressure rather than timeout.
Operator Alerting Operate Repair Lamp
System Response Display Fault Description: AUTO LUBE FAULT
Resulting Problem(s) Insufficient lube may result and if left uncorrected could lead to equipment damage.
fault.
34
Table
Auto Lube Pressure 0: Pressure switch has transferred at 13790 kPa (2000 psi)
Sw (IM3Y) 1: Pressure switch at low pressure or solenoid circuit not on
Fault(s): A304, A305, A361
Low Steering Pressure 0: steering pressure normal (required for lube cycle to proceed)
Sw (IM2S) 1: low steering pressure
Fault(s): A279
(CAN/RPC) (IM1i,j,k) > 0 for 10 seconds: truck is moving
Fault(s): A233
GE Batt+ Off (IM3M) 0: power to GE control is off
1: power to GE control is on
Auto Lube Output Status - Open Load: Unexpected. Troubleshoot
(IM1T) Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected except momentarily at termination of a lube
cycle. If detected any other time, troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: Turns off between lubrication cycles.
1. Turns on during lubrication cycle.
35

Reference
Auto Lube Pressure Refer to 58E-06-02311, sheet 15, zones N9 through N19 830E
GE Batt+ Off Refer to 58E-06-02311, sheet 6, zones B2 through C4 830E
Refer to 58F-06-02311, Sheet 6, zones B2 through C4 930E
Auto Lube Solenoid Refer to 58E-06-02311, sheet 15, zones N9 through N19 830E
Refer to 58E-06-02321, sheet 2, zone B4
36
Fault Code A193: Hydraulic Tank Oil Temperature is high

Operator Action Stop: Park: Run Eng
Fault Code A193
Description Hydraulic Tank Oil Temperature is high
Fault Conditions Sets at 120ºC (248ºF) 4.5 volts after 5 seconds
Resets at 103ºC (217ºF) 4.4 volts after 5 seconds or at steering bleed.
Operator Alerting Operate LED on Oil Temp Gauge
System Response Sound Buzzer
Flash IM Warning indicator
Display Operator Action: STOP: PARK: RUN ENG
Display Fault Description: HOT HYD OIL TANK
Resulting Problem(s) Excessively hot oil can cause equipment damage and may reduce service brake effec-
tiveness.
fault.
Table
1. This fault's logic contains just one parameter. This fault may be resolved by resolving the parameter(s) active
fault code(s). Refer to the Troubleshooting Instructions for the active parameter fault(s).
Steering Bleed Valve 0: steering bleed is off
1: steering bleed is on

Reference
connection to IM
37
Fault Code A194: Left front hydraulic oil temperature is high

Operator Action Stop; Park; Run Engine
Fault Code A194
Description Left front hydraulic oil temperature is high.
Fault Conditions Sets at 120ºC (248ºF) [4.13 Volts] after 5 seconds.
Resets at 103ºC (217ºF) [3.78 Volts] after 5 seconds or at steering bleed.
Display Fault Description: HOT HYD OIL LF
tiveness.
fault.
Table
Steering Bleed Valve 0: steering bleed valve is off.
1: steering bleed valve is on.
38

Reference
39
Fault Code A195: Right front hydraulic oil temperature is high

Fault Code A195
Description Right front hydraulic oil temperature is high.
Display Fault Description: HOT HYD OIL RF
tiveness.
fault.
Table
40

Reference
41
Fault Code A196: Left rear hydraulic oil temperature is high

Fault Code A196
Description Left rear hydraulic oil temperature is high.
Display Fault Description: HOT HYD OIL LR
tiveness.
fault.
Table
42

Reference
43
Fault Code A197: Right rear hydraulic oil temperature is high

Fault Code A197
Description Right rear hydraulic oil temperature is high.
Display Fault Description: HOT HYD OIL RR
tiveness.
fault.
Table
Steering Bleed Valve 0: steering bleed valve is off
1: steering bleed valve is on
44

Reference
45
Fault Code A198: Hoist Pressure 1 Sensor is high

Fault Code A198
Description Hoist Pressure 1 Sensor is high.
Fault Conditions Sets at 27751 kPa (4025 psi) 20.1mA for 5 seconds.
Resets at 25165 kPa (3650 psi) 18.6 mA for 5 seconds.
System Response Display Fault Description: HOIST PRES 1 SENS HI
Resulting Problem(s) Monitoring of hoist pressures in KOMTRAX Plus will be compromised.
fault.
Table
Hoist Pressure 1 2.4 mA to 20.1 mA: good readings
Sensor (IM3s) < 2.4 mA or > 20.1 mA: Defective sensor or circuit
Fault(s): A202

Reference
Hoist Pressure 1 Refer to 58E-06-02311, sheet 15, zones H1 through H8 830E
Sensor connection to Refer to 58E-06-02321, sheet 31, zone A9
IM Refer to 58F-06-02311, Sheet 15, zones H1 through H8 930E
46
Fault Code A199: Hoist Pressure 2 Sensor is high

Fault Code A199
Description Hoist Pressure 2 Sensor is high.
System Response Display Fault Description: HOIST PRES 2 SENS HI
fault.
Table
Sensor (IM3q) < 2.4 mA or > 20.1 mA: Defective sensor or circuit
Fault(s): A203

Reference
Hoist Pressure 2 Refer to 58E-06-02311, sheet 15, zones I1 through I8 830E
IM Refer to 58F-06-02311, Sheet 15, zones I1 through I8 930E
47
Fault Code A200: Steering Pressure Sensor High

Fault Code A200
Description Steering Pressure Sensor High
System Response Display Fault Description: STRG PRES SENS HI
Resulting Problem(s) Monitoring of steering pressure in KOMTRAX Plus will be compromised.
fault.
Table
Steering Pressure 2.4 mA to 20.1 mA: good readings
Sensor (IM3d) < 2.4 mA or > 20.1 mA: Defective sensor or circuit
Fault(s): A204

Reference
Steering Pressure Refer to 58E-06-02311, sheet 15, zones H1 through H8 830E
Sensor connection to Refer to 58E-06-02321, sheet 31, zone B5
48
Fault Code A201: Brake Pressure Sensor High

Fault Code A201
Description Brake Pressure Sensor High
System Response Display Fault Description: BRAKE PRES SENS HI
Resulting Problem(s) Monitoring of the service brake system for driver input as well as KOMTRAX Plus data
will be compromised.
fault.
Table
Brake Pressure Sensor 2.4 mA to 20.1 mA: good readings
(IM3p) < 2.4 mA or > 20.1 mA: Defective sensor or circuit
Fault(s): A205

Reference
Brake Pressure Refer to 58E-06-02311, sheet 15, zones K1 through K8 830E
Sensor connection to Refer to 58E-06-02321, sheet 5, zone E10
IM Refer to 58F-06-02311, Sheet 15, zones K1 through K8 930E
Refer to 58F-06-10561, Sheet 5, zone E10
Refer to 58B-06-03570, Sheet 5, zone E10
49
Fault Code A202: Hoist Pressure 1 Sensor Low

Fault Code A202
Description Hoist Pressure 1 Sensor Low
Fault Conditions Sets at -2765 kPa (-401 psi) 2.4 mA for 5 seconds with cranking state not sensed (<
600 engine rpm and < 18 battery volts).
Resets at -1420 kPa (-206 psi) 3.2 mA
System Response Display Fault Description: HOIST PRES 1 SENS LO
fault.
Table
Sensor (IM3s) < 2.4 mA or > 20.1 mA: Defective sensor or circuit
Fault(s): A198
Volt (IM1A) < 18 Volt: Low battery voltage (while cranking) blocks this fault.
Fault(s): A153, A154, A155, A250
Fault(s): A184
50

Reference
Hoist Pressure 1 Refer to 58E-06-02311, Sheet 15, zones H1 through H8 830E
Sensor connection to Refer to 58E-06-02321, Sheet 31, zone A9
51
Fault Code A203: Hoist Pressure 2 Sensor Low

Fault Code A203
Description Hoist Pressure 2 Sensor Low
System Response Display Fault Description: HOIST PRES 2 SENS LO
fault.
Table
Sensor (IM3q) < 2.4 mA or > 20.1 mA: Defective sensor or circuit
Fault(s): A199
Fault(s): A153, A154, A155, A250
Fault(s): A184
52

Reference
Hoist Pressure 2 Refer to 58E-06-02311, sheet 15, zones I1 through I8 830E
IM Refer to 58F-06-02311, Sheet 15, zones I1 through I8 930E
53
Fault Code A204: Steering Pressure Sensor Low

Fault Code A204
Description Steering Pressure Sensor Low
System Response Display Fault Description: STRG PRES SENS LO
Resulting Problem(s) Monitoring of steering pressure in KOMTRAX Plus will be compromised.
fault.
Table
Steering Pressure 2.4 mA to 20.1 mA: good readings
Sensor (IM3d) < 2.4 mA or > 20.1 mA: Defective sensor or circuit
Fault(s): A200
Fault(s): A153, A154, A155, A250
Fault(s): A184
54

Reference
Steering Pressure Refer to 58E-06-02311, sheet 15, zones H1 through H8 830E
Sensor connection to Refer to 58E-06-02321, sheet 31, zone B5
55
Fault Code A205: Brake Pressure Sensor Low

Fault Code A205
Description Brake Pressure Sensor Low
System Response Display Fault Description: BRAKE PRES SENS LO
Resulting Problem(s) Monitoring of brake pressure in KOMTRAX Plus will be compromised.
fault.
Table
Fault(s): A201
Fault(s): A153, A154, A155, A250
A184
56

Reference
57
Fault Code A206: Ambient Temperature Sensor High

Fault Code A206
Description Ambient Temperature Sensor High
Fault Conditions Sets at 133º C (271º F) 4.89V for 3 seconds.
Resets at 107º C (225º F) 4.77V for 3 seconds.
System Response Display Fault Description: AMBIENT TEMP SENS HI
Resulting Problem(s) Monitoring of temperatures will be compromised without ambient temperature
information.
fault.
Table
Ambient Temperature 0.016 Volt to 4.89 Volt: Good Readings
Sensor (IM3e) < 0.016 Volt or > 4.89 Volt: Defective Sensor or Circuit
Fault(s): A207

Reference
Ambient Temperature Refer to 58E-06-02311, sheet 15, zones L9 through L21 830E
Sensor connection to Refer to 58E-06-02321, sheet 5, zone D10
IM Refer to 58F-06-02311, Sheet 15, zones L9 through L21 930E
58
Fault Code A207: Ambient Temperature Sensor Low

Fault Code A207
Description Ambient Temperature Sensor Low
Fault Conditions Sets at -62º C (-80º F) 0.016V for 3 seconds.
Resets at -59º C (-74º F) 0.032V for 3 seconds.
System Response Display Fault Description: AMBIENT TMP SENS LO
Resulting Problem(s) Monitoring of temperatures will be compromised without ambient temperature informa-
tion.
fault.
Table
Ambient Temperature 0.016 Volt to 4.89 Volt: Good Readings
Sensor (IM3e) < 0.016 Volt or > 4.89 Volt: Defective Sensor or Circuit
Fault(s): A206

Reference
Ambient Temperature Refer to 58E-06-02311, sheet 15, zones L9 through L21 830E
Sensor connection to Refer to 58E-06-02321, sheet 5, zone D10
IM Refer to 58F-06-02311, Sheet 15, zones L9 through L21 930E
59
Fault Code A213: The parking brake should have applied but is detected as not having
applied
Operator Action Secure Vehicle
Fault Code A213
Description The parking brake should have applied but is detected as not having applied.
Fault Conditions Sets if park brake does not come on in 2 seconds with no Park Brake Release
Command and either a Selector Switch (forward, neutral, or reverse) signal or a Park
Brake Request input or a Selector Switch park input is active.
Also sets if park brake does not come on in 2 seconds after Steering Bleed Valve
operates.
Also sets if park brake does not come on in 15 seconds after Engine Speed drops to 0
and there is no Park Brake Release Command and J1939 control link is working.
Resets after 3 seconds if the park brake applies, or if the park brake request is
canceled and the shifter is not in the park position and the shifter is in the forward,
neutral, or reverse positions and the engine is running.
Display Operator Action: SECURE VEHICLE
Display Fault Description: NO PARK BRAKE
Resulting Problem(s) The parking brake may be non-functional.
Engine cranking may be prevented.
Smart Timed Engine Shutdown may be prevented.
fault.
60
Table
Selector Switch (FNR) 0: shifter is not in forward, neutral, or reverse
(IM2N) 1: shifter is in forward, neutral, or reverse
Selector Switch (Park) 0: shifter is not park
(IM3T) 1: shifter is in park
Park Brake Request 0: shifter is not in the forward, neutral, or reverse positions or the engine oil pressure is
(IM3V) below the set point of the engine oil pressure switch
1: shifter is in the forward, neutral, or reverse positions and the engine oil pressure is
above the set point of the engine oil pressure switch
Fault(s): A264
brake
(IM2M) brake
Fault(s): A214
(CAN/J1939) (IM1q,r,s) > 0: engine is running
Fault(s): A184
Park Brake Solenoid Status - Open Load: Unexpected. Troubleshoot.
(IM1E) Status - Normal: Expected. No Problem.
Status - Shorted to Ground: Expected if shifter is in the forward, neutral, or reverse
positions and the engine oil pressure is above the set point of the engine oil pressure
switch. Otherwise unexpected and must troubleshoot.
0: shifter is not in the forward, neutral, or reverse positions or the engine oil pressure is
below the set point of the engine oil pressure switch and either the speed of the truck
has been 0.8 kph (0.5 mph) or less for 1 second or the service brakes are applied
61

Reference
through H10
through H8
zones E6
62

Reference
Selector Switch Refer to 58E-06-02311, sheet 9, zones H12 through H16 830E
Selector Switch Refer to 58E-06-02311, sheet 9, zones J16 through L17 830E
connections at IM Refer to 58E-06-02321, sheet 17, zone C2
Refer to 58F-06-02311, Sheet 9, zones J16 through L17 930E
Refer to 58B-06-02390, Sheet 10, zones I16 through K17 980E
Selector Switch Refer to 58E-06-02311, sheet 9, zones J5 through K5 830E
connections at VEC Refer to 58E-06-02321, sheet 17, zone C3
Refer to 58F-06-02311, Sheet 9, zones J5 through K5 930E
Refer to 58B-06-02390, Sheet 10, zones I7 through J7 980E
Park Brake Solenoid Refer to 58E-06-02311, sheet 9, zone K17 830E
connection to IM Refer to 58E-06-02321, sheet 5, zones A7 through B7
Refer to 58B-06-02390, Sheet 10, zone J17 980E
connection to VEC Refer to 58E-06-02321, sheet 5, zones A7 through B7
Park Brake Solenoid Refer to 58E-06-02311, sheet 7, zone G11 830E
Refer to 58F-06-02311, Sheet 7, zone G11 930E
Refer to 58B-06-02390, Sheet 10, zone G3 980E
63
Fault Code A214: The parking brake should have released but is detected as not having
released
Operator Action Stop: Park
Fault Code A214
Description The parking brake should have released but is detected as not having released.
Fault Conditions Sets if Park Brake does not release after the engine has been running for 90 seconds
with the Keyswitch (OR) on and Selector Switch Park off and Park Brake Request
input off for 3 seconds.
Park brake release is defined as the closure of the park brake release pressure switch
and the opening of the park brake set pressure switch.
Resets if Keyswitch (OR) is turned off, engine stops running or Park Brake releases for
3 seconds or Selector Switch (Park) input is on for 3 seconds or Park Brake Request
input is on for 3 seconds.
System Response Park Brake Status Lamp stays on
Display Operator Action: STOP: PRK: PWR: CHK
Display Fault Description: PARK BRAKE ON
Resulting Problem(s) Operation of the truck may be prevented or the parking brake may be damaged.
fault.
64
Table
Selector Switch (Park) 0: shifter is not in park
Fault(s): A264
(IM2M) brake
1: parking brake pressure switch indicating lower pressure and an applied parking
brake
1: parking brake pressure switch indicating higher pressure and a released parking
brake
Fault(s): A213
Fault(s): A184
Fault(s): A240
Status - Shorted to Ground: Expected if shifter is in the forward, neutral, or reverse
switch. Otherwise unexpected and must troubleshoot.
0: shifter is not in the forward, neutral, or reverse positions or the engine oil pressure is
below the set point of the engine oil pressure switch and either the speed of the truck
has been 0.8 kph (0.5 mph) or less for 1 second or the service brakes are applied
65

Reference
through H10
through H8
zones E6
66

Reference
67

Reference
68
NOTES
69
Fault Code A215: Brake auto apply valve circuit is defective

Operator Action Go To Shop
Fault Code A215
Description Brake auto apply valve circuit is defective.
Fault Conditions Sets if the output driver circuit detects an open circuit or short to ground when the
keyswitch is on and the parking brake is requested, or sets if the output driver circuit
does not detect an open circuit with the key switch on and the parking brake not
requested.
Resets only at power down.
Display Fault Description: BRK AUTO APPLY FLT
Resulting Problem(s) Park brake may not be protected in an application while rolling, or service brake may
not release and permit movement.
fault.
70
Table
2. If there are no active parameter fault codes then based on the truck's setup while this fault is active, deter-
mine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data Monitor
program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the unex-
pected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the malfunc-
tion is still unresolved then check each of the parameters in the Table for proper functionality. Troubleshoot all
item(s) related to the parameter(s) which are found to be malfunctioning.
Park Brake Request 0: Shift lever is not in Forward, Neutral, or Reverse or the engine oil pressure is below
(IM3V) the set point of the engine oil pressure switch.
1: Shift lever is in Forward, Neutral, or Reverse and the engine oil pressure is above
the set point of the engine oil pressure switch.
Keyswitch (IM3G) 0: Keyswitch is OFF and the truck is not moving and the engine is not running.
1: Keyswitch is ON or the truck is moving (GE power not yet off).
Fault(s): A240
Auto Brake Apply Status - Open Load: Unexpected if parking brake request and keyswitch are on. But
Relay (IM1R) expected if parking brake request is off or keyswitch is off. Troubleshoot if inconsis-
tent.
Status - Normal: Expected if park brake request and keyswitch are on. Troubleshoot if
status is normal with park brake request off or keyswitch off.
Status - Shorted to ground: Unexpected. Troubleshoot.
0: Normal operation with parking brake either on or off. This valve operates only tran-
siently when the parking brake is turned on.
1: Brake auto apply relay operates the brake lock valve for 1.5 seconds after the park-
ing brake is turned on if the truck is stopped. If moving, it will not operate until truck
speed has dropped to 0.8 kph (0.5 mph).
Fault(s): A359
71

Reference
Park Brake Release Refer to 58F-06-02311, Sheet 9, zone J16 930E
Request connection at Refer to 58F-06-10561, Sheet 5, zone C5
IM Refer to 58B-06-02390, Sheet 10, zone J16 980E
Park Brake Release Refer to 58F-06-02311, Sheet 9, zone J6 930E
Request connection at Refer to 58F-06-10561, Sheet 5, zone B6
R22 Refer to 58B-06-02390, Sheet 10, zone I6 980E
R22 Coil Circuit Refer to 58F-06-02311, Sheet 9, zone J5 and Sheet 7, zone K10 930E
Refer to 58B-06-02390, Sheet 10, zone I5 and Sheet 7, zone L9 980E
Park Brake Protection Refer to 58F-06-02311, Sheet 9, zone L17 930E
Relay connection at IM Refer to 58F-06-10561, Sheet 5, zone C5
Refer to 58B-06-02390, Sheet 10, zone L17 980E
Park Brake Protection Refer to 58F-06-02311, Sheet 9, zone N8 930E
Relay coil circuit Refer to 58F-06-10561, Sheet 5, zones B5 through C5
Refer to 58B-06-02390, Sheet 10, zone M8 980E
72
NOTES
73
Fault Code A216: An open or short to ground has been detected in the park brake com-
mand valve circuit
Operator Action Stop, Park
Fault Code A216
Description An open or short to ground has been detected in the park brake command valve
circuit.
Fault Conditions Sets if valve circuit is open or short to ground with keyswitch and park brake request
on, or if valve circuit is open with keyswitch on and without park brake request being
on.
Resets if any conditions change.
Display Fault Description: PRK BRK COMMAND FLT
Resulting Problem(s) Park Brake may not apply or release properly causing equipment and roll away
concerns.
fault.
74
Table
Status - Shorted to Ground: Expected if Park Brake Request is in the 24 volt condition.
Otherwise unexpected and must troubleshoot.
0: Park Brake Request Input is in the low voltage (request) condition
1: Park Brake Request Input is in the high voltage (not requested) condition
Fault(s): A351
Fault(s): A264
1: keyswitch is on or the truck is moving or the engine is running
Fault(s): A240
75

Reference
76

Reference
77
Fault Code A223: Excessive engine cranking has occurred or a jump start has been
attempted
Operator Action Wait 120 sec, Retry
Fault Code A223
Description Excessive engine cranking has occurred or a jump start has been attempted.
Fault Conditions Sets after 30 seconds of continuous cranking or if either cranking motor is energized
without the start enable circuit (jump start).
Resets after 120 seconds of no cranking.
Operator Alerting Sound Buzzer - Single Burst
System Response Display Operator Action: WAIT 120 SEC: RETRY
Display Fault Description: EXCESS CRANKING
Resulting Problem(s) Starters can be damaged by excessive engine cranking.
fault.
78
Table
1. The primary correction for this fault is not to excessively crank the engine. Starting problems must be
corrected, or starter failures will result.
Crank Sense (IM3U) 0: Engine not being cranked
1: Engine is being cranked
Fault(s): A152, A275, A316
Fault(s): A152, A275, A316
Start Enable (IM1B) Status - Open Load: Unexpected. Troubleshoot
Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected. Troubleshoot.
0: One of several interlocking situations exist to prevent cranking (excessive cranking
history, selector switch in wrong position, engine red light, J1939 not OK, engine
speed either not 0 to begin cranking or over 400 rpm while cranking).
1. No interlocking situations exist to prevent cranking.
Fault(s): A252
79

Reference
zones B2 through D4
zones H2 through H4
Start Enable Circuit Refer to 58E-06-02311, sheet 5, zones K4 through K15 830E
Refer to 58E-06-02321, sheet 4, zones A7 through A9
80
NOTES
81
Fault Code A230: Park brake has been requested while truck still moving
Operator Action Move Shifter from Park
Fault Code A230
Description Park brake has been requested while truck still moving.
Fault Conditions Sets if park brake is requested (selector switch moved from forward, neutral, reverse)
while moving 0.8 kph (0.5 mph) and with park brake released.
Resets if any condition changes.
Display Operator Action: MOVE SHFTR FROM PRK
Display Fault Description: PRK BRK SETTING ERR
Resulting Problem(s) Park Brake could be damaged if protective circuitry did not work.
fault.
82
Table
1. The primary correction for this fault is just not to move the selector switch while the truck is in motion.
Truck Speed [kph] < 0.8 kph (0.5 mph): truck is not moving
(CAN/RPC) (IM1i,j,k) > 0.8 kph: truck is moving
Fault(s): A233
brake
Fault(s): A213
(IM2M) brake
1: parking brake pressure switch indicating low pressure and an unreleased parking
brake
Fault(s): A214
83

Reference
84

Reference
85
Fault Code A231: The body is up while traveling or intending to travel

Operator Action Lower body
Fault Code A231
Description The body is up while traveling or intending to travel.
Fault Conditions Sets after 30 seconds if body is up with selector in forward or reverse and truck
moving or engine running.
Truck moving is defined as speed greater than 0 or if no communication from drive
system and the park brake not set.
Resets if body is down, selector not in forward or reverse, and truck not moving and
engine not running.
Display Operator Action: LOWER BODY
Display Fault Description: BODY UP
Resulting Problem(s) Operation with body up can cause accidents or damage to pivot pins.
fault.
86
Table
1. No correction is necessary for normal bleeding with the truck properly parked.
Body Up (CAN/RPC) 0: Body is raised off the truck frame
(IM1i,j,k) 1: Body is down on the truck frame
Fault(s): A233
Fault(s): A184
Selector Switch 0: Selector Switch is not in Forward
(Forward) (CAN/RPC) 1: Selector Switch is in Forward
(IM1I,j,k) Fault(s): A233
Selector Switch 0: Selector Switch is not in Reverse
(Reverse) (CAN/RPC) 1: Selector Switch is in Reverse
Truck Speed [kph] Zero: truck is not moving
(CAN/RPC) (IM1I,j,k) > 0: truck is moving
Fault(s): A233
brake
Fault(s): A213
(IM2M) brake
Fault(s): A214
87

Reference
through H10
through H8
zones E6
88

Reference
Brake Lock connection Refer to 58E-06-02311, sheet 9, zones M11 through M17 830E
to IM Refer to 58E-06-02321, sheet 5, zone C4
Refer to 58F-06-02311, Sheet 9, zones M11 through N17 930E
Refer to 58B-06-02390, Sheet 10, zones M11 through N17 980E
89
Fault Code A233: Drive system CAN/RPC Control Link not connected
Operator Action Stop; Park Power down
Fault Code A233
Description Drive system CAN/RPC Control Link not connected
Fault Conditions Sets after 5 seconds if Park Brake is not set, GE Control Power is on, Crank Request
is not on, and Keyswitch, is on or sets after 60 seconds if Park Brake is set, GE
Control Power is on, Crank Request is not on, and Keyswitch is on
Resets if truck speed is received from GE.
Display Fault Description: NO DRIVE SYS DATA
Resulting Problem(s) Control commands not available to drive system. Warnings not available to driver or
KOMTRAX Plus.
fault.
90
Table
Drive System Control Should operate 60 seconds after initial power up
Link (IM1i, j, k) Fault(s): A237, A257
Fault(s): A240
GE Batt+ Off (IM3M) 0: power to GE control is off
1: power to GE control is on
Crank Request (IM2j) 0: cranking not attempted
1: cranking is attempted
brake
Fault(s): A213
(IM2M) brake
Fault(s): A214
91

Reference
92

Reference
Crank Request Refer to 58E-06-02311, sheet 5, zone E9 830E
connection at Key Refer to 58E-06-02321, sheet 4, zone E1
Refer to 58F-06-02311, Sheet 5, zone E9 930E
Refer to 58B-06-02390, Sheet 5, zone E9 980E
Crank Request Refer to 58E-06-02311, sheet 5, zone J5 830E
connection at IM Refer to 58E-06-02321, sheet 4, zone E1
Refer to 58F-06-02311, Sheet 5, zone J5 930E
93
Fault Code A235: Steering accumulator is in the process of being bled down
Operator Action Park, do not steer
Fault Code A235
Description Steering accumulator is in the process of being bled down.
Fault Conditions Sets if steering bleed valve comes on and the steering accumulator bleed pressure
switch has yet to operate and 90 seconds have yet to elapse.
Resets either at 90 second timeout or when steering accumulator bleed pressure
switch indicates bleeddown is complete.
Operator Alerting Sound Buzzer - Single Burst
System Response Display Operator Action: PARK: DO NOT STEER
Display Fault Description: STEERING IS BLEEDING
Resulting Problem(s) Bleeding the steering accumulator is normal and not a problem as long as the truck is
properly parked during bleeddown.
fault.
94
Table
1. No correction is necessary for normal bleeding with the truck properly parked.
Steering Bleed Valve Status - Open Load: Expected with key switch on. No problem. Otherwise,
(IM1P) unexpected. Must troubleshoot.
Status - Normal: Expected only with key off and steering bleed in process. Trouble
shoot if found with key on.
0: steering bleed valve is off. This is expected in normal running operation.
1: steering bleed valve is on This is expected after key off initiates steering bleed
operation.
Fault(s): A236, A253, A262, A263, A358
Steering Accum Bled 0: Accumulator is bled.
Pressure Sw (IM2Z) 1: Accumulator is not completely bled.
95

Reference
Steering Bleed Valve Refer to 58E-06-02311, sheet 15, zone B10 830E
connection at IM Refer to 58E-06-02321, sheet 31, zone B1
Refer to 58F-06-02311, Sheet 15, zone B10 930E
Steering Bleed Valve Refer to 58E-06-02311, sheet 15, zone C18 830E
connection at Fuse Refer to 58E-06-02321, sheet 31, zone A1
Steering Bleed Switch Refer to 58E-06-02311, sheet 15, zone O3 830E
Refer to 58E-06-02321, sheet 31, zone C2
Refer to 58F-06-02311, Sheet 15, zone O3 930E
Refer to 58B-06-02390, Sheet 16, zone O2 980E
96
NOTES
97
Fault Code A236: The steering accumulator has not properly bled after 90 seconds
Operator Action Park, do not steer
Fault Code A236
Description The steering accumulator has not properly bled down after 90 seconds.
Fault Conditions Sets if the steering accumulator bleed pressure switch does not indicate bleeddown
complete within 90 seconds.
Resets either at power down, or if keyswitch is turned back on, thereby turning off the
steering bleed valve.
Display Operator Action: PARK: DO NOT STEER
Display Fault Description: STEERING BLEED FLT
Resulting Problem(s) Failure to bleed the steering accumulator can create dangerous situations under the
truck.
fault.
98
Table
operation.
Fault(s): A253, A262, A263, A358
99

Reference
100
Fault Code A237: The CAN/RPC connection to the Display is open

Operator Action Stop, Park, Power Down
Fault Code A237
Description The CAN/RPC connection to the Display is open.
Fault Conditions Sets if no communication for 1 second (10 seconds at initial power up).
Resets if communication is established.
Display Fault Description: NO DISPLAY DATA
Resulting Problem(s) Many operational and equipment warnings will not be available to the operator, making
further operation unwise.
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the display or replace the
Interface Module.
CAN/RPC (IM1jki) Fault(s):A233, A257

Reference
CAN/RPC connection Refer to 58E-06-02311, sheet 10, zone H8 and sheet 17, zone B19 830E
at Display Refer to 58E-06-02321, sheet 6, zone D2
Refer to 58F-06-02311, Sheet 10, zone H8 and Sheet 17, zone B19 930E
Refer to 58B-06-02390, Sheet 11, zone H8 and Sheet 18, zone B19 980E
101
Fault Code A240: The keyswitch input to the Interface Module is open
Operator Action Stop, Park, Repair
Fault Code A240
Description The keyswitch input to the Interface Module is open.
Fault Conditions Sets if both Keyswitch input and Steering Bleed valve are missing for 20 seconds.
Resets if either one turns on.
Display Operator Action: STOP: PARK: REPAIR
Display Fault Description: IM KEYSW POWER LOST
Resulting Problem(s) Many warnings will be non functional. Some controls will not function as normal.
Steering will bleed as soon as truck comes to a complete stop and the engine stops
running without the keyswitch being turned off.
fault.
Table
1. The primary correction for this fault is to correct the wiring from the keyswitch to the Interface Module.
2. This fault's logic contains just one parameter.
Fault(s):

Reference
102
Fault Code A242: The fuel gauge within the display panel is defective
Fault Code A242
Description The fuel gauge within the display panel is defective.
Fault Conditions Sets if display panel reports a fuel gauge fault.
Resets if display panel clears the fault.
System Response Display Fault Description: FUEL GAUGE FAULT
Resulting Problem(s) Truck could run out of fuel.
fault.
Table
1. This fault is entirely contained within the display panel. The panel and communication to it must be working
in order for IM to be aware of the fault. Therefore the only diagnostic effort is to check the gauge and wiring
within the panel and replace if necessary.

Reference
Fuel Gauge Refer to 58E-06-02311, sheet 10 D5 830E
Refer to 58F-06-02311, Sheet 10 D5 930E
Refer to 58B-06-02390, Sheet 11 D5 980E
103
Fault Code A243: The engine coolant temp gauge within the display panel is defective
Operator Action Go to Shop
Fault Code A243
Description The engine coolant temp gauge within the display panel is defective.
Fault Conditions Sets if display panel reports an engine coolant temperature gauge fault.
Resets if digital display clears the fault or steering bleed valve comes on.
Display Fault Description: ENG COOL TEMP GAUGE
Resulting Problem(s) Engine could overheat without warning.
fault.
Table
1. Except for being masked by the steering bleed process, this fault is entirely contained within the display
panel. The panel and communication to it must be working in order for IM to be aware of the fault. Therefore
the only diagnostic effort is to check the gauge and wiring within the panel and replace if necessary.

Reference
Coolant Temperature Refer to 58E-06-02311, sheet 10, zone D4 830E
Gauge Refer to 58E-06-02321, sheet 7, zone A10
Refer to 58F-06-02311, Sheet 10, zone D4 930E
Refer to 58B-06-02390, Sheet 11, zone D4 980E
104
Fault Code A244: Drive system temperature gauge within the dash display panel is defec-
tive
Fault Code A244
Description Drive system temperature gauge within the dash display panel is defective.
Fault Conditions Sets if a drive system temperature gauge fault is reported.
Resets if the fault clears or steering bleed valve comes on.
Display Fault Description: DRIVE SYS TEMP GAUGE
Resulting Problem(s) Drive system could overheat without warning.
fault.
Table
1. Except for being masked by the steering bleed process, this fault is entirely contained within the dash display
panel. The panel and communication to it must be working in order for interface module (IM) to be aware of the
fault. Therefore the only diagnostic effort is to check the gauge and wiring within the panel and replace if
necessary.
Steering Bleed Valve 0: Steering bleed valve is off.
1: Steering bleed valve is on.

Reference
Drive System Refer to 58F-06-02311, Sheet 10, zone E6 930E
Temperature Gauge Refer to 58F-06-10561, Sheet 7, zone A10
105
Fault Code A245: The hydraulic oil temp gauge within the display panel is defective
Fault Code A245
Description The hydraulic oil temp gauge within the display panel is defective.
Fault Conditions Sets if display panel reports a hydraulic oil temperature gauge fault.
Resets if display panel clears the fault or steering bleed valve comes on.
Display Fault Description: HYD OIL TEMP GAUGE
Resulting Problem(s) Hydraulic oil could overheat without warning.
fault.
Table
panel. The panel and communication to it must be working in order for IM to be aware of the fault. Therefore
the only diagnostic effort is to check the gauge and wiring within the panel and replace if necessary.

Reference
Hydraulic Oil Refer to 58E-06-02311, sheet 10, zone E4 830E
Temperature Gauge Refer to 58E-06-02321, sheet 7, zone A10
106
Fault Code A246: PLM reports truck overload

Operator Action Speed Limit
Fault Code A246
Description PLM reports truck overload.
Fault Conditions Sets if PLM reports an overloaded truck.
Resets if PLM clears the overloaded truck report.
System Response Display Operator Action: MAX SPEED LIMIT
Display Fault Description: LOAD EXCEEDS LIMIT
Resulting Problem(s) Truck could be damaged by operating in overload condition.
fault.
Table
1. This fault is entirely contained within PLM (payload meter). The panel and communication to it must be
working in order for IM to be aware of the fault. Normal corrective measures would be to correct the loading
process.
2. Any faults within the payload meter system that might affect its accuracy are developed and reported by
PLM4.

None None
107
830E Dump truck

930E Dump truck
980E Dump truck
108
CEN40180-00
DUMP TRUCK
830E
930E
980E

830E-5 A50005 and up
930E-5 A40004 and up
980E-5 A50005 and up
40 Troubleshooting
Fault Code A247: Low steering pressure warning ................................................................................................ 4
Fault Code A248: Status module within the dash display panel is defective ........................................................ 6
Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted ....................................... 8
Fault Code A250: Battery voltage is low with the truck parked ........................................................................... 10
Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground ................. 14
Fault Code A252: Start enable output circuit is either open or shorted to ground .............................................. 16
Fault Code A253: Steering bleed circuit is not open while running..................................................................... 18
Fault Code A256: Red warning lamp in the dash display (driven by IM) is open................................................ 20
Fault Code A257: Payload CAN/RPC is not connected...................................................................................... 22
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective ............................................ 24
Fault Code A260: Parking brake failure .............................................................................................................. 26
Fault Code A261: Low brake accumulator pressure warning ............................................................................. 30
Fault Code A262: Steering bleed valve circuit open during shutdown ................................................................ 32
Fault Code A264: Parking brake relay circuit is defective................................................................................... 36
Fault Code A265: Service brake failure .............................................................................................................. 38
Fault Code A266: Shift lever was not in park while attempting to crank engine ................................................. 40
1
Fault Code A267: Parking brake was not set while attempting to crank engine ................................................. 42
Fault Code A268: Secondary engine shutdown while cranking .......................................................................... 44
Fault Code A270: Brake lock switch power supply is not on when required....................................................... 46
Fault Code A272: Brake lock switch power supply is not off when required ....................................................... 50
Fault Code A272: Brake lock switch power supply is not off when required ....................................................... 50
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit............ 54
Fault Code A274: A brake setting fault has been detected................................................................................. 56
Fault Code A275: A starter has been detected as engaged without a cranking attempt .................................... 58
Fault Code A277: Parking brake applied while loading....................................................................................... 60
Fault Code A278: Service brake applied while loading....................................................................................... 62
Fault Code A279: Low Steering Pressure Switch bad ........................................................................................ 64
Fault Code A280: Steering accumulator bleed down switch is defective ............................................................ 66
Fault Code A281: Brake lock degrade switch is defective .................................................................................. 68
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has
reached 7 ..................................................................................................................................................... 70
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set .................. 74
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was oper-
ated .............................................................................................................................................................. 78
Fault Code A285: The parking brake was not set when the keyswitch was turned off ....................................... 80
Fault Code A286: A fault was detected in the shutdown delay relay circuit........................................................ 82
Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off ........... 84
2
NOTES
3
Fault Code A247: Low steering pressure warning

Fault Code A247
Description This is a low steering pressure warning for display to operator. It is designed to give
immediate information to the operator regardless of the cause of the problem.
Fault Conditions Sets if low steering pressure input to interface module (IM) is on with engine running at
300 rpm or above or if truck begins to move at 0.8 kph (0.5 mph) or more.
Resets if pressure returns or engine stops running and truck stops moving for 1
second.
Display Operator Action: STOP: RUN WHEN CLR'D
Display Fault Description: LOW STRG PRESSURE
Resulting Problem(s) Truck may not steer properly.
fault.
Table
Low Steering Pressure 0: Steering pressure is normal.
Switch (IM2S) 1: Steering pressure is low.
Fault(s): A279, A115, A253
Engine Speed [RPM] 0: Engine is not running.
> 300: Engine is running.
> 1200: Engine is running fast enough to maintain steering pressure.
Truck Speed [kph] 0: Truck is not moving.
(IM1g,h) > 0.8kph (0.5 mph): Truck is moving.
4

Reference
through H10
through H8
zones E6
5
Fault Code A248: Status module within the dash display panel is defective
Fault Code A248
Description Status module within the dash display panel is defective.
Fault Conditions Sets if a status module fault is reported.
Resets if the fault clears or steering bleed comes on.
Display Fault Description: STATUS MODULE FLT
Resulting Problem(s) Proper operation will be difficult without status information.
fault.
Table
1. Except for being masked by the steering bleed process, this fault is entirely contained within the dash display
panel. The panel and communication to it must be working in order for interface module (IM) to be aware of the
fault. Therefore the only diagnostic effort is to check the gauge and wiring within the panel and replace if
necessary.
(IM1P) 1: Steering bleed valve is on.

Reference
Status Module Refer to 58E-06-02311, sheet 10, zone D2 830E
Refer to 58E-06-02321, sheet 7, zones A10 through C10
6
NOTES
7
Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted
Fault Code A249
Description Red warning lamp within the dash display (driven by IM) is shorted.
Fault Conditions Sets if the red warning lamp feedback voltage is high for 400 ms with the red warning
lamp on.
Resets at power down.
Display Fault Description: RED WARN LAMP FLT
Resulting Problem(s) Warnings will be audible only.
fault.
Table
1. This fault's logic contains no additional external parameters. The red warning lamp feedback connection is
made internally.
2. Check wiring and connections between interface module (IM) and the dash display, the wiring within the
display to the red warning lamp, and the lamp itself.
Red Warning Lamp 0: Red lamp is not on.
(IM1G) 1: Red lamp is on.
Fault(s): A256
Red Warning Lamp > 3.75 volts for 400 ms with the lamp on: Shorted
Feedback (IM1G) < 3.75 volts for 400 ms with the lamp on: Normal
IM Protected 24V '+24VDC with IM operating
Output (IM1W) 0 V with IM not operating
8

Reference
Warn Lamp connection Refer to 58E-06-02311, sheet 10, zones D4 through D17 830E
to IM and Display Refer to 58E-06-02321, sheet 7, zones B4 through B6
Refer to 58F-06-02311, Sheet 10, zones E4 through F17 930E
Refer to 58B-06-02390, Sheet 11, zones E4 through F17 980E
Warn Lamp Power Refer to 58E-06-02311, sheet 5, zone K12 830E
connection to IM Refer to 58E-06-02321, sheet 18, zone A6
9
Fault Code A250: Battery voltage is low with the truck parked
Operator Action Charge Batteries
Fault Code A250
Description Battery voltage is low with the truck parked.
Fault Conditions Sets if battery voltage with the engine not running, truck not moving, crank state not
sensed, and not in steering bleed is below 23 volts for 5 seconds.
- Engine not running is defined as engine speed at less than 300 rpm.
- Truck not moving is defined as truck speed equal to 0 or, if truck speed is bad,
parking brake is set.
- Crank state sensed is defined as battery less than 18 volts for 1 second with engine
speed less than 600 rpm.
- Parking brake set is defined as closure of the parking brake set pressure switch and
opening of the parking brake release pressure switch.
Resets if voltage recovers to 25.5 volts.

Display Operator Action: CHARGE BATTERIES
Display Fault Description: BATTERY VOLTS LOW
Resulting Problem(s) Voltage may continue to drop and cause improper operation of the many electrical
controls on the truck.
fault.
10
Table
1. The primary correction for this fault is to charge the batteries.
Battery Voltage, 24 < 23.0 volts: Too low to continue operation.
Volt (IM1A) > 23.0 volts: OK to continue operation.
< 18 volts: cranking is sensed.
Fault(s): A153, A154, A155
Engine Speed [RPM] < 600 RPM: engine not being cranked
(CAN/J1939) (IM1q,r,s) < 300 RPM: engine is not running
Fault(s): A184
(CAN/RPC) (IM1i,j,k) > 0 for 1 second: truck is moving
Fault(s): A233
brake
Fault(s): A213
(IM2M) brake
Fault(s): A214
11

Reference
through H10
through H8
zones E6
12

Reference
13
Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to
ground
Fault Code A251
Description Sonalert used with the dash display (driven by IM) is open or shorted to ground.
Fault Conditions Sets if the sonalert circuit is open or short to ground for 400 ms and steering bleed not
on.
Resets if circuit is normal for 400 ms or if steering bleed valve comes on.
Display Fault Description: SONALERT IM FAULT
Resulting Problem(s) Warnings will be visual only.
fault.
Table
Sonalert (IM1M) Status - Open Load: Unexpected. Troubleshoot
0: No faults are active that require buzzer operation.
1. One or more faults are active that require buzzer action.
Fault(s): A356
IM Protected 24V '+24VDC with IM operating
Output (IM1W) 0 V with IM not operating
14

Reference
Sonalert connection to Refer to 58E-06-02311, sheet 10, zones E9 through E17 830E
IM Refer to 58E-06-02321, sheet 7, zones B2 through B5
Refer to 58F-06-02311, Sheet 10, zones E9 through E17 930E
Sonalert connection to Refer to 58E-06-02311, sheet 10, zone G15 830E
Keyswitch Refer to 58E-06-02321, sheet 7, zone B3
Sonalert Power Refer to 58E-06-02311, sheet 5, zone K12 830E
15
Fault Code A252: Start enable output circuit is either open or shorted to ground
Fault Code A252
Description Start enable output circuit is either open or shorted to ground.
Fault Conditions Sets if the start enable relay circuit is open or short to ground for 2 seconds.
Operator Alerting Repair Status Light On
Display Fault Description: STRT ENABLE CKT FLT
Resulting Problem(s) Starting will either not be possible, or will lack the protections that IM provides for the
start enable circuit (excessive cranking, selector switch position, J1939 OK, and
engine speed 0 to start and not above 400rpm at finish).
fault.
Table
Fault(s): A350
16

Reference
17
Fault Code A253: Steering bleed circuit is not open while running
Fault Code A253
Description Steering bleed circuit is not open while running,
Fault Conditions Sets if the steering bleed circuit is not open for 2 seconds, beginning 11 seconds after
the keyswitch is turned on.
Display Fault Description: STG BLD CKT NOT OPN
Resulting Problem(s) Steering bleed will be possible during normal running, if IM or some of its inputs should
also malfunction.
fault.
Table
operation.
Fault(s): A262, A263, A358
Fault(s): A240
18

Reference
Steering Bleed Circuit Refer to 58E-06-02311, sheet 15, zones B10 through C19 830E
Refer to 58B-06-02390, Sheet 16, zones F9 through G14 980E
Keyswitch OR Power Refer to 58E-06-02311, sheet 6, zones A10 through C14 830E
to VEC89 Refer to 58E-06-02321, sheet 3, zone C6 and sheet 4, zone F6
Refer to 58F-06-10561, Sheet 3, zone C6 and Sheet 4, zone F6
Refer to 58B-06-03570, Sheet 3, zone C6 and Sheet 4, zone F6
19
Fault Code A256: Red warning lamp in the dash display (driven by IM) is open
Fault Code A256
Description Red warning lamp in the dash display (driven by IM) is open.
Fault Conditions Sets if red lamp stays open for 1 second with steering bleed valve off. (The red lamp is
open if feedback voltage stays low for 400 ms with red lamp off.)
Resets if red lamp returns to normal or steering bleed valve operates for 1 second.
(The red lamp is normal if feedback voltage goes high for 400 ms with red lamp off.)
Display Fault Description: RED WARN LAMP FLT
Resulting Problem(s) Warnings will be audible only.
fault.
Table
1. This fault's logic contains no additional external parameters. The red warning lamp feedback connection is
made internally.
2. Check wiring and connections between IM and the dash display and wiring within the display to the red
warning lamp as well as the lamp itself.
Red Warning Lamp 0: Red lamp is off.
(IM1G) 1: Red lamp is on.
Fault(s): A249
Red Warning Lamp Below 3.75 volts for 400 ms with the lamp off: open
Feedback (IM1G) Above 3.75 volts for 400 ms with the lamp off: normal
20

Reference
Warn Lamp connection Refer to 58E-06-02311, sheet 10, zones D4 through D17 830E
to IM and Display Refer to 58E-06-02321, sheet 7, zones B4 through B6
Refer to 58F-06-02311, Sheet 10, zones E4 through F17 930E
Refer to 58B-06-02390, Sheet 11, zones E4 through F17 980E
Warn Lamp Power Refer to 58E-06-02311, sheet 5, zone K12 830E
21
Fault Code A257: Payload CAN/RPC is not connected

Fault Code A257
Description Payload CAN/RPC is not connected.
Fault Conditions Sets if payload has not been updated for 10 seconds and keyswitch has been ON at
least 11 seconds since power up.
Resets when payload is updated.
Operator Alerting Repair Status Light on
Display Fault Description: NO PAYLOAD DATA
Resulting Problem(s) Payload and overload data is not properly recorded.
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the display or replace the
interface module (IM).
CAN/RPC (IM1j,k,i) Fault(s): A237, A233

Reference
22
NOTES
23
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective
Fault Code A258
Description Steering accumulator bleed pressure switch circuit is defective.
Fault Conditions Sets if switch input continues to indicate steering accumulator bled down after 90 sec-
onds of engine running above 300 rpm.
Display Fault Description: STRG BLEED PRESS SW
Resulting Problem(s) Indication of steering bleeddown is unreliable.
fault.
Table
Fault(s): A280
(CAN/J1939) (IM1q,r,s) > 300 rpm: engine is running
Fault(s): A184
24

Reference
Steering Accum Bled Refer to 58E-06-02311, sheet 15, zones O2 through O8 830E
Pressure Switch to IM Refer to 58E-06-02321, sheet 31, zones B2 through C2
Refer to 58F-06-02311, Sheet 15, zones O2 through O8 930E
25
Fault Code A260: Parking brake failure

Fault Code A260
Description Parking brake failure (Assumed if truck rolls after application of parking brake or if
parking brake is applied while moving.)
Fault Conditions Two cases are tested: After truck is stopped completely (defined as park brake set and
truck not moving for 1.5 seconds and reset only by park brake release), and truck
rolling (defined as not stopped completely).
Truck Rolling After Stop: Sets if truck rolls 2 kph (1.2 mph) for 1.5 seconds after the
truck is stopped completely. This case resets if conditions change.
Park Brake Application While Moving: Sets if trucks speed is 0.8 kph (0.5 mph) or over
for 1.5 seconds with park brake not released (park brake released is defined as park
brake release switch being on and park brake set switch being off). This case resets
only at power down.
Display Fault Description: PARK BRAKE FAILURE
Resulting Problem(s) Parking brake may not hold truck.
fault.
26
Table
Pressure Switch brake
(IM2M) 1: parking brake pressure switch indicating lower pressure and an applied parking
brake
Fault(s): A214
Park Brake Set 0: parking brake pressure switch indicating low pressure and an applied parking brake
Pressure Switch (IM2f) 1: parking brake pressure switch indicating higher pressure and a released parking
brake
Fault(s): A213
Truck Speed [kph] < 2.0 kph (1.2 mph): truck is not moving in case: Truck Rolling After Stop
(CAN/RPC) (IM1i,j,k) < 0.8 kph (0.5 mph): truck is not moving in case: Park Brake Applied While Moving
> 2.0 kph (1.2 mph): truck is moving in case: Truck Rolling After Stop
> 0.8 kph (0.5 mph): truck is moving in case: Park Brake Applied While Moving
Fault(s): A233
27

Reference
Body Up Switch Refer to 58E-06-02311, sheet 15, zone K9 830E
connection to PLM Refer to 58E-06-02321, sheet 31, zones D1 through E1
28
NOTES
29
Fault Code A261: Low brake accumulator pressure warning

Fault Code A261
Description Low brake accumulator pressure warning for display to operator. It is designed to give
immediate information to the operator, regardless of the cause of the problem.
Fault Conditions Sets if pressure is low while engine is running or truck is moving 0.8 kph (0.5 mph) for
1 second.
Resets if pressure returns or engine stops running and truck stops moving for 1
second.
Display Operator Action: STOP: RUN WHEN CLR'D
Display Fault Description: LOW BRAKE PRESSURE
fault.
Table
1. This fault is generated by more than one parameter, but the independent parameters do not have fault codes
for situations that will affect this fault.
Brake Accumulator 0: Brake accumulator pressure is normal.
Pressure Switch 1: Brake accumulator pressure is low.
(IM2U)
Engine Speed [RPM] 0: Engine is not running.
> 300 RPM: engine is running.
Truck Speed [kph] 0: Truck is not moving.
(IM1g,h) > 0.8 kph (0.5 mph): Truck is moving.
30

Reference
through H10
through H8
zones E6
Brake Accumulator Refer to 58E-06-02311, sheet 15, zones F9 through F16 830E
Pressure Switch to IM Refer to 58E-06-02321, sheet 5, zones E3 through F3
Refer to 58F-06-02311, Sheet 15, zones F9 through F16 930E
Refer to 58B-06-02390, Sheet 16, zones F9 through F16 980E
31
Fault Code A262: Steering bleed valve circuit open during shutdown
Fault Code A262
Description Steering bleed valve circuit is open during shutdown.
Fault Conditions Sets if steering bleed valve circuit is open for 1 second when the key switch has been
turned off, the engine no longer runs, and the truck is stopped (drive system control
power turned off). Energization of the steering bleed valve is delayed for 2 seconds to
provide a valid test.
Display Fault Description: STG BLEED CKT OPEN
Resulting Problem(s) Steering will not bleed down properly if circuit is open.
fault.
32
Table
(IM1P) unexpected, must troubleshoot.
operation.
Fault(s): A240
Fault(s): A184
(CAN/RPC) (IM1i,j,k) > 0: truck is moving
Fault(s): A233
33

Reference
Steering Bleed Circuit Refer to 58E-06-02311, sheet 15, zones B10 through C19 830E
Battery Power to Refer to 58E-06-02311, sheet 6, zones A5 through C14 830E
VEC89 Refer to 58E-06-02321, sheet 3, zones D1 through D6 and sheet 4,
zones F5
Refer to 58F-06-02311, Sheet 6, zones A5 through C14 930E
Refer to 58F-06-10561, Sheet 3, zones D1 through D6 and Sheet 4,
zones F5
Refer to 58B-06-03570, Sheet 3, zones D1 through D6 and Sheet 4,
zones F5
34
NOTES
35
Fault Code A264: Parking brake relay circuit is defective

Fault Code A264
Description Parking brake relay circuit is defective.
Fault Conditions Sets if park brake request is not on when selector switch is not in forward, neutral, or
reverse, or engine has not been running for 15 seconds.
Sets if park brake request is on when selector switch is in forward, neutral, or reverse
and engine has been running for 15 seconds.
System Response Display Fault Description: PARK BRAKE RELY CKT
Resulting Problem(s) Parking brake may not set or release when expected.
fault.
Table
Park Brake Request 0: Park Brake Set is Requested (shifter is not in the forward, neutral, or reverse
(IM3V) positions or the engine oil pressure is below the set point of the engine oil pressure
switch)
1: Park Brake Release is Requested (shifter is in the forward, neutral, or reverse
switch)
Fault(s): A184
36

Reference
Engine Run Oil Refer to 58E-06-02311, sheet 7, zone L1 830E
Pressure Switch Refer to 58E-06-02321, sheet 5, zone B4
Refer to 58F-06-02311, Sheet 7, zone L1 930E
Refer to 58B-06-02390, Sheet 7, zone L1 980E
Engine Run Oil Refer to 58E-06-02311, sheet 9, zone I2 830E
Pressure Switch at Refer to 58E-06-02321, sheet 5, zone B4
VEC Refer to 58F-06-02311, Sheet 9, zone I2 930E
Refer to 58B-06-02390, Sheet 10, zone H3 980E
Engine Run Oil Refer to 58E-06-02311, sheet 7, zone K8 830E
Pressure Switch at Refer to 58E-06-02321, sheet 5, zone B4
TB28 Refer to 58F-06-02311, Sheet 7, zone K8 930E
37
Fault Code A265: Service brake failure

Fault Code A265
Description A service brake failure exists. Operation of either brake lock or brake pedal does not
produce brake light switch operation.
Fault Conditions Sets if brake lock is on or if front brake pressure is above 1724 kPa (250 psi) for 2
seconds and the service brake pressure switch does not turn on if the engine has been
running for 90 seconds.
Resets if conditions change for 2 seconds.
Display Fault Description: SERV BRAKE FAILURE
Resulting Problem(s) Service brake may not respond to brake lock switch or pedal.
Brake light switch and brake lights may not respond to brake application.
fault.
Table
Brake Lock Input (IM2i) 0: brake lock valve is off
1: brake lock valve is on
Brake Pressure (kPa) < 1724 kPa (250 psi): front brake not applied
(IM3bp) > 1724 kPa (250 psi): front brake applied
Service Brake 0: Service brake not applied
Pressure Switch 1: Service brake applied
(IM3C)
Engine Speed [RPM] < 400 rpm: engine is not running
(CAN/J1939) (IM1q,r,s) > 400 rpm for 15 seconds: engine is running
Fault(s): A184
38

Reference
Brake Lock Switch Refer to 58E-06-02311, sheet 9, zones N10 through N17 830E
Service Brake Refer to 58E-06-02311, sheet 7, zone F12 830E
Pressure Switch Refer to 58E-06-02321, sheet 5, zones D1 through E1
Refer to 58E-06-02311, sheet 7, zone F12 930E
Refer to 58E-06-02321, sheet 5, zones D1 through E1
Service Brake Refer to 58E-06-02311, sheet 9, zones J16 through L17 830E
connection to IM Refer to 58F-06-02311, Sheet 9, zones J16 through L17 930E
39
Fault Code A266: Shift lever was not in park while attempting to crank engine
Operator Action Put Selector in Park
Fault Code A266
Description Shift lever was not in Park while attempting to crank engine.
Fault Conditions Sets if selector switch is not in park or is in forward, neutral, or reverse while
attempting to crank engine.
Resets if selector switch is put in park or cranking attempt is stopped.
System Response Display Operator Action: PUT SELECTOR IN PARK
Display Fault Description: CAN'T CRANK
Resulting Problem(s) IM will not permit cranking if selector switch is not in park.
fault.
Table
Selector Switch (Park) 0: shifter is not park
40

Reference
41
Fault Code A267: Parking brake was not set while attempting to crank engine
Operator Action Set Park Brake
Fault Code A267
Description Parking brake was not set while attempting to crank engine.
Fault Conditions Sets if park brake is not set while attempting to crank engine. Park brake set is defined
as closure of the park brake set pressure switch and opening of the park brake release
pressure switch.
Resets if park brake sets or cranking attempt is stopped.
System Response Display Operator Action: SET PARK BRAKE
Resulting Problem(s) IM will not permit cranking if park brake is not set.
fault.
Table
brake
Fault(s): A213
(IM2M) brake
Fault(s): A214
42

Reference
43
Fault Code A268: Secondary engine shutdown while cranking

Operator Action Do Not Shut Down
Fault Code A268
Description Secondary engine shutdown while cranking.
Fault Conditions Sets if secondary engine shutdown switch is activated while attempting to crank
engine.
Resets if secondary engine shutdown switch is deactivated or cranking attempt is
stopped.
System Response Display Operator Action: DO NOT SHUT DOWN
Resulting Problem(s) IM will not permit cranking if park brake is not set.
fault.
Table
1. This fault's logic contains more than one parameter, but no additional fault codes are available for them.
2. Since there are no active parameter fault codes then based on the truck's setup while this fault is active,
Secondary Engine 0: secondary engine shutdown is not on
Shutdown (IM3E) 1: secondary engine shutdown is on
44

Reference
Secondary Engine Refer to 58E-06-02311, sheet 5, zone D16 830E
Shutdown Switch Refer to 58E-06-02321, sheet 12, zone C1
Secondary Engine Refer to 58E-06-02311, sheet 5, zone H4 830E
Shutdown Switch at IM Refer to 58E-06-02321, sheet 12, zone D1
Refer to 58F-06-02311, Sheet 5, zone H4 930E
45
Fault Code A270: Brake lock switch power supply is not on when required
Operator Action Go to Shop Now
Fault Code A270
Description Brake lock switch power supply is not on when required.
Fault Conditions Sets if brake lock switch power supply is off when steering is not bleeding down, truck
speed above 1 kph (0.6 mph) and park brake not set or with park brake requested and
the engine running 400 rpm for 15 seconds and the delayed shutdown relay not on.
Resets at beginning of steering bleeddown.
Display Fault Description: BRK LOCK CKT FAULT
Resulting Problem(s) Missing brake lock power supply makes it impossible to use the brake lock in a normal
manner for loading a dumping operations
fault.
46
Table
Brake Lock Switch 0: now power available for brake lock switch
Power Supply (IM3L) 1: power is available for brake lock switch
Fault(s): A272
Truck Speed [kph] < 1 kph (0.6 mph): truck is not moving
(CAN/RPC) (IM1i,j,k) > 1 kph: truck is moving
Fault(s): A233
(CAN/J1939) (IM1q,r,s) > 400 rpm for 15 seconds: engine is running
Fault(s): A184
brake
Fault(s): A213
(IM2M) brake
Fault(s): A214
Fault(s): A264
Shutdown Delay Relay 0: Shutdown delay is off
(IM1H) 1: Shutdown delay is on
47

Reference
Brake Control Circuits Refer to 58E-06-02311, sheet 9, zones J4 through L17 830E
Refer to 58B-06-02390, Sheet 10, zones I4 through M17 980E
Delayed Shutdown Refer to 58E-06-02311, sheet 5, zone D10 830E
Relay Refer to 58E-06-02321, sheet 4, zone E2
Delayed Shutdown Refer to 58E-06-02311, sheet 5, zone I4 830E
Relay connection at IM Refer to 58E-06-02321, sheet 4, zone F2
Refer to 58F-06-10561, Sheet 4, zone F2
Refer to 58B-06-03570, Sheet 4, zone F2
48
NOTES
49
Fault Code A272: Brake lock switch power supply is not off when required
Fault Code A272
Description Brake lock switch power supply not off when required.
Fault Conditions Sets if brake lock switch power supply is not off when brake lock is off, and truck speed
is less than 0.5 kph (0.3 mph) and park brake request is on or engine speed has been
0 for 15 seconds and J1939 data link is OK, or the shutdown relay is on or the key-
switch is off, for 3 seconds. Resets at power down.
Alternatively sets if brake lock switch power supply is not off when brake lock is on and
truck speed is less than 0.5 kph (0.3 mph) and park brake request is on or engine
speed has been 0 for 15 seconds and J1939 data link is OK, or the shutdown relay is
on or the keyswitch is off, for 1 second.
Resets in 1 second if conditions change.
Display Fault Description: BRK LOCK CKT FAULT
Resulting Problem(s) Defective brake lock power supply circuitry makes it impossible to use the brake lock
in a normal manner for loading a dumping operations.
fault.
50
Table
Brake Lock Switch 0: now power available for brake lock switch
Power Supply (IM3L) 1: power is available for brake lock switch
Fault(s): A270
1: brake lock is on
Truck Speed [kph] < 1 kph (0.6 mph): truck is not moving
(CAN/RPC) (IM1i,j,k) > 1 kph: truck is moving
Fault(s): A233
Engine Speed [RPM] 0 rpm for 15 seconds with J1939 working: engine is not running
(CAN/J1939) (IM1q,r,s) > 0 rpm or J1939 not working: engine is running
Fault(s): A184
Fault(s): A264
Fault(s): A240
Shutdown Delay Relay 0. Turns off when conditions clear or engine speed drops to zero.
(IM1H) 1: Turns on when Keyswitch, Direct is off, Engine Shutdown Delay is on, Park brake is
set, Selector Switch is in park, but not J1939 Not Connected, not High Batt Charge
Voltage, not Starter Stuck On, not Active Engine Red Light, and engine speed above
300 rpm.
51

Reference
Brake Control Circuits Refer to 58E-06-02311, sheet 9, zones J4 through L17 830E
Refer to 58B-06-02390, Sheet 10, zones I4 through M17 980E
52
NOTES
53
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure
switch circuit
Fault Code A273
Description A fault has been detected in the hoist or steering pump filter pressure switch circuit.
Fault Conditions Sets if the pump filter pressure switch circuit indicates high pressure across the filters
for 2 seconds with the engine not running at least 300 rpm.
Resets if pump filter pressure switch circuit indicates normal pressure across the filters
or the engine begins to run.
System Response Display Fault Description: HYD OIL FLT CIRCUIT
Resulting Problem(s) Hydraulic oil filters might plug up and stop filtering without warning.
fault.
Table
1. This fault's logic contains more than one parameter, but no additional fault codes are available for them.
Pump Filter Switches 0: No hydraulic filter switches open
(IM2Y) 1: One or more hydraulic filter switches open
Fault(s): A101
Fault(s): A184
54

Reference
Pump Filter Switch Refer to 58E-06-02311, sheet 15, zones D9 through D22 830E
connection at IM Refer to 58E-06-02321, sheet 31, zones B6 through C8
55
Fault Code A274: A brake setting fault has been detected

Fault Code A274
Description A brake setting fault has been detected.
Fault Conditions Sets after 5 seconds if park brake and brake lock are on simultaneously and brake
lock not applied by drive system or brake auto apply and not auto mode operation
requested.
Resets after 5 seconds if conditions cease to exist.
Display Fault Description: BRAKE MALFUNCTION
Resulting Problem(s) Improperly controlled brakes are dangerous to equipment as well as operator.
fault.
Table
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data Mon-
itor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the malfunc-
tion is still unresolved then check each of the parameters in the Table for proper functionality. Troubleshoot all
item(s) related to the parameter(s) which are found to be malfunctioning.
brake
Fault(s): A213
(IM2M) brake
Fault(s): A214
1: brake lock is on
56

Reference
Service Brake Refer to 58E-06-02311, Sheet 7, zone F12 830E
Refer to 58F-06-02311, Sheet 7, zone F12 930E
Service Brake Refer to 58E-06-02311, Sheet 9, zones J16 through L17 830E
57
Fault Code A275: A starter has been detected as engaged without a cranking attempt
Operator Action Stop, park, power down, check
Fault Code A275
Description A starter has been detected as engaged without a cranking attempt.
Fault Conditions Sets if either starter is engaged for 2 seconds without crank sense being on and while
steering is not bleeding down.
Resets after 2 seconds if conditions change.
Display Operator Action: STOP: PRK: PWR : CHK
Display Fault Description: STARTER STUCK ON
Resulting Problem(s) Starters may be destroyed by continued operation when stuck on.
fault.
Table
1. The normal corrective measure for this fault is to check the starter motors and engagement to the flywheel.
Starter Motor 1 0: Starter motor 1 is not energized.
Energized (IM3R) 1: Starter motor 1 is energized.
Energized (IM3S) 1: Starter motor 2 is energized.
Crank Sense (IM3U) 0: No cranking is in process.
1: Cranking is in process.
58

Reference
zones B2 through D4
zones H2 through H4
59
Fault Code A277: Parking brake applied while loading

Operator Action Turn Off Parking Brake
Fault Code A277
Description Parking brake is applied while loading the dump body.
Fault Conditions Sets if park brake is set and PLM reports a loading state. Park brake set is defined as
closure of the park brake set pressure switch and opening of the park brake release
pressure switch.
Resets if loading state is cleared or park brake is released.
Display Operator Action: MOVE SHFTR FROM PARK
Display Fault Description: IMPROPER BRK USAGE
Resulting Problem(s) Park brake may be damaged; load weights may contain error.
fault.
Table
1. The normal corrective measure for this fault is to release the parking brake. If this does not work, verify that
the input parameters are correct.
5. If a false loading state signal is suspected, it will be necessary to thoroughly troubleshoot the PLM system.
Parking Brake Set 0: parking brake pressure switch indicating low pressure and an applied parking brake
(IM2f) 1: parking brake pressure switch indicating higher pressure and an unapplied parking
brake
Fault(s): A213
(IM2M) brake
Fault(s): A214
Loading State (PLM The loading state input is developed by PLM and communicated to IM via CAN/RPC.
CAN/RPC)
60

Reference
61
Fault Code A278: Service brake applied while loading

Operator Action Release Service Brake
Fault Code A278
Description Service brake is applied while loading the dump body.
Fault Conditions Sets if PLM declares a loading state while the front brake pressure is at 1207 kPa (175
psi) or more for 10 seconds.
Resets if loading state is cleared or front brake pressure drops below 1034 kPa (150
psi) for 1 second.
Display Operator Action: RELEASE SERVICE BRAKE
Display Fault Description: IMPROPER BRK USAGE
Resulting Problem(s) Load weights may contain errors.
fault.
Table
1. The normal corrective measure for this fault is to release the service brake. If this does not work, verify that
the input parameters are correct.
5. If a false loading state signal is suspected, it will be necessary to thoroughly troubleshoot the PLM system.
Loading State The loading state input is developed by PLM and communicated to IM via CAN/RPC.
(PLM CAN/RPC)
Brake Pressure > 1207 kPa (175 psi) for 10 seconds: front brakes applied
(IM3bp) < 1034 kPa (150 psi) for 1 second; front brakes not applied
Fault(s): 201, 205
62

Reference
63
Fault Code A279: Low Steering Pressure Switch bad

Operator Action Stop: Park: Power Down: Check
Fault Code A279
Description Low Steering Pressure Switch bad
Fault Conditions Sets if low steering pressure switch fails to turn on by the time the steering
accumulator bleed pressure switch indicates that bleeding is complete.
Resets if low steering pressure switch actuates (reports low pressure).
Display Operator Action: STOP: PRK: PWR: CHK
Display Fault Description: BAD STRG PRESS SW
Resulting Problem(s) Loss of steering may not be reported.
fault.
Table
Fault(s): A280
(IM1P) 1: steering bleed valve is on
64

Reference
65
Fault Code A280: Steering accumulator bleed down switch is defective

Fault Code A280
Description Steering accumulator bleed down switch is defective.
Fault Conditions Sets if steering accumulator bleed pressure switch comes on with engine running and
steering pressure normal.
Resets if steering accumulator bleed pressure switch deactuates.
Display Fault Description: BAD STRG BLED SW
Resulting Problem(s) Improper bleed may not be reported.
fault.
Table
Fault(s): A279
Fault(s): A184
66

Reference
Steering Bleed Switch Refer to 58E-06-02311, Sheet 15, zone O3 830E
Refer to 58E-06-02321, Sheet 31, zone C2
Steering Bleed Switch Refer to 58E-06-02311, Sheet 15, zone O7 830E
connection at IM Refer to 58E-06-02321, Sheet 31, zone B2
67
Fault Code A281: Brake lock degrade switch is defective

Fault Code A281
Description Brake lock degrade switch is defective.
Fault Conditions Sets if brake lock degrade switch is not on when neither service brake nor brake lock
are on for 5 seconds. Service brake is off when the service brake pressure switch is off
and front brake pressure is below 1034 kPa (150 psi).
Resets if brake lock degrade switch actuates.
Display Fault Description: BAD BRK DEGRADE SW
Resulting Problem(s) Operator may not be warned of degradation of brake lock pressure.
fault.
Table
Brake Lock Degrade 0: brake lock degrade not on
Sw (IM2V) 1: brake lock degrade is on
1: brake lock is on
(IM3C)
Brake Pressure (kPa) < 1034 kPa (150 psi): front brake not applied
(IM3bp) > 1034 kPa (150 psi): front brake applied
68

Reference
Service Brake Refer to 58E-06-02311, sheet 15, zones G9 through G16 830E
Degrade Pressure Refer to 58E-06-02321, sheet 5, zones E3 through F3
Switch to IM Refer to 58F-06-02311, Sheet 15, zones G9 through G16 930E
69
Fault Code A282: The number of excessive cranking counts and jump starts without the
engine running has reached 7
Operator Action Stop; Park; Power Down; Check
Fault Code A282
Description The number of excessive cranking counts and jump starts without the engine running
has reached 7.
Fault Conditions Count is increased every time cranking reaches 30 seconds continuous and every
time a jump start is attempted (engagement of either starter without start enable). A
count of 7 disables further start attempts until the power is shut off.
Display Operator Action: STOP: PRK: PWR : CHK
Display Fault Description: EXCESS CRANKING
Resulting Problem(s) Excessive cranking destroys starters.
fault.
70
Table
1. The normal corrective measure for this fault is to check and correct engine and/or starting system
deficiencies.
Crank Sense (IM3U) 0: No cranking is in process.
Fault(s): A184
Start Enable (IM1B) 0: One of several interlocking situations exist to prevent cranking (excessive cranking
Fault(s): A152, A223, A275, A316
Fault(s): A152, A223, A275, A316
71

Reference
zones B2 through D4
zones H2 through H4
72
NOTES
73
Fault Code A283: An engine shutdown delay was aborted because the parking brake was
not set
Fault Code A283
Description An engine shutdown delay was aborted because the parking brake was not set.
Fault Conditions Sets if keyswitch is turned OFF and engine shutdown delay is on and engine is
running but parking brake set is not on. (Parking brake set is defined as closure of the
parking brake set pressure switch and opening of the parking brake release pressure
switch.)
Resets if keyswitch is turned ON, engine shutdown delay is off, and engine is running.
System Response Display Fault Description: NO SHT DWN DEL / PB
Resulting Problem(s) The engine can suffer damage when shut down immediately rather than in a controlled
delay.
fault.
74
Table
1. The normal corrective measure for this fault is to set the parking brake before turning off the key switch.
Keyswitch, Direct 0: Keyswitch is OFF.
(IM2P) 1: keyswitch is ON.
Fault(s): A240
Engine Shutdown 0: Engine shutdown delay signal is off.
Delay (IM3F) 1: Engine shutdown delay signal is on.
Fault(s): A284
Park Brake Set (IM2f) 0: Parking brake pressure switch indicates low pressure and an applied parking brake.
1: Parking brake pressure switch indicates high pressure and a released parking
brake.
Fault(s): A213
Park Brake Released 0: Parking brake pressure switch indicates high pressure and a released parking.
(IM2M) brake
1: Parking brake pressure switch indicates low pressure and an applied parking brake.
Fault(s): A214
Fault(s): A184
75

Reference
Keyswitch Direct Refer to 58E-06-02311, sheet 5, zone E9 830E
connection at Refer to 58E-06-02321, sheet 4, zone E1
Keyswitch Refer to 58F-06-02311, Sheet 5, zone E9 930E
Keyswitch Direct Refer to 58E-06-02311, sheet 5, zone J4 830E
Engine Shutdown Refer to 58E-06-02311, sheet 7, zone D2 830E
Delay at Engine Refer to 58E-06-02321, sheet 12, zone F1
Engine Shutdown Refer to 58E-06-02311, sheet 5, zone I4 830E
Delay at IM Refer to 58E-06-02321, sheet 12, zone D1
76
NOTES
77
Fault Code A284: An engine shutdown delay was aborted because the secondary
shutdown switch was operated
Fault Code A284
Description An engine shutdown delay was aborted because the secondary shutdown switch was
operated.
Fault Conditions Sets if keyswitch is turned OFF and engine shutdown delay is on and engine is
running but secondary engine shutdown switch is operated.
Resets if keyswitch is turned back on, engine shutdown delay is off, and engine is
running.
System Response Display Fault Description: NO SHT DWN DEL / SEC
Resulting Problem(s) The engine can be damaged when shut down immediately, rather than in a controlled
delay.
fault.
Table
1. The normal corrective measure for this fault is to shut down the engine with the keyswitch.
Secondary Engine 0: Engine is being shut down by secondary switch.
Shutdown Switch 1: Engine is not being shut down by secondary switch.
(IM3E)
Fault(s): A240
Fault(s): A283
Fault(s): A184
78

Reference
Secondary Engine Refer to 58E-06-02311, sheet 5, zone D16 830E
Shutdown Switch Refer to 58E-06-02321, sheet 12, zone C1
Secondary Engine Refer to 58E-06-02311, sheet 5, zone H4 830E
Shutdown Switch at IM Refer to 58E-06-02321, sheet 12, zone D1
Refer to 58F-06-02311, Sheet 5, zone H4 930E
Delay at engine Refer to 58E-06-02321, sheet 12, zone F1
79
Fault Code A285: The parking brake was not set when the keyswitch was turned off
Operator Action Set parking brake
Fault Code A285
Description The parking brake was not set when the keyswitch was turned off.
Fault Conditions Sets if parking brake is not already set when keyswitch is turned OFF. (Parking brake
set is defined as closure of the parking brake set pressure switch and opening of the
parking brake release pressure switch.)
Resets if parking brake is set or if keyswitch is turned back ON.
Display Operator Action: SET PARK BRAKE
Display Fault Description: PRK BRK SETTINGS ERR
Resulting Problem(s) Truck could roll away if parking brake is not set at shutdown.
fault.
Table
1. The normal corrective measure for this fault is to set the parking brake before turning off the key switch.
Fault(s): A240
brake.
Fault(s): A213
Park Brake Released 0: Parking brake pressure switch indicates high pressure and a released parking.
(IM2M) brake
Fault(s): A214
80

Reference
81
Fault Code A286: A fault was detected in the shutdown delay relay circuit
Fault Code A286
Description A fault was detected in the shutdown delay relay circuit.
Fault Conditions Sets if an open circuit or short to ground is detected in the relay driver circuit.
System Response Display Fault Description: SHT DWN DEL REL CKT
Resulting Problem(s) A malfunctioning shutdown delay circuit could cause damage to the engine.
fault.
Table
Shutdown Delay Relay Status - Open Load: Unexpected. Troubleshoot
(IM1H) Status - Normal: Expected. No problem.
0. Turns off when conditions clear or engine speed drops to zero.
1: Turns on when Keyswitch, Direct is off, Engine Shutdown Delay is on, Park brake is
300 rpm.
Fault(s): A292
Fault(s): A240
82

Reference
83
Fault Code A292: The shutdown delay relay has remained on after the latched key switch
circuit is off
Fault Code A292
Description The shutdown delay relay has remained on after the latched key switch circuit is off.
Fault Conditions Sets if the shutdown relay is still on after the latched key switch circuit is off (GE
latches the circuit until the truck and engine have stopped completely).
Resets if key switch is turned back on or shutdown delay relay turns off.
System Response Display Fault Description: SHT DWN DEL REL FLT
Resulting Problem(s) A malfunctioning shutdown delay circuit could cause damage to the engine.
fault.
Table
Fault(s): A283
0: Turns off when conditions clear or engine speed drops to 0.
1: Turns on when Keyswitch, Direct is off, engine shutdown delay is on, parking brake
is set, shift lever is in Park, but not J1939 not connected, not high battery charge
voltage, not starter stuck on, not active engine red light, and engine speed above 300
rpm.
Fault(s): A286
Fault(s): A240
84

Reference
Delay at engine Refer to 58E-06-02321, sheet 12, zone F1
85
830E Dump truck

930E Dump truck
980E Dump truck
86
CEN40181-00
DUMP TRUCK
830E
930E
980E

830E-5 A50005 and up
930E-5 A40004 and up
980E-5 A50005 and up
40 Troubleshooting
Fault Code A303: Shift lever is defective .............................................................................................................. 4
Fault Code A304: Auto lube grease level fault...................................................................................................... 6
Fault Code A307: Both GE inverters are disabled ................................................................................................ 7
Fault Code A309: No brakes applied when expected ........................................................................................... 8
Fault Code A310: Low fuel warning .................................................................................................................... 12
Fault Code A311: Brake lock switch is on when it should not be ........................................................................ 14
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings ...................................... 18
Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings ...................................... 20
Fault Code A315: DCDC converter 12 volt circuit is low..................................................................................... 22
Fault Code A316: Starter engagement has been attempted with engine running .............................................. 24
Fault Code A317: Operation of brake auto apply circuit without a detected response ....................................... 28
Fault Code A318: Unexpected power loss to interface module .......................................................................... 32
Fault Code A328: Drive system not powered up ................................................................................................ 33
Fault Code A332: Seat belt not buckled ............................................................................................................. 34
Fault Code A333: The hydraulic ladder controller has declared a ladder fault ................................................... 38
Fault Code A334: Selector switch not in park when propel was either not ready or at rest ................................ 40
1
Fault Code A337: Engine Air Filter Circuit Fault ................................................................................................. 42

Fault Code A338: Engine Air Filter Fault............................................................................................................. 44
Fault Code A339: The diesel exhaust fluid level gauge within the display panel is defective ............................. 46
Fault Code A340: The shifter controller has declared a fault .............................................................................. 48
Fault Code A341: The shifter control circuit is defective ..................................................................................... 50
Fault Code A342: The Accessory Pump Filter Switch has actuated................................................................... 52
Fault Code A343: Truck speed is limited by GE.................................................................................................. 54
Fault Code A344: GE has posted a No Retarding fault ...................................................................................... 55
Fault Code A345: Engine speed limited by GE................................................................................................... 56
Fault Code A346: Delayed Shut Down by GE .................................................................................................... 57
Fault Code A347: Operator Override of GE is active .......................................................................................... 58
Fault Code A348: GE has disabled load box operation ...................................................................................... 59
Fault Code A349: GE has limited load box operation ......................................................................................... 60
Fault Code A350: Overload on output 1B ........................................................................................................... 62
Fault Code A351: Overload on output 1E ........................................................................................................... 64
Fault Code A352: Overload on output 1H ........................................................................................................... 66
Fault Code A353: Overload on output 1J............................................................................................................ 68
Fault Code A354: Overload on output 1K ........................................................................................................... 70
Fault Code A355: Overload on output 1L............................................................................................................ 71
Fault Code A356: Overload on output 1M........................................................................................................... 72
Fault Code A357: Overload on output 1N ........................................................................................................... 74
Fault Code A358: Overload on output 1P ........................................................................................................... 76
Fault Code A359: Overload on output 1R ........................................................................................................... 78
Fault Code A360: Overload on output 1S ........................................................................................................... 80
Fault Code A361: Overload on output 1T ........................................................................................................... 82
Fault Code A362: Overload on output 1U ........................................................................................................... 84
Fault Code A363: Overload on output 1X ........................................................................................................... 85
Fault Code A364: Overload on output 1Y ........................................................................................................... 86
Fault Code A365: Overload on output 1Z ........................................................................................................... 87
Fault Code A366: Axle box cooling fault ............................................................................................................. 88
2
NOTES
3
Fault Code A303: Shift lever is defective

Fault Code A303
Description Shift lever is defective.
Fault Conditions Sets if selector switch (FNR) and selector switch (Park) operate simultaneously for 1
second.
Resets if conditions change for 1 second.
Display Operator Action: STOP: PARK: PWR
Display Fault Description: SHIFTER DEFECTIVE
Resulting Problem(s) Control of truck and parking brake will be defective.
fault.
Table
Selector Switch (Park) 0: Shift lever is not in Park.
(IM3T) 1: Shift lever is in Park.
Fault(s): A271
Selector Switch (FNR) 0: Shift lever is not in Forward, Neutral, or Reverse.
(IM2N) 1: Shift lever is in Forward, Neutral, or Reverse.
Fault(s): A271
4

Reference
Selector Switch Refer to 58E-06-02311, Sheet 9, zones H12 through H16 830E
Refer to 58E-06-02321, Sheet 17, zones A1 through B1
Selector Switch Refer to 58E-06-02311, Sheet 9, zones J16 through L17 830E
connections at IM Refer to 58E-06-02321, Sheet 17, zone C2
5
Fault Code A304: Auto lube grease level fault

Fault Code A304
Description Low auto lube grease level is detected.
Fault Conditions Sets when input switch indicates low grease level for 3 seconds.
Resets when input switch indicates normal grease level for 3 seconds.
System Response Display Fault Description: AUTO LUBE GREASE LO
Resulting Problem(s) Auto lubrication will not be completed without grease.
fault.
Table
1. The primary correction for this fault is to replenish the grease.
2. If plenty of grease exists, then check sensor and wiring.
Auto Lube Grease 0: Auto lube grease level is low.
Level Low Input 1: Auto lube grease level is not low.
(IM3W)

Reference
Grease Level Switch Refer to 58E-06-02311, sheet 15, zones O10 through P18 830E
connection to IM Refer to 58E-06-02321, sheet 2, zone C3
Refer to 58F-06-02311, Sheet 15, zones O10 through P18 930E
Refer to 58B-06-02390, Sheet 16, zones N10 through O18 980E
6
Fault Code A307: Both GE inverters are disabled

Fault Code A307
Description Both GE inverters are disabled.
Fault Conditions Sets if both inverters are reported to be disabled by GE via CAN/RPC while CAN/RPC
is working.
Resets if condition changes for 2 seconds.
Display Fault Description: GE INV1 & INV2 DISABL
Resulting Problem(s) Truck will not operate in propel or retard.
fault.
Table
1. The primary correction for this fault is to troubleshoot the GE drive system to determine why the inverters
have been shut off.
GE INV1 Disabled - 0: INV1 not disabled
CAN/RPC Input 1: INV1 disabled
GE INV2 Disabled - 0: INV2 not disabled
CAN/RPC Input 1: INV2 disabled
(IM1I,J,K) Fault(s): A233
Truck Speed - CAN/ 0: No speed message received
RPC ok 1: Speed message received
Fault(s): A233

None None
7
Fault Code A309: No brakes applied when expected

Operator Action Apply brake or travel
Fault Code A309
Description No brakes applied when expected.
Fault Conditions Sets if truck speed is 0, park brake is not set, service brake is not set, and engine is
running for 2 seconds.
Display Operator Action: APPLY BRK OR TRAVEL
Display Fault Description: NO BRAKES SET
Resulting Problem(s) No brakes set may let truck roll away.
fault.
8
Table
brake
Fault(s): A213
Park Brake Released 0: Parking brake pressure switch indicates high pressure and a released parking
(IM2M) brake.
Fault(s): A214
(IM3C) Fault(s): A265, A274, A309
(CAN/RPC) (IM1i,j,k) > 0: truck is moving
Fault(s): A233
Fault(s): A184
9

Reference
10
NOTES
11
Fault Code A310: Low fuel warning

Operator Action Refuel Soon
Fault Code A310
Description This is a low fuel warning driver that activates display elements in response to A139.
Fault Conditions A310 sets if A139 is on. It stays on for 3.3 seconds to flash the lamp and buzzer, then
waits 15 minutes before trying again.
System Response Operate IM Warning Indicator
Display Operator Action: REFUEL SOON
Display Fault Description: LOW FUEL LEVEL
Resulting Problem(s) Possible running out of fuel on haul road. Possible engine damage.
fault.
Table
1. The primary correction for this fault is to add fuel to the tank.
Fuel Level Sensor 0.57 to 8.2 Volts: Good readings at 24 volt battery (varies with battery voltage)
(IM3g) <0.57 or >8.2 Volts: Defective sensor or circuit at 24 volt battery (varies with battery
voltage)
Battery Voltage, >18 Volt: Good reading
24 Volt (IM1A) <18 Volt: Low battery voltage (while cranking) blocks this fault code.
Fault(s): A240
Engine Speed [RPM] < 600 RPM: Combined with low voltage means cranking is in process and fault is
blocked.
> 300 RPM for 4 seconds: Engine is running.
12

Reference
13
Fault Code A311: Brake lock switch is on when it should not be

Operator Action Turn Off Brake Lock Switch
Fault Code A311
Description Brake lock switch is on when it should not be.
Fault Conditions Sets if park brake is set and brake lock is on.
Resets when conditions clear for 2 seconds.
Display Operator Action: TURN OFF BRK LOC SW
Display Fault Description: BRK LOC & PRK BRK ON
Resulting Problem(s) The roll away protection of the braking systems could be defeated by improper
operation.
fault.
14
Table
brake.
Fault(s): A213
Park Brake Released 0: Parking brake pressure switch indicates high pressure and a released parking
(IM2M) brake.
Fault(s): A214
Brake Lock (IM2i) 0: Brake lock not on.
1: Brake lock is on.
Fault(s): A272
15

Reference
16
NOTES
17
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings
Fault Code A312
Description The 24VDC to 12VDC converter 12 volt circuit sensing is producing low readings.
Fault Conditions Sets if voltage at 12 volt input drops to 0.2 volts for 3 seconds.
Resets if voltage at 12 volt input rises to 0.8 volts for 3 seconds.
System Response Display Fault Description: DCDC 12V SENSE LOW
Resulting Problem(s) Monitoring is lost for the 12 volt output of the DCDC Converter.
fault.
Table
1. The primary correction for this fault is to correct any external wiring to the 12 volt input.
DCDC Converter, 0.2 volts to 16.1 volts: Normal measurement range.
12 Volt (IM3h) < 0.2 or > 16.1: Bad sensing circuit or external connection.
Fault(s): A315
18

Reference
DCDC Converter Refer to 58E-06-02311, sheet 6, zone D5 830E
connections Refer to 58E-06-02321, sheet 4, zone D6
12 Volt connection at Refer to 58E-06-02311, sheet 6, zone B3 830E
IM Refer to 58E-06-02321, sheet 4, zone E6
19
Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings
Fault Code A313
Description The 24VDC to 12VDC converter 12 volt circuit sensing is producing high readings.
Fault Conditions Sets if voltage at 12 volt input rises to 16.1 volts for 3 seconds.
Resets if voltage at 12 volt input drops to 15.5 volts for 3 seconds.
System Response Display Fault Description: DCDC 12V SENSE HIGH
Resulting Problem(s) Monitoring is lost for the 12 volt output.
fault.
Table
1. The primary correction for this fault is to correct any external wiring to the 12 volt input.
DCDC Converter, 0.2 volt to 16.1 volts: Normal measurement range
12 Volt (IM3h) <0.2 volt or >16.1 volts: Bad sensing circuit or external connection
Fault(s): A314
20

Reference
21
Fault Code A315: DCDC converter 12 volt circuit is low

Fault Code A315
Description The DCDC Converter 12 volt circuit is low.
Fault Conditions When engine is running and battery voltage is above 22, sets if voltage is below 12.5
volts or if battery voltage is below 22, sets if more than 1.5 volts below battery voltage
divided by 2.
Resets at power down only.
System Response Display Fault Description: DCDC 12V LOW
Resulting Problem(s) The 12 Volt DCDC Converter is putting out low voltage. Correction is required to
continue good performance in the 12 volt loads.
fault.
Table
1. The primary correction for this fault is to eliminate any overload or replace the converter.
DCDC Converter, <12.5 volts when battery voltage is >22 volts: Voltage is low.
12 Volt (IM3h) < (Batt Voltage / 2) - 1.5 volts: Voltage is low.
Otherwise: Voltage is normal.
Fault(s): A312
Battery Voltage, > 22 volts: 12 volt circuit should have normal readings
24 Volt (IM1A) < 22 volts: 12 volt circuit might have abnormal readings
Fault(s): A153, A154, A155, A250
Fault(s): A184
22

Reference
23
Fault Code A316: Starter engagement has been attempted with engine running
Operator Action Do Not Crank
Fault Code A316
Description Starter engagement has been attempted with engine running.
Fault Conditions If not steering bleed, sets after 2 seconds if either starter engages with engine speed
above 500 rpm with crank sense on.
Resets after 2 seconds if conditions change.
Display Operator Action: DO NOT CRANK
Display Fault Description: STARTER ENGAGE FLT
Resulting Problem(s) Damage to starter and engine flywheel may occur.
fault.
24
Table
1. The normal corrective measure for this fault is to not engage the starter with the engine already running.
Energized (IM3R) 1: Starter motor 1 is energized.
Energized (IM3S) 1: Starter motor 2 is energized.
(CAN/J1939) (IM1q,r,s) > 500 rpm: engine is running
Fault(s): A184
Crank Sense (IM3U) 0: Cranking is not in process.
Start Enable (IM1B) 0: One of several interlocking situations exist to prevent cranking (excessive cranking
25

Reference
zones B2 through D4
zones H2 through H4
26
NOTES
27
Fault Code A317: Operation of brake auto apply circuit without a detected response
Operator Action Go to shop now
Fault Code A317
Description Operation of brake auto apply circuit without a detected response.
Fault Conditions Sets if operation of brake auto apply relay for 1 second does not cause the service
brake pressure switch to operate or the front brake pressure to increase.
Park brake release is defined as the closure of the park brake release pressure switch
and the opening of the park brake set pressure switch.
Resets when park brake is released for 5 seconds.
Resulting Problem(s) Failure of brake auto apply circuit could cause damage to parking brake.
fault.
28
Table
Auto Brake Apply Status - Open Load: Unexpected if park brake request and keyswitch are on. But
Relay (IM1R) expected if park brake request is off or keyswitch is off. Troubleshoot if inconsistent.
Status - Normal: Expected if park brake request and keyswitch are on. Troubleshoot if
status is normal with park brake request off or keyswitch off.
Status - Shorted to ground: Unexpected. Troubleshoot
0: normal operation with park brake either on or off. This valve operates only
transiently when the park brake is turned on.
1: brake auto apply valve operates for 1.5 seconds after the park brake is turned on if
the truck is stopped. If moving, it will not operate until truck speed has dropped to 0.8
kph(0.5 mph).
Fault(s): A215
(IM3C)
(IM2M) brake
1: parking brake pressure switch indicating lower pressure and an applied parking
brake
Fault(s): A214
1: parking brake pressure switch indicating higher pressure and a released parking
brake
Fault(s): A213
Fault(s): A205
29

Reference
Park Brake Set Refer to 58F-06-02311, Sheet 15, zone F10 to F16 930E
Pressure Switch Refer to 58F-06-10561, Sheet 5, zone C8
connection to IM Refer to 58B-06-02390, Sheet 16, zone F10 to F16 980E
Park Brake Release Refer to 58F-06-02311, Sheet 5, zones H5 through H14 930E
Pressure Switch to IM Refer to 58F-06-10561, Sheet 5, zone C9
Brake Pressure Refer to 58F-06-02311, Sheet 15, zones K1 through K8 930E
Sensor connection to Refer to 58F-06-10561, Sheet 5, zone E10
IM Refer to 58B-06-02390, Sheet 16, zones K1 through K12 980E
Service Brake Refer to 58F-06-02311, Sheet 7, zone F12 930E
Pressure Switch Refer to 58F-06-10561, Sheet 5, zones D1 through E1
Auto Brake Apply Refer to 58F-06-02311, Sheet 9, zones L5 through O17 930E
Relay & Circuit Refer to 58F-06-10561, Sheet 5, zones B4 through C5
Refer to 58B-06-02390, Sheet 10, zones L5 through O17 980E
30
NOTES
31
Fault Code A318: Unexpected power loss to interface module

Fault Code A318
Description Unexpected power loss to interface module (IM).
Fault Conditions Sets if open file markers are discovered at power up.
Resets if no open file markers are discovered at power up.
System Response Display Fault Description: PWR LOSS NOT EXPECT
Resulting Problem(s) Data may be compromised by irregular shutdowns.
fault.
Table
1. The primary corrective action for this fault is to keep the interface module (IM) working and shutting itself
down in a regular manner.
Open file markers Stored in IM FLASH
Battery Voltage, > 22 volts: 12 volt circuit should have normal readings
24 Volt (IM1A) < 22 volts: 12 volt circuit might have abnormal readings
Fault(s): A153, A154, A155, A250

Reference
32
Fault Code A328: Drive system not powered up

Fault Code A328
Description Drive system not powered up.
Fault Conditions Sets if drive system does not power up within 30 seconds after engine is running.
Display Operation Action: STOP: PRK
Display Fault Description: NO DRIVE SYS POWER
Resulting Problem(s) Drive system can neither retard nor propel without control power.
fault.
Table
1. Check wiring from GE control power to the interface module
2. Check control power wiring, relay, and drive circuitry from GE
A184
Drive System Control 0: Control power is off
Power (IM3M) 1: Control power is on

Reference
GE Control Power Refer to 58E-06-02311, sheet 6, zone C3 830E
connection to IM Refer to 58E-06-02321, sheet 4, zone E6
33
Fault Code A332: Seat belt not buckled

Operator Action Buckle Seat Belt
Fault Code A332
Description Seat belt not buckled.
Fault Conditions Sets if seat belt is not buckled, engine is running, and parking brake is not set for 10
seconds. (Parking brake set is defined as closure of the parking brake set pressure
switch and opening of the parking brake release pressure switch.)
Display Operator Action: BUCKLE SEAT BELT
Display Fault Description: BELT NOT BUCKLED
Resulting Problem(s) Unbuckled seat belt cannot prevent injury to operator.
fault.
34
Table
Seat Belt Switch Input 0: Seat belt is buckled.
(IM2g) 1: Seat belt is not buckled.
Engine Speed [RPM] < 300 RPM: Engine is not running
(CAN/J1939) (IM1q,r,s) > 300 RPM for 4 seconds: Engine is running
Fault(s): A184
brake
Fault(s): A213
Park Brake Released 0: parking brake pressure switch indicating high pressure and a unapplied parking
(IM2M) brake
Fault(s): A214
Seat Belt Alarm Output Status - Open Load: Unexpected. Troubleshoot
(IM1J) Status - Normal: Expected. No problem.
0. Turns off when belt is buckled or truck is parked or engine is not running.
1: Turns on when belt is not buckled and engine is running and park brake is not
applied.
Fault(s): A353
35

Reference
Seat Belt Switch Refer to 58E-06-02311, sheet 15, zone A10 830E
connection to IM Refer to 58E-06-02321, sheet 16, zone B4
Refer to 58F-06-02311, Sheet 15, zone A10 930E
Refer to 58B-06-02390, Sheet 16, zone A10 980E
Seat Belt Alarm Option Refer to 58E-06-02311, sheet 15, zone B18 830E
Refer to 58B-06-02390, Sheet 16, zone B18 980E
36
NOTES
37
Fault Code A333: The hydraulic ladder controller has declared a ladder fault
Operator Action Stop; Park; Repair
Fault Code A333
Description The hydraulic ladder controller has declared a ladder fault.
Fault Conditions Sets if the hydraulic ladder controller declares a fault.
Resets when the hydraulic ladder controller clears the fault.
Display Operation Action: STOP: PARK: REPAIR
Display Fault Description: HYD LADDER FAULT
Resulting Problem(s) Ladder may not stow properly for traveling or may not operate for ascent or descent.
fault.
Table
1. This fault is generated by the hydraulic ladder controller in response to problems within the controller or
external switches and limit switches that control the hydraulic ladder.
Hydraulic Ladder 1: An alarm exists.
Alarm (IM2a) 0: No alarm exists.

None None
38
NOTES
39
Fault Code A334: Selector switch not in park when propel was either not ready or at rest
Fault Code A334
Description Selector switch not in park when propel was either not ready or at rest.
Fault Conditions Sets when Selector Switch is moved from Park position with either “Propel not Ready”
on or “Propel at Rest” on.
Resets when conditions change.
Display Operation Action: STOP: PARK
Display Fault Description: PROPEL NOT READY
Resulting Problem(s) Truck could roll away if parking brake is released with Propel Not Ready or Propel at
Rest signal.
fault.
Table
1. Primary corrective measure is to leave selector switch in park until drive system is ready to go.
Selector Switch (FNR) 0: Shifter is not in forward, neutral, or reverse
(IM2N) 1: Shifter is in forward, neutral, or reverse
GE Propel at Rest or 1: Ge has generated a propel not ready or propel at rest signal
Not Ready (CAN/RPC) 0: No propel at rest or propel not ready signal exists
(IM1i,j,k)
40

Reference
41
Fault Code A337: Engine Air Filter Circuit Fault

Fault Code A337
Description Engine Air Filter Circuit Fault
Fault Conditions Sets if Engine Air Filter Restriction Switch indicates full filter with engine speed at zero
for 2 seconds.
Resets if Engine Air Filter Restriction Switch indicates filter OK or engine begins to
run.
Operator Alerting Display: Repair Item
System Response Display Fault Description: ENG AIR FILT CIRCUIT
Resulting Problem(s) Failure to monitor engine air filter restriction could result in engine problems.
fault.
Table
1. The normal corrective measure for this fault is to change the engine air filter restriction switch or correct the
wiring.
Engine Air Filter 0: Engine Air Filter Restriction Switch not operating
Restriction Switch 1: Engine Air Filter Restriction Switch indicating filter restriction
(IM2X) Fault(s): A338
Engine Speed [RPM] 0 for 2 seconds: Engine is not running
(CAN/J1939) (IM1q,r,s) > 0: Engine is running
Fault(s): A184
42

Reference
Engine Air Filter Refer to 58E-06-02311, sheet 15, zone B2 830E
Restriction Switch Refer to 58E-06-02321, sheet 12, zone F3
43
Fault Code A338: Engine Air Filter Fault

Fault Code A338
Description Engine Air Filter Fault
Fault Conditions Sets if Engine Air Filter Switch indicates filter is full for 2 seconds with the engine
running.
Resets if Engine Air Filter Switch turns off or engine stops running.
Display Fault Description: ENG AIR FILT RSTRICT
Resulting Problem(s) Plugged filter could damage engine.
fault.
Table
1. The normal corrective measure for this fault is to change the engine air filter.
Engine Air Filter 0: Engine Air Filter Restriction Switch not operating
Restriction Switch 1: Engine Air Filter Restriction Switch indicating filter restriction
(IM2X) Fault(s): A337
Engine Speed [RPM] <300 RPM: Engine is not running
(CAN/J1939) (IM1q,r,s) >300 RPM: Engine is running
Fault(s): A184
44

Reference
Engine Air Filter Refer to 58E-06-02311, sheet 15, zone B2 830E
Restriction Switch Refer to 58E-06-02321, sheet 12, zone F3
45
Fault Code A339: The diesel exhaust fluid level gauge within the display panel is defective
Fault Code A339
Description The diesel exhaust fluid level gauge within the display panel is defective.
Fault Conditions Sets if display panel reports a diesel exhaust fluid level gauge fault.
Reset if display panel clears the fault or at steering bleed.
Display Fault Description: DEF FLUID LEVEL GAGE
Resulting Problem(s) Running low on Diesel Exhaust Fluid will cause operator inducements (limitation of
truck performance).
Related Information
Table
panel. The panel and communication to it must be working in order for IM to be aware of the fault. Therefore the
only diagnostic effort is to check the gauge and wiring within the panel and replace if necessary.

Reference
Diesel Exhaust Fluid Refer to 58E-06-02311, sheet 10, zone E6 830E
Level Gauge Refer to 58E-06-02321, sheet 7, zone A9
46
NOTES
47
Fault Code A340: The shifter controller has declared a fault

Fault Code A340
Description The shifter controller has declared a fault.
Fault Conditions Sets if the Shifter Controller detects a fault with the Keyswitch, on for 3 seconds.
Resets if the fault goes away for 3 seconds or the steering bleed valve comes on.
Display Fault Description: SHIFT CONTROL FAULT
Resulting Problem(s) Truck may not be operational.
fault.
Table
1. Except for being masked by the steering bleed process, this fault is contained within the Shifter Controller,
the Shifter itself, or associated wiring.
2. This fault's logic contains just one parameter, which may have additional fault codes.
3. Based on the truck's setup while this fault is active, determine which of the parameters in the Table is not
shown in its expected state on the IM Realtime Data Monitor program. Refer to the schematic to identify which
item(s) may be causing the parameter(s) to be in the unexpected state. Troubleshoot these items.
Shifter Controller Fault 0: operation normal
Input (IM2m) 1: fault exists
Fault(s): A341
48

Reference
Shifter Controller Fault Refer to 58E-06-02311, sheet 9, zone J16 830E
Input to IM Refer to 58E-06-02321, sheet 27, zone C2
49
Fault Code A341: The shifter control circuit is defective

Fault Code A341
Description The shifter control circuit is defective.
Fault Conditions Sets if shifter is not in either Park or FNR (forward, neutral, reverse) position for 2 sec-
onds with keyswitch on.
Display Fault Description: SHIFT CONT CIRC FLT
Resulting Problem(s) Truck may not be operational.
fault.
Table
1. Except for being masked by the keyswitch, OR signal to IM, this fault is contained within the wiring of the
shifter to IM.
2. This fault's logic contains more than one parameter, which may have additional fault codes.
Selector Switch (Park) 0: Switch not in Park
(IM3T) 1: Switch in Park position
Fault(s): A340
Selector Switch (FNR) 0: Keyswitch, OR off
(IM2N) 1: Keyswitch, OR on
Fault(s): A240
Keyswitch, Or (IM3G) 0: Keyswitch, OR off
1: Keyswitch, OR on
Fault(s): A240
50

Reference
51
Fault Code A342: The Accessory Pump Filter Switch has actuated
Fault Code A342
Description The Accessory Pump Filter Switch has actuated.
Fault Conditions Sets if switch is on, engine is running, and oil temperature is above 50º C (122º F) for
10 seconds.
Resets if conditions clear for 10 seconds.
Display Fault Description: ACC HYD OIL FILT RST
Resulting Problem(s) High oil temperatures may cause equipment damage.
fault.
Table
1. The primary cause for this fault is a plugged filter.
Accessory Pump Filter 0: Switch off, normal operation
Switch (IM3X) 1: Switch on, pressure is high
Hydraulic Oil Temp - < 50º C (122º F): Normal operating range
Tank (IM3m) >50º C (122º F): High temperature range
Fault(s): A103, A104, A193
52

Reference
connection to IM
Accessory Pump Filter Refer to 58E-06-02311, sheet 15, zone E10 830E
Switch input to IM Refer to 58E-06-02321, sheet 30, zone C6
53
Fault Code A343: Truck speed is limited by GE

Fault Code A343
Description Truck speed is limited by GE.
Fault Conditions Sets when GE transmits a Speed Limit signal on CAN/RPC.
Resets when GE clears the Speed Limit signal on CAN/RPC.
Operator Alerting Single Burst of Sound on Buzzer
System Response No Warning Indicator
Display Operator Action: MAX SPEED LIMITED
Display Fault Description: GE SPEED LIMT
Resulting Problem(s) Truck will not perform well.
fault.
Table
1. This fault is developed within the GE drive system and transmitted to IM via CAN/RPC.
2. Troubleshoot the GE drive and check for malfunction in CAN/RPC.
CAN/RPC (IM i, j, k) Fault: A233

Reference
54
Fault Code A344: GE has posted a No Retarding fault

Fault Code A344
Description GE has posted a No Retarding fault.
Fault Conditions Sets when GE transmits a No Retarding message on CAN/RPC.
Resets when GE clears the No Retarding message on CAN/RPC.
System Response Flash Warning Indicator
Display Fault Description: NO RETARD
Resulting Problem(s) Truck can not continue to operate without retarding.
fault.
Table

Reference
55
Fault Code A345: Engine speed limited by GE

Fault Code A345
Description Engine speed limited by GE
Fault Conditions Sets when GE transmits an Engine Speed Limited message on CAN/RPC.
Resets when GE clears the Engine Speed Limited message on CAN/RPC.
Display Fault Description: ENG SPD LIMIT BY GE
Resulting Problem(s) Performance will be limited.
fault.
Table

Reference
56
Fault Code A346: Delayed Shut Down by GE

Fault Code A346
Description Delayed Shut Down by GE
Fault Conditions Sets when GE transmits a Delayed Shut Down warning on CAN/RPC.
Resets when GE clears the Delayed Shut Down warning on CAN/RPC.
Display Fault Description: LIMITED RETARD
Resulting Problem(s) Truck will soon be non-operational.
fault.
Table

Reference
57
Fault Code A347: Operator Override of GE is active

Fault Code A347
Description Operator Override of GE is active.
Fault Conditions Sets when Ge transmits an Operator Override of GE Active message on CAN/RPC.
Resets when GE clears the Operator Override of GE Active message on CAN/RPC.
Display Fault Description: OVERRIDE ACTIVE
Resulting Problem(s) Truck performance will be limited.
fault.
Table
3. Troubleshoot the Override Switch and override input to GE.

Reference
58
Fault Code A348: GE has disabled load box operation

Fault Code A348
Description GE has disabled load box operation.
Fault Conditions Sets when GE transmits a Load Box Disabled signal on CAN/RPC.
Resets when GE clears the Load Box Disabled signal on CAN/RPC.
Display Fault Description: LOAD BOX DISABLED
Resulting Problem(s) Load box operation can not continue.
fault.
Table

Reference
59
Fault Code A349: GE has limited load box operation

Fault Code A349
Description GE has limited load box operation.
Fault Conditions Sets when GE transmits a Limited Load Box message on CAN/RPC.
Resets when GE clears the Limited Load Box message on CAN/RPC.
Display Fault Description: LOAD BOX LIMITED
Resulting Problem(s) Load box operation only at reduced level.
fault.
Table

Reference
60
NOTES
61
Fault Code A350: Overload on output 1B

Fault Code A350
Description Overload on output 1B.
Fault Conditions Sets if driver chip detects over current or over temp on output 1B. Output is turned off
when overload is detected.
System Response Display Fault Description: STRT ENABLE CKT FLT
Resulting Problem(s) Starting circuit is disabled.
fault.
Table
1. This fault's logic contains just one parameter, which may have additional fault code(s). This fault may be
resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting Instructions for the
active parameter fault(s).
Fault(s): A252g situations exist to prevent cranking.
Fault(s): A252
62

Reference
Start Enable Relay coil Refer to 58E-06-02311, sheet 5, zone K14 830E
circuit Refer to 58E-06-02321, sheet 4, zone A8
63
Fault Code A351: Overload on output 1E

Fault Code A351
Description Overload on output 1E.
Fault Conditions Sets if driver chip detects over current or over temp on output 1E. Output is turned off
Display Fault Description: PRK BRK COMMAND FLT
Resulting Problem(s) Parking brake solenoid valve circuit is disabled (parking brake will not release).
fault.
Table
Status - Shorted to Ground: Expected if parking rake request is in the 24 volt condition.
Otherwise, unexpected. Troubleshoot.
0: Parking brake request input is in the low voltage (request) condition.
1: Parking brake request input is in the high voltage (not requested) condition.
64

Reference
65
Fault Code A352: Overload on output 1H

Fault Code A352
Description Overload on output 1H.
Fault Conditions Sets if driver chip detects over current or over temp on output 1H. Output is turned off
System Response Display Fault Description: SHUTDOWN DELAY CKT
Resulting Problem(s) Shutdown delay circuit is disabled.
fault.
Table
0. Turns off when conditions clear or engine speed drops to zero.
1: Turns on when Keyswitch, Direct is off, Engine Shutdown Delay is on, Park brake is
300 rpm.
66

Reference
Shutdown Delay Relay Refer to 58E-06-02311, sheet 5, zone D10 830E
coil circuit Refer to 58E-06-02321, sheet 4, zone E2
Refer to 58F-06-02311, sheet 5, zone D10 930E
Refer to 58F-06-10561, sheet 4, zone E2
Refer to 58B-06-02390, sheet 5, zone D10 980E
Refer to 58B-06-03570, sheet 4, zone E2
67
Fault Code A353: Overload on output 1J

Fault Code A353
Description Overload on output 1J.
Fault Conditions Sets if driver chip detects over current or over temp on output 1J. Output is turned off
System Response Display Fault Description: SEAT BELT ALARM FLT
Resulting Problem(s) Seat belt alarm relay is disabled.
fault.
Table
1. This fault's logic contains just one parameter. There are no additional fault codes to investigate.
Seat Belt Alarm Output Status - Open Load: Unexpected. Troubleshoot
(IM1J) Status - Normal: Expected. No problem.
0. No seat belt alarm
1: Seat belt alarm exists
68

Reference
Seat Belt Alarm Option Refer to 58E-06-02311, sheet 15, zone B18 830E
relay coil circuit Refer to 58E-06-02321, sheet 16, zone B4
Refer to 58F-06-02311, sheet 15, zone B18 930E
Refer to 58F-06-10561, sheet 16, zone B4
Refer to 58B-06-02390, sheet 16, zone B18 980E
Refer to 58B-06-03570, sheet 18, zone B4
Seat Belt Alarm Option Refer to 58E-06-02311, sheet 5, zone K12 830E
relay coil circuit Refer to 58E-06-02321, sheet 18, zone A6
voltage Refer to 58F-06-02311, sheet 5, zone K12 930E
Refer to 58F-06-10561, sheet 18, zone A6
Refer to 58B-06-02390, sheet 5, zone J11 980E
Refer to 58B-06-03570, sheet 20, zone A6
69
Fault Code A354: Overload on output 1K

Fault Code A354
Description Overload on output 1K.
Fault Conditions Sets if driver chip detects over current or over temp on output 1K. Output is turned off
System Response Display Fault Description: IM ON SIGNAL FAULT
Resulting Problem(s) Loss of interface module (IM) ON signal causes the display to stop functioning.
fault.
Table
IM On Signal (IM1K) Status - Open Load: Unexpected. Troubleshoot.
0: Off. Display is permitted to go to sleep.
1: On. Display is awakened.

Reference
IM On Signal load Refer to 58E-06-02311, sheet 10, zones G5 through G17 830E
circuit Refer to 58E-06-02321, sheet 7, zone C9
Refer to 58F-06-02311, sheet 10, zones G5 through G17 930E
Refer to 58F-06-10561, sheet 7, zone C9
Refer to 58B-06-02390, sheet 11, zones G5 through G17 980E
Refer to 58B-06-03570, sheet 7, zone C8
70
Fault Code A355: Overload on output 1L

Fault Code A355
Description Overload on output 1L.
Fault Conditions Sets if driver chip detects over current or over temp on output 1L. Output is turned off
System Response Display Fault Description: IM OUTPUT 1L FAULT
Resulting Problem(s) Unused outputs with short circuits on them might damage the driver chip if not
corrected.
fault.
Table
2. Any spare wires connected to this output should be removed to prevent ultimate failure of the driver chip.
Spare IM Output Status - Open Load: Expected. No problem.
(IM1L) Status - Normal: Expected. No problem.
0. Off
1: On

None None
71
Fault Code A356: Overload on output 1M

Fault Code A356
Description Overload on output 1M.
Fault Conditions Sets if driver chip detects over current or over temp on output 1M. Output is turned off
Display Fault Description: SONALERT IM FAULT
Resulting Problem(s) The sonalert with the display cannot be driven.
fault.
Table
Sonalert (IM1M) Status - Open Load: Unexpected. Troubleshoot
0: No faults are active that require buzzer operation.
1. One or more faults are active that require buzzer action.
Fault(s): A251
72

Reference
Sonalert connection to Refer to 58E-06-02311, sheet 10, zones E9 through E17 830E
IM Refer to 58E-06-02321, sheet 7, zones B2 through B5
Refer to 58F-06-02311, sheet 10, zones E9 through E17 930E
Refer to 58F-06-10561, sheet 7, zone B2 through B5
Refer to 58B-06-02390, sheet 11, zones E9 through E17 980E
Refer to 58B-06-03570, sheet 7, zones B2 through B5
Sonalert connection to Refer to 58E-06-02311, sheet 10, zone G15 830E
Keyswitch Refer to 58E-06-02321, sheet 7, zone B3
Refer to 58F-06-02311, sheet 10, zone G15 930E
Refer to 58B-06-02390, sheet 11, zone G15 980E
Sonalert Power Refer to 58E-06-02311, sheet 5, zone K12 830E
Refer to 58F-06-02311, sheet 5, zone K12 930E
Refer to 58B-06-02390, sheet 5, zone K12 980E
73
Fault Code A357: Overload on output 1N

Fault Code A357
Description Overload on output 1N.
Fault Conditions Sets if driver chip detects over current or over temp on output 1N. Output is turned off
System Response Display Fault Description: IM OUTPUT 1N FAULT
corrected.
fault.
Table
Spare IM Output Status - Open Load: Unexpected. Troubleshoot.
(IM1N) Status - Normal: Expected. No problem.
0: Off.
1: On.

None None
74
NOTES
75
Fault Code A358: Overload on output 1P

Fault Code A358
Description Overload on output 1P.
Fault Conditions Sets if driver chip detects over current or over temp on output 1P. Output is turned off
Display Fault Description: STG BLEED CKT FAULT
Resulting Problem(s) The steering bleed circuit might not work properly, therefore causing a threat to
operators and mechanics.
fault.
Table
(IM1P) unexpected. Troubleshoot.
Status - Normal: Expected only with keyswitch OFF and steering bleed in process.
Troubleshoot if found with key ON.
0: Steering bleed valve is off. This is expected in normal running operation.
1: Steering bleed valve is on. This is expected after keyswitch OFF initiates steering
bleed operation.
Fault(s): A235, A236, A253, A262
76

Reference
Refer to 58F-06-02311, sheet 15, zone B10 930E
Refer to 58B-06-02390, sheet 16, zone C12 980E
Refer to 58F-06-02311, sheet 15, zone C18 930E
77
Fault Code A359: Overload on output 1R

Fault Code A359
Description Overload on output 1R.
Fault Conditions Sets if driver chip detects over current or over temp on output 1R. Output is turned off
Resulting Problem(s) A non-functional brake auto apply valve might cause damage to the parking brake.
fault.
Table
Auto Brake Apply Status - Open Load: Unexpected if parking brake request and keyswitch are on.
Solenoid (IM1R) Expected if parking brake request is off or keyswitch is off. Troubleshoot if
inconsistent.
Status - Normal: Expected if parking brake request and keyswitch are on.
Troubleshoot if status is normal with parking brake request off or keyswitch off.
Status - Shorted to ground: Unexpected. Troubleshoot.
0: Normal operation with parking brake either applied or released. This valve operates
only transiently when the parking brake is set.
1: Brake auto apply relay operates the brake lock valve for 1.5 seconds after the
parking brake is applied if the truck is stopped. If moving, it will not operate until truck
speed has dropped to 0.8 kph (0.5 mph).
78

Reference
Auto Brake Apply Refer to 58F-06-02311, sheet 9, zones L5 through O17 930E
Relay & Circuit Refer to 58F-06-10561, sheet 5, zones B4 through C5
Refer to 58B-06-02390, sheet 10, zones L5 through O17 980E
Refer to 58B-06-03570, sheet 5, zones B4 through C5
79
Fault Code A360: Overload on output 1S

Fault Code A360
Description Overload on output 1S.
Fault Conditions Sets if driver chip detects over current or over temp on output 1S. Output is turned off
System Response Display Fault Description: IM OUTPUT 1S FAULT
corrected.
fault.
Table
(IM1S) Status - Normal: Expected. No problem.
0: Off
1: On

None None
80
NOTES
81
Fault Code A361: Overload on output 1T

Fault Code A361
Description Overload on output 1T.
Fault Conditions Sets if driver chip detects over current or over temp on output 1T. Output is turned off
System Response Display Fault Description: AUTO LUBE CIRCUIT
Resulting Problem(s) Auto lube circuit is disabled.
fault.
Table
1. This fault's logic contains more than one parameter, which may have additional fault code(s). This fault may
be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting Instructions for the
Auto Lube Output Status - Open Load: Unexpected. Troubleshoot.
(IM1T) Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected except momentarily at termination of a lube
cycle. If detected any other time, troubleshoot.
0: Turns off between lubrication cycles.
1: Turns on during lubrication cycle.
Fault(s): A190
82

Reference
Auto Lube Solenoid Refer to 58E-06-02311, sheet 15, zones N9 through N19 830E
Refer to 58F-06-02311, sheet 15, zones N9 through N19 930E
Refer to 58B-06-02390, sheet 16, zones M9 through M21 980E
83
Fault Code A362: Overload on output 1U

Fault Code A362
Description Overload on output 1U.
Fault Conditions Sets if driver chip detects over current or over temp on output 1U. Output is turned off
System Response Display Fault Description: IM OUTPUT 1U FAULT
corrected.
fault.
Table
(IM1U) Status - Normal: Expected. No problem.
0: Off
1: On

None None
84
Fault Code A363: Overload on output 1X

Fault Code A363
Description Overload on output 1X.
Fault Conditions Sets if driver chip detects over current or over temp on output 1X. Output is turned off
System Response Display Fault Description: IM OUTPUT 1X FAULT
corrected.
fault.
Table
Brake Cooling RPM Status - Open Load: Unexpected. Troubleshoot.
Advance 2: (IM1X) Status - Normal: Expected. No problem.
0: Off
1: On
Fault(s): A146

None None
85
Fault Code A364: Overload on output 1Y

Fault Code A364
Description Overload on output 1Y.
Fault Conditions Sets if driver chip detects over current or over temp on output 1Y. Output is turned off
System Response Display Fault Description: IM OUTPUT 1Y FAULT
corrected.
fault.
Table
(IM1Y) Status - Normal: Expected. No problem.
0: Off
1: On

None None
86
Fault Code A365: Overload on output 1Z

Fault Code A365
Description Overload on output 1Z.
Fault Conditions Sets if driver chip detects over current or over temp on output 1Z. Output is turned off
Operator Alerting Repair Monitor
System Response Display Fault Description: IM OUTPUT 1Z FAULT
corrected.
fault.
Table
(IM1Z) Status - Normal: Expected. No problem.
0: Off
1: On

None None
87
Fault Code A366: Axle box cooling fault

Fault Code A366
Description Axle box cooling fault.
Fault Conditions Sets if Blower Speed Full Request remains on for 10 seconds while the Axle Box
Blower Speed remains below 100%.
Resets if Axle Box Blower Speed returns to 100% for 10 seconds.
Display Fault Description: AXLE BOX COOL FLT
Resulting Problem(s) Poor cooling can cause equipment damage.
fault.
Table
Brake Pressure 2.4 mA to 20.1 mA: good readings
IM(3b,3p) < 2.4 mA or more than 20.1 mA: Defective sensor or circuit
Truck Speed [kph] Fault(s): A233
(CAN/RPC) (IM1i,j,k)
Wheel Blower Speed
(%) (CAN/RPC)
(IM1i,J,K)
88

Reference
Refer to 58F-06-02311, sheet 15, zones K1 through K8 930E
Refer to 58F-06-10561, sheet 5, zone E10
Refer to 58B-06-02390, sheet 16, zones K1 through K12 980E
Refer to 58B-06-03570, sheet 5, zone E10
Refer to 58F-06-02311, sheet 15, zone I12 and sheet 17, zone B5 930E
Refer to 58B-06-02390, sheet 16, zone D6 and sheet 18, zone B8 980E
IM Refer to 58F-06-02311, sheet 17, zone C4 930E
89
830E Dump truck

930E Dump truck
980E Dump truck
90
CEN40182-00
DUMP TRUCK
830E
930E
980E

830E-5 A50005 and up
930E-5 A40004 and up
980E-5 A50005 and up
40 Troubleshooting
Fault Code A400: Tire 1 (Front Left) High Pressure RED Fault............................................................................ 4
Fault Code A401: Tire 1 (Front Left) High Pressure AMBER Fault....................................................................... 5
Fault Code A402: Tire 1 (Front Left) Low Pressure RED Fault............................................................................. 6
Fault Code A403: Tire 1 (Front Left) Low Pressure AMBER Fault ....................................................................... 7
Fault Code A404: Tire 1 (Front Left) No Data / Sensor Failure / Not Connected Fault......................................... 8
Fault Code A405: Tire 1 (Front Left) High Temperature RED Fault ...................................................................... 9
Fault Code A406: Tire 1 (Front Left) High Temperature AMBER Fault............................................................... 10
Fault Code A407: Tire 1 (Front Left) Bad Value Sensor Error / Not Connected Fault .........................................11
Fault Code A408: Tire 2 (Front Right) High Pressure RED Fault ....................................................................... 12
Fault Code A409: Tire 2 (Front Right) High Pressure AMBER Fault .................................................................. 13
Fault Code A410: Tire 2 (Front Right) Low Pressure RED Fault ........................................................................ 14
Fault Code A411: Tire 2 (Front Right) Low Pressure AMBER Fault ................................................................... 15
Fault Code A412: Tire 2 (Front Right) No Data / Sensor Failure / Not Connected Fault .................................... 16
Fault Code A413: Tire 2 (Front Right) High Temperature RED Fault.................................................................. 17
Fault Code A414: Tire 2 (Front Right) High Temperature AMBER Fault ............................................................ 18
Fault Code A415: Tire 2 (Front Right) Bad Value Sensor Error / Not Connected Fault ...................................... 19
1
Fault Code A416: Tire 3 (Rear Left Outboard) High Pressure RED Fault........................................................... 20
Fault Code A417: Tire 3 (Rear Left Outboard) High Pressure AMBER Fault ..................................................... 21
Fault Code A418: Tire 3 (Rear Left Outboard) Low Pressure RED Fault ........................................................... 22
Fault Code A419: Tire 3 (Rear Left Outboard) Low Pressure AMBER Fault ...................................................... 23
Fault Code A420: Tire 3 (Rear Left Outboard) No Data / Sensor Failure / Not Connected Fault ....................... 24
Fault Code A421: Tire 3 (Rear Left Outboard) High Temperature RED Fault..................................................... 25
Fault Code A422: Tire 3 (Rear Left Outboard) High Temperature AMBER Fault................................................ 26
Fault Code A423: Tire 3 (Rear Left Outboard) Bad Value Sensor Error / Not Connected Fault ......................... 27
Fault Code A424: Tire 4 (Rear Left Inboard) High Pressure RED Fault ............................................................. 28
Fault Code A425: Tire 4 (Rear Left Inboard) High Pressure AMBER Fault ........................................................ 29
Fault Code A426: Tire 4 (Rear Left Inboard) Low Pressure RED Fault .............................................................. 30
Fault Code A427: Tire 4 (Rear Left Inboard) Low Pressure AMBER Fault ......................................................... 31
Fault Code A428: Tire 4 (Rear Left Inboard) No Data / Sensor Failure / Not Connected Fault .......................... 32
Fault Code A429: Tire 4 (Rear Left Inboard) High Temperature RED Fault........................................................ 33
Fault Code A430: Tire 4 (Rear Left Inboard) High Temperature AMBER Fault .................................................. 34
Fault Code A431: Tire 4 (Rear Left Inboard) Bad Value Sensor Error / Not Connected Fault ............................ 35
Fault Code A432: Tire 5 (Rear Right Inboard) High Pressure RED Fault ........................................................... 36
Fault Code A433: Tire 5 (Rear Right Inboard) High Pressure AMBER Fault...................................................... 37
Fault Code A434: Tire 5 (Rear Right Inboard) Low Pressure RED Fault............................................................ 38
Fault Code A435: Tire 5 (Rear Right Inboard) Low Pressure AMBER Fault....................................................... 39
Fault Code A436: Tire 5 (Rear Right Inboard) No Data / Sensor Failure / Not Connected Fault........................ 40
Fault Code A437: Tire 5 (Rear Right Inboard) High Temperature RED Fault ..................................................... 41
Fault Code A438: Tire 5 (Rear Right Inboard) High Temperature AMBER Fault ................................................ 42
Fault Code A439: Tire 5 (Rear Right Inboard) Bad Value Sensor Error / Not Connected Fault.......................... 43
Fault Code A440: Tire 6 (Rear Right Outboard) High Pressure RED Fault ........................................................ 44
Fault Code A441: Tire 6 (Rear Right Outboard) High Pressure AMBER Fault ................................................... 45
Fault Code A442: Tire 6 (Rear Right Outboard) Low Pressure RED Fault ......................................................... 46
Fault Code A443: Tire 6 (Rear Right Outboard) Low Pressure AMBER Fault.................................................... 47
Fault Code A444: Tire 6 (Rear Right Outboard) No Data / Sensor Failure / Not Connected Fault ..................... 48
Fault Code A445: Tire 6 (Rear Right Outboard) High Temperature RED Fault .................................................. 49
Fault Code A446: Tire 6 (Rear Right Outboard) High Temperature AMBER Fault ............................................. 50
Fault Code A447: Tire 6 (Rear Right Outboard) Bad Value Sensor Error / Not Connected Fault....................... 51
2
NOTES
3
Fault Code A400: Tire 1 (Front Left) High Pressure RED Fault
Fault Code A400
Description Tire 1 (Front Left) High Pressure RED Fault
Fault Conditions Sets if Pressure hardware max or Pressure limit RED max or Pressure band RED high
are on and Bad Value Sensor Error / Not Connected Fault is not on.
Resets when conditions change or steering bleed comes on.
Display Fault Description: #1 TIRE PRESSURE HI
Resulting Problem(s) Potential tire damage.
fault.
Table
This fault is based entirely on data transmitted by the Tire Monitor.
Tire 1 Data (CAN/RPC) Faults: A401, A402, A403, A404, A405, A406, A407
(IMI,j,k)

None None
4
Fault Code A401: Tire 1 (Front Left) High Pressure AMBER Fault
Fault Code A401
Description Tire 1 (Front Left) High Pressure AMBER Fault
Fault Conditions Sets if pressure band AMBER high is on and Bad Value Sensor Error / Not Connected
Fault is not on.
fault.
Table
(IMI,j,k)

None None
5
Fault Code A402: Tire 1 (Front Left) Low Pressure RED Fault
Fault Code A402
Description Tire 1 (Front Left) Low Pressure RED Fault.
Fault Conditions Sets if Pressure hardware min or Pressure limit RED low or Pressure band RED low
Display Fault Description: #1 TIRE PRESSURE LO
fault.
Table
(IMI,j,k)

None None
6
Fault Code A403: Tire 1 (Front Left) Low Pressure AMBER Fault
Fault Code A403
Description Tire 1 (Front Left) Low Pressure AMBER Fault.
Fault Conditions Sets if pressure band AMBER low is on and Bad Value Sensor Error / Not Connected
Fault is not on.
fault.
Table
(IMI,j,k)

None None
7
Fault Code A404: Tire 1 (Front Left) No Data / Sensor Failure / Not Connected Fault
Fault Code A404
Description Tire 1 (Front Left) No Data / Sensor Failure / Not Connected Fault
Fault Conditions Sets if Tag time out is on and Bad Value sensor Error / Not Connected Fault is not on.
Resets if conditions change.
Display Fault Description: TIRE #1 NO DATA
Resulting Problem(s) Loss of tire monitoring could permit tire damage.
fault.
Table
(IMI,j,k)

None None
8
Fault Code A405: Tire 1 (Front Left) High Temperature RED Fault
Fault Code A405
Description Tire 1 (Front Left) High Temperature RED Fault.
Fault Conditions Sets if Temp limit RED is on and Bad Value sensor Error / Not Connected Fault is not
on.
Resets if conditions change or if steering bleed begins.
Display Fault Description: #1 TIRE TEMP HI
fault.
Table
(IMI,j,k)

None None
9
Fault Code A406: Tire 1 (Front Left) High Temperature AMBER Fault
Fault Code A406
Description Tire 1 (Front Left) High Temperature AMBER Fault.
Fault Conditions Sets if Temp limit AMBER is on and Bad Value Sensor Error / Not Connected Fault is
not on.
Resets if conditions change or steering bleed valve comes on.
fault.
Table
(IMI,j,k)

None None
10
Fault Code A407: Tire 1 (Front Left) Bad Value Sensor Error / Not Connected Fault
Fault Code A407
Description Tire 1 (Front Left) Bad Value Sensor Error / Not Connected Fault.
Fault Conditions Sets if Last Tag Status Input is equal to 2. Resets if not equal to 2.
System Response Display Fault Description: TIRE #1 BAD VALUE
Resulting Problem(s) Tire data is bad.
fault.
Table
(IMI,j,k)

None None
11
Fault Code A408: Tire 2 (Front Right) High Pressure RED Fault
Fault Code A408
Description Tire 2 (Front Right) High Pressure RED Fault
Resets when conditions change or steering bleed valve comes on.
fault.
Table
(IMI,j,k)

None None
12
Fault Code A409: Tire 2 (Front Right) High Pressure AMBER Fault
Fault Code A409
Description Tire 2 (Front Right) High Pressure AMBER Fault
Fault is not on.
fault.
Table
(IMI,j,k)

None None
13
Fault Code A410: Tire 2 (Front Right) Low Pressure RED Fault
Fault Code A410
Description Tire 2 (Front Right) Low Pressure RED Fault.
fault.
Table
(IMI,j,k)

None None
14
Fault Code A411: Tire 2 (Front Right) Low Pressure AMBER Fault
Fault Code A411
Description Tire 2 (Front Right) Low Pressure AMBER Fault.
Fault is not on.
fault.
Table
(IMI,j,k)

None None
15
Fault Code A412: Tire 2 (Front Right) No Data / Sensor Failure / Not Connected Fault
Fault Code A412
Description Tire 2 (Front Right) No Data / Sensor Failure / Not Connected Fault
fault.
Table
(IMI,j,k)

None None
16
Fault Code A413: Tire 2 (Front Right) High Temperature RED Fault
Fault Code A413
Description Tire 2 (Front Right) High Temperature RED Fault.
on.
Resulting Problem(s) Potential Tire Damage
fault.
Table
(IMI,j,k)

None None
17
Fault Code A414: Tire 2 (Front Right) High Temperature AMBER Fault
Fault Code A414
Description Tire 2 (Front Right) High Temperature AMBER Fault.
not on.
fault.
Table
(IMI,j,k)

None None
18
Fault Code A415: Tire 2 (Front Right) Bad Value Sensor Error / Not Connected Fault
Fault Code A415
Description Tire 2 (Front Right) Bad Value Sensor Error / Not Connected Fault.
fault.
Table
(IMI,j,k)

None None
19
Fault Code A416: Tire 3 (Rear Left Outboard) High Pressure RED Fault
Fault Code A416
Description Tire 3 (Rear Left Outboard) High Pressure RED Fault
fault.
Table
(IMI,j,k)

None None
20
Fault Code A417: Tire 3 (Rear Left Outboard) High Pressure AMBER Fault
Fault Code A417
Description Tire 3 (Rear Left Outboard) High Pressure AMBER Fault
Fault is not on.
fault.
Table
(IMI,j,k)

None None
21
Fault Code A418: Tire 3 (Rear Left Outboard) Low Pressure RED Fault
Fault Code A418
Description Tire 3 (Rear Left Outboard) Low Pressure RED Fault.
fault.
Table
(IMI,j,k)

None None
22
Fault Code A419: Tire 3 (Rear Left Outboard) Low Pressure AMBER Fault
Fault Code A419
Description Tire 3 (Rear Left Outboard) Low Pressure AMBER Fault.
Fault is not on.
fault.
Table
(IMI,j,k)

None None
23
Fault Code A420: Tire 3 (Rear Left Outboard) No Data / Sensor Failure / Not Connected
Fault
Fault Code A420
Description Tire 3 (Rear Left Outboard) No Data / Sensor Failure / Not Connected Fault
fault.
Table
(IMI,j,k)

None None
24
Fault Code A421: Tire 3 (Rear Left Outboard) High Temperature RED Fault
Fault Code A421
Description Tire 3 (Rear Left Outboard) High Temperature RED Fault.
on.
fault.
Table
(IMI,j,k)

None None
25
Fault Code A422: Tire 3 (Rear Left Outboard) High Temperature AMBER Fault
Fault Code A422
Description Tire 3 (Rear Left Outboard) High Temperature AMBER Fault.
not on.
Resets if conditions change or steering bleed comes on.
fault.
Table
(IMI,j,k)

None None
26
Fault Code A423: Tire 3 (Rear Left Outboard) Bad Value Sensor Error / Not Connected Fault
Fault Code A423
Description Tire 3 (Rear Left Outboard) Bad Value Sensor Error / Not Connected Fault.
fault.
Table
(IMI,j,k)

None None
27
Fault Code A424: Tire 4 (Rear Left Inboard) High Pressure RED Fault
Fault Code A424
Description Tire 4 (Rear Left Inboard) High Pressure RED Fault
fault.
Table
(IMI,j,k)

None None
28
Fault Code A425: Tire 4 (Rear Left Inboard) High Pressure AMBER Fault
Fault Code A425
Description Tire 4 (Rear Left Inboard) High Pressure AMBER Fault
Fault is not on.
fault.
Table
(IMI,j,k)

None None
29
Fault Code A426: Tire 4 (Rear Left Inboard) Low Pressure RED Fault
Fault Code A426
Description Tire 4 (Rear Left Inboard) Low Pressure RED Fault.
fault.
Table
(IMI,j,k)

None None
30
Fault Code A427: Tire 4 (Rear Left Inboard) Low Pressure AMBER Fault
Fault Code A427
Description Tire 4 (Rear Left Inboard) Low Pressure AMBER Fault.
Fault is not on.
fault.
Table
(IMI,j,k)

None None
31
Fault Code A428: Tire 4 (Rear Left Inboard) No Data / Sensor Failure / Not Connected Fault
Fault Code A428
Description Tire 4 (Rear Left Inboard) No Data / Sensor Failure / Not Connected Fault
fault.
Table
(IMI,j,k)

None None
32
Fault Code A429: Tire 4 (Rear Left Inboard) High Temperature RED Fault
Fault Code A429
Description Tire 4 (Rear Left Inboard) High Temperature RED Fault.
on.
Resets if conditions change or if steering bleed valve begins.
fault.
Table
(IMI,j,k)

None None
33
Fault Code A430: Tire 4 (Rear Left Inboard) High Temperature AMBER Fault
Fault Code A430
Description Tire 4 (Rear Left Inboard) High Temperature AMBER Fault.
not on.
fault.
Table
(IMI,j,k)

None None
34
Fault Code A431: Tire 4 (Rear Left Inboard) Bad Value Sensor Error / Not Connected Fault
Fault Code A431
Description Tire 4 (Rear Left Inboard) Bad Value Sensor Error / Not Connected Fault.
fault.
Table
(IMI,j,k)

None None
35
Fault Code A432: Tire 5 (Rear Right Inboard) High Pressure RED Fault
Fault Code A432
Description Tire 5 (Rear Right Inboard) High Pressure RED Fault
fault.
Table
(IMI,j,k)

None None
36
Fault Code A433: Tire 5 (Rear Right Inboard) High Pressure AMBER Fault
Fault Code A433
Description Tire 5 (Rear Right Inboard) High Pressure AMBER Fault
Fault is not on.
fault.
Table
(IMI,j,k)

None None
37
Fault Code A434: Tire 5 (Rear Right Inboard) Low Pressure RED Fault
Fault Code A434
Description Tire 5 (Rear Right Inboard) Low Pressure RED Fault.
fault.
Table
(IMI,j,k)

None None
38
Fault Code A435: Tire 5 (Rear Right Inboard) Low Pressure AMBER Fault
Fault Code A435
Description Tire 5 (Rear Right Inboard) Low Pressure AMBER Fault.
Fault is not on.
fault.
Table
(IMI,j,k)

None None
39
Fault Code A436: Tire 5 (Rear Right Inboard) No Data / Sensor Failure / Not Connected
Fault
Fault Code A436
Description Tire 5 (Rear Right Inboard) No Data / Sensor Failure / Not Connected Fault
fault.
Table
(IMI,j,k)

None None
40
Fault Code A437: Tire 5 (Rear Right Inboard) High Temperature RED Fault
Fault Code A437
Description Tire 5 (Rear Right Inboard) High Temperature RED Fault.
on.
Resets if conditions change or if steering bleed valve begins.
fault.
Table
(IMI,j,k)

None None
41
Fault Code A438: Tire 5 (Rear Right Inboard) High Temperature AMBER Fault
Fault Code A438
Description Tire 5 (Rear Right Inboard) High Temperature AMBER Fault.
not on.
fault.
Table
(IMI,j,k)

None None
42
Fault Code A439: Tire 5 (Rear Right Inboard) Bad Value Sensor Error / Not Connected Fault
Fault Code A439
Description Tire 5 (Rear Right Inboard) Bad Value Sensor Error / Not Connected Fault.
fault.
Table
(IMI,j,k)

None None
43
Fault Code A440: Tire 6 (Rear Right Outboard) High Pressure RED Fault
Fault Code A440
Description Tire 6 (Rear Right Outboard) High Pressure RED Fault
fault.
Table
(IMI,j,k)

None None
44
Fault Code A441: Tire 6 (Rear Right Outboard) High Pressure AMBER Fault
Fault Code A441
Description Tire 6 (Rear Right Outboard) High Pressure AMBER Fault
Fault is not on.
fault.
Table
(IMI,j,k)

None None
45
Fault Code A442: Tire 6 (Rear Right Outboard) Low Pressure RED Fault
Fault Code A442
Description Tire 6 (Rear Right Outboard) Low Pressure RED Fault.
fault.
Table
(IMI,j,k)

None None
46
Fault Code A443: Tire 6 (Rear Right Outboard) Low Pressure AMBER Fault
Fault Code A443
Description Tire 6 (Rear Right Outboard) Low Pressure AMBER Fault.
Fault is not on.
fault.
Table
(IMI,j,k)

None None
47
Fault Code A444: Tire 6 (Rear Right Outboard) No Data / Sensor Failure / Not Connected
Fault
Fault Code A444
Description Tire 6 (Rear Right Outboard) No Data / Sensor Failure / Not Connected Fault
fault.
Table
(IMI,j,k)

None None
48
Fault Code A445: Tire 6 (Rear Right Outboard) High Temperature RED Fault
Fault Code A445
Description Tire 6 (Rear Right Outboard) High Temperature RED Fault.
on.
fault.
Table
(IMI,j,k)

None None
49
Fault Code A446: Tire 6 (Rear Right Outboard) High Temperature AMBER Fault
Fault Code A446
Description Tire 6 (Rear Right Outboard) High Temperature AMBER Fault.
not on.
fault.
Table
(IMI,j,k)

None None
50
Fault Code A447: Tire 6 (Rear Right Outboard) Bad Value Sensor Error / Not Connected
Fault
Fault Code A447
Description Tire 6 (Rear Right Outboard) Bad Value Sensor Error / Not Connected Fault.
fault.
Table
(IMI,j,k)

None None
51
830E Dump truck

930E Dump truck
980E Dump truck
52
CEN40104-03
DUMP TRUCK
860E
960E
980E

860E-1K A30003 and up 980E-4 A40003 and up
860E-1KT A30003 and up 980E-4AT A40083 and up
960E-1K A50003 - A50010 980E-5 A50005 and up
960E-2K A50011 and up
960E-2KT A50028 and up
40 Troubleshooting
Steering system
Steering circuit troubleshooting chart.................................................................................................................... 2
Steering circuit troubleshooting guidelines............................................................................................................ 4
Basic hydraulic system checks ............................................................................................................................. 5
System leakage check .......................................................................................................................................... 6
Steering pump troubleshooting guide ................................................................................................................... 8
Pump pressure control checks.............................................................................................................................11
1
Steering circuit troubleshooting chart
SUGGESTED CORRECTIVE
TROUBLE POSSIBLE CAUSE
ACTION
1. Overloaded steering axle 1. Reduce axle loading.
2. Malfunctioning relief valve preventing 2. Check system pressure.
Slow steering, hard adequate system pressure build-up Adjust or replace relief valve.
steering or loss of power
assist 3. Worn or malfunctioning pump 3. Replace pump.
4. Restricted high pressure filter or suction 4. Replace filter element or clean
strainer strainer.
1. A small rate of extension may
1. Rod end of cylinder slowly extends be normal on a closed center
Drift - truck veers slowly in without turning the steering wheel system.
one direction. 2. Inspect and replace linkage if
2. Worn or damaged steering linkage necessary. Check alignment
or toe-in of the front wheels.
1. Correct oil supply problem or
1. Air in system due to low oil level, pump bleed air.
cavitation, leaking fitting, pinched hoses 2. Repair or replace steering
2. Loose cylinder piston cylinder.
3. Broken centering springs (spool valve, 3. Repair or replace steering
Wander - truck will not stay steering valve) control unit.
in straight line
4. Worn mechanical linkage 4. Repair or replace.
5. Bent linkage or cylinder rod 5. Repair or replace defective
6. Severe wear in steering control unit components.
6. Repair or replace steering
control unit.
Slip - a slow movement of 1. Leakage of steering cylinder piston 1. Repair or replace steering
steering wheel fails to steer seals cylinder.
front wheels 2. Worn steering control unit meter 2. Replace steering control unit.
1. Low oil level 1. Service hydraulic tank and
Spongy or soft steering 2. Air in hydraulic system. Probably air check for leakage.
trapped in cylinders or lines. 2. Bleed air from system.
1. Air in system due to low oil level, 1. Correct condition and add oil
cavitating pump, leaky fittings, pinched as necessary.
Erratic steering hose, etc. 2. Repair or replace steering
2. Loose steering cylinder piston cylinder.
1. Splines of steering column/steering 1. Repair or replace steering
control unit coupling may be column or coupling.
Free wheeling - steering disengaged or damaged 2. Repair as required:
wheel turns freely with no 2. No flow to steering control unit: a. Add oil and check for
back pressure - front a. Low oil level leakage.
wheels do not steer b. Ruptured hose b. Replace hose.
c. Broken steering control unit gerotor c. Repair or replace steering
drive pin control unit.
2
SUGGESTED CORRECTIVE
TROUBLE POSSIBLE CAUSE
ACTION
1. Check for loose fitting
bearings at anchor points in
1. Broken or worn linkage between
Excessive free play at steering linkage between
steering cylinder and steered wheels
steered wheels cylinder and steered wheels.
2. Leaky steering cylinder seals
2. Repair or replace steering
cylinder.
1. Align column to steering
1. Binding or misalignment in steering control unit.
column or splined coupling and steering 2. Remove restriction in the lines
control unit or circuit. Check for
2. High back pressure in tank can cause obstruction or pinched lines.
Binding or poor centering of
slow return to center - should not 3. Clean steering control unit and
steered wheels
exceed 2 068 kPa (300 psi) filter the oil. If another
3. Large particles can cause binding component has malfunctioned
between the spool and sleeve in the (generating contaminating
steering control unit materials), flush the entire
hydraulic system.
1. Clean the steering control unit.
1. Large particles in meter section 2. Check hydraulic system
Steering control unit locks
2. Insufficient hydraulic power pressure.
up
3. Severe wear and/or broken pin 3. Repair or replace steering
control unit.
1. Check line routing and
Steering wheel oscillates or 1. Lines connected to wrong ports
connections.
turns by itself 2. Parts assembled wrong; steering
2. Reassemble correctly and re-
control unit improperly timed
time control valve.
Steered wheels turn in
opposite direction when 1. Inspect and correct line
1. Lines connected to wrong cylinder ports
operator turns steering connections.
wheel
3
Steering circuit troubleshooting

guidelines
These troubleshooting guidelines are intended to
assist in diagnosing steering pump problems. How-
ever, before troubleshooting the pump, basic checks Verify all pressure gauges being used are in good
should be performed on the steering and braking sys- working condition and properly calibrated.
tems. These checks are listed in the topic Basic
Hydraulic System Checks. These checks are
sequenced to determine whether the issue is due to
the pump or elsewhere in the system. Failure to per-
form these checks may result in unnecessary compo- To prevent hydraulic system contamination,
nent replacement or unnecessary repairs. clean system components before installing
gauges or removing hoses, fittings, etc. Use caps
and plugs on open hoses and fittings to keep dirt
from entering the system during testing and
maintenance.
Various hydraulic pressure settings are
referenced in this bulletin. Use only those values
for the truck model being serviced. Damage or
injury may result if incorrect values are used.
DO NOT loosen or disconnect hydraulic lines or

components until the engine is stopped and the
key switch has been OFF for at least 90 seconds.
Pressurized hydraulic fluid can have sufficient

force to enter a person's body by penetrating the
skin. This can cause serious injury and possibly
death. If fluid has penetrated the skin,
immediately seek the proper medical treatment
by a physician familiar with this injury.
Depressurize system accumulators before

opening hydraulic circuits or installing test
gauges.
For the steering circuit, turn the key switch to

OFF and allow 90 seconds for the accumulators
to depressurize. After 90 seconds, turn the
steering wheel to verify that pressure has been
purged from the circuit. If the wheels do not
move, the steering circuit is safe to service.
For the brake circuit, chock the wheels. Then

open the shut-off valves on the brake manifold.
Opening the valves allows accumulator pressure
to be released.
4
Basic hydraulic system checks

Table 1: Basic Hydraulic System Checks
Truck Condition Verification Check Corrective Action
Truck parked on level Confirm reported problem:

ground with wheels - Talk to operator
Refer to the service
chocked, engine at low - Operator repair report
manual to determine the
idle, steering and braking - Truck warning lights
cause.
system pressurized (if - Truck audible alarms
possible) - Truck fault code record (if equipped)
Verify oil level in hydraulic tank. Refill as needed.
Verify hydraulic tank breather(s) are not plugged. Repair.
Visually inspect for external leakage. Repair.
Verify pump suction shut-off valve (if equipped) is fully open. Fully open valve.
Visually inspect hoses for kinks or damage. Look for abrasions,

cracks, blisters, separations, delaminations and bulges.
Disconnect and inspect interior if suspect. Inspect each hose:
- Suction / inlet Repair.
Truck parked on level
- Pressure / outlet
ground with wheels
- Accumulator feedback
chocked, key off, engine
- Case drain
off, hydraulic steering and
braking system Inspect for unusual odors such as burnt oil and elastomers
depressurized Locate and repair.
(seals) near pump, valves and cylinders.
Visually inspect pump drive shaft connection. Repair.
Verify pump stroke adjuster setting.

Reset. Refer to Testing
Altitude < 3 050 m (10,000 ft)
and Adjusting, Steering,
- Full out
brake cooling and hoist
Altitude > 3 050 m (10,000 ft)
hydraulic system.
- 6.5 turns in
Verify bleeddown manifold solenoid actuates while cycling the

Repair.
key off and on.
Visually inspect for external leakage Repair.
Visually inspect hoses for kinks, distortion, collapses and bulges.

Turn off engine, depressurize, disconnect and inspect hose
interior if suspect. Inspect each hose:
- Suction / inlet
Repair.
Truck parked on level - Pressure / outlet
ground with wheels - Accumulator feedback
chocked, engine at low - Pump Case drain
idle, steering and braking Note: Maximum pump case pressure = 172 kPa (25 psi)
system pressurized (if
Listen for unusual sounds such as bypassing oil, mechanical
possible) Locate and repair.
grinding, aeration and cavitation (rapid popping sound in pump).
Inspect components for abnormal local heat generation using

Locate and repair.
hand contact or infrared temperature gun.
Check for system leakage. Refer to "System leakage

check".
5
System leakage check 4. Connect a 0 - 35 000 kPa (0-5000 psi) pressure

1. Park the truck on level ground and turn the gauge to GPA test port (7, Figure 40-1) on the
engine off. Wait 90 seconds for the steering steering pump. Connect a second 0 - 35 000
accumulators to depressurize. Turn the steering kPa (0-5000 psi) pressure gauge to the steering
wheel to verify that the steering system is no bleeddown manifold at test port TP2 (2,
longer pressurized. Figure 40-2).
2. Chock the wheels. 5. Start the engine and allow the steering and
brake accumulators to pressurize. Do not turn
3. Open both brake accumulator bleeddown
the steering wheel or apply the brakes until the
valves to completely depressurize the brake
test is complete. The steering pump should
accumulators.
unload if operating properly.
FIGURE 40-1. STEERING PUMP PORTS AND COMPONENTS

1. GP4 Test Port 5. Case Drain Fitting
2. Outlet To Filter 6. Suction
3. Unload Valve 7. GPA Test Port
4. Stroke Adjuster 8. GP2 Test Port
6
6. Allow the system pressure to stabilize for a 7. Turn the engine off by pulling up on the engine
minimum of three minutes after the manifold shutdown switch on the center console, but
gauge has reached its maximum pressure. The leave the key switch in the ON position. This will
pressure gauge at GPA test port (7, Figure 40- stop the engine without bleeding down the
1) should also rise to within 172 kPa (25 psi) of steering accumulators.
the pressure gauge at test port TP2 (2,
NOTE: The key switch must remain ON. The steering
Figure 40-2). For the purposes of this test, the
accumulator bleeddown cycle will initiate if the key
manifold pressure is permitted to be less than
switch is turned to the OFF position.
the specified reload/unload pressure range. If it
is greater, adjust the pressure controls as 8. Observe the gauges as the engine stops. The
outlined in the topic "Setting pump pressure pump pressure gauge will drop to zero.
controls". a. Slow pressure drop - If the manifold pressure
NOTE: Incorrect pressure readings could occur if the gauge remains near the original (engine on)
system is not allowed to stabilize for at least three pressure or drops slowly [less than 1 034
minutes. kPa (150 psi) per minute], minimal leakage is
present. Pump functions may be confirmed
a. If both gauges are at or near 0 kPa (0 psi), a referring to "Steering pump troubleshooting
pump problem is indicated. Refer to "Pump guide".
case drain check".
b. Gradual pressure drop - If the manifold
b. If the pump gauge indicates pressure and the pressure gauge exhibits a gradual drop in
manifold gauge is at or near 0 kPa (0 psi), pressure (between 1 042 kPa (151 psi) and
confirm the manifold gauge is connected to 4 137 kPa (600 psi) per minute), leakage is
the correct port. If the gauge is on the correct present, but does not require repair prior to
port, inspect the system for blockage. confirming the pump functions by referring to
Blockage may be caused by a defective "Steering pump troubleshooting guide".
hose, a stuck inlet check valve or other Hydraulic pump controls settings may require
obstruction, or a hose installed on the wrong minor re-adjustment after the leaks are
port. repaired.
c. Excessive pressure drop - If both pressure
gauges drop rapidly to zero (greater than
4 137 kPa (600 psi) per minute), excessive
leakage is present. The system downstream
of the pump is leaking excessively. Locate
and repair the leakage before proceeding to
"Steering pump troubleshooting guide".

1. Bleeddown Manifold 2. Test Port TP2
7
Steering pump troubleshooting guide

The pump troubleshooting guide assumes the
steering and braking systems have successfully
passed the recommended checks listed in Table 1.
Failure to perform these checks prior to
troubleshooting may result in misdiagnosis, Follow the safety guidelines outlined in the shop
unnecessary component replacement or delayed manual when working with the hydraulic system.
repairs. Serious injury or death may occur if proper safety
guidelines are not followed.
Table 2: Steering pump troubleshooting guide

SYMPTOM POSSIBLE CAUSE DIAGNOSTIC VERIFICATION CORRECTIVE ACTION
Pump input shaft not Verify internal part movement by

Repair.
turning placing hand on pump case.
Bleed trapped air. Refer to

Perform audible check with the
Air trapped inside pump Steering and Brake Pump -
engine on.
No output flow Installation in Section 50.
Pump pressure control

Perform pump pressure control Refer to "Pump pressure control
malfunctioning or set
checks. checks"
incorrectly
Pump internal parts Refer to "Pump case drain

Perform pump case drain check.
worn check".
Pump pressure control Perform pump pressure control Refer to "Pump pressure control
settings incorrect checks. checks"
Low flow -
Initial charge time Pump internal parts Refer to "Pump case drain
exceeds 2 minutes worn check".
with truck stationary
and engine idling Check for clogged suction strainer.
Clean hydraulic tank and
Limited oil at pump inlet Note: Maximum suction vacuum =
strainer.
35 mm (1.4 in.) Hg.
Check warning light in cab.

Note: Precharge switch factory Refill with nitrogen as needed.
Accumulator precharge setting = 7 584 kPa (1100 psi). Refer to steering accumulator
low Verify precharge pressure of 9 653 charging procedure in Section
kPa (1400 psi) at 21° C (70° F) with 30.
gauge.
Pump short cycling -
Demand exceeds pump
Cycle period less Excessive steering or braking usage. Train operator.
capacity
than specification.
Inspect movement audibly or with
Accumulator piston
sensors. Inspect for excess oil above Repair.
travel restricted
piston.
Inspect for hot oil flow in

Refer to "Pump control valve
Unload valve leakage accumulator feedback hose using
inspection and trouble shooting".
hand contact or infrared heat gun.
8

Pump pressure control Perform pump pressure control Refer to "Pump pressure control
settings incorrect checks. checks".

Low pressure worn check".
Check for clogged suction strainer.

strainer.
35 mm (1.4 in.) Hg.
Pump pressure controls Perform pump pressure control Refer to "Pump pressure control
malfunctioning checks. checks".

Sluggish response worn check".

strainer.
35 mm (1.4 in.) Hg.
Visually inspect suction hoses and

Air entering pump Tighten loose fittings, repair
connections. Coat suspect areas
suction seals as needed.
with heavy oil or grease
Check indicator light in cab.

Clogged hydraulic
Note: Filter switch factory setting = Replace element.
steering filter
241 kPa (35 psi) drop.
Unsteady or surging
Pump pressure controls Refer to "Pump pressure control
pressure Check pump pressure controls.
malfunctioning checks".

worn check".

Clogged hydraulic tank Clean hydraulic tank and
Note: Maximum suction vacuum =
suction strainers strainer.
35 mm (1.4 in.) Hg.
Pump pressure controls

Perform pump pressure control Refer to "Setting pump pressure
Excessive pressure malfunctioning or set
checks. controls".
incorrectly
9

Reset. Refer to Testing and

Pump stroke adjuster set too high. Adjusting section, Steering,
(High altitude trucks only.) brake cooling and hoist
hydraulic system.
Verify hydraulic oil viscosity is

Restricted oil at inlet Correct or warm oil before
correct for current ambient
starting.
temperature.

Note: Maximum suction vacuum =
strainer.
35 mm (1.4 in.) Hg.
Pump case has Disconnect hose at pump fitting.

Fill case.
insufficient oil Verify case is full.

Noisy connections. Coat suspect areas
with heavy oil or grease.
Verify driveshaft fasteners are

Install and tighten as needed.
present and secure.
Pump input shaft Verify pump mounting fasteners and

misaligned brackets are present and secure.
Note: Maximum pump input shaft Install and tighten as needed.
misalignment = 0.13 mm (0.005 in.)
TIR.
Replace pump and flush system.

Examine hydraulic steering filter
Install new steering and hoist
element for debris.
Internal pump damage filter elements.
Refer to "Pump case drain

check".

connections. Coat suspect areas
with heavy oil or grease.
Measure suction and case drain oil

temperatures near the pump.
Repair or replace.
Excessive heat Maximum temperature rise through
Pump internal parts case drain = 15° C (59° F).
worn Measure suction and outlet oil
temperatures near the pump.
Repair or replace.
Maximum temperature rise through
main line = 7° C (45° F).
10
Pump pressure control checks To verify pump reloading:

To verify pump unload pressure: 1. With the steering accumulators charged and the
engine at low idle, observe the pressures on the
NOTE: The critical pressure setting is the reload
gauges. A drop in pressure indicates a loss of
pressure. The unload pressure cannot be set
oil from the steering accumulator system. Some
independently, but should be approximately 1 380 -
loss of oil is acceptable. Record the pressure at
3 795 kPa (200 - 550 psi) above the reload pressure.
which the pump reloads (starts pumping) to
The purpose of this check is to determine if the
recharge the accumulator system.
unload valve is functioning properly by unloading in
the correct pressure range above reload pressure. NOTE: If desired, the rate of pressure drop may be
increased by slightly opening a brake accumulator
1. Connect a 0 - 35 000 kPa (0 - 5000 psi)
manual bleeddown valve, or by turning the steering
pressure gauge to GPA test port (7, Figure 40-
wheel. Refer to the shop manual for the location of
1) on the steering pump.
the brake manifold bleeddown valves.
2. Start the engine. With the engine idling, the
accumulators should charge in less than two
minutes. Refer to the Pump Control Set Points
table for new truck charge time estimates. The
pressure indicated by the gauge will increase as
the accumulators charge. Note the pressure at
which the steering pump unloads (switches to Ensure that there is adequate clearance and no
stand-by). Pump unloading is indicated by an personnel in the area before turning the steering
abrupt reduction in the pump sound level. wheel.
a. If the unload pressure approximates the a. If the reload pressure is 1 380 - 3 792 kPa
value listed in Table 4, continue to verify (200 - 550 psi) below the observed unload
pump reloading. pressure, the unload valve is functioning
b. If the pressure exceeds the specified value properly. Specified unload pressure values
by more than 1 724 kPa (250 psi), or if the are approximate. Observed pressures may
pump does not unload, refer to "Pump fails to differ.
unload". b. Next, verify the reload pressure is within the
c. If the pressure is significantly less than the specifications listed in Table 4. Refer to
specified value, refer to "Pump fails to "Setting pump pressure controls" if
develop pressure". adjustment is required.
d. If the charging time exceeds two minutes, c. If the reload pressure is more than 3 792 kPa
refer to "Pump slow in developing pressure". (550 psi) below the unload pressure that was
observed in Step 1, the unload valve is not
functioning properly. Repair or replace the
control valve assembly. Refer to "Pump
control valve inspection and trouble
shooting" for details.
2. Close the brake accumulator bleeddown valves
that were opened during the test. Remove all
gauges. Cap or close all test ports.
11
Pump fails to unload Pump fails to develop pressure

1. Install a 0 - 35 000 kPa (0 - 5000 psi) pressure 1. Install a 0 - 35 000 kPa (0 - 5000 psi) pressure
gauge in GPA test port (7, Figure 40-1). gauge in GPA test port (7, Figure 40-1).
2. Start the engine and allow the system to 2. Start the engine and allow the system to
pressurize. Do not turn the steering wheel or pressurize. Do not turn the steering wheel or
apply the brakes until the check is complete. apply the brakes until the check is complete.
3. Check the pressure on the gauge. a. If the pressure is 2 413 ± 1 034 kPa (350 ±
a. If the pressure is above 17 237 kPa (2500 150 psi) and constant, turn adjustment screw
psi) and constant, turn the adjustment screw on unload valve (1, Figure 40-1) inward
on unload valve (1, Figure 40-1) outward (clockwise).
(counterclockwise). •If the pump unloads at a higher pressure, the
•If the pump unloads at a lower pressure, valve has been set incorrectly. Reset the
reset the valve as outlined in "Setting pump valve as outlined in "Setting pump pressure
pressure controls". controls".
•If no change in pressure occurs, the control •If the pressure remains low, but above 1 379
valve assembly is malfunctioning. Inspect kPa (200 psi), inspect the pump control
the control valve assembly as outlined in valve assembly. Refer to "Pump control
"Pump control valve inspection and trouble valve inspection and trouble shooting".
shooting". b. If the pressure is 1 034 kPa (150 psi) or less,
b. If the pressure is below 17 237 kPa (2500 the pump has internal damage. Repair or
psi), turn the adjustment screw on unload replace the pump.
valve (1, Figure 40-1) outward
(counterclockwise). The pressure should
drop. Turn the adjustment screw inward
(clockwise) by 2 1/2 turns.
•If the pressure increases, continue until
17 237 kPa (2500 psi) is achieved. Repeat
Step 3a.
•If no change in pressure occurs, or if 17 237
kPa (2500 psi) is not achieved, the control
valve assembly is malfunctioning. Inspect
the control valve assembly as outlined in
"Pump control valve inspection and trouble
shooting".
Table 3: Steering pump control pressures vs. stroke position

Pump State GPA GP2 GP4 Stroke Adjuster
(Output Pressure) (Control Pres- (Bias Pressure) Stud
sure) (Pump Stroke)1
Pumping System pressure near 0 kPa (0 psi) same as GPA Stud tight
- (re)loading no pressure - maximum stroke
Standby 1 379 - 2 758 kPa 1 379 - 2 758 kPa near 0 kPa (0 psi) Stud loose
- unloaded (200 - 400 psi) (200 - 400 psi) no pressure - minimum stroke
(1) Loosen the stud jam nut before testing. Retighten after testing is complete.
12
Pump slow in developing pressure Pump control valve inspection and trouble
1. Install 0 - 35 000 kPa (0 - 5000 psi) pressure shooting
gauges in GPA test port (7, Figure 40-1) and To inspect the 4-way valve:
GP4 test port (1). Start the engine and observe
1. Use a 7/8" wrench to remove cap (7, Figure 40-
the gauges. As the pump cycles, the pressures
3) and the spring opposite the control block
at both gauges should rise and fall at nearly the
pressure adjustment.
same rate.
2. Use a 7/8" wrench to remove cap (4). Remove
a. If the pressures at the GPA test port and the 4-way valve spool (6).
GP4 test port rise and fall simultaneously,
proceed to Step 2. NOTE: Valve sleeve (10) is permanently fixed in the
control valve body and should not be removed.
b. If the pressure change at the GP4 test port is
noticeably slower than the GPA test port, 3. Verify the valve is free of contaminants and all
perform the following checks: orifices and passages are open. The spool is
hollow and contains small orifices. Flush with
•Inspect the orifice in the four-way valve. clean hydraulic fluid or filtered, dry low pressure
Refer to "Pump control valve inspection and air. Do not use probes made of hard materials.
trouble shooting".
4. Inspect the spool outer diameter for scratches
•Verify that the pump control piston seal ring and indications of binding. Verify that the spool
is not broken. Replace the ring or replace slides freely within the control valve assembly.
the pump as necessary. Replace the spool if defective.
•If no cause is found, the pump is leaking 5. Install the spool, spring and end caps. Tighten
internally. Repair or replace the pump. each cap to 68 N•m (50 ft lb).
2. Loosen the jam nut on stroke adjuster (4,
To inspect the unload valve:
Figure 40-1) and note the effort required to turn
the stud while the pump cycles. Refer to 1. Use a 1-1/4" wrench to remove the unload valve
Table 3. When the pump is unloaded, the stud bonnet (3), spring and poppet.
will turn easily. When the pump is loaded, the 2. Use a 7/16" socket to remove unload valve seat
stud will be difficult to turn. Do not use (11) and the push pin.
excessive force.
3. Verify that the seat seals are in good condition.
a. If the stud is always loose or always tight, the If the seal on the seat nose is missing or
pump has internal damage. Repair or replace severely eroded, replace the seals and seat.
the pump. 4. Verify that the sealing edges of the poppet and
b. If the stud turns easily when unloaded, and is seat are well defined, free of chips, impressions
difficult to turn when loaded, the pump and embedded material. Replace as needed.
control valves are functioning properly. 5. Inspect the outer diameter of the push pin for
Tighten the jam nut on the stroke adjuster. scratches and indications of binding. Verify that
Continue to the next troubleshooting item. the pin slides freely within the valve seat.
Replace the pin if defective.
6. Use a 7/8" wrench to remove cap (8).
7. Use a 3/16" hex wrench to remove the stop
plug.
8. Verify that the valve is free of contaminants and
that all orifices and passages are open.
13
NOTE: The stop plug is hollow and contains an 11. Insert the push pin into unload valve seat (11)
orifice. and install the seat into the control block.
9. Install the stop plug. Tighten the stop plug to Tighten the seat to 20 N•m (15 ft lb).
163 N•m (120 in. lb). 12. Install the poppet, spring and unload valve
10. Install cap (8). Tighten the cap to 61 N•m (45 ft bonnet (3). Tighten the bonnet body to 115 N•m
lb). (85 ft lb).
13. Verify the final valve setting. Refer to "Setting
pump pressure controls" for details.
FIGURE 40-3. CONTROL VALVE ASSEMBLY

1. Adjustment Screw 6. 4-Way Valve Spool 9. Accumulator Feedback
2. Locking Cap (with Orifices) Port (ACC)
3. Unload Valve Bonnet 7. Cap (Spring Access) 10. Valve Sleeve
4. Cap (Spool) 8. Cap 11. Unload Valve Seat
5. Pressure (From Pump)
14
Pump case drain check Setting pump pressure controls

1. With the engine off, disconnect the case drain
hose from fitting (5, Figure 40-1). Plug the hose
to prevent contamination. Table 4: Pump Control Set Points
2. Connect a hose to case drain fitting (5) and Pump Control Set Points
place the other end in an empty container [19
liters (5 gal) or larger] to collect the hydraulic oil. Reload 22 236 ± 172 kPa
3. Although the pump is not turning, hydraulic oil (3225 ± 25 psi)
may flow from the hose. If flow occurs, measure
Unload (1) 24 304 kPa
and record the volume of oil that is discharged
(approximate) (3525 psi)
during a 60 second time period.
4. Start the engine and operate at idle. Charge time limits See Note 2
5. Measure and record the volume of oil that is (reference)
discharged in 60 seconds. • Initial startup 60 sec
6. Visually inspect the oil for metallic
contaminants. If found, replace the pump, flush • Recharge 6 sec
the system and clean the hydraulic filters and
• Cycle period (minimum) 5.2 min
the tank.
7. Compare the recorded volumes. (1) Reload and unload set points are not independently
adjustable. One adjustment screw controls both. Set
a. If the volume obtained in Step 5 is less than the adjustment screw for the specified reload value.
that obtained in Step 3, repeat the test. Actual unload values may vary from that shown.
b. If the two volumes are equal, the pump input (2) With engine at low idle, truck stationary, oil above
shaft is not turning or the suction line is 20° C (68° F)
blocked. Inspect and repair as needed.
c. If the volume obtained in Step 5 is less than
13.3 liters (3.5 gal) above the volume Reload set point - The pressure where the pump
obtained in Step 3, excessive internal pump switches from its standby state to its pumping state
wear is not indicated. Return to as the pressure within the steering and braking sys-
troubleshooting. tem declines.
d. If the volume obtained in Step 5 is greater Unload set point - The pressure where the pump
than 13.3 liters (3.5 gal) above the volume switches from its pumping state to its standby state
obtained in Step 3, excessive internal pump as the pressure within the steering and braking sys-
wear is indicated. Repair or replace the tem increases.
pump.
Initial startup time - The time it takes to initially
charge the steering and braking system from a
depressurized (0 kPa/psi) shut-down state to the
pump unload pressure.
Recharge time - The time it takes to charge the
steering and braking system from the pump reload
pressure to the unload pressure with the system at
operating temperature.
Cycle period - The time between consecutive pump
reloads (or unloads) with the system at operating
temperature. For example, this is the total time it
takes to cycle through a pump reload, then unload,
and return to reload.
NOTE: Cycle periods greater than the values listed
are desirable.
15
This adjustment procedure assumes the following: 11. Turn the key switch to the OFF position to stop
the engine. Close the bleeddown valve that was
• Truck parked on level ground with parking brake
set opened in Step 7.
• Key switch in OFF position with engine off, and 12. Start the engine and operate at low idle.
hydraulic system depressurized Observe the reload and unload settings on the
pressure gauge while slowly steering the truck.
• Hydraulic tank filled to proper level Turn the key switch to the OFF position to stop
• Steering pump functioning properly the engine.
a. If the reload setting is within specifications,
proceed to Step 13.
1. Connect a 0 - 35 000 kPa (0 - 5000 psi)
pressure gauge to test port TP2 (2, Figure 40-2) b. If the reload setting is not within
on the steering accumulator bleeddown specifications, return to Step 5.
manifold. 13. Turn the key switch to the OFF position to stop
2. Start the engine and operate at low idle. the engine. Allow 90 seconds for the steering
Observe the reload and unload settings on the accumulators to completely depressurize. Turn
pressure gauge while slowly steering the truck. the steering wheel to verify that no pressure
Turn the key switch to the OFF position to stop remains.
the engine.
14. Remove the pressure gauge and cap test port
3. If the reload setting is within specifications, TP2.
proceed to Step 11.
15. If the pump control valve cannot be adjusted to
4. If the reload setting is not within specifications, specifications, return to the "Steering pump
proceed to the next step. troubleshooting guide".
5. Remove cap (2, Figure 40-3) located on unload
valve (3).
6. Start the engine and operate at low idle.
7. Gradually open either brake accumulator
bleeddown valve on the brake manifold so that
the pump unloads every 20 to 30 seconds.
8. Slowly turn adjustment screw (1) outward
(counterclockwise) until the pump unloads.
While observing the pressure gauge, continue
to back out the screw (1/4 turn or less per cycle)
until the pump reloads at a pressure
approximately 3 447 kPa (500 psi) less than the
reload pressure listed in Table 4.
9. Slowly turn the adjustment screw inward
(clockwise) until the specified reload pressure is
obtained for a minimum of three consecutive
cycles.
10. Repeat Steps 6 and 7 as necessary. Install and
tighten cap (2).
16
NOTES
17
860E Dump truck

960E Dump truck
980E Dump truck
18
CEN40200-00
DUMP TRUCK
830E
930E
980E

830E-5 A50005 and up
930E-5 A40004 and up
980E-5 A50005 and up
40 Troubleshooting
KomVision
KomVision fault codes .......................................................................................................................................... 3
1
NOTES
2
KomVision fault codes
Table 1: KomVision® Troubleshooting

KAC SUB PHENOMENON KLTD
FAULT PART ACTION
CODE CODE NAME CODE
CM0001 ‐ Camera Output power supply low Please check camera harness. DBP5KP
controller output voltage fault (under 6V） Please exchange controllers, when there is no
power supply1 problem in harness.
(for camera 8V)
CM0002 ‐ Camera over temperature Please turn off the power for a while. Please DBP0N
controller over exchange controllers, when the same error takes R
temperature place, even if it switches on a power supply again.
CM0003 ‐ Camera Communication fault Check the CAN5 harness DBPVK
controller CAN5 R
CM0004 ‐ Camera Communication fault Check the CAN4 harness DBPUK
controller CAN4 R
CM0005 ‐ Camera Communication fault Check the CAN3 harness DBPTK
controller CAN3 R
CM0006 ‐ Camera Communication fault Check the CAN2 harness DBPQK
controller CAN2 R
CM0007 ‐ Camera Communication fault Check the CAN1 harness DBPRK
controller CAN1 R
CM0008 ‐ LED Wire break Check the harness DUMBK
A
CM0009 ‐ Objection Wire break Check the harness DV00KA
detection alarm
CM0010 ‐ Fault alarm Wire break Check the harness DV01KA
CM0011 ‐ Monitor display Wire break Check the harness DPQ4K
ON/OFF A
CM0012 ‐ Relay output Wire break Check the harness D1J0KA
CM0013 ‐ LED Short-circuit Check the harness DUMBK

B
CM0014 ‐ Objection Short-circuit Check the harness DV00KB
detection alarm
CM0015 ‐ Fault alarm Short-circuit Check the harness DV01KB
CM0016 ‐ Monitor display Short-circuit Check the harness DPQ4K

ON/OFF B
CM0017 ‐ Relay output Short-circuit Check the harness D1J0KB
CM0018 LP01 I/F switch panel FRONT Switch Check the monitor panel harness DPQ1LD
CM0018 LP02 I/F switch panel RH FRONT Switch Check the monitor panel harness DPQ1LD
CM0018 LP03 I/F switch panel RH REAR Switch Check the monitor panel harness DPQ1LD
CM0018 LP04 I/F switch panel REAR Switch Check the monitor panel harness DPQ1LD
CM0018 LP05 I/F switch panel LH REAR Switch Check the monitor panel harness DPQ1LD
CM0018 LP06 I/F switch panel LH FRONT Switch Check the monitor panel harness DPQ1LD
CM0018 LP07 I/F switch panel Monitor Display Mode Check the monitor panel harness DPQ1LD
Switch
3

FAULT PART ACTION
CODE CODE NAME CODE
CM0018 LP08 I/F switch panel Guide Line Display Switch Check the monitor panel harness DPQ1LD
CM0018 LP09 I/F switch panel Lower Body Display Switch Check the monitor panel harness DPQ1LD
CM0018 LP10 I/F switch panel Object Clear Switch Check the monitor panel harness DPQ1LD
CM0019 CA01 Camera The abnormalities of a Exchange the Camera controller DBP0KT
controller inner main board
CM0019 CA02 Camera The abnormalities of an Exchange the Camera controller DBP0KT
controller inner image-processing board
CM0019 CA03 Camera Device open error Exchange the Camera controller DBP0KT
controller inner
CM0019 CA04 Camera Memory error Exchange the Camera controller DBP0KT
controller inner
CM0019 CA05 Camera LUT generation error Exchange the Camera controller DBP0KT
controller inner
CM0019 CA06 Camera C drive file IO error Exchange the Camera controller DBP0KT
controller inner
CM0019 CA07 Camera D drive file IO error Please carry out Check disc. DBP0KT
controller inner Please exchange controllers, when not improved.
CM0019 CA08 Camera The abnormalities in a Exchange the Camera controller DBP0KT
controller inner thread
CM0019 CA09 Camera The abnormalities in an Exchange the Camera controller DBP0KT
controller inner application manager
CM0019 CA10 Camera The file IO error for Exchange the Camera controller DBP0KT
controller inner communication
CM0019 CA11 Camera Other errors Exchange the Camera controller DBP0KT
controller inner
CM0020 SA01 Camera The calibration is not Please carry out the 6 camera calibration. DBP0K
controller setting carried out. M
CM0020 SA02 Camera The Main setting is not Please carry out the main setting. DBP0K
CM0020 SA03 Camera The radar setup is not Please carry out a radar setup. DBP0K
CM0050 - NTSC 1 input NTSC 1 input - Wire break Check the camera harness. If the harness has no DR10KA
problem, please exchange the camera1.
CM0056 - Mirror output Mirror output - Short-circuit Check the camera harness DR11KB
4

FAULT PART ACTION
CODE CODE NAME CODE
CM0100 - UWB Radar 1 ERR_SENS_TEMP_HIGH Exchange the Radar1 DQ11NR
（107 degrees or more）
CM0101 RC04 UWB Radar 1 ERR_SENS_VOLTAGE_IN Exchange the Radar1 DQ11MA
PUT
CM0101 RC01 UWB Radar 1 ERR_SENS_SENSITIVITY Exchange the Radar1 DQ11MA
_LOW_EXTERNAL
CM0101 RC02 UWB Radar 1 ERR_SENS_BLOCKAGE Please check whether the radar is interrupted by DQ11MA
something. If there is nothing that is interrupted,
Exchange the Radar1
CM0101 RC03 UWB Radar 1 ERR_SENS_SENSITIVITY Exchange the Radar1 DQ11MA
_LOW_EXTERNAL_NO_V
EL
CM0102 - UWB Radar 1 HARNESS_FAULT Exchange the Radar1 DQ11KQ
CM0103 RA01 UWB Radar 1 ERR_SENS_SENSITIVITY Exchange the Radar1 DQ11KT
_LOW_INTERNAL
CM0103 RA02 UWB Radar 1 ERR_SENS_HARDWARE Exchange the Radar1 DQ11KT
_FAILURE_INIT
CM0103 RA03 UWB Radar 1 ERR_SENS_CALIBRATIO Exchange the Radar1 DQ11KT
N_FAILURE
_FAILURE_ONLINE
CM0104 RB01 UWB Radar 1 COMMUNICATION_ERRO Please check whether there are any abnormalities in DQ11KR
R a controller. If there are no abnormalities in a
controller, Exchange the Radar1
CM0104 RB02 UWB Radar 1 ERR_SENS_CAN_MESSA Exchange the Radar1 DQ11KR
GE_MISSING_OR_CONT
ENT_INVALID
CM0104 RB03 UWB Radar 1 ERR_SENS_CAN_SYNC_ Exchange the Radar1 DQ11KR
TIMING_INVALID
CM0105 - UWB Radar 1 VERSION FAULT Exchange the Radar1. It may be caused by DQ11KM
disconnection when the disconnection error has
occurred simultaneously.
Please cancel a disconnection error first.
CM0200 - UWB Radar 2 ERR_SENS_TEMP_HIGH Exchange the Radar2 DQ12N
（107 degrees or more） R
CM0201 RC04 UWB Radar 2 ERR_SENS_VOLTAGE_IN Exchange the Radar2 DQ12M
PUT A
CM0201 RC01 UWB Radar 2 ERR_SENS_SENSITIVITY Exchange the Radar2 DQ12M
_LOW_EXTERNAL A
CM0201 RC02 UWB Radar 2 ERR_SENS_BLOCKAGE Please check whether the radar is interrupted by DQ12M
something. If there is nothing that is interrupted, A
Exchange the Radar2
_LOW_EXTERNAL_NO_V A
EL
CM0202 - UWB Radar 2 HARNESS_FAULT Exchange the Radar2 DQ12K
Q
5

FAULT PART ACTION
CODE CODE NAME CODE
_LOW_INTERNAL
_FAILURE_INIT
N_FAILURE
_FAILURE_ONLINE
GE_MISSING_OR_CONT
ENT_INVALID
TIMING_INVALID
CM0205 - UWB Radar 2 VERSION FAULT Exchange the Radar2. It may be caused by DQ12K
disconnection when the disconnection error has M
occurred simultaneously. Please cancel a
disconnection error first.
PUT A
_LOW_EXTERNAL A
Exchange the Radar3
EL
Q
_LOW_INTERNAL
_FAILURE_INIT
N_FAILURE
_FAILURE_ONLINE
GE_MISSING_OR_CONT
ENT_INVALID
6

FAULT PART ACTION
CODE CODE NAME CODE
TIMING_INVALID
PUT A
_LOW_EXTERNAL A
Exchange the Radar4
EL
Q
_LOW_INTERNAL
_FAILURE_INIT
N_FAILURE
_FAILURE_ONLINE
GE_MISSING_OR_CONT
ENT_INVALID
TIMING_INVALID
PUT A
_LOW_EXTERNAL A
7

FAULT PART ACTION
CODE CODE NAME CODE
Exchange the Radar5
EL
Q
_LOW_INTERNAL
_FAILURE_INIT
N_FAILURE
_FAILURE_ONLINE
GE_MISSING_OR_CONT
ENT_INVALID
TIMING_INVALID
PUT A
_LOW_EXTERNAL A
Exchange the Radar6
EL
Q
_LOW_INTERNAL
_FAILURE_INIT
N_FAILURE
8

FAULT PART ACTION
CODE CODE NAME CODE
_FAILURE_ONLINE
GE_MISSING_OR_CONT
ENT_INVALID
TIMING_INVALID
CM0605 - UWB Radar 6 VERSION FAULT Exchange the Radar6 DQ16K
It may be caused by disconnection when the M
disconnection error has occurred simultaneously.
PUT A
_LOW_EXTERNAL A
Exchange the Radar7
EL
Q
_LOW_INTERNAL
_FAILURE_INIT
N_FAILURE
_FAILURE_ONLINE
GE_MISSING_OR_CONT
ENT_INVALID
TIMING_INVALID
9

FAULT PART ACTION
CODE CODE NAME CODE
PUT A
_LOW_EXTERNAL A
Exchange the Radar8
EL
Q
_LOW_INTERNAL
_FAILURE_INIT
N_FAILURE
_FAILURE_ONLINE
GE_MISSING_OR_CONT
ENT_INVALID
TIMING_INVALID
10
NOTES
11
830E Dump truck

930E Dump truck
980E Dump truck
12
CEN50046-02
DUMP TRUCK
980E

980E-4 A40003 and up
980E-5 A50005 and up

Service tools
Special tool group ................................................................................................................................................. 3
Additional service tools ......................................................................................................................................... 3
KomVision calibration tools ................................................................................................................................... 4
Locally made tools ................................................................................................................................................ 4
1
CEN50046-02 50 Disassembly and assembly
NOTES
2
50 Disassembly and assembly CEN50046-02
Special tool group

The following tools are included in special tool group that is shipped with the truck.
Part number Description Qty. Use

58B-06-00800 Custom meter kit (0-2000VDC) 1 Control cabinet capacitor discharge
58C-98-00310 12-point socket - 1 1/4", 1" square drive 1 Steering arm installation
Power module removal and
EH8687 Roller assembly 2
installation
58E-98-01180 Alignment tool 1 Steering linkage installation
EK6089 Front brake tool group 1
Brake assembly and installation
EK6090 Rear brake tool group 1
EM1275 Front brake wear indicator 1
Brake wear measurement
EM3708 Rear brake wear indicator 1
PB9067 Bulkhead connector 1 Auxiliary battery power source
Operator cab removal and
PC1980 Offset box end wrench - 1 11/16" 1
installation
PC2228 HD wrench handle - 3/4" square drive 1 Various
XB5777 Steering bypass hose 1
Hydraulic system flushing
XB7075 Fitting assembly 1
XB0887 Hydraulic tank vacuum kit 1 Hydraulic system service
Additional service tools

The following tools may be required for servicing the truck.

EB1759 Nitrogen charging kit 1 Accumulator charging
EC6027 Suspension oil charging kit 1 Suspension charging
58B-98-90020 Seal installation ring 1
Hoist cylinder seal installation
58B-98-90030 Seal installation ring 1
XC2293 Spacer block 2
Body pad installation
C1624 Capscrew - 1/2" - 13NC X 4" 4
PC2660 Body retention sling 1
Body up retention
PC0367 Shackle assembly 2
XA6348 Piston push rod 1
Piston accumulator assembly
XA6349 Sleeve 1
PC3034 Flushing blocks 2 Hydraulic system flushing
XA5340 Steel spacer 1 Wheel motor installation
58E-98-00330 Smart rim expander tool 1 Smart rim installation
3
KomVision calibration tools

The following tools are required for calibrating the KomVision system.

58B-98-00600 Tripod stand 1
58B-98-00910 Calibration sheet - front 1
58B-98-00920 Calibration sheet - side 2 KomVision calibration
58B-98-00930 Calibration sheet - rear 1
XB0841 Radar reflector 1
Locally made tools

The following tools must be made locally. Contact your Komatsu service representative for the required
drawings.

SS1143 Hoist cylinder quill installation tool 1
Hoist cylinder quill installation
SS1158 Check ball plug installation tool 1
- Spindle removal tool 1 Spindle removal
The following table shows the dimensions for locally manufacturing the spindle removal tool. Refer to the
drawing on the following page.
Dimension Description Value
A Bolt hole diameter 34.8 mm (1.37 in.)
B Plate outside diameter 600 mm (23.62 in.)
C Bolt circle diameter 539.75 mm (21.25 in.)
D Plate inside diameter 50.8 mm (2 in.)
E Plate thickness 34.8 mm (1.37 in.)
F Pusher cylinder height 133.4 mm (5.25 in.)
G Pusher cylinder outside diameter 346.3 mm (13.63 in.)
H Pusher cylinder inside diameter 228.6 mm (9 in.)
K Holes (equally spaced) 27
L Hole pattern bolt circle 28
M Angle 12.86 degrees
4
5
980E Dump truck

6
CEN50047-02
DUMP TRUCK
980E

980E-4 A40003 and up
980E-5 A50005 and up

Wheels, spindles and rear axle
General precautions for tires and rims.................................................................................................................. 3
Rim components ................................................................................................................................................... 4
Wheel stud maintenance ...................................................................................................................................... 5
Removal and installation of front wheel ................................................................................................................ 6
Removal and installation of rear wheel ................................................................................................................. 8
Rim and tire service .............................................................................................................................................11
Removal and installation of front wheel hub and spindle .................................................................................... 25
Disassembly and assembly of front wheel hub and spindle ............................................................................... 32
Hub floating ring seal assembly and installation ................................................................................................. 49
Removal and installation of rear axle .................................................................................................................. 56
Removal and installation of anti-sway bar .......................................................................................................... 59
Removal and installation of pivot pin .................................................................................................................. 62
Pivot eye and bearing service............................................................................................................................. 64
Removal and installation of wheel motor ............................................................................................................ 66
Removal and installation of rear brake assembly ............................................................................................... 73
1
NOTES
2
General precautions for tires and rims • DO NOT use lock rings with open ends (ends that
do not touch). There is a danger that the lock ring
Improper servicing of tires and rims entails a serious
will not set correctly.
risk of an explosive separation of the rim, which can
lead to serious, even fatal, accidents for the worker • DO NOT remove or install components or
as well as to others in the vicinity. Workers and otherwise modify a rim in such a way that the
persons responsible for supervising the work must product specifications are changed.
comply strictly with the following precautions. • DO NOT make modifications involving welding,
heating, soldering, etc. Such modifications could
lead to the deformation as well as the
deterioration of the strength and structural
integrity of the rim components.
• When the tire is being mounted, it is strictly
• When servicing tires and rims, always start by forbidden to perform tasks that may generate
completely deflating the tire. heat, flames, or sparks such as welding,
• Before removing the tire and rim from a truck, soldering or grinding. Resulting gases inside the
completely deflate the tire before removing the tire may ignite, causing an explosion.
clamp components and other parts installed in the • Prior to inflation, it may be necessary to tap the
rim base. rim components into position to set them. DO
• Before servicing a tire, remove the valve core to NOT use a steel mallet. Use a soft metal or hard
ensure that all of the air can escape. plastic mallet. Using a steel mallet could cause
deformation or cracking of components.
• Identify the appropriate combination of rim
components by using the matching charts and • While inflating the tire, when the air pressure
product markings. reaches 35 kPa (5 psi), check whether the rim
components are set correctly. If they are not set
• If air pressure has fallen 80% below the pressure correctly, immediately stop the work in progress,
at the time of inflation, or the tire has been deflate the tire completely and disassemble the
punctured, dismantle the rim and determine the components. Inspect the component's mating
cause. After the cause has been determined, surfaces and discard any components or
replace any deformed or damaged rim materials that interfere with complete assembly.
components that may have caused air leaks. When the problem is resolved, resume assembly.
• Until the above-mentioned checks have been • Comply with the air pressure recommended by
performed, DO NOT inflate the tire. the tire manufacturer. DO NOT exceed the
standard air pressure without checking first with
• DO NOT combine rim components from different your authorized tire dealer.
manufacturers. There may be differences in
terms of shape and other features between
components from other companies and
components manufactured by an authorized
supplier (lock rings, rim bases, bead seat bands,
side rings). Ensure that components are not
mixed by checking the manufacturer’s markings
prior to assembly.
3
Rim components
1 2 3 4 5 6 7 8 9
15
16 14 11 10
13
12
84826
FIGURE 50-1. RIM COMPONENTS
1. Side Ring 5. Rim Base 9. Outboard Driver Pocket 13. Valve Access Notch
2. Knurling 6. Bead Seat Band 10. Valve Hole (Tube Type) 14. Bolt Hole
3. Bead Seat Area 7. Lock Ring 11. Gutter 15. Disc Weld
4. Rim Circum-Weld 8. Outboard Driver Key 12. Disc 16. Back Flange
Smart rim component layout
1 2 3 4 3 2
1 4 3 2
84829
FIGURE 50-3. SMART RIM (7-PIECE)
1. Rim Base 3. Bead Seat band
2. Lock Ring 4. Side Ring
84828
FIGURE 50-2. STANDARD RIM (5-PIECE)
1. Rim Base 3. Bead Seat band
2. Lock Ring 4. Side Ring
4
Wheel stud maintenance

The wheel mounting hardware used on some trucks
may no longer be able to maintain the specified
clamping force (tightening torque). Inadequate
clamping force may lead to broken studs, stripped
threads, and/or failure of the stud knurl which would While replacing missing or damaged studs, the
allow the stud to rotate when the nut is loosened or condition of all other stud threads must be
tightened. Stud replacement is necessary based on inspected. If minor corrosion or dirt is found in
the following guidelines: the threads, wire brush thoroughly. If damaged
(nicked or highly corroded) threads are found,
• The maximum allowable number of missing or the stud(s) must be replaced.
damaged studs in any one bolt circle is four.
• The position of missing or damaged studs must
not be in consecutive locations. In addition, there
must be a minimum of four properly functioning
studs between each missing stud. Refer to Figure
50-4.
FIGURE 50-4. MISSING/DAMAGED WHEEL STUD ALLOWANCE
5
Removal and installation of front wheel 5. Inspect the brake hydraulic lines for damage
and leaking fittings. Repair as needed.
Removal
6. Grip the tire and wheel assembly with a tire
1. Park the truck on level ground and chock the handler. Remove flanged nuts (1, Figure 50-5)
rear wheels to prevent truck movement. that secure the wheel assembly.
2. Place the directional control lever in PARK and 7. Pull the wheel assembly straight away from the
turn the rest switch ON. Turn the key switch wheel hub and move it to a clean work area. Be
OFF to shut down the engine and allow 90 careful not to damage tire inflation hose (2)
seconds for the steering system accumulators during tire removal.
to bleed down.
3. Place a jack under the spindle or frame at the
front cross tube. Refer to the topic "Jack point
locations" in the Foreword, safety and general
information section. Do not attempt to disassemble a wheel assembly
4. Raise the front end of the truck until the tire until all air pressure is bled off. Always keep
clears the ground. Block up the truck securely personnel away from a wheel assembly when it is
under the frame. being removed or installed.
1 2
TIRE INFLATION
VALVE 86452
FIGURE 50-5. FRONT WHEEL HUB AND RIM ASSEMBLY
1. Flanged Nut
2. Tire Inflation Hose
6
Installation
NOTE: Clean all mating surfaces and check stud
threads before installing wheel assemblies. Refer to
the topic "Wheel stud maintenance".
a
1. Remove all dirt and rust from mating parts
before installing the wheel assembly. d d
2. Grip the wheel assembly with the tire handler
and align tire inflation hose (2, Figure 50-5) and
the wheel hub. Position the rim onto the wheel b c
hub studs. e
c b
d d
Grease containing molybdenum disulphide must a
never be used on wheel mounting hardware. Use
of this type of grease on wheel mounting
86453
hardware may result in wheel mounting studs
stretching beyond their elastic limit, making them FIGURE 50-6. NUT TIGHTENING
susceptible to breakage. SEQUENCE
3. Lubricate all stud threads and nut seating
flanges with a lithium based grease that does
not contain molybdenum disulphide. Install and
tighten flanged nuts (1) in the following 4. Remove the blocking and lower the jack.
sequence (see Figure 50-6): 5. Operate the truck for one load, then retighten
a. Install six nuts at the 12 o'clock and six nuts the wheel nuts a clockwise direction to 2 500 ±
at the 6 o'clock positions. Tighten each nut to 136 N·m (1,843 ± 100 ft lb).
2 655 ± 136 N·m (1,958 ± 100 ft lb).
b. Install three nuts directly below the 3 o'clock
and three nuts directly above the 9 o'clock
positions. Tighten the nuts to 2 655 ± 136
N·m (1,958 ± 100 ft lb).
c. Install three nuts directly above the 3 o'clock
and three nuts directly below the 9 o'clock
positions. Tighten these nuts to 2 655 ± 136
N·m (1,958 ± 100 ft lb).
d. Install the remaining nuts and torque in a
clockwise direction to 2 655 ± 136 N·m
(1,958 ± 100 ft lb).
e. Retighten all nuts in a clockwise direction to
2 655 ± 136 N·m (1,958 ± 100 ft lb).
7
Removal and installation of rear wheel 7. Pull the wheel assembly straight away from the
wheel hub and move it to a clean work area. Be
Removal careful not to damage the tire inflation hose
1. Park the truck on level ground and chock the during tire removal.
front wheels to prevent truck movement. NOTE: Adapter ring (2) will remain attached to the
2. Place the directional control lever in PARK and outer rim. The adapter ring may be removed from the
turn the rest switch ON. Turn the key switch outer rim, if necessary, by removing outer flanged
OFF to shut down the engine and allow 90 nuts (4).
seconds for the steering system accumulators
8. If removal of the inner wheel is necessary,
to bleed down.
remove inner tire inflation extension (5).
3. Place a jack under the rear suspension
9. Position the tire handler to grip the inner wheel.
mounting plates. Refer to the topic "Jack point
Remove flanged nuts (6).
locations" in the Foreword, safety and general
information section. 10. Pull the wheel assembly straight away from the
wheel hub and move it to a clean work area. Be
4. Raise the rear axle housing until the tires are off
careful not to damage the tire inflation hose
the ground. Securely block up the rear axle
during tire removal.
housing near the wheel motor mounting flange.
5. Remove tire inflation hose outer extension (1,
Figure 50-7) at the clamp on the outer wheel,
then disconnect the outer extension from tire
inflation hose inner extension (5).
If the wheel motor is to be removed from the truck
6. Grip outer wheel and tire with the tire handler. for service, install approximately eight flanged
Remove inner flanged nuts (3) from adapter ring nuts with appropriate spacers in place of the
(2) that secures the outer rim to the wheel motor outer wheel adapter ring and nuts. This will
hub. provide additional support for the wheel motor
transmission during removal and transportation.
5
1
4
6 2
INNER RIM 3 OUTER RIM 86454
FIGURE 50-7. DUAL REAR WHEEL ASSEMBLY

1. Tire Inflation Hose Outer Extension 4. Outer Flanged Nut
2. Adapter Ring 5. Tire Inflation Hose Inner Extension
3. Inner Flanged Nut 6. Flanged Nut
8
Installation
NOTE: Clean all mating surfaces and check stud
threads before installing wheel assemblies. Refer to
the topic "Wheel stud maintenance".
a
1. If either wheel motor has been removed, bleed
d d
the brakes before installing the rear tires. Refer
to "Wet disc brake bleeding procedure" in
Testing and adjusting section Brake system.
2. If removed, grip the inner wheel assembly with
b c
the tire handler and install it onto the wheel hub. e
Ensure that the tire inflation hose on the inner c b
rim is aligned with the clamps for inner
extension (5, Figure 50-7).
d d
a
86453
Grease containing molybdenum disulphide must
never be used on wheel mounting hardware. Use FIGURE 50-8. NUT TIGHTENING
of this type of grease on wheel mounting SEQUENCE
hardware may result in wheel mounting studs
stretching beyond their elastic limit, making them
susceptible to breakage.
3. Lubricate all stud threads and nut seating
tighten flanged nuts (6) in the following
sequence (see Figure 50-8):
a. Install six nuts at the 12 o'clock and six nuts
at the 6 o'clock positions. Tighten each nut to
2 655 ± 136 N·m (1,958 ± 100 ft lb).
N·m (1,958 ± 100 ft lb).
N·m (1,958 ± 100 ft lb).
d. Install the remaining nuts and torque in a
clockwise direction to 2 655 ± 136 N·m
(1,958 ± 100 ft lb).
e. Retighten all nuts in a clockwise direction to
2 655 ± 136 N·m (1,958 ± 100 ft lb).
9
4. Install inner tire inflation extension (5, Figure 50- 6. Grip the outer wheel assembly with the tire
7) to the inner rim tire inflation hose. handler and install it onto the wheel hub. Ensure
that the tire inflation hose bracket is aligned with
NOTE: The nut torque for installing the adapter ring inner tire inflation extension (5, Figure 50-7).
onto the outer rim is greater than the nut torque for
installing the rims onto the truck. 7. Lubricate all stud threads and nut seating
5. If removed, install adapter ring (2) onto the outer
rim. Lubricate all stud threads and nut seating
tighten inner flanged nuts (3) in the following
sequence (see Figure 50-8):
tighten outer flanged nuts (4) in the following a. Install six nuts at the 12 o'clock and six nuts
sequence (see Figure 50-8): at the 6 o'clock positions. Tighten each nut to
2 655 ± 136 N·m (1,958 ± 100 ft lb).
a. Install six nuts at the 12 o'clock and six nuts
at the 6 o'clock positions. Tighten each nut to b. Install three nuts directly below the 3 o'clock
2 655 ± 136 N·m (1,958 ± 100 ft lb). and three nuts directly above the 9 o'clock
N·m (1,958 ± 100 ft lb).
positions. Tighten the nuts to 2 655 ± 136 c. Install three nuts directly above the 3 o'clock
N·m (1,958 ± 100 ft lb). and three nuts directly below the 9 o'clock
N·m (1,958 ± 100 ft lb).
positions. Tighten these nuts to 2 655 ± 136 d. Install the remaining nuts and tighten in a
N·m (1,958 ± 100 ft lb). clockwise direction to 2 655 ± 136 N·m
(1,958 ± 100 ft lb).
d. Install the remaining nuts and tighten in a
clockwise direction to 2 655 ± 136 N·m e. Retighten all nuts in a clockwise direction to
(1,958 ± 100 ft lb). 2 655 ± 136 N·m (1,958 ± 100 ft lb).
e. Retighten all nuts in a clockwise direction to 8. Install tire inflation hose outer extension (1,
2 655 ± 136 N·m (1,958 ± 100 ft lb). Figure 50-7). Secure the tire inflation hoses to
the clamps on the outer rim.
9. Remove the blocks from under the truck and
lower the truck to the ground.
10. Operate the truck for one load and retighten the
flanged nuts.
• Retighten flanged nuts (4) and (6) to 2 655 ±
136 N·m (1,958 ± 100 ft lb).
• Retighten flanged nuts (3) to 2 655 ± 136 N·m
(1,958 ± 100 ft lb).
10
Rim and tire service Lock ring retainer installation
Lubricants 1. Inspect the retainers, capscrews and lock ring

threads before use. Look for damage or cracks
The proper amount and type of lubricant is key to on the retainers. The screws and threads must
successful mounting of radial off-road tires. be in good condition and threads must be
• Use only water-based or vegetable-based cleaned before installing the retainers.
lubricants. Lubricants should be of a type that 2. Insert the capscrews through the retainers and
vaporize over time and not leave any residue on into the lock ring. Tighten the capscrews slightly.
the rim or tire surfaces.
• Paste lubricants should be diluted with water
according to the specific lubricant manufacturer’s
recommendations.
• Only lubricate the parts on the rim that are in
contact with the bead sole area of the tire. Be 84834
careful not to apply lubricant in the O-ring gutter.
FIGURE 50-10.
• When lubricating the tire bead, lubricant should
be sparingly applied to the tire bead surface only.
The lubricant should be painted or sprayed on
uniformly without any lumps in the paste or soap. 3. Insert retainer bolt (2, Figure 50-11) through the
retainer with no thread and into the retainer that
is threaded. Tighten the bolt slightly.
Tire inflation
1. Wherever possible, place the tire and rim inside
a tire inflation safety cage, then inflate tire.
During inflation, keep away from the tire.
1 2
84839
FIGURE 50-11.
1. Capscrews 2. Retainer Bolt
84825
4. Keep the retainers parallel to each other while
FIGURE 50-9. tightening both capscrews (1) hand-tight. Then
tighten retainer bolt (2) hand-tight.
5. Tighten retainer bolt (2) to a final torque of 40
N·m (30 ft lb) and both capscrews (1) to a final
2. When tire has been inflated to a pressure of torque of 110 N·m (81 ft lb).
approximately 35 kPa (5 psi), check assembly
of tire and rim components.
3. If assembled correctly, continue inflating up to
the rated value.
11
Removing the lock ring 5. Expand the lock ring expander tool to an
acceptable gap that will achieve a minimal slid-
ing diameter for the lock ring.
NOTE: DO NOT expand the lock ring unnecessarily.
Keep fingers clear of the area between the lock

ring and the lock ring groove and rim base.
1. Adjust the expander tool jaws into the lock ring
holes.
2. Insert the capscrews through the holes of the
lock ring expander tool jaws and into the lock
ring holes.
84838
FIGURE 50-15.
6. Lift and slide the expanded lock ring along the

outer rim base and install the lock ring into the
outside lock ring groove of the outer dual.
84835 7. Place the lock ring expander tool at an easily
FIGURE 50-12. accessed position.
8. Place the pneumatic power tool on the end of
the lock ring expander tool lead screw, then
3. Check that the capscrews are completely unscrew the lead screw until the lock ring is
installed in the lock ring holes and the lock ring seated in the lock ring groove.
expander tool is seated into position.
Be careful not to over-drive the lock ring

expander tool.
9. Remove the capscrews from the lock ring and
place the lock ring expander tool in a safe stor-
84836 age location.
FIGURE 50-13. 10. Remove the lock ring from the outside of the
outer dual.

the lock ring expander tool lead screw.
84837
FIGURE 50-14.
12
Installing the lock ring 6. Expand the lock ring expander tool to an
acceptable gap that will achieve a minimal slid-
ing diameter for the lock ring.
Keep fingers clear of the area between the lock

ring and the lock ring groove and rim base.
1. Install the lock ring onto lock ring groove at the
outside position of the outer dual.
2. Adjust the expander tool jaws by hand until the 84838
holes line up with the lock ring holes. FIGURE 50-19.
3. Insert the capscrews through the holes of the
lock ring expander tool jaws and into the lock
ring holes.
7. Outside position of inner dual: Lift and slide
the expanded lock ring along the rim base of the
outer dual and guide it into the lock ring groove
on the outside of inner dual.
Inside position of outer dual: Lift and remove
the expanded lock ring from the outside position
of outer dual and rotate it so that the interface
area with bead seat band is facing outward.
84835 8. Place the lock ring expander tool at an easily
accessed position.
FIGURE 50-16.
the lock ring expander tool lead screw. Unscrew
4. Check that the capscrews are completely
the lead screw until the lock ring is seated in the
installed in the lock ring holes and the lock ring
lock ring groove.
expander tool is seated into position.
Be careful not to over-drive the lock ring

expander tool.
10. Remove the capscrews from the lock ring and
FIGURE 50-17. 84836 place the lock ring expander tool in a safe stor-
age location.
the lock ring expander tool lead screw.
84837
FIGURE 50-18.
13
Removing the tire from the front rim 1. Before demounting the tire from the rim, release
(5-piece rim) the air by using valve tool (3) to remove valve
core housing (2, Figure 50-20).
If the proper procedure for performing mainte-

nance or replacement of the wheel or tire is not
used, the wheel or tire may burst, causing dam-
age, serious injury, or even death. When perform-
ing such maintenance, consult your authorized
regional Komatsu distributor or the tire manufac-
turer.
DO NOT stand in front of a rim and locking ring

when inflating a tire mounted on the machine.
Observers must not be permitted in the area.
DO NOT weld or heat the rim assembly with the 1 2 3

tire mounted on the rim. Resulting gases inside
the tire may ignite, causing explosion of the tire 84830
and rim. FIGURE 50-20. VALVE REMOVAL
If dual assemblies (tires and rims) require 1. Valve 3. Valve Tool
service, both dual tires must be deflated prior to 2. Valve Core Housing
commencing work regardless if rims or wheels
are involved.
Be aware of the trajectory of the valve core as it

may shoot out during its removal. 2. After fully releasing the air, place the tire and rim
on the ground with the gutter side facing up.
84831
FIGURE 50-21.
14
3. Mount bead breaker on the bead seat band. 7. Use the tire lever to push down on the bead
Operate the bead breaker, push down the side seat band so that the O-ring is freed. Remove
ring, and unseat the tire bead from the bead the O-ring.
seat band.
84855
84859
FIGURE 50-24.
FIGURE 50-22.
8. Use lifting equipment to remove the bead seat

band.
4. Remove capscrews (1, Figure 50-32) and the
retainers that secure the lock ring to the rim.
1 2
84839
FIGURE 50-23.
84861
FIGURE 50-25.
5. Move the bead seat band to gain access to the
lock ring groove and O-ring groove.
6. Remove the expanded lock ring. Refer to
"Removing the lock ring"
15
9. Use lifting equipment to remove the side ring. 11. Mount bead breaker on the rim base. Operate
the bead breaker, push down the side ring, and
unseat the tire bead from the bead seat band.
84862
FIGURE 50-26.
84864
10. Use lifting equipment to turn over the tire and FIGURE 50-28.
rim, and place them on the ground.
12. Use lifting equipment to remove the rim base.
84863
84865
FIGURE 50-27.
FIGURE 50-29.
13. Use lifting equipment to remove the side ring.
84871
FIGURE 50-30.
16
Removing the tire from the rear outer dual rim 1. Before demounting the tire from the rim, release
(7-piece Smart rim) the air by using valve tool (3) to remove valve

regional Komatsu distributor, or the tire manufac-
turer.

DO NOT weld or heat the rim assembly with the 1 2 3

the tire may ignite, causing explosion of the tire
84830
and rim.
FIGURE 50-31. VALVE REMOVAL
If dual assemblies (tires and rims) require 1. Valve 3. Valve Tool
service, both dual tires must be deflated prior to
2. Valve Core Housing
commencing work regardless if rims or wheels
are involved.

may shoot out during its removal. 2. Remove capscrews (1, Figure 50-32) and the
1 2
84839
FIGURE 50-32.
17
3. Move the bead seat band to gain access to the 7. Move the rock ejector out of the way.
4. Remove the lock ring from the outside of the
outer dual.
Rock ejector bar must be secured. If the rock
ejector falls it may result in injury to people or
damage to equipment.
8. Remove the O-ring from the inner side of the
outer dual.
9. Remove the capscrews and retainer of the
inside lock ring of the outer dual.
Outer dual Inner dual
10. Remove the expanded lock ring from the inside
85031 lock ring groove of outer dual. Refer to "Remov-
FIGURE 50-33.
ing the lock ring".
5. Remove the O-ring from the rim.

6. Remove the tire and rim components as one
unit. Store the tire in a safe and clean area.
85032
FIGURE 50-35.
84833
FIGURE 50-34.
18
Removing the tire from the rear inner dual rim 1. Before demounting the tire from the rim, release
(5-piece rim) the air by using valve tool (3) to remove valve

regional Komatsu distributor, or the tire manufac-
turer.

DO NOT weld or heat the rim assembly with the

1 2 3
the tire may ignite, causing explosion of the tire
and rim. 84830
FIGURE 50-36. VALVE REMOVAL
If dual assemblies (tires and rims) require
service, both dual tires must be deflated prior to 1. Valve 3. Valve Tool
commencing work regardless if rims or wheels 2. Valve Core Housing
are involved.

may shoot out during its removal. 2. Remove capscrews (1, Figure 50-37) and the
1 2
84839
FIGURE 50-37.
19
3. Move the bead seat band to gain access to the Preparation before assembly
1. Confirm tire and rim component combination.
4. Remove the expanded lock ring from the
a. Check the tire size and markings on the rim
outside the inner dual. Refer to "Removing the
base, and ensure that the combination is
lock ring".
correct.
b. Check the markings on rim components and
matching charts, and ensure that the combi-
nation is correct.
2. Clean rim components with a wire brush so that
examination, maintenance, and mounting can
be done correctly.
85033
FIGURE 50-38.
5. Remove the O-ring from the rim.

6. Apply a bead breaker to the back flange area.
Remove the tire bead from the bead seat of the
rim back flange.
84840
FIGURE 50-41.
3. Check that there is no deformation, cracking,

wear, corrosion, or damage on the rim compo-
nents.
4. Re-coat any areas where the anti-corrosive oil
Outer dual Inner dual or paint is peeling.
5. Confirm there are no tire defects.
85034
FIGURE 50-39. 6. Apply lubricant to both tire bead seats. Refer to
“Lubricants” for details.
7. Remove the tire and rim components as a unit.

Store the tire in a safe and clean area.
DO NOT apply tire lubricant to areas other than

where the rim components come in contact with
the tire. Doing so could cause circumferential
slippage between rim components when the
vehicle is being driven. Consult your tire dealer
when selecting tire lubricant.
Outer Inner
85035
FIGURE 50-40.
20
Installing the tire on the front rim 5. Place the tire on the rim base and assemble the
(5-piece rim) rim.
1. Place the rim base on a rim base stand with the 6. Install the side ring on the tire rim.
gutter side up.
2. Install the side ring.
84862
FIGURE 50-44.
7. Insert the bead seat band into the side ring and
rim base.
84872
FIGURE 50-42.
3. Install the valve.

4. Apply lubricant to both tire bead seats. Refer to
“Lubricants” for details.
Lubricate Lubricate
85029
FIGURE 50-45.
FIGURE 50-43.
21
8. Use the tire lever to push in the bead seat band 10. Install the lock ring. Refer "Installing the lock
so that its edge fits with the tire bead. ring".
11. Starting opposite the lock ring gap, lightly tap the
lock ring with a soft metal or hard plastic ham-
mer in both directions back to the lock ring gap
to ensure that the lock ring is clamped into the
Keep fingers away during installation. lock ring groove.
12. Ensure that the combinations, facings, and posi-
tions of rim components are correct.
85030
FIGURE 50-46.
9. Install O-ring in the O-ring groove of the rim.
84869
FIGURE 50-47.
22
Installing the tire on the rear inner dual rim 5. Install the tire on the inner dual.
(5-piece rim)
Inspection of the rim component and seating

must be performed to prevent serious injury and
death to people and damage to equipment. It is
vital to follow these instructions to manage the Outer dual Inner dual
component seating process safely.
Inspection must be performed prior to assembly,

before inflation, after initial inflation, during
inflation and after inflation is completed.
Appropriate lifting equipment must be used while

handling heavy items.
Be cautious while moving tire and rims to avoid Outer dual Inner dual
accidental drops or falls that could injure
personnel. 84849
FIGURE 50-49.
Rock ejector bar must be secured. If the rock Excessive force may push the vehicle off its
ejector falls it may result in injury to people or stands.
damage to equipment.
1. Move the rock ejector out of the way. lock ring groove and O-ring groove.
2. Perform a rim component inspection before 7. Install O-ring over the rim and into the O-ring
assembly. Refer "Preparation before assembly". groove.
3. Lift and install the side ring into position on the 8. Install the lock ring to the outside of the inner
rim to interface with the back flange. dual. Refer "Installing the lock ring".
4. Apply lubricant to the tire bead/rim interface.
Refer to "Lubricants".

84848
FIGURE 50-48.
84850
FIGURE 50-50.
9. Install the retainer and capscrews to the lock

ring. Refer "Lock ring retainer installation".
23
Installing the tire on the rear outer dual rim 4. Install the tire and rim components to the rim.
(7-piece Smart rim)
Inspection of the rim component and seating

must be performed to prevent serious injury and
death to people and damage to equipment. It is Outer dual Inner dual
vital to follow these instructions to manage the
component seating process safely.
Inspection must be performed prior to assembly,

before inflation, after initial inflation, during
inflation and after inflation is completed.
Appropriate lifting equipment must be used while

handling heavy items.
Be cautious while moving tire and rims to avoid
accidental drops or falls that could injure person-
84851
nel.
FIGURE 50-51.
1. Install the expanded lock ring to the inside of the

outer dual. Refer "Installing the lock ring".
ring. Refer "Lock ring retainer installation".
Excessive force may push the vehicle off its
3. Install the O-ring over the rim and into the O-
stands.
ring groove.
6. Install the O-ring over the rim and into the O-
ring groove.
7. Install the lock ring to outside of the outer dual.
84852
FIGURE 50-52.

ring. Refer to "Lock ring retainer installation".
24
Removal and installation of front wheel 5. Install vacuum pump kit (XB0887) on the
hub and spindle hydraulic tank to prevent the loss of oil when
disconnecting hydraulic lines.
Removal
6. Disconnect front wheel speed sensor harness
(1, Figure 50-54) from the top of the brake
assembly. Tie back the cable to prevent damage
during hub and spindle removal.

1
86456
procedure" in Testing and adjusting section FIGURE 50-54. FRONT WHEEL SPEED SENSOR
1. Front Wheel Speed Sensor Harness
hydraulic system.
2. Activate the battery disconnect switches.
3. Remove the front tire and rim assembly. Refer 7. Disconnect brake cooling lines (1, Figure 50-55)
to "Removal and installation of front wheel". and brake apply line (2) at the inlet and outlet
ports on the brake housing. Plug the lines and
4. Install three shipping brackets (1, Figure 50-53)
ports to help prevent contamination.
120 degrees apart to prevent movement of the
hub on the spindle. 8. After the hydraulic lines have been plugged,
turn off the vacuum pump.
1
1
86537
FIGURE 50-53. WHEEL HUB & SPINDLE

SHIPPING BRACKET INSTALLATION
1. Shipping Bracket
2
86532
FIGURE 50-55. FRONT BRAKE LINES

1. Brake Cooling Line 2. Brake Apply Line
25
9. Remove drain plugs (1, Figure 50-56) and (2) 11. Disconnect the steering cylinder and the tie rod
and allow the oil to drain from the brake housing from the spindle that is being removed. Refer to
and catchment tank into a suitable container. "Removal and installation of steering cylinders
and tie rod" in Disassembly and assembly
section Steering system.
Use lifting equipment with adequate capacity to

remove and install the components.
NOTE: The front wheel hub, spindle and brake
1 assembly weighs approximately 6 681 kg (14,728 lb).
12. Position a fork lift under the wheel hub and
2 spindle assembly as shown in Figure 50-58.
Use blocking as necessary to keep the spindle,
86533
hub and brake assembly level.
FIGURE 50-56. FRONT BRAKE DRAIN PLUGS
1. Brake Housing 2. Catchment Tank

Drain Plug Drain Plug
10. Remove magnetic drain plug (1, Figure 50-57)

and allow the oil to drain from the front hub
bearing into a suitable container.
FIGURE 50-58. TYPICAL LIFTING DEVICE

(FORKLIFT)
1
86534
FIGURE 50-57. FRONT HUB BEARING

MAGNETIC DRAIN PLUG
1. Front Hub Bearing Magnetic Drain Plug
26
13. Remove 12-point capscrews (1, Figure 50-59) 14. Remove 16 of 27 12-point capscrews (4) and
and hardened flat washers (2) that secure hardened flat washers (2) as follows:
retainer plate (3) to the front suspension
a. Refer to Figure 50-60. Remove only the
cylinder. To prevent thread damage, loosen the
capscrews that are designated by an “X”.
capscrews in a circular pattern in torque
increments of 678 N·m (500 ft lb). Remove b. Loosen the capscrews using a circular
retainer plate (3). pattern in torque increments of 678 N·m (500
ft lb). Do not attempt to remove each
There is a total of 15 capscrews.
capscrew in one sequence.
15. Run a tap (1 1/4” - 12 UNF) in the threads after
the capscrews are removed.
4 2
2
3
1 86535
FIGURE 50-59. FRONT SPINDLE REMOVAL AND

INSTALLATION
1. 12-Pt. Capscrews 3. Retainer Plate
(for retainer plate) 4. 12-Pt. Capscrews
2. Hardened Flat Washers (for steering arm)
FIGURE 50-60. SPINDLE REMOVAL TOOL
27
NOTE: Older spindle removal tools (5, Figure 50-61)

may have been made with a round tube (shown as a
dotted line) welded on one side. The tool can be
installed upside down and used with a hydraulic ram
as shown.
Do not apply pressure to the hydraulic ram until
The spindle removal tool may be fabricated locally to all 16 capscrews are installed.
aid in spindle removal. Refer to Disassembly and
assembly section General information for The maximum force that can be applied during
fabrication information. Use of this tool is described in the spindle removal process is not to exceed
the following steps. 701 000 kgf (1,545,600 lb).
The hydraulic ram must be a low profile hydraulic ram
(pancake jack) to fit in this area. Most hydraulic rams 20. Install the remaining 13 capscrews and tighten
that will fit in this area are rated at 150 tons. them to 68 N·m (50 ft lb). This is to ensure that
all capscrews will pull evenly when pressure is
applied by the hydraulic ram.
16. Locate 16 capscrews (1, Figure 50-61) and
hardened flat washers (2) as specified below:
Capscrew (KC7095) . . . . . . .1 1/4" - 12NF x 8"
Hardened flat washer (WA0366) . . . . . . . 1 1/4"
NOTE: Hardened flat washers must be used under
the removal tool capscrews to prevent galling.
17. Lubricate the capscrew threads and flat washers
with chassis grease.
18. Install spindle removal tool (5) as shown in
Figure 50-61 using only three capscrews (1),
three washers (2) and three spacers (6). The
three capscrews must be evenly spaced.
Tighten the three capscrews to 68 N·m (50 ft
lb).
NOTE: Verify that the minimum thread engagement
of 41.1 mm (1.62 in.) is achieved for the removal tool
capscrews when inserted.
FIGURE 50-61. SPINDLE REMOVAL TOOL
19. Ensure that hydraulic ram (4) is completely
INSTALLATION WITH RAM
retracted. Install the hydraulic ram with reaction
plate (3) on top of the hydraulic ram. 1. Capscrew (KC7095) 6. Spacer
NOTE: If there is a large gap between reaction plate 2. Hardened Flat Washer 7. Steering Arm
(3) and suspension piston (9), it may be necessary to (WA0366) 8. Spindle
add steel spacers below the hydraulic ram to close 3. Reaction Plate 9. Suspension Piston
the gap. 4. Hydraulic Ram 10. Area to heat
5. Spindle Removal Tool
28
Spindle removal (off the truck)

If the hydraulic ram method (with heat) did not sepa-
rate the spindle from the suspension piston, the spin-
dle, hub and brake and the front suspension must be
Heavy components and high forces are involved removed from the truck as an assembly. With the
in this procedure. Use caution at all times when suspension on the ground, the spindle removal tool
applying force to these parts. Sudden release of can be used to separate the spindle from the suspen-
the spindle could cause components to move sion piston. Refer to Disassembly and assembly sec-
forcefully and unexpectedly. tion Suspensions for the front suspension removal
procedure.
21. Start applying pressure to the hydraulic ram to
separate spindle (8) from suspension piston (9). The spindle removal tool may be fabricated locally to
aid in spindle removal. Refer to Disassembly and
22. If the specified maximum force of the hydraulic assembly section General information for
ram is reached and the spindle has not been fabrication information. Spacers and/or multiple
separated from the suspension piston, slowly hardened flat washers may be required under the
and uniformly apply heat to spindle area (10, capscrews to be effective.
Figure 50-61).
Heat must be applied in two locations 180
degrees apart. Allow the heat to penetrate into
the spindle. Reapply heat as required. Do not
exceed 454 °C (850 °F) anywhere on the Use lifting equipment and lifting devices with
spindle. adequate capacity to support the components.
1. Position the front suspension and spindle, hub
and brake assembly on the work floor as shown
in Figure 50-62.
The wheel hub must be supported with an over-
Heating the spindle in excess of 454° C (850° F) head hoist.
may cause serious damage to the spindle.
2. Locate 16 capscrews and hardened flat
23. Use heat as specified in the previous step and a washers (1, Figure 50-62) as specified below:
large hammer to carefully tap the top surface of
spindle (8) until the spindle breaks free. Capscrew (KC7095) . . . . . . . 1 1/4" - 12NF x 8"
If the spindle does not separate from the sus- Hardened flat washer (WA0366) . . . . . . .1 1/4"
pension piston, the spindle, hub and brake and NOTE: Hardened flat washers must be used under
the front suspension must be removed from the the removal tool capscrews to prevent galling.
truck as an assembly. Refer to "Spindle removal
(off the truck)" to separate the spindle from the 3. Lubricate the capscrew threads and flat
suspension. washers with chassis grease.
24. After separation, lower the spindle, hub and 4. Install spindle removal tool (2) as shown in
brake assembly from the suspension piston. Be Figure 50-62 using capscrews and washers (1).
careful during removal to prevent damage to the
NOTE: Verify that the minimum thread engagement
suspension piston rod taper and the tapered
of 41.1 mm (1.62 in.) is achieved for the removal tool
spindle bore.
capscrews when inserted.
25. Move the spindle, hub and brake assembly to a
clean work area for repair.
29
Heavy structures and high forces are involved in Heating the spindle in excess of 454° C (850° F)
this procedure. Use caution at all times when may cause serious damage to the spindle.
applying force to these parts. Sudden release of 7. Tighten the capscrews again to the maximum
the spindle could cause components to move specified torque as described in step 5.
forcefully and unexpectedly.
8. Use a large hammer and heat at the specified
5. After the spindle removal tool has been locations to carefully tap on the top surface of
installed, progressively increase the torque on the spindle until the piston breaks free.
the capscrews in a circular pattern until the
tapered piston breaks loose, or until the maxi- NOTE: In extreme cases, it may be necessary to
mum specified torque on the capscrews of remove additional steering arm retaining capscrews
2 142 N·m (1,580 ft lb) is reached. and use additional capscrews to apply more force.
6. If the specified torque is reached and the parts 10. After separation, use the lifting device to move
have not separated, slightly loosen the cap- the spindle, hub and brake assembly to a clean
screws, then slowly and uniformly apply heat to work area for repair.
spindle area (3 Figure 50-62).
Heat must be applied in two locations 180
degrees apart. Allow the heat to penetrate into
the spindle. Reapply heat as required. Do not
exceed 454 °C (850 °F) anywhere on the
spindle.
FIGURE 50-62. SPINDLE REMOVAL TOOL INSTALLATION

OFF THE TRUCK
1. Capscrew & Hardened Flat Washer 3. Area to heat

2. Spindle Removal Tool
30
Installation 6. Connect the steering cylinder and the tie rod to

NOTE: If the spindle and front suspension had to be the spindle. Refer to "Removal and installation
removed from the truck as an assembly, first install of steering cylinders and tie rod" in Disassembly
the suspension on the truck. Refer to Disassembly and assembly section Steering system.
and assembly section Suspensions for the front 7. Install vacuum pump kit (XB0887) on the
suspension installation procedure. hydraulic tank to prevent the loss of oil when
1. Clean the spindle bore and suspension piston reconnecting hydraulic lines.
taper so that they are free of rust, dirt and oil. 8. Install brake cooling lines (1, Figure 50-55) and
2. Lubricate the spindle bore and suspension brake apply line (2) at the inlet and outlet ports
piston taper with lithium based multi-purpose EP on the brake housing. Use new O-rings.
NLGI 2 grease containing no molybdenum- 9. Ensure that drain plug (1, Figure 50-57) for the
disulphide. front hub bearing is installed.
10. Ensure that drain plugs (1, Figure 50-56) and (2)
for the brake housing and catchment tank are
installed.
11. After all hydraulic lines have been reconnected,
Use of anti-seize compounds that contain copper
turn off the vacuum pump and remove the
are prohibited from use on spindle bores and
vacuum pump from the hydraulic tank.
piston tapers. These lubricants can cause severe
damage. Only use lithium based multi-purpose 12. Connect front wheel speed sensor harness (1,
EP NLGI 2 grease containing no molybdenum- Figure 50-54) to the wheel speed sensor at the
disulphide. top of the brake assembly.
3. Position the spindle, hub and brake assembly 13. Remove shipping brackets (1, Figure 50-53)
on a fork lift or similar lifting device as shown in from the hub.
Figure 50-58. Raise the spindle, hub and brake
14. Perform the hydraulic system checkout
assembly into position on the suspension piston
procedure and the brake system checkout
taper.
procedure. Refer to the appropriate Testing and
4. Lubricate the threads and seats of 12-point adjusting sections in the shop manual.
capscrews (1, Figure 50-59) and hardened flat
15. Install the wheel and tire. Refer to "Removal and
washers (2) with lithium based multi-purpose
installation of front wheel".
EP NLGI 2 grease containing no molybdenum-
disulphide.
5. Secure the spindle to the suspension piston by
installing retainer plate (3), hardened flat
washers (2) and 12-point capscrews (1).
Tighten the capscrews as follows:
a. Tighten the capscrews uniformly to 678 N·m
(500 ft lb).
b. Continue to tighten the capscrews uniformly
in increments of 339 N·m (250 ft lb) until a
final torque of 2 705 ± 135 N·m (1,995 ± 100
ft lb) is obtained.
31
Disassembly and assembly of front

wheel hub and spindle
Cross Section View
2 1 23
22
3
DETAIL B
4 21
20
B
5
6
12 13
7
9 14
A
DETAIL A
10
15
11
19 18 17 16
86570
FIGURE 50-63. SPINDLE, HUB & BRAKE ASSEMBLY

1. Brake Assembly 9. Outer Bearing Cone 17. Oil Seal
2. Shipping Bracket 10. Outer Bearing Cup 18. Seal Carrier/Speed Sensor Gear
3. Wheel Hub 11. Magnetic Drain Plug 19. Shims
4. Fill Plug 12. Shims 20. Spacer
5. Hub Cover 13. Inner Bearing Cone 21. Seal Assembly (Oil Separator)
6. Check Valve 14. Inner Bearing Cup 22. Seal Carrier (Spindle)
7. Sight Gauge 15. Spindle 23. Seal Carrier (Wheel Hub)
8. Bearing Retainer 16. Seal Assembly (Brake)
32
Disassembly 4. Disconnect the wheel speed sensor from cable

bracket (1, Figure 50-65). Loosen capscrews (3)
and flat washers (4), then remove wheel speed
sensor (2) from sensor bracket (5).
Use a lifting device with adequate capacity to 1

1. Remove the wheel hub and spindle. Refer to
"Removal and installation of front wheel hub and 2
spindle".
2. Remove any dirt and mud from the assembly.
3. Remove remaining 12-point capscrews (1,
Figure 50-64) and hardened flat washers (2)
that secure steering arm (3) to spindle (4). 4 3 5 86538
Loosen the capscrews using a circular pattern in FIGURE 50-65. WHEEL SPEED SENSOR
torque increments of 678 N·m (500 ft lb). Do not REMOVAL & INSTALLATION
attempt to remove each capscrew in one
sequence. Run a tap (1 1/4” - 12 UNF) in the 1. Cable Bracket 4. Flat Washer
threads after the capscrews are removed. 2. Wheel Speed Sensor 5. Sensor Bracket
3. Capscrew
5. Remove capscrews (1, Figure 50-66),

4 lockwashers (2) and hub cover (3) from the
wheel hub. Discard the O-ring.
3 1 2
3 1 2 86536
FIGURE 50-64. STEERING ARM INSTALLATION

1. 12-Pt. Capscrews 3. Steering Arm
2. Hardened Flat Washers 4. Spindle
NOTE: To aid in the complete disassembly of the

wheel hub and spindle assembly, use a fabricated 86539
spindle stand to support the assembly in a vertical FIGURE 50-66. WHEEL HUB COVER
position (hub cover up). REMOVAL & INSTALLATION
1. Capscrew 3. Hub Cover
2. Lockwasher
33
6. Remove ten capscrews (1, Figure 50-67) and 8. Remove 12-point capscrews (1, Figure 50-68)
hardened flat washers (2). and hardened flat washers (2).
7. Remove bearing retainer (3), O-ring (4), and There is a total of 54 capscrews.
shims (5). Discard the O-ring.
2 3
4
2
5
1
86541
FIGURE 50-68. WHEEL HUB/BRAKE ASSEMBLY

REMOVAL & INSTALLATION
1. 12-Pt. Capscrew 2. Hardened Flat
Washer
86540
FIGURE 50-67. WHEEL HUB BEARING

RETAINER REMOVAL
1. Capscrew 4. O-ring
2. Hardened Flat Washer 5. Shims
3. Bearing Retainer
34
9. Attach a lifting device to wheel hub/brake 11. Rotate the hub/brake assembly 180 degrees
assembly (1, Figure 50-69) and carefully lift it and place it on blocking to prevent damage to
straight up and off spindle (2). the wheel studs and machined surfaces.
10. Remove outer bearing cone (3) and retainer pin 12. Remove O-ring (1, Figure 50-70) from the brake
(4) from the wheel hub. piston housing.
13. Remove eight Allen head capscrews (2), seal
carrier (4) with one half of seal assembly (3) and
4 O-ring (5) from the hub.
3
1
86542
FIGURE 50-69. WHEEL HUB/BRAKE ASSEMBLY

1. Wheel Hub/Brake 3. Outer Bearing Cone
Assembly 4. Retainer Pin 86543
2. Spindle FIGURE 50-70. SEAL CARRIER

1. O-ring 4. Seal Carrier
2. Allen Head Capscrew 5. O-ring
3. Seal Assembly
35
14. Remove 12-point capscrews (1, Figure 50-71) 16. Ring gear retainer bars (1, Figure 50-72) must
and hardened flat washers (2) that secure the be installed to retain the inner gear inside the
brake assembly inner gear to the wheel hub. brake assembly.
15. Remove shipping brackets (3) that secure the 1
brake assembly to the wheel hub.
1
86415
FIGURE 50-72. RING GEAR RETAINER BARS

ON BRAKE ASSEMBLY
1. Ring Gear Retainer Bars
86544
FIGURE 50-71. BRAKE ASSEMBLY REMOVAL

1. 12-Pt. Capscrew 3. Shipping Bracket
36
17. Attach lifting eyes and an overhead hoist to 18. Turn over the brake assembly so that the
brake assembly (1, Figure 50-73). Carefully lift catchment tank is facing upward. Remove seal
the brake assembly from wheel hub (2). ring (1, Figure 50-74) and O-ring (2) from the
brake back plate.
NOTE: The front brake assembly weighs
approximately 1 687 kg (3,719 lb). These components are one half of the complete
seal assembly.
NOTE: For brake assembly rebuild instructions, refer
to Disassembly and assembly section Brake
system.
1 2
86546
FIGURE 50-74. SEAL ASSEMBLY REMOVAL
1. Seal Ring 2. O-ring

86545
FIGURE 50-73. BRAKE ASSEMBLY

1. Brake Assembly 2. Wheel Hub
37
19. Remove two capscrews and hardened flat 23. If the bearings require replacement, press
washers (1, Figure 50-75) at six locations bearing cups (1, Figure 50-76) and (2) from the
around the wheel hub. Remove seal carrier/ wheel hub.
speed sensor gear (3) and shims (2).
20. Remove seal carrier O-ring (7) from the wheel
hub. 1
21. Remove oil seal (4) from the seal carrier.
22. Remove seal ring (6) and O-ring (5) from the
seal carrier.
These components are one half of the complete
seal assembly.
4 2
3
7
86549
FIGURE 50-76. BEARING REPLACEMENT
1. Inner Bearing Cup 2. Outer Bearing Cup

86548
FIGURE 50-75. SEAL CARRIER REMOVAL
1. Capscrews & 4. Oil Seal

Hardened Flat Washers 5. O-ring
2. Shims 6. Seal Ring
3. Seal Carrier/ 7. Seal Carrier O-ring
Speed Sensor Gear
38
24. Remove inner bearing cone (1, Figure 50-77), Cleaning and inspection
retainer pin (8) and spacer (2) from spindle (7).
1. Clean all metal parts in fresh cleaning solvent.
25. Remove eight Allen head capscrews (3), seal
2. Remove and clean magnetic drain plug (1,
carrier (5) with one half of seal assembly (4) and
Figure 50-78).
O-ring (6) from the spindle.
3. Remove and inspect sight gauge (3) and check
valve (4).
1 4. Inspect wheel studs (2). Replace any studs that
are damaged or broken.
2 NOTE: If new studs are being installed, coat the hole
3 in the hub and the serrated portion of the stud with an
anti-seize compound before installation. Do not coat
4 the threads.
5. Inspect all threaded holes in the spindle and
5 wheel hub. Re-tap the holes as necessary.
6. Inspect the bearing seating surfaces in the
6 wheel hub and on the spindle. Inspect the
bearing spacer. Use a stone to carefully dress
high spots that may interfere with reassembly.
7. Inspect all other machined surfaces for damage.
7
4
2 1
86551
FIGURE 50-78. WHEEL HUB CLEANING &

86550
INSPECTION
FIGURE 50-77. SEAL CARRIER 1. Magnetic Drain Plug 3. Sight Gauge
REMOVAL & INSTALLATION 2. Wheel Stud 4. Check Valve
1. Inner Bearing Cone 5. Seal Carrier
2. Spacer 6. Seal Carrier O-ring
3. Allen Head Capscrew 7. Spindle
4. Seal Assembly 8. Retainer Pin
39
Assembly 2. Position the spindle vertically (hub end up).

3. Check both bearing cones for a slip fit on the
spindle.
4. Install spacer (1, Figure 50-77). If necessary,
tap lightly to seat the spacer against spindle (2).
Use a lifting device with adequate capacity to The spacer must fit tightly against the spindle
remove and install the components. shoulder.
5. Lightly lubricate the bearings with clean TO50
hydraulic oil before installation.
6. Install retainer pin (4) in the pin groove, then
install inner bearing cone (5) against the spacer.
All mating surfaces of the wheel and brake The bearing cone is a loose fit on the spindle.
components must be clean and dry during
assembly. No thread lubricant is permitted on NOTE: To facilitate wheel bearing adjustment, do not
these surfaces. install the brake assembly at this time.
7. Install wheel hub (3) onto spindle (2).
NOTE: Always use new O-ring seals during
assembly. 8. Install outer bearing cone (6) and retainer pin
(7) in the wheel hub.
1. If removed, install bearing cups (1, Figure 50-
76) and (2) in the wheel hub as follows:
a. Preshrink the bearing cups by packing them
in dry ice or by placing them in a deep-freeze
unit.
Do not cool below -65°C (-54°F). Cooling below

this temperature can cause microstructure
changes in the steel which may result in
premature bearing failure. Liquid nitrogen MUST
NOT be used for cooling.
b. Install the bearing cups in the wheel hub
bores.
c. After the bearing cups have warmed to
ambient temperature, press the bearing cups
tight against the hub shoulder as follows:
Inner cup - Apply 22 680 kg (25 tons) of force.
Outer cup - Apply 20 860 kg (23 tons) of force.
40
Wheel bearing adjustment

9. Install bearing retainer (3, Figure 50-80) without
7
the O-ring or shims.
6
NOTE: The thickness of the bearing retainer is
etched on the surface of the retainer. This side must
be facing outward when installed.
10. Use five of ten capscrews (2) and hardened flat
washers (3) to secure the bearing retainer. The
capscrews must be equally spaced so that two
of the capscrews are adjacent to small access
holes (4).
3 2 1 3
5
2 4
86553
1
4 FIGURE 50-80. BEARING RETAINER
INSTALLATION
1. Capscrew 3. Bearing Retainer
2. Hardened Flat Washer 4. Access Hole
11. Seat the wheel bearings by using the following

procedure:
a. Tighten the five capscrews to 95 N·m (70 ft
lb). Rotate the wheel hub at least three full
revolutions.
86552 b. Tighten the five capscrews to 190 N·m (140
FIGURE 50-79. WHEEL BEARING ADJUSTMENT ft lb). Rotate the wheel hub at least three full
PREPARATION revolutions.
1. Spacer 5. Inner Bearing Cone c. Repeat Step 11b until the torque is
2. Spindle 6. Outer Bearing Cone maintained.
3. Wheel Hub 7. Retainer Pin d. Loosen the five capscrews and rotate the
4. Retainer Pin hub at least three revolutions.
e. Tighten the five capscrews to 54 N·m (40 ft
lb). Rotate the wheel hub at least three full
revolutions.
f. Repeat Step 11e until the torque is
maintained.
41
12. Place a depth micrometer through each small Seal assembly gap adjustment
access hole (4) to measure and record the 17. Before the assembly of the wheel hub and brake
distance between the face of the bearing is completed, the gap between the seal seat of
retainer and spindle. the wheel hub and the brake assembly back
13. Add the two dimensions measured in the Step plate must be measured and adjusted if
12. Divide the sum by 2 to obtain the average necessary.
depth.
a. Measure dimension “A” (Figure 50-82) from
14. Subtract the bearing retainer thickness that is the flange of spindle (2) to the seal seat of
etched on the surface of bearing retainer (3), wheel hub (1). Record the results.
from the result calculated in Step 13. Then
subtract an additional 0.23 mm (0.009 in.).
1 2
15. Assemble a shim pack that equals the
dimension calculated in Step 14 ± 0.03 mm
(0.001 in.).
NOTE: The above procedure results in a shim pack
which will provide a nominal 0.56 mm (0.022 in.)
preload for the bearings after assembly. The shim
pack must be compressed while measuring to obtain
an accurate measurement.
Example:
Step 13 average depth 1.416 in.
Step 14 subtract etched dim. -1.375 in.
Step 14 subtract additional -0.009 in. A 86555
Step 15 Required shim pack = 0.032 in. FIGURE 50-82. SEAL ASSEMBLY GAP CHECK
1. Wheel Hub 2. Spindle
16. Install hub cover (3, Figure 50-81), capscrews
(1) and lockwashers (2). Install sight gauge (4)
and check valve (5) in the hub cover.
b. Measure dimension “B” (Figure 50-83) of the
brake assembly from the face of piston
4 5 housing (2) to the face of the seal cavity of
3 1 2 back plate (1). Record the results.
86554
FIGURE 50-81. HUB COVER INSTALLATION 2 86556
1. Capscrew 4. Sight Gauge FIGURE 50-83. SEAL ASSEMBLY GAP CHECK

2. Lockwasher 5. Check Valve 1. Back Plate 2. Piston Housing
3. Hub Cover
42
c. Measure dimension “C” (Figure 50-83), Seal installation

which is the total thickness of the seal carrier/
18. Remove the hub cover, bearing retainer, outer
speed sensor gear. Record the results.
bearing cone, retainer pin and wheel hub from
the spindle in preparation for brake assembly
1 installation.
C
19. Lubricate and install new O-ring (4, Figure 50-
85) on the wheel hub.
86557 20. Place the necessary number of shims (2) that
was determined in Step 17 at each of the six
FIGURE 50-84. SEAL ASSEMBLY GAP CHECK locations around the wheel hub. Install seal
carrier/speed sensor gear (3) onto the wheel
1. Seal Carrier/Speed Sensor Gear
hub. Secure the components to the wheel hub
with capscrews (1).
21. Apply a bead of silicone sealant in the area
d. Subtract dimension “B” and "C" from between the wheel hub and the seal carrier/
dimension “A”. The target result is 3.90 ± speed sensor gear to seal the area between the
0.13 mm (0.154 ± 0.005 in.). hub and seal carrier.
• If the result is 3.90 ± 0.13 mm (0.154 ± 0.005
in.), no shims are necessary.
3
• If the gap is more than 4.03 mm (0.159 in.),
subtract 3.90 mm (0.154 in.) from the result,. 4
Then, add shims (2, Figure 50-75) at each
location until the gap is within the target
range. 2
NOTE: Two different shim thicknesses can be used
to adjust the gap: 0.51 mm (0.020 in.) and 0.25 mm 1
(0.010 in.). Make sure that the shim pack at each
location is identical.
Example:
Step 17a Dimension "A" 420.52 mm
86558
Step 17b Dimension "B" -362.05 mm
Step 17c Dimension "C" - 53.20 mm FIGURE 50-85. SEAL CARRIER INSTALLATION
Step 17d Resulting gap = 5.27 mm
Resulting gap > 4.03 in. - 3.90 mm 1. Capscrews & 3. Seal Carrier/
Required shim pack = 1.37 mm Hardened Flat Washers Speed Sensor Gear
2. Shims 4. O-ring
Add two 0.51 mm shims and one 0.25 mm shim
at each location to bring the gap to 4.00 mm.
After a shim pack has been determined, the shim

pack, spindle, wheel hub, spacer, and bearings
are now an interdependent group. If any of the
parts are replaced, the shim pack is no longer
valid and a new pack must be calculated.
43
22. Use installation tool (58F-98-00110) to install NOTE: Visually inspect both halves of the duo cone
each half of seal assembly (3, Figure 50-86) into seal assembly before installation. Check for nicks,
the back plate of brake assembly (1) and seal dents and damage to the metal rings and toric rings.
carrier/speed sensor gear (2). If there is any damage, the entire duo cone seal
assembly must be replaced.
NOTE: Refer to the topic "Brake floating ring seal
assembly and installation" in Disassembly and 24. Lubricate and install O-ring (3, Figure 50-87) in
assembly section Brake System for the proper seal carrier (2).
installation instructions for seal assembly (3).
25. Install the seal carrier on the wheel hub. Install
23. Install oil seal (4) into the back plate of brake and tighten eight Allen head capscrews (4) to
assembly (1). Pack the area between the oil 142 ± 13 N·m (105 ± 10 ft lb).
seal lips with grease.
26. Install one half of seal assembly (1) in seal
carrier (2). The metal ring must be facing
outward.
3
NOTE: Refer to the topic ""Hub floating ring seal
assembly and installation" for the proper installation
2 instructions for both halves of seal assembly (1).
1
4
3 2
1
3
86559
FIGURE 50-86. SEAL INSTALLATION
1. Brake Assembly 3. Seal Assembly

2. Seal Carrier/ 4. Oil Seal 86561
Speed Sensor Gear
1. Seal Assembly 3. O-ring

2. Seal Carrier 4. Allen Head Capscrew
44
27. Lubricate and install O-ring (3, Figure 50-88) in Brake installation
seal carrier (2).
NOTE: Do not remove the shipping bars from the
28. Install the seal carrier on the spindle. Install and brake assembly piston housing until the inner gear is
tighten eight Allen head capscrews (4) to 142 ± secured to the wheel hub in Step 31.
13 N·m (105 ± 10 ft lb).
30. Install lifting eyes on brake assembly (1, Figure
29. Install the other half of seal assembly (1) in seal 50-89) and attach it to an overhead hoist. Lower
carrier (2). The metal ring must be facing the brake assembly onto wheel hub (2).
outward.
1 4
86562

INSTALLATION
1. Brake Assembly 2. Wheel Hub
86560
1. Seal Assembly 3. O-ring

2. Seal Carrier 4. Allen Head Capscrew
45
31. Install 12-point capscrews (1, Figure 50-90) and 34. Lubricate and install O-ring (4, Figure 50-91)
hardened flat washers (2) that secure the brake onto spindle (3). Ensure that the O-ring is not
assembly inner gear to the wheel hub. Tighten twisted.
the capscrews to 2 705 ± 135 N·m (1,995 ± 100
35. Install wheel hub/brake assembly (5) onto the
ft lb).
spindle. Align the brake assembly with the
There is a total of 32 capscrews. spindle by installing three 12-point capscrews
(1) and hardened flat washers (2) hand-tight
32. Remove the shipping bars from the brake
only.
assembly.
36. Install bearing cone (6) and retainer pin (7).
33. Install shipping brackets (3) with flat washers
and nuts at three equally-spaced locations
around the wheel hub.
7
6
1
86544 3
INSTALLATION
1. 12-Pt. Capscrew 3. Shipping Bracket 2
86563
FIGURE 50-91. WHEEL HUB/BRAKE

INSTALLATION
1. 12-Pt. Capscrew 5. Wheel Hub/Brake
2. Hardened Flat Washer Assembly
3. Spindle 6. Bearing Cone
4. O-ring 7. Retainer Pin
46
37. Install remaining capscrews (1) and hardened 41. Lubricate and install a new O-ring on cover (3,
washers (2). Tighten all 54 capscrews to 1 166 ± Figure 50-93). Install the cover, capscrews (1)
116 N·m (860 ± 86 ft lb). and lockwashers (2). Tighten the capscrews to
the standard torque.
38. Lubricate and install O-ring (4, Figure 50-92)
onto bearing retainer (3). Ensure that the O-ring
is not twisted.
3 1 2
39. Install shim pack (5) that was determined in Step
15.
40. Install bearing retainer (3), capscrews (1), and
hardened flat washers (2). While rotating the
hub, tighten the capscrews alternately in several
successive increments to a final torque of 1 017
± 102 N·m (750 ± 75 ft lb).
2 3
4
86539
5
FIGURE 50-93. WHEEL HUB COVER
1. Capscrew 3. Hub Cover
2. Lockwasher
42. Perform a hydraulic pressure test on the wheel

hub to ensure the integrity of the seals. Refer to
"Wheel Hub Pressure Test" in Testing and
adjusting section Brake system.
86540
FIGURE 50-92. WHEEL HUB BEARING

RETAINER REMOVAL
1. Capscrew 4. O-ring
2. Hardened Flat Washer 5. Shims
3. Bearing Retainer
47
Speed sensor installation and adjustment 45. Rotate the hub so that fill plug (1, Figure 50-96)
43. Install wheel speed sensor (2, Figure 50-94) in is at the 12 o'clock position above sight gauge
sensor bracket (5). Tighten two capscrews (3) (2) as shown. Remove the fill plug.
and flat washers (4) to the standard torque. 46. Add TO50 hydraulic oil through the plug port
Connect the sensor cable to cable bracket (1). until the floating ball is at the highest position.
The capacity of the bearing oil cavity is
approximately 68 L (18 gal).
1
1
2
4 3 5 86538
FIGURE 50-94. WHEEL SPEED SENSOR

1. Cable Bracket 4. Flat Washer
2. Wheel Speed Sensor 5. Sensor Bracket
3. Capscrew
2 87606
44. Adjust the sensor as follows:
FIGURE 50-96. ADDING OIL TO WHEEL HUB
a. Rotate the hub to position the center line of a
gear tooth directly under the sensor tip. 1. Fill Plug 2. Sight Gauge
b. Turn in the sensor until the tip contacts the
gear tooth. Then, back off 1/2 turn.
c. Continue turning out the sensor until the flats
of the sensor housing are perpendicular to
the gear tooth motion (See Figure 50-95).
d. Lock the sensor in place. Rotate the hub 180
degrees to verify that there is enough sensor
clearance. There should be 2.0 ± 0.1 mm
(0.079 ± 0.004 in.) of clearance.
FIGURE 50-95. SPEED SENSOR ADJUSTMENT
48
47. Remove the spindle, hub and brake assembly Hub floating ring seal assembly and
from the spindle stand. installation
48. Install steering arm (3, Figure 50-97) onto Failures of floating seals are usually caused by a
spindle (4). Install all 12-point capscrews (1) combination of factors rather than one single cause,
and hardened flat washers (2), then tighten the but many failures have one common denominator -
capscrews in an alternating pattern to 2 705 ± assembly and installation issues.
135 N·m (1,995 ± 100 ft lb).
There are five common failure modes:
• Oil leakage
• Galling
4 • Pumping mud past the toric
• Toric failure
• Seal ring breakage
The following procedure using necessary installation

tools must be accomplished to be assured of
satisfactory floating seal performance.
3 1 2 86536
FIGURE 50-97. STEERING ARM INSTALLATION

1. 12-Pt. Capscrews 3. Steering Arm
2. Hardened Flat Washers 4. Spindle
FIGURE 50-98. SEAL TERMINOLOGY
1. Seal Ring 5. Seal Ring Housing

2. Rubber Toric 6. Seal Ring Face
3. Housing Retainer Lip 7. Seal Ring Ramp
4. Housing Ramp 8. Seal Ring Retainer Lip
49
3. Carefully inspect the polished sealing surfaces

on the seal rings for scratches or any other
damage. Inspect the entire seal contact area on
all the parts for scratches or nicks that may
damage the O-rings during installation or cause
Floating ring seals must always be installed in a path of leakage after installation. If scratches
matched pairs. The seal rings must be new. DO are present, hone and then clean the damaged
NOT mate a new ring with a used ring. DO NOT area.
install two used rings. Always install new O-rings
(toric rings). 4. Use clean, lint-free cloths and isopropyl alcohol
to remove all traces of oil, dust, protective
1. Prepare a completely clean work area to handle coating or other foreign matter from the metal
the large seal rings, O-rings and seal carriers. seal rings, the O-rings, the back plate and the
Absolute cleanliness is essential during the seal contact areas on all of the parts. Allow the
assembly process to prevent premature seal surfaces to dry completely.
failure and possible oil leaks.
NOTE: Oil from adjacent bearing installations or seal
NOTE: Use isopropyl alcohol in a spray bottle to ring face lubrication must not get on the ramp or toric
clean the parts prior to assembly. Use clean, lint-free until after both seal rings are together in their final
material such as Micro-Wipes # 05310 for cleaning assembled position.
and wiping. Do not use Stanosol or any other liquid
5. Place the O-rings on a clean flat surface.
that leaves an oily film or does not evaporate quickly.
Ensure that the O-rings are not twisted. Use a
2. Thoroughly clean the rubber O-rings with white paint pen to mark a continuous line or dots
isopropyl alcohol to remove the white powder every 38 mm (1.5 in.) on the O-rings (as shown
like coating and any other contaminants. Use in Figure 50-99) all the way around the
isopropyl alcohol to clean the seal contact circumference of the O-ring.
surfaces on housing ramp (4, Figure 50-98)
where the O-rings will be seated on the brake
housings and on the seal carriers. Also clean
the polished sealing surface on the seal rings.
72609
FIGURE 50-99. LOCATION OF WHITE LINE
1. White Marker 3. O-Ring
2. 45° Angle
50
6. Install O-rings (2, Figure 50-100) to seal rings

(1). After installation, check the O-rings for any
twisting with reference to the white line or dots,
or the flash line in the middle of the ring. Ensure
that the O-ring is straight and uniform all the
way around the seal ring, and that the O-ring is
seated against the retaining lip. Adjust the O-
ring as necessary.
1 2
72610
FIGURE 50-100. O-RING INSTALLATION
1. Seal Ring 2. O-Ring
51
7. Place installation tool onto the seal ring with the 8. With all surfaces of the toric ring wet, use the
toric ring. Lower the rings into a container of installation tool to position seal ring and toric
isopropyl alcohol until all surfaces of the toric ring squarely against the seal housing.Push on
ring are wet. the tool (NOT the seal ring) evenly during
installation until the O-ring is installed. The O-
ring should squeeze (or pop) into place below
the retaining lip before the installation tool
touches the housing.
NOTE: Each floating seal comes with its own unique

installation tool designed for leakage and damage
free installation of the seal. Use appropriate
installation tool.
ALTERNATE PROCEDURE: 9. After installing the floating seal assemblies,

check the O-ring for twisting. The white line or
After positioning the seal squarely over the retaining dots. should be visible around the entire
lip, thoroughly lubricate the ring by spraying it with tri- circumference of the O-ring as indicated by the
chloroethane #111. white dot in Figure 50-101. Adjust the O-ring if
DO NOT USE Stanosol or any other liquid that leaves necessary, but DO NOT push directly on the
an oily film or does not evaporate quickly. seal ring.
NOTE: Handle the seal ring carefully. Nicks and
scratches on the seal ring face can cause leaks.
72613
1
FIGURE 50-101. SEAL INSPECTION
1. White Dots
52
10. Use a gauge (Figure 50-102) to check the seal

height variation (marked by arrows, Figure 50-
104) between seal ring (2) and back plate (1).
Check the assembled height in four places that
are 90° apart. The height variation around the
assembled ring must be less than 1.0 mm (0.04
in).
If small adjustments are necessary, do not
push directly on the seal ring. Use the
installation tool to make any required
adjustments. The seal rings must be level as
shown in Figure 50-106.
FIGURE 50-102. CHECKING SEAL RING
The O-rings can twist during adjustments,

especially if there is a dry spot on the O-ring or if FIGURE 50-104. CHECKING SEAL HEIGHT
there are burrs or fins on the housing retaining
1. Back Plate 2. Seal Ring
lip. Verify that the O-rings are not twisted as
shown in Figure 50-103. A bulging O-ring or
crooked seal ring will lead to eventual failure.
NOTE: Toric ring must not slip on ramps of either seal
ring or housing. To prevent slippage, wait at least two
minutes. Let all solvent evaporate before further
assembly. Once correctly in place, the toric ring must
roll on the ramps only. If correct installation is not
obvious, repeat steps 1 through 10.
FIGURE 50-103. TWISTED O-RING
53
11. After both seal ring heights have been checked

and adjusted, wipe the polished seal ring
surfaces with a lint-free material and isopropyl
alcohol to remove all foreign material and
fingerprints.
FIGURE 50-105. CORRECT ASSEMBLY
No foreign particles of any kind are allowed on

the polished seal ring faces. Something as small
as a paper towel fiber will hold the seal faces
apart and could cause damage or leakage.
12. Apply a thin film of clean hydraulic oil (C-4 type
SAE 10W) on the polished seal faces on both
seal rings. Use a lint-free applicator or a clean
finger to distribute the oil evenly. Ensure that no
oil comes in contact with the rubber toric rings or
their mating surfaces.
13. During assembly, ensure that both housings are
square, concentric and in correct alignment as
FIGURE 50-106. CORRECT ALIGNMENT
shown in Figure 50-106. Move the parts slowly
and carefully toward each other. Do not slam,
bump or drop the seal rings together. High
impact can damage the seal ring face and
cause leakage.
54
55
Removal and installation of rear axle 6. Disconnect and unclamp all electrical
harnesses that are attached to the rear axle
Removal housing.
7. Disconnect and unclamp all automatic
lubrication system hoses that are attached to
the rear axle housing. Secure the hoses to the
frame to prevent interference during removal of
Hydraulic oil escaping under pressure can have the rear axle housing.
8. Remove the power cable grips at power cable
mount (1, Figure 50-107) on the right side of the
rear axle housing. Pull the power cables from
the rear axle housing.
hydraulic system.
2. Remove the dump body. Refer to Disassembly
and assembly section Body and structures.
3. Remove the rear suspensions. Refer to
Disassembly and assembly section
Suspensions.
4. Remove the anti-sway bar. Refer to "Removal
and installation of anti-sway bar". 1
86567
5. Remove the wheel motors. Refer to "Removal FIGURE 50-107. POWER CABLES
and installation of wheel motor".
1. Power Cable Mount
56
10. Install vacuum pump kit (XB0887) on the

hydraulic tank to prevent the loss of oil when
disconnecting hydraulic lines.
11. Disconnect and unclamp the hoses at hydraulic
hose manifold (1, Figure 50-108) and dual relay Use a lifting device with adequate capacity to
valve (2) on the left side of the rear axle remove and install the components.
housing. Cap the fittings and plug the hoses to
prevent contamination. Do not allow the lifting chains/slings to contact
the truck frame while hoisting the rear axle
housing. Pulling on the truck frame could cause
1 2 the truck frame to fall.
13. Attach one overhead hoist or crane to nose
cone lifting eye (1, Figure 50-109). Attach a
second overhead hoist or crane through rear
suspension mount lifting eyes (2) Lower the
nose cone and carefully move the rear axle
housing toward the rear of the truck.
86568
FIGURE 50-108. REAR BRAKE HOSES

1. Hydraulic Hose Manifold
2. Dual Relay Valve
12. Remove the pivot pin. Refer to "Removal and

installation of pivot pin".
2
2
86569
FIGURE 50-109. REAR AXLE HOUSING

LIFTING EYES
1. Nose Cone Lifting Eye
2. Rear Suspension Mount Lifting Eye
14. Lower the nose cone to the ground, then

remove the overhead hoist or crane. Use a fork
truck to move the rear axle housing away from
the truck.
57
Cleaning and inspection Installation

1. Thoroughly clean the capscrew holes and wheel 1. Use a fork truck to position the rear axle
motor mounting faces. Re-tap the holes if the housing under the truck frame.
threads are damaged.
2. Check the wheel motor mounting faces for
nicks, scratches and other damage. Inspect all
welds and repair them as necessary.
Use a lifting device with adequate capacity to
3. Inspect the pivot pin bearing. If it is worn or remove and install the components.
damaged, refer to "Pivot eye and bearing
service". Do not allow the lifting chains/slings to contact
4. Inspect the hoses inside the rear axle housing. the truck frame while hoisting the rear axle
Inspect the hose connections at the hydraulic housing. Pulling on the truck frame could cause
hose manifold and dual relay valve. Repair the truck frame to fall.
leaks or damaged hoses as required. 2. Attach one overhead hoist or crane to nose
5. Inspect the wheel motor power cables, cone lifting eye (1, Figure 50-109). Attach a
terminals, cable grips and clamps. Replace any second overhead hoist or crane through rear
cables or hardware that is worn or damaged. suspension mount lifting eyes (2) Raise the
nose cone and carefully move the rear axle
housing toward the rear of the truck.
3. Align the pivot pin bores and install the pivot pin.
Refer to Refer to "Removal and installation of
All propulsion system power cables must be pivot pin".
properly secured in their wood or other non- 4. Install the anti-sway bar. Refer to "Removal and
ferrous cable cleats. If any clamps are cracked or installation of anti-sway bar".
broken, replace them with new parts. Inspect the
cable insulation and replace the entire cable if the 5. Install the rear suspensions. Refer to
insulation is damaged. Disassembly and assembly section
Suspensions.
6. Connect and clamp all automatic lubrication
system hoses and electrical harnesses to the
rear axle housing.
7. Route the power cables through power cable
mount (1, Figure 50-107) on the right side of the
rear axle housing. Clamp them in place. Install
the cable grips at the power cable mount.
8. Connect and clamp the hoses at hydraulic hose
manifold (1, Figure 50-108) and dual relay valve
(2) on the left side of the rear axle housing.
9. Install the wheel motors. Refer to "Removal and
installation of wheel motor".
58
Removal and installation of anti-sway bar 5. Disconnect lubrication lines (1) from both ends
of the anti-sway bar.
Removal
1. Park truck on a hard, level surface and block all
the wheels.
2. Place the directional control lever in PARK and
turn the rest switch ON. Turn the key switch 1
OFF to shut down the engine and allow 90
to bleed down.
3. Position the frame and the rear axle housing to
allow use of a puller arrangement to remove the
pins.
4. Securely install support blocks (2, Figure 50-
110) between main frame (1) and rear axle
housing (3).
86461
FIGURE 50-111. ANTI-SWAY BAR BEARINGS

LUBRICATION LINES
1. Lubrication Lines
FIGURE 50-110. SUPPORT BLOCK
1. Main Frame 3. Rear Axle Housing

2. Support Block
59
8. Attach a puller and remove pin (2) from each

end of the anti-sway bar.
NOTE: The anti-sway bar mounting arrangement is
identical at each end.
remove and install the components. 9. Remove the anti-sway bar from the mounting
brackets.
6. Position a fork lift or attach an appropriate lifting
device to anti-sway bar (1, Figure 50-112). 10. Remove bearing spacers (6) and inspect for
damage and wear. Replace if necessary.
7. Remove locknut (5), flat washer (4) and
shoulder bolt (3) at each mount.
1 3
5
2
86462
FIGURE 50-112. ANTI-SWAY BAR REMOVAL & INSTALLATION

1. Anti-Sway Bar 4. Locknut
2. Shoulder Bolt 5. Pin
3. Flat Washer 6. Bearing Spacer
60
11. If necessary, remove retainer rings (1, Figure Installation

50-113) from the bores at both ends of the anti-
1. If removed, press new bearings (2, Figure 50-
sway bar and press out spherical bearings (2).
113) into the anti-sway bar and install retainer
12. If the bearings are removed, inspect the bearing rings (1). Ensure that the retainer rings are
bores of the anti-sway bar. If the bores are properly seated in the grooves.
damaged, repair or replace the anti-sway bar.
2. Install one bearing spacer (6, Figure 50-112).
3. Place pin (2) into position at the front of the
frame mount. Push the pin through the spacer.
1

4. Raise anti-sway bar (1) into position. Push pin
(2) through the spherical bearing. Insert the
second bearing spacer on the other side of the
pin bore, then continue pushing the pin into the
other mounting bore.
NOTE: The pin may need to be rotated to align the
hole for the shoulder bolt with the hole in the
mounting bracket.
1 5. Install shoulder bolt (3), flat washer (4) and
locknut (5). Tighten the locknut to 68 N·m (50 ft
86463
lb).
FIGURE 50-113. SPHERICAL BEARING 6. Repeat the steps 2 - 5 to install the remaining
REMOVAL & INSTALLATION pin and spacers at the opposite end of the bar.
Start the pin into the bore from the rear of the
1. Retainer Ring 2. Spherical Bearing frame mount.
7. Attach lubrication lines (1, Figure 50-111). Pump
grease into the bearing to verify that the line and
the automatic lubrication system are
operational.
8. Remove support blocks (2, Figure 50-110)
between main frame (1) and rear axle housing
(3).
9. If necessary, charge the suspensions. Refer to
Testing and adjusting section Accumulators
and suspensions for the proper charging
procedure.
61
Removal and installation of pivot pin 8. Place a jack under the pivot eye or attach a
crane to the lifting eye to control the downward
Removal movement of the front of the axle housing.
1. Park truck on a hard, level surface and block all 9. Disconnect pivot eye bearing lubrication line (1,
the wheels. Figure 50-115). Remove ground wire (2)
2. Place the directional control lever in PARK and between the pivot eye and the main frame.
to bleed down. 1
3. Ensure that the body is resting on the frame.
4. Charge the rear suspensions with nitrogen until
the pistons are fully extended. Refer to Testing
and adjusting section Accumulators and 2
suspensions for the proper charging
procedure.
5. Place blocks or jack stands under each frame
member beneath the hoist cylinders.
6. Release the nitrogen from the front
suspensions, then release the nitrogen from the 86473
rear suspensions.
FIGURE 50-115. TOP OF PIVOT EYE
7. Remove rear axle blower hose (1, Figure 50-
114) and the support bracket to allow access to 1. Lubrication Line 2. Ground Wire
pivot eye (2).
10. Remove three capscrews (1, Figure 50-116) and
lockwashers (2).
11. Remove seven 12-point capscrews (3) and pin
2 retainer (4).
86472
FIGURE 50-114. REAR AXLE BLOWER HOSE 2 1 86475
1. Rear Axle Blower Hose 2. Pivot Eye FIGURE 50-116. PIN RETAINER
1. Capscrew 3. 12-Point Capscrew
2. Lockwasher 4. Pin Retainer
62
12. Install a puller in tapped holes in the head of Installation

pivot pin (1). Pull out the pivot pin.
NOTE: It may be necessary to place a pry bar or jack
between the mounting structure and the pivot eye to
push the pivot eye downward and away from the
mounting structure. Both spacers (2) will fall free. Use a lifting device with adequate capacity to
1. Raise the pivot eye into position between the
frame bores. Ensure that the inner race of the
pivot eye bearing is aligned with the pin bore.
2. Install one bearing spacer (2, Figure 50-117).
2 3. Place pin (1) into position on the right side of the

frame mount. Push the pin through the spacer.
4. Push pin (1) through the pivot eye bearing.
Insert the second bearing spacer on the other
side of the pin bore, then continue pushing the
pin into the other mounting bore.
1 5. Install pin retainer (4, Figure 50-116) and 12-
point capscrews (3) on the end of the pivot pin.
6. Install capscrews (1) and lockwashers (2) to
secure the pivot pin.
86476
7. Tighten capscrews (1) to 237 N·m (175 ft lb).
FIGURE 50-117. PIVOT PIN REMOVAL & Tighten 12-point capscrews (3) to 2 325 N·m
INSTALLATION (1,715 ft lb).
1. Pivot Pin 2. Spacer 8. Install ground wire (2, Figure 50-115) between
the pivot eye and the main frame.
9. Connect pivot eye bearing lubrication line (1).
Pump grease into the bearing to verify that the
line and the automatic lubrication system are
operational.
10. Charge the front suspension. Refer to Testing
and adjusting section Accumulators and
procedure.
11. Charge the rear suspensions with nitrogen until
the pistons are fully extended. Refer to Testing
procedure.
12. Release the nitrogen from the rear suspension,
then charge them again.
63
Pivot eye and bearing service

Bearing replacement
1 3
1. Remove the pivot pin. Refer to the topic
"Removal and installation of pivot pin".
2. Remove 12-point capscrews (1, Figure 50-118)
5
and locknuts (2). There is a total of 16.
3. Remove bearing retainers (3).
4. Setup an appropriate tool to press spherical
bearing (4) from pivot eye (5).
5. Inspect all parts for excessive wear and 4
damage. Replace parts as required.
Spherical bearing O.D.:
281.66 - 281.70 mm (11.089 - 11.090 in.)
Spherical bearing I.D.:
177.77 - 177.80 mm (6.999 - 7.000 in.)
3
6. Set up an appropriate tool to press spherical 2

bearing (4) into pivot eye (5). Ensure that the
bearing is centered and properly installed in the 86478
pivot eye to allow proper lubrication. FIGURE 50-118. PIVOT EYE BEARING REMOVAL
7. Install bearing retainers (3), 12-point capscrews & INSTALLATION
(1) and locknuts (2). Tighten the capscrews to 1. 12-Point Capscrew 4. Spherical Bearing
the standard torque. 2. Locknut 5. Pivot Eye
3. Bearing Retainer
64
Pivot eye repair 5. Inspect the pivot eye bore for excessive wear
and damage. Replace the pivot eye if
necessary.
Pivot eye bore (new):
307.023 ± 0.013 mm (12.0875 ± 0.0005 in.)
6. Setup an appropriate tool to press bearing
1. Attach an appropriate lifting device to the lifting carrier (4) into the pivot eye bore.
eye on pivot eye (1, Figure 50-119).
NOTE: With parts of the correct size, the fit of the
2. Remove capscrews (2) and flat washers (3). bearing carrier into the pivot eye bore may be 0.025 -
Remove pivot eye (1) from the rear axle 0.080 mm (0.001 - 0.003 in.) interference fit. Freezing
housing. the bearing carrier will ease installation.
3. If installed, setup an appropriate tool to press
the spherical bearing from the pivot eye.
4. Setup an appropriate tool to press bearing
carrier (4) out of the pivot eye bore.
Bearing carrier I.D. (new): The lubrication groove in the outer diameter of
281.660 ± 0.013 mm (11.0889 ± 0.0005 in.) the bearing carrier must be aligned with the
lubrication fitting hole in the pivot eye.
Bearing carrier O.D. (new):
307.160 ± 0.013 mm (12.0929 ± 0.0005 in.) 7. Press bearing carrier (4) into the pivot eye bore.
Ensure that the bearing carrier is pressed fully
into the pivot eye bore and flush with the sides
to allow proper lubrication.
8. Press the spherical bearing into the pivot eye.
2 3 9. Ensure that the mating surfaces of the rear axle
housing and pivot eye (1) are clean and not
damaged.
4 10. Attach an appropriate lifting device to the lifting

eye on pivot eye (1). Lift the pivot eye into
position on the front of the rear axle housing.
Insert several capscrews (2) and flat washers
(3) to align the parts, then remove the lifting
device.
11. Install the remaining capscrews and flat
washers. Tighten the capscrews alternately until
the pivot eye is properly seated, then tighten the
capscrews to 3 078 ± 307 N·m (2,270 ± 227 ft
lb).
86458
FIGURE 50-119. PIVOT EYE REPAIR

1. Pivot Eye 3. Flat Washer
2. Capscrew 4. Bearing Carrier
65
Removal and installation of wheel motor Removal
Preparation NOTE: If suitable equipment is available to lift the

wheel motor assembly from the axle housing, it is not
Read and observe the following instructions before necessary to remove the dump body. The equipment
attempting any repairs on propulsion system used must be capable of lifting and supporting the
components. weight of the complete wheel motor assembly. It must
also be mobile and capable of aligning the wheel
motor with the axle housing mounting flange during
installation. If the wheel motor must be removed by
use of a crane or overhead hoist, refer to
Disassembly and assembly section Body and
• Do not step on or use any power cable as a structures, for dump body removal instructions.
hand hold when the engine is running.
1. Block up the truck and remove the rear wheels.
• All removal, repairs and installation of Refer to "Removal and installation of rear
propulsion system electrical components, wheel".
cables, etc, must be performed by an
electrical maintenance technician properly NOTE: Ensure that additional capscrews have been
trained to service the system. installed to provide support for the wheel motor
• In the event of a propulsion system transmission housing while the rear tires are
malfunction, a qualified technician should removed.
inspect the truck and verify that the 2. Install vacuum pump kit (XB0887) on the
propulsion system does not have dangerous
hydraulic tank to prevent the loss of oil when
voltage levels present before repairs are
started. disconnecting hydraulic lines.
3. Remove drain plug (2, Figure 50-120) at the
bottom of both rear brakes (1). Drain the oil from
the brakes into a suitable container.

hydraulic system. 1 2
86459
2. After the truck is parked for the repairs, the truck

FIGURE 50-120. REAR BRAKE DRAIN PLUG
must be shut down properly to ensure the safety
of those working in the area of the wheel 1. Rear Brake 2. Drain Plug
motors, control cabinet and retarding grids.
Ensure that the electrical system is properly
discharged before repairs are started.
66
4. Disconnect brake cooling hoses (1, Figure 50- 7. After all disconnected hydraulic lines have been
121) and brake apply hoses (2) from both of the plugged, turn off the vacuum pump.
rear brakes. Plug the hoses and ports.
8. Disconnect six wheel motor power cables (1,
5. Remove the clamps that secure the brake Figure 50-123) and wheel speed sensor
hoses to the brake ports. harnesses (2) from each wheel motor.
9. Tie up any cables and hoses as necessary to
prevent damage during wheel motor removal.
1
1 1
86460
FIGURE 50-121. REAR BRAKE HOSES

1. Brake Cooling Hose 2. Brake Apply Hose
6. Open the rear axle access hatch. Disconnect

and plug parking brake hoses (2, Figure 50-122)
from parking brake (1) on each wheel motor.
86525
FIGURE 50-123. WHEEL MOTOR POWER

1 CABLES
1. Wheel Motor Power Cables
2. Wheel Speed Sensor Harness
2 86524
FIGURE 50-122. PARKING BRAKE HOSES

1. Parking Brake 2. Parking Brake Hose
67
11. Remove 12-point capscrews (1, Figure 50-125)

and hardened flat washers (2) that secure the
wheel motor to the rear axle housing. There is a
total of 66 capscrews and flat washers per
Use lifting devices with adequate capacity to wheel motor assembly.
remove and install the components. 12. Move the wheel motor assembly out of the rear
axle housing. Be careful not to damage the
brake hoses and power cables.
When lifting the wheel motor assembly, do not

place lifting straps/cables on, or lift from, the
inner wheel rim adapter ring. Lifting straps/cables
should be placed so the weight of the wheel
motor assembly is supported by wheel motor
mounting flange (1, Figure 50-124) and machined
hub surface (2).
10. Attach a lifting device to the wheel motor
assembly. See Figure 50-124 for a typical
example.
1 2 86530
FIGURE 50-125. WHEEL MOTOR REMOVAL

1. 12-Point Capscrews
2. Hardened Flat Washers
1 2 86528
FIGURE 50-124. LIFTING THE WHEEL MOTOR

1. Wheel Motor 2. Machined Hub
Mounting Flange Surface
68

1. Thoroughly clean the threaded holes and the NOTE: Refer to the drive system manual for wheel
mounting faces of the rear axle housing and motor to transmission mating procedures.
wheel motor.
1. Apply a lithium based grease containing 3%
2. Inspect the capscrew holes in the rear axle molybdenum-disulphide to the threaded
housing for damage. Re-tap any holes that have capscrew holes in the rear axle housing.
damaged threads. Thoroughly clean any
capscrew holes that have been re-tapped. 2. Install two guide pins 180° apart (3 o’clock and
9 o’clock positions) in the rear axle housing.
3. Check the mounting faces of the rear axle
housing and the wheel motor for surface defects
(nicks, scratches, etc). Repair any defects
before installing the wheel motor.
4. Check the flatness of both mounting faces of the
rear axle housing. Check the flatness at four Use lifting devices with adequate capacity to
equally spaced intervals (for example, 0°, 45°, remove and install the components.
90° and 135°).
The maximum allowable variation in flatness is
2.29 mm (0.09 in.). Do not use a rear axle hous-
ing that does not meet this specification.
When lifting the wheel motor assembly, do not
5. Inspect the brake system relay valve and hoses place lifting straps/cables on, or lift from, the
inside the rear axle housing for leaks. Repair inner wheel rim adapter ring. Lifting straps/cables
leaks or damaged hoses as required. should be placed so the weight of the wheel
6. Inspect the wheel motor power cables, motor assembly is supported by wheel motor
terminals and clamps. Replace any cables or mounting flange (1, Figure 50-124) and machined
hardware that is worn or damaged. hub surface (2).
3. Attach a lifting device to the wheel motor
assembly. See Figure 50-124 for a typical
example.
Lift the wheel motor into position on the rear
All propulsion system power cables must be axle housing. Ensure that all cables and hoses
properly secured in their wood clamps or other are clear before installation.
non-ferrous cable cleats. If clamps are cracked or
If the brake system hoses are installed, guide
broken, replace them with new parts. If the cable
them through the holes in the wheel motor
insulation is damaged, replace the entire cable.
mounting flange during installation.
69
The wheel motors must be properly aligned High tightening force is required to install the
before installing them onto the rear axle housing. capscrews that secure the wheel motors to the
Two sets of dimples are located on each wheel rear axle housing. Repeated tightening will result
motor mounting flange at the 3 o’clock and 9 in capscrew fatigue and damage.
o’clock positions. The hole closest to the
identification plate on the motor side of the Do not reuse any wheel motor mounting
mounting flange is the 12 o’clock position of the hardware (capscrews and hardened washers).
wheel motor. Replace the hardware after one use.
The rear axle housing also has two sets of Do not retighten any wheel motor mounting
dimples next to the wheel motor mounting capscrew that has loosened after the truck has
surface at the 3 o’clock and 9 o’clock positions. been placed into operation. If any wheel motor
Refer to Figure 50-126. mounting capscrew has loosened during truck
operation, all of the capscrews and hardened
When installing the wheel motors, ensure that the washers must be replaced with new hardware.
dimples on both components are aligned, then
rotate each wheel motor slightly clockwise (while The capscrews that are used to secure the wheel
viewed from the outer end) to align the capscrew motors to the rear axle housing are specially
holes properly. hardened to meet or exceed grade 8
specifications. Replace these capscrews with
only new capscrews of the correct hardness.
Refer to the appropriate parts book for the
correct part number.
The use of dry threads in this application is not

recommended. Due to the high tightening force
that is required to install the wheel motor
mounting capscrews, dry threads may cause
damage to tools, capscrews or the rear axle
housing.
Komatsu does not recommend the use of special

friction-reducing lubricants, such as Copper
Coat, Never-Seez® or other similar products, on
the threads of standard fasteners where standard
torque values are applied. The use of special
1 2 friction-reducing lubricants will significantly alter
86531 the clamping force during the tightening process.
FIGURE 50-126. ALIGNING THE WHEEL MOTOR If a special friction-reducing lubricant is used,
excessive stress and possible breakage of the
1. Wheel Motor 2. Axle Housing
fasteners may result.
Alignment Dimples Alignment Dimples
70
4. Select the hardware to be installed in Group 1 of

the tightening sequence. Refer to Figure 50-
128.
Inspect each capscrew for rust, corrosion and
surface defects on any seat or thread. Do not
use any capscrew if a defect is suspected.
5. Lubricate the capscrew threads, capscrew head
seats and washer faces with a lithium based
grease containing 5% molybdenum disulphide.
NOTE: The special hardened washers that are used
in this application may have a punch lip on one side
due to the manufacturing process. When placing this
washer under the capscrew head, the washers must
be installed with the punch lip facing away from the
capscrew head to prevent damage to the fillet FIGURE 50-127. INSTALLING HARDENED
between the capscrew head and the shank. Refer to
Figure 50-127. 1. Washer 2. Capscrew
GROUP 2
8 CAPSCREWS
GROUP 6 GROUP 7
8 CAPSCREWS 8 CAPSCREWS
GROUP 4 GROUP 3
GROUP 8 GROUP 5
GROUP 1
8 CAPSCREWS
86302
FIGURE 50-128. WHEEL MOTOR MOUNTING HARDWARE INSTALLATION SEQUENCE
71
6. Install the hardware for Group 1. Tighten each

capscrew to 542 N·m (400 ft lb).
All propulsion system power cables must be

properly secured in their wood clamps or other
non-ferrous cable cleats. If clamps are cracked or
Install and tighten all of the hardware in a group
broken, replace them with new parts. If the cable
before proceeding to the next group in the
insulation is damaged, replace the entire cable.
tightening sequence. Remove the guide pins that
were installed in step 2 when installing the 14. Connect six power cables (1, Figure 50-123)
hardware for Groups 3 and 4. and wheel speed sensor harnesses (2) to their
appropriate locations.
7. Repeat steps 4 - 6 for each remaining group in
the tightening sequence. Refer to Figure 50- 15. After all hydraulic lines have been reconnected,
128. turn off the vacuum pump and remove the
vacuum pump from the hydraulic tank. Check
8. After all of the hardware in all of the groups has
for leaks from the hoses in the rear axle
been installed and tightened to 542 N·m (400 ft
housing.
lb), move back to Group 1. Increase the torque
on each capscrew in Group 1 to 4 040 N·m 16. Close the rear axle housing hatch.
(2,980 ft lb). Repeat this step for each
17. Check the oil level in each wheel motor. Rotate
remaining group in the tightening sequence.
one of the eight plugs to the 6 o’clock position
and remove the plug. The oil level should be
9. Install vacuum pump kit (XB0887) on the even with the bottom of the plug opening. Refer
hydraulic tank to prevent the loss of oil when to Figure 50-129. Fill the wheel motor with the
reconnecting hydraulic lines. recommended oil as necessary.
10. Connect brake apply hose (2, Figure 50-121)
and brake cooling hoses (1) to the each rear
brake assembly. Use new O-rings.
11. To prevent cooling air loss, use Uniseal® 310S
sealant or an equivalent sealant to seal the gap
around the brake cooling hoses where the
hoses pass through the mounting flange holes.
12. After both wheel motors are installed, open the
rear axle access hatch. Connect parking brake
hoses (2, Figure 50-122) to parking brake (1) on
each wheel motor.
13. Install the remaining hose clamps. If removed,
connect the nylon tube to the blower pressure
switch.
FIGURE 50-129. WHEEL MOTOR OIL LEVEL
72
18. Check the hydraulic tank oil level before and Removal and installation of rear brake
after engine start-up. Service the hydraulic tank assembly
oil as necessary. Refer to the appropriate GE service manual for the
19. Bleed the air from the brake apply lines. Refer to removal and installation procedures.
"Wet disc brake bleeding procedure" in Testing
NOTE: The rear wheel brake assembly weighs
and adjusting section Brake system.
approximately 2 031 kg (4,479 lb).
20. Check the hydraulic tank oil level after the brake
bleeding procedure. Service the hydraulic tank
oil as necessary.
21. Install the tires and rims. Refer to "Removal and
installation of rear wheel".
High tightening force is required to install the

capscrews that secure the wheel motors to the
rear axle housing. Repeated tightening will result
in capscrew fatigue and damage.
Do not retighten any wheel motor mounting

capscrew that has loosened after the truck has FIGURE 50-130. WHEEL MOTOR ASSEMBLY
been placed into operation. If any wheel motor
mounting capscrew has loosened during truck 1. Wheel Motor 3. Wheel Hub
operation, all of the capscrews and hardened 2. Brake Assembly 4. Transmission
washers must be replaced with new hardware.
73
980E Dump truck

74
CEN50023-00
DUMP TRUCK
980E

980E-5 A50005 and up

Brake system
Removal and installation of brake valve ............................................................................................................... 3
Disassembly and assembly of brake valve ........................................................................................................... 5
Removal and installation of dual relay valve ......................................................................................................... 8
Removal and installation of brake manifold ........................................................................................................ 10
Disassembly and assembly of brake manifold.....................................................................................................11
Removal and installation of piston brake accumulator........................................................................................ 13
Disassembly and assembly of piston brake accumulator ................................................................................... 15
Disassembly and assembly of front wheel brake................................................................................................ 19
Disassembly and assembly of rear wheel brake................................................................................................. 25
Brake floating ring seal assembly and installation .............................................................................................. 33
Removal and installation of parking brake .......................................................................................................... 40
Disassembly and assembly of parking brake...................................................................................................... 42
1
NOTES
2
Removal and installation of brake valve 3. Clean brake valve (2, Figure 50-2) and the
surrounding area to help avoid contaminating
Removal the hydraulic oil when the hoses are
NOTE: If the brake valve is to be removed from the disconnected.
truck, additional equipment will be required as NOTE: Before disconnecting hydraulic hoses, tag the
outlined in the disassembly and assembly hoses for proper identification during installation. See
procedures. Minor repairs and service adjustment Figure 50-4.
may not require the removal of the brake valve.
4. Disconnect and plug six hydraulic hoses (1)
from the brake valve.

sufficient force to enter a person's body by 2
hydraulic lines. Tighten all connections securely 1
87546
hydraulic system.
2. Remove front access cover (1, Figure 50-1) FIGURE 50-2. BRAKE VALVE REMOVAL &
from the operator cab. INSTALLATION
1. Hydraulic Hoses 2. Brake Valve
1
87545
FIGURE 50-1. ACCESSING THE BRAKE VALVE

1. Front Access Cover
3
5. Disconnect the retarder pedal harness from the Installation

truck harness.
1. Slide brake valve/pedal assembly (3, Figure 50-
6. Remove capscrews (1, Figure 50-3) and 3) into position in the cab and secure it with
lockwashers (2) that secure brake valve/pedal capscrews (1) and lockwashers (2). Tighten the
assembly (3) to the cab. capscrews to the standard torque.
7. Slide the brake valve/pedal assembly through 2. Unplug and connect six hydraulic hoses (1,
the hole and remove it from the cab. Move the Figure 50-2) to their proper ports on brake valve
brake valve/pedal assembly to a clean work (2). Refer to Figure 50-4.
area for disassembly, if required.
P2 P1
3
B2 B1
2 1
T
PX
86388
87547
FIGURE 50-3. BRAKE VALVE REMOVAL & FIGURE 50-4. BRAKE VALVE PORT
INSTALLATION IDENTIFICATION
1. Capscrews 3. Brake Valve/
2. Lockwashers Pedal Assembly “P1” - Pressure Inlet “B2” - Regulated Output
“P2” - Pressure Inlet “T” - Return to Tank
“B1” - Regulated Output “PX” - Pilot Inlet
4
3. Connect the retarder pedal harness to the truck Disassembly and assembly of brake
harness. valve
4. With the engine off and the key switch OFF,
Disassembly
open both brake accumulator bleed down
valves (1, Figure 50-5) on brake manifold (2). 1. Remove electronic retarder pedal (1, Figure 50-
Precharge both brake accumulators. Refer to 6) from the brake pedal by removing two
Testing and adjusting section Accumulators retaining clips and pivot shaft (2).
and suspensions for the accumulator charging 2. Remove hose fittings (7) from the brake valve
procedure. ports. Rotate the brake valve over a suitable
5. Close both accumulator bleed down valves after container and allow the oil to drain.
the accumulators have been properly charged.
8
2
9
1. Brake Accumulator Bleed Valves 4 8
2. Brake Manifold
5
6. Before checking the brake valve operation, the

steering accumulators must have the proper
nitrogen precharge. Refer to Testing and
suspensions for the accumulator charging 6
procedure.
7. Bleed the air from the brakes and brake lines. 7
Refer to "Wet disc brake bleeding procedure" in
Testing and adjusting section Brake system.
8. Check for oil leaks at the brake valve.
86389
9. Install front access cover (1, Figure 50-1) on the
operator cab. FIGURE 50-6. BRAKE VALVE/PEDAL
ASSEMBLY
NOTE: When installing the front access cover, ensure
that the bottom false hinge of the cover is engaging 1. Retarder Pedal 6. Brake Valve
into the bottom edge of the sheet metal panel of the 2. Pivot Shaft 7. Hose Fittings
cab front enclosure. 3. Brake Pedal Actuator 8. Spring Pivot
4. Retainer Clip 9. Spring
5. Pivot Shaft
5
NOTE: During disassembly, precision machined parts Assembly

should be ink marked or tagged to ensure proper
1. Inspect threaded inserts (7, Figure 50-7) in
reassembly and minimize adjustment time. All items
actuator base (6). If any of the threads are
must be placed back into the bores from which they
damaged, the inserts must be replaced.
were removed.
2. If any threaded inserts (7) were removed from
3. Match mark each section of the brake valve
actuator base (6), position the actuator base
Place the brake valve in an upright position and
upside down on the work bench and support it
secure it in a vice.
directly under each of the four mounting holes.
4. Remove spring pivots (8) and spring (9).
3. Install the threaded inserts into the actuator
5. To remove brake pedal actuator (3), remove two base by tapping lightly with a small hammer until
retainer clips (4), then use a punch and hammer the insert flanges become flush with the
to drive out pivot shaft (5). actuator base. To avoid breaking the base,
6. Remove four button head screws (3, Figure 50- make sure that the base is supported.
7) that secure retainer plate (4). 4. Thoroughly clean the actuator base and set it
7. Remove retainer plate (4), boot (2) and actuator aside.
cap (1) as an assembly by grasping the boot 5. Examine boot (2) for any cracks, tears, or other
and gently lifting it from the valve body. damage. If damage is evident, the boot must be
replaced.
6. If damaged, remove the boot from actuator cap
(1) and discard the old boot. Thoroughly clean
the sides of the cap by using a knife or suitable
scraper to scrape the lip where the cap contacts
the boot. Clean the cap thoroughly to remove all
adhesive or particles of the old boot.
7. Apply a thin bead of Loctite® Prism 410 onto the
upper sides of the cap. Apply the bead to the
two long sides only. Do not apply it to the
rounded ends. The rounded ends must not be
sealed to allow the boot to “breathe”.
8. Carefully position the cap into the new boot
groove. Wipe off any excess glue.
9. Position the boot so that it conforms to the
contour of the cap, then set it aside. The
adhesive requires about 30 minutes to cure.
10. Once the adhesive has cured, install actuator
base (6, Figure 50-7) on top of the valve body.
Position the actuator base properly for correct
port direction. Install and tighten two socket
head capscrews (5) to 20 - 21 N·m (180 - 190 in
lb).
FIGURE 50-7. ACTUATOR CAP & BOOT
11. Ensure that jam nut (2, Figure 50-9) and
1. Actuator Cap 5. Capscrew adjustment screw (1) are installed in the brake
2. Boot 6. Actuator Base pedal actuator.
3. Allen Screw 7. Threaded Insert
4. Retainer Plate
6
12. Install one retainer clip (7, Figure 50-8) to one

end of pivot shaft (4). Ensure that nylon
bushings (5) are installed in both shaft bores of
the brake pedal actuator.
13. Align the shaft bores of the brake pedal actuator
and the brake valve actuator base, then partially
insert pivot shaft (4). Move the brake pedal
actuator to the “B2” side of the brake valve and
insert shims (6) between the mounting ears to
fill the gap. Fully insert the pivot shaft, then
install remaining retainer clip (7).
2 1 2
3 3 3
6
4
5 5 5
6 6 3
1 2
7 7
86390
FIGURE 50-8. BRAKE VALVE/PEDAL

ASSEMBLY PIVOT SHAFTS
1. Pivot Shaft 5. Nylon Bushing 86390
2. Retaining Clip 6. Shims FIGURE 50-9. BRAKE VALVE/PEDAL

3. Nylon Bushing 7. Retainer Clip ASSEMBLY
4. Pivot Shaft
1. Adjustment Screw 4. Spring
2. Jam Nut 5. Jam Nut
3. Spring Pivot 6. Adjustment Screw
7
14. Inspect spring pivots (3, Figure 50-9) for wear. If Removal and installation of dual relay
any wear is evident, replace the spring pivots. valve
15. Assemble spring (4) and both spring pivots (3) Removal
onto the brake pedal.

Install the spring assembly so that the larger ball sufficient force to enter a person's body by
socket end is toward the brake pedal and the penetrating the skin and cause serious injury,
smaller end is toward the brake valve. and possibly death, if proper medical treatment is
NOTE: When the pedal is adjusted properly, the
spring assembly will not interfere with pedal travel. Relieve pressure before disconnecting any
16. Install nylon bearings (3, Figure 50-8) in the
shaft bores of the retarder pedal.
17. Align the shaft bores of the brake pedal actuator
and the retarder pedal, then insert pivot shaft Refer to the "Hydraulic system bleeddown
(1). Install two retainer clips (2). procedure" in Testing and adjusting section Steering,
18. Loosen jam nut (5, Figure 50-9) and turn hoist, brake cooling and auxiliary hydraulic
adjustment screw (6) until the roller on the system.
retarder pedal just contacts the brake pedal
actuator. Tighten jam nut (5).
19. Bench test the brake valve. Refer to Testing and
adjusting section Brake system for the test
procedure.
8
Front brake circuit 1 Rear brake circuit 1

1. Tag and remove all hydraulic lines from dual 1. Remove protective cover (1, Figure 50-11) from
relay valve (1, Figure 50-10). Plug all lines and the left side of the rear axle housing.
ports to prevent possible contamination. 2. Tag and remove all hydraulic lines from dual
2. Remove two capscrews and washers that relay valve (2). Plug all lines and ports to
secure the valve to the rear wall of the hydraulic prevent possible contamination.
brake cabinet. Remove the valve and move it to 3. Remove two capscrews and washers that
a clean work area for disassembly. secure the relay valve to the mounting bracket.
Remove the relay valve and move it to a clean
work area for disassembly.
1 2
1 86392
FIGURE 50-11. REAR DUAL RELAY VALVE

87548
1. Protective Cover 2. Dual Relay Valve
FIGURE 50-10. FRONT DUAL RELAY VALVE
1. Dual Relay Valve
9
Installation Removal and installation of brake

manifold
Front brake circuit 1
1. Install dual relay valve (1, Figure 50-10) in the Removal
hydraulic brake cabinet. Install the two mounting
capscrews and lockwashers to secure the relay NOTE: If the brake manifold is leaking oil, an O-ring
valve. Tighten the capscrews to the standard or cartridge can be replaced without removing the
torque. manifold from the truck. Refer to "Disassembly and
assembly of brake manifold".
2. Unplug all hoses and fittings and attach the
hoses to the proper valve ports. See Figure 50-
12.
3. Start the engine and check for leaks and proper
brake operation. Shut off the engine.
Rear brake circuit 1 sufficient force to enter a person's body by
1. Install dual relay valve (2, Figure 50-11) on the penetrating the skin and cause serious injury,
mounting bracket on the rear axle housing. and possibly death, if proper medical treatment is
Install the two mounting capscrews and not received immediately.
lockwashers to secure the relay valve. Tighten
the capscrews to the standard torque. Relieve pressure before disconnecting any
2. Unplug all hoses and fittings and attach the
hoses to the proper valve ports. See Figure 50-
12. 1. Refer to the "Hydraulic system bleeddown
3. Start the engine and check for leaks and proper procedure" in Testing and adjusting section
brake operation. Shut off the engine. Steering, hoist, brake cooling and auxiliary
hydraulic system.
4. Install protective cover (1) and the mounting
hardware. Tighten the four capscrews to the 2. Close all accumulator bleed valves by rotating
standard torque. them clockwise.
3. Disconnect and tag all hydraulic lines from the
brake manifold. Plug all hydraulic lines and
ports to prevent possible contamination.
4. Disconnect and tag all electrical wiring from the
brake manifold components.
5. Remove mounting hardware (1, Figure 50-13)
from the bottom of the hydraulic brake cabinet
and move the brake manifold to a clean work
area for disassembly.
1
2
86446
FIGURE 50-12. DUAL RELAY VALVE PORTS
1. Return to Tank 3. B1 Pressure

2. P1 Pressure Inlet 4. B2 Pressure
10
Disassembly and assembly of brake

manifold
Disassembly
1. Mark all plugs, valves and cartridges before
removal to ensure proper assembly.
2. Remove the plugs, valves and cartridges as
needed.
NOTE: Check valve (4, Figure 50-14) and reducing
valve (5) both have an orifice disc located below
them. The two orifices are different sizes. Therefore,
it is very important to properly match each orifice with
the correct installation location.
3. Clean all parts with an approved cleaning
solution.
1
86393 4. Blow all parts dry with pressure air and protect
them from dust and any foreign matter until
FIGURE 50-13. BRAKE MANIFOLD REMOVAL
installation.
& INSTALLATION
5. Replace all O-rings and any other items that are
1. Brake Manifold Mounting Hardware deemed unsuitable for further usage.
Installation 7 11 10 9 8
1. Place the brake manifold into position in the
hydraulic brake cabinet. Install and tighten 7 6
mounting hardware (1, Figure 50-13) to the
standard torque.
2. Remove all plugs and connect all lines and
electrical wiring to the proper locations.
3. Start the engine. Check for leaks and for proper
operation.
4. Shut off the engine and ensure that the
hydraulic tank is filled to the proper level.
5
1 2 3 4 86394

COMPONENTS
1. Automatic Apply Sequence Valve
2. Parking Brake Solenoid Valve
3. Brake Lock Solenoid Valve
4. Check Valve (with Orifice Disc)
5. Pressure Reducing Valve (with Orifice Disc)
6. Parking Brake Release Pressure Switch
7. Check Valve
8. Parking Brake Apply Pressure Switch
9. Low Brake Pressure Switch
10. Hot Oil Cartridge
11. Load Shuttle Cartridge
11
Assembly
1. Install new O-rings on all components that were
removed from the manifold.
2. Coat all bores, cartridges and O-rings with clean
hydraulic oil.
NOTE: Do not overtighten any cartridges or
solenoids. Damage to the cartridge may occur.
3. When installing parking brake solenoid valve (2,
Figure 50-14) and brake lock solenoid valve (3)
into the brake manifold, tighten the cartridges to
34 - 36 N·m (24 - 26 ft lb). Tighten the solenoid
nut to 7 - 9 N·m (5 - 7 ft lb).
4. Before installing check valve (4) or reducing
valve (5), refer to Figure 50-15 for proper orifice
disc installation. The orifice discs must be
installed in the direction shown for proper
operation.
• Check valve orifice - 1.58 mm (0.062 in.)
• Reducing valve orifice - 2.54 mm (0.100 in.)
5. Install all remaining components in the correct
bores (see Figure 50-14). Tighten each FIGURE 50-15. ORIFICE INSTALLATION
cartridge to 34 - 36 N·m (24 - 26 ft lb).
1. Cartridge 3. Cavity
2. Brake Manifold 4. Orifice Disc
12
Removal and installation of piston brake

accumulator
1
Removal
2
and possibly death, if proper medical treatment is 3
hydraulic system.
2. Remove valve cover (1, Figure 50-16) and
spacer (2). 86395
FIGURE 50-16. TOP OF PISTON

ACCUMULATOR
1. Valve Cover 3. Charging Valve
2. Spacer
Wear a face mask or goggles. Make sure that only
valve assembly may result in the valve assembly
being ejected from the accumulator by the gas 1
pressure inside.
3. Discharge the nitrogen pressure from the piston
accumulator as follows:
a. Remove valve cap (1, Figure 50-17) from the 2
charging valve.
b. Hold valve body (3) with one wrench, then
turn swivel nut (2) counterclockwise three
turns with a second wrench. Do not turn the 3
swivel nut more than three turns. Do not
turn the charging valve body.
84483
c. Connect the nitrogen charging kit to the
charging valve. Refer to Testing and FIGURE 50-17. PISTON ACCUMULATOR
adjusting section Accumulators and CHARGING VALVE
suspensions for the charging kit installation
information. 1. Valve Cap 3. Valve Body
(Small Hex Nut)
13
4. Disconnect hydraulic hose (1, Figure 50-18)

from the flange at the bottom of accumulator (3).
Plug the hose and the accumulator port.
3
5. Attach a lifting device to the top of the
accumulator and take up slack.
6. Remove clamps (2) that secure the accumulator
to the frame mounting bracket. 2
7. Lift accumulator (3) from the lower mounting
bracket. Move the accumulator to a clean work
area.
86396
FIGURE 50-18. PISTON ACCUMULATOR

1. Hydraulic Hose 3. Accumulator
2. Clamp
14
Installation Disassembly and assembly of piston

1. New or rebuilt piston accumulators should have brake accumulator
1.4 L (48 oz) of oil in the gas end to prevent Disassembly
rusting of the accumulator walls and to provide
for piston seal lubrication.
If the accumulator does not have oil in the gas
end, remove charging valve (3, Figure 50-16)
and add 1.4 L (48 oz) of clean C-4 hydraulic oil
to the gas end of the accumulator. This provides Wear a face mask or goggles. Make sure that only
enough oil above the top of the piston for seal the swivel nut turns. Turning the entire charging
lubrication. valve assembly may result in the valve assembly
being ejected from the accumulator by the gas
pressure inside.
1. Before disassembly, ensure that all pressure
has been discharged from the piston
Use a lifting device with adequate capacity to accumulator as follows:
remove and install the components. a. Remove valve cap (1, Figure 50-19) from the
2. Keep the accumulator upright and attach a lift- charging valve.
ing device to the top of the accumulator. Ensure b. Hold valve body (3) with one wrench, then
that the base ring is installed in the lower mount- turn swivel nut (2) counterclockwise three
ing bracket, then lift accumulator (3, Figure 50- turns with a second wrench. Do not turn the
18) into position in the lower mounting bracket. swivel nut more than three turns. Do not
3. Install clamps (2) and the hardware that secure turn the charging valve body.
the accumulator to the frame mounting bracket. c. Connect the nitrogen charging kit to the
Tighten the capscrews to the standard torque. charging valve. Refer to Testing and
4. Remove the plugs from the hose and accumula- adjusting section Accumulators and
tor port. Install a new O-ring in the flange, then suspensions for the charging kit installation
connect hydraulic hose (1) at the bottom of the information.
accumulator. 2. Loosen valve body (3) to remove the charging
5. Precharge the piston accumulator. Refer to valve from the top of the accumulator.
"Piston accumulator charging procedure" in
and suspensions. 1
84483
CHARGING VALVE
(Small Hex Nut)
15
3. Remove the hose fitting, flange (1, Figure 5-20) 4. Secure the accumulator horizontally in a chain
and plugs (2) from the bottom of the piston vise.
accumulator. 5. Install two lifting eyes or long capscrews in two
of the three 5/8" - 11UNC lifting holes in the end
cap.
2 6. Use a bar to turn the end cap counterclockwise.
Remove the end cap.
7. Repeat steps 5 and 6 for the other end cap.
1
3
2
2 84480
FIGURE 50-20. BOTTOM OF PISTON

ACCUMULATOR
1. Flange 2. Plug
84479
FIGURE 50-21. REMOVING THE END CAP

1. Capscrew 3. End Cap
2. Bar
16
8. Use a long dowel (wood, plastic or padded) or Cleaning and inspection

push rod (XA6348) to carefully tap piston (1,
1. Check the seals on the piston and end caps for
Figure 5-22) out of the accumulator housing. Be
cuts, score marks and other damage. If there
careful not to damage the piston or seals on the
are excessive cuts on the seals, perform a
end cap threads.
thorough examination of the metal surfaces for
NOTE: Never use pressurized air to remove the damage.
piston. 2. Clean the piston and housing bore. Use a
cleaning solvent and dry them with a soft, clean
towel or rag.
3. Inspect the piston and housing bore for foreign
1 material, scratches and other damage. Replace
the piston if damaged. Scratches on the housing
bore must be removed to ensure optimal service
life of the seals.
Repair of the housing by welding, machining or

plating to salvage a worn area is NOT
APPROVED. These procedures may weaken the
housing and result in serious injury to personnel
when pressurized.
2
84481
FIGURE 50-22. PISTON REMOVAL (TYPICAL)

1. Piston 2. End Cap
17
Piston seal replacement Assembly

NOTE: Replace all seals when the accumulator is NOTE: Assemble the accumulator in a dust and lint
completely disassembled. free area. Maintain complete cleanliness during
1. Apply clean hydraulic oil to the seals, piston assembly to prevent possible contamination.
lands and grooves. 1. Secure the accumulator horizontally in a vise,
2. Assemble the seals into the appropriate piston preferably a chain vise.
grooves. Start with seal (5, Figure 50-23), then 2. Carefully insert piston assembly (2, Figure 50-
move outward to seals (2) to reduce the risk of 24) into the accumulator housing bore. Avoid
seal damage. Ensure that seals (2) and (5) are cocking to prevent damaging the piston and/or
not folded or twisted. seals on the end cap threads. If necessary, tap
3. Insert backup rings (3) and (4) carefully so as the piston lightly with a soft hammer. Be careful
not to stretch any more than necessary. Ensure not to pinch the backup rings.
that the backup ring gaps are offset from one NOTE: Assembly sleeve (1) may be used to help
another as they are installed and not aligned on install and prevent damage to the piston assembly.
one side of the piston.
1 2
1
4
84482
5 FIGURE 50-24. PISTON ASSEMBLY
1. Assembly Sleeve 2. Piston Assembly

4 (XA6349)
1
85209
FIGURE 50-23. PISTON REPLACEMENT SEALS

1. Piston Bearing 4. Backup Ring (thin)
2. Piston Seal - “U” 5. Piston Seal - “T”
3. Backup Ring (thick)
18
3. Assemble the backup ring and O-ring into the Disassembly and assembly of front
end cap groove. The backup ring must be wheel brake
toward the threaded side or outside of the end
cap. Apply a light coat of grease to the threads Disassembly
and O-ring of the end cap.
NOTE: Check the face of piston and tube for any
contamination before installing the end caps.
4. Secure the accumulator horizontally in a chain Disassemble and reassemble the brake assembly
vise. on a clean, dry work surface. The work surface
should be wooden. If the work surface is metal or
5. Install two lifting eyes or long capscrews in two
concrete, use padding to prevent damage to
of the three 5/8" - 11UNC lifting holes in the end
machined surfaces. Handle all parts carefully to
cap.
avoid damage to polished sealing surfaces.
6. Use a bar to tighten the end cap clockwise to a
torque of 300 N·m (221 ft lb).
After the end cap is tightened, the end cap
should be flush ± 1.5 mm (± 0.06 in) with the
end of the accumulator housing.
7. Repeat steps 5 and 6 for the other end cap. remove and install the components.
8. Remove the screws from both end caps. Clean
1. Remove the brake assembly from the truck.
the excess lubricant from the end cap areas at
Refer to the Disassembly and assembly section
both ends of the accumulator.
Wheels, spindles and rear axle.
9. Install plugs (2, Figure 5-20) in the oil end cap.
2. Ring gear retainer bars (1, Figure 50-25) must
Also install a plug in place of flange (1) and the
be installed to retain the inner gear inside the
hose fitting.
brake assembly.
10. Before closing up the ports, add 1.4 L (48 oz) of 3. Position the brake assembly on a work surface
oil to the gas end. so that the ring gear retainer bars are on the
11. Install the charging valve with a new O-ring. bottom as shown in Figure 50-26.
Tighten valve body (3, Figure 5-19) to 22 N·m
(16 ft lb).
12. Test the accumulator for leaks. Refer to "Piston 1
accumulator leak testing" in Testing and
suspensions.
1
86415

ON BRAKE ASSEMBLY
19
4. Match mark the brake assembly across the 6. Remove capscrews (2, Figure 50-27) and
back plate, outer ring gear and piston housing to hardened flat washers (3) from back plate (1).
ensure proper orientation during assembly. 7. Insert 3/4” - 10UNC x 2” pusher bolts (4) in each
5. Remove four capscrews (1, Figure 50-26) and of the three tapped holes in the back plate.
flat washers (2). Lift catchment tank (3) from the Tighten the bolts evenly to lift the back plate
brake assembly and remove adapter (4). from outer ring gear (6).
8. Remove and discard O-ring (5).
2 1 3
4 3 2 1 4
86416
FIGURE 50-26. CATCHMENT TANK REMOVAL &

INSTALLATION 5
1. Capscrew 3. Catchment Tank
2. Flat Washer 4. Adapter
6 86404
FIGURE 50-27. BACK PLATE REMOVAL &

INSTALLATION
1. Back Plate 4. Pusher Bolt
2. Capscrew (12 Pt.) 5. O-ring
3. Hardened Flat Washer 6. Outer Ring Gear
20
NOTE: Note the order of the discs, plates and 10. Turn over the brake assembly to position ring
dampers as they are removed from the brake pack. gear retainer bars (1, Figure 50-29) on top as
9. Remove damper (2, Figure 50-28) from the top shown.
of brake pack (1). Remove friction discs (3), 11. Remove capscrews and flat washers (2) that
separator plates (4), and the remaining damper attach the retainer bars to the piston housing.
at the bottom of brake pack (1).
12. Attach a lifting strap through ring gear retainer
bars (1), then lift inner gear (5) out of outer ring
gear (6).
2 13. Remove capscrews and lockwashers (3) that
attach the retainer bars to inner gear (5).
Remove retainer bars (1) and spacers (4).
3
1 3 4 2
4
1
86405
FIGURE 50-28. BRAKE PACK REMOVAL &

INSTALLATION 6 86417
1. Brake Pack 3. Friction Disc FIGURE 50-29. INNER GEAR REMOVAL &
2. Damper 4. Separator Plate INSTALLATION
1. Ring Gear Retainer Bars 4. Spacer
2. Capscrew & Flat Washer 5. Inner Gear
3. Capscrew & Lockwasher 6. Outer Ring Gear
21
14. Remove capscrews (1, Figure 50-30) and 16. Turn over the piston assembly so that the piston
hardened flat washers (2) from piston assembly retract springs are on top as shown.
(4).
17. Apply a small amount of heat to the piston
15. Insert 7/8” - 9NC x 2” pusher bolts (3) in each of housing. Remove capscrews (1, Figure 50-31),
the three tapped holes in the piston housing. spring guides (2), and piston retract springs (3).
Tighten the bolts evenly to lift the piston
NOTE: The capscrew threads are coated with
assembly from outer ring gear (6). Remove and
Loctite® during assembly. A small amount of heat is
discard O-ring (5).
required for removal.
18. Carefully lift piston (4) out of piston housing (7).
Remove seal assemblies (5) and (6) from the
1 2 3 3 3 piston.
4 3
5 5
6
7
6 86418
FIGURE 50-30. PISTON ASSEMBLY

1. Capscrew (12 Pt.) 4. Piston Assembly 86419
2. Hardened Flat Washer 5. O-ring

FIGURE 50-31. PISTON REMOVAL &
3. Pusher Bolt 6. Outer Ring Gear
INSTALLATION
1. Capscrew 5. Seal Assembly
2. Spring Guide 6. Seal Assembly
3. Piston Retract Spring 7. Piston Housing
4. Piston
22
Cleaning and inspection 6. Inspect separator plates (4, Figure 50-28) for
warping and tooth wear.
Disc thickness (new):

. . . . . . . . . . . . 3.7 ± 0.1 mm (0.146 ± 0.004 in.)
Flatness (new): . . . . . . .0.5 mm (0.020 in.)
If the brake wear indicator test indicates that
internal brake components are worn to the 7. Inspect dampers (2, Figure 50-28) for warping,
maximum allowable limit, all friction discs, tooth wear and excessive facing material wear.
separator plates and dampers must be replaced
with new parts. Always replace seal assemblies Disc thickness including facing material:
and O-rings with new parts. . . . . . . . . . . . . 6.9 ± 0.5 mm (0.272 ± 0.020 in.)
Disc thickness, steel plate only (new):
1. Clean all parts thoroughly before inspection.
. . . . . . . . . . . . 3.7 ± 0.1 mm (0.146 ± 0.004 in.)
2. Inspect piston housing (7, Figure 50-31) for
Flatness, steel plate (new):
nicks and scratches in the piston seal area. If
. . . . . . . . . . . . . . . . . . . . . . .0.5 mm (0.020 in.)
any nicks or scratches cannot be removed by
polishing, replace the piston housing. 8. Inspect outer ring gear (6, Figure 50-30) for
3. Inspect the piston seal assembly grooves for excessive tooth wear and for nicks and
damage. scratches in the O-ring seal grooves.
4. Inspect piston retract springs (3, Figure 50-31). 9. Inspect inner gear (5, Figure 50-29) for
Check the free height and test for height under excessive tooth wear and damage at the
load. Replace the springs if they are not within capscrew holes.
approximately 10% of specification.
Free Height:. . . . . . . . . 88.9 mm (3.50 in.)
Height at 1 290 N (290 lb) working load:
. . . . . . . . . . . . . . . . . . . . 74.60 mm (2.937 in.)
Height at 2 936 N (660 lb) working load:
. . . . . . . . . . . . . . . . . . . . 56.46 mm (2.223 in.)
5. Inspect friction discs (3, Figure 50-28) for

warping, tooth wear, and excessive friction
material wear. Replace the friction discs if wear
exceeds the minimum allowable groove depth.
Disc thickness including friction material:

. . . . . . . . . . . . . 7.7 ± 0.3 mm (0.30 ± 0.01 in.)
Friction material thickness (new):
. . . . . . . . . . . . . . . . . . . . . . . 1.1 mm (0.04 in.)
Nominal friction material groove depth:
. . . . . . . . . . . . . . . . . . . . 0.63 mm (0.025 in.)
Minimum allowable friction material groove
depth: . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Flatness over friction material (new):
. . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.018 in.)
23
Assembly 7. Assemble twelve capscrews (1), spring guides

(2) and retract springs (3). Apply Loctite® 271 to
the capscrew threads and install the assembled
parts through the piston and into the tapped
holes in the piston housing. Tighten the
Disassemble and reassemble the brake assembly capscrews to 122 N·m (90 ft lb).
on a clean, dry work surface. The work surface 8. Install any missing plugs in the piston housing,
should be wooden. If the work surface is metal or then test the piston for leakage. For instructions,
concrete, use padding to prevent damage to refer to "Brake piston leakage test" in Testing
machined surfaces. Handle all parts carefully to and adjusting section Brake system.
9. After completing the piston leakage test, release
the pressure, remove the hydraulic pressure
test device, and drain the oil from the piston
apply cavity. Plug the ports to prevent
contamination.
Use a lifting device with adequate capacity to 10. Install O-ring (5, Figure 50-30) in the groove of
remove and install the components. outer ring gear (6).
1. Position piston housing (7, Figure 50-31) on a 11. Attach lifting eyes to the piston assembly and
clean work surface with the bore facing upward. lower it into position over outer ring gear (6).
2. Lubricate the square O-ring portion of piston Ensure that the piston assembly is oriented
seal assemblies (5) and (6) with clean hydraulic properly according to the match marks that were
oil and install the seals in the grooves in piston made during disassembly. Install capscrews (1)
(4). Ensure that the seal assemblies are not and hardened flat washers (2). Alternately
twisted. tighten the capscrews to 1 166 N·m (860 ft lb).
NOTE: It is recommended that the seals be heated to 12. Install retainer bars (1, Figure 50-29), spacers
80-100°C (176-212°F) before installation by using hot (4), capscrews and lockwashers (3) to inner
oil, hot air or hot water. This allows for easier seal gear (5). Attach a lifting strap through the
installation without stretching the seals. retainer bars, then lift the inner gear into the
piston assembly.
3. Lubricate the piston groove and outer piston
seal rings. Install the seal ring portion of piston 13. Attach the retainer bars to the piston housing by
seal assemblies (5) and (6) in the grooves over installing capscrews and flat washers (2) at the
the O-ring portions. Use your fingers or a ends of the retainer bars.
smooth rounded object to push the seal ring into 14. Attach lifting eyes to the brake assembly. Turn
the groove. over the assembly so that the piston housing is
4. Install two equally spaced 1/2” - 13NC x 5” on the bottom.
guide studs in piston housing (7) in the tapped
mounting holes for piston retract springs (3).
5. Lubricate the piston housing bore. Install lifting
eyes and attach an overhead hoist to piston (4).
Position the piston over the piston housing with
the piston retract spring mounting holes aligned
with the guide studs. Place spring guide (2) over
each stud to aid in alignment.
6. Carefully lower the piston straight into the piston
housing bore until it is seated against the
housing. If necessary, seat the piston by tapping
it with a soft mallet. Remove the guide studs.
24
15. Install brake pack (1, Figure 50-28) as follows: Disassembly and assembly of rear wheel
a. Insert one damper into the outer ring gear. brake
The friction material must be facing the Disassembly
piston.
b. Insert one friction disc (3).
c. Install one separator plate (4).
d. Continue installing the remaining friction Disassemble and reassemble the brake assembly
discs and separator plates, alternating each on a clean, dry work surface. The work surface
type as installed. should be wooden. If the work surface is metal or
e. Install remaining damper (2) on top of the last machined surfaces. Handle all parts carefully to
friction disc. The friction material must be avoid damage to polished sealing surfaces.
facing away from the top friction disc.
NOTE: The brake pack contains eleven friction discs,
ten separator plates and two dampers.
16. Install a new O-ring (5, Figure 50-27) on back
plate (1). Install back plate (1) over outer ring Use a lifting device with adequate capacity to
gear (6). Ensure that the back plate is oriented remove and install the components.
properly according to the match marks that were
made during disassembly. 1. Remove the brake assembly from the truck.
Refer to the Disassembly and assembly section
17. Install 12 pt. capscrews (2) and hardened flat Wheels, spindles and rear axle.
washers (3). Alternately tighten capscrews (2) to
a final torque of 1 166 N·m (860 ft lb). 2. Ring gear retainer bars (1, Figure 50-32) must
be installed to retain the inner gear inside the
18. Install adapter (4, Figure 50-26) with new O- brake assembly.
rings in the back plate. Install catchment tank (3)
3. Position the brake assembly on a work surface
with four capscrews (1) and flat washers (2).
so that the ring gear retainer bars are on the
NOTE: For installation of the brake assembly, refer to bottom as shown in Figure 50-33.
the Disassembly and assembly section Wheels,
spindles and rear axle.
1
1
86402

ON BRAKE ASSEMBLY
25
4. Match mark hub adapter (4, Figure 50-33) and 7. Remove capscrews (2, Figure 50-34) and
the back plate of brake assembly (1) to ensure hardened flat washers (3) from back plate (1).
proper orientation during assembly. 8. Insert 3/4” - 10UNC x 2” pusher bolts (4) in each
5. Remove capscrews (2) and hardened flat of the three tapped holes in the back plate.
washers (3). Lift hub adapter (4) from the brake Tighten the bolts evenly to lift the back plate
assembly. Note the number of shims that are from outer ring gear (6).
used at six locations around the hub adapter. 9. Remove and discard O-ring (5).
6. Remove seal carrier (6) and the seals. Remove
two dowel pins (5) that hold the seal carrier to
the hub adapter.
4 3 2 1 4
3 2
4
4
5
5
6 5
1 6 86404
86403
FIGURE 50-33. HUB ADAPTER/SEAL CARRIER FIGURE 50-34. BACK PLATE REMOVAL &
REMOVAL & INSTALLATION INSTALLATION
1. Brake Assembly 4. Hub Adapter 1. Back Plate 4. Pusher Bolt

2. Capscrew (12 Pt.) 5. Dowel Pin 2. Capscrew (12 Pt.) 5. O-ring
3. Hardened Flat Washer 6. Seal Carrier 3. Hardened Flat Washer 6. Outer Ring Gear
26
NOTE: Note the order of the discs, plates and 11. Turn over the brake assembly to position ring
dampers as they are removed from the brake pack. gear retainer bars (1, Figure 50-36) on top as
10. Remove damper (2, Figure 50-35) from the top shown.
of brake pack (1). Remove friction discs (3), 12. Remove capscrews and flat washers (2) that
separator plates (4), and the remaining damper attach the retainer bars to the piston housing.
at the bottom of brake pack (1).
13. Attach a lifting strap through ring gear retainer
bars (1), then lift inner gear (5) out of outer ring
gear (6).
2 14. Remove capscrews and lockwashers (3) that
attach the retainer bars to inner gear (5).
Remove retainer bars (1) and spacers (4).
1 3 4 2
4
1
86405
FIGURE 50-35. BRAKE PACK REMOVAL & 6 86406

INSTALLATION
FIGURE 50-36. INNER GEAR REMOVAL &
1. Brake Pack 3. Friction Disc INSTALLATION
2. Damper 4. Separator Plate
1. Ring Gear Retainer Bars 4. Spacer
2. Capscrew & Flat Washer 5. Inner Gear
3. Capscrew & Lockwasher 6. Outer Ring Gear
27
15. Remove six remaining capscrews (1, Figure 50- 17. Turn over the piston assembly so that the piston
37) and hardened flat washers (2) from piston retract springs are on top as shown.
assembly (4).
18. Apply a small amount of heat to the piston
16. Insert 7/8” - 9UNC x 2” pusher bolts (3) in each housing. Remove capscrews (1, Figure 50-38),
of the three tapped holes in the piston housing. spring guides (2), and piston retract springs (3).
Tighten the bolts evenly to lift the piston
NOTE: The capscrew threads are coated with
assembly from outer ring gear (6). Remove and
Loctite® during assembly. A small amount of heat is
discard O-ring (5).
required for removal.
19. Carefully lift piston (4) out of piston housing (7).
Remove seal assemblies (5) and (6) from the
3 3 2 1 3 piston.
4 3
5 5
6
7
6 86407
FIGURE 50-37. PISTON ASSEMBLY

1. Capscrew (12 Pt.) 4. Piston Assembly 86408
2. Hardened Flat Washer 5. O-ring

FIGURE 50-38. PISTON REMOVAL &
3. Pusher Bolt 6. Outer Ring Gear
INSTALLATION
1. Capscrew 5. Seal Assembly
2. Spring Guide 6. Seal Assembly
3. Piston Retract Spring 7. Piston Housing
4. Piston
28
Cleaning and inspection 6. Inspect friction discs (3, Figure 50-35) for
warping, tooth wear, and excessive friction
material wear. Replace the friction discs if wear
exceeds the minimum allowable groove depth.
Disc thickness including friction material:

If the brake wear indicator test indicates that . . . . . . . . . . . . . . 7.7 ± 0.3 mm (0.30 ± 0.01 in.)
internal brake components are worn to the Friction material thickness (new):
maximum allowable limit, all friction discs, . . . . . . . . . . . . . . . . . . . . . . . .1.1 mm (0.04 in.)
separator plates and dampers must be replaced
Nominal friction material groove depth:
with new parts. Always replace seal assemblies
. . . . . . . . . . . . . . . . . . . . .0.63 mm (0.025 in.)
and O-rings with new parts.
Minimum allowable friction material groove
1. Clean all parts thoroughly before inspection. depth:. . . . . . . . . . . . . . . . .0.25 mm (0.010 in.)
2. For the rear brake assembly, remove and Flatness over friction material (new):
discard the seal assemblies in seal carrier (6, . . . . . . . . . . . . . . . . . . . . . .0.45 mm (0.018 in.)
Figure 50-33) and back plate (1, Figure 50-34).
3. Inspect piston housing (7, Figure 50-38) for 7. Inspect separator plates (4, Figure 50-35) for
nicks and scratches in the piston seal area. If warping and tooth wear.
any nicks or scratches cannot be removed by
Disc thickness (new):
polishing, replace the piston housing.
. . . . . . . . . . . . 3.7 ± 0.1 mm (0.146 ± 0.004 in.)
4. Inspect the piston seal assembly grooves for
Flatness (new): . . . . . . .0.5 mm (0.020 in.)
damage.
5. Inspect piston retract springs (3, Figure 50-38). 8. Inspect dampers (2, Figure 50-35) for warping,
Check the free height and test for height under tooth wear and excessive facing material wear.
load. Replace the springs if they are not within
approximately 10% of specification. Disc thickness including facing material:
. . . . . . . . . . . . 6.9 ± 0.5 mm (0.272 ± 0.020 in.)
Free Height:. . . . . . . . . 88.9 mm (3.50 in.)
Disc thickness, steel plate only (new):
Height at 1 290 N (290 lb) working load: . . . . . . . . . . . . 3.7 ± 0.1 mm (0.146 ± 0.004 in.)
. . . . . . . . . . . . . . . . . . . . 74.60 mm (2.937 in.) Flatness, steel plate (new):
Height at 2 669 N (600 lb) working load: . . . . . . . . . . . . . . . . . . . . . . .0.5 mm (0.020 in.)
. . . . . . . . . . . . . . . . . . . . 56.46 mm (2.223 in.)
9. Inspect outer ring gear (6, Figure 50-37) for
excessive tooth wear and for nicks and
scratches in the O-ring seal grooves.
10. Inspect inner gear (5, Figure 50-36) for
excessive tooth wear and damage at the
capscrew holes.
29
Assembly parts through the piston and into the tapped

holes in the piston housing. Tighten the
8. Install any missing plugs in the piston housing,
then test the piston for leakage. For instructions,
Disassemble and reassemble the brake assembly refer to "Brake piston leakage test" in Testing
on a clean, dry work surface. The work surface and adjusting section Brake system.
should be wooden. If the work surface is metal or
9. After completing the piston leakage test, release
the pressure, remove the hydraulic pressure
machined surfaces. Handle all parts carefully to
test device, and drain the oil from the piston
apply cavity. Plug the ports to prevent
contamination.
10. Install O-ring (5, Figure 50-37) in the groove of
outer ring gear (6).
11. Attach lifting eyes to the piston assembly and
Use a lifting device with adequate capacity to lower it into position over outer ring gear (6).
remove and install the components. Ensure that the piston assembly is oriented
1. Position piston housing (7, Figure 50-38) on a properly according to the match marks that were
clean work surface with the bore facing upward. made during disassembly. Install capscrews (1)
2. Lubricate the square O-ring portion of piston and hardened flat washers (2). Alternately
seal assemblies (5) and (6) with clean hydraulic tighten the capscrews to 1 166 N·m (860 ft lb).
oil and install the seals in the grooves in piston 12. Install retainer bars (1, Figure 50-36), spacers
(4). Ensure that the seal assemblies are not (4), capscrews and lockwashers (3) to inner
twisted. gear (5). Attach a lifting strap through the
NOTE: It is recommended that the seals be heated to retainer bars, then lift the inner gear into the
80-100°C (176-212°F) before installation by using hot piston assembly.
oil, hot air or hot water. This allows for easier seal 13. Attach the retainer bars to the piston housing by
installation without stretching the seals. installing capscrews and flat washers (2) at the
3. Lubricate the piston groove and outer piston ends of the retainer bars.
seal rings. Install the seal ring portion of piston 14. Attach lifting eyes to the brake assembly. Turn
seal assemblies (5) and (6) in the grooves over over the assembly so that the piston housing is
the O-ring portions. Use your fingers or a on the bottom.
smooth rounded object to push the seal ring into
the groove. 15. Install brake pack (1, Figure 50-35) as follows:
4. Install two equally spaced 1/2” - 13NC x 5” a. Insert one damper into the outer ring gear.
guide studs in piston housing (7) in the tapped The friction material must be facing the
mounting holes for piston retract springs (3). piston.
5. Lubricate the piston housing bore. Install lifting b. Insert one friction disc (3).
eyes and attach an overhead hoist to piston (4). c. Install one separator plate (4).
Position the piston over the piston housing with
the piston retract spring mounting holes aligned d. Continue installing the remaining friction
with the guide studs. Place spring guide (2) over discs and separator plates, alternating each
each stud to aid in alignment. type as installed.
6. Carefully lower the piston straight into the piston e. Install remaining damper (2) on top of the last
housing bore until it is seated against the friction disc. The friction material must be
housing. If necessary, seat the piston by tapping facing away from the top friction disc.
it with a soft mallet. Remove the guide studs.
NOTE: The brake pack contains eleven friction discs,
7. Assemble twelve capscrews (1), spring guides ten separator plates and two dampers.
(2) and retract springs (3). Apply Loctite® 271 to
the capscrew threads and install the assembled
30
NOTE: Before installing the hub adapter on the rear

brake, check the integrity of the brake seals. Refer to
the instructions in Testing and adjusting section
Brake system.
16. Insert three shims (1, Figure 50-39) with
capscrews and flat washers (2) at six locations Cleanliness and proper installation are critical
around the flange of hub adapter (3). factors for proper brake seal function. Refer to
the topic "Brake floating ring seal assembly and
installation" for detailed instructions.
18. Install each half of seal assembly (2, Figure 50-
3
40) in brake assembly (4) and hub adapter (1).
2 19. Install oil seal (3) in the back plate of brake
assembly (4) with Loctite® 648. Pack the area
between the seal lips with grease.
NOTE: Apply grease to the oil seal only. Do not apply
grease to any part of seal assembly (2).
86410
FIGURE 50-39. HUB ADAPTER SHIM 2

INSTALLATION
1. Shims 3. Hub Adapter
2. Capscrew & Flat Washer
3
4
17. Ensure that dowel pins (5, Figure 50-33) are
installed in seal carrier (6). Install seal carrier (6)
with new O-rings into hub adapter (4). 86411

1. Hub Adapter 3. Oil Seal
2. Seal Assembly 4. Back Plate
31
20. Install a new O-ring (5, Figure 50-34) on back 23. Gently lower hub adapter (4, Figure 50-42) onto
plate (1). Install back plate (1) over outer ring the inner gear in the brake assembly. Orient the
gear (6). Ensure that the back plate is oriented hub adapter according to the match marks that
properly according to the match marks that were were made during disassembly.
made during disassembly.
NOTE: Be careful not to have any sudden
21. Install three support plates (4, Figure 50-41) and movements or impacts. The seal halves should come
1" - 8NC X 4" capscrews (3) at three equally together very gently so as not to damage either
spaced positions around the back plate. Install sealing face.
remaining 12 pt. capscrews (1) and hardened
24. Install capscrews (3) and hardened flat washers
flat washers (2). Alternately tighten capscrews
to secure hub adapter (4) to the inner gear.
(1) to a final torque of 1 166 N·m (860 ft lb).
Alternately tighten the capscrews to a final
torque of 2 705 N·m (1,995 ft lb).
25. Install new O-ring (5) on hub adapter (4).
3
2 1 26. Install spacers (1) at each support plate using
three socket head capscrews (2) and two flat
4 washers at each capscrew.
4
2 3 4
5
4
86409
FIGURE 50-41. SUPPORT PLATE INSTALLATION

86412
1. Capscrew (12 Pt.) 3. Capscrew

2. Hardened Flat Washer 4. Support Plate FIGURE 50-42. HUB ADAPTER INSTALLATION
1. Socket Head Capscrew 3. Capscrew (12 Pt.)
2. Spacer 4. Hub Adapter
22. Use a lint free cloth and isopropyl alcohol to

clean the face of each metal sealing face of seal
assembly (2, Figure 50-40). Allow the sealing NOTE: For installation of the brake assembly, the
faces to dry completely, then apply a light coat rear seal carrier and its seals, refer to the appropriate
of oil. GE service manual.
32
Brake floating ring seal assembly and 1. Prepare a completely clean work area to handle
installation the large seal rings, O-rings and seal carriers.
Failures of floating seals are usually caused by a Absolute cleanliness is essential during the
combination of factors rather than one single cause, assembly process to prevent premature seal
but many failures have one common denominator - failure and possible oil leaks.
assembly and installation issues. NOTE: Use isopropyl alcohol in a spray bottle to
clean the parts prior to assembly. Use clean, lint-free
There are five common failure modes: material such as Micro-Wipes # 05310 for cleaning
and wiping. Do not use Stanosol or any other liquid
• Oil leakage
that leaves an oily film or does not evaporate quickly.
• Galling
2. Thoroughly clean the rubber O-rings with
• Pumping mud past the toric isopropyl alcohol to remove the white powder
• Toric failure like coating and any other contaminants. Use
• Seal ring breakage isopropyl alcohol to clean seal contact surfaces
(2, Figure 50-43) where the O-rings will be
seated on the brake housings and on the seal
The following procedure using necessary installation carriers. Also clean the polished sealing surface
tools must be accomplished to be assured of on the seal rings.
satisfactory floating seal performance.
3. Carefully inspect the polished sealing surfaces
on the seal rings for scratches or any other
damage. Inspect the entire seal contact area on
all the parts for scratches or nicks that may
damage the O-rings during installation or cause
Floating ring seals must always be installed in a path of leakage after installation. If scratches
matched pairs. The seal rings must be new. DO are present, hone and then clean the damaged
NOT mate a new ring with a used ring. DO NOT area.
install two used rings. Always install new O-rings
(toric rings).
1 2
A
VIEW A
72607
FIGURE 50-43. O-RING CONTACT AREA

1. Back Plate 2. Seal Contact Surface
33
4. Use clean, lint-free cloths and isopropyl alcohol 6. Place the O-rings on a clean flat surface.
to remove all traces of oil, dust, protective Ensure that the O-rings are not twisted. Use a
coating or other foreign matter from the metal white paint pen to mark a continuous line or dots
seal rings, the O-rings, the back plate and the every 38 mm (1.5 in.) on the O-rings (as shown
seal contact areas on all of the parts. Allow the in Figure 50-45) all the way around the
surfaces to dry completely. circumference of the O-ring.
5. Apply clean hydraulic oil (C-4 type SAE 10W) to
the O-ring ramp surface (2, Figure 50-44) on the
back plate and the O-ring ramp area on the seal
carrier.
1 2
A
VIEW A
72608
FIGURE 50-44. BACK PLATE

1. Back Plate Housing 2. Lubricant Area On Seal Ramp
72609
FIGURE 50-45. LOCATION OF WHITE LINE
1. White Marker 3. O-Ring
2. 45° Angle
34
7. Install O-rings (2, Figure 50-46) to seal rings (1). 8. Position the floating seal assembly on the back
After installation, check the O-rings for any plate and apply clean hydraulic oil (C-4 type
twisting with reference to the white line or dots, SAE 10W) to the O-ring all the way around as
or the flash line in the middle of the ring. Ensure shown in Figure 50-47.
that the O-ring is straight and uniform all the
way around the seal ring, and that the O-ring is
seated against the retaining lip. Adjust the O-
ring as necessary.
1 2
72610
FIGURE 50-46. O-RING INSTALLATION
1. Seal Ring 2. O-Ring
72611
FIGURE 50-47. ADDING LUBRICANT
35
9. Set seal installation tool (1, Figure 50-48) in 11. Repeat Steps 5-10 to install the floating seal
place on top of the seal assembly. assembly into the seal carrier.
NOTE: Each floating seal comes with its own unique 12. After installing the floating seal assemblies,
installation tool designed for leakage and damage check the O-ring for twisting. The white line or
free installation of the seal. Use appropriate dots. should be visible around the entire
installation tool. circumference of the O-ring as indicated by the
white dot in Figure 50-48. Adjust the O-ring if
10. Push on the tool (NOT the seal ring) evenly
necessary, but DO NOT push directly on the
during installation until the O-ring is installed.
seal ring.
The O-ring should squeeze (or pop) into place
below the retaining lip before the installation tool NOTE: Handle the seal ring carefully. Nicks and
touches the housing. scratches on the seal ring face can cause leaks.
72612
1. Seal Installation Tool 3. Housing
2. O-Ring 4. Seal Ring
36
13. Use a gauge (Figure 50-49) to check the seal

height variation (marked by arrows, Figure 50-
51) between seal ring (2) and back plate (1).
Check the assembled height in four places that
are 90° apart. The height variation around the
assembled ring must be less than 1.0 mm (0.04
in).
push directly on the seal ring. Use the
installation tool to make any required
adjustments. The seal rings must be level as
shown in Figure 50-53.
FIGURE 50-49. CHECKING SEAL RING
The O-rings can twist during adjustments,

especially if there is a dry spot on the O-ring or if FIGURE 50-51. CHECKING SEAL HEIGHT
there are burrs or fins on the housing retaining
1. Back Plate 2. Seal Ring
lip. Verify that the O-rings are not twisted as
shown in Figure 50-50. A bulging O-ring or
crooked seal ring will lead to eventual failure.
FIGURE 50-50. TWISTED O-RING
37
14. Use a gauge to check the seal height variation 15. After both seal ring heights have been checked
(marked by arrows, Figure 50-52) between seal and adjusted, wipe the polished seal ring
ring (3) and seal carrier (2). Check the surfaces with a lint-free material and isopropyl
assembled height in four places that are 90° alcohol to remove all foreign material and
apart. The height variation around the fingerprints.
assembled seal ring must be less than 1.0 mm
(0.04 in).
push directly on the seal ring. Make any
required adjustments using the installation tool. No foreign particles of any kind are allowed on
The seal rings must be level as shown in Figure the polished seal ring faces. Something as small
50-53. as a paper towel fiber will hold the seal faces
apart and could cause damage or leakage.
16. Apply a thin film of clean hydraulic oil (C-4 type
SAE 10W) on the polished seal faces on both
seal rings. Use a lint-free applicator or a clean
finger to distribute the oil evenly.
17. During assembly, ensure that both housings are
square, concentric and in correct alignment as
shown in Figure 50-54. Move the parts slowly
and carefully toward each other. Do not slam,
bump or drop the seal rings together. High
impact can damage the seal ring face and
cause leakage.
FIGURE 50-53. CORRECT ASSEMBLY
FIGURE 50-52. CHECKING SEAL HEIGHT

1. Housing 3. Seal Ring
2. Seal Carrier
FIGURE 50-54. CORRECT ALIGNMENT
38
18. To test the floating seal assembly installation,

place the spindle, hub and brake assembly on a
test stand as shown in Figure 13. Pump oil
through the brake cooling chamber at an inlet
pressure of 83 - 103 kPa (12 - 15 psi). Rotate
the hub as follows:
a. Run right at 12 rpm for 10 minutes.
b. Run left at 12 rpm for 10 minutes.
c. Run right at 24 rpm for 10 minutes.
d. Run left at 24 rpm for 10 minutes.
e. Run right at 36 rpm for 10 minutes
f. Run left at 36 rpm for 10 minutes
85363
FIGURE 50-55. SPINDLE, HUB AND BRAKE
No visible leakage should be detected during ASSEMBLY TEST STAND
this test.
39
Removal and installation of parking

brake
Removal
NOTE: Whenever possible, parking brake repairs Use a lifting device with adequate capacity to
should be performed when the wheel motor is remove and install the components.
removed from the truck. If repairs are necessary 3. If the wheel motor is installed in the rear axle
when the wheel motor is installed, a lifting device housing, open the rear axle housing hatch. Set
must be set up inside the rear axle housing to support up a lifting device inside the rear axle housing to
the weight of the parking brake assembly when it is support the weight of the parking brake
removed from the wheel motor. assembly.
If the wheel motor is removed from the truck,
attach a suitable lifting device to the parking
brake.
4. Remove eight capscrews and lockwashers (2,
Hydraulic oil escaping under pressure can have Figure 50-56). Install guide studs in two of the
sufficient force to enter a person's body by mounting holes to support parking brake (1)
penetrating the skin and cause serious injury, when it is removed from the wheel motor frame.
5. Disconnect supply hose (3) from the parking
brake. Plug and cap the hose and port to help
Relieve pressure before disconnecting any prevent contamination.
hydraulic lines. Tighten all connections securely 6. Slide the parking brake off the wheel motor
before applying pressure. frame.
1. Refer to the "Hydraulic system bleeddown 7. If adapter gear (6) is worn, damaged, or
procedure" in Testing and adjusting section otherwise requires removal, perform the
Steering, hoist, brake cooling and auxiliary following steps:
hydraulic system.
NOTE: The adapter gear is shrink fit on the splined
2. Close the brake accumulator bleed valves by motor shaft.
rotating them clockwise.
a. Remove capscrew and hardened flat washer
(4) from the shaft. Remove retainer plate (5).
b. Install a gear puller using the tapped holes
provided in adapter gear (6).
c. Apply heat around gear hub area while
tightening the puller until the adapter gear is
removed from the rotor shaft.
40
5
6 3 86397
FIGURE 50-56. PARKING BRAKE REMOVAL & INSTALLATION
1. Parking Brake 4. Capscrew & Hardened Flat Washer

2. Capscrew & Lockwasher 5. Retainer Plate
3. Supply Hose 6. Adapter Gear
41
Installation Disassembly and assembly of parking

1. If adapter gear (6, Figure 50-56) was removed, brake
install the adapter gear before installing the NOTE: Disassemble and reassemble the brake
parking brake on the wheel motor frame: assembly on a clean, dry work surface. The surface
a. Thoroughly clean the adapter gear and the should be wooden or, if it is metal, covered with
rotor shaft. Inspect the splines and remove padding to prevent damage to machined surfaces.
any burrs that may interfere with installation.
Disassembly
b. Heat the adapter gear to 280°C (536°F).
1. Draw match mark line (1, Figure 50-57) across
Immediately install the adapter gear on the
the brake pack housing, piston housing and end
shaft. The adapter gear must be fully seated
cap to properly orient the components during
against the shoulder of the rotor shaft.
assembly.
c. Install retainer plate (5). Secure the retainer
plate with hardened flat washer and
capscrew (4). Tighten the capscrew to 595 -
670 N·m (440 - 495 ft lb).
2. Install two guide studs in the wheel motor frame
mounting holes to guide the parking brake into The following procedure is necessary to properly
position. Ensure that the mating surfaces are relieve the pressure exerted by the Belleville
clean and free of burrs. springs on the end cap. Failure to follow this
3. Lift parking brake (1) into position for procedure could result in capscrew failure and
installation. Note the proper orientation personal injury during disassembly.
depending on whether the parking brake is to be
installed on the left or right wheel motor. (The 2. Loosen 12 capscrews (2) evenly in 27 N·m (20
bleeder screw at the top of the parking brake will ft lb) increments. Alternate by selecting a
be tilted toward the front of the truck.) successive capscrew that is located
4. Slide the parking brake over the guide studs approximately 180 degrees from the previously
and adapter gear (6). loosened capscrew.
5. Install eight capscrews and lockwashers (2). Continue loosening capscrews until the spring
Tighten the capscrews evenly to ensure that the pressure is released and the capscrews and flat
parking brake housing is properly seated on the washers can be removed by hand.
wheel motor frame. Tighten the capscrews to a
final torque of 420 N·m (310 ft lb).
6. If the wheel motor is still installed in the rear
axle housing, connect supply hose (3) and 2
remove the lifting equipment.
7. Before operating the truck, bleed the air from
the parking brake and supply line. Refer to
"Parking brake bleeding procedure" in Testing
and adjusting section Brake system.
1 86398

DISASSEMBLY & ASSEMBLY
1. Match Mark Line 2. Capscrew (12 Pt.)
42
3. Remove 12 capscrews (1, Figure 50-58), 5. Remove piston (1, Figure 50-59) from piston
hardened flat washers (2) and end cap (3). Lift housing (4). Remove and discard piston seals
Belleville washers (4) out of the piston. (2) and (3).
4. Lift piston housing (5) and the piston from brake 6. If necessary, remove bleed valve (5).
pack housing (6).
1
2 1
3
3
4
86400
5 FIGURE 50-59. PARKING BRAKE

1. Piston 4. Piston Housing
2. Piston Seal 5. Bleed Valve
3. Piston Seal
86399

1. Capscrew (12 Pt.) 4. Belleville Washers
2. Hardened Flat Washer 5. Piston Housing
3. End Cap 6. Brake Pack Housing
43
7. Remove four separator discs (1, Figure 50-60), Cleaning and inspection
three friction discs (2), and compression springs
1. Clean all parts thoroughly.
(3) from brake pack housing (5).
2. It is recommended that the separator discs and
friction discs be replaced if the friction material
on either side of the friction disc is worn to less
1 than 1.5 mm (0.06 in.).
3. Check the piston and piston housing bore for
scratches, nicks, pitting and other defects that
may cause seal leakage. Slight defects may be
3 repaired by polishing.
2 4. Inspect dowel pins (4, Figure 50-60). If the
dowel pins are grooved from excessive wear or
otherwise damaged, press the dowel pins out of
brake pack housing (5).
5. Check the free height of compression springs
3 (3) and test for height under load. Replace the
springs if they are not within approximately 10%
of specification.
Free Height:. . . . . . . . . . . . . . . 11.58 mm (0.456 in.)
Height at 162 N (36.4 lb): . . . . . .8.89 mm (0.350 in.)
3 6. Inspect the compression springs for cracks and

damage. Replace any springs that are damaged
or significantly worn.
7. Measure the unsprung total height (cone height
+ material thickness) of the Belleville washers.
The height must be greater than or equal to
4 21.16 mm (0.833 in.). Discard any Belleville
washers that do not meet this specification.
5
86401

1. Separator Disc 4. Dowel Pin
2. Friction Disc 5. Brake Pack Housing
3. Compression Spring
44
8. A load deflection test must now be conducted to e. Note the depth indicator as it moves from
determine whether the Belleville washers will be 10% to 100% compression of the cone
reused or discarded. The equipment that is height. Record the force that is required to
needed for this test are as follows: deflect the Belleville washer in 10%
increments up to 100% of the unsprung cone
• Universal Testing Machine (UTM) -
capacity minimum of 18 144 kgf (40,000 lbf) in height as shown in Table 1.
compression f. Repeat Steps c through e two more times.
• Machined flat plate g. Average the three recorded force values
• Height stand and depth indicator with minimum from Steps c through e for a respective
range of 25 mm (1 in.) deflection percentage.
a. Place the Belleville washer on a clean, flat h. Compare the average force values with the
and leveled testing machine bed. "Minimum" values in Table 1. If all of the
average force values are above or equal to
b. Put the machined flat plate on top of the
the minimum specified values, the Belleville
Belleville washer. Make sure that the plate
washer is acceptable for use in the parking
will not slip from the Belleville washer when
brake assembly.
force is applied.
i. If any of the average force values are below
c. Adjust the height stand so that the depth
the minimum specified values, the Belleville
indicator is at zero.
washer will not be of sufficient strength to
d. Gradually apply force. Follow all necessary cause the piston to compress and hold the
safety precautions for operating the UTM. disc pack. Discard the Belleville washer and
The Belleville washer will start deflecting due replace it with a new one during assembly.
to compression as shown in the example in
Figure 50-61.
FIGURE 50-61. BELLEVILLE WASHER DEFLECTION
45
Table 1: BELLEVILLE WASHER DEFLECTION SPECIFICATIONS

Load
Percentage Deflection
Average Minimum
10% 0.94 mm (0.037 in.) 2 285 kgf (5,038 lbf) 1 828 kgf (4,030 lbf)
Cleaning and inspecting new discs 3. Thoroughly clean the teeth with an organic-
based cleaning solvent as detailed previously.
A rust preventive coating is applied to separator discs
and friction discs. This coating must be removed
before installing the parking brake.
NOTE: Use a cleaner containing organic-based
solvents, such as acetone, methanol or ethanol, to
clean the coating from the discs. Water-based
cleaners, such as mild soaps and detergents, do not
adequately remove the rust preventive coating.
1. Spray or coat both sides of the disc with the
cleaner.
2. Use a cloth to quickly wipe away the coating
before the cleaner evaporates.
3. Reapply the cleaner and wipe as necessary.
During the manufacture of friction discs, excess

adhesive, which is used to bond the friction material FIGURE 50-62. FRICTION DISC INNER TEETH
to the disc, may get onto the inner teeth of the friction
1. Adhesive
disc and solidify. This adhesive may prevent the
2. Excess Adhesive on Inner Tooth
friction disc from properly engaging the parking brake
adapter gear.
1. Inspect the inner teeth of each friction disc. The
NOTE: If a new wheel motor is installed or adapter
teeth must be free of burrs and excess
gear (6, Figure 50-56) is replaced, clean the rust
adhesive. Refer to Figure 50-62.
preventive coating from the adapter gear teeth with
2. If adhesive is found on the teeth, use a diamond an organic-based cleaning solvent as detailed
needle file (half-round, 150 grit) to slowly and previously. Do not install the parking brake until the
carefully remove the excess adhesive from the adapter gear is completely dry.
inside of each affected tooth.
46
Assembly 7. Lubricate the piston seals and insert piston (1)

into piston housing (4).
NOTE: New friction discs and separator discs must
be cleaned and inspected to ensure proper parking 8. If removed, install bleed valve (5).
brake operation. If new discs are being installed, refer 9. Install piston housing (5, Figure 50-58) over the
to the topic “Cleaning and inspecting new discs”. dowels in brake pack housing (6). Ensure that
1. If dowel pins (4, Figure 50-60) have been the match mark lines are aligned.
removed, press new dowel pins into the holes in 10. Place Belleville washers (4) into piston (5) so
brake pack housing (5) until they are fully that the convex sides are facing each other.
seated against the shoulder.
11. Place end cap (3) on the top of the assembly.
2. Install one separator disc (1) over the dowel Ensure that the match mark lines are aligned.
pins. Insert one compression spring (3) over
each of the dowel pins. Insert one friction disc 12. Insert 12 capscrews (1) and hardened flat
(2). washers (2). Do not tighten the capscrews.
3. Install second separator disc (1) over the dowel

pins. Install second compression spring (3) over
each of the dowel pins. Insert second friction
disc (2).
4. Install third separator disc (1) over the dowel The following procedure is necessary to properly
pins. Install third compression spring (3) over compress the Belleville washers. Failure to follow
each of the dowel pins. Insert third friction disc this procedure could result in capscrew failure
(2). and personal injury during assembly.
5. Install remaining separator disc (1) over the
13. Select three capscrews that are 120 degrees
dowel pins.
apart and mark them.
NOTE: The internal teeth of the friction discs must be a. Tighten the marked capscrews to 41 N·m (30
aligned and must be concentric with the pilot ft lb). Snug the remaining capscrews.
diameter machined on the rear of the housing to
enable the completed assembly to be installed b. Retighten the marked capscrews until the
properly. If available, an adapter gear as installed on gap between the end cap and piston housing
the wheel motor rotor shaft should be used to simplify is equalized. Snug the remaining capscrews.
alignment. c. Retighten the marked capscrews in 27 N·m
6. Assemble piston seals (2, Figure 50-59) and (3) (20 ft lb) increments until they are fully
on piston (1) as follows: tightened to 122 N·m (90 ft lb).
a. Install the O-ring seal in the bottom of each d. Tighten the remaining capscrews to 122 N·m
groove. Ensure that the O-rings are not (90 ft lb).
twisted. 14. Install a fitting in one of the oil supply ports and
b. If available, use an expander to expand the attach a hydraulic power source. Install an O-
outside diameter of each seal enough to ring plug in the remaining port.
allow it to slide onto the piston. 15. Slowly apply pressure and open the bleeder
NOTE: If an expander tool is not available, the seals valve to bleed air from the piston cavity. Close
may be heated to a maximum of 204°C (400°F). This the bleeder valve. Apply 2 068 kPa (300 psi) of
will allow the ring to be manually expanded until it will hydraulic pressure and hold it for one minute.
fit over the piston. 16. Check for oil leakage. If leakage occurs, the
c. When each seal is over the groove, resize by parking brake assembly must be disassembled
compressing the seal ring. Use a full circle and repaired.
clamp with any sharp edges or grooves
covered to prevent damage to the seal
surfaces.
d. Install the quad ring in each seal.
47
980E Dump truck

48
CEN50045-00
DUMP TRUCK
980E

980E-5 A50005 and up

Steering system
Removal and installation of steering control unit .................................................................................................. 3
Disassembly and assembly of steering control unit .............................................................................................. 5
Removal and installation of steering column ...................................................................................................... 10
Removal and installation of steering wheel......................................................................................................... 12
Removal and installation of bleeddown manifold ................................................................................................ 13
Removal and installation of flow amplifier ........................................................................................................... 15
Removal and installation of steering cylinders and tie rod .................................................................................. 16
Disassembly and assembly of steering cylinders ............................................................................................... 18
Removal and installation of steering/brake pump ............................................................................................... 21
Removal and installation of piston steering accumulator .................................................................................... 23
Disassembly and assembly of piston steering accumulator ............................................................................... 25
1
NOTES
2
Removal and installation of steering 3. Clean steering control unit (2, Figure 50-2) and
control unit the surrounding area to help avoid
contaminating the hydraulic oil when the hoses
Removal are disconnected.
NOTE: Before disconnecting hydraulic hoses, tag the
hoses for proper identification during installation. See
Figure 50-3.
4. Disconnect and plug five hydraulic hoses (1)
Hydraulic oil escaping under pressure can have from the steering control unit.
penetrating the skin and cause serious injury, 5. Remove mounting hardware (3). Remove
and possibly death, if proper medical treatment is steering control unit (2) and the mounting plate.
not received immediately. If necessary, remove mounting plate (4) from
the steering control unit. Move the steering
Relieve pressure before disconnecting any control unit to a clean work area for
hydraulic lines. Tighten all connections securely disassembly, if required.
hydraulic system.
2 4
2. Remove front access cover (1, Figure 50-1)
from the operator cab.
1 2
87545
FIGURE 50-1. ACCESSING THE STEERING

CONTROL UNIT
87549
FIGURE 50-2. STEERING CONTROL UNIT
1. Hydraulic Hoses 3. Mounting Hardware
2. Steering Control Unit 4. Mounting Plate
3
Installation
NOTE: Whenever the steering column or steering
control unit is removed for service, inspect the splines
of the steering column shaft. Refer to "Removal and
installation of steering column". Serious personal injury to the operator or to
1. Lubricate the splines of the steering column anyone positioned near the front wheels may
shaft with a molybdenum disulphide or multi- occur if a truck is operated with the hydraulic
purpose NLGI grease. steering hoses improperly installed. Improperly
installed hoses can result in uncontrolled
2. If removed, install mounting plate (4, Figure 50- steering and/or sudden and rapid rotation of the
2) on steering control unit (2) steering wheel as soon as the steering wheel is
3. Align the steering control unit with the steering moved. It will turn rapidly and cannot be stopped
column shaft splines. Secure the steering manually.
control unit in place with mounting hardware (3).
Tighten the capscrews finger tight at this time. After servicing the steering control unit, check
the hydraulic steering hoses for correct hook-up
4. Check for proper steering wheel rotation.
before starting the engine.
Ensure that the steering wheel does not bind
and that it returns to the centered position after
being rotated by 1/4 turn to the left and right. If 7. Start the engine. Check for proper steering
necessary, adjust the steering control unit and/ function and leaks.
or steering column to realign the components.
8. Install front access cover (1, Figure 50-1) on the
5. Tighten capscrews (3) to the standard torque. operator cab.
6. Unplug and connect five hydraulic hoses (1) to
NOTE: When installing the front access cover, ensure
their proper ports on the steering control unit.
that the bottom false hinge of the cover is engaging
into the bottom edge of the sheet metal panel of the
cab front enclosure.

PORT IDENTIFICATION
1. Steering Control Unit “L” - Left Steering
“T” - Return to Tank “R” - Right Steering
“P” - Supply from Pump “LS” - Load Sensing
4
Disassembly and assembly of steering 4. Remove end cover (4, Figure 50-5) and O-ring
control unit (2).
Disassembly 5. Remove the outer gear of gear wheel set (1)

and the O-ring between the gear set and the
NOTE: The steering control unit is a precision unit distribution plate.
manufactured to close tolerances. Therefore,
complete cleanliness is essential when handling the
unit. Perform the work in a clean area and use lint
free wiping materials or dry compressed air.
1. Allow the oil to drain from the valve ports.
2. Match mark the gear wheel set and end cover to
ensure proper relocation during reassembly.
3. Remove the end cover capscrews and washers.
Remove capscrew with rolled pin (3, Figure 50-
4). Mark the hole location of the capscrew with
rolled pin on end cover (4) to aid in reassembly.
FIGURE 50-5. END COVER REMOVAL

1. Gear Wheel Set
2. O-Ring
FIGURE 50-4. MARKING VALVE COMPONENTS

1. Valve Assembly 3. Capscrew With
2. Match Marks Rolled Pin
4. End Cover
5
1. Dust Seal 7. Bearing Assembly 13. Tube 19. End Cover

2. Housing & Spools 8. Ring 14. O- ring 20. Washers
3. Ball 9. Cross Pin 15. Distribution Plate 21. Rolled Pin
4. Threaded Bushing 10. Neutral Position Springs 16. Gear Wheel Set 22. Capscrew With Pin
5. O-ring 11. Cardan Shaft 17. O-ring 23. Capscrews
6. Kin Ring 12. Spacer 18. O-ring
6
6. Lift the inner gear off cardan shaft (11, Figure Assembly
50-6).
1. Clean all parts carefully with fresh cleaning
7. Remove cardan shaft (11), distribution plate solvent.
(15) and O-ring (14).
2. Inspect all parts carefully and make any
8. Remove threaded bushing (4) and ball (3). replacements necessary.
9. With the valve housing positioned with the spool NOTE: All O-rings, seals and neutral position springs
and sleeve vertical, carefully lift the spool must be replaced. Before reassembly, thoroughly
assembly out of the housing bore. lubricate all parts with clean type C-4 hydraulic oil.
NOTE: When assembling the spool and sleeve, only
one of the two possible matching positions of the
spring slots can be used because, in the other end of
the sleeve and spool (opposite end of the spring
If housing is not vertical when spool and sleeve slots), there are three slots in the spool and three
are removed, pin (9) may slip out of position and holes in the sleeve. These must be opposite each
trap spools inside housing bore. other upon assembly so that the holes are partly
10. Remove O-ring (5), kin ring (6) and bearing visible through the slots in the spool. Refer to Figure
assembly (7). 50-8.
11. Remove ring (8) and pin (9) and carefully push
the inner spool out of the outer sleeve.
12. Press neutral position springs (10) out of their
slot in the inner spool.
13. Use a screwdriver to remove dust seal (2,
Figure 50-7). Be careful not to scratch or
damage the dust seal bore.
FIGURE 50-8. SPOOL AND SLEEVE ASSEMBLY

1. Slots 3. Spool
2. Hole 4. Sleeve
FIGURE 50-7. DUST SEAL REMOVAL

1. Screwdriver 3. Housing
2. Dust Seal
7
FIGURE 50-9. NEUTRAL POSITION SPRING INSTALLATION
3. To install the neutral position springs, place a

screwdriver in the spool slot as shown in Figure
50-9.
4. Place one flat neutral position spring on each
side of the screwdriver blade. Do not remove
the screwdriver.
5. Push two curved neutral position springs in
between one side of the screwdriver blade and
a flat spring. Repeat for the opposite side.
Remove the screwdriver.
6. Slide the inner spool in the sleeve. Compress
the ends of the neutral position springs and
push the neutral position springs in place in the
sleeve.
7. Install cross pin (2, Figure 50-10).
8. With neutral position springs (7) centered in
spool and sleeve, install ring (3), rear bearing
race (4), thrust bearing (5) and front bearing
race (6) in that order. The chamfer on the rear
bearing must be facing away from the bearing.
9. Place dust seal (1, Figure 50-6) in position. FIGURE 50-10. BEARING INSTALLATION
Using a flat iron block over the seal, tap it into 1. Sleeve 5. Thrust Bearing
the housing. 2. Cross Pin 6. Bearing Race
10. Position O-ring (5) and kin ring (6) on the spool. 3. Ring 7. Neutral Position
4. Bearing Race (with Springs
chamfer)
8
11. Position the steering control unit so that housing 16. Position the inner gear wheel onto the cardan
(1, Figure 50-11) is horizontal. Slowly guide shaft. It may be necessary to rotate the gear
lubricated spool assembly (2) with fitted parts slightly to find the matching splines on the
into the bore using light turning movements. cardan shaft. Splines are machined to ensure
proper alignment of the cardan shaft and inner
gear wheel.
17. Lubricate O-rings (17) and (18) on both sides of
the outer gear wheel with light grease and install
them.
18. Align the outer gear wheel bolt holes with the
tapped holes in the housing and the match
marks.
19. Align cover (19), using the match marks as a
reference. Install capscrews (23) and washers
(20).
20. Install capscrew with pin (22) into the proper
hole.
21. Install the end cover. Install and tighten the
capscrews with washers hand-tight in a criss-
cross pattern.
FIGURE 50-11. SPOOL INSTALLATION
1. Housing
2. Spool Assembly
The cross pin must remain horizontal when the

spool and sleeve are pushed into the bore to
prevent the pin from dropping out of the spool.
12. Install check ball (2, Figure 50-12) in hole (1).
Install and lightly tighten the threaded bushing.
13. Lubricate O-ring (3) with light grease and install
it in the groove of housing (4).
14. Install distribution plate (15, Figure 50-6) so that
the plate holes match the corresponding holes
in the housing.
15. Guide cardan shaft (11) down into the bore with FIGURE 50-12. CHECK BALL INSTALLATION
the slot in the cardan shaft aligned with cross 1. Hole 3. O-ring
pin (9). 2. Check Ball 4. Housing
9
Removal and installation of steering 4. Disconnect and unclamp speed control switch
column harness (1, Figure 50-14) and multi-function
switch harness (2).
Removal
5. Remove steering column bottom cover (3) and
1. Park truck on a hard, level surface and block all coupling cover (4).
the wheels.
to bleed down.
3. Remove lower dash panel cover (1, Figure 50-
13).
3 1
4 2 87551
FIGURE 50-14. REMOVING THE STEERING

COLUMN
1. Speed Control Switch 3. Steering Column
Harness Bottom Covers
2. Multi-Function Switch 4. Coupling Cover
1 87550
Harness
FIGURE 50-13. ACCESSING THE STEERING

COLUMN
1. Lower Dash Panel Cover
10
6. Remove four internal hex mounting capscrews Installation

and flat washers (1, Figure 50-15). Remove the
1. Slide the steering column assembly into the
steering column from the instrument panel.
instrument panel.
NOTE: Coupling (2) may be detached from the 2. If coupling (2, Figure 50-15) is installed on the
steering column shaft and remain installed in the end of the steering column, lubricate the male
steering control unit. splines on the end of the coupling and guide the
coupling into the mating female part of the
steering control unit.
If the coupling remained with the steering
control unit, attach the end of the coupling to
the steering column shaft. Tighten the clamping
screw securely.
3. Install four internal hex mounting capscrews
and flat washers (1). Tighten the capscrews to
the standard torque.
4. Check for proper steering wheel rotation.
Ensure that the steering wheel does not bind
and that it returns to the centered position after
being rotated by 1/4 turn to the left and right. If
necessary, adjust the steering column to realign
the components.
1 1
5. Connect and clamp speed control switch
harness (1, Figure 50-14) and multi-function
switch harness (2).
6. Start the engine. Check for proper steering
function.
7. Install steering column bottom cover (3, Figure
2 87552 50-14) and coupling cover (4).
FIGURE 50-15. STEERING COLUMN MOUNTING 8. Install lower dash panel cover (1, Figure 50-13).
HARDWARE
1. Capscrews & Hardened Flat Washers
2. Coupling
11
Removal and installation of steering Installation

wheel 1. If removed, install horn contact (5, Figure 50-16)
Removal in the bracket notch. Install cover (4).
2. Place steering wheel (3, Figure 50-16) into
position on the steering column shaft while
the wheels.
guiding the horn wire through the access hole in
2. Place the directional control lever in PARK and the steering wheel. Align the marks on the
turn the rest switch ON. Turn the key switch steering wheel and the shaft that were made
OFF to shut down the engine and allow 90 during disassembly. Align the serrations and
seconds for the steering system accumulators push the steering wheel onto the shaft.
to bleed down.
NOTE: Do NOT lubricate the spline or taper. Use
3. Use a small screwdriver to pry horn button (1, Loctite® Threadlocker Blue 242 on the retaining nut
Figure 50-16) from steering wheel (3). threads.
4. Disconnect the horn wire and set the horn 3. Install retaining nut (2). Tighten the nut to 81 ± 7
button aside. N·m (60 ± 5 ft lb).
5. Remove retaining nut (2). 4. Connect the horn wire to horn button (1).
6. Use a marker to make alignment marks on the 5. Install the horn button onto the steering wheel.
steering wheel and the shaft. Verify that the horn functions properly.
7. 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.
8. If necessary, remove cover (4) and horn contact
(5).
3
1 2 87553
FIGURE 50-16. STEERING WHEEL

1. Horn Button 4. Cover

2. Retaining Nut 5. Horn Contact
3. Steering Wheel
12
Removal and installation of bleeddown

manifold
2 1
Removal
NOTE: It may not be necessary to remove the
bleeddown manifold from the truck for component
replacement. If the problem area has been isolated,
remove the inoperative component and replace it.

Steering, hoist, brake cooling and auxiliary 1
hydraulic system.
2. Remove mounting hardware (1, Figure 50-17)
and protective cover (2). 86358
FIGURE 50-17. BLEEDDOWN MANIFOLD COVER

1. Mounting Hardware 2. Protective Cover
13
3. Disconnect all solenoids, switches and sensors Installation

on bleeddown manifold (2, Figure 50-18).
NOTE: Use vacuum pump kit (XB0887) to hold the oil
back in the hydraulic tank.
4. Tag the hoses for proper identification during
installation. Disconnect and plug all hydraulic
hoses from the bleeddown manifold.
1. Position the bleeddown manifold on the

mounting bracket on the left side of the truck
frame. Install and tighten four long capscrews
(1, Figure 50-18) to the standard torque.
remove and install the components. NOTE: Use vacuum pump kit (XB0887) to hold the oil
5. Remove four long capscrews (1). Lift 2. Unplug the hydraulic hoses. Install new O-rings
bleeddown manifold (2) off the mounting at the flange fittings and attach the hoses to the
bracket. proper ports. Tighten the connections securely.
6. Clean the exterior of the bleeddown manifold 3. Connect all solenoids, switches and sensors on
before removing any components from the the bleeddown manifold. If the check valves or
manifold. relief valves were removed, install new O-ring
seals before installation.
4. Start the engine. Check the steering system and
brake system for proper operation and leaks.
1 2
5. Install the protective cover (2, Figure 50-17) and
mounting hardware (1).
NOTE: Relief valves are factory preset. Do not
attempt to reset the relief valves or repair defective
relief valves. Replace relief valves as a unit. The
check valves must also be replaced only as units.
procedures. Refer to Testing and adjusting
section Steering, brake cooling and hoist
hydraulic system.
1
86364

REMOVAL
1. Mounting Hardware 2. Bleeddown Manifold
14
Removal and installation of flow amplifier NOTE: Use vacuum pump kit (XB0887) to hold the oil
Removal 3. Unplug the hydraulic hoses and tubes. Install
new O-rings on the flange fittings and connect
the hydraulic lines at their proper locations.
Tighten the fittings securely.
Hydraulic oil escaping under pressure can have procedures. Refer to Testing and adjusting
sufficient force to enter a person's body by section Steering, brake cooling and hoist
penetrating the skin and cause serious injury, hydraulic system.
hydraulic system.
back in the hydraulic tank. Before disconnecting
hydraulic hoses, tag the hoses for proper
identification during installation.
2. Disconnect and plug all hydraulic hoses and
tubes from the flow amplifier.
2
If necessary, use a lifting device with adequate

capacity to remove and install the components.
NOTE: The weight of the flow amplifier is
approximately 29 kg (64 lb). 1
3. Support the flow amplifier so that it does not fall.

Remove mounting hardware (1, Figure 50-19),
then remove flow amplifier (2).
Installation
1. Move flow amplifier (2, Figure 50-19) into REAR VIEW 86368
position and support the flow amplifier against

FIGURE 50-19. FLOW AMPLIFIER
the mounting bracket.
2. Install and tighten mounting hardware (1) to the
standard torque. 1. Mounting Hardware 2. Flow Amplifier
15
Removal and installation of steering Installation

cylinders and tie rod NOTE: Use the sleeve alignment tool included in the
NOTE: The steering cylinders and tie rod mounting tool group to hold bearing spacers (6, Figure 50-20)
arrangements are similar. The same removal and in position when the pins are inserted during
installation procedures are applicable to both assembly.
components.
1. Align the bearing bore of the steering cylinder or
Removal tie rod with the pin bores in the spindle or frame.
Insert bearing spacers (6).
NOTE: The tie rod must be installed with the heads of
the clamping bolts toward the front of the truck. The
steering cylinders must be installed with the hydraulic
hose ports facing upward.
sufficient force to enter a person's body by 2. Install pin (5), retainer (7), capscrews (3),
penetrating the skin and cause serious injury, hardened flat washers (4) and nuts (8) at each
and possibly death, if proper medical treatment is pin joint. Tighten each nut to 420 ± 41 N·m (310
not received immediately. ± 30 ft lb).
Relieve pressure before disconnecting any NOTE: Ensure that the air has been bled from the
hydraulic lines. Tighten all connections securely steering cylinders and hydraulic hoses.
before applying pressure. 3. Unplug and connect the hydraulic hoses to
1. Refer to the "Hydraulic system bleeddown steering cylinder (1) or the lubrication lines to tie
procedure" in Testing and adjusting section rod (2). Turn the steering wheel and check for
Steering, hoist, brake cooling and auxiliary leaks and proper operation.
hydraulic system. 4. Perform the toe-in adjustment. Refer to Testing
2. Disconnect the two hydraulic hoses from and adjusting section Steering, brake and
steering cylinder (1, Figure 50-20) and/or the hoist hydraulic system for the procedure.
lubrication line from tie rod (2). Plug all open
fittings and cylinder ports to prevent
contamination of the hydraulic system.
If necessary, use lifting equipment and a lifting

device with adequate capacity to remove and
install the components.
3. Support the steering cylinder or tie rod so that it
does not fall. Remove nuts (8), hardened flat
washers (4), capscrews (3) and retainer (7) from
each pin joint.
4. Remove pin (5) from each pin joint. Move the
steering cylinder or tie rod to a clean work area.
Bearing spacers (6) are secured by the pin. Keep

the spacers from falling during removal of the
pin. Damage to the spacers and/or personal
injury may result.
16
SEE
PIN DETAIL
SEE
PIN DETAIL
2
4
PIN DETAIL 8
86369
FIGURE 50-20. STEERING CYLINDER / TIE ROD REMOVAL & INSTALLATION
1. Steering Cylinder 5. Pin

2. Tie Rod 6. Bearing Spacers
3. Capscrews 7. Retainer
4. Hardened Flat Washers 8. Nut
17
Disassembly and assembly of steering 2. Remove four short capscrews (1, Figure 50-22),
cylinders two long capscrews (2) and flat washers (3).
Pull rod (4), piston (6) and gland (5) out of
NOTE: For proper seal installation and contamination
cylinder housing (7) as one unit.
prevention, disassembly and assembly work must be
done in a clean, temperature controlled environment.
Disassembly
1. If spherical bearings (2, Figure 50-21) require
replacement, place the steering cylinder on
stands and secure it with a chain vise. Remove
retainer rings (1) and press the bearing from the 2
bore. 1
NOTE: Do not use metal tools to strike the bearings. 3
3
1 4
5
2
6
1 7
86375
FIGURE 50-21. SPHERICAL BEARING REMOVAL
1. Retainer Ring 2. Spherical Bearing

86370
FIGURE 50-22. STEERING CYLINDER ROD

1. Short Capscrew 5. Gland
2. Long Capscrew 6. Piston
3. Flat Washer 7. Cylinder Housing
4. Rod
18
3. Remove screw (4, Figure 50-23), then unscrew 4. Remove wiper seal (1, Figure 50-24), main seal
piston (3) from the end of rod (1). Pull the rod (2), buffer seal (3), and bearing (4) from the
free of gland (2). bore of gland (5).
5. Remove O-ring (7) and backup ring (6) from the
outside of gland (5).
2 4
1
3
5
2
6
7
86373
FIGURE 50-24. GLAND DISASSEMBLY &

3 ASSEMBLY
1. Wiper Seal 5. Gland
2. Main Seal 6. Backup Ring
3. Buffer Seal 7. O-ring
4 4. Rod Bearing
86371
FIGURE 50-23. STEERING CYLINDER ROD

1. Rod 3. Piston
2. Gland 4. Screw
19
6. Remove piston bearing (5, Figure 50-25) and Assembly

piston seal assembly (4) from the outside of NOTE: Lubricate the O-rings with clean hydraulic oil
piston (3). before installation.
7. Remove both backup rings (1) and O-ring (2)
1. Install O-ring (2, Figure 50-25) and both backup
from the bore of piston (3).
rings (1) in the bore of piston (3).
2. Install piston seal assembly (4) and piston
bearing (5) on the outside of piston (3).
2 3. Install bearing (4, Figure 50-24), buffer seal (3),
1
main seal (2), wiper seal (1) in the bore of gland
(5).
4. Install O-ring (7) and backup ring (6) on the
outside of gland (5).
3 5. Slowly push rod (1, Figure 50-23) through the
top of gland (2). Be careful not to damage the
seals and bearing.
4 6. Screw piston (3) onto rod (1). Tighten the piston
to 294 ± 29 N·m (217 ± 21 ft lb).
7. Apply Loctite No. 262 to the threads of screw
(4). Install and tighten the screw to 59 - 74 N·m
5 (44 - 55 ft lb).
86372 8. Coat the piston and the rod with clean hydraulic
oil, then carefully install the rod, piston and
FIGURE 50-25. PISTON DISASSEMBLY & gland assembly into cylinder housing (7, Figure
ASSEMBLY 50-22). Ensure that the backup ring and O-ring
1. Backup Rings 4. Piston Seal on gland (5) are not damaged during
2. O-ring Assembly installation.
3. Piston 5. Piston Bearing 9. Install four short capscrews (1), two long
capscrews (2) and flat washers (3). Tighten the
capscrews evenly to the standard torque.
Cleaning and inspection 10. If spherical bearings (2, Figure 50-21) were
removed, place the steering cylinder on stands
and secure it with a chain vise and install the
spherical bearings. Install retainer rings (1) to
secure the bearings.
When using cleaning agents, follow the solvent NOTE: Before installation, spherical bearings must
manufacturer's instructions. be shrunk by freezing. The temperature must not be
below -54°C (-65°F). A press may be necessary for
1. Clean all parts thoroughly in fresh cleaning
installation. Do not use metal tools to strike the
solvent. Use a solvent that does not leave a film
bearings.
after evaporation such as trichloroethane,
acetone or lacquer thinner. 11. Test the performance of the steering cylinder.
2. Dry all parts completely using only dry, filtered Refer to "Steering cylinder leakage test" in the
compressed air and lint free wiping materials. Testing and adjusting section Steering system.
3. Inspect all parts for evidence of wear or
damage. Inspect plated surfaces for scratches,
nicks or other defects. Replace or repair any
damaged parts.
NOTE: Contact your local Komatsu distributor for
repair information and instructions not covered in this
manual.
20
Removal and installation of

steering/brake pump
Removal
Always maintain complete cleanliness when

opening any hydraulic connection. Ensure that all
system lines and components are capped while
the component is removed from the truck.
Hydraulic oil escaping under pressure can have 3. Disconnect steering filter hose (1, Figure 50-
sufficient force to enter a person's body by 26), unloader feedback hose (2), supply hose
penetrating the skin and cause serious injury, (3) and case drain hose (4) and from the
and possibly death, if proper medical treatment is steering/brake pump. Plug all hoses and ports
not received immediately. to prevent oil contamination.
before applying pressure. 4
Steering, hoist, brake cooling and auxiliary 3
hydraulic system.
2. Clean the steering/brake pump and surrounding 1
area carefully to help avoid contamination of
hydraulic oil when the hoses are disconnected 2 86377
are opened. FIGURE 50-26. STEERING/BRAKE PUMP HOSES
1. Steering Filter Hose 3. Supply Hose

2. Unloader Feedback Hose 4. Case Drain Hose
21
Installation
NOTE: Lubricate the O-ring with clean Type C-4
hydraulic oil before installation.
1. Install new O-ring (2, Figure 50-27) and seating
Use a lifting device with adequate capacity to rings (6) in the hoist pump mounting flange.
2. Ensure that the steering/brake pump splined
4. Support steering/brake pump (1, Figure 50-27) coupler is in place inside the hoist pump before
and the rear section of the hoist pump. Remove installation.
two capscrews (3), two nuts (4) and two
lockwashers (5).
5. Move the steering/brake pump rearward to
disengage the drive coupler splines from the
hoist pump. Remove the steering/brake pump.
6. Remove seating rings (6) and O-ring (2) from Use a lifting device with adequate capacity to
the hoist pump mounting flange. remove and install the components.
7. Move the pump to a clean work area for 3. Move steering/brake pump (1, Figure 50-26)
disassembly. into position. Engage the pump shaft with the
splined drive coupler in the hoist pump.
4. Install two nuts (4), two lockwashers (5) and two
capscrews (3). Tighten the hardware to the
4 5 standard torque.
5. Remove all plugs from the hoses and ports.
Install new O-rings on the flange fittings and
connect steering filter hose (1, Figure 50-26),
unloader feedback hose (2) and supply hose (3)
to the steering/brake pump. Tighten the
capscrews securely.
2 6 NOTE: Do not connect case drain hose (4) at this
time.
1 3 86378
6. Before connecting the case drain hose, remove
FIGURE 50-27. STEERING/BRAKE PUMP the hose fitting from the pump housing. Add
REMOVAL & INSTALLATION clean C-4 hydraulic oil to the pump through the
opening until the pump housing is full. This may
1. Steering/Brake Pump 4. Nut require 2 to 3 liters (2 to 3 qt.) of oil.
2. O-ring 5. Lockwasher
7. Install the case drain fitting and tighten it to the
3. Capscrew (12 Point) 6. Seating Ring
standard torque. Connect case drain hose (4) to
the fitting.
procedures. Refer to Testing and adjusting
section Steering, brake cooling and hoist
hydraulic system.
22
Removal and installation of piston

steering accumulator
Removal
1

sufficient force to enter a person's body by 2 4
3
hydraulic system.
2. Remove valve cover (1, Figure 50-28) and
spacer (2). Remove switch cover (4).
84476
FIGURE 50-28. TOP OF PISTON

ACCUMULATOR
1. Valve Cover 3. Charging Valve
2. Spacer 4. Switch Cover
being forced out of the suspension by the gas 1
pressure inside.
3. Discharge the nitrogen pressure from the piston
a. Remove valve cap (1, Figure 50-29) from the 2
charging valve.
b. Hold valve body (3) with one wrench, then
turn swivel nut (2) counterclockwise three
turns with a second wrench. Do not turn the 3
swivel nut more than three turns. Do not
turn the charging valve body.
84483
charging valve. Refer to Testing and FIGURE 50-29. PISTON ACCUMULATOR
adjusting section Accumulators and CHARGING VALVE
suspensions for the charging kit installation
information. 1. Valve Cap 3. Valve Body
(Small Hex Nut)
23
4. Disconnect the wiring harness from pressure

switch (4, Figure 50-30).
5. Disconnect hydraulic hose (1) from the flange at 4
the bottom of accumulator (3). Plug the hose
and the accumulator port.

6. Attach a lifting device to the top of the accumu-
lator and take up slack.
3
7. Remove clamps (2) that secure the accumulator
to the frame mounting bracket.
8. Lift accumulator (3) from the lower mounting
bracket. Move the accumulator to a clean work
area.
1 86379

1. Hydraulic Hose 3. Accumulator
2. Clamp 4. Pressure Switch
24
Installation Disassembly and assembly of piston

1. New or rebuilt piston accumulators should have steering accumulator
1.5 L (3 pt) of oil in the gas end to prevent Disassembly
rusting of the accumulator walls and to provide
for piston seal lubrication.
If the accumulator does not have oil in the gas
end, remove charging valve (3, Figure 50-28)
and add 1.5 L (3 pt) of clean C-4 hydraulic oil to
the gas end of the accumulator. This provides Wear a face mask or goggles. Make sure that only
enough oil above the top of the piston for seal the swivel nut turns. Turning the entire charging
lubrication. valve assembly may result in the valve assembly
2. Install the charging valve with a new O-ring. being ejected from the accumulator by the gas
Tighten valve body (3, Figure 50-29) to 22 N·m pressure inside.
(16 ft lb). 1. Before disassembly, ensure that all pressure
has been discharged from the piston
charging valve.
Use a lifting device with adequate capacity to b. Hold valve body (3) with one wrench, then
remove and install the components. turn swivel nut (2) counterclockwise three
3. Keep the accumulator upright and attach a lift- turns with a second wrench. Do not turn the
ing device to the top of the accumulator. Ensure swivel nut more than three turns. Do not
that the base ring is installed in the lower mount- turn the charging valve body.
ing bracket, then lift accumulator (3, Figure 50- c. Connect the nitrogen charging kit to the
30) into position in the lower mounting bracket. charging valve. Refer to Testing and
4. Install clamps (2) and the hardware that secure adjusting section Accumulators and
the accumulator to the frame mounting bracket. suspensions for the charging kit installation
Tighten the capscrews to the standard torque. information.
5. Install pressure switch (4) and connect the 2. Loosen valve body (3) to remove the charging
switch to the wiring harness. valve from the top of the accumulator.
6. Remove the plugs from the hose and accumula-
tor port. Install a new O-ring in the flange, then
connect hydraulic hose (1) at the bottom of the 1
accumulator.
7. Precharge the piston accumulator. Refer to
"Piston accumulator charging procedure" in 2
and suspensions.
84483
CHARGING VALVE
(Small Hex Nut)
25
3. Remove pressure switch (1, Figure 5-38) and 5. Secure the accumulator horizontally in a chain
valve assembly (2) vise.
6. Install two lifting eyes or long capscrews (1,
Figure 50-34) in two of the three 5/8" - 11UNC
2 1 lifting holes in end cap (3).
7. Use a bar to turn the end cap counterclockwise.
Remove the end cap.
3
3
2
84478
FIGURE 50-32. PISTON ACCUMULATOR END CAP

1. Pressure Switch 3. Charging Valve
2. Valve Assembly
4. Remove the hose fitting, flange (1, Figure 5-39)

and plugs (2) from the bottom of the piston
accumulator. 1
84479
FIGURE 50-34. REMOVING THE END CAP

1 1. Capscrew 3. End Cap
2. Bar
2 84480
FIGURE 50-33. PISTON ACCUMULATOR END CAP

1. Flange 2. Plug
26
9. Use a long dowel (wood, plastic or padded) or Cleaning and inspection

push rod (XA6348) to carefully tap piston (1,
1. Check the seals on the piston and end caps for
Figure 5-35) out of the accumulator housing. Be
cuts, score marks and other damage. If there
careful not to damage the piston or seals on the
are excessive cuts on the seals, perform a
end cap threads.
thorough examination of the metal surfaces for
NOTE: Never use pressurized air to remove the damage.
piston. 2. Clean the piston and housing bore. Use a
cleaning solvent and dry them with a soft, clean
towel or rag.
3. Inspect the piston and housing bore for foreign
1 material, scratches and other damage. Replace
the piston if damaged. Scratches on the housing
bore must be removed to ensure optimal service
life of the seals.
Repair of the housing by welding, machining or

plating to salvage a worn area is NOT
APPROVED. These procedures may weaken the
housing and result in serious injury to personnel
when pressurized.
2
84481
FIGURE 50-35. PISTON REMOVAL (TYPICAL)

1. Piston 2. End Cap
27
Piston seal replacement Assembly

NOTE: Replace all seals when the accumulator is NOTE: Assemble the accumulator in a dust and lint
completely disassembled. free area. Maintain complete cleanliness during
1. Apply clean hydraulic oil to the seals, piston assembly to prevent possible contamination.
lands and grooves. 1. Secure the accumulator horizontally in a vise,
2. Assemble the seals into the appropriate piston preferably a chain vise.
grooves. Start with seal (5, Figure 50-36), then 2. Carefully insert piston assembly (2, Figure 50-
move outward to seals (2) to reduce the risk of 37) into the accumulator housing bore. Avoid
seal damage. Ensure that seals (2) and (5) are cocking to prevent damaging the piston and/or
not folded or twisted. seals on the end cap threads. If necessary, tap
3. Insert backup rings (3) and (4) carefully so as the piston lightly with a soft hammer. Be careful
not to stretch any more than necessary. Ensure not to pinch the backup rings.
that the backup ring gaps are offset from one NOTE: Assembly sleeve (1) may be used to help
another as they are installed and not aligned on install and prevent damage to the piston assembly.
one side of the piston.
1 2
1
4
84482
5 FIGURE 50-37. PISTON ASSEMBLY
1. Assembly Sleeve 2. Piston Assembly

4 (XA6349)
1
85209
FIGURE 50-36. PISTON REPLACEMENT SEALS

1. Piston Bearing 4. Backup Ring (thin)
2. Piston Seal - “U” 5. Piston Seal - “T”
3. Backup Ring (thick)
28
3. Assemble the backup ring and O-ring into the 9. Install plugs (2, Figure 5-39) in the oil end cap.
end cap groove. The backup ring must be Also install a plug in place of flange (1) and the
toward the threaded side or outside of the end hose fitting.
cap. Apply a light coat of grease to the threads
10. Before closing up the ports, add 1.4 L (48 oz) of
and O-ring of the end cap.
oil to the gas end.
NOTE: Check the face of piston and tube for any 11. Install the charging valve with a new O-ring.
contamination before installing the end caps. Tighten valve body (3, Figure 5-31) to 22 N·m
4. Secure the accumulator horizontally in a chain (16 ft lb).
vise.
12. Test the accumulator for leaks. Refer to "Piston
5. Install two lifting eyes or long capscrews (1, accumulator leak testing" in Testing and
Figure 50-34) in two of the three 5/8" - 11UNC adjusting section Accumulators and
lifting holes in end cap (3). suspensions.
6. Use a bar to tighten the end cap clockwise to a
13. If the accumulator is being installed on a truck:
torque of 300 N·m (221 ft lb).
a. Install pressure switch (1, Figure 5-38) into
After the end cap is tightened, the end cap valve assembly (2).
should be flush ± 1.5 mm (± 0.06 in) with the
end of the accumulator housing. b. Install flange (1, Figure 5-39). Install the hose
fitting and tighten to standard torque.
8. Remove the screws from both end caps. Clean
the excess lubricant from the accumulator head
area at both ends of the accumulator.
29
980E Dump truck

30
CEN50049-01
DUMP TRUCK
980E

980E-4 A40003 and up
980E-5 A50005 and up

Suspensions
Removal and installation of front suspension ....................................................................................................... 3
Disassembly and assembly of front suspension ..................................................................................................11
Removal and installation of rear suspension ...................................................................................................... 16
Disassembly and assembly of rear suspension.................................................................................................. 20
1
NOTES
2
Removal and installation of Removal

front suspension 1. Remove the front tire and rim. Refer to
Disassembly and assembly section Wheels,
General information
Hydrair® II suspensions are hydro-pneumatic 2. Remove the front wheel hub and spindle. Refer
components containing oil and nitrogen gas. The oil to Disassembly and assembly section Wheels,
and gas in the four suspensions carry the gross truck spindles and rear axle.
weight less wheels, spindles and rear axle assembly. 3. Remove the clamp and boot (1, Figure 50-1)
The front suspension cylinders consist of two basic from the front suspension.
components: a suspension housing attached to the 4. Remove protective cover (2) from the charging
truck frame and a suspension rod attached to the valve block.
front spindle.
Check valves and orifice dampening holes control
suspension travel to provide good ride qualities on 2
haul roads under loaded and empty conditions.
The front suspension rods also act as kingpins for
steering the truck.
The suspension cylinder requires only normal care
when handling as a unit. However, after being
disassembled, these parts must be handled carefully
to prevent damage to the machined surfaces.
Surfaces are machined to extremely close tolerances
and are precisely fitted. All parts must be completely
clean during assembly.
86317
FIGURE 50-1. FRONT SUSPENSION

1. Boot 2. Protective Cover
3

A
being ejected from the suspension by the gas
pressure inside.
5. Discharge the nitrogen pressure from the
suspension as follows:
a. Remove the cap from charging valve (2,
Figure 50-2).
b. Turn charging valve swivel nut (3)
2
counterclockwise three full turns to unseat
the valve seal. Do not turn the swivel nut
more than three turns. Do not turn
charging valve body (4).
charging valve. Refer to "Suspension oiling
and charging procedures" in Testing and
4 suspensions for the charging kit installation
information.
6. Remove pressure sensor (1) from the charging
valve block.
7. Place a suitable container under the suspension
cylinder. Remove recessed drain plug (2, Figure
50-3) and allow the cylinder to drain completely.
A properly charged front suspension cylinder
contains approximately 151.4 L (40 gal) of oil.
3
DETAIL A 83222
FIGURE 50-2. SUSPENSION CHARGING VALVE
1. Pressure Sensor 4. Charging Valve Body

2. Charging Valve (Large Hex)
3. Swivel Nut (Small Hex)
1 2 86318
FIGURE 50-3. FRONT SUSPENSION DRAIN PLUG
1. Piston Plug Retaining 2. Drain Plug

Plate Capscrew
4
Installation
1. Remove all paint, rust, dirt and foreign debris
from the suspension mounting surfaces. See
Figure 50-4.
8. Use a fork truck or suitable lifting device to the
suspension. Secure the suspension to the fork
truck or lifting device.
10. Remove six upper capscrews (1, Figure 50-4).
11. Remove four lower outer capscrews (4).
12. Remove four lower capscrews (4) with spacers
(7).
13. Move the suspension to a clean work area for
disassembly.
14. Discard the suspension mounting capscrews,
washers and nuts.
FIGURE 50-4. REMOVING DEBRIS FROM
MOUNTNG SURFACES
2. Clean and dry the mounting surfaces on both

High tightening torque is required to load the
the suspension and the frame. Use a cleaning
front suspension mounting capscrews. Repeated
agent that does not leave a film after
tightening will result in capscrew fatigue and
evaporation, such as isopropyl alcohol, acetone
damage. DO NOT reuse mounting capscrews,
or lacquer thinner.
washers and nuts. Replace the hardware after
each use. 3. Inspect the mounting surfaces of the
suspension and frame for damage or wear.
Suspension mounting capscrews are hardened Check for the following criteria:
to meet or exceed grade 8 specifications. Replace  Flatness of each surface must be within
only with capscrews of correct hardness. Refer to 0.25 mm (0.010 in.).
the appropriate parts book for the correct part
numbers.  Surface finish must not exceed 6.4 µm (250
µ in.) roughness average (Ra).
If measurements are not within specifications,
contact your Komatsu customer service
manager for further instructions.
4. Clean and dry all suspension mounting
hardware. Use the same cleaning agent that
was used to clean the mounting surfaces.
5
High tightening torque is required to load the The use of dry threads in this application is not
front suspension mounting capscrews. Repeated recommended. Due to the high tightening forces
tightening will result in capscrew fatigue and required to load these capscrews, dry threads or
damage. DO NOT reuse mounting capscrews, threads lubricated with anti-seize compounds
washers and nuts. Replace the hardware after may result in damage. Only use the approved
each use. lubricant specified below.
Suspension mounting capscrews are hardened

to meet or exceed grade 8 specifications. Replace 5. Lubricate the capscrew threads, capscrew head
only with capscrews of correct hardness. Refer to seats, washer faces and nut seats with a lithium
the appropriate parts book for the correct part based multi-purpose EP NLGI 2 grease (3%
numbers. minimum molybdenum-disulphide).
6. Identify and separate the hardware according to
location on the suspension. Refer to Figure 50-
5.
FIGURE 50-5. HARDWARE IDENTIFICATION
1. Capscrew - 1 1/2" - 6NC x 6 1/2" (G8)

2. Hardened Flat Washer - 1 1/2"
3. Nut - 1 1/2" - 6NC (G8)
4. Capscrew - 2" - 4.5NC x 15" (G8)
5. Hardened Flat Washer - 2"
6. Nut - 2" - 4.5NC (G8)
7. Spacer
8. Shear Key
9. Part Of Frame
6
NOTE: Most hardened flat washers used on the front

suspensions are punched during the manufacturing
process. When assembling the capscrews and
washers, position the punched lip away from the
capscrew head to prevent damage. Refer to Figure
50-6.
7. Lift the front suspension into position on the
frame.
8. Install the mounting hardware and the shear
key. Install the shear key flush with the side face
of the suspension.
Install one washer under each capscrew head
and one washer under each nut (where
applicable).
FIGURE 50-6. FLAT WASHER ORIENTATION
1. Hardened Flat Washer 2. Capscrew
FIGURE 50-7. SUSPENSION INSTALLATION
7
9. Tighten all 14 capscrews to 1 356 ± 136 N·m 10. The mounting capscrews now must be loosened
(1,000 ± 100 ft lb) in the sequence shown in one at time and then tightened one at time by
Figure 50-8. This ensures that the suspension turning the hardware by a specified number of
has been seated properly on the frame. Use a degrees. This is known as angle advance.
properly calibrated torque wrench to ensure
Use the map shown in Figure 50-8 for the
accuracy.
proper tightening sequence. Refer to the angle
NOTE: Do not exceed 4 rpm tightening speed. Do not advance methods on the following pages for the
hammer or jerk the wrench while tightening. proper tightening procedures. After tightening is
complete, continue with step 11 below.
Failure to tighten all capscrews to the proper

torque and in the proper sequence could affect The capscrews at the upper mounting joint
the integrity of the joint. require a different tightening procedure than the
capscrews at the lower mounting joint. It is
important to refer to the correct procedure as
each capscrew is tightened in sequence.
11. Install pressure sensor (1) in the charging valve

block.
12. Charge the front suspension with dry nitrogen to
fully extend the suspension piston before
installing the front wheel hub and spindle. Refer
to Testing and adjusting section Accumulators
and suspensions.
13. Install spindle, wheel and tire. Refer to
Disassembly and assembly section Wheels,
14. Service the front suspensions. Refer to Testing
suspensions for the oiling and charging
procedure.
15. Install boot (1, Figure 50-1) and the clamp.
FIGURE 50-8. TIGHTENING SEQUENCE MAP
8
Upper mounting joint - 60° advance 5. Make new reference lines along the capscrew,
1. Loosen the capscrew. All other capscrews must nut and frame at the rear of the joint as shown in
remain tightened. Figure 50-10. These reference lines will be used
to verify the capscrews have maintained their
2. Tighten the capscrew to 95 N·m (70 ft lb). torque.
NOTE: Do not exceed 4 rpm tightening speed. Do not NOTE: If for any reason these fasteners need to be
hammer or jerk the wrench while tightening. checked for tightness after completing this
3. Mark a corner of the capscrew head with a paint procedure, replace all the hardware and repeat the
marker as shown in Figure 50-9. Draw a entire process.
reference line on the suspension surface next to
the marked corner on the capscrew. Draw a
reference line on the suspension 60 degrees in
advance of the marked corner on the capscrew.
4. Advance the capscrew to the 60° advance
mark. Hold the nut at the rear of the joint
stationary while tightening.
FIGURE 50-10. MAKING REFERENCE LINES

FIGURE 50-9. 60 DEGREE ADVANCE
9
Lower mounting joint - 90° advance 5. Make new reference lines along the capscrew,
1. Loosen the capscrew. All other capscrews must nut and frame at the rear of the joint as shown in
remain tightened. Figure 50-10. For the four capscrews with
spacers, refer to Figure 50-12. These reference
2. Tighten the capscrew to 475 N·m (350 ft lb). lines will be used to verify the capscrews have
NOTE: Do not exceed 4 rpm tightening speed. Do not maintained their torque.
hammer or jerk the wrench while tightening. NOTE: If for any reason these fasteners need to be
3. Mark a corner of the capscrew head with a paint checked for tightness after completing this
marker as shown in Figure 50-11. Draw a procedure, replace all the hardware and repeat the
reference line on the suspension surface (or entire process.
frame) next to the marked corner on the
capscrew. Draw a reference line on the
suspension surface (or frame) 90 degrees in
advance of the marked corner on the capscrew.
4. Advance the capscrew to the 90° advance
mark. Hold the nut at the rear of the joint (where
applicable) stationary while tightening.
FIGURE 50-12. MAKING REFERENCE LINES
FIGURE 50-11. 90 DEGREE ADVANCE

Inspection
Visual inspections of the bolted joints are necessary
after the truck has been released for operation.
Inspect the joints at each front suspension at the
following intervals: 8 hours, 50 hours, 250 hours, and
500 hours.
• If the reference lines on the hardware (Figure 50-
10 and Figure 50-12) have remained in
alignment, the trucks may remain in operation.
• If at least one of the capscrews has shown signs
of movement, the truck must be taken out of
service. The suspension mounting capscrews
must be removed, cleaned, and inspected. If any
capscrews have signs of damage, replace all
capscrews. Install the capscrews again according
to this installation procedure.
10
Disassembly and assembly of 2. With the suspension housing and piston held in
front suspension a vertical position (end cap up), remove
capscrews (1, Figure 50-14) and hardened
NOTE: For proper seal installation and contamination washers (2).
prevention, disassembly and assembly work must be
done in a clean, temperature controlled environment. 3. Attach a hoist to top cap (3) and lift the top cap,
upper bearing retainer and piston out of the
Disassembly suspension housing as one unit.
1. Loosen charging valve body (4, Figure 50-13)

and remove the charging valve assembly.
2 1 3
86320
FIGURE 50-14. TOP CAP REMOVAL

1. Capscrew 3. Top Cap
2. Hardened Washer
3
DETAIL A 83222

11
4. Support the bottom of piston (4, Figure 50-15). 5. Remove spring pins (1, Figure 50-16), wheel
Remove capscrews (1) and hardened washers nut (2), piston stop (3) and key (4). Separate top
(2). Separate upper bearing retainer (3) and the cap (9) from upper bearing retainer (5).
top cap from piston (4). 6. Remove two O-rings (7) and backup rings (8)
NOTE: The check balls may fall free from four bosses from the top cap. Remove upper bearing (6)
(5) when the upper bearing retainer and top cap are from upper bearing retainer (5).
removed.
2 1 3
7 8
4 3
4
1
1 86322
86321
FIGURE 50-16. BEARING RETAINER / END CAP

FIGURE 50-15. BEARING RETAINER / PISTON SEPARATION
SEPARATION
1. Spring Pin 6. Upper Bearing
1. Capscrew 4. Piston 2. Wheel Nut 7. O-rings
2. Hardened Washer 5. Boss 3. Piston Stop 8. Backup Rings
3. Upper Bearing Retainer 4. Key 9. Top Cap
5. Upper Bearing Retainer
12
7. Rotate the suspension housing 180 degrees. 10. If necessary, remove capscrew (7, Figure 50-
8. Remove capscrews (1, Figure 50-17), hardened 18), flat washer (8) and retaining plate (6) from
washers (2) and wiper retainer plate (3), if the bottom of piston (1). Push piston plug (4)
equipped. Install eye bolts and remove lower upward far enough to remove retaining ring (5).
bearing retainer (7).
9. Remove wiper seal (4), main seal (5), buffer
seal (6), O-rings (9) and backup rings (10) from
the suspension housing.
10. Remove lower bearing (8) from lower bearing DO NOT use compressed air to remove the piston
retainer (7). plug. Damage to components may occur.
11. Re-install capscrew (7) and use a slide hammer
to remove the piston plug from the piston.
1 2 Remove backup ring (2) and O-ring (3) from pis-
ton plug (4).
3
4 1
7 2 3
4
8
5
10 9 6
8 7
86323
FIGURE 50-18. PISTON PLUG REMOVAL

1. Piston 5. Retaining Ring
2. O-Ring 6. Retaining Plate
3. Backup Ring 7. Capscrew
86319
4. Piston Plug 8. Flat Washer
FIGURE 50-17. LOWER BEARING REMOVAL
1. Capscrew 6. Buffer Seal
2. Hardened Washer 7. Lower Bearing
3. Wiper Retainer Plate Retainer
(if equipped) 8. Lower Bearing
4. Wiper Seal 9. O-Ring
13
Cleaning and inspection
When installing backup rings with the main seal

When using cleaning agents, follow the solvent and the buffer seal, ensure that the radius is
manufacturer's instructions. positioned toward the seal and the white dot is
positioned away from the seal.
solvent. Use a solvent that does not leave a film 4. Install new buffer seal (6, Figure 50-17), new
after evaporation such as trichloroethane, main seal (5) and new wiper seal (4) in the
acetone or lacquer thinner. suspension housing.
2. Dry all parts completely using only dry, filtered 5. Install new O-rings (9) and backup rings (10) in
compressed air and lint free wiping materials. their appropriate grooves on lower bearing
retainer (7).
damage. Inspect plated surfaces for scratches, NOTE: The backup rings must be positioned toward
nicks or other defects. Replace or repair any the bearing retainer bolt flange with the concave side
damaged parts. toward the O-ring as shown in Figure 50-19.
NOTE: Contact your local Komatsu distributor for 6. Install new lower bearing (8, Figure 50-17) into
repair information and instructions not covered in this lubricated lower bearing retainer (7). Install the
manual. lower bearing retainer into the suspension
housing.
7. If equipped, install wiper retainer plate (3),
Assembly hardened washers (2) and capscrews (1).
Tighten the capscrews to 678 N·m (500 ft lb).
Be careful not to damage the machined or plated

surfaces, O-rings or seals when installing the
piston assembly.
NOTE: Lubricate all interior parts and bores with
clean suspension oil.
1. If piston (1, Figure 50-18) was disassembled,
thoroughly lubricate and install new O-ring (2)
and backup ring (3) on piston plug (4).
2. Use a rubber mallet to seat piston plug (4) in the
bottom of piston (1). Install the piston plug just
far enough to expose the retaining ring groove.
FIGURE 50-19. BACKUP RING REPLACEMENT
Install retaining ring (5).
3. Install retaining plate (6), flat washer (8) and 1. O-ring 3. Lower Bearing
capscrew (7). Tighten the capscrew to 122 N·m 2. Backup Ring Retainer
(90 ft lb).
14
8. Install new O-rings (7, Figure 50-16) and NOTE: If the suspension is to be stored, put in one
backup rings (8) in the grooves of top cap (9). liter (two pints) of a rust preventive oil. This oil must
Backup rings must be positioned toward the be drained when the suspension is put into service.
flange of the end cap. 17. Install a new O-ring onto charging valve (2,
9. Install new upper bearing (6) on upper bearing Figure 50-13). Install the charging valve onto
retainer (5). the cylinder. Tighten charging valve body (4) to
10. Slide upper bearing retainer (5) over the top cap 23 N·m (17 ft lb).
rod. If a new charging valve is being used, tighten
11. Install key (4) and piston stop (3) on the top cap swivel nut (3) to 15 N·m (11 ft lb), then loosen
rod. Ensure that the piston stop is fully seated and retighten the swivel nut to 15 N·m (11 ft lb).
against the rod shoulder. Loosen the swivel nut again, then retighten it to
6 N·m (50 in lb). Install the valve cap finger-
12. Install wheel nut (2) until it is snug against the tight.
piston stop. Tighten the wheel nut by an addi-
tional 1/2 turn until the hole for the spring pins is 18. Pressure test the suspension. Refer to the
in alignment. Install spring pins (1). Testing and adjusting section Accumulators
and suspensions.
13. Attach a lifting device to top of the top cap.
Lower the end cap/bearing retainer assembly 19. After a successful pressure test, add
onto piston (4, Figure 50-15). approximately 151.4 liters (40 gallons) of
suspension oil.
NOTE: Ensure that the check balls are installed in all
four bosses (5) before fully seating the upper bearing 20. Apply rust preventative grease to any exposed
retainer on top of the piston. A small amount of machined surfaces.
petroleum jelly should prevent the balls from
dropping out during assembly.
14. Install new capscrews (1) and hardened wash-
ers (2) that secure piston (4) to upper bearing
retainer (3). Tighten the capscrews to 678 N·m
(500 ft lb).
Always use new capscrews during assembly.

Used capscrews will be stressed and fatigued
because of loads imposed on these capscrews
during operation.
15. Apply a light coating of petroleum jelly to all of
the seals and both bearings. With the suspen-
sion housing in a vertical position, carefully
lower the top cap/upper bearing retainer/piston
assembly into the bore of the suspension hous-
ing until the piston taper passes through the
wiper seal and the top cap is in position on top
of the suspension housing.
16. Install capscrews (1, Figure 50-14) and hard-
ened washers (2). Tighten the capscrews to
1 017 N·m (750 ft lb).
15
Removal and installation of rear Removal

suspension 1. Remove the clamp and boot (1, Figure 50-20)
from the front suspension.
General information
2. If necessary, remove protective cover (2) to
Hydrair® II suspensions are hydro-pneumatic access the charging valve.
components containing oil and nitrogen gas. The oil
and gas in the four suspensions carry the gross truck
weight less wheels, spindles and rear axle assembly.
The rear suspension cylinders consist of two basic
components: a suspension housing attached to the
frame and a suspension rod attached to the rear axle
housing.
The suspension cylinder requires only normal care
when handling as a unit. However, after being 2
disassembled, these parts must be handled carefully
to prevent damage to the machined surfaces.
Surfaces are machined to extremely close tolerances
and are precisely fitted. All parts must be completely
clean during assembly.
86326
FIGURE 50-20. REAR SUSPENSION

1. Boot 2. Protective Cover
16
4 3

being ejected from the suspension by the gas
pressure inside.
3. Discharge the nitrogen pressure from the
suspension as follows:
a. Connect the nitrogen charging kit to the
charging valve. Refer to "Suspension oiling
and charging procedures" in Testing and
adjusting section Accumulators and sus-
pensions for the charging kit installation
information.
b. If necessary, charge the suspension that is
being removed with dry nitrogen until the rod
is exposed approximately 127 mm (5 in.).
c. Place stands or cribbing under the truck
frame at each hoist cylinder mount.
d. Open the valve on the suspension charging
kit to release nitrogen from the suspension.
1 2
Ensure that the suspension is resting on
stands or cribbing. 86327
e. Disconnect the suspension charging kit.

4. Disconnect the lubrication lines and remove
pressure sensor (1).
17
NOTE: Remove the lower pin first. The mounting

arrangement for the top and bottom pins is identical.
6. Remove locknut (4, Figure 50-22), flat washer
(3) and shoulder bolt (2) at pin (1). Drive the pin
Use lifting equipment/lifting devices with from the bore.
adequate capacity to remove and install the NOTE: Spacers (5) will fall free.
components.
7. Repeat step 6 for the upper pin.
5. Secure the rear suspension to a lift truck or
8. Remove rear suspension (6) from the truck.
crane by using a suitable lifting device.
Move the suspension to a clean work area for
disassembly.
7 1 2
5 5
86328
FIGURE 50-22. REAR SUSPENSION PIN REMOVAL & INSTALLATION

1. Pin 5. Spacer
2. Shoulder Bolt 6. Rear Suspension
3. Flat Washer 7. Shoulder Bolt Hole
4. Locknut
18
Installation 9. Adjust the height of the piston rod until the lower
1. Inspect mounting bores and bearing spacers (5, suspension eye aligns with the lower frame
Figure 50-22) for damage and wear. Check the mounting ears. Repeat steps 3-8 to install the
fit of the pins in the bores before installing the bottom pin.
suspension. Replace worn or damaged parts. NOTE: The mounting arrangement for the top and
NOTE: The suspension assembly must be retracted bottom pins is identical.
as far as possible before installation. 10. Connect the lubrication lines and the pressure
sensor (1).
11. Service the rear suspensions. Refer to Testing
suspensions for the oiling and charging
Use lifting equipment/lifting devices with procedure.
adequate capacity to remove and install the 12. Install boot (1, Figure 50-20) and the clamp.
components.
2. Secure the rear suspension to a lift truck or
crane by using a suitable lifting device.
3. Position the top suspension eye between the
upper frame mounting ears. Orient the cylinder
so that the charging valve is facing the opposite
suspension cylinder.
4. Lubricate all pin bores with anti-seize
compound. Lubricating the pin bores aids in
removal and installation, as well as prevention
of rust and corrosion.
5. Align the shoulder bolt hole in pin (1) with
matching shoulder bolt hole (7) in the outer
frame mounting ear. Drive the pin far enough
into the outer frame mounting ear so that the pin
is held in position.
6. Insert one bearing spacer (5) between the top
suspension eye and the outer frame mounting
ear, then continue to drive in the pin through the
spherical bearing in the top suspension eye.
7. Insert remaining spacer (5) on the other side of
the top suspension eye and continue to drive in
the pin until the shoulder bolt hole in pin (1) is
aligned with matching shoulder bolt hole (7) in
the outer frame mounting ear.
8. Install shoulder bolt (2), flat washer (3) and
locknut (4). Tighten the locknut to 68 N·m (50 ft
lb).
19
Disassembly and assembly of rear 5. With the suspension in a vertical position (piston
suspension rod down), remove drain plug (1, Figure 50-24)
and allow the suspension oil to drain. A properly
NOTE: For proper seal installation and contamination charged rear suspension cylinder contains
prevention, disassembly and assembly work must be approximately 64.4 L (17 gal) of oil.
done in a clean, temperature controlled environment.
NOTE: There is another drain plug on the opposite
Disassembly side of the rod eye. Only one should be removed.
1. Place the rear suspension in a fixture with the
rod end down. The fixture should allow the
suspension to be rotated 180 degrees vertically.
2. If installed, remove protective cover (1, Figure
50-23).
To avoid possible injury, wear a face mask or

goggles while relieving nitrogen gas pressure.
3. Use a tool such as a screwdriver to depress the
valve stem of charging valve (2) to ensure that 1
all nitrogen gas pressure has been released.
4. After all nitrogen pressure has been relieved,
loosen the charging valve body (large hex) and
remove the charging valve assembly.
86335
1
FIGURE 50-24. REAR SUSPENSION DRAIN PLUG
1. Drain Plug
86330
1. Protective Cover 2. Charging Valve
20
8. Remove and wiper seal (1, Figure 50-26), main

seal (2), buffer seal (3) and rod bearing (4) from
the inside of bearing retainer (5).
9. Remove O-ring (7) and backup ring (6) from the
Use a lifting device with adequate capacity to outside of bearing retainer (5). Discard the O-
remove and install the components. ring and backup ring.
6. Rotate the cylinder 180 degrees. Remove
capscrews (1, Figure 50-25) and flat washers
(2). Lift piston (3) and bearing retainer (4) from 1
housing (6).
7. Remove bearing retainer (4) and piston bearing
(5) from piston (3). 2
3
2 1 3
5 6
7
86337
FIGURE 50-26. BEARING RETAINER SEALS

6
1. Wiper Seal 5. Bearing Retainer
3. Buffer Seal 7. O-ring
4. Rod Bearing
86336
FIGURE 50-25. PISTON ROD REMOVAL

1. Capscrew 4. Bearing Retainer
2. Flat Washer 5. Piston Bearing
3. Piston Rod 6. Housing
21
10. If spherical bearings (2, Figure 50-27) require Cleaning and inspection
replacement, remove retaining rings (1) and
press the bearing from the bore.
NOTE: Do not use metal tools to strike the spherical
bearings.
When using cleaning agents, follow the solvent
manufacturer's instructions.
1
solvent. Use a solvent that does not leave a film
after evaporation such as trichloroethane,
2 acetone or lacquer thinner.
2. Dry all parts completely using only dry, filtered
compressed air and lint free wiping materials.
damage. Inspect plated surfaces for scratches,
nicks or other defects. Replace or repair any
damaged parts.
1 NOTE: Contact your local Komatsu distributor for
repair information and instructions not covered in this
manual.
86338
1. Retaining Ring 2. Spherical Bearing
22
Assembly
NOTE: Lubricate all interior parts and bores with
clean suspension oil.
1. If removed, install spherical bearings (2, Figure
50-27). Install retaining rings (1) to secure the
bearings.
NOTE: Before installation, spherical bearings must
be shrunk by freezing. The temperature must not be
below -54°C (-65°F). A press may be necessary for
installation. Do not use metal tools to strike the
spherical bearings. Be careful during piston installation to prevent
2. Install bearing (4, Figure 50-26), buffer seal (3), damage to machined and chrome surfaces.
main seal (2) and wiper seal (1) on the inside of
bearing retainer (5). 4. Slide piston bearing (5, Figure 50-25) onto
3. Install new O-ring (7) and backup ring (6) on the lubricated piston (3).
outside of bearing retainer (5). 5. With housing (6) held in a vertical position,
lower the piston assembly partially into the
NOTE: Refer Figure 50-28 for the proper orientation housing. Slide bearing retainer (4) over the
of the seals. piston and into the housing. Install flat washers
(2) and capscrews (1). Tighten the capscrews to
420 ± 42 N·m (310 ± 31 ft lb).
NOTE: If the suspension is to be stored, fill with one
liter (two pints) of a rust preventive oil. This oil must
1 be drained when the suspension is put back into
service.
6. Install a new O-ring onto charging valve (2,
Figure 50-23). Install the charging valve into the
2 cylinder. Tighten the charging valve body (large
hex) to 23 N·m (17 ft lb).
If a new charging valve is being used, tighten
the swivel nut (small hex) to 15 N·m (11 ft lb),
then loosen and retighten the swivel nut to 15
N·m (11 ft lb). Loosen the swivel nut again, then
3 retighten it to 6 N·m (50 in lb). Install the valve
cap finger-tight.
7. Install protective cover (1).
8. Pressure test the rear suspension. Refer to the
4 Testing and adjusting section Accumulators
and suspensions.
5
86339
FIGURE 50-28. SEAL ORIENTATION

1. Wiper Seal 4. Backup Ring
2. Main Seal 5. O-ring
3. Buffer Seal
23
980E Dump truck

24
CEN50051-02
980E

980E-4 A40003 and up
980E-5 A50005 and up

Hoist circuit
Removal and installation of hoist pump ................................................................................................................ 3
Disassembly and assembly of hoist pump............................................................................................................ 8
Removal and installation of hoist valve ............................................................................................................... 17
Disassembly and assembly of hoist valve .......................................................................................................... 19
Overcenter manifold service ............................................................................................................................... 27
Removal and installation of hoist pilot valve ....................................................................................................... 28
Disassembly and assembly of hoist pilot valve................................................................................................... 30
Removal and installation of hoist cylinders ......................................................................................................... 32
Disassembly and assembly of hoist cylinders..................................................................................................... 35
1
NOTES
2
Removal and installation of hoist pump

Removal 2
NOTE: The hoist pump can be removed without
disconnecting the steering/brake pump hydraulic
hoses from the truck if desired.

penetrating the skin and cause serious injury, 1 86430
not received immediately. FIGURE 50-1. REAR AXLE BLOWER HOSE
Relieve pressure before disconnecting any 1. Rear Axle Blower Hose
hydraulic lines. Tighten all connections securely 2. Hoist Pump
hydraulic system.
2. Remove rear axle blower hose (1, Figure 50-1)
and the support bracket to allow hoist pump (2)
to be lowered from the pump mount bracket.
3. Clean the hoist pump and surrounding area
carefully to help avoid contamination of
hydraulic oil when the hoses are disconnected
are opened.
3
4. Loosen the capscrews that secure the outlet

hoses (1, Figure 50-2) and (2) and inlet hoses
(3) and (4) to the hoist pump. Allow the oil to
drain from each hose into a suitable container.
Always maintain complete cleanliness when 5. Remove the outlet hoses and inlet hoses. Cap or
opening any hydraulic connection. Ensure that all cover all hoses and pump ports to prevent
system lines and components are capped while contamination.
the component is removed from the truck.
3 2
86431
FIGURE 50-2. HOIST PUMP HOSE REMOVAL & INSTALLATION
1. Outlet Hose to Filter 3. Inlet Hose from Tank

2. Outlet Hose to Filter 4. Inlet Hose from Tank
4
7. Open the driveshaft guard. Remove flange

mounting hardware (3) that secures the hoist
pump companion flange to the driveshaft. There
are a total of eight capscrews.
Use a lifting device with adequate capacity to 8. Remove hoist pump mounting hardware (2) that
remove and install the component. secures the hoist pump to the mounting
structure. There are a total of four capscrews.
6. Attach a suitable lifting device to hoist pump (1,
Figure 50-3). Attach a support to the front end of
the steering/brake pump to hold it in place
during removal of the hoist pump.
2 1
3
86432
FIGURE 50-3. HOIST PUMP REMOVAL & INSTALLATION

1. Hoist Pump 3. Flange Mounting Hardware
2. Hoist Pump Mounting Hardware
5
9. Ensure that the lifting and support devices are in 11. Remove two capscrews (3). Slide the hoist
place on both pumps. Loosen (but do not pump forward to disengage the splines of the
remove) two capscrews (3, Figure 50-4) that coupling from steering/brake pump shaft (5).
secure steering/brake pump (2) to hoist pump
12. Move the hoist pump to a clean work area for
(1).
disassembly.
10. Remove two nuts, lockwashers and flat washers
(4), then slide the threaded stud out of the
support bracket. Lower the pumps, allowing
hoist pump (1) to come down farther than
steering/brake pump (2).
2
1
5
86433
FIGURE 50-4. HOIST PUMP REMOVAL & INSTALLATION

1. Hoist Pump 4. Nut, Lockwasher and Flat Washer
2. Steering/Brake Pump 5. Pump Shaft
3. Capscrew
6
Installation 4. Slide the threaded studs through the pump

mounting holes and support bracket, then install
NOTE: The following procedure assumes that the
two nuts, lockwashers and flat washers (4).
steering/brake pump hydraulic hoses are already
Tighten the nuts to the standard torque.
connected.
5. Install hoist pump mounting hardware (2) that
1. Install new O-ring (2, Figure 50-5) and shaft secures the hoist pump to the mounting
coupling (1) on the hoist pump. structure. Tighten the four capscrews to the
standard torque.
6. Install flange mounting hardware (1, Figure 50-
3) that secures the hoist pump companion
2 flange to the driveshaft. Tighten the eight
1
capscrews to the standard torque. Close the
driveshaft guard.
7. Uncap the inlet hoses, the outlet hoses and the
pump ports. Attach the hoses to the pump with
86434
new O-rings. Tighten the capscrews securely.
FIGURE 50-5. HOIST PUMP SHAFT COUPLING 8. Fill the hydraulic tank with clean hydraulic oil.
1. Shaft Coupling 2. O-ring
If trapped air is not bled from the pump, possible

pump damage and no output may result.
Use a lifting device with adequate capacity to 9. To bleed trapped air from the pump, loosen the
remove and install the component. capscrews on inlet hoses (3, Figure 50-2) and
(4) at the pump, then loosen the capscrews on
2. Attach a suitable lifting device to the hoist pump. outlet hoses (1) and (2) at the pump. Tighten all
Move the pump into position for installation. capscrews securely.
3. Lubricate the splines of steering/brake pump 10. Install rear axle blower hose (1, Figure 50-1)
shaft (5, Figure 50-4) and align it with the shaft and the support bracket.
coupling on hoist pump (1). Install the hoist
pump onto steering/brake pump (2) using
capscrews (3) with hardened washers. Tighten
the capscrews to the standard torque. Raise the
pumps into position.
7
Disassembly and assembly of hoist pump 3. Place hoist pump (1, Figure 50-7) on wood
blocks (2) so that the shaft of input drive gear (3)
Disassembly is facing downward. Draw a match mark across
NOTE: As parts are removed, they should be laid out each section of the hoist pump to aid in
in a group in the same order in which they are reassembly.
removed.
1. Thoroughly clean the exterior of the pump
assembly. If the steering/brake pump is
attached, remove the steering/brake pump from
the hoist pump.
2. Remove coupling (1, Figure 50-6) from
transition plate (2). Remove and discard the
internal snap ring if installed.
1
2
86505
FIGURE 50-6. HOIST PUMP DISASSEMBLY & 3

ASSEMBLY 86506
1. Coupling 2. Transition Plate FIGURE 50-7. HOIST PUMP DISASSEMBLY &

ASSEMBLY
1. Hoist Pump 3. Input Drive Gear
2. Wood Blocks
8
4. Remove four nuts (1, Figure 50-8) and flat 6. Remove eight nuts (1, Figure 50-9) and flat
washers (2). Remove transition plate (3) and washers (2). Remove connector plate (3) and
bearing plate (4) as a unit. Remove the O-ring the O-ring. If the connector plate is stuck, tap it
from the bearing plate. lightly with a plastic hammer to loosen it.
5. Remove the capscrews that secure bearing 7. Remove studs (4), the dowels and shaft
plate (4) to transition plate (3). Separate the bearings from connector plate (3) if necessary.
plates and remove the O-ring. Remove the
dowels if necessary.
4 3
2 1
3
2 1
2 1
4
86509
86508
FIGURE 50-9. HOIST PUMP DISASSEMBLY &
ASSEMBLY
ASSEMBLY 1. Nut 3. Connector Plate
2. Flat Washer 4. Stud
1. Nut 3. Transition Plate
2. Flat Washer 4. Bearing Plate
9
8. Remove O-ring (1, Figure 50-10) and backup 11. Remove bearing plate (1, Figure 50-11) and the
ring (2). Remove dowels (5) from gear plate (4) O-ring. Remove eight stud O-rings (2). Remove
if necessary. dowels (4) if necessary.
9. Grasp idler gear (6) and rear drive gear (7) and 12. Remove coupling (6). Remove retainer ring (5) if
pull straight up and out of the bore of gear plate replacement is necessary.
(4). Remove pressure plate (3) from the gears.
NOTE: Disassembly of the rear pump section is now
10. Remove gear plate (4). Remove remaining complete. Do not remove studs (3) at this time as the
pressure plate (3), backup ring (2) and O-ring studs serve as guides for disassembly.
(1).
3 4
A 6 7 A 2
5
5
1
4
6
1 2 3
3 2
86507

ASSEMBLY
1 1. Bearing Plate 4. Dowel
2. Stud O-ring 5. Retainer Ring
VIEW A - A 3. Stud 6. Coupling
86510

ASSEMBLY
1. O-ring 5. Dowel
2. Backup Ring 6. Idler Gear
3. Pressure Plate 7. Rear Drive Gear
4. Gear Plate
10
13. Remove connector plate (1, Figure 50-12) and 17. Remove gear plate (4). Remove remaining
both O-rings. If the connector plate is stuck, tap pressure plate (3), backup ring (2) and O-ring
it lightly with a plastic hammer to loosen it. (1).
14. Remove 16 stud O-rings (2). Remove dowels
(3) if necessary.
A 6 7 A
3
5
2
1 4
1 2 3
3 2
86513

ASSEMBLY
1. Connector Plate 3. Dowel
2. Stud O-ring
1
VIEW A - A 86515
15. Remove O-ring (1, Figure 50-13) and backup FIGURE 50-13. HOIST PUMP DISASSEMBLY &
ring (2). Remove dowels (5) from gear plate (4) ASSEMBLY
if necessary.
1. O-ring 5. Dowel
16. Grasp idler gear (6) and drive gear (7) and pull 2. Backup Ring 6. Idler Gear
straight up and out of the bore of gear plate (4). 3. Pressure Plate 7. Input Drive Gear
Remove pressure plate (3) from the gears. 4. Connector Plate
11
18. Unscrew and remove eight studs (1, Figure 50- 21. After the shaft seals and retainer ring have been
14) from flange (2). Remove dowels (5) if removed, clean the bore thoroughly. If
necessary. necessary, the bore may be smoothed with
19. Remove inboard shaft seal (4) and snap ring (5) number 400 emery paper only.
from the flange bore.
20. Use a hammer and punch to tap outboard shaft
seal (6) out of the flange bore (see Figure 50-
15). Be careful not to mar, scratch or damage
the seal bore surface or bearings.
5 7
6 86516

ASSEMBLY
1. Stud 4. Inboard Shaft Seal
2. Flange 5. Snap Ring
3. Dowel 6. Outboard Shaft Seal
FIGURE 50-15. SHAFT SEAL REMOVAL
1. Flange 3. Bearings
2. Punch
12
Inspection 5. Inspect the bearings. If they are worn beyond

1. Inspect the gear bores in both gear plates (2, the gray TeflonTM into the bronze material, the
Figure 50-16). During the initial break-in, the entire flange, connector plate or bearing plate
gears cut into the aluminum gear plates. The must be replaced.
nominal depth of this cut is 0.203 mm (0.008 in.)
and should not exceed 0.381 mm (0.015 in.).
As the gear teeth cut into the gear plates, metal
is rolled against the pressure plates. Use a knife
or sharp pointed scraper to remove the metal
that was rolled against the pressure plates.
Remove all metal chips that were broken loose.
When removing the rolled up metal, do not

attempt to remove gear track-in grooves (1).
2. Inspect the pressure plates. They should not FIGURE 50-16. GEAR BORE INSPECTION
show excessive wear on the bronzed side. If 1. Gear Track-In Groove 2. Gear Plate
deep, curved wear marks are visible, replace
the pressure plates.
3. Inspect the gears. If excessive wear is visible on
NOTE: Installing a new bearing in the flange,
the journals, sides, or face of the gears, or at the
connector plates or bearing plate is not
point where the drive gear rotates in the lip seal,
recommended due to close tolerances and special
replace the gears.
tooling required for crimping the bearing in place to
4. If any of the internal parts show excessive wear, prevent bearing spin.
replace them. Replace all O-rings and seals.
6. Inspect the flange seal bore for scratches and
gouges which may interfere with shaft seal
installation.
13
Assembly 3. Lubricate the shaft seals with clean type C-4

hydraulic oil. Position inboard shaft seal (4,
NOTE: A suitable seal press ring or plug and two
Figure 50-14) so that the metal face is toward
small wood blocks should be available.
the outboard end of flange (2).
The following seal installation procedure is outlined 4. Position the press ring over the inboard shaft
for use with a vise, but it can be adapted for use with seal. Ensure that the seal stays centered and
a press if one is available. true with the bore, then start applying pressure
1. Open the vise jaws wide enough to accept the with the vise. Continue pressing the seal until it
combined thickness of the flange, wood blocks just clears the retainer ring groove in the bore.
and press ring. 5. Install snap ring (5) so that the retainer ring
2. Place wood blocks (2, Figure 50-17) flat against opening is over the weep hole (7).
the fixed jaw of the vise. Place flange (1) against 6. Install outboard shaft seal (6) so that the metal
the wood blocks so that bearing projections (3) face is toward the outboard end of flange (2)
are between the wood blocks and clear of the until it just contacts snap ring (5).
vise jaw. 7. Remove flange (2) from the vise (or press).
Place the flange on wood blocks so that, when
installed, the input driveshaft is facing
downward. See Figure 50-7.
8. Lubricate the threads of four short studs (1,
Figure 50-18) and four long studs (2) with clean
type C-4 hydraulic oil. Thread the studs into
flange (2) until they bottom out. Refer to Figure
50-18 for proper stud location.
2
SUCTION
1 1
FIGURE 50-17. SHAFT SEAL INSTALLATION

1. Flange 3. Bearing Projection
2. Wood Blocks DISCHARGE
2
86517
FIGURE 50-18. STUD INSTALLATION

1. Short Studs 2. Long Studs
14
NOTE: Align the match marks when assembling the 17. Lubricate and install both O-rings and 16 stud
pump plates. O-rings (2, Figure 50-12) in connector plate (1).
9. Lubricate and install the O-ring in flange (2 Lubricate the bearings in the connector plate.
Figure 50-14). If removed, install dowels (3). 18. If removed, install dowels (3). Install connector
10. Install gear plate (4, Figure 50-13). Ensure that plate (1).
the recess in the gear plate is facing upward. 19. Install retainer ring (5, Figure 50-11) and
11. Install backup ring (2) and O-ring (1) into the coupling (6).
gear bores. Ensure that the O-ring and backup 20. Lubricate and install the O-ring and eight stud
ring are oriented toward the discharge side of O-rings (2) in bearing plate (1). If removed,
the gear plate. Refer to Figure 50-18. install dowels (4). Install bearing plate (1).
12. Slide pressure plate (3, Figure 50-13) down into 21. If removed, install dowels (5, Figure 50-10).
the gear bores until the backup ring and O-ring Install gear plate (4). Ensure that the recess in
are seated in the groove. Do not force the the gear plate is facing downward.
pressure plate down into the gear bores. If it
gets stuck, work the pressure plate back and 22. Install backup ring (2) and O-ring (1) into the
forth until it slides freely into place. gear bores. Ensure that the O-ring and backup
ring are oriented toward the discharge side of
13. Lubricate the bearings in the gear plate, idler the gear plate. Refer to Figure 50-18.
gear (6) and drive gear (7) with clean type C-4
hydraulic oil. 23. Slide pressure plate (3, Figure 50-10) down into
the gear bores until the backup ring and O-ring
NOTE: To ensure that the hoist pump is correctly are seated in the groove. Do not force the
timed during reassembly, place a mark on the end of pressure plate down into the gear bores. If it
the input shaft to indicate the location of the valley gets stuck, work the pressure plate back and
between any two gear teeth. Refer to Figure 50-19 forth until it slides freely into place.
which illustrates gear timing.
24. Lubricate the bearings in the gear plate, idler
gear (6) and drive gear (7) with clean type C-4
hydraulic oil.
25. Install idler gear (6) and rear drive gear (7). The
rear drive gear must be timed with the input
Do not drop the drive gear in the bore. Damage to drive gear by lining up a tooth on the rear drive
the bronze face of the pressure plate could result. gear with the valley of two teeth on the input
drive gear as shown in Figure 50-19.
14. Carefully insert the shaft of input drive gear (7,
Figure 50-13) through the shaft seals in the
flange until the drive gear is resting on pressure
plate (3).
15. Install idler gear (6).
16. Install the other pressure plate (3), backup ring
(2) and O-ring (1) into the gears. Ensure that the
O-ring and backup ring are facing upward and
oriented toward the discharge side of the gear
plate. Refer to Figure 50-18.
FIGURE 50-19. PUMP GEAR TIMING
15
26. Install the other pressure plate (3, Figure 50-10), 32. Lubricate the threads of the two of eight studs
backup ring (2) and O-ring (1) into the gears. that are 180 degrees apart. Install two flat
Ensure that the O-ring and backup ring are washers (2, Figure 50-9) and nuts (1). Tighten
facing upward and oriented toward the the nuts to 325 - 339 N·m (240 - 250 ft lb).
discharge side of the gear plate. Refer to Figure
33. Turn over the pump so that the shaft of the input
50-18.
drive gear is facing upward. Use a 45 cm (18
27. Lubricate and install the O-ring in connector in.) adjustable wrench to check the pump
plate (3, Figure 50-9). Lubricate the bearings in driveshaft rotation (See Figure 50-20). The
the connector plate, then install connector plate driveshaft will be tight but should turn freely with
(3). If removed, install dowels (4). a maximum torque of 7 - 14 N·m (5 - 10 ft lb)
28. Lubricate and install the O-ring in transition plate after the initial surge.
(3, Figure 50-8). Use the capscrews to 34. If the driveshaft will not turn properly,
assemble bearing plate (4) onto the transition disassemble the pump and inspect the parts for
plate. Tighten the capscrews to the standard burrs or foreign material that may be causing
torque. buildup or interference between parts.
29. Lubricate and install the O-ring in the bottom of 35. When the driveshaft turns properly, install the
bearing plate (4). Install assembled the bearing remaining six flat washers (2, Figure 50-9) and
plate/transition plate assembly onto the nuts (1). Tighten the nuts to 325 - 339 N·m (240
connector plate. - 250 ft lb).
30. Install flat washers (2) and nuts (1). Tighten the
nuts to the standard torque.
31. Install coupling (1, Figure 50-6).
A snap ring may have been installed previously

inside the coupling. This snap ring is not
necessary and must not be used. In some cases,
depending on tolerance stack-up, the snap ring
can cause excessive axial loading, leading to
premature pump failure.
FIGURE 50-20. CHECKING PUMP DRIVE

ROTATION
1. Wrench 3. Pump
2. Driveshaft
16
Removal and installation of hoist valve 1. Refer to the "Hydraulic system bleeddown
Removal Steering, hoist, brake cooling and auxiliary
hydraulic system.
2. Thoroughly clean the exterior of hoist valve (1,
Figure 50-21).
3. Disconnect six hydraulic tubes (2) and three
Hydraulic oil escaping under pressure can have hydraulic hoses (3) at the hoist valve.
sufficient force to enter a person's body by Disconnect three hydraulic hoses from pilot
penetrating the skin and cause serious injury, hose fittings (4).
and possibly death, if proper medical treatment is 4. Plug the hydraulic lines and valve ports to help
not received immediately. prevent contamination. Mark each hydraulic line
Relieve pressure before disconnecting any to aid in correct installation.
2 4 2
1 2 2
3
2
2 4
3
4
86435
FIGURE 50-21. HOIST VALVE & PIPING

1. Hoist Valve 3. Hose
2. Tube 4. Pilot Hose Fitting
17
10. Remove three nuts (1, Figure 50-22),

lockwashers (2), flat washers (3) and capscrews
(4) that secure hoist valve (5) to the mount.
11. Attach a lifting device to the hoist valve and
Use a lifting device with adequate capacity to remove it from the truck. Move the hoist valve to
remove and install the component. a clean work area for disassembly.
1 2
3 4
86436
FIGURE 50-22. HOIST VALVE REMOVAL & INSTALLATION

1. Nut 4. Capscrew
2. Lockwasher 5. Hoist Valve
3. Flat Washer
18
Installation Disassembly and assembly of hoist valve

O-ring replacement
NOTE: It is not necessary to remove the individual
valve sections to accomplish repairs unless the O-
rings between the valve sections must be replaced to
Use a lifting device with adequate capacity to prevent leakage. Loosening and re-tightening the
remove and install the component. main valve tie rod nut could cause distortion,
1. Attach a suitable lifting device to hoist valve (5, resulting in binding or severely sticking plungers,
Figure 50-22). Move the hoist valve into position poppet and spools.
on top of the mount.
To replace the O-rings between the valve sections:
2. Secure the hoist valve with three nuts (1),
lockwashers (2), flat washers (3) and capscrews 1. Remove four nuts and washers (5, Figure 50-
(4). Tighten the nuts to the standard torque. 23) from the tie rods on one end of the hoist
valve. Slide tie rods (6) from the valve and
3. Unplug the hydraulic lines and valve ports.
separate the valve sections.
Install new O-rings at the flange fittings, then
connect six hydraulic tubes (2, Figure 50-21)
and three hydraulic hoses (3) to the hoist valve.
Tighten the flange capscrews to the standard
torque.
4. Connect three hydraulic hoses to pilot hose
fittings (4).
5. Check the hydraulic tank oil level and add oil, if
needed.
6. Start the engine. Raise the body and remove
the body-up retention cable. Lower and raise
the body to check for proper operation and
leaks.
FIGURE 50-23. HOIST VALVE ASSEMBLY

1. Inlet Section (Rear) 4. Inlet Section (Front)
2. Spool Section (Work 5. Nuts and Washers
Ports) 6. Tie Rods
3. Spool Section 7. Tube
(Tank Ports) 8. Separator Plate
19
2. Inspect the machined sealing surfaces for 5. Use a torque wrench to tighten the nuts in the
scratches and nicks. If scratches or nicks are pattern shown in Figure 50-25. Tighten the tie
found, remove them by lapping on a smooth flat rod nuts evenly in the following sequence:
steel surface with fine lapping compound.
a. First, tighten the nuts to 20 N·m (15 ft lb) in
3. Lubricate the new O-rings lightly with order 1, 4, 2, 3.
multipurpose grease and install them between
b. Next, tighten the nuts to 43 N·m (32 ft lb) in
the valve sections. Stack the valve sections
order 1, 4, 2, 3.
together, making sure that the O-rings between
the sections are properly positioned. c. Finally, tighten the nuts to 142 N·m (105 ft lb)
4. Install the four tie rods with the dished washer in order 1, 4, 2, 3.
between the nut and housing (See Figure 50-
24).
FIGURE 50-24. TIE ROD INSTALLATON FIGURE 50-25. TIGHTENING SEQUENCE
20
Disassembly of inlet section 2. Remove capscrews (1, Figure 50-26) and inlet
cover (2). Remove springs (3) and (5) and flow
NOTE: Match mark or identify each part when
control/main relief valve (4). Remove sleeve (6),
removed in respect to its location or mating bore to
low pressure relief valve (7) and O-rings (8).
aid in reassembly.
3. Remove capscrews (14) and cover (13).
NOTE: The inlet section is shown removed from the Remove springs (12), check valves (11) and O-
main valve body for clarity. rings (10).
1. Disconnect tube (7, Figure 50-23) from inlet
cover (2, Figure 50-26).
FIGURE 50-26. INLET SECTION DISASSEMBLY
1. Capscrew 6. Sleeve 10. O-Rings

2. Inlet Cover 7. Secondary Low Pressure 11. Check Valves
3. Spring (Orange) Relief Valve 12. Springs
4. Flow Control/Main Relief Valve 8. O-Rings 13. Cover
5. Spring 9. Inlet Valve Body 14. Capscrews
21
NOTE: If removal of the restrictor poppet in inlet Assembly of inlet section

cover (2) is required, proceed to the next step.
1. Discard all O-rings and backup rings. Clean all
4. Remove sleeve (9, Figure 50-27), backup ring parts in solvent and dry with compressed air.
(8), O-ring (7) and backup ring (6). Remove
2. Inspect all springs for breaks and distortion.
backup ring (5), O-ring (4), backup ring (3) and
Inspect poppet seating surfaces for nicks or
restrictor poppet (2).
excessive wear. All seats must be sharp and
5. Repeat the procedure for the opposite inlet free of nicks.
section if disassembly is required.
3. Inspect all bores and surfaces of sliding parts
for nicks, scores and excessive wear.
4. Inspect the poppets in their respective bore for
proper fit. Poppets should move freely through a
complete revolution without binding.
5. Inspect the fit and movement between the
sleeve and low pressure relief valve.
6. Coat all parts, including the housing bores, with
clean type C-4 hydraulic oil. Lightly lubricate
new O-rings with a multipurpose grease.
7. If restrictor poppet (2, Figure 50-27) was
removed, reassemble it in the order shown.
8. Install check valves (11, Figure 50-26) in their
respective bores. Install springs (12).
9. Install O-rings (10) and cover (13). Install and
tighten capscrews (14) to 81 N·m (60 ft lb).
10. Install low pressure relief valve (7) in sleeve (6),
then install the assembly in housing (9). Install
flow control/main relief valve (4), springs (3) and
(5), and inlet cover (2). Install and tighten
capscrews (1) to 81 N·m (60 ft lb).
11. Connect tube (7, Figure 50-23) and tighten the
nuts to 34 N·m (25 ft lb).
FIGURE 50-27. RESTRICTOR POPPET REMOVAL

(Inlet Cover)
1. Inlet Cover 6. Backup Ring
2. Restrictor Poppet 7. O-ring
3. Backup Ring 8. Backup Ring
4. O-Ring 9. Sleeve
5. Backup Ring
22
Disassembly of rear spool section 5. Remove spool assembly (20, Figure 50-29).
Note the color of the lower spring (blue) to
NOTE: It is not necessary to remove inlet sections (1,
ensure proper location during reassembly. Also
Figure 50-23) or (4) to disassemble spool sections (2)
note the “V” groove on the top end of the spool.
or (3).
6. Remove plug (3) from the end of the spool.
NOTE: Match mark or identify each part when Remove spring seat (2) and spring (11).
removed in respect to its location or respect to its Remove poppet (21) and spool end (15).
mating bore to aid reassembly.
NOTE: Pay special attention to poppets (12), (21)
1. Remove the capscrews and lift spool cover (1, and (22) during removal to ensure proper location
Figure 50-29) from the housing. during reassembly. Poppets may be identified with a
2. Remove poppet (6) from the spool cover. colored dot (red, green or white). If the poppets are
Remove and discard O-ring (8). not color coded, use the table below and the
NOTE: The poppet contains a small steel ball (7). Do specified drill bit to measure the orifice diameter for
not misplace it. proper identification.
3. Remove and discard O-rings (4) and (5).
4. Remove restrictor poppet (1, Figure 50-28). POPPET ORIFICE DRILL
Remove and discard O-ring (2) and backup ring COLOR DIAMETER SIZE
(3), if used. Note the position of the restrictor Red 3.556 mm (.140 in.) #28
poppet when removed to ensure correct
Green 2.362 mm (.093 in.) #42
reassembly.
White 1.600 mm (.063 in.) #52
7. Repeat step 6 to disassemble the opposite end

of spool assembly (20). Note that there is no
plug or restrictor poppet in the opposite end and
the spring is blue.
8. Remove spool assembly (14). At the top end of
the spool, remove plug (3). Remove spring seat
(2) and spring (11). Remove restrictor poppet
(12) and spool end (15).
9. At the opposite end, remove plug (3), spring
seat (2) and spring (16). Remove restrictor
poppet (22) and spool end (15).
10. Remove spool cover (19) and O-rings (4), (5)
and (10). Remove poppet (18).
FIGURE 50-28. RESTRICTOR POPPET

1. Restrictor Poppet 4. O-Ring
2. O-Ring * 5. O-Ring
3. Backup Ring *
* Items 2 and 3 not used on all valves.
23
FIGURE 50-29. REAR SPOOL SECTION ASSEMBLY

1. Spool Cover 8. O-Ring 14. Spool Assembly 21. Restrictor Poppet
2. Spring Seat 9. Restrictor Poppet 15. Spool End (Green)
3. Plug 10. O-Ring 16. Spring (Blue) 22. Restrictor Poppet
4. O-Ring 11. Spring 17. O-Ring (White)
5. O-Ring 12. Restrictor Poppet 18. Poppet
6. Poppet (Red) 19. Spool Cover
7. Steel Ball 13. Spool Housing 20. Spool Assembly
24
Assembly of rear spool section 11. Lubricate the assembled spool and install it in
1. Discard all O-rings and backup rings. Clean all the spool housing (See Figure 50-30). Make
parts in solvent and blow dry with compressed sure that “V” groove (1) in spool assembly (2) is
air. positioned up as noted.
2. Inspect all springs for breaks and distortion. NOTE: Spool assemblies (14, Figure 50-29) and (20)
Inspect the poppet seating surfaces for nicks are physically interchangeable. Ensure that spool
and excessive wear. All seats must be sharp assembly (14) is installed toward the base port of the
and free of nicks. spool housing.
3. Inspect all bores and surfaces of sliding parts 12. If used, install O-ring (2, Figure 50-28) and
for nicks, scores and excessive wear. backup ring (3) on restrictor poppet (1). Install
4. Inspect all poppets in their respective bore for the poppet in the spool housing as shown in
proper fit. Poppets should move freely through a Figure 50-29.
complete revolution without binding. 13. Install new O-rings (4, Figure 50-29), (5) and
5. Lubricate O-rings (4, Figure 50-29), (5) and (10) (10).
with clean hydraulic oil. Install the O-rings in 14. Install a new O-ring (and backup ring, if used)
spool housing (13). Install poppet (18). Install on poppet (6). Ensure that small steel ball (7) is
spool cover (19) and secure it with the installed in the poppet. Install the poppet in
capscrews. Tighten the capscrews to 81 N·m spool cover (1).
(60 ft lb).
15. Position spool cover (1) over spool housing (13).
6. Install spring (11) in spool assembly (20). Install
Install and tighten the capscrews to 81 N·m (60
spring seat (2). Apply Loctite to the threads of
ft lb).
spool end (15). Install the spool end and tighten
it to 34 N·m (25 ft lb). Install restrictor poppet NOTE: The cover must be positioned according to
(21). Apply Dri-loc #204 to the threads of plug the match marks that were made during disassembly.
(3). Install and tighten the plug to 20 N·m (15 ft Do not reverse the cover position.
lb).
NOTE: Poppets (12), (21) and (22) may be color
coded and must be installed in their original location.
7. Repeat Step 6 for the opposite end of spool
assembly (20). Ensure that spring (16) is blue. A
poppet and plug are not installed in the lower
end.
8. Lubricate the spool assembly and carefully
install it in the spool housing (See Figure 50-30).
Make sure that “V” groove (1) in spool assembly
(2) is positioned up as noted.
9. Install spring (11, Figure 50-29) in the top
(grooved) end of remaining spool assembly
(14). Install spring seat (2). Apply Loctite to the
threads of spool end (15). Install spool end and
tighten it to 34 N·m (25 ft lb). Install red
restrictor poppet (12). Apply Dri-loc #204 to the
threads of plug (3). Install and tighten the plug to FIGURE 50-30. SPOOL INSTALLATION
20 N·m (15 ft lb).
10. Repeat Step 9 for the bottom end of spool 1. “V” Groove 3. Work Ports Spool
assembly (14). Ensure that spring (16) is blue. 2. Spool Assembly Section
25
Disassembly of front spool section 1. Remove the capscrews and lift spool cover (4,
Figure 50-31) from spool housing (1).
NOTE: It is not necessary to remove inlet sections (1,
Figure 50-23) or (4) to accomplish spool section 2. Remove and discard O-rings (5) and (6).
disassembly and repair. 3. Remove the capscrews and spool cover (9)
from spool housing (1). Remove and discard the
NOTE: Match mark or identify each spool in respect
O-rings.
to its mating bore when removed.
4. Remove springs (8). Push spools (7) out of the
housing bores.
FIGURE 50-31. FRONT SPOOL SECTION ASSEMBLY

1. Spool Housing 4. Spool Cover 7. Spool
2. Plug 5. O-Ring 8. Spring
3. O-Ring 6. O-Ring 9. Spool Cover
26
Assembly of front spool section 6. Lubricate O-rings (5) and (6) and install them in
1. Discard all O-rings. Clean all parts in solvent the top of the spool housing. Install top cover (4)
and blow dry with compressed air. and secure it in place with capscrews. Tighten
the capscrews to 81 N·m (60 ft lb).
2. Inspect the springs for breaks and distortion.
7. If removed, install plugs (2) with new O-rings
3. Inspect the housing bores and surfaces of the (3).
spools for nicks, scoring and excessive wear.
4. Lubricate spools (7, Figure 50-31) with clean Overcenter manifold service
hydraulic oil and reinstall them in their original
Overcenter manifold (1, Figure 50-32) is located at
bores. Install springs (8).
the rear of the hoist valve. The O-rings and backup
5. Lubricate O-rings (5) and (6) with clean rings on counterbalance valve (2), needle valve (3)
hydraulic oil. Install the O-rings in the bottom of and check valves (4) may need to be replaced if
the spool housing. Install bottom cover (9) and leaking occurs.
secure it in place with capscrews. Tighten the
SEE
1 DETAIL A
2
DETAIL A 86521
FIGURE 50-32. OVERCENTER MANIFOLD VALVES

1. Overcenter Manifold 3. Needle Valve
2. Counterbalance Valve 4. Check Valve
27
Removal and installation of hoist pilot Installation

valve 1. Place hoist pilot valve (1, Figure 50-33) into
Removal position on the mounting bracket. Secure the
hoist pilot valve with mounting hardware (2).
2. Connect hydraulic lines (3) to the correct
fittings. Tighten the hydraulic line connections
securely.
Hydraulic oil escaping under pressure can have 3. Place the hoist control lever in the spring-
sufficient force to enter a person's body by centered position. Adjust the pilot valve spool
penetrating the skin and cause serious injury, until the centerline of the cable attachment hole
and possibly death, if proper medical treatment is extends 29.5 mm (1.16 in.) from the face of the
not received immediately. valve body.
4. Align the eye of control cable (7) with the pilot
valve spool hole, then insert pin (10). Secure
the pin with cotter pin (6).
5. Thread sleeve (9) upward until it contacts the
valve body. Move flange (4) into position and
secure it two machine screws (5).
hydraulic system. 6. Thread jam nut (8) against sleeve (9). Tighten
the jam nut securely.
2. Disconnect hydraulic lines (3, Figure 50-33) at
hoist pilot valve (1) located in the hydraulic 7. Start the engine and check for proper hoist
brake cabinet. Mark each line and its hoist pilot operation and leaks.
valve fitting to aid in proper installation. Plug the
lines to help prevent contamination from
entering the hydraulic system.
3. Remove two machine screws (5).
4. Loosen and unthread jam nut (8). Unthread
sleeve (9) until cotter pin (6) and pin (10) are
exposed. Remove the cotter pin and pin to
unhook control cable (7).
5. Remove mounting hardware (2) and hoist pilot
valve (1).
28
1 3
29.5 mm 4 2
(1.16 in.)
5
10
FLOAT 6
Position
3
9
86522
FIGURE 50-33. HOIST PILOT VALVE & PIPING

1. Hoist Pilot Valve 4. Flange 7. Control Cable 10. Pin
2. Mounting Hardware 5. Machine Screw 8. Jam Nut
3. Hydraulic Lines 6. Cotter Pin 9. Sleeve
29
Disassembly and assembly of hoist pilot 8. Remove nuts (8) and (10, Figure 50-35) and
valve remove tie rods (9). Separate the valve
housings. Remove O-ring (11). Remove the
Disassembly poppet check and spring (located on the outlet
1. Thoroughly clean the exterior of the valve. housing side of the spool housing) from the
Match mark inlet housing (18) and outlet spool housing.
housing (7) in relation to spool housing (17) to
ensure proper reassembly.
2. Remove machine screws (15, Figure 50-35),
seal plate (16), wiper (13) and O-ring (12).
3. Remove snap ring (1), capscrews (6), cap (24),
spacer (23), and detent sleeve (22). Detent balls
(2) and (21) will fall free when the cap and
detent sleeve are removed. Separate cap (24),
spacer (23) and detent sleeve (22).
4. Carefully slide spool (14) out of spool housing
(17). Remove seal retainer (25), wiper (26) and
O-ring (27) from the spool.
5. Insert a rod in the cross holes of detent pin (3)
and unscrew it from spool (14). Exert slight
pressure against the detent pin as it disengages
and spring tension is released.
6. Remove spring seats (19), spring (4) and
spacer (5).
7. Remove relief valve (2, Figure 50-34) from
spool housing (1).

1. Snap Ring 15. Machine Screw
2. Ball (4) 16. Seal Plate
3. Detent Pin 17. Spool Housing
4. Spring 18. Inlet Housing
5. Spacer 19. Spring Seat
6. Capscrew 20. Spring
7. Outlet Housing 21. Ball (1)
86523 8. Nut 22. Detent Sleeve
FIGURE 50-34. HOIST PILOT RELIEF VALVE 9. Tie Rod 23. Spacer
10. Nut 24. Cap
1. Spool Housing 2. Relief Valve
11. O-Ring 25. Seal Retainer
12. O-Ring 26. Wiper
13. Wiper 27. O-Ring
14. Spool
30
Cleaning and inspection 9. Install new O-ring (12) and wiper (13). Install
1. Clean all parts, including the housings, in seal plate (16) and machine screws (15).
solvent and blow dry with compressed air. 10. Install relief valve (2, Figure 50-34) with new O-
2. Inspect the seal counter bores. They must be rings in spool housing (1).
free of nicks and grooves.
3. Examine springs for breaks or distortion.
4. Inspect spool (14, Figure 50-35). The spool
must be free of longitudinal score marks, nicks
or grooves.
5. Test spool (14) in spool housing (17) for proper
fit. The spool must fit and rotate freely through a
complete revolution without binding.
NOTE: Spool housing (17), spool (14), inlet housing
(18) and outlet housing (7) are not serviced
separately. If any of these parts require replacement,
the entire hoist pilot valve must be replaced.
Assembly
1. Thoroughly coat all parts, including the housing
bores, with clean type C-4 hydraulic oil.
2. If the inlet and outlet housings were removed:
a. Install check poppet (2, Figure 50-36) and
spring (3) in spool housing (1). 1. Spool Housing 4. O-Ring
2. Check Poppet 5. Outlet Housing
b. Install new O-ring (4) in spool housing. Place 3. Spring
the inlet and outlet housings on the spool
housing.
c. Install the tie rods and nut. Tighten the tie rod
nuts to the torques shown in Figure 50-37.
3. Install new O-ring (27, Figure 50-35) and wiper
(26). Install seal retainer (25).
4. Install spacer (5), spring seats (19), and spring
(4). Thread detent pin (3) into spool (14). Exert
slight pressure to compress the detent spring.
Tighten the detent pin to 9 - 11 N·m (84 - 96 in
lb). Install spring (20). Carefully install the spool
into the spool housing.
5. Apply grease to the cross holes of the detent pin
(3) to hold balls (2) and (21).
6. Slide detent sleeve (22) into cap (24) and place
it over a punch. Use the punch to depress ball
(21) and insert balls (2) in the cross holes.
7. While holding down ball (21), slide detent
sleeve (22) and cap (24) as an assembly over
detent pin (3). Continue to insert detent sleeve FIGURE 50-37. TIE ROD NUT TORQUE
(22) until it contacts spring seat (19). 1. Nut 4. Tie Rod
8. Secure cap (24) in place with capscrews (6). 2. Tie Rod 5. Outlet Housing
Tighten the capscrews to 7 N·m (5 ft lb). Install 3. Nut
spacer (23) and snap ring (1).
31
Removal and installation of hoist cylinders

Removal 1

hydraulic system.
2. Disconnect lubrication lines (1, Figure 50-38) for
the upper and lower bearings of the hoist
cylinder.
86498
FIGURE 50-38. HOIST CYLINDER BEARING

LUBRICATION LINES
1. Lubrication Line
32
3. Remove capscrews (3, Figure 50-39),

lockwashers (4) and flange clamps (2).
Disconnect hydraulic hoses (1) from the bottom
of the hoist cylinder. Cap and plug all lines and
ports to prevent excessive spillage and
contamination.
remove and install the component.
NOTE: The cylinder should be secured to the frame
to prevent movement.
4. At the hoist cylinder upper mount, remove nut
(6, Figure 50-40), flat washer (5) and shoulder
bolt (4). Use a brass drift and hammer to drive
pivot pin (3) from upper pivot structure (1).
3 4
NOTE: Do not lose two spacers (2) between the
cylinder bearing and upper pivot structure (1).
2
4 3
1
2
86438
FIGURE 50-39. HOIST CYLINDER HOSES

1. Hydraulic Hose 3. Capscrew
2. Flange Clamps 4. Lockwasher
FIGURE 50-40. HOIST CYLINDER UPPER MOUNT

1. Upper Pivot Structure 4. Shoulder Bolt
2. Spacer 5. Flat Washer
3. Pivot Pin 6. Nut
33
10. Carefully lower the hoist cylinder until it lies Installation

against the inner dual tire. Attach a suitable
lifting device to the upper cylinder mounting eye.
11. Install a retaining strap or chain to prevent the
cylinder from extending while handling.
12. At the lower mount, straighten the locking plate Use a lifting device with adequate capacity to
tabs to allow removal of the capscrews. remove and install the component.
Remove capscrews (1, Figure 50-41), locking 1. Install a retaining strap or chain to prevent the
plate (2) and retaining plate (3). cylinder from extending while handling.
13. Carefully remove the cylinder from the frame 2. Raise the cylinder into position over the pivot
pivot by pulling it outward. Move the cylinder to point on the frame. The cylinder should be
a clean area for disassembly. positioned so that the air bleed vent plug is on
top and facing toward the front of the truck.
NOTE: Do not lose spacer (6) between the cylinder Install spacer (6, Figure 50-41). Align the
bearing and frame. bearing eye with the pivot point and push the
14. Clean the exterior of the cylinder thoroughly. cylinder into place.
3. Install retaining plate (3), locking plate (2) and
capscrews (1). Tighten the capscrews to
standard torque. Bend the locking plate tabs
over the capscrew flats.
4. Align the hoist cylinder upper bearing eye
between the bores of upper pivot structure (1,
Figure 50-40).
5. Align the bolt hole in pivot pin (3) with the bolt
hole in upper pivot structure (1). Install the pivot
pin through the first spacer (2), then align the
second spacer with the bore on the other side of
hoist cylinder bearing eye. Finish installing the
pin through second spacer (2).
6. Install shoulder bolt (4) through each pin.
4
NOTE: Do not use a flat washer under the head of
3 the shoulder bolt. This will ensure that the shoulder
2 1 bolt does not run out of threads when tightening.
86499
7. Install flat washer (5) and nut (6) onto the
FIGURE 50-41. HOIST CYLINDER LOWER MOUNT threaded end of each shoulder bolt. Tighten the
1. Capscrew 3. Retaining Plate nuts to 339 N·m (250 ft lb).
2. Locking Plate 4. Spacer 8. Install hydraulic hoses (1, Figure 50-39) with
new O-rings at the bottom of the hoist cylinder.
Secure the flange clamps with capscrews and
lockwashers. Tighten the capscrews to the
standard torque.
9. Connect lubrication lines (1, Figure 50-38) at
the upper and lower hoist cylinder bearings.
10. Start the engine. Raise and lower the body
several times to bleed air from the hoist
cylinders. Check for proper operation and leaks.
11. Check the hydraulic tank oil level and fill if
necessary.
34
Disassembly and assembly of hoist 2. Mount the hoist cylinder in a fixture which will
cylinders allow it to be rotated 180 degrees.
3. Position the cylinder so that top cap (1, Figure
Disassembly
50-43) is at the top. Remove capscrews (2) and
1. If spherical bearings (2, Figure 50-42) require flat washers (3) that secure the top cap to
replacement, place the hoist cylinder on stands cylinder housing (7).
and secure it with a chain vise. Remove retainer 4. Install two threaded capscrews - 22 mm (0.88
rings (1) and press the bearing from the bore. in.) diameter x 229 mm (9 in.) length - into the
NOTE: Do not use metal tools to strike the bearings. two threaded lifting holes in top cap (1). Thread
the capscrews evenly until the top cap can be
removed. Lift the top cap straight up until quill
assembly (5) is clear of cylinder housing (7).
5. Remove O-ring (5) and backup ring (4) from top
cover (1).
Do not allow the bearings to fall to the ground.
Damage to the bearings and/or personal injury
could result. 2
1
3
1
4
2
6 5
1
7
86500
1. Retainer Ring 2. Spherical Bearing
NOTE: As internal parts are exposed during

disassembly, protect machined surfaces from 86439
scratches or nicks.
FIGURE 50-43. HOIST CYLINDER TOP COVER
1. Top Cap 5. O-ring
2. Capscrew 6. Quill Assembly
3. Flat Washer 7. Cylinder Housing
4. Backup Ring
35
6. Remove capscrews (1, Figure 50-44), plate (2), NOTE: A retainer bar is required to prevent the first
snap ring (3) rod bearing retainer (4) and seal and second stage cylinders from dropping out when
(5). the housing is inverted.
7. Use a 25.4 x 76.2 x 508 mm (1" x 3" x 20") steel
flat to fabricate retainer bar (1, Figure 50-45).
1 Drill two 27.8 mm (1 3/32in.) diameter holes in
the retainer bar that align with a pair of tapped
holes spaced 180 degrees apart at the top of
the cylinder housing.
2
8. Use two top cap capscrews (2) to attach
retainer bar (1) to the cylinder housing.
3
2 1 2
4
86440
FIGURE 50-44. ROD BEARING RETAINER

86441
REMOVAL
FIGURE 50-45. CYLINDER RETAINER BAR
1. 12 Pt. Capscrew 4. Rod Bearing Retainer
INSTALLATION
2. Plate 5. Seal
3. Snap Ring 1. Retainer Bar 2. Capscrew
36
9. Rotate the cylinder assembly 180 degrees to 11. Fabricate a round disc to the following
position the lower mounting eye at the top. specifications:
10. Attach a lifting device through the mounting eye  328 mm (12.9 in.) diameter
on pivot rod (1, Figure 50-46). Lift the pivot rod
 10 mm (0.38 in.) thick
out of cylinder housing (2).
 14.27 - 14.53 mm (0.562 - 0.572 in.) hole in
the center
12. Rotate the cylinder housing 180 degrees.
Remove retainer bar (1, Figure 50-45).
13. Insert fabricated round disc (2, Figure 50-47) in
the bottom of the cylinder housing.
14. Insert threaded rod (1) - 13 mm (0.50 in.)
diameter x 1350 mm (53 in.) long - through the
top of the cylinder housing the hole in the round
disc. Thread nut (3) onto the bottom end of the
1 threaded rod below the disc.
2
86442
FIGURE 50-46. PIVOT ROD

REMOVAL 3 86443
1. Pivot Rod 2. Cylinder Housing FIGURE 50-47. FIRST & SECOND STAGE
1. Threaded Rod 3. Nut
2. Round Disc
37
15. Screw a lifting eye into the top end of the 16. Remove the lifting tools from the first and
threaded rod. Attach it to a lifting device, then lift second stage cylinders.
first and second stage cylinders (1, Figure 50-
17. Slide second stage cylinder (2, Figure 50-49)
48) out of cylinder housing (2) as one unit
down inside first stage cylinder (1). Remove
snap ring (3) from inside the first stage cylinder.
18. Remove second stage cylinder (2) from first
stage cylinder (3) by sliding it out the top.
19. Remove all bearings, O-rings, and seals from
the hoist cylinder components.
86444
FIGURE 50-48. FIRST & SECOND STAGE

1. First & Second Stage 2. Cylinder Housing
Cylinders 86445
FIGURE 50-49. FIRST & SECOND STAGE

1. First Stage Cylinder 3. Snap Ring
2. Second Stage Cylinder
38

NOTE: Use only fresh cleaning solvent, a lint-free
wiping cloth and dry, filtered compressed air when
cleaning and handling hydraulic cylinder parts.
Immediately after cleaning and inspection, coat all
surfaces and parts with clean Type C-4 hydraulic oil.
1. Thoroughly clean and dry all parts.
2. Inspect all parts for damage and excessive
wear.
3. If the cylinder bores or plated surfaces are
excessively worn or grooved, the parts must be
replaced or, if possible, re-plated and machined
to original specifications.
4. Check the tightness of quill assembly (2, Figure
50-50) if it has not previously been tack welded.
a. Use special tightening tool SS1143 (see
Figure 50-50 and Disassembly and assembly
section General information) to apply a
tightening torque of 1 356 N·m (1,000 ft lb)
to the quill.
b. If the quill moves, remove the quill and clean FIGURE 50-50. QUILL ASSEMBLY TIGHTENING
the threads in the cover assembly and quill.
1. Cap Assembly
c. To install the quill, refer to "Installation of the 2. Quill Assembly
quill".
5. When the cylinder assembly is dismantled,
check all capscrews carefully for distress.
Replace the capscrews if in doubt.
39
Installation of the quill

NOTE: Use only new seals, bearings and O-rings
during reassembly. Thoroughly lubricate all parts and
seals with hydraulic oil to aid in assembly and to
provide lubrication during initial operation.
1. Inspect plugs (3, Figure 50-51) and check balls
(4) in the quill to ensure that the plugs are tight
and the ball seats are not damaged. Refer to
"Installation of check balls and plugs in quill" on
the next page.
2. Secure cap assembly (1) in a sturdy fixture.
Ensure that the threads in the cap and the
threads on the quill are clean, dry and free of oil
and solvent.
3. Spray the mating threads of both cap assembly
(1) and quill assembly (2) with LOCQUIC®
Primer T (Komatsu part number TL8753) or
equivalent. Allow the primer to dry for three to
five minutes.
4. Apply Loctite® Sealant #277 (Komatsu part
number VJ6863) or equivalent to the mating
threads of both the cap assembly and quill
assembly.
5. Install the quill. Use SS1143 tool to tighten the
quill to 1 356 N·m (1,000 ft lb). Allow the parts
to cure for two hours before exposing the
threaded areas to oil.
NOTE: If LOCQUIC Primer T (TL8753) was not used,
the cure time will require 24 hours instead of two
hours.
6. Tack weld the quill in two places as shown in
Figure 50-51.
7. Remove all slag and foreign material from the
tack weld area before assembling the cylinder.
During future cylinder rebuilds, removal of the quill
will not be necessary unless it has loosened or is
damaged. Removal will require a break-loose force of
at least 2 712 N·m (2,000 ft lb) after the tack welds
are ground off.
FIGURE 50-51. QUILL ASSEMBLY INSTALLATION
1. Cap Assembly 3. Plug

2. Quill Assembly 4. Check Ball
40
Installation of check balls and plugs in quill 1. Use the newer plugs. Ensure that the threads in
the quill tube and on the plugs are clean, dry
Check balls (4, Figure 50-51) in the side of quill
and free of oil and solvent.
assembly (2) are held in place with threaded plugs
(3). 2. Spray the mating threads of both plugs (3,
Figure 50-51) and quill assembly (2) with
If a plug is missing and the check ball is not found in LOCQUIC Primer T (Komatsu part number
the cylinder, inspect the opposite side hoist cylinder TL8753) or equivalent. Allow the primer to dry
and the plumbing leading to the hoist valve for for 3 to 5 minutes.
damage. Also, check the hoist valve itself to see
3. Apply Loctite Sealant #277 (Komatsu part
whether the ball or plug has caused internal damage
number VJ6863) or equivalent to the mating
to the spool. Peening of the necked down sections of
threads of both plugs and the quill assembly.
the spool may result. Spool sticking may also occur.
4. Place check balls (4) in the quill tube and install
NOTE: Refer to Figure 50-52 for SS1158 plug plugs (3) with the concave side facing the ball.
installation and removal tool that can be fabricated for Use the SS1158 plug installation and removal
installing and removing the check ball plugs. tool to tighten the plugs to 95 N·m (70 ft lb).
Check the plugs during any cylinder repair to ensure Allow the parts to cure for two hours before
that they are tight. If they move, remove the plugs exposing the threaded areas to oil.
and check whether the ball seat in the quill is NOTE: If LOCQUIC Primer T (TL8753) was not used,
deformed. the cure time will require 24 hours instead of two
• If deformation of the ball seat has occurred, the hours.
quill should be replaced. 5. Stake the plug threads in two places between
• If the ball seat area is not deformed, measure the the holes, as shown in Figure 50-52, to prevent
plug thickness as shown in Figure 50-52: loosening of the plug.
Older plug: 6.35 ± 0.50 mm (0.25 ± 0.02 in.) NOTE: If removal of the plug is necessary in a later
Newer plug: 9.65 ± 0.50 mm (0.38 ± 0.02 in.) rebuild, it will be necessary to carefully drill out the
stake marks and destroy the plug. A new plug must
be installed and staked as previously detailed.
FIGURE 50-52. SS1158 PLUG INSTALLATION & REMOVAL TOOL
41
Assembly 3. Mount the cylinder housing in a fixture which will

allow it to be rotated 180 degrees so that the top
NOTE: Lubricate all bearings and seals with clean
cap end is positioned at the top.
type C-4 hydraulic oil before installation.
4. Place a wood block beneath the cylinder
1. Install inner bearing (1), buffer seal (2), rod seal housing to help to locate the first and second
(3) and wiper seal (4) on the second stage stage cylinders.
cylinder (Figure 50-53), the first stage cylinder
(Figure 50-54) and the cylinder housing (Figure The wood block must not interfere with the lifting
50-55). tool that was fabricated during the disassembly
2. Install piston seal (6) on the second stage procedure.
cylinder (Figure 50-53) and the first stage
cylinder (Figure 50-54).
NOTE: Piston seal (6) consists of two pieces: an 5 6
expander and a nylon cap. Do not install the nylon
cap at this time.
5 6
2 1
2 1 3
3 4 86448
4 FIGURE 50-54. FIRST STAGE

86447
BEARING & SEAL INSTALLATION
FIGURE 50-53. SECOND STAGE
BEARING & SEAL INSTALLATION 1. Inner Bearing 4. Wiper Seal
2. Buffer Seal 5. Outer Bearing
1. Inner Bearing 4. Wiper Seal 3. Rod Seal 6. Piston Seal
2. Buffer Seal 5. Outer Bearing
3. Rod Seal 6. Piston Seal
42
5. Install the lifting tool (see Figure 50-47) that was 7. Lower the first stage cylinder until it is resting on
used during disassembly into the first stage the wood block. Remove the lifting tool and
cylinder. install it into the second stage cylinder.
6. Align and slide the first stage cylinder into the NOTE: Seal installation rings (58B-98-40020) and
top of the cylinder housing. See Figure 50-48. (58B-98-40030) will ease assembly of the first and
Allow the first stage cylinder to protrude far second stage cylinders, but it is not required.
enough to install the nylon cap on piston seal (6, 8. Lubricate the seal installation ring with clean
Figure 50-54), then install outer bearings (5). type C-4 hydraulic oil or petroleum jelly and
install it in the snap ring groove inside first stage
cylinder (1, Figure 50-49). The seal installation
ring allows the seals to glide over the snap ring
groove without being damaged.
9. Align and slide second stage cylinder (2) inside
first stage cylinder (1).
Allow the second stage cylinder to protrude far
enough to install the nylon cap on piston seal (6,
Figure 50-53), then install outer bearings (5).
10. Lower the second stage cylinder past the seal
installation ring. Remove the seal installation
ring, then install snap ring (3, Figure 50-49) on
the inside of the first stage cylinder.
11. Install two 7/8" - 9NC eye bolts in the lifting holes
on the top of the rod bearing retainer. Install O-
ring (4, Figure 50-56), backup rings (3), piston
seal (2), and bearings (1) on the rod bearing
retainer.
2 1
4
3 86450
2 1
3
1. Outer Bearing 3. Backup Ring
4 86449
2. Piston Seal 4. O-ring
FIGURE 50-55. CYLINDER HOUSING
1. Inner Bearing 3. Rod Seal
2. Buffer Seal 4. Wiper Seal
43
12. Lubricate the seal installation ring with clean 15. Install retainer bar (1, Figure 50-45) with two top
type C-4 hydraulic oil or petroleum jelly and cap capscrews (2) on the top of the cylinder
install it in the snap ring groove inside the housing. Rotate the cylinder housing 180
second stage cylinder. The seal installation ring degrees.
allows the seals to glide over the snap ring
16. Attach a lifting device to the eye of pivot rod (1,
groove without being damaged.
Figure 50-58) and align it over cylinder housing
13. Align and lower rod bearing retainer (2, Figure (4). Lubricate the pivot rod with clean type C-4
50-57) into the second stage cylinder until it is hydraulic oil.
past the snap ring groove in the second stage
cylinder.
14. Remove the seal installation ring and install
snap ring (1).
2 1
2
86501
3
INSTALLATION
1. Snap Ring 2. Rod Bearing Retainer
86502
FIGURE 50-58. PIVOT ROD

REMOVAL
1. Pivot Rod 3. Seal
2. Guide Inserts 4. Cylinder Housing
44
17. Thread two 1" - 8NC X 4" guide inserts (2) in the 21. Rotate the housing 90 degrees to position the
bolt holes at the end of the pivot rod. Install seal top cap end at the top. Install O-ring (5, Figure
(3) on the end of the pivot rod. 50-43) and backup ring (4) on top cap (1).
18. Lower the pivot rod into the cylinder housing. Lower the cover onto cylinder housing (7).
Align the guide inserts into the rod bearing 22. Lubricate capscrews (2) and flat washers (3)
retainer capscrew holes. with a lithium based grease. Install the
19. Detach the lifting device from the pivot rod. capscrews and flat washers, then tighten the
Rotate the cylinder assembly 90 degrees and capscrews in an alternating pattern to 1 017
remove the retainer bar. N·m (750 ft lb).
23. If removed, install spherical bearings (2, Figure
20. Lubricate 12-point capscrews (1, Figure 50-59)
50-42). Place the hoist cylinder on stands and
with a lithium based grease. Install plate (2) and
secure it with a chain vise. Press the bearing
eight of the capscrews. Remove the guide
inserts and install the remaining two capscrews. into the bore and install retainer rings (1).
Tighten all ten capscrews in an alternating NOTE: Do not use metal tools to strike the bearings.
pattern to 1 166 N·m (860 ft lb).
24. After assembly is complete, refer to Testing and
Adjusting section Steering, brake cooling and
hoist hydraulic system for the hoist cylinder
leakage test requirements.
1 2 86504

PLATE INSTALLATION
1. 12 Pt. Capscrew 2. Plate
45
980E Dump truck

46
CEN50077-00
980E

980E-5 A50005 and up

Body and structures
Removal and installation of dump body ................................................................................................................ 3
Removal and installation of body pads ................................................................................................................. 6
Removal and installation of diagonal ladder/hood and grille assembly ................................................................ 8
Removal and installation of RH deck .................................................................................................................. 10
Removal and installation of LH deck................................................................................................................... 12
Removal and installation of fuel tank (with DEF tank)......................................................................................... 14
Removal and installation of fuel gauge sender ................................................................................................... 16
Removal and installation of hydraulic tank.......................................................................................................... 17
Removal and installation of hydraulic tank strainers ........................................................................................... 19
1
NOTES
2
Removal and installation of dump body Removal

the wheels.
Inspect the condition and rating of all lifting OFF to shut down the engine and allow 90
devices, slings, chains, and cables. Refer to the seconds for the steering system accumulators
manufacturer's manual for correct capacities and to bleed down.
safety procedures when lifting components.
3. Attach lifting cables (1, Figure 50-1) and a lifting
Replace any questionable items.
device to the dump body and take up the slack.
Ensure that the lifting device is rated for the 4. Remove the mud flaps from both sides of the
appropriate capacity. Slings, chains, and cables dump body. Remove any electrical wiring and
used for lifting components must be rated to hoses that are attached to the dump body.
supply a safety factor of approximately 2.5X the 5. Attach chains around the upper end of the hoist
weight being lifted. When in doubt as to the cylinders to support them after the mounting
weight of components or any service procedure, pins are removed.
contact the Komatsu area representative for 6. At the hoist cylinder upper mounting bracket,
further information. remove locknut (6, Figure 50-2), flat washer (5)
and shoulder bolt (4). Use a brass drift and
Lifting eyes and hooks must be fabricated from hammer to drive pivot pin (3) from mounting
the proper materials and rated to lift the load bracket (1).
being placed on them.
NOTE: Do not lose two spacers (2) between the
Never stand beneath a suspended load. Use of cylinder bearing and mounting bracket (1).
guy ropes are recommended for guiding and
positioning a suspended load.
Before raising or lifting the body, ensure that

there is adequate clearance between the body
and overhead structures or electric power lines.
FIGURE 50-2. HOIST CYLINDER UPPER MOUNT

FIGURE 50-1. DUMP BODY REMOVAL
1. Mounting Bracket 4. Shoulder Bolt
1. Lifting Cables 2. Guide Rope 2. Spacer 5. Flat Washer
3. Pin 6. Locknut
3
7. Remove shoulder bolt (1, Figure 50-3), flat Inspection

washer (2) and locknut (3) from both body pivot
1. Inspect body ears (6, Figure 50-3), the frame
pins (4).
pivot and the pivot bushings for excessive wear
8. Attach a body pivot pin support fixture to the or damage.
bracket on the underside the dump body to aid
2. Inspect the body guide wear points. Body guide
in supporting the pin as it is removed.
(2, Figure 50-4) should be centered between
9. Remove pivot pins (4) far enough to allow shims wear plates (3) with a maximum gap of 4.8 mm
(5) to drop out. Complete removal of the pins is (0.19 in.) at each side (new wear plates).
not necessary unless new pins are being
installed. If the gap becomes excessive, install new parts.
NOTE: To prevent the pivot pins from falling while

removing the dump body, use chains to secure the
pins to the truck frame.
10. Lift the dump body clear of the chassis and
move it to a work area. Block up the dump body
to prevent damage to the body guide.
FIGURE 50-4. BODY GUIDE
1. Dump Body 3. Body Guide Wear

2. Body Guide Plates
FIGURE 50-3. DUMP BODY PIVOT PINS

1. Shoulder Bolt 4. Pivot Pin
2. Flat Washer 5. Shims
3. Locknut 6. Body Ear
4
Installation 8. Align the hoist cylinder bearing eye with the

1. Park truck on a hard, level surface and block all bore of hoist cylinder upper mounting bracket
the wheels. (1, Figure 50-2).
2. Place the directional control lever in PARK and 10. Align the bolt hole in pivot pin (3) with the bolt
turn the rest switch ON. Turn the key switch hole in mounting bracket (1). Install the pivot pin
OFF to shut down the engine and allow 90 through the first spacer (2), then align the
seconds for the steering system accumulators second spacer with the bore on the other side of
to bleed down. hoist cylinder bearing eye. Finish installing the
pin through second spacer (2).
3. Attach lifting cables (1, Figure 50-1) and a lifting
device to the dump body and take up the slack. 11. Install shoulder bolt (4) through each pin. Install
flat washer (5) and locknut (6). The locknut must
4. Lower the body over the truck frame and align
be tight against the flat washer, and the flat
the body pivots with the frame pivot holes.
washer must be tight against the shoulder on
5. Install shims (5, Figure 50-3) in both body the shoulder bolt. Ensure that the shoulder bolt
pivots, as required, to fill the outside gaps and has some end play.
center the body on the frame pivot. Do not
install shims on the inside. A minimum of one NOTE: Do not use a flat washer under the head of
shim is required at the outside end of both frame the shoulder bolt. This will ensure that the shoulder
pivots. bolt does not run out of threads when tightening.
6. Align the bolt hole in pivot pin (4) with the bolt NOTE: If locknut (6) is not a self-locking nut, tighten
hole in the pin retainer of body ear (6). Push the the nut to 339 N·m (250 ft lb).
pivot pin through shims (5) and into the frame
12. Install all mud flaps, electrical wiring and hoses
pivot. Repeat this step for the other pivot pin.
to the dump body.
7. Install shoulder bolt (1) through each pin. Install
13. Adjust the body-up switch and hoist limit switch.
flat washer (2) and locknut (3). The locknut must
Refer to Structure, functions and maintenance
be tight against the flat washer, and the flat
standard section Electrical system, 24 volt for
washer must be tight against the shoulder on
the correct dimensions.
the shoulder bolt. Ensure that the shoulder bolt
has some end play.
NOTE: Do not use a flat washer under the head of
the shoulder bolt. This will ensure that the shoulder
bolt does not run out of threads when tightening.
NOTE: If locknut (2) is not a self-locking nut, tighten
the nut to 339 N·m (250 ft lb).
5
Removal and installation of body pads Installation
Removal 1. Install new body pads (4) with the same number
of shims (3) that were removed.
2. Install the mounting hardware. Tighten nuts (1)
to 88 N·m (65 ft lb).
3. Remove the blocks from the frame. Lower the
dump body onto the frame.
To avoid serious personal injury or death, the
4. All pads (except the rear pad on each side)
body retention sling must be installed anytime
should contact the frame with approximately
equal compression of the rubber.
on the truck with the dump body in the raised
position. A gap of approximately 1.9 mm (0.075 in.) is
required at each rear pad. This can be
NOTE: It is not necessary to remove the dump body
accomplished by using one less shim at each
to replace the body pads. Body pads should be rear pad.
inspected during scheduled maintenance inspections
and replaced if worn excessively. If pad contact appears to be unequal, refer to
"Body pad shimming procedure".
1. Raise the unloaded dump body to a height that
is sufficient to allow access to all of the body
pads.
2. Install the body retention sling. Refer to “Secur-
ing the dump body” in the Foreword, safety
and general information section for the body
retention sling installation procedure.
3. Place blocks between the body and frame.
Secure the blocks in place.
4. Remove the pad mounting hardware.
5. Remove body pad (4, Figure 50-5) and shims
(3). Note the number of shims installed at each
pad location. The rear pad on each side should
have one less shim than the other pads.
FIGURE 50-5. BODY PAD INSTALLATION
1. Nut 4. Body Pad
2. Lockwasher 5. Flat Washer
3. Shim(s) 6. Capscrew
6
Body pad shimming procedure 9. Subtract the body pad thickness of 39.7 mm
1. Park the truck on a flat, level surface. (1.56 in.) from each measurement that was
recorded in Step 8. There will be a total of eight
2. Raise the unloaded dump body to a height that measurements “B” per side. Refer to Figure 50-
is sufficient to allow access to all of the body 6.
pads.
“A” - 39.7 mm (1.56 in.) = “B”
10. Divide each measurement “B” by the single
shim thickness of 1.5 mm (0.06 in.) to determine
the number of shims required for each mounting
location.
To avoid serious personal injury or death, the “B” / 1.5 mm (0.06 in.) = number of shims
body retention sling must be installed anytime
11. Remove one shim from the calculation for the
most rearward body pad on both sides.
position. NOTE: Using half shims is allowed if necessary. Half
3. Install the body retention sling. Refer to “Secur- shims must be installed at the top of the stack.
ing the dump body” in the Foreword, safety NOTE: The frame rail and the body bolster do not
and general information section for the body have to be parallel.
retention sling installation procedure.
4. Remove all of the body pads and shims.
5. Bolt one spacer block (XC2293) to each side of
the body. Use the pad mounting holes closest to
the front of the dump body.
6. Remove the body retention sling. Lower the
dump body onto the spacer blocks.
7. Check the dump body’s position and fit on the
truck. If there is any interference when the body
is on the spacer blocks, contact your local
Komatsu distributor to resolve the issue.
8. With the body lowered, measure the distance
from the frame rail to each pair of bolt holes at
the dump body’s pad mounting locations. There
will be a total of eight measurements “A” per
side. Refer to Figure 50-6.
FIGURE 50-6. MEASUREMENT DETAILS

1. Shims 2. Body Pad
7
Removal and installation of diagonal Installation

ladder/hood and grille assembly
NOTE: It may be necessary to remove the dump
body to provide clearance for any lifting equipment. If
body removal is not required, the body must be
raised and properly secured with the body retention Use a lifting device with adequate capacity to
sling. remove and install the components.
Removal 1. Use an appropriate lifting device to lift grille and

hood assembly (4, Figure 50-7) into position on
the truck.
2. Align the mounting hardware holes with the
brackets attached to the radiator assembly.
Install hood mounting hardware (5). Tighten the
capscrews to the standard torque.
3. Adjust and tighten both radiator bumpers.
1. Park the truck on a flat, level surface.
4. Use an appropriate lifting device to lift diagonal
2. Attach an appropriate lifting device to diagonal ladder (1) and support (2) into position over the
ladder (1, Figure 50-7). mounting pads on the front bumper. Align the
3. Remove ladder mounting hardware (3). mounting holes and install shims (6) as needed
4. Lift the structure off the truck. Collect shims (6). to level the structure.
5. Disconnect wiring harnesses and remove 5. Install ladder mounting hardware (3). Tighten
clamps as necessary to allow removal of the the capscrews to the standard torque.
grille and hood assembly. 6. Connect all cables, wiring harnesses, hoses
and clamps that were removed previously.
NOTE: The secondary egress ladders on the sides of
the hood and the front handrail on top of the hood do 7. If the secondary egress ladders on the sides of
not need to be removed unless desired. the hood and/or the front handrail on top of the
hood were removed, install them and tighten the
6. Attach an appropriate lifting device to hood and
mounting hardware to the standard torque.
grille assembly (4).
7. Remove all hood mounting hardware (5) on
both sides of the hood.
8. Loosen the radiator bumpers on both decks.
9. Lift the grille and hood assembly from the truck
and move it to a work area.
8
FIGURE 50-7. DIAGONAL LADDER, HOOD AND GRILLE REMOVAL & INSTALLATION
1. Diagonal Ladder 3. Ladder Mounting Hardware 5. Hood Mounting Hardware
2. Support 4. Hood and Grille Assembly 6. Shims
NOTE: The LH diagonal ladder configuration is

shown in Figure 50-7. Removal and installation of the
RH diagonal ladder option is the same.
9
Removal and installation of RH deck Installation
Removal

remove and install the components. Do not attach lifting slings or chains to the
handrails. Only use proper lifting points to attach
Do not attach lifting slings or chains to the the lifting device.
handrails. Only use proper lifting points to attach
the lifting device.
1. Tighten radiator bumpers (3, Figure 50-8) on
both decks. Clean all deck mount mating
1. Remove the access covers from retarding grid surfaces.
(1, Figure 50-8). Tag and disconnect all
2. Install an appropriate lifting device to the lifting
electrical leads in preparation for removal.
eyes at each corner of the deck and take up any
Reinstall the access covers.
slack. Do not attach the lifting device to the
2. Remove retarding grid mounting hardware (2) at handrails.
six locations.
3. Carefully lift and position the deck on the deck
3. Attach an appropriate lifting device to the lifting supports. Ensure that any wiring harnesses,
eyes on the retarding grid. Lift the retarding grid cables and hoses that may still be attached to
clear of deck structure (4) and move it to a work the deck are moved out of the way.
area.
NOTE: Shimming may be necessary at the deck
NOTE: If repairs to the grid assembly or cooling mounting hardware locations to level the RH deck
blower are required, refer to the applicable GE with the center deck.
publication for service and maintenance procedures.
4. Install deck mounting hardware (5) and any
4. Disconnect deck lighting harness (6). Inspect necessary shims at eight locations on the deck
the underside of the deck. If necessary, remove support and the front upright. Tighten the
any hoses or cables that remain connected to capscrews to the standard torque.
the deck.
5. Connect deck lighting harness (6) and any
NOTE: The lighting harness and clamps do not hoses or cables that were disconnected from
require removal. the deck. Ensure that all electrical harnesses
5. Remove the egress gate from the handrail at and clamps are undamaged and reinstalled
the front of the deck. securely. Replace any components as
necessary.
eyes at each corner of the deck and take up any 6. Attach an appropriate lifting device to the lifting
slack. Do not attach the lifting device to the eyes on the retarding grid. Lift retarding grid (1)
handrails. onto deck structure (4).
7. Remove deck mounting hardware (5) and any 7. Install retarding grid mounting hardware (2) at
shims at eight locations on the deck support and six locations. Tighten the capscrews to the
the front upright. standard torque.
8. Loosen radiator bumpers (3) on both decks. 8. Remove the access covers from the retarding
grid. Connect all electrical leads to their correct
9. Ensure that all wiring harnesses, cables and
locations. Reinstall the access covers.
hoses have been removed. Carefully lift the
deck from the deck supports.
10
4 3
5
5
86312
FIGURE 50-8. RH DECK AND RETARDING GRID REMOVAL & INSTALLATION

1. Retarding Grid 4. Deck Structure
2. Retarding Grid Mounting Hardware 5. Deck Mounting Hardware
3. Radiator Bumper 6. Deck Lighting Harness
11
Removal and installation of LH deck Installation
Removal

If air conditioning system components must be
removed, refer to Testing and adjusting section Do not attach lifting slings or chains to the
Cab air conditioning for instructions on handrails. Only use proper lifting points to attach
discharging the air conditioning system before the lifting device.
disconnecting any air conditioning lines and
servicing the air conditioning system after 1. Tighten radiator bumpers radiator bumpers (7,
installation. Figure 50-9) on both decks. Clean all deck
mount mating surfaces.
eyes at each corner of the deck and take up any
Use a lifting device with adequate capacity to handrails.
remove and install the components. 3. Carefully lift and position the deck on the deck
supports. Ensure that any wiring harnesses,
Do not attach lifting slings or chains to the cables and hoses that may still be attached to
handrails. Only use proper lifting points to attach the deck are moved out of the way.
the lifting device. 4. Install deck support (6) and support mounting
hardware (5).
1. Remove the operator cab. Refer to Disassembly NOTE: Shimming may be necessary at the deck
and assembly section Operator cab for cab mounting hardware locations to level the LH deck
removal instructions. with the center deck.
2. Disconnect deck lighting harness (7, Figure 50- 5. Install rear deck mounting hardware (4) and any
9). Inspect the underside of the deck. If necessary shims.
necessary, remove any hoses or cables that
remain connected to the deck. 6. Install rear deck mounting hardware (3) and any
necessary shims.
NOTE: The lighting harness and clamps do not 7. Install front deck mounting hardware (2) and
require removal. any necessary shims.
3. Install an appropriate lifting device to the lifting 8. Tighten all of the deck mounting hardware to the
eyes at each corner of the deck and take up any standard torque.
handrails. 9. Connect deck lighting harness (1) and any
hoses or cables that were disconnected from
4. Remove front deck mounting hardware (2) and the deck. Ensure that all electrical harnesses
the shims. and clamps are undamaged and reinstalled
5. Remove rear deck mounting hardware (3) and securely. Replace any components as
the shims. necessary.
6. Remove rear deck mounting hardware (4) and 10. Install the operator cab. Refer to Disassembly
the shims. and assembly section Operator cab for cab
7. Remove support mounting hardware (5) and installation instructions.
deck support (6).
8. Loosen radiator bumpers (7) on both decks.
9. Ensure that all wiring harnesses, cables and
hoses have been removed. Carefully lift the
deck from the deck supports.
12
7 2 1 2
3
4
4 3
5
DETAIL A
86313
FIGURE 50-9. LH DECK REMOVAL & INSTALLATION

1. Deck Lighting Harness 4. Rear Deck Mounting Hardware
2. Front Deck Mounting Hardware and Shim (58F-54-20540)
and Shim (58F-54-10690) 5. Support Mounting Hardware
3. Rear Deck Mounting Hardware 6. Deck Support
and Shim (EG6224) 7. Radiator Bumper
13
Removal and installation of fuel tank

(with DEF tank)
Removal
9. Attach a lifting device to the lifting eyes on each
side of the tank.
To avoid serious personal injury or death, the 10. Remove capscrews (17), lockwashers (18), flat
body retention sling must be installed anytime washers (19), large washers (20) and rubber
personnel are required to perform maintenance mounts (21).
position. 11. Remove capscrews (1), lockwashers (2) and
mounting caps (3).
the wheels. 12. Lift the fuel tank from the upper mounting
brackets and move it to a work area.
to bleed down. NOTE: If a tank has been damaged and requires
3. Install the body retention sling. Refer to structural repair, perform the repairs before final
“Securing the dump body” in the Foreword, cleaning.
safety and general information section for the
body retention sling installation procedure.
NOTE: When draining fuel or removing fuel lines, be
prepared to catch spilled fuel by having adequate
containers and cleanup equipment. If a tank is to be weld repaired, special
precautions are necessary to prevent fire or
4. Loosen filler cap (5, Figure 50-10) and open explosion. Consult local authorities for safety
drain cock (16) on the bottom of the fuel tank to regulations before proceeding.
drain the fuel from the tank into clean
containers. Tighten the filler cap when the fuel is The fuel tank has a drain cock (16, Figure 50-10),
completely drained. magnetic plug (15) and a cleaning port in the side
5. Remove mud flaps (3) from both sides of the that allow steam or solvent to be used for cleaning
fuel tank. Remove all hoses and wiring tanks that have accumulated foreign material.
harnesses from DEF tank (4). It is not necessary to remove the tank from the truck
6. Close fuel supply shutoff valve (9). Remove fuel for cleaning of sediment. However, rust and scale on
return hose (7), fuel supply hose (8) and quick the walls and baffles may require complete tank
fill hose (14). removal. This allows cleaning solutions to be in
7. Disconnect the fuel tank harness from hoist filter contact with all interior surfaces by rotating the tank in
assemblies (11), steering filter assembly (13) various positions.
and the RH rail harness. Before a cleaning procedure of this type, the fuel
8. Remove hoist circuit filter assemblies (11) and gauge sender, vent assembly (6), vent filter (12) and
steering circuit filter assembly (12) from the fuel all hose connections must be removed and
tank. Support the filter assemblies by placing a temporarily sealed. After cleaning is complete, the
chain over the frame rail. It is not necessary to temporary plugs can be removed.
disconnect the hydraulic hoses. If the tank is to remain out of service, a small amount
of light oil should be sprayed into the tank to prevent
rust. Seal all openings for rust prevention.
14
7 8
6 1
SEE
UPPER MOUNT
5 DETAIL
2
4
3
UPPER MOUNT
DETAIL
9
SEE
LOWER MOUNT
DETAIL
10
14
11
20
18 12 13
21
19 15
17
LOWER MOUNT 16
DETAIL 87555
FIGURE 50-10. FUEL TANK REMOVAL & INSTALLATION

1. Capscrew 7. Fuel Return Hose 13. Steering Circuit Filter 19. Flat Washer
2. Flat Washer 8. Fuel Supply Hose 14. Quick Fill Hose 20. Large Washer
3. Mounting Cap 9. Shutoff Valve 15. Magnetic Plug 21. Rubber Mount
4. DEF Tank 10. Mud Flaps 16. Drain Cock
5. Filler Cap 11. Hoist Circuit Filters 17. Capscrew
6. Vent Assembly 12. Vent Filter 18. Lockwasher
15
Installation Removal and installation of fuel gauge

1. Thoroughly clean the frame mounting brackets sender
and the mounting hardware holes. Re-tap the Removal
threads if damaged.
1. Remove cover (1. Figure 50-11) from the top of
the fuel tank.
2. Disconnect the wiring harness from fuel gauge
sender (2).
Use a lifting device with adequate capacity to 3. Remove the sender mounting hardware.
remove and install the components. Carefully remove the fuel gauge sender and
2. Attach a lifting device to the lifting eyes on each gasket (3).
side of the tank. Lift the fuel tank into position
Installation
over the upper mounting brackets and lower the
tank into position. 1. Clean the mating surfaces. Install a new gasket
3. Install mounting caps (3, Figure 50-10), (3, Figure 50-11).
lockwashers (3) and capscrews (2). Do not 2. Install fuel gauge sender (2) into the fuel tank.
tighten the capscrews at this time. Ensure that the float moves freely.
4. Install rubber mounts (21), large washers (20), 3. Install the sender mounting hardware and
flat washers (19), lockwashers (18) and tighten the capscrews to the standard torque.
capscrews (17). Tighten the lower mounting 4. Connect the wiring harness to the fuel gauge
capscrews to 800 ± 80 N·m (590 ± 59 ft lb). sender.
5. Tighten the upper mounting capscrews to 712 ± 5. Install cover (1) on the top of the fuel tank.
72 N·m (525 ± 53 ft lb).
6. Install hoist circuit filters (11) and steering circuit
filter (13) on the tank.
7. Ensure that vent assembly (6) and vent filter
(12) are installed and that the hoses are
connected and clamped securely.
8. Connect fuel return hose (7), fuel supply hose
(8) and quick fill hose (14). Open fuel supply
shutoff valve (9).
9. Connect the fuel tank harness to hoist circuit 1
filters (11) and steering circuit filter (13).
10. Connect and securely clamp all hoses and
wiring harnesses to DEF tank (4).
2
11. Install mud flaps (3) on both sides of the fuel
tank. 3
86314
FIGURE 50-11. FUEL GAUGE SENDER

1. Cover 3. Gasket
2. Fuel Gauge Sender
16
Removal and installation of hydraulic tank

Removal
Be careful to avoid contact with hot oil if the truck

has been operating. Avoid spillage and
contamination.
If a component in the hydraulic system fails, 3. Open drain valve (1, Figure 50-12) to drain the
perform an oil analysis before replacing any hydraulic tank into suitable containers. Refer to
component. If foreign particles are evident, the the Operation and Maintenance Manual for the
system must be flushed. Refer to the Hydraulic capacity of the hydraulic tank.
System Flushing instructions. 4. Disconnect the hydraulic lines. Plug all lines to
prevent possible contamination to the system.
Close both suction line shutoff valves. Tag each
line at removal for proper identification during
installation.
not received immediately. Use a lifting device with adequate capacity to
5. Attach a suitable lifting device to the lifting eyes
on the top of the hydraulic tank.
6. Disconnect ground wire (9) from the hydraulic
tank.
Steering, hoist, brake cooling and auxiliary 7. Remove two capscrews (5), lockwashers (6),
hydraulic system. large washers (7) and rubber mounts (8).
2. Thoroughly clean the outside of the hydraulic 8. Remove capscrews (3), flat washers (4) and
tank and attached equipment. mounting caps (2).
NOTE: If the oil is to be reused, clean containers 9. Lift the hydraulic tank from the upper mounting
must be used with a 3-micron filtering system brackets. Move the hydraulic tank to a clean
available for refill. work area.
NOTE: When draining oil or removing oil lines, be
prepared to catch spilled oil by having adequate
containers and cleanup equipment.
17
Installation
10 3 4
2
1. Lift the hydraulic tank into position on the frame.
2. Install mounting caps (2, Figure 50-12), flat
washers (4) and capscrews (3). Tighten the
capscrews to 622 ± 62 N·m (459 ± 45 ft lb).
3. Install two rubber mounts (7), flat washers (7),
lockwashers (5) and capscrews (5) at the rear of
the hydraulic tank. Tighten the capscrews to 800
± 80 N·m (590 ± 59 ft lb).
4. Connect ground wire (9) from the frame to the
hydraulic tank.
5. Uncap the hydraulic lines and attach them to the
proper connections on the hydraulic tank.
6. Replace breather filters (10), if required.
7. Close drain valve (1) and fill the hydraulic tank.
Refer to the Operation and Maintenance
Manual for the proper procedure.
8. Loosen the capscrews on the suction hoses at
the pump to bleed any trapped air, then loosen
1 the capscrews on the pressure hoses at the
pump to bleed any trapped air. Tighten all
capscrews securely.
8 5
NOTE: If trapped air is not bled from the steering
pump, possible pump damage and no output may
result.
6
7
9
86315
FIGURE 50-12. HYDRAULIC TANK

1. Drain Valve 6. Lockwasher
2. Mounting Cap 7. Flat Washer
3. Capscrew 8. Rubber Mount
4. Flat Washer 9. Drain Valve
5. Capscrew 10. Breather Filters
18
Removal and installation of hydraulic tank

strainers
Removal
Be careful to avoid contact with hot oil if the truck

has been operating. Avoid spillage and
contamination.
3. Open drain valve (1, Figure 50-12) to drain the
If a component in the hydraulic system fails, hydraulic tank into suitable containers. Refer to
perform an oil analysis before replacing any the Operation and Maintenance Manual for the
component. If foreign particles are evident, the capacity of the hydraulic tank.
system must be flushed. Refer to the Hydraulic 4. Disconnect the pump suction hoses from the
System Flushing instructions. hydraulic tank. Plug all lines to prevent possible
contamination to the system. Tag each line at
removal for proper identification during
installation.
5. Remove capscrews (2, Figure 50-13) and
Hydraulic oil escaping under pressure can have lockwashers (3). Remove suction cover plate
sufficient force to enter a person's body by (1). Discard the gasket.
penetrating the skin and cause serious injury, 6. Remove capscrews (5), lockwashers (6) and flat
and possibly death, if proper medical treatment is washers (7). Remove both strainers (4).
hydraulic system. 4
2. Thoroughly clean the outside of the hydraulic
tank and attached equipment. 7 6 5
NOTE: If the oil is to be reused, clean containers
must be used with a 3-micron filtering system
available for refill.
NOTE: When draining oil or removing oil lines, be
prepared to catch spilled oil by having adequate
containers and cleanup equipment.
1 2 3 86316
FIGURE 50-13. HYDRAULIC TANK STRAINER

1. Suction Cover Plate 5. Capscrew
2. Capscrew 6. Lockwasher
3. Lockwasher 7. Flat Washer
4. Strainer
19

1. Inspect the strainers thoroughly for metallic 1. Install both strainers (4, Figure 50-13). Install
particles and varnish build up (if oil has been capscrews (5), lockwashers (6) and flat washers
overheated). The quantity and size of any (7). Tighten the capscrews to standard torque.
particles may be an indication of excessive wear 2. Install suction cover plate (1) and a new gasket.
of components in the hydraulic system. Install capscrews (2) and lockwashers (3).
2. Clean the strainers from the inside out with Tighten the capscrews to standard torque.
fresh cleaning solvent. 3. Uncap the pump suction hoses and attach them
3. Inspect the strainers for cracks and wear. to the proper connections on the hydraulic tank.
Replace the strainers if necessary. 4. Close drain valve (1, Figure 50-12) and fill the
4. Clean any sediment from the bottom of the hydraulic tank. Refer to the Operation and
hydraulic tank. Maintenance Manual for the proper procedure.
5. Loosen the capscrews on the suction hoses at
the pump to bleed any trapped air, then loosen
the capscrews on the pressure hoses at the
pump to bleed any trapped air. Tighten all
capscrews securely.
NOTE: If trapped air is not bled from the steering
pump, possible pump damage and no output may
result.
20
NOTES
21
980E Dump truck

22
CEN50079-00
830E
930E
980E

830E-5 A50005 and up
930E-5 A40004 and up
980E-5 A50005 and up

Operator cab
Removal and installation of operator cab.............................................................................................................. 3
Removal and installation of cab door .................................................................................................................... 6
Disassembly and assembly of cab door ............................................................................................................... 8
Adjustment of cab door ....................................................................................................................................... 16
Removal and installation of side window glass ................................................................................................... 18
Removal and installation of windshield and rear window glass .......................................................................... 21
Removal and installation of windshield wiper components ................................................................................. 22
Removal and installation of cab seats ................................................................................................................ 24
Removal and installation of seat belts ................................................................................................................ 25
1
NOTES
2
Removal and installation of operator cab Removal

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. Relieve pressure before disconnecting any
NOTE: It may be necessary to remove the body to
provide clearance for lifting equipment to be used. If
removal of the dump body is not required, the body 1. Refer to the "Hydraulic system bleeddown
must be raised and the body retention sling installed. procedure" in Testing and adjusting section
Refer to the topic "Securing the dump body" in Index Steering, hoist, brake cooling and auxiliary
and foreword section Foreword, safety and general hydraulic system.
information. 2. Remove cover (2, Figure 50-2). Disconnect all
NOTE: The base weight of the operator cab with the hydraulic hoses that are routed to the frame
hydraulic brake cabinet attached is approximately from the bottom of hydraulic brake cabinet (1).
2 767 kg (6,100 lb). However, due to options that may Cap all fittings and plug the hoses to prevent
be added, the weight of the operator cab may be as contamination.
much as 2 950 kg (6,500 lb). The rear portion of the
operator cab assembly is heavier than the front
portion.
NOTE: The angle of the lifting chains must be 45
degrees or greater. Refer to Figure 50-1. 1
45°
min.
2 86420
87605
FIGURE 50-2. REAR OF OPERATOR CAB
FIGURE 50-1. LIFTING THE OPERATOR CAB
1. Hydraulic Brake Cabinet 2. Cover
3
3. Close the shutoff valves for cab heater hoses

(1, Figure 50-3). Disconnect the hoses and
drain the water from the heater core.
Federal regulations prohibit venting air

conditioning system refrigerants into the
atmosphere. An approved recovery/recycle
station must be used to remove the refrigerant
1 from the air conditioning system.
4. Before removing the air conditioner hoses,
evacuate the air conditioning system. Refer to
Testing and adjusting section Cab air
conditioning for the correct procedure.
5. Disconnect all wiring harnesses (1, Figure 50-4)
and HVAC hoses (2) from the bottom of the
operator cab.
6. Check for any other clamps, hoses or wiring
LH SIDE which may interfere with cab removal. Remove
any additional components as needed.
1
2
RH SIDE 87561
FIGURE 50-3. SHUTOFF VALVES
1. Cab Heater Hose 2. DEF Coolant Return 2 87563
Hose FIGURE 50-4. BOTTOM OF OPERATOR CAB
1. Wiring Harnesses 2. HVAC Hoses
4
8. Remove mount covers (2) at each corner of the

operator cab.
9. Remove capscrews (3), plate (4), bushings (5)
and sleeves (6) from the mounting pads.
Use a crane and lifting devices with adequate 10. Lift the operator cab off the truck and move it to
capacity to remove and install the operator cab. a work area for further service if needed.
The angle of the lifting chains must be 45 degrees
or greater. NOTE: Before the operator cab is lowered to the
floor, place blocking under each mounting pad to
7. Attach a lifting device to four lifting eyes (1,
prevent damage to the floor pan and any components
Figure 50-5) provided on top of the operator
attached to the bottom of the operator cab.
cab.
5
7
87564
FIGURE 50-5. OPERATOR CAB REMOVAL & INSTALLATION

1. Lifting Eye 4. Plate 7. Cab Mounting Pad
2. Mount Cover 5. Bushing
3. Capscrew 6. Sleeve
5
Installation Removal and installation of cab door

NOTE: To perform repairs on the door, it is usually
easier, but not necessary, to remove the door from
the operator cab and lower it to the floor for service.
Removal
Use a crane and lifting devices with adequate
capacity to remove and install the operator cab.
The angle of the lifting chains must be 45 degrees
or greater.
1. Install sleeve (6, Figure 50-5) and two bushings
(5) into each capscrew hole in cab mounting Use lifting device with adequate capacity to
pads (7) as shown. remove and install the component.
2. Attach a lifting device to lifting eyes (1) provided 1. Lower door glass (1, Figure 50-6) far enough to
on top of the operator cab. Lift the operator cab allow insertion of a lifting sling.
and align the cab mounting pad holes with the 2. Disconnect the window regulator harness from
deck mounting pad holes. connector (2).
3. Install plate (4) and at least one capscrew (3) at 3. Detach door check strap (3). Open the cab door.
each of the four cab mounting pads before
4. Insert a lifting sling through the open window
lowering the cab onto the truck.
and attach it to a hoist.
4. After the cab is positioned, install the remaining
capscrews. Tighten the capscrews to 2 750 N·m
(2,028 ft lb).
5. Install HVAC hoses (2, Figure 50-4) and the
clamps to the underside of the operator cab.
1
6. Connect the other end of each cab heater hose
(1, Figure 50-3) to the fittings at heater hose
shutoff valves. Open the shutoff valves.
7. Route and connect all wiring harnesses (1,
Figure 50-4) to the connector plates on the
underside of the cab.
8. Remove the caps and plugs from the hydraulic
hoses and fittings. Install the hoses at the
bottom of hydraulic brake cabinet (1, Figure 50- 2
2).
9. Reinstall any clamps, hoses and wiring as
needed. 3
10. Remove the caps and reinstall the air
conditioning system hoses to the compressor
and receiver/drier. Refer to Testing and 4
adjusting section Cab air conditioning for
detailed instructions about evacuation and 87565
recharging with refrigerant.
FIGURE 50-6. CAB DOOR REMOVAL &
11. Start the engine and verify proper operation of INSTALLATION
all controls. Ensure that the air conditioning
1. Door Glass 3. Inner Door Panel
system is properly recharged.
2. Connector 4. Door Check Strap
6
5. Remove capscrews (1, Figure 50-7) that secure 5. Refer to Figure 50-8. With the door closed,
door hinge (2) to the operator cab. Lift the door dimension "A" must be 6.1 mm (0.240 in.) in
from the operator cab. order to maintain a gap of 5.7 mm (0.225 in.)
6. Place the door on blocks or on a work bench to while opening the door. A stainless steel shim
protect the window glass and allow access to may be used between hinge (1) and ROPS
internal components for repair. frame (3) to maintain the proper gap.
Installation
1. Before installing the door, check the inner and A
outer door seals for damage. Replace the seals
as necessary.
1 3
Use lifting device with adequate capacity to

remove and install the component.
2. Insert a lifting sling through the open window
and attach it to a hoist.
3. Lift the cab door up to the deck and position the 2
door in the opening of the operator cab.
4. Align the door on door hinge (2, Figure 50-7)
and install capscrews (1).
1
87568
FIGURE 50-8. CAB DOOR HINGE CLEARANCE

1. Door Hinge 3. ROPS Frame
2. Door Frame
6. Attach door check strap (3, Figure 50-6).

7. Connect the window regulator harness to
2 connector (2). Verify proper operation of the
power window.
87566
FIGURE 50-7. CAB DOOR REMOVAL &

INSTALLATION
1. Capscrew 2. Door Hinge
7
Disassembly and assembly of cab door 5. Place a wood block under door glass (3, Figure
50-10) to prevent the glass from falling.
NOTE: The cab doors can be serviced without
removing the door from the operator cab. 6. Remove four window lift mounting screws (2).
7. Remove the mounting screws for all four
Removing the window regulator regulator brackets (1).
1. Lower door glass (1, Figure 50-9) at least 153 8. Remove regulator (4) from the door. All four of
mm (6 in.). the regulator brackets can be removed from
2. Disconnect the window regulator harness from regulator and reused.
connector (2).
3. Detach door check strap (4). Open the cab door.
4. Remove 10 door panel screws and inner door
panel (3).
1 1
1
2
2
1 4
3 1
87567
3 FIGURE 50-10. WINDOW REGULATOR

1. Regulator Bracket 3. Door Glass
4 2. Window Lift Mounting 4. Window Regulator
Screws
87565
FIGURE 50-9. INNER DOOR PANEL

1. Door Glass 3. Inner Door Panel
2. Connector 4. Door Check Strap
8
Installing the window regulator

1. Loosely install all four regulator brackets (1,
Figure 50-10) onto window regulator (4). 9
Tighten the mounting hardware on the regulator
motor, but leave the other brackets loose. 2 3
2. Loosely install the regulator with the attached 4 5 6 7
brackets into the door. Do not tighten the
mounting hardware.
3. Use the window lift mounting hardware to attach
door glass (3) to the window lift bracket. Tighten
four window lift mounting screws (2) securely,
then remove the wood block that supports the
door glass.
NOTE: See Figure 50-11 for the correct installation of 1 3 2
the window lift mounting hardware.
6 8
4. Connect the window regulator harness to 87569
connector (2, Figure 50-9). FIGURE 50-11. WINDOW LIFT MOUNTING

5. Turn the engine start switch ON, then press the HARDWARE
window switch to test the operation of the 1. Window Lift Bracket 6. Washer
window regulator. 2. Gasket 7. Machine Screw -
6. With the door glass lowered, tighten the 3. Nylon Bushing M6 X 1.00 X 16
mounting hardware on both lower regulator 4. Window Stopper 8. Capscrew -
brackets. Bracket M6 X 1.00 X 12
7. With the door glass raised, tighten the mounting 5. Tube Sliding Bracket 9. Door Glass
hardware on both upper regulator brackets.
8. Install inner door panel (3, Figure 50-9). Tighten
the 10 door panel screws securely.
9. Attach door check strap (4).
9
Removing the door glass 4. Remove screw cover (1, Figure 50-13) from
1. Perform the procedure for "Removing the window frame (2). Remove 22 screws that
window regulator". Removal of the window secure the window frame to the door.
regulator itself is optional. NOTE: The screws along the bottom of the window
2. Lift the door glass and support it at the top of the frame should be shorter than the screws along the
door frame. top and sides.
3. Remove self-tapping screw (2, Figure 50-12) at
the lower end of both window channels (1).
2
NOTE: It may be necessary to pull the rubber felt
insert out of the channel to be able to remove the
screws.
1 2
87572
FIGURE 50-12. DOOR GLASS REMOVAL

1. Window Channel 2. Self-Tapping Screw
87573
FIGURE 50-13. WINDOW FRAME

1. Screw Cover 2. Window Frame
10
5. Lift the door glass into the window frame so that Installing the door glass
it is near the top. While holding the glass in
1. Before installing the door glass, inspect glass
place, tilt the window frame outward and lift
wipe (1, Figure 50-15) and frame filler (2) for
window assembly (1, Figure 50-14) out of the
wear and damage. Replace components if
door.
necessary.
6. Move the window assembly to a work area
2. Ensure that the rubber felt inserts in both
where the glass can be removed. Slide the
window channels (3) are in good condition.
glass down and out of the window channels.
Replace the inserts if necessary.
1 1
87574
FIGURE 50-14. WINDOW ASSEMBLY REMOVAL 87575
1. Window Assembly 2. Window Inner Seal FIGURE 50-15. WINDOW ASSEMBLY

1. Glass wipe 3. Window Channel
2. Frame Filler
11
3. Check the window frame seals and window

inner seal (3) for wear and damage. Replace
the seals if necessary.
4. Slide the new door glass into the window
2
channels. Move the door glass to the top of the
frame.
Do not allow the door glass to fall while installing

the window assembly. Damage to the glass will
occur if allowed to forcefully strike a hard
surface.
5. While holding the door glass at the top of the
frame, lift window assembly (1) and lower the
window assembly into the door.
6. Carefully lower the door glass. Place a wood
block at the bottom of the door for support.
The screws along the bottom of the window

frame should be shorter than the screws along 87570
the top and sides. The shorter screws must be
used in this area to prevent possible damage to FIGURE 50-16. DOOR SEAL INSTALLATION
the door glass during operation of the window. 1. Outer Door Seal 2. Inner Door Seal
7. Install the 22 screws that secure window frame
(2, Figure 50-13) to the door. Install screw cover
(1) on the window frame.
Replacing the outer door seal
8. Install self-tapping screw (1, Figure 50-12) at
the lower end of both window channels (2). 1. Locate the seam of outer door seal (1, Figure
Ensure that the rubber felt insert is in place after 50-16) near the door check strap. Pull one end
the screws are installed. to remove the seal from the door jamb.
9. Perform the procedure for "Installing the window 2. Inspect the cab door channel for damage, dirt,
regulator". and oil. Repair or clean the cab door as
necessary. Remove all dirt and existing sealant.
Ensure that the entire perimeter of the cab door
is clean and free of burrs.
Replacing the inner door seal
3. Install the outer door seal in the door jamb all
1. Inner door seal (2, Figure 50-16) is glued to the the way around the door frame. Starting near
door. Peel the seal away from the door frame. the door check strap, work the seal into the
Use a suitable cleaner to remove any remaining channel. Ensure that the seal fits tightly.
seal residue and glue from the door.
NOTE: It may be necessary to trim off some of the
2. Ensure that the door frame is dry and free of dirt seal.
and oil. Pull the backing paper off the new seal
to expose a pressure sensitive adhesive, then 4. Ensure that the door closes properly after the
press the new seal into place. seal is installed.
12
Removing the interior door handle and door latch 2. Remove two screws (1, Figure 50-18) and
1. Remove 10 door panel screws and inner door detach push lever (2) to access the end of the
panel (1, Figure 50-17). latch cable.
3. Detach latch cable (3) from lever cam (4). Push
NOTE: There should be enough slack in the window and hold door latch lever (5) to loosen the cable
regulator harness so that disconnection of the as needed.
harness is not required.
2
1
1
5
4
3
1
2 87596
87595 FIGURE 50-18. REMOVING THE PUSH LEVER

FIGURE 50-17. INNER DOOR PANEL 1. Screw 4. Cam Lever
1. Inner Door Panel 2. Interior Door Handle 2. Push Lever 5. Door Latch Lever
3. Latch Cable
13
4. Detach the other end of latch cable (3, Figure 5. Remove four screws (2, Figure 50-20), door
50-19) from plastic catch (2) at door latch lever handle (1) and floating plates (3). Retain the
(1). floating plates for proper installation of the door
handle.
Use the tip of a screwdriver to push up the latch
cable. Ensure that the plastic catch stays down.
The end of the cable will rotate at one end of the
plastic catch while the cable clears the clips. 3
After the cable is free of the clips, slide the cable
out of the plastic catch.
NOTE: Ensure that the plastic catch remains on the
door latch lever. The plastic catch can be replaced
only after the cable is removed.
3
2 1
87598
FIGURE 50-20. REMOVING THE DOOR HANDLE

1. Door Handle 3. Floating Plate
2. Screw
2
87597
FIGURE 50-19. REMOVING THE LATCH CABLE

1. Door Latch Lever 3. Latch Cable
2. Plastic Catch
14
NOTE: Do not allow the door latch to slide down Installing the interior door handle and door latch
inside the door channel after the screws are
1. Install door latch (3, Figure 50-21), external
removed.
tooth lockwashers (2) and four screws (1).
6. Remove four screws (1, Figure 50-21), external Tighten the screws securely.
tooth lockwashers (2) and door latch (3).
2. To install door handle (1, Figure 50-20), first
secure the end of the handle that is closest to
the door latch with two screws (2). Ensure that
A floating plate (3) is installed first.
3. While installing the floating plate and two
screws at the other end of the handle, keep
2
1 elbow sections (2, Figure 50-22) of the handle
pushed into straight section (1) so that there are
no gaps between the handle sections. Tighten
all four screws securely.
2
A
1 87602
FIGURE 50-22. INSTALLING THE DOOR HANDLE

3 1. Straight Section 2. Elbow Section
4. Engage the end of latch cable (3, Figure 50-19)

in plastic catch (2) of door latch lever (1). Rotate
VIEW A-A 87601
the cable downward to lock the end of the cable
FIGURE 50-21. REMOVING THE DOOR LATCH into the clips of the plastic catch.
1. Screw 3. Door Latch 5. Attach latch cable (3, Figure 50-18) to lever cam
2. Lockwasher (4). Push and hold door latch lever (5) to loosen
the cable as needed.
6. Attach push lever (2) with two screws (1).
7. Actuate the push lever several times to ensure
that the door latch is functioning properly.
8. Install inner door panel (1, Figure 50-17) and 10
door panel screws.
15
Adjustment of cab door 4. The door seal should firmly grip the paper all
along the top, front, and bottom edge of the
Door jamb bolt adjustment door. If the paper is loose all around, repeat
Over time, the door latch mechanism may wear. To Step 2. If the paper is firmly gripped, but can be
ensure proper latching of the door, the door jamb bolt removed without tearing it, open the door and
may need to be adjusted periodically. tighten the jamb bolt completely without
affecting the adjustment.
NOTE: Always check the condition of the door
5. If the paper slips out from the door seal easily
assembly seal before making adjustments.
along the top but the bottom (or vise versa), the
door itself will have to be adjusted.
a. If the seals are tight at the bottom of the door
but not at top, place a 4" x 4" block of wood
at the bottom edge of the door, below the
handle. Close the door on the wood block
and press firmly inward on the top corner of
the door. Press in one or two times, then
remove the wood block and check the seal
tension again using the paper method. Seal
compression should be equal all the way
around the door. If the seal is still loose at the
top, repeat the procedure again until seal
compression is the same all the way around.
b. If the seals are tight at the top of the door but
not at the bottom, place a 4" x 4" block of
wood at the top corner of the door and press
FIGURE 50-23. DOOR JAMB BOLT ADJUSTMENT firmly inward on the lower corner of the door.
Press in one or two times, then remove the
1. Washer 3. Frame
wood block and check seal compression
2. Striker Bolt 4. Door Seal
again using the paper method. Seal
compression should be equal all the way
around the door. If seal is still loose at the
bottom, repeat the procedure again until seal
If the door closes, but not tightly enough to give a compression is the same all the way around.
good seal between the door seal and the cab 1
If the door springs back when trying to close it 1
1. Mark washer location (1, Figure 50-23) portion
of the door jamb bolt with a marker, pen, or Striker bolt (2, Figure 50-24) has probably loosened
pencil by circumscribing the outside edge of the and slipped down from where the catch can engage
washer onto the jamb. with the bolt.
2. Loosen striker bolt (2). Move it straight inwards 1. Open the door and close both latches (3) and
1.5 mm (1/16 inch) and retighten the bolt. (5) on the catch until they are both fully closed.
3. Hold a piece of paper where door seal (4) will 2. Transfer the center of this opening onto the skin
contact the skin of the cab and firmly close the of the cab nearest where the door jamb bolt is
door on the paper. located. Use a T-square or other measuring
equipment and mark on the cab with a pencil.
NOTE: The door latch mechanism has a double
catch mechanism. Ensure that the door latches on NOTE: Release the door catch before trying to close
the second catch. the door.
16
Exterior door handle release button adjustment

If the exterior door handle does not function, the
handle or latch mechanism may need to be replaced.
Often, the door handle release button may simply
need to be adjusted. The following is a procedure for
adjusting the release button.
1. To determine the amount of free play in the door
release plunger, push door handle release
button (1, Figure 50-25) until capscrew (2) just
contacts the latch mechanism. Measure the
distance that the plunger travels from this
position to where the plunger is fully released.
FIGURE 50-24. DOOR JAMB BOLT ADJUSTMENT

1. Cab 4. Door
2. Striker Bolt 5. Lower Latch 2 3 87579
3. Upper Latch
FIGURE 50-25. MEASURING TRAVEL DISTANCE
OF PLUNGER
3. Loosen and vertically align (center) the door 1. Release Button 3. Locknut
jamb bolt with the mark and tighten it firmly 2. Capscrew
enough to hold it in place but still allow some
slippage.
4. Carefully try to close the door and determine
whether this adjustment has helped the
“springing” problem.
a. If the door latches but not firmly enough,
perform the procedure for "If the door closes,
but not tightly enough to give a good seal
between the door seal and the cab".
b. If the door latch does not catch, move the
bolt outward and try again. When corrected,
perform the procedure for "If the door closes,
but not tightly enough to give a good seal
between the door seal and the cab" to
ensure a good seal.
17
2. Remove the inner door panel. Removal and installation of side window
3. Remove three internal hex screws (1, Figure glass
50-26) and plate (2) that secure the exterior
Recommended tools and supplies
door handle to the door.
• Cold knife, pneumatic knife, or a piano wire
cutting device, long knife. Cutout tools are
available at an auto glass supply store.
• Heavy protective gloves
• Safety eyeglass goggles
• Windshield adhesives, proper cleaners, primers
and application gun
• SM2897 glass installation bumpers
(9 for front side window, 11 for rear side window)
Recommended adhesives:
• SikaTack Ultrafast or Ultrafast II (both heated).
2 1 Vehicle can be put into service in 4 hours under
optimum conditions. Heated adhesives require a
Sika approved oven to heat adhesive to 80° C
(176° F).
87578 • Sikaflex 255FC or Drive (unheated). Vehicle can
be put into service in 8 hours under optimum
FIGURE 50-26. DOOR LATCH
conditions.
1. Internal Hex Screws 2. Plate Sika Corporation
30800 Stephenson Hwy.
Madison Heights, MI 48071
Toll Free Number: 1-800-688-7452
4. Adjust capscrew (2, Figure 50-25) Fax number: 248-616-7452
counterclockwise to increase the height of door http://www.sika.com or
handle release button (1). http://www.sikasolutions.com
5. To lock the capscrew in place, push in the
release button while tightening locknut (3).
Apply Loctite® to prevent the capscrew from
loosening.
Due to the severe duty application of off-highway

vehicles, the cure times listed by the adhesive
manufacturer should be doubled before a truck is
moved. If the cure time is not doubled, vibration
or movement from a moving truck will weaken the
adhesive bond before it cures, and the glass may
fall off the cab.
If another adhesive manufacturer is used, follow
that manufacturer's instructions for use,
including the use of any primers, and double the
allowances for proper curing time.
18
Removal Installation
1. Clean the metal with Sika Aktivator. Allow it to
dry for ten minutes. Then paint on a thin coat of
Sika Primer 206G+P and allow it to dry for ten
minutes.
The first concern with all glass replacement is 2. Using only the new side window(s) which are to
SAFETY! Wear heavy protective gloves and be bonded in place, center the new glass over
safety eyeglass goggles when working with the opening in the cab. Use a permanent
glass. marker to mark on the cab skin along all the
edges of the new glass that is to be installed. All
1. Use a cut-out tool to slice into the existing edges must be marked on the cab in order to
urethane adhesive and remove the window apply the adhesive in the proper location.
glass.
3. Use Sika Primer 206G+P to touch up any bright
2. Carefully clean and remove all broken glass metal scratches on the metal frame of the truck.
chips from any remaining window adhesive. The Do not prime the existing urethane bed. Allow it
surface should be smooth and even. Use only to dry for ten minutes.
clean water.
4. Use a clean, lint free cloth to apply Sika
NOTE: Removal of all old adhesive is not required. Aktivator to the black ceramic Frit surrounding
Remove just enough to provide an even bedding the new window. Use a clean, dry cloth and
base. wipe off the Sika Aktivator. Allow it to dry for ten
3. Use a long knife to cut the remaining urethane minutes.
from the opening, leaving a bed 2 - 4 mm (0.08 - 5. For front side windows (2, Figure 50-27), use
0.15 in.) thick. If the existing urethane is loose, nine glass installation bumpers (SM2897). For
completely remove it. Leave the installation rear side windows (3), use eleven glass
bumpers in place, if possible. installation bumpers (SM2897). Space them
equally around the previously marked glass
perimeter, approximately 25 mm (1 in.) inboard
from where the edge of the glass will be when it
is installed.
The rubber bumpers are used to ensure a
proper adhesive installed thickness. If too thin,
the glass may break when the cab flexes. If too
thick, both improper sealing and the risk of glass
not being properly bonded are possible.
19
NOTE: Be careful not to place the adhesive too far 7. Immediately install the glass. Carefully locate
inboard, as it will make any future glass replacement the glass in place with the black masking side
more difficult. toward the adhesive. Press firmly, but not
6. Apply a continuous, even bead of adhesive abruptly, into place to ensure that the glass is
[approximately 10 mm (0.38 in.) in diameter] to properly seated. Do not pound the glass into
the cab skin at a distance of 13 - 16 mm (0.50 - place.
0.63 in.) inboard from the previously marked 8. Use a wooden prop and duct tape to hold the
final location of the glass edges from Step 2. glass in place for at least two hours or double
the adhesive manufacturer’s curing time,
whichever time is longer.
9. Remove the tape or prop from the glass only
after the cure time has expired.
1 4
2 3 3 2
FRONT REAR 87576
FIGURE 50-27. CAB WINDOWS

1. Windshield 3. Rear Side Window
2. Front Side Window 4. Rear Window
20
Removal and installation of windshield and Installation

rear window glass 1. If window seal (1, Figure 50-28) that was
NOTE: Two people are required to remove and install removed is broken, weathered, or damaged in
windshield (1, Figure 50-27) or rear window glass (4). any way, install a new window seal.
One person must be inside the cab, and the other
NOTE: Using a non-oily rubber lubricant or water-
person must be on outside the cab.
based hand cleaner on the weatherstrip material and
Special tools that are helpful in removing and cab opening will make the following installation
installing automotive glass are available from local easier.
tool suppliers.
a. Install the window seal around the window
opening. Start with one end of the seal at the
Removal
lower center part of the window opening and
NOTE: If the windshield is to be replaced, lift the press the seal over the edge of the opening.
windshield wiper arms out of the way first.
b. Continue installing the weatherstrip all
1. Starting at the lower center of the glass, pull out around the opening. When the seal ends (2)
window seal (1, Figure 50-28). Use a non-oily meet at the lower center part of the window
rubber lubricant and a screwdriver to release opening, there must be 12.7 mm (0.5 in.) of
the locking lip. overlapping material.
2. Remove the glass from the window seal by NOTE: The ends of the seal need to be square-cut to
pushing it out from inside the cab. assure a proper fit.
3. Clean all dirt and old sealant from the seal
c. Lift both ends so that they meet squarely.
grooves. Ensure that the perimeter of the
Then, while holding the ends together, force
window opening is clean and free of burrs.
them back over the lip of the opening.
2. Lubricate the groove of the window seal where
the glass is to be seated.
3. Lower the glass into the groove along the
bottom of the window opening.
4. Have one person on the outside of the cab
pushing in on the glass against the opening,
while another person on the inside uses a soft
flat tool (such as a plastic knife) to work the seal
over the edge of the glass all the way around.
A
5. After the glass is in place, inspect around the
A entire window seal to ensure that the glass is
2 securely installed in the seal.
NOTE: If the windshield was replaced, lower the
GLASS
windshield wiper arms back onto the glass.
1 CAB SHEET
VIEW A-A 87594
FIGURE 50-28. WINDSHIELD AND REAR

WINDOW GLASS
1. Window Seal 2. Seal Ends
21
Removal and installation of windshield Installing the windshield wiper motor

wiper components 1. Place wiper motor (1, Figure 50-30) into position
Removing the windshield wiper motor on the mounting plate.
2. Install three capscrews (5), flat washers (6) and
1. Remove front access cover (1, Figure 50-29)
lockwashers (7). Tighten the capscrews to 8-9
from the operator cab.
N·m (71-79 in. lb).
3. Slide wiper linkage (3) onto the motor output
shaft. Hold the linkage stationary and tighten
capscrew (4) to 22-24 N·m (16-18 ft lb).
4. Reconnect wiper motor harness (2).
NOTE: In case the wiper motor operates incorrectly,
lift the wiper arms off the windshield to avoid possible
damage.
5. Verify that the wipers operate properly and park
in the proper position (see Figure 50-29).
1 A
87545
FIGURE 50-29. ACCESSING THE WIPER MOTOR

2. Disconnect the wiper motor harness (2, Figure

50-30).
7 4 3
6 5
Some wiper linkage arms may have extremely

sharp edges. Wear protective gloves and long
sleeves when handling wiper linkage arms.
3. While holding wiper linkage (3) stationary, 2
loosen capscrew (4) and disconnect the wiper
linkage from wiper motor (1).
4. Remove three capscrews (5), flat washers (6)
1
and lock washers (7) that attach the wiper motor DETAIL A 87580
to the mounting plate. Remove the wiper motor
assembly. FIGURE 50-30. WIPER MOTOR REMOVAL &
INSTALLATION
1. Wiper Motor 5. Capscrew
2. Wiper Motor Harness 6. Flat Washer
3. Wiper Linkage 7. Lockwasher
4. Capscrew
22
6. Install front access cover (1, Figure 50-29) on 4. Loosen capscrew (5, Figure 50-32) that secures
the operator cab. the wiper linkage drive arm to wiper motor (6).
NOTE: When installing the front access cover, ensure 5. Remove cover (1), nut (2), thin washer (3) and
that the bottom false hinge of the cover is engaging thick washer (4) from both wiper arm shafts.
into the bottom edge of the sheet metal panel of the 6. Remove capscrews and flat washers (7) from
cab front enclosure. both ends of wiper linkage (8).
7. Carefully remove the wiper linkage from the
Removing the windshield wiper arm and linkage
operator cab so as not to damage the washer
NOTE: Note the parked position of the wiper arms in fluid hoses.
Figure 50-31 for proper installation.
1. Lift wiper arm cover (2, Figure 50-31). Remove
flanged nut (3). 1
2. Disconnect washer fluid hose (5), then remove
wiper arm (4). 2
3. If the wiper linkage is also being serviced,
remove front access cover (1) from the operator 3
cab. 5
4 8
6
87582
FIGURE 50-32. WIPER LINKAGE REMOVAL &

INSTALLATION
1 1. Cover 6. Wiper Motor
2. Nut 7. Capscrew &
3. Washer (thin) Flat Washer
2 3 4. Washer (thick) 8. Wiper Linkage
5. Capscrew
5 4
DETAIL A 87581
FIGURE 50-31. WIPER ARM REMOVAL &

INSTALLATION
1. Front Access Cover 4. Wiper Arm
2. Wiper Arm Cover 5. Washer Fluid Hose
3. Flanged Nut
23
Installing the windshield wiper arm and linkage Removal and installation of cab seats
1. Carefully place wiper linkage (8, Figure 50-32) NOTE: Removal and installation instructions for the
into position in the operator cab so as not to passenger seat are identical to the instructions for the
damage the washer fluid hoses. Ensure that the operator seat.
wiper linkage drive arm is connected to the shaft
of wiper motor (6).
2. Install capscrews and flat washers (7) at both
ends of the wiper linkage.
3. Install thick washer (4), thin washer (3) and nut
(2) on both wiper arm shafts. Tighten the nuts to Do not remove the handrail from the deck to
18-20 N·m (160-177 in. lb). allow room to remove the operator seat from the
cab. There is a risk of personnel of falling off the
truck if the handrail is removed.
Removal
1. Disconnect the door check strap so the door
Do not overtighten the nut. The threads on the can swing open wider.
wiper arm shafts are easily stripped when
improperly tightened. If necessary, remove the door from the cab to
allow room to remove the seat. Refer to the
topic "Removal and installation of cab door".
4. Install cap (1) over both wiper arm shafts.
2. Remove cotter pins (4, Figure 50-33) so that
5. Tighten capscrew (5) to secure the wiper
seat tethers (5) can be disconnected from the
linkage drive arm to the shaft of wiper motor (6).
eye bolts in the cab floor.
NOTE: When the wiper motor is parked, the drive 3. Disconnect the seat harness on the floor of the
arm will be in the 3 o’clock position as shown in operator cab.
Figure 50-32.
4. Remove four capscrews (1), flat washers (2),
6. Place wiper arm (4, Figure 50-31) into the and lockwashers (3) that secure the seat to the
parked position that was noted during removal. riser.
Install flanged nut (3). Tighten the nut to 16-20
N·m (142-177 in. lb). Close wiper arm cover
(2).
7. Connect washer fluid hose (5) to the wiper arm.
8. Verify that the wipers operate properly and park
in the proper position. Use lifting device with adequate capacity to
remove and install the seat. Do not lift the seat by
9. Install front access cover (1) on the operator using the arm rests as they could be damaged.
cab.
5. Remove the seat from the operator cab, then
NOTE: When installing the front access cover, use a suitable lifting device to lift the seat from
ensure that the bottom false hinge of the cover is the deck.
engaging into the bottom edge of the sheet metal
panel of the cab front enclosure.
24
Installation Removal and installation of seat belts
Use lifting device with adequate capacity to Inspect the date of manufacture on the seat belt.
remove and install the seat. Do not lift the seat by If the seat belt is over five years old, or if the seat
using the arm rests as they could be damaged. belt has been in service for more than three
1. Use a suitable lifting device to lift the seat to the years, replace the seat belt.
deck.
Removal
2. Position the seat in the operator cab. Install new
grade 5 capscrews (1, Figure 50-33), flat 1. Remove capscrew (1, Figure 50-34) that
washers (2) and lockwashers (3) that secure the secures lap belt retractor (2) and seat tether (3)
seat to the riser. Tighten the capscrews to the to the seat.
standard torque. 2. Remove carriage bolt (4) that secures shoulder
3. Connect the seat harness. belt retractor (5) to the mounting bracket.
4. Fasten seat tethers (5) to the eye bolts in the
floor of the operator cab. Install cotter pins (4).
5. Connect the door check strap. If the door was
removed, install the door. Refer to the topic
"Removal and installation of cab door".
5
5
2
4
4
1
3 87587
1 FIGURE 50-34. LOWER SEAT BELT MOUNT
2 1. Capscrew 4. Carriage Bolt

2. Lap Belt Retractor 5. Shoulder Belt
3. Seat Tether Retractor
3
87583
FIGURE 50-33. CAB SEAT REMOVAL &

INSTALLATION
1. Capscrew 4. Cotter Pin
2. Flat Washer 5. Seat Tether
3. Lockwasher
25
3. Disconnect seat belt minder harness (1, Figure Installation

50-35).
NOTE: Use new hardware when installing the seat
4. Remove capscrew (2) that secures seat belt belt.
latch (3) and seat tether (4) to the seat.
1. Slide upper seat belt mount (1, Figure 50-36)
onto the mounting bracket. Install the capscrew,
foam pad (2) and nut (3). Tighten the nut to the
standard torque.
2. Install seat tether (4, Figure 50-35), seat belt
latch (3) and new capscrew (2) onto the seat.
Ensure that the seat tether is installed under the
3 seat belt latch. Tighten the capscrew to the
standard torque.
3. Connect seat belt minder harness (1).
4. Use carriage bolt (4, Figure 50-34) to secure
shoulder belt retractor (5) to the mounting
4 bracket.
5. Install seat tether (3), lap belt retractor (2) and
2 new capscrew (1) onto the seat. Ensure that the
seat tether is installed under the lap belt
retractor. Tighten the capscrew to the standard
1 87588 torque.
FIGURE 50-35. RH SEAT BELT MOUNT 6. Ensure that the seat belt pulls out and retracts
smoothly and that the seat belt buckle clicks
1. Seat Belt Minder Harness 3. Seat Belt Latch securely into the seat belt latch. Ensure that the
2. Capscrew 4. Seat Tether seat tethers are secured properly to the eye
bolts on the cab floor.
5. Remove nut (3, Figure 50-36), the capscrew
and foam pad (2). Slide upper seat belt mount
(1) off the mounting bracket.
1 2
87586
FIGURE 50-36. UPPER SEAT BELT MOUNT

1. Upper Seat Belt Mount 2. Nut
2. Foam Pad
26
NOTES
27
28
830E Dump truck

930E Dump truck
980E Dump truck
29
30
CEN50028-02
730E 960E
830E 980E
860E
930E
730E-8 A40004 and up 960E-2K A50011 and up
830E-5 A50005 and up 960E-2KT A50028 and up
860E-1K A30031 and up 980E-4 A40003 and up
860E-1KT A30031 and up 980E-4AT A40083 and up
930E-5 A40004 and up 980E-5 A50005 and up
960E-2 A30027 and up
960E-1K A50009 - A50010

Replacement of air conditioning system components........................................................................................... 3
1
NOTES
2
Replacement of air conditioning system Expansion valve

components 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
Never use any lubricant or joint compound to expansion valve from the evaporator inlet. Expansion
lubricate or seal any A/C connections. 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
Hoses and fittings clean surfaces and replace or attach any insulating
material.
When replacing hoses, use the same type and size of
hose that was removed. When hoses or fittings are
shielded or clamped to prevent vibration damage,
ensure that these are in position or secured. Receiver-drier
NOTE: When installing the heater hose elbows and The receiver-drier can not be serviced or repaired. It
hose connectors to the junction plate, use Loctite® must be replaced whenever the system is opened for
Thread Sealant 567™. any service. The receiver-drier has a pressure switch
to control the clutch, and should be removed and
installed onto the new unit.
Lines
Always use two wrenches when disconnecting or Thermostat
connecting A/C fittings attached to metal lines.
Copper and aluminum tubing can kink or break very A thermostat can be stuck open or closed due to
easily. When grommets or clamps are used to contact point wear or fusion. The thermostat
prevent line vibration, ensure that these are in place temperature sensing element (capillary tube) may be
and secure. 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
It is important to always torque fittings to the capillary tube or a kink, burned thermostat contact or
proper torque. Failure to do this may result in just no contact. When troubleshooting, bypass the
improper contact between mating parts and thermostat by hot wiring the clutch coil with a fused
leakage may occur. Refer to the following torque lead. If the clutch engages, replace the thermostat.
chart for tightening specifications.
Thermostat contact points may be fused (burned)
closed and the clutch will not disengage. Causes are
Fitting Size Torque a faulty switch that could be due to fatigue. The
6 14 - 20 N·m (10 - 15 ft lb) thermostat must be replaced. When the clutch will not
disengage you may also note that condensate has
8 33 - 39 N·m (24 - 29 ft lb) frozen on the evaporator fins and blocked air flow.
There will also be below normal pressure on the low
10 36 - 42 N·m (26 - 31 ft lb) side of the system. Side effects can be compressor
12 41 - 47 N·m (30 - 35 ft lb) 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.
Installation torque for the single M10 or 3/8 in.
capscrews securing the inlet and outlet fittings onto
the compressor ports is 15 - 34 N·m (11 - 25 ft lb).
3
Compressor Clutch
The compressor can fail due to shaft seal leaks (no Clutch problems include electrical failure in the clutch
refrigerant in the system), defective valve plates, coil or lead wire, clutch pulley bearing failure, worn or
bearings, or other internal parts or problems warped clutch plate or loss of clutch plate spring
associated with high or low pressure, heat, or lack of temper. Defective clutch assembly parts can not be
lubrication. Ensure that the compressor is securely replaced. Replace the entire A/C compressor as an
mounted and the clutch pulley is properly aligned with assembly.
the drive pulley.
The fast way to check electrical failure in the lead
Use a mechanic's stethoscope to listen for noises wire or clutch coil is to hot wire the coil with a fused
inside the compressor. 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
When installing a new compressor, the by poor alignment of the clutch and clutch drive
compressor must be completely drained of its oil pulley.
before installation. Add 300 ml (10.1 oz.) of new
PAG oil (PC2279) to the compressor as shown in Sometimes it may be necessary to use shims or
Figure 50-1 to ensure proper system oil level. enlarge the slots in the compressor mounting bracket
Failure to adjust the amount of oil in the to achieve proper alignment.
compressor will lead to excessive system oil and Excessive clutch plate wear is caused by the plate
poor A/C performance. rubbing on the clutch pulley when the clutch is not
engaged or the clutch plate slipping when the clutch
coil is energized. A gap that is too small or too large
between the plate and clutch pulley or a loss of clutch
plate spring temper are possible causes.
It is important to note that often times a weak clutch
Under no circumstances should the A/C
coil may be mistaken for a seized compressor. When
compressor be stood upright onto the clutch
a coil’s resistance has increased over time and the
assembly. Damage to the compressor clutch will
magnetic field weakens, the coil may not be able to
result, leading to premature compressor failures.
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:
17.6 ± 0.6 Ohms at 20° C (68° F)
The temperatures specified above are roughly typical
FIGURE 50-1. COMPRESSOR B of a summer morning before first start-up and the
300 ml - (10.1 oz.) PC2279 PAG OIL heat beside an engine on a hot day. At temperatures
in between those listed above, the correct resistance
is proportionate to the difference in temperature.
Accumulator NOTE: The outer threads of installer (J-9480-01) are
The accumulator can not be serviced or repaired. It left handed threads.
must be replaced whenever the system is opened for
any service.
4
NOTES
5
730E Dump truck

830E Dump truck
860E Dump truck
930E Dump truck
960E Dump truck
980E Dump truck
6
CEN50078-00
980E

980E-5 A50005 and up

Power module
Removal and installation of power module ........................................................................................................... 3
Removal and installation of alternator................................................................................................................. 15
Removal and installation of radiator.................................................................................................................... 27
Repairing the radiator ......................................................................................................................................... 33
Removal and installation of engine ..................................................................................................................... 36
1
NOTES
2
Removal and installation of power module Read and observe the following instructions before
attempting any repairs.
General
The radiator, engine and alternator assemblies are
mounted on a roller-equipped subframe which is
contained within the truck's main frame. This
arrangement, referred to as a “power module”,
permits removal and installation of these components • Do not attempt to work in the deck area until
with a minimum amount of disconnect by utilizing the the body up retention cable or sling has been
“roll in/roll out” feature. installed.
Although the instructions in this section are primarily • Do not step on or use any power cable as a
based upon the “rollout” method for major component handhold when the engine is running.
removal, the radiator and fan may be removed as • Do not open any control cabinet doors or
separate items. Optional equipment may also be covers, and do not touch the retarding grid
installed on the truck, requiring additional removal elements, until all shutdown procedures have
and installation steps not listed. been completed.
The procedures outlined in this section of the manual • All removal, repair and installation of
are general instructions for power module removal propulsion system electrical components and
and installation. It may be necessary to perform some cables must be performed by an electrical
maintenance technician who is properly
procedures in a different order or use different
trained to service the system.
methods for component removal and installation,
depending on the lifting equipment available. • In the event of a propulsion system
malfunction, a qualified technician must
Prior to removal or repair procedures, it may be inspect the truck and verify that dangerous
necessary to remove the body to provide clearance voltage levels are not present in the
for lifting equipment to be used. If body removal is not propulsion system before repairs are started.
required, the body should be raised and secured with
the body up retention cable or sling.
3
Removal
the wheels.
turn the rest switch ON. Turn the key switch The system is charged with HFC-134A refrigerant.
OFF to shut down the engine and allow 90 Federal regulations prohibit venting air
seconds for the steering system accumulators conditioning system refrigerants into the
to bleed down. atmosphere. An approved recovery/recycle
station must be used to remove the refrigerant
from the air conditioning system.
6. Evacuate the air conditioning system. Refer to
Testing and adjusting section Cab air
conditioning for the procedures that are
required to properly evacuate the refrigerant
Use lifting equipment with adequate capacity to from the air conditioning system.
7. Unclamp and disconnect refrigerant hoses (1,
3. Remove the diagonal ladder and support from Figure 50-2) from A/C compressor (2) and
truck. Refer to Disassembly and assembly condenser (3). Plug the hoses and ports. Move
section, Body and structures, for the removal the hoses away from engine compartment to
procedure. prevent interference with power module
NOTE: The power module may be removed with the removal.
hood and grille installed if desired.
4. It is not necessary to remove the radiator before
removing the power module. However, the 2
coolant must be drained and the piping to the
brake cooling heat exchanger must be
removed. Refer to the topic "Removal and
installation of radiator" for more information.
5. Disconnect all electrical cables from the battery
box. Remove the mounting hardware from each 1
corner, then lift battery box assembly (1, Figure
50-1) from the truck.
3
1
86691
FIGURE 50-2. REFRIGERANT HOSE REMOVAL

1. Refrigerant Hose 3. Condenser
86687
2. A/C Compressor
FIGURE 50-1. BATTERY BOX REMOVAL &
INSTALLATION
1. Battery Box Assembly
4
8. Open bottom drive shaft cover (1, Figure 50-3). 9. Remove the blower ducts from the traction
Remove eight capscrews and lockwashers to alternator.
disconnect drive shaft (2) from traction
a. Disconnect cables and hoses as required.
alternator (3).
b. Remove control cabinet blower transition (1,
Figure 50-4).
c. Remove wheel motor blower transition (2).
d. Remove alternator blower transition (3).
e. Remove drive axle blower hose (4)
f. Cover all openings to prevent foreign
material from entering the system.
FIGURE 50-3. HOIST PUMP DRIVE SHAFT

REMOVAL
1. Bottom Drive Shaft Cover
2. Drive Shaft
3. Traction Alternator
FIGURE 50-4. ALTERNATOR BLOWER DUCTS
1. Control Cabinet Blower Transition

2. Wheel Motor Blower Transition
3. Alternator Blower Transition
4. Drive Axle Blower Hose
5
10. Remove engine air intake duct support rods (3, 11. Remove heat shields (2) from the bottom of the
Figure 50-5) from the bottom of center deck (1). center deck.
Remove any hoses, electrical cables and
12. Install lifting bolts and attach an overhead hoist
ground straps that are attached to the center
to the center deck. Remove the deck mounting
deck.
hardware, then lift center deck (1) from truck.
3 1 3
2 2 2
4 5
5 9
5 6 5 6
7 7
8 8
MOUNTING MOUNTING
DETAIL B DETAIL A 86681
FIGURE 50-5. CENTER DECK REMOVAL & INSTALLATION

1. Center Deck 6. Spacers
2. Heat Shield 7. Lockwasher
3. Duct Support Rod 8. Nut
4. Capscrew 9. Rubber Mount
5. Flat Washer
6
13. Disconnect the wiring harnesses from pressure 15. Disconnect inlet ducts (3) at each of the six
switches (1, Figure 50-6) on the inlet ducts. turbochargers. Remove the inlet ducts from the
14. Loosen the clamps on hump hoses (2) between truck. Cover the openings at the turbochargers
the engine inlet ducts and the air cleaner outlet and at both ends of the inlet ducts.
ducts.
2 3
2 A
B
2
1
1
DETAIL A DETAIL B 86682
FIGURE 50-6. ENGINE INLET DUCT REMOVAL & INSTALLATION

1. Pressure Switch 3. Inlet Duct
2. Hump Hose
16. Remove the exhaust tube clamps from hanger 1 2

rods (2, Figure 50-7).
1 2
17. Remove the capscrews, lockwashers and nuts
that secure exhaust tubes (1) to the
turbocharger outlet flanges. Remove the
exhaust tubes and cover the turbocharger outlet
openings on the engine.
86683
FIGURE 50-7. ENGINE EXHAUST PIPING

1. Exhaust Tube 2. Hanger Rod
7
18. Close fuel shutoff valve (1, Figure 50-8). 20. Close the shutoff valves for cab heater water
Disconnect and cap fuel hoses (2) at the hoses (1, Figure 50-10). Disconnect the hoses
mounting bracket. and drain the water from the heater core.
Secure the hoses away from engine
compartment to prevent interference with power
module removal.
1
1 2
2
86684 LH SIDE
FIGURE 50-8. FUEL HOSES
1. Fuel Shutoff Valve 2. Fuel Hose
1
19. Close the shutoff valve for DEF coolant supply

hose (1, Figure 50-9) and DEF coolant return
hose (2, Figure 50-10). Disconnect and plug the
hose. Move the hose away from engine
module removal. 2
RH SIDE 87561
1. Cab Heater Water 2. DEF Coolant Return

Hose Hose
87562

1. DEF Coolant Supply Hose
8
21. Disconnect service center hose (1, Figure 50- 23. Disconnect all power cables (1, Figure 50-13)
11) from engine oil pan (2). Plug the hose and and other wiring from the traction alternator.
port. Move the hose away from engine
module removal. 1
NOTE: The hose may be connected to either side of
the engine depending on which side of the truck the
service center is located.
86686
2 87560
FIGURE 50-13. TRACTION ALTERNATOR
FIGURE 50-11. ENGINE OIL HOSE POWER CABLES
1. Service Center Hose 2. Engine Oil Pan 1. Power Cables
22. Disconnect service center hose (1, Figure 50- 24. Remove upper support rod (1, Figure 50-14) at
12) from the coolant pipe beneath the radiator. both sides of the radiator.
Plug the hose and port. Move the hose away
from engine compartment to prevent
interference with power module removal.
1
86576
FIGURE 50-14. UPPER SUPPORT ROD

1 86692
FIGURE 50-12. SERVICE CENTER 1. Upper Support Rod

COOLANT HOSE
1. Service Center Coolant Hose
9
25. Remove the mounting hardware and subframe 27. Remove capscrews (3, Figure 50-16), flat
rubber mounts (2, Figure 50-15) on both sides washers (4) and caps (2) that secure the
of the subframe. subframe to mounting bushings (1) on both
26. Install a safety chain around the engine sides of the rear of the engine subframe.
subframe cross member and the main frame to 28. Check the engine and the alternator to ensure
prevent the power module from rolling when the that all cables, wires, hoses, tubing and linkages
subframe rollers are installed. have been disconnected.
1
5
2
3 1
4 2 3 4
86694 86695
FIGURE 50-15. FRONT SUBFRAME MOUNTS FIGURE 50-16. REAR SUBFRAME

MOUNTING BUSHINGS
1. Capscrew 4. Nut
2. Rubber Mount 5. Front Subframe 1. Mounting Bushing 4. Flat Washer
3. Lockwasher Lifting Points 2. Cap 5. Rear Subframe
3. Capscrew Lifting Point
10
29. Place a jack under the rear of the power

module. Raise the rear portion of engine
subframe and install subframe rollers (1, Figure
50-17) on both sides of the power module.
Lower the rear portion of the subframe carefully
Lift the power module only at the lifting points on
until the rollers rest on the main frame guide rail.
the subframe and engine/alternator cradle
NOTE: Subframe rollers are supplied in the optional structure. Refer to Figure 50-18. Ensure that the
tool group. lifting devices have adequate capacity.
31. Roll the power module forward so that adequate
clearance is provided in front of the control
cabinet for the lifting device to be attached to
front subframe lifting points (5, Figure 50-15)
and rear subframe lifting points (5, Figure 50-
16). Place stands or blocking under the front of
the subframe. Lower the hoist until the front of
the subframe is supported. Install a safety chain
to prevent the subframe from rolling.
32. Attach lifting tool (1, Figure 50-18) to the hoist
and attach it to subframe lifting points (3) as
1 shown in Figure 50-18. Remove the safety
chain.
86696 33. Raise the power module slightly to determine
whether the module is on an even plane. Move
FIGURE 50-17. SUBFRAME ROLLER
the power module straight out of the truck to a
INSTALLATION
clean work area for further disassembly.
1. Subframe Roller
30. Position the hoist at front subframe lifting points

(5, Figure 50-15). Raise the engine subframe
until the engine is on a level plane. Remove the
safety chain that was installed in step 25.
FIGURE 50-18. POWER MODULE LIFTING TOOL

INSTALLATION
1. Lifting Tool 4. Engine
2. Alternator 5. Power Module
3. Subframe Lifting Points Subframe
11
Installation 8. Install a safety chain around the truck frame and

1. Inspect the subframe guide rails on the inside of the subframe to prevent the power module from
the main frame. Remove any debris that could rolling forward.
interfere with installation of the power module. 9. Place a small block behind each rear subframe
2. Clean the main frame rear support brackets. roller to prevent rolling.
Apply a light film of soap solution to each 10. Lower the hoist to allow the subframe to rest on
mounting bushing (3, Figure 50-16) located at the stands and subframe rollers. Remove lifting
the rear of the subframe. tool (1, Figure 50-18).
3. Check subframe rollers (1, Figure 50-17) on 11. Attach the hoist to front subframe lifting points
both sides of the power module. Ensure that (5, Figure 50-15).
they are installed correctly and roll freely.
12. Remove the small blocks behind the subframe
rollers. Remove the safety chain and slowly roll
the power module into position over the front
main frame mounts.
13. Install rubber mounts (1, Figure 50-20) without
Lift the power module only at the lifting points on the mounting hardware, then lower the hoist
the subframe and engine/alternator cradle until front subframe mounts (2) are aligned with
structure. Refer to Figure 50-18. Ensure that the and seated on front main frame mounts (3).
lifting devices have adequate capacity. Reinstall the safety chain.
4. Attach lifting tool (1, Figure 50-18) to subframe
lifting points (3).
5. Raise the power module and align the subframe
rollers onto the subframe guide rails.
6. Lower the power module to the subframe guide
rails. Relax the hoist slightly and roll the power
module into truck frame as far as possible
before the lifting chains contact the control
cabinet (see Figure 50-19).
7. Place stands or blocking under the front of the 2
subframe to support the power module while the
hoist is repositioned. 1
1
86698
FIGURE 50-20. FRONT SUBFRAME MOUNTS

1. Rubber Mount 3. Front Main Frame
2. Subframe Mount Mount
FIGURE 50-19. POWER MODULE INSTALLATION
12
14. Place a jack under the rear of the subframe to 20. Install all ground straps between the frame and
support the power module. Raise the power subframe. Reconnect wire harnesses at the
module just enough to permit removal of the power module subframe connectors. Connect
subframe rollers. Remove subframe rollers (1, all power cables (1, Figure 50-13) and other
Figure 50-17). wiring to the traction alternator.
15. Lower the rear of the subframe until both 21. Unplug and connect all service center hoses,
subframe mounts (1, Figure 50-21) are seated engine oil hoses, fuel hoses and water lines.
on mounting bushings (2) on the main frame of See Figure 50-8 through Figure 50-12.
the truck.
22. Uncover the exhaust tube openings and
turbocharger outlets. Install exhaust tubes (1,
Figure 50-7) on the turbocharger outlet flanges.
Tighten the capscrews to the standard torque.
23. Uncover the openings at the turbochargers and
at both ends of the inlet ducts. Install inlet ducts
(3, Figure 50-6) at each of the six
turbochargers.
24. Install hump hoses (2) between the engine inlet
ducts and the air cleaner outlet ducts. Clamp the
ducts securely to ensure a positive seal is
made. Refer to Figure 50-22 for examples of
correct installation.
1
2 86697
25. Install lifting bolts and attach an overhead hoist
to the center deck. Lift center deck (1, Figure
FIGURE 50-21. REAR SUBFRAME MOUNTS 50-5) into position, then install the mounting
1. Subframe Mount 2. Mounting Bushing hardware at each mounting bracket. Tighten the
26. Install heat shields (2) to the bottom of the
center deck. Tighten the capscrews to the
standard torque.
16. After the subframe is seated on the front main
frame mounts and the rear mounting bushings, 27. Install all clamps and hangers that support the
remove the safety chain. exhaust tubes and engine inlet ducts.
17. Install rubber mounts (2, Figure 50-15), 28. Inspect the flexible transitions and gaskets and
capscrews (1), lockwashers (3) and nuts (4) at replace them if damaged. Install alternator
the front engine mounts on both sides of the blower transition (1, Figure 50-4), wheel motor
subframe. Tighten the capscrews to 712 ± 72 blower transition (2) and control cabinet blower
N·m (525 ± 53 ft lb). transition (3). Install drive axle blower hose (4).
18. Install caps (2, Figure 50-16) over mounting 29. Open bottom drive shaft cover (1, Figure 50-3).
bushings (1). Secure the caps with lubricated Connect drive shaft (2) to traction alternator (3)
capscrews (3) and flat washers (4). Tighten the by installing eight capscrews and lockwashers.
capscrews to 552 ± 20 N·m (407 ± 15 ft lb). Tighten the capscrews to the standard torque.
Close the bottom drive shaft cover.
NOTE: If the radiator has been removed, install the
radiator at this time. Refer to "Removal and 30. Unplug and connect refrigerant hoses (1, Figure
installation of radiator". 50-2) to A/C compressor (2) and condenser (3).
19. Install upper support rod (1, Figure 50-14) on

both sides of the radiator.
13
31. Install the diagonal ladder and vertical support. 36. Ensure that all electrical wiring is connected to
Refer to Disassembly and assembly section, the power module components. Deactivate the
Body and structures, for the installation battery disconnect switches.
procedure.
37. Refill the radiator with coolant and service the
32. Attach an appropriate lifting device to the lifting engine with the appropriate fluids. Refer to the
eyes on the battery box, then lift battery box Operation and Maintenance Manual for the
assembly (1, Figure 50-1) into position at the cooling system capacity and fluid specifications.
front of the truck. Install the mounting hardware
38. Recharge the air conditioning system according
at each corner of the battery box and tighten the
to the instructions in Testing and adjusting
section Cab air conditioning.
33. Connect all electrical wiring to the battery box.
34. Connect air cleaner restriction indicator nylon
tubes (1, Figure 50-6) to the inlet ducts.
35. Open both water shutoff valves (1, Figure 50-
10) and fuel shutoff valve (1, Figure 50-8).
FIGURE 50-22. AIR INLET PIPING CONNECTIONS
14
Removal and installation of alternator

Removal
NOTE: The following instructions cover the removal
of the traction alternator from the engine after the
power module has been removed from the truck. Use lifting equipment with adequate capacity to
The power module must be placed on solid level
ground before removing the traction alternator. 1. Attach a hoist with two lifting chains to lifting
eyes (1, Figure 50-23) on top of the traction
alternator. Take up the slack in the lifting chains.
2. Block up the rear of the engine.
3. Loosen engine cradle adjustment setscrews (3).
4. Loosen capscrews (2) that secure engine cradle
(4) to the traction alternator.
4
3
2
86680
FIGURE 50-23. TRACTION ALTERNATOR REMOVAL
1. Lifting Eyes 3. Adjustment Setscrews
2. Capscrew & Lockwasher 4. Engine Cradle
15
5. Remove access cover (1, Figure 50-24) on the Use engine turner (2) to rotate the crankshaft to
right side of the flywheel housing. Reach align each capscrew with the access hole.
through the access opening to remove 20 Ensure that all 20 capscrews have been
capscrews and hardened flat washers (3) that removed.
join engine drive ring (4) to the alternator rotor.
1
3
86689
FIGURE 50-24. ENGINE DRIVE RING/ALTERNATOR ROTOR CONNECTION

1. Access Cover 3. Capscrew (5/8" - 11NC) & Hardened
2. Engine Turner Flat Washer
4. Engine Drive Ring
16
6. Remove 18 capscrews and flat washers (1, 8. Keep the alternator as level as possible and
Figure 50-25) that secure flywheel housing move it away from the engine.
adapter (2) to the alternator housing. 9. Note the location and quantity of the shims.
7. Remove capscrews and lockwashers (2, Figure Keep the shims for possible reuse during
50-23) that secure engine cradles (4) on both installation.
sides of the traction alternator.
2 3 86690
FIGURE 50-25. FLYWHEEL ADAPTER/ALTERNATOR HOUSING CONNECTION

1. Capscrew (5/8" - 11NC) & Hardened 3. Capscrew (M12 X 1.75) & Hardened
Flat Washer Flat Washer
2. Flywheel Housing Adapter
17
10. If removal of the flywheel housing adapter is Installation

necessary:
1. If the flywheel housing adapter is removed:
a. Remove mounting hardware (1, Figure 50-
a. Install flywheel housing adapter (2, Figure
26) and bracing (2) between the flywheel
50-25) on the engine flywheel housing. Install
housing adapter and the engine.
16 capscrews and hardened flat washers (3).
b. Remove 16 capscrews and hardened flat Tighten the capscrews to 95 N·m (70 ft lb).
washers (3, Figure 50-25) that secure
b. Install bracing (2, Figure 50-26) and
flywheel housing adapter (2) to the engine
mounting hardware (1) between the flywheel
flywheel housing.
housing adapter and the engine. Tighten the
NOTE: For further disassembly instructions for the hardware to the standard torque.
traction alternator, refer to the appropriate GE service
manual.
The following instructions must be followed to

1 ensure proper alignment and engine crankshaft
endplay. Failure to follow these instructions can
result in serious damage to the engine and/or
alternator.
• Loosen or remove fan belts before measuring
crankshaft endplay to ensure that the crankshaft
moves easily and completely.
1 • When taking measurements, always clean mating
surfaces, then take four equally spaced readings
and average them.
2 86688
• A reference to crankshaft rotation - clockwise
FIGURE 50-26. ALTERNATOR/FLYWHEEL (CW) or counterclockwise (CCW) - is the
HOUSING BRACING REMOVAL direction of rotation when looking at the front
1. Mounting Hardware 2. Bracing (damper end) of engine.
• All measurements are set to three decimal
places.
• Ensure that a surface reference (such as a flat
steel bar) used for dial indicating is calibrated
periodically for flatness and dimensional
accuracy to within +/-.0009 in. Also, ensure that
all instruments used for measurements are
calibrated on a periodic basis.
• Forward is defined as the front of truck and
rearward is defined as the rear of the truck.
18
Engine Flywheel Adapter Face Runout

1. Thoroughly clean all mounting surfaces: the
Summary of Axial & Radial Runout Limits alternator housing, rotor, flywheel, and flywheel
Description Specification housing.
Engine Crankshaft Endplay 0.13 mm (.005 in.) - 2. Locate the dial indicator base on the machined
0.51 mm (.020 in.) face of the flywheel/flexplate and zero the probe
Alternator Endplay 0.51 mm on the face of the flywheel housing adapter. See
(0.020 in.) Figure 50-27.
Flywheel Housing Radial 0.30 mm

Runout (0.012 in.)
Flywheel Housing Face 0.30 mm
Runout (0.012 in.)
Flywheel/Flexplate Radial 0.13 mm
Runout (0.005 in.)
Flywheel/Flexplate Face 1.00 mm
Runout (0.040 in.)
Rotor Shaft Radial Runout 0.13 mm
(assembled) (0.005 in.)
FIGURE 50-27. DIAL INDICATOR SETUP
3. Move the crankshaft frontwards. Use an engine

barring device to slowly rotate the engine
crankshaft 1/4 turn. Document the reading.
Move the crankshaft frontwards after every 1/4
turn and continue this procedure for two full rev-
olutions, documenting the reading at every 1/4
turn.
4. The difference between the highest and lowest
values for each revolution is the flywheel
housing adapter face runout. If the average of
the two measurements exceeds 0.30 mm
(0.012 in.), contact your Komatsu
representative for further instructions.
Adapter Face Runout =____________________
19
Engine Crankshaft Endplay 1st measurement - 12 o’clock (CR1): ____________

5. Mount a magnetic base on the front of the
engine and a dial indicator on the front of the 2nd measurement - 6 o’clock (CR2): _____________
crankshaft to measure the total crankshaft
3rd measurement - 3 o’clock (CR3): _____________
endplay.
6. Move the crankshaft forward and rearward as 4th measurement - 9 o’clock (CR4): _____________
far as possible. This is accomplished by either
removing a hand-hole cover and prying gently
on a crankshaft counterweight or using a rubber Cavg1 : (CR1+CR2+CR3+CR4) / 4 =___________
mallet to strike the front end of the crankshaft.
7. Confirm that the measurement is equal in both
forward and rearward directions. Record both
values and confirm that the engine crankshaft
endplay is 0.13 - 0.51 mm (0.005 - 0.020 in.). 11. Move the crankshaft forward to its end travel.
12. Repeat the same procedure in three more
locations, 90 degrees apart from each other in
Crankshaft Endplay (forward) =_______________ the perimeter, to find the values CF2, CF3, and
Crankshaft Endplay (rearward) =______________ CF4.
Engine Flywheel to Flywheel Housing Adapter - 1st measurement - 12 o’clock (CF1): _____________
Measurement “C”
2nd measurement - 6 o’clock (CF2): _____________
8. Move the crankshaft rearward to its end travel.
9. Bolt a calibrated flat steel bar across the 3rd measurement - 3 o’clock (CF3): _____________
flywheel housing as a surface reference to
4th measurement - 9 o’clock (CF4): _____________
measure the distance between the flywheel
housing and the flywheel adapter plate. See
Figure 50-28. This will be measurement CR1.
Cavg2 : (CF1+CF2+CF3+CF4) / 4 =___________
10. Repeat the same procedure in three more
locations, 90 degrees apart from each other in
the perimeter, to find the values CR2, CR3, and
CR4.
13. The total engine axial play is calculated as:
TEAP = (Cavg1 - Cavg2) = ______________
14. The mean absolute value of the relative location

of the flywheel with respect to the flywheel
housing is:
C = TEAP / 2 + Cavg1 = ________________
FIGURE 50-28. ENGINE FLYWHEEL TO

FLYWHEEL HOUSING MEASUREMENT
20
Alternator Housing to Rotor - 18. Remove the flat steel bar and bolt a calibrated
Measurement “A” flat steel bar across the alternator housing as a
15. Install a 5/8” - 11 x 4 1/2” capscrew hand tight in reference to measure the distance between the
the threaded hole provided on the stator frame alternator housing and rotor. See Figure 50-30
to support the alternator adapter. and Figure 50-31. This will be measurement A11
at the 12 o’clock position.
16. Remove the rotor support from the alternator by
removing the two mounting bolts. Save the rotor NOTE: When taking the measurements, ensure that
support for future re-use. the readings are taken from the mating surfaces.
NOTE: The alternator rotor must be supported by

rotor support whenever the alternator is removed
from the engine for extended storage or during
transportation of the alternator.
17. To move the alternator rotor rearward, bolt a flat

steel bar to the center of the alternator rotor.
Install two 5/8” - 11NC capscrews through both
ends of the bar and fasten the bar to the alter-
nator housing. See Figure 50-29.
Alternately tighten each capscrew until the rotor
reaches the end of travel. Do not exceed 16
N·m (12 ft lb).
FIGURE 50-30. ALTERNATOR HOUSING TO

ROTOR MEASUREMENT
FIGURE 50-29. MOVING THE ALTERNATOR

ROTOR
FIGURE 50-31. ALTERNATOR HOUSING TO

ROTOR MEASUREMENT
21
19. Repeat the same procedure in three more 21. To determine the correct shims to use, compare
locations, 90 degrees apart from each other in measurement “C” (step 14) to measurement “A”
the perimeter, to find the values A12, A,13 A14. (step 20).
If C is greater than A, subtract A from C:

1st measurement - 12 o’clock (A11): ____________
C - A = ______________Shim pack thickness
2nd measurement - 6 o’clock (A12): _____________ to be installed at location “B”, Figure 50-32.
3rd measurement - 3 o’clock (A13): _____________ Rotor-to-Flywheel

Location “B”
4th measurement - 9 o’clock (A14): _____________
Shim Part Number Shim Thickness
EL3332 0.10 mm (0.004 in.)
Aavg1 : (C11+C12+C13+C14) / 4 =___________ EL3331 0.18 mm (0.007 in.)
20. Assume that the rotor endplay is set by the If A is greater than C, subtract C from A:
factory to the nominal value of 0.0273 in. (GE
specification). Since the mean relative position A - C = _______________Shim pack thickness
is the rotor centered in the housing, add 1/2 of to be installed at location “D”, Figure 50-32.
this nominal value (approximately 0.014 in.) to
the average rearward measurement obtained in Alternator-to-Flywheel Housing Adapter
step 19. Location “D”
Shim Part Number Shim Thickness
A = Aavg1 + 0.014 in. = ________________
EJ1056 0.10 mm (0.004 in.)
EJ1055 0.18 mm (0.007 in.)
A
1 D 3
2
B
5
85022
FIGURE 50-32. SHIM LOCATIONS
1. Alternator Housing 3. Adapter Plate 5. Flexplate
2. Alternator Rotor 4. Flywheel Housing
22
NOTE: For new installations, it is assumed that the

following dimensions are within specification from the
supplier. However, these measurements may be
used for service rebuilds and/or troubleshooting to
confirm that the dimensions are within the tolerance
Ensure the lifting device to be used has adequate specifications of the engine manufacturer.
capacity. Lift the traction alternator only at the
lifting eyes.
22. Carefully move the traction alternator into Flywheel Housing Face Runout
position, then engage the engine drive end and
1. Locate the dial indicator base on the machined
the alternator rotor.
face of the flywheel/flexplate and zero the probe
23. Fasten flywheel housing adapter (2) to the on the face of the flywheel housing. See Figure
alternator housing. Install 18 capscrews and 50-33.
hardened flat washers (1). Tighten the
DIAL FLYWHEEL
24. Fasten engine drive ring (4, Figure 50-24) to the INDICATOR HOUSING
alternator rotor. Install 20 capscrews and
hardened flat washers (3). Tighten the
25. Install access cover (1).
Measurements After Joining the Alternator and

Engine
26. Mount a magnetic base on the front of the
engine and a dial indicator on the front of the
crankshaft to measure the total crankshaft
endplay.
The total engine crankshaft endplay must FLYWHEEL
match the original measurement taken in steps
5 - 7 before the alternator was installed. If the
new measurement is less than the original mea-
surement, re-shimming is required.
85024

Total Crankshaft Endplay =______________
2. Use an engine barring device to slowly rotate
the engine crankshaft 1/4 turn. Document the
27. Remove the 5/8” - 11NC x 4 1/2” capscrews that reading.
are supporting the rotor.
Continue this procedure for two full revolutions,
28. Rotate the crankshaft one full revolution and
documenting the reading at every 1/4 turn.
listen for any unusual noise caused by moving
components contacting stationary parts. 3. The difference between the highest and lowest
values for each revolution is the flywheel
29. Reset and record engine fan belt tension. housing face runout. If the average of the two
measurements exceeds 0.30 mm (0.012 in.),
contact your Komatsu representative for further
instructions.
Flywheel Housing Face Runout =____________
23
Flywheel Housing Radial Runout Flywheel/Flexplate Face Runout

1. Locate the dial indicator base on the machined 1. Locate the dial indicator base on the machined
face of the flywheel/flexplate and zero the probe face of the flywheel housing and zero the probe
on the inside diameter of the flywheel housing on the face of the flywheel/flexplate. See Figure
pilot bore. See Figure 50-34. 50-35.
DIAL FLYWHEEL DIAL FLYWHEEL

INDICATOR HOUSING INDICATOR HOUSING
FLYWHEEL FLYWHEEL
85025 85026
FIGURE 50-34. DIAL INDICATOR SETUP FIGURE 50-35. DIAL INDICATOR SETUP
2. Use an engine barring device to slowly rotate 2. Use an engine barring device to slowly rotate
the engine crankshaft 1/4 turn. Document the the engine crankshaft 1/4 turn. Document the
reading. reading.
Continue this procedure for two full revolutions, Continue this procedure for two full revolutions,
documenting the reading at every 1/4 turn. documenting the reading at every 1/4 turn.
3. The difference between the highest and lowest 3. The difference between the highest and lowest
values for each revolution is the flywheel values for each revolution is the flywheel/
housing radial runout. If the average of the two flexplate face runout. If the average of the two
measurements exceeds 0.30 mm (0.012 in.), measurements exceeds 1.00 mm (0.040 in.),
contact your Komatsu representative for further contact your Komatsu representative for further
instructions. instructions.
Flywheel Housing Radial Runout =___________ Flywheel/Flexplate Face Runout =____________
24
Flywheel/Flexplate Radial Runout Rotor Shaft Radial Runout (assembled)

1. Locate the dial indicator base on the machined 1. Install and tighten the capscrews that secure
face of the flywheel housing and zero the probe the driven member to the engine flywheel
on the inside diameter of the flywheel/flexplate housing. Install at least four of the capscrews
pilot bore. See Figure 50-36. from the driven member to the flywheel/
flexplate hand-tight.
2. Locate the dial indicator base on the side of the
DIAL FLYWHEEL
INDICATOR HOUSING alternator housing. Insert the probe through the
radial port of the alternator housing and zero the
probe on the machined surface of the flywheel/
flexplate. See Figure 50-37.
RADIAL
PORT
FLYWHEEL
DIAL
INDICATOR
85028
85027 FIGURE 50-37. DIAL INDICATOR SETUP

3. Use an engine barring device to slowly rotate

2. Use an engine barring device to slowly rotate the engine crankshaft 1/4 turn. Document the
the engine crankshaft 1/4 turn. Document the reading.
reading. Continue this procedure for two full revolutions,
3. Continue this procedure for two full revolutions, documenting the reading at every 1/4 turn.
documenting the reading at every 1/4 turn. 4. The difference between the highest and lowest
4. The difference between the highest and lowest values for each revolution is the rotor shaft
values for each revolution is the flywheel/ radial runout. The maximum allowed radial
flexplate radial runout. If the average of the two runout is 0.13 mm (0.005 in.).
measurements exceeds 0.13 mm (0.005 in.),
contact your Komatsu representative for further
instructions. Rotor Shaft Radial Runout =________________
Flywheel/Flexplate Radial Runout =__________
25
5. If the average of the two measurements is less

than 0.13 mm (0.005 in.), install and tighten the
remaining capscrews that secure the driven
member to the flywheel/flexplate and the
flywheel housing. Check the rotor shaft radial
runout again to ensure that it is still less than the
maximum allowed value.
6. If the average of the two measurements is
greater than 0.13 mm (0.005 in.), perform the
following procedure:
a. Determine the point on the rotor shaft that
has the greatest amount of radial runout.
Turn the rotor shaft so that this point is at the
top (12 o' clock) position.
b. Completely loosen the capscrews that
secure the driven member to the flywheel/
flexplate. Then re-tighten the capscrews.
This should allow the driven member to
center itself and reduce the runout.
c. Check the rotor shaft radial runout again. If
the average of the two measurements is less
than 0.13 mm (0.005 in.), the measurement
process is complete.
d. If the average of the two measurements
remains greater than 0.13 mm (0.005 in.),
remove the flywheel/flexplate capscrews.
Hold the attachment stationary while rotating
the engine crankshaft 90 degrees. Attach the
driven member to the flywheel/flexplate, then
check the rotor shaft radial runout again.
26
Removal and installation of radiator 4. Remove the diagonal ladder and the hood and
grille assembly. Refer to Disassembly and
Removal assembly section Body and structures for the
NOTE: This procedure assumes that the complete removal instructions.
power module is installed on the truck.
the wheels.
turn the rest switch ON. Turn the key switch The cooling system is pressurized due to thermal
OFF to shut down the engine and allow 90 expansion of coolant. DO NOT remove the
seconds for the steering system accumulators radiator cap while the engine and coolant are hot.
to bleed down. Severe burns may result.
Allow heat and pressure to dissipate before

draining the cooling system.
5. Remove the radiator cap, then open drain cocks
(1, Figure 50-38) below the radiator. Allow the
The system is charged with HFC-134A refrigerant. coolant to drain into suitable containers. Refer
Federal regulations prohibit venting air to the Specification section for the cooling
conditioning system refrigerants into the system capacity.
atmosphere. An approved recovery/recycle 6. Disconnect fuel cooler tubes (4, Figure 50-38).
station must be used to remove the refrigerant Remove all clamps that secure the lines to the
from the air conditioning system. radiator.
3. Evacuate the air conditioning system. Refer to 7. Remove outlet elbows (2) and (3) at the bottom
Testing and adjusting section Cab air of the radiator. Cap all coolant lines to prevent
conditioning for the procedures that are contamination.
required to properly evacuate the refrigerant
from the air conditioning system.
3 3
1 2 1 4 2 4
5 86571
FIGURE 50-38. RADIATOR PIPING - LOWER

1. Drain Cock 4. Fuel Cooler Tube
2. Outlet Elbow (Front) 5. Heat Exchanger
3. Outlet Elbow (Rear)
27
8. Disconnect, cap and unclamp four upper surge 10. Disconnect two top tank tubes (3) from the
tank hoses (1, Figure 50-39). Mark each hose radiator. Remove the tubes and cap the ports at
for proper installation. the radiator and engine.
9. Disconnect, cap and unclamp two lower surge 11. Disconnect and unclamp the harness from
tank hoses (2). Mark each hose for proper coolant level switch (4). Remove the switch from
installation. the surge tank.
3
1
1
4
1
3
2 2
86572
FIGURE 50-39. RADIATOR PIPING - UPPER

1. Upper Surge Tank Hoses 3. Top Tank Tube
2. Lower Surge Tank Hoses 4. Coolant Level Switch
28
12. Remove the clamps and disconnect inlet hose 14. Remove the mounting hardware for both
(4, Figure 50-40) and outlet hose (5) at the support rods (1, Figure 50-41) and (2) at the fan
condenser. guard. The support rods may remain attached to
13. Remove mounting hardware (3), then remove the engine.
condenser (2) from radiator assembly (1).
2
FIGURE 50-40. AIR CONDITIONER CONDENSER
1. Radiator Assembly 4. Inlet Hose
2. Condenser 5. Outlet Hose
3. Mounting Hardware
86573
FIGURE 50-41. FAN GUARD SUPPORT RODS
1. Fan Guard Support 2. Fan Guard Support
Rod - LH Rod - RH
29
15. Remove the mounting hardware that secures

three-piece fan guard (1, Figure 50-42) to
radiator shroud (2).
There is a total of 11 capscrews, lockwashers
and flat washers.
Use lifting equipment with adequate capacity to
16. Remove the fan guard from the radiator shroud. remove and install the components.
NOTE: The fan guard may be removed as a 17. Attach a hoist to the radiator and take up any
complete unit, dismantled into three separate pieces, slack.
or simply moved back toward the engine to clear the
18. Remove stabilizer bars (1, Figure 50-43) from
shroud during removal of the radiator.
both sides of the radiator.
86575
FIGURE 50-43. STABILIZER BAR REMOVAL

1. Stabilizer Bar
1 19. Remove upper support rods (1, Figure 50-44)

from both sides of the radiator.
1
ENGINE 2 86574
FIGURE 50-42. FAN GUARD REMOVAL

1. Fan Guard 2. Radiator Shroud
86576
FIGURE 50-44. UPPER SUPPORT ROD REMOVAL

1. Upper Support Rod
30
20. Remove capscrews (1, Figure 50-45), hardened 21. Ensure that all hoses, tubes and wiring have
flat washers (2), lockwashers (3) and nuts (4) been removed. Use the hoist to lift radiator (1,
that secure the radiator and to the power Figure 50-46) slightly and move the radiator
module subframe at eight locations. forward until it is clear of engine fan (2). Move
the radiator to a work area for service.
2
A
DETAIL A
4 86577
FIGURE 50-45. RADIATOR MOUNTING

HARDWARE REMOVAL 1
86578
1. Capscrew 3. Lockwasher FIGURE 50-46. RADIATOR REMOVAL

2. Flat Washer 4. Nut
1. Radiator 2. Engine Fan
31
Installation 10. Install condenser (2, Figure 50-40) in front of

radiator assembly (1). Install and tighten
mounting hardware (3) to the standard torque.
11. Uncap and connect four upper surge tank hoses
(1, Figure 50-39), two lower surge tank hoses
(2) and two top tank tubes (3) between the
Use lifting equipment with adequate capacity to radiator and the engine. Ensure that the hoses
remove and install the components. and tubes are fully seated. Tighten the clamps
securely.
1. Attach a hoist to the radiator (1, Figure 50-46)
and lift it into position on the power module 12. Install coolant level switch (4) into the surge
subframe. Be careful when moving the radiator tank. Connect the harness and tighten the
back toward engine fan (2). clamps securely.
2. Install the radiator mounting hardware at the 13. Uncap and install outlet elbows (2, Figure 50-
lower radiator mounting brackets. Do not tighten 38) and (3) at the bottom of the radiator.
capscrews (1, Figure 50-45) at this time.
14. Connect fuel cooler tubes (4). Install any clamps
3. Inspect the rubber mounts for upper support that secure the lines to the radiator.
rods (1, Figure 50-44). Replace the mounts if
wear or damage is evident. 15. Connect inlet hose (4, Figure 50-40) and outlet
hose (5) to the condenser. Install and tighten the
4. Install the upper support rods and the mounting
clamps securely.
hardware on both sides of the radiator. Do not
tighten the hardware at this time. 16. Recharge the air conditioning system according
5. Adjust the upper support rods until the radiator to the instructions in Testing and adjusting
is positioned perpendicular to the subframe section Cab air conditioning.
within ± 3.0 mm (0.12 in.) measured at top of 17. Install the diagonal ladder and the hood and
radiator. When the position is established, grille assembly. Refer to Disassembly and
tighten the upper support rod locknuts and assembly section Body and structures for the
recheck the perpendicularity of the radiator. installation instructions.
6. Tighten capscrews (1, Figure 50-45) at the 18. Ensure that coolant drain cocks (1, Figure 50-
lower radiator mounting brackets to the 38) are closed, all pipe plugs are installed, and
standard torque. all hoses and tubes are connected securely. Fill
7. Install stabilizer bars (1, Figure 50-43) on both the radiator with the recommended mixture and
sides of the radiator. Tighten the mounting amount of coolant. Refer to the Operation and
hardware to the standard torque. Maintenance Manual for the filling procedure
8. Install three-piece fan guard (1, Figure 50-42) to and cooling system capacity. Check for leaks
radiator shroud (2). the mounting hardware that and repair as needed.
secures Tighten the mounting hardware to 55 19. Start and operate the engine until the cooling
N·m (40 ft lb). system reaches normal operating temperature.
There is a total of 11 capscrews, lockwashers Recheck for leaks during engine operation. Turn
and flat washers. off the engine and repair any leaks.
NOTE: The fan guard may be installed as a complete

unit or as three separate pieces. If the three-piece fan
guard was disassembled, tighten the capscrews that
clamp the pieces together to 34 N·m (25 ft lb).
9. Attach both support rods (1, Figure 50-41) and
(2) to the fan guard by installing the mounting
hardware. Tighten the hardware to the standard
torque.
32
Repairing the radiator Disassembly
Internal inspection
If desired, an internal inspection can be performed on
the radiator before complete disassembly. The
inspection involves removing tubes from the radiator
core and cutting them open. This type of inspection To aid in removal of the tubes, clean the radiator
can indicate overall radiator condition as well as prior to disassembly. Heating the seals with hot
coolant and additive breakdown. water helps to loosen the grip on the tubes.
Cleaning the radiator prior to disassembly also
To perform this inspection, remove four random tubes
reduces the risk of internal contamination. After
from the air inlet side of the radiator. Remove tubes
cleaning, spray lubricating oil at the top end of
from both the top and bottom cores and near each
the tubes.
end of the radiator. Analyze any contaminant residue
inside the tube to determine the cause of
contamination. Flush the system before returning the
truck to service.
Contact your nearest L&M Radiator facility for further
instructions or visit the L&M website at
www.mesabi.com.
External cleaning
Many radiator shops use a hot alkaline soap, caustic
soda or chemical additives in their boil-out tanks,
which can attack solders. These tanks are generally
not recommended. Before such tanks are used for FIGURE 50-47. BREAKER TOOL (XA2307)
cleaning, ensure that the cleaning solutions are
not harmful to solder. Otherwise, damage to the
radiator will result. Completely rinse the cleaned 1. Start at the top row of tubes. Use breaker tool
(XA2307) to loosen the tube to be removed.
tube or core in clean water after removing it from the
When using the breaker tool, position it at the
boil-out tank. top or bottom of the tube. Never position it in the
As an alternative to boil-out tanks, radiators can be middle of the tube or damage may result. Use
cleaned externally with a high pressure washer and the breaker tool to lightly twist the tube back and
soap. In most cases, it may be best to blow out any forth within the seals to loosen the grip. Refer to
dry dirt with a high pressure air gun prior to washing Figure 50-47.
the core with the high pressure washer.
Pressure washers should not exceed 8 275 kPa
(1,200 psi). Unlike conventional cores, the spray
nozzle can be used right up next to the core. Starting
from the air exit side, place the high pressure washer
nozzle next to the fins. Concentrate on a small area,
slowly working from the top down. Spray straight into
the core, not at an angle. Continue washing until the
exit water is free of dirt. Repeat from the opposite
side.
FIGURE 50-48. INSTALLATION TOOL (VJ6567)
33
2. After the tube is loose, position installation tool Cleaning and inspection
(VJ6567) at the bottom of the tube to be
1. Use a drill with a 19 mm (3/4 in.) wire brush to
removed. Refer to Figure 50-48. The upper jaw
remove any foreign material from the tube
of the installation tool should be positioned just
holes, then wipe the holes clean.
below the rectangular section of the tube. The
bottom jaw should rest on the seal. Squeeze the 2. Clean the inside of the tanks and tubes. In most
installation tool just enough to allow the bottom cases, just flushing the inside with soap and a
of the tube to be removed from the bottom seal. high pressure hot water washer will be
sufficient. If not, contact an L&M manufacturing
NOTE: To ease in the removal of tubes, use the facility for further instructions or visit the L&M
breaker tool and installation tool simultaneously. website at www.mesabi.com.
3. Check for signs of internal blockage in the tubes
and tanks. If desired, you may cut open tubes
for inspection. If contamination is present, the
tube should be analyzed. The radiator must be
properly flushed of all contaminants and
corrective action must be taken to prevent such
contamination from occurring in the future.
Refer to Internal Inspection in this section.
4. Buff the tube ends with a polishing wheel and a
copper polishing compound. If any debris can
not be removed by buffing, using an emery
cloth, steel wool or a wire wheel with a wire size
of 0.15 - 0.20 mm (0.006 - 0.008 in.) is
acceptable. Be careful not to mar the tube ends.
FIGURE 50-49. ANGLING TUBE DURING
3. Pull the tube from the top seal while

simultaneously twisting the tube. Angle the tube
only far enough to clear the radiator. Refer to
Figure 50-49. Removing the tube at an
excessive angle may cause damage to the tube.
4. Remove all the top tubes before removing the
bottom tubes. After all of the tubes are removed,
use pliers to remove the seals from the tanks.
Discard all seals. New seals must be used for
assembly.
34
Assembly 5. Inspect the seals and tube ends for damage

before trying to reinstall a tube. Replace as
NOTE: For easier installation, soak the seals in hot
necessary.
water before installing.
6. Working from the front of the radiator (opposite
of fan side), install the bottom row of tubes
starting with the fan side row.
When installing the tubes, center the top of the
tube in the top seal while angling the tube only
as much as necessary. Twist the tube while
applying upward force. Push the tube into the
seal until enough clearance is available to install
the bottom end of the tube into the bottom seal.
FIGURE 50-50. PROPER SEAL INSTALLATION
1. Install new tube seals onto the bottom tank and

the bottom side of the center tank. Do not install
seals in the top core at this time. Seals for the
top of the tubes do not have locking grooves;
bottom tube seals do. Ensure the correct seals
are installed in the proper position.
The seal holes must be dry during installation.
Use a rubber mallet and a flat metal plate to FIGURE 50-51. USING INSTALLATION TOOL
lightly tap the seals into place. Using excessive (VJ6567) TO INSTALL TUBE
force will drive the seals in too far. When
installed properly, the seals should be slightly
convex. Improperly installed seals are concave 7. Center the bottom end of the tube in the bottom
with a smaller diameter hole. Refer to Figure 50- seal. Push the tube downward until the formed
50. bead on the tube is seated inside the lock ring
groove in the seal. If necessary, use installation
2. Use a 13 mm (1/2 in.) diameter brush to tool (VJ6567) to pull the tube downward into the
lubricate the seals with lube/release agent seal. The tool has a hooking device on the end
(XA2308). of one of the handles for aiding in installation.
3. Use a spray bottle to lubricate the tube ends Refer to Figure 50-51.
with the lube/release agent. 8. Ensure that all tube beads are seated in their
4. When installing tubes, start at one end and work respective bottom seals. Align and straighten all
toward the center. After you reach the center, tubes during the installation of each row to allow
move to the opposite end, and again work maximum air flow through the radiator.
toward the center. If any of the tubes are difficult 9. Install tube stay ends. Install the felt air baffles
to install, do not force the tube. Remove the behind the front and back rows while completing
tube and determine the problem. Possible tube installation.
causes may be:
10. After all the tubes are installed, pressure test the
• inadequate seal/tube lubrication radiator.
• improperly installed seal
• damaged seal or tube end
• tube angle excessive during installation and/
or tube not centered in seal.
35
Pressure testing Removal and installation of engine

The radiator should be pressure tested at 103 kPa Removal
(15 psi) for 30 minutes. Various methods of pressure
testing include the following: NOTE: Refer to previous sections for removal
procedures for the power module, alternator and
• Pressurize the radiator and submerge into a test radiator assembly.
tank. Watch for leaks.
• Lay the front side of the radiator on the floor. Cap
off ports, and fill the radiator with hot water.
Pressurize the radiator and check for leaks.
• Cap off radiator ports. Install an air pressure
gauge and pressurize to 103 kPa (15 psi). Use lifting equipment with adequate capacity to
Remove the air source and monitor the pressure remove and install the components.
gauge.
1. Disconnect the grounding cable between the
• Pressurize the radiator with air, and spray sealed
engine and the subframe.
joints with soapy water.
2. Remove the 12-point capscrew and flat washer
at both front engine mounts (1, Figure 50-52).
Additional service information can be found on 3. To ensure that the engine stays level while
the L&M Radiator website at www.mesabi.com. lifting, attach a spreader bar with lifting straps to
the engine lifting eyes.
4. Remove the 12-point capscrews and flat
washers that secure engine cradle (2) to the
engine.
5. Lift the engine from the subframe and move it to
a clean work area.
Service
Complete instructions for the disassembly, assembly
and maintenance of the engine and its components
can be found in the engine manufacturer's service
manual.
36
2 1
86679
FIGURE 50-52. ENGINE MOUNTING

1. Front Engine Mount 2. Engine Cradle
Installation
1. Align the engine with the subframe. Carefully
lower the engine onto the subframe and install
the 12-point capscrews and flat washers at both
front engine mounts (1, Figure 50-52). Tighten
the capscrews to the standard torque.
2. Attach both engine cradles (2) to the engine by
installing the 12-point capscrews and flat
washers, but do not tighten at this time.
3. After the traction alternator is installed, adjust
setscrew (3, Figure 50-53) to equalize gaps (5)
between engine cradle (1) and subframe (4) at
the left side and right side. Lock the setscrew
with jam nut (2).
4. Install the grounding cable between the engine
and the subframe.
FIGURE 50-53. ENGINE CRADLE GAP
1. Engine Cradle 4. Subframe
2. Jam Nut 5. Gaps
3. Setscrew
37
980E Dump truck

38
CEN90014-00
980E

980E-4 A40003 and up
980E-5 A50005 and up

Hydraulic circuit diagrams
Steering, hoist and brake cooling hydraulic circuit schematic...........................................................58B-60-21400
Brake hydraulic circuit schematic......................................................................................................58B-33-00030
Auxiliary system hydraulic circuit schematic .....................................................................................58E-60-01680
1
CEN90014-00 90 Diagrams and drawings
NOTES
2
58B-60-21400-02 APR 18
STEERING, HOIST & BRAKE COOLING
HYDRAULICS SCHEMATIC
980E-4: A40003 & UP
980E-5: A50005 & UP
58B-33-00030-02 APR 18
BRAKE HYDRAULICS SCHEMATIC
960E-1/-2: A30001 & Up
960E-1K/-2K: A50003 & Up
980E-4: A40003 & Up
980E-5: A50005 & Up
58E-60-01680-02 MAY 17
AUXILIARY HYDRAULIC SCHEMATIC
730E-8: A40004 & Up
830E-5: A50005 & Up
930E-5: A40004 & Up
980E-4: A40003 & Up
980E-5: A50005 & Up
90 Diagrams and drawings CEN90014-00
NOTES
3
980E Dump truck

4
CEN90028-00
980E

980E-5 A50005 and up

Electrical circuit diagrams
Electrical circuit diagram ...................................................................................................................58B-06-02390
1
NOTES
2
HARNESS REFERENCE
AUXILIARY CABINET CONNECTIONS FOR FRAME HARNESSES HARNESS REF. KEY
REFERENCE TRUCK LOCATION
CABLE DESIGNATION TABLE
ATTRIBUTE PART NO. DESCRIPTION
HARNESS DESIGNATION TABLE
ATTRIBUTE PART NUMBER DESCRIPTION
SEE SHEET 2 A
B
AUXILIARY CABINET
BRAKE CABINET
AA6
AA15
58E-06-06900
58E-06-07561
CABLE, CAT5E GE
CABLE, CAT5E PLM4
AA1
AA2
58B-06-20620
58B-06-20670
WIRING HARNESS, AUXB INTERN
WIRING HARNESS, AUXB INTERN PWR
CN11 CN13 CN46 CN14 C OPERATOR CAB AA21 58E-06-06981 CABLE, USER PC AA3 58B-06-20590 WIRING HARNESS, GE INTERF
CN12 CN16 CN15
D REAR CASE AA22 58E-06-06981 CABLE, KOMTRAX+ AA4 58B-06-20680 WIRING HARNESS, PLM4
AH1 AJ1
AA24 58B-06-20820 CABLE, BLACK 1/0 AA5 58E-06-00541 WIRING HARNESS, CAN RPC
AR1 AR2 AJ2
E ENGINE
RIGHT FRONT FRAME RAIL

AH2
RIGHT REAR FRAME RAIL AD1 F RIGHT DECK AA25
AA26
58B-06-20810 CABLE, RED 1/0 AA7
AA8
XC2803
58B-06-30090
WIRING HARNESS, AHT PLUG1
WIRING HARNESS, AHT PLUG2
FRONT PAYLOAD / WHL SPEED HARNESS FRONT LEFT FRAME RAIL LADDER OPTION HARNESS LEFT REAR FRAME RAIL G LEFT DECK 58E-06-06981 CABLE, PTX-C
REAR AXLE WHEEL MOTOR SPEED H RIGHT FRAME AA28 58B-06-20690 CABLE, VID ETHERNET AA9 58E-06-10821 WIRING HARNESS, CAN RPC
CN505 CN535
JJ2 LADDER LIGHT SW J LEFT FRAME AH3 58B-06-19090 CABLE, LINE HEATER POWER AA10 58E-06-10831 WIRING HARNESS, CAN J1939
ENGINE OIL RESERVE
CONTROL MODULE
OPTION LOCATION
HOIST PUMP
CN565
JT1 CENTER DECK
K
L
BATTERY BOX
RADIATOR GRILL
AJ3
AK1
58B-06-20160
58B-06-20151
CABLE STR 2/0 BLK
CABLE STR 2/0 RED
AA11
AA12
58E-06-10730
58E-06-10720
WIRING HARNESS, CAN RPC
WIRING HARNESS, CAN J1939
CN501 CN151 PRESSURE SW 1 LIGHT 1
JJ5
LEFT FRONT CC11 58E-06-05641 CABLE, PTX-C AA13 58B-06-20830 WIRING HARNESS, 3RD PARTY
CN536 GROUND LEVEL CN721 M BODY
SUCTION HEATED LINES PAYLOAD SENSOR LH ENGINE SHUTDOWN SW HOIST PUMP CENTER DECK LEFT WHEEL MOTOR N ISOLATION STATION CC21 58E-06-05632 CABLE, CAT5E PC CAB AA14 58E-06-08060 WIRING HARNESS, 3RD PARTY
CN502 SERVICE LIGHT SW OPTION LOCATION PRESSURE SW 2 AMBIENT AIR LIGHT 2 SPEED SENSOR AA16 58E-06-07572
P PANTOGRAPH CC22 58E-06-05622 CABLE, CAT5E KOMTRAX CAB WIRING HARNESS, ENET SW PWR
CN150 TEMP SENSOR CN720
JR1
RETURN HEATED LINES RIGHT FRONT R FRONT FRAME CC23 58E-06-15621 CABLE, CAT5E BULLET CAB AA23 58E-06-07532 WIRING HARNESS, KWB AUX
CN538 FUEL TANK MARKER RIGHT WHEEL MOTOR
CN503 PAYLOAD SENSOR HYDRAULIC LADDER LIGHT (OPT) STEERING PRESSURE SPEED SENSOR CC24 58B-06-20850 CABLE, CAB VID ETHERNET AB1 58B-06-20580 WIRING HARNESS, AUXB HYD
S PROPULSION ALTERNATOR
SOLENOID SENSOR DT1 CH2236 CABLE STR 7M1A1 AC1 58B-06-19200 WIRING HARNESS, AUXB CAB-GE
TEMP SWITCH T CONTROL CABINET
AHT LEFT REAR BRAKE
JJ1 BODY UP SW U AHT ODS BOX DT2 CH2237 CABLE STR 7M1A2 AC2 58B-06-19210 WIRING HARNESS, AUXB CAB-DIAG
CN506 LEFT FRONT WHEEL CN511 GROUND LEVEL LOW STEERING PRESSURE SENSOR (OPT)
LADDER ALARM PRESURE SW DT3 CH2238 CABLE STR 7M1B1 AC3 58B-06-19220 WIRING HARNESS, AUXB CAB-DASH
PUMP SPEED SENSOR AUTOLUBE SOL
FUEL TANK HARNESS AHT RIGHT REAR BRAKE DT4 CH2239 CABLE STR 7M1B2 AC4 58B-06-19230 WIRING HARNESS, AUX CAB OH
HH4
CN180 GROUND LEVEL CN730 STEERING ACCUMULATOR PRESSURE SENSOR (OPT)
DT5 CH2240 CABLE STR 7M1C1 AC51 58B-06-19240 WIRING HARNESS, ENET AUX/CAB
OIL RESERVE SYSTEM RIGHT FRONT WHEEL LADDER ALARM RELAY HOIST FILTER BLEEDDOWN SOLENOID
CONTROL BOX AUTOLUBE LEVEL SW (OPT) DT6 CH2241 CABLE STR 7M1C2 AD1 58B-06-20340 WIRING HARNESS, REAR WHEEL SPD
SPEED SENSOR PRESSURE SW 1
CN170 GROUND LEVEL LADDER STEERING ACCUMULATOR DT7 CH2242 CABLE STR 7M2A1 AE1 58B-06-20630 WIRING HARNESS, QSK60/78
OIL RESERVE SYSTEM OVERRIDE SWITCH HOIST FILTER BLEEDDOWN PRESS SW DT8 CH2243 CABLE STR 7M2A2 AE2 58B-06-20640 WIRING HARNESS, ENG AUX BOX
LEVEL SW (OPT) ACCUMULATOR AUXILIARY HYDRAULIC PRESSURE SW 2 CN732
STARTER # 1 RELAY DT9 CH2244 CABLE STR 7M2B1 AF1 58B-06-20051 WIRING HARNESS, PLM AUXB LH
PRE-CHARGE PRESS SW #1 PRESSURE SWITCH HYDRAULIC TANK
LADDER UP RELAY DT10 CH2245 CABLE STR 7M2B2 AG1 58F-06-02331 WIRING HARNESS, KWB
RH ENGINE STEERING FILTER MARKER LIGHT (OPT)
SERVICE LIGHT SW HYRDAULIC TAP PRESSURE SW DT11 CH2246 CABLE STR 7M2C1 AH1 58B-06-20061 WIRING HARNESS, RIGHT FRONT
ACCUMULATOR STARTER #2 RELAY MANIFOLD SOLENOID HYDRAULIC TANK
CAB LADDER DT12 CH2247 CABLE STR 7M2C2 AH2 58B-06-20350 WIRING HARNESS, RIGHT REAR
PRE-CHARGE PRESS SW #2 ALARM RELAY FUEL LEVEL LEVEL SENDER
SENDER EE4 58B-06-20550 CABLE, PRELUBE AJ1 58B-06-20071 WIRING HARNESS, LEFT FRONT
HOIST
AIR RESTRICTION SW #1
BATTERY BOX LADDER UP
SENSOR
LIMIT SW HOIST LIMIT
SOLENOID
EE5
EE6
CH4327
CH4303
PRELUBE GND CABLE 1/0 BLK
CABLE STR 1/0 BLK
AJ2
AR1
58B-06-20091
58B-06-20450
WIRING HARNESS, LEFT REAR
WIRING HARNESS, FRONT WHEEL SPD
RIGHT REAR AR2 58B-06-20190
EE9 CH4605 CABLE STR 2/0 BLK WIRING HARNESS, RH LADDER
LADDER DOWN PAYLOAD SENSOR BRAKE FILTER
SENSOR PRESSURE SW EE10 CH4503 CABLE STR 2/0 BLK BB1 58F-06-02481 WIRING HARNESS, IND BRAKE HYD CAB
AUTO LUBE EJ1 58B-06-20490 CABLE, ALTERNATOR GND BC1 58E-06-09230 WIRING HARNESS, WASHER
AIR RESTRICTION SW #2 LADDER PRESSURE SW STEERING FILTER EJ2 58B-06-20520 CABLE, ALTERNATOR GND CC1 58E-06-05882 WIRING HARNESS, OP CONTROLS
CONTROLLER PRESSURE SW (AHT OPT)
EK2 58B-06-20470 CABLE, ALTERNATOR POS CC2 58E-06-05892 WIRING HARNESS, CENTER CONSOLE
CN710 EK3 58B-06-20480 CABLE, ALTERNATOR POS CC3 58E-06-05902 WIRING HARNESS, CAB DASH
DD1 RH REAR BRAKE TEMP

SENSOR
EN1
EN2
58B-06-21070
58B-06-21080
CABLE STR 4/0 RED
CABLE STR 4/0 RED
CC4
CC5
58E-06-05912
EJ1556
WIRING HARNESS, BASIC CAB
HRN STR RADIO JUMPER
DD4
REAR AXLE CN703
CN72 EN3 58B-06-21090 CABLE STR 4/0 BLK CC7 EJ6371 VHMS JUMPER PLUG (CN2B)
EXTERNAL HARNESS BLOWER CN709
RIGHT UPRIGHT PRESSURE SW LH REAR BRAKE TEMP EN4 58B-06-21100 CABLE STR 4/0 BLK CC8 EJ6372 VHMS HARNESS CODE JUMPER (CN1-6)
CN541 HARNESS SENSOR EN5 58E-06-01830 CC9 58E-06-02193 WIRING HARNESS, DOOR DRIV
CABLE ASSY PRELUBE FUSE LINK
FH1 UPPER ENG CN540
LEFT UPRIGHT
FRAME RAIL
LEFT REAR
PAYLOAD SENSOR
CN708
RH FRONT BRAKE TEMP
EN6 58B-06-20540 CABLE ASSY PRELUBE FUSE LINK CC10 58E-06-02203 WIRING HARNESS, DOOR PASS
GJ1
SERVICE LIGHT SENSOR GG4 58F-06-01280 CABLE, KWB CC12 58E-06-02932 WIRING HARNESS, ARCS CAB
UPPER ENG AHT MODE CN707 HH2 58B-06-20860 CABLE, LINE HEATER CC13 58E-06-02941 WIRING HARNESS, CAB CAM
LOWER ENG SERVICE LIGHT LIGHTS (OPT) LH FRONT BRAKE TEMP JN1 58F-06-00820 CABLE STR 2/0 BLK CC25 58E-06-11580 WIRING HARNESS, TURN SIGNAL
SERVICE LIGHT CN73 SENSOR KK2 CH5827 CABLE STR 4/0 RED CD2 58B-06-02480 WIRING HARNESS, RADAR 5-8
LOWER ENG CN563
SERVICE LIGHT SERVICE LIGHT KK3 CH5828 CABLE STR 4/0 RED CG1 58B-06-02460 WIRING HARNESS, CAMERA 2-6
CN502 RIGHT DECK HARNESS DD2 INTERFACE (OPT) KK4

KK5
CH5755
CH5756
CABLE STR 4/0 BLK
CABLE STR 4/0 BLK
CL1
CR1
58B-06-02450
58B-06-02490
WIRING HARNESS, CAMERA 1
WIRING HARNESS, RADAR 1-4
FF1 RIGHT PLM
REAR AXLE LIGHT
BAR HARNESS KK6 CH5829 CABLE STR 4/0 BLK DD1
DD2
58B-06-20330
58E-06-08381
WIRING HARNESS, REAR AXLE
WIRING HARNESS, LIGHT BAR
RED LIGHT KK7 CH5829 CABLE STR 4/0 BLK
CN503 LEFT DECK HARNESS LEFT REAR RIGHT REAR CIRCUIT INDEX KK9 58F-06-02901 CABLE STR, 2/0 RED DD4 EL9925 HRN STR BLWR PRESS SW
RIGHT RADIATOR
RIGHT PLM
YELLOW LIGHT GG1 LEFT PLM
BACKUP HORN BACKUP HORN
CIRCUIT SHT KN1 58F-06-00640 CABLE STR 4/0 RED DD6 58F-06-03670 WIRING HARNESS, RADAR 5-6
RED LIGHT LEFT REAR 12VDC SUPPLY KN2 58F-06-00650 CABLE STR 4/0 RED EE2 58B-06-21050 WIRING HARNESS, PRE LUBE
RIGHT REAR 6
GRILL HARNESS RIGHT PLM
CN543 STOP/TAIL LIGHT STOP/TAIL LIGHT AFTERTREATMENT CAN NETWORKS KN3 58F-06-00830 CABLE STR 4/0 BATT BLK EE3 58B-06-20440 WIRING HARNESS, EXTERNAL QSK78
8
HL1 SHUTTER CONTROL
GREEN LIGHT LEFT PLM
YELLOW LIGHT LEFT REAR RIGHT REAR AFTERTREATMENT DOSING MODULES 9 KN4
ST1
58F-06-00840
CH3687
CABLE STR 4/0 BATT BLK
CABLE STR 71J
EH1
EK1
58B-06-19120
58B-06-20460
WIRING HARNESS, DEF SYS
WIRING HARNESS, START RELAY
SOLENOID RIGHT HEATED RETARD LIGHT RETARD LIGHT AFTERTREATMENT LINE HEATERS 9
MIRROR LEFT PLM AHT CONNECTION OPTION ST2 CH3688 CABLE STR 74D FF1 58B-06-21002 WIRING HARNESS, DECK RH
18
LOW MOUNT GREEN LIGHT LEFT REAR RIGHT REAR FG1 58B-06-21140 WIRING HARNESS, SCOREBOARD LH/RH
LEFT RADIATOR AUTOLUBE SYSTEM 16
RIGHT LOW BEAM RIGHT BACKUP BACKUP LIGHT BACKUP LIGHT
GRILLE HARNESS FG2 58B-06-21150 WIRING HARNESS, TANK LTS
LIGHT CN542 LEFT HEATED AUXILIARY CABINET HARNESS LAYOUT 2
LOW MOUNT RIGHT
HIGH BEAM RIGHT TURN/CLEARANCE
JL1 CN520
ETHER START
MIRROR BATTERY BOX
BODY/HOIST LIMIT
4
13
FH1
GG1
58B-06-21011
58B-06-20430
WIRING HARNESS, UPRIGHT RH
WIRING HARNESS, DECK LH
LIGHT 1 SOLENOID LEFT TURN/CLEARANCE GJ1 58B-06-20420 WIRING HARNESS, UPRIGHT LH
RIGHT FOG CAB ENTERTAINMENT RADIO 6
LIGHT 1 HH1 58B-06-19030 WIRING HARNESS, DEF RELAY
MM2
LIGHT RIGHT TURN/CLEARANCE LOW MOUNT LEFT CN54 CAB SPARE WIRES 11
LIGHT 2 LOW BEAM LEFT TURN/CLEARANCE LEFT STOP/TURN/CLEARANCE CAMERA SYSTEM CAN NETWORKS HH3 EM5759 HRN STR AUTOLUBE
21
HIGH MOUNT RIGHT LIGHT 2 LIGHT 1 HH4 58E-06-00030 WIRING HARNESS, FUEL TANK
LOW BEAM CAMERA SYSTEM OPTION 20
RIGHT ROTATING LOW MOUNT LEFT HL1 58B-06-20230 WIRING HARNESS, RH HEADLIGHT
LEFT ROTATING LEFT STOP/TURN/CLEARANCE CAMERA SYSTEM SWITCH PANEL 21
BEACON HIGH BEAM
HIGH MOUNT RIGHT LIGHT 2 CAN 3RD PARTY HL2 EM3430 HRN STR SHUTTER CONTROL
BEACON 18
HIGH BEAM RIGHT DECK AHT LEFT FOG JJ1 EM5759 HRN STR AUTOLUBE
CAN J1939 18
MODE LIGHTS (OPT) LIGHT LEFT BACKUP JJ2 EM7830 HRN STR LADDER SWITCH JUMPER LH
RIGHT DECK CAN RPC 18
LIGHT #1 HIGH MOUNT LEFT LOW
BEAM
LIGHT CN55
MM1 RIGHT STOP/TURN/CLEARANCE
LIGHT 1
CUSTOMER ACCESSORY POWER 6 JJ5
JJ10
58F-06-02770
58D-06-01091
WIRING HARNESS, ESDS JUMPER
JUMPER, RLS
DIRECTIONAL SHIFTER 10
RIGHT DECK HORN
ELECTRONIC GAUGE DISPLAY JL1 58B-06-20220 WIRING HARNESS, LH HEADLIGHT
LIGHT #2 11
HIGH MOUNT LEFT RIGHT STOP/TURN/CLEARANCE JR1 58B-06-02410 WIRING HARNESS, RLS
HIGH BEAM LEFT DECK AHT ENGINE INTERFACE 7
LIGHT 2 JR2 58F-06-03200 WIRING HARNESS, LADDER
MODE LIGHTS (OPT) ENGINE OIL RESERVE SYSTEM OPTION 7
CN537 LEFT DECK LIGHT ENGINE SHUTDOWN JT1 58F-06-03020 WIRING HARNESS, CONT CAB LIGHTS
5
MASTER GROUND NN1 AJ1 (OPTIONAL) ENGINE SHUTTER OPTION 7

KK1
MM1
XB3625
58B-06-03011
HRN STR BATTERY BOX
WIRING HARNESS, RIGHT BODY LIGHTS
DISCONNECT SW LEFT DIAGONAL ENGINE START PRE-LUBE 4
ENGINE STARTERS MM2 58B-06-03001 WIRING HARNESS, LEFT BODY LIGHTS
LADDER LIGHT 4
MASTER LOCKOUT ETHER START OPTION NN1 58E-06-01310 WIRING HARNESS, ISO STATION IND
7
SW CLOSED LIGHT FRAME HARNESS GROUND RETURNS RR1 58B-06-10291 WIRING HARNESS, ORS JUMPER
6
GE ALTERNATOR 18
STARTER LOCKOUT
DISCONNECT SW GE INTERFACE 13
CN03
GE INTERFACE 15
STARTER LOCKOUT SW
RELAY
CN01
CC1 CN02
CC2 CC3
CN04
CC4 GE WHEEL MOTOR POWER CABLES 18
OPERATOR CONTROLS CENTER CONSOLE CAB DASH BASIC CAB GE WHEEL MOTOR SPEED SENSORS 13
KEY SW
STARTER LOCKOUT HEATED MIRRORS 17
SW OPEN LIGHT DIAG2 CN142
12V POWER HVAC CONTROL HORN FRONT VEHICLE 14
PLUG 1 THIRD PARTY DIAG MODULE HOT START OPTION 18
STARTER LOCKOUT
SW CLOSED LIGHT CN236 KP-A CN43 CN170 SONA HYDRAULIC BRAKE CABINET 16
ACCELERATOR 12V POWER CAB FAN
GB12 PLUG 2 KOMTRAX PLUS A/C SWITCH SONALERT HYDRAULIC CABINET 5
PROPEL PEDAL THERMOSTAT
CN237 CN601 KP-B HYDRAULIC LADDER OPTION 19
LOCKOUT SW CN136 SBL LFSPK
RETARD/SERVICE COMM RADIO SERVICE INTERFACE MODULE 5
GB12 KOMTRAX PLUS HVAC ECU LEFT FRONT SPEAKER
BRAKE COMBO PEDAL CONNECTOR (OPT) BRAKE LIGHT INTERFACE MODULE 16
PROPEL LOCKOUT
CN602 CNA CN138 DRL LRSPK
SW RELAY FIRE SUPPRESSION ISOLATION STATION 4
ORBCOMM HVAC ECU DYNAMIC
CONNECTOR (OPT) RETARD LIGHT LEFT REAR SPEAKER KEY SWITCH 5
PROPEL LOCKOUT MODEM
SW OPEN LIGHT P022 CNP1 CN108 CNB CN141 HEAT/DEF RRBB RFSPK KOMTRAX PLUS 15
SPEED CONTROL ACTIA DASH ORBCOMM ROTATING
DIRECTIONAL SHIFTER DUCT DOOR RIGHT FRONT SPEAKER LAMP ROTATING BEACON OPTION 17
PROPEL LOCKOUT SW MODULE PANEL 1 MODEM BEACON (OPT)
CN07 ACTUATOR RRSPK LAMPS AUX BOX DOME 6
CLOSED LIGHT CNP2 CN109 CN137 CDL1
ACTIA DASH DIRECTIONAL SHIFTER LAMPS BACKUP 14
WIPER MOTOR HVAC MODULE DOME LIGHT 1 RIGHT REAR SPEAKER
PANEL 2 CONTROLLER LAMPS CLEARANCE 12
GROUND
CN36 WADT CN139 CDL2 CN210 LAMPS DECK AND LADDER 12
HOIST UP/DOWN WASHER DELAY HVAC MODULE
DOME LIGHT 2
CC5
SWITCH TIMER CN737 LAMPS ENGINE SERVICE 13
MASTER DISCONNECT
SW RELAY CN18 CN39 CN08 CN23 CDL3 CN211 LAMPS FOG 12
DISPLAY PANEL WIPER RELAY FOG LIGHT RADIO
BRAKE LOCK SW DOME LIGHT 3 LAMPS FRONT TURN 12
DIMMER HIGH SW
MASTER DISCONNECT LAMPS HAZARD 12
SW OPEN LIGHT DSSW CN09 CN21 CDL4 GB12
WIPER RELAY LADDER LIGHT LAMPS HEADLIGHT 11
DATA STORE SW LOW DOME LIGHT 4
CN61 SW LAMPS HYDRAULIC CABINET 14
SYSTEM BUSY LIGHT
CN35 CAB SECONDARY ESS CN33 CN071 LAMPS PUMP MODULE SERVICE OPTION 13
LADDER PASSENGER WINDOW
ENGINE SHUTDOWN HAZARD LIGHT SW CAB FAN LAMPS REAR TURN AND TAIL 14
CONTROL SWITCH SWITCH
ISOLATION
SWITCH
DIAG6 DIAG3 CN22 CN072 LAMPS STOP 14
CN60 KOM-NET MANUAL BACKUP DRIVER WINDOW
GE DIAGNOSTIC OP-CAB WINDOW MOTORS 13
SERVICE LIGHT SW SWITCH
OPERATOR CAB HVAC 7
DIAG1 CONNECTORDIAG4 CN10
WIPER DELAY OPERATOR CAB SEAT 10
STATION INTERFACE MODULE GE VID PANEL DATA PORT TIMER ORBCOMM MODULE 15
PTX-C CN30 PARK BRAKE/BRAKE LOCK 10
MODULAR MINING TRACTION
CC10
PAYLOAD METER IV 17
DISPLAY PWR IN CONTROL SWITCH
CN121 CN31 CN058 POWER DISTRIBUTION 6
CNX07 STEERING COLUMN ENGINE PASSENGER DOOR HARNESS PASSENGER WINDOW REFERENCE AUX BOX HARNESS LAYOUT 2
TO KOMVISION MAIN COMBO CNTL LEVER WARMING SW MOTOR REFERENCE CAMERA HARNESS LAYOUT 3
CAB HARNESS CN20 CN25 CN51 DPSW2
PRE-SHIFT REFERENCE CONNECTOR TABLE 27
CN227 SHEET 3 HEADLIGHT SW PASSENGER DOOR
DRIVER AIR BRAKE TEST SW REFERENCE DEVICE TABLE 26
SWITCH
SEAT P20T4B1 REFERENCE ENGINE & HYD CABINET HARNESS LAYOUT 2
GB23 REFERENCE FRAME AND OP-CAB HARNESS LAYOUT 1
P20T4B2 CN24
ROTATING BEACON
CC9
DRIVER DOOR HARNESS
CN059 REFERENCE HARNESS INDEX TABLE 1
DRIVER WINDOW REFERENCE ISOLATION STATION HARNESS LAYOUT 1
P30T5B1
SW (OPT) MOTOR
CN50 REFERENCE TERMINAL BOARD TABLE 26
CN230 DPSW1
P30T17B1 DRIVER DOOR REFERENCE WIRE TABLE 22
PASSENGER CN29
AIR SEAT SPEED CONTROL SWITCH REFERENCE WIRE TABLE 23
GB12
SWITCH REFERENCE WIRE TABLE 24
CN120 P30T17B2 CN28 REFERENCE WIRE TABLE 25
HORN BUTTON HEATED
MIRROR SW TIER IV AFTERTREATMENT INTERFACE 8
SWITCH
CN26 TIER IV AFTERTREATMENT INTERFACE 9
P40T14B1 P40T14D
DISPLAY MODE VEC BLOCK POWER AND GROUND 6
SWITCH 1 WINDSHIELD WIPER AND WASHER 14
CN27
DISPLAY MODE P40T14B2 P40T16B1
SWITCH 2
58B-06-02390-00 APR 16
BC1
OPERATOR CAB ELECTRICAL SCHEMATIC
CNWW
WINDSHIELD
WASHER MOTOR
980E-5
A50005 & UP
Sheet 1 of 27
HARNESS REFERENCE
AUXILIARY CABINET
PAYLOAD
METER 4 CN264
AA4
MODULE TERMINAL
IM1
BLOCKS
KEY SW
POWER RELAY
IM2
INTERFACE
PAYLOAD COMMA
MODULE
TERMINAL
GE CNTRL / KEY IM3 BLOCKS TERMINAL
METER 4 COMMB SW POWER RELAY DOME KEY SW
POWER RELAY
BLOCKS
AA3 CN301
LIGHT SW
COMM BOX HIGH MOUNT
HEADLIGHT RELAY DOME GE CNTRL / KEY CN302
LIGHT 1 SW POWER RELAY
CN362
LOW MOUNT
HEADLIGHT RELAY
24VDC
DOME HIGH MOUNT CN303
GE
CONTROL
RTMR1 LIGHT 2 HEADLIGHT RELAY CABINET
PLM RS232 PORT HI-BEAM HEADLIGHT GB31
BLOCK INTERFACE
RELAY DOME LOW MOUNT CN304 CONNECTIONS
LIGHT 3 HEADLIGHT RELAY
(INVERTEX II)
BACKUP LIGHT
RELAY VEC-89 KOMVISION DOME HI-BEAM HEADLIGHT CN305
VEHICLE ELECT CENTER 89
POWER & ON/OFF SW LIGHT 4 RELAY
(VEC-89) CONNECTORS
HORN RELAY P1,P2,P4,P9,P11,P12 GROUND
ENGINE SERVICE DOME BACKUP LIGHT
LIGHT TIMER LIGHT 5 CN701
RELAY
12V POWER AHT INTERFACE
RELAY VEHICLE ELECT CENTER 90 VEC-90 LADDER LIGHT CONNECTOR #1
DOME 12V POWER
LADDER LIGHT
(VEC-90) CONNECTORS
P1,P2,P3,P4,P9,P11,P12
POWER &
GROUND
RELAY LIGHT 6 SUPPLY CN701
AHT CONNECTION
CN702
AHT INTERFACE AHT
RELAY CONNECTOR #1
OPTION
CB60 12V POWER (OPT)
RELAY DIAG5 R57
ENGINE SERVICE VEHICLE ELECT CENTER 91 VEC-91 GE RS232 DIAGNOSTIC AHT WHEEL SPD
INTERFACE
LIGHT TIMER (VEC-91) CONNECTORS POWER & CONNECTOR RESISTOR R57
P1,P2,P3,P4,P9,P10,P11,P12 GROUND
CN500 R58
HYD PUMP SERVICE
LIGHT TIMER AA2 AA2 DID POWER SUPPLY AHT WHEEL SPD
RESISTOR R58
AA1 AA1 AA1 AA1 AA1
TERMINAL
BLOCKS
GB31
TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL

BLOCKS TERMINAL TERMINAL BLOCKS BLOCKS BLOCKS BLOCKS
BLOCKS BLOCKS
CN11 CN13 CN12 CN16 CN14 CN15
AC1 AC2 AC3 AC4

AB1 OP-CAB DIAGNOSTIC CAB LOWER DASH OVERHEAD DASH
GE CONTROL / ELECTRONIC DASH
BRAKE CABINET
AE2 AE1 AF1

FRAME RAIL HARNESS CONNECTIONS
SCORE BOARD OPTION
CN01 CN02 CN03 CN04
SEE SHEET 1
CN240
BB1 LOW BRAKE
CNLIN
PRESSURE SW
EE3
OPERATOR CAB HARNESS CONNECTIONS
CN801 CN808
SERVICE BRAKE LEFT PLM
PRESSURE SENSOR SCOREBOARD
GND OPTION
PARK BRAKE APPLY
PRESSURE SW SEE SHEET 1
BRAKE LOCK START MOTOR 1 CNLO
SOLENOID GB71 INPUT
PARK BRAKE START MOTOR 2

SOLENOID INPUT
QSK78 T4 CN804 CN802
FG1
CUMMINS COOLANT LEVEL SW DM1
SERVICE BRAKE INTERFACE DOSING
DEGRADE PRESSURE SW CN805 CN803 MODULE 1
A/C COMPRESSOR AT DM2
LOW BRAKE CLUTCH AMBIENT AIR DOSING
PRESSURE SW CN806 TEMP SENSOR MODULE 2
A/C RECEIVER DRIER SMC DM3
PARK BRAKE RELEASE PRESSURE SW SUPPLY MODULE DOSING
PRESSURE SW CN809 LP COOLANT SOLENOID MODULE 3
TC DM4
FUEL FILTER
DEF TANK COOLANT DOSING
SERVICE LIGHT 1
CN810 WIF SOLENOID MODULE 4
WATER IN FUEL SCR1 DSP1
SERVICE LIGHT 2 SEPERATOR SCR1 EXHAUST DEF SUPPLY
CN820 TEMP SENSOR PUMP 1
SCR2 DSP2
ENGINE J1939 GB3 CNRIN
SERVICE LIGHT SWITCH SCR2 EXHAUST DEF SUPPLY
CN826 TEMP SENSOR PUMP 2
PRELUBE MFHU DSP3
FUEL FILTER CONN
PRESSURE SW MULTI-FUNCTION DEF SUPPLY RIGHT PLM
HOIST PILOT VALVE
CN800 HEAD UNIT PUMP 3 SCOREBOARD
PRELUBE NOX1 DSP4 OPTION
HOIST PILOT VALVE MAG SW DEF SUPPLY
NOX ECU 1
PUMP 4
PRELUBE NOX2 LH1
RELAY LINE HEATER DEF
NOX ECU 2
PRESSURE 1
ENGINE RUN OIL LH2
PRESSURE SW LINE HEATER DEF
HYD CABINET CN807
EH1 LH3
RETURN 1
LINE HEATER DEF

CN811 PRESSURE 2
TERM #6 LH4
LINE HEATER DEF
TERMINATING RESISTOR
RTMR3 CN49 RETURN 2
TERM #7 LH5
RTMR BLOCK 3
LINE HEATER DEF
TERMINATING RESISTOR
RTMR4 PRESSURE 3
RTMR BLOCK 4 DHP1 LH6
LINE HEATER DEF
DEF PUMP HEATER 1 RETURN 3
LHR
DHP2 LH7
LINE HEATER RELAY LINE HEATER DEF
HH1
DEF PUMP HEATER 2 PRESSURE 4
DHP3 LH8
LINE HEATER DEF
DEF PUMP HEATER 3 RETURN 4
DHP4 LH9
LINE HEATER DEF
DEF PUMP HEATER 4
LH13 LH10
SUCTION 1
58B-06-02390-00 APR 16
ELECTRICAL SCHEMATIC
DEF TRANSFER LINE HEATER DEF
LINE HEATER SUCTION 2
DFFR LH11
LINE HEATER DEF
980E-5
DEF FAST FILL
RECEIVER HEATER SUCTION 3
DFFV LH12
TIER IV ENGINE
DEF FAST FILL LINE HEATER DEF
VALVE HEATER SUCTION 4 A50005 & UP
Sheet 2 of 27
KOMVISION HARNESS LAYOUT
J119
KOMVISION
RADAR 1
J122
KOMVISION
RADAR 2
J123
KOMVISION
RADAR 3
CN01X CR1
RADARS 1-4
J124
KOMVISION
RADAR 4
CNX07
TO CAB CENTER
CONSOLE HARNESS
SHEET 1
AUTOLIV
NETWORK TEE
TX0
TERMX1
P21TX0B2
P21TX0D CC13
KOMVISION CAMERA CAB HARNESS
CNX10 CF1
KOMVISION CAMERA 1 HARNESS
CAM2
KOMVISION CONTROLLER LOCATED ON RIGHT DECK
AUTOLIV TEE FACING FORWARD
CAM3
LOCATED ON RIGHT DECK
FACING RIGHT OF TRUCK
KVIS-A CAM4
LOCATED ON REAR AXLE
KOMVISION
KVIS-B
CONTROLLER
NTSC1 CNX11 CL1
KOMVISION CAMERA 2 HARNESS
CAM1
LOCATED ON ACCESS LADDER
CAM5
P0028X CC6 CN0178X CC12 LOCATED ON LEFT DECK

FACING LEFT OF TRUCK
KOMVISION DIM KOMVISION SWITCH PANEL KOMVISION MAIN CAB CAM6
SWITCH RGB LOCATED ON LEFT DECK
P0128X FACING FORWARD
KOMVISION
CANCEL SWITCH
P0038X
KOMVISION BODY
SWITCH
P0048X CN44
KOMVISION
GRIDLINE SWITCH KOMVISION
P0058X DISPLAY
KOMVISION MODE
SWITCH MONITOR
P0068X CN45
KOMVISION
REAR SWITCH
P0078X
KOMVISION RH
REAR SWITCH
P0088X ESON
KOMVISION RH KOMVISION
FRONT SWITCH ERROR ALARM
P0168X RSON
KOMVISION LH KOMVISION
REAR SWITCH RADAR ALARM
P0158X
KOMVISION LH
FRONT SWITCH
P0148X
KOMVISION
FRONT SWITCH
P0138X
KOMVISION
LOCK SWITCH
P0098X
KOMVISION POWER
INDICATOR CNX16
P0018X TO BASIC CAB HARNESS
KOMVISION SHEET 1
BRIGHT SWITCH
RPR
RADAR POWER RELAY
CN251X
KOMVISION SERVICE
CONNECTOR CD2
RADARS 7-8
CN16X DD6 J125
RADARS 5-6
KOMVISION RADAR 5
AUTOLIV
NETWORK TEE
TX9 J127 J126
TERMX3
P22TX9B2
KOMVISION RADAR 7 KOMVISION RADAR 6
P22TX9D
KOMVISION CONTROLLER J128
AUTOLIV TEE
KOMVISION RADAR 8
OPERATOR CAB CN09X
58B-06-02390-00 APR 16
980E-5
A50005 & UP
Sheet 3 of 27
LAMP LED SYSTEM OPERATING
BATTERY ISOLATION STATION
BATTERY BOX / ISOLATION STATION BAT(+)-015-NN1 (RED 16ga ) 1 RED
2 BLACK
SYS 74SB1-003-AJ1 (DBL 14ga ) 21 21 74SB1-002-AA1 (DBL 18ga ) SH21:J-17

58E-06-01990
P12 J12
74SB1-004-NN1 (DBL 16ga ) 4 4
71GG-000-NN1 (YEL 16ga ) 3 3 71GG-001-AJ1 (YEL 16ga ) SH5:A-2
SWITCH PROPEL LOCKOUT (PLOS)
1 F1 F2 1 71GH-000-NN1 (ORG 16ga ) 2 2 71GH-001-AJ1 (ORG 16ga ) SH5:B-2

D70
BAT(+)-013-NN1 (RED 16ga ) 1 B1 B2 1 71PS-000-NN1 (LBL 16ga )
2 1 72RQ-000-NN1 (GRY 16ga ) 1 1 72RQ-001-AJ1 (GRY 16ga ) 29 29 72RQ-002-AA1 (GRY 14ga ) SH15:M-5
PC2528
PC2834 J537 P537
P12 J12
71PS-001-NN1 (LBL 16ga )
CH5509 CH5510
RELAY PROPEL LOCKOUT LAMP LED PROPEL
1
2
1
2
(+) (-) 72RRQ-001-NN1 (DBL 16ga ) LOCKOUT ON
71PS-001-NN1 (LBL 16ga ) 86 85
BATTERY BOX
71PS-000-NN1 (LBL 16ga ) 1 RED
(NO) 87
BATT1 BATT2 30 (C) 2 BLACK
BAT(+)-013-NN1 (RED 16ga ) 0-032-NN1 (BLK 16ga )
1 - + 1 1 - + 1 (NC) 87A
0-516-KK6 (BLK 4/0 ) BAT(+)-000-KK2 (RED 4/0 ) BAT(+)-009-NN1 (RED 16ga ) PLON
PLREL_K 58E-06-01990
58E-06-10020
VZ0639 VZ0639 PLREL_K
BATT3 BATT4 LAMP LED PROPEL
- + - + LOCKOUT LOCKED OUT
1 1 0-517-KK7 (BLK 4/0 ) 1 1 BAT(+)-001-KK3 (RED 4/0 ) RELAY STARTER LOCKOUT
(+) (-)
VZ0639 VZ0639 BAT(+)-002-KK1 (RED 6ga ) 86 85 72RRQ-000-NN1 (DBL 16ga ) 1 RED
1
BUSS BAR 2 BLACK
0-033-NN1 (BLK 16ga )
24VDC (NO) 87
BATT BOX JB1 PLLO
30 (C) 58E-06-01990
XB3583 (NC)
1
1 BAT(+)-010-NN1 (RED 16ga ) 87A 0-448-NN1 (BLK 16ga ) 8
SLREL_K 0-033-NN1 (BLK 16ga ) 7
1
58E-06-10020
BAT(+)-007-KN1 (RED 4/0 ) 1 BAT(+)-011-NN1 (RED 16ga ) SLREL_K 0-032-NN1 (BLK 16ga ) 6
BAT(+)-012-NN1 (RED 16ga ) 0-030-NN1 (BLK 16ga ) 5
BAT(+)-008-KN2 (RED 4/0 ) 1 0-031-NN1 (BLK 16ga ) 4
2
EC1725 0-034-NN1 (BLK 16ga ) 3
STARTER 0-366-NN1 (BLK 16ga ) 2
BAT(+)-003-KK1 (RED 6ga ) DISCONNECT (SDISC) 0-027-NN1 (BLK 16ga ) 1 LAMP LED STARTER
56B-06-11530 LOCKOUT OPEN
1
1
BAT(-)-001-KK4 (BLK 4/0 ) 0-048-AJ1 (BLK 14ga ) 11ST-001-EN2 (RED 4/0 )
21PT-009-AJ1 (PNK 14ga )
1 1S-000-NN1 (DGR 16ga ) 1 RED
RELAY ENG STARTER 1 RELAY ENG STARTER 2 11ST-005-NN1 (RED 16ga )

1 1 11ST-006-NN1 (RED 16ga ) 0-034-NN1 (BLK 16ga ) 2 BLACK
(ESREL1) (ESREL2) 11ST-002-EN1 (RED 4/0 )
86 86 RELAY MASTER SLLO
1
1 85 1 1 85 1
BUSS BAR + - + - DISCONNECT 58E-06-01990
BAT(-) (+) (-)
86 85 LAMP LED STARTER
BAT(+)-014-NN1 (RED 16ga )
LOCKOUT CLOSED
1
1 88 88a 1 1 88 88a 1
1 1 (NO) 87 1 RED
BAT(-)-002-KN3 (BLK 4/0 ) BAT(-)-004-NN1 (BLK 16ga ) 11ST-006-NN1 (RED 16ga )
30 (C)
PC1903 PC1903 (NC)
BAT(-)-003-KN4 (BLK 4/0 ) 1 SWITCH MASTER 87A 0-366-NN1 (BLK 16ga ) 2 BLACK
2
BAT(-)-000-KK5 (BLK 4/0 ) GROUND MLREL_K 58E-06-10020 SLON
DISCONNECT 58E-06-01990
(DISC-) MLREL_K
LAMP LED MASTER
BAT(+)-004-KK9 (RED 2/0 ) EC1725 DISCONNECT CLOSED
1
1
0-004-EN3 (BLK 4/0 )
FUSE AUX BOX 1 BAT(+)-011-NN1 (RED 16ga ) 1 RED
0-003-EN4 (BLK 4/0 )
1 2
11-007-AK1 (RED 2/0 ) SH6:F-3
300A 0-000-JN1 (BLK 2/0 ) 1 0-026-NN1 (BLK 16ga ) 0-026-NN1 (BLK 16ga ) 2 BLACK
1
58E-06-07090
0-027-NN1 (BLK 16ga ) MLLON
FUSE ALT1
58E-06-01990
1 2
300A LAMP LED MASTER
58E-06-07090 DISCONNECT OPEN
FUSE ALT2
1 2 1 1M-000-NN1 (LTG 16ga ) 1 RED
300A
58E-06-07090
BAT(-)-004-NN1 (BLK 16ga ) 2 BLACK
MLLO
58E-06-01990
25A-000-EK1 (DGR 6ga )
SH6:G-18 0-050-AA1 (BLK 14ga ) 54 54 0-049-AJ1 (BLK 14ga )
53 53
GB70 FRAME GND
SH6:H-3 21PT-001-AA1 (DBL 14ga ) 21PT-000-AJ1 (DBL 14ga )
1 A1 A2 1
GB31-B
E1
1 B1 B2 1 0-002-AJ3 (BLK 2/0 )
J12 P12
25B-000-EK1 (LTG 6ga )
MOTOR STARTER 1 MOTOR STARTER 2

(STRT1) (STRT2)
BAT(+)-018-EK1 (RED 12ga ) 2A 1 2A 1
25A-000-EK1 (DGR 6ga ) 1 3 1 3
1
SEN 1 1A 2B 1 1 1A 2B 1
11ST-001-EN2 (RED 4/0 ) MOTOR 11ST-002-EN1 (RED 4/0 ) MOTOR
11ALT1-000-EK2 (RED 2/0 ) 1 (+) (-) 1 0-001-EJ1 (BLK 2/0 ) 1B 2C 1
1B 2C
24VDC ALTERNATOR 1 1C 1C
4A 4B 4A 4B
XA3660 1 XA3660
1
24VDC ALTERNATOR 2
0-028-EE10 (BLK 2/0 )

11ALT2-000-EK3 (RED 2/0 ) 1 (+) (-) 1 0-043-EJ2 (BLK 2/0 )
11ST-003-EE9 (RED 2/0 )
SEN
1
BAT(+)-017-EK1 (RED 12ga )
ENGINE STARTERS
11ST-000-EN5 (RED 1/0 )
11SM2-003-EE3 (DGR 14ga ) R R 11SM2-001-AE2 (DGR 14ga ) SH5:K-10

11SM1-003-EE3 (GRY 14ga ) S S 11SM1-001-AE2 (GRY 14ga ) SH5:K-10
B B
C C
F F 21PS-001-AE2 (BRN 14ga ) SH5:K-10
ENGINE START PRE-LUBE G G 21PT-007-AE2 (DBL 14ga ) SH6:H-3
J801 P801
SWITCH ENGINE PRELUBE OIL PRESS (PLPSW)
SP108
2 C NO 1
21PS-004-EE3 (BRN 14ga ) 21PS-003-EE3 (BRN 14ga )
4psi
21PT-006-EE3 (DBL 14ga )
PLPSW PLPSW
D87
21PT-003-EE3 (DBL 14ga ) 21PT-012-EE3 (DBL 14ga ) 2 1

SP107 NOTE:
PC2834 DIODE D87 PROVIDES CONTINUOUS
21PT-004-EE3 (DBL 14ga )
PRE-LUBE DURING CRANKING
21PL-001-EE3 (DBL 14ga )
RELAY ENGINE PRELUBE
85 85 86 86
21PT-005-EE3 (DBL 14ga )
87 87
30 30
87A
21PS-005-EE3 (BRN 14ga )
87A
GB5 FRAME GB4 ENG SUBFRAME
P800 GND BLOCK GND BLOCK
PC1146
P800 1 1
0-042-EE3 (BLK 14ga ) 1 0-471-EE6 (BLK 1/0 ) 1
58B-06-02390-00 APR 16
RELAY ENGINE PRELUBE GB3 ENG
MAG SWITCH (PLMS) GND BLOCK
0-041-EE3 (BLK 14ga ) 1 B1

+ -
980E-5
21PL-000-EE3 (DBL 14ga ) 1 1
FUSE LINK1 ENGINE PRELUBE HIGH VOLUME PUMP 1 B3
(300A)
PUMP
11ST-000-EN5 (RED 1/0 ) 1 1 11PL-000-EN6 (RED 1/0 ) 1 1 2 1
11PF-000-EE4 (RED 1/0 ) 1 + - 1 0-040-EE5 (BLK 1/0 )
FUS-1 FUS-2 PLMS-1 VL6217 PLMS-2 PLPM-(+)
XA4488
PLPM-(-) A50005 & UP
Sheet 4 of 27
SH4:C-21 71GG-001-AJ1 (YEL 16ga ) 31 31 71GG-002-AA1 (YEL 16ga )
SH4:C-21 71GH-001-AJ1 (ORG 16ga ) 30 30 71GH-002-AA1 (ORG 16ga )
P12 J12
VEC-90
TB34 F17
2E 2F GE CONTROL INTERFACE
SH17:I-8 39G-001-AA4 (DBL 20ga ) T2 T1 39G-000-AA1 (DBL 16ga ) E F 11-010-AA1 (RED 16ga ) SH6:F-3
5 TB25
SWITCH GROUND VEC90-P2 VEC90-P2 71GG-002-AA1 (YEL 16ga ) 1 K1 K2 1 71GG-003-AA3 (YEL 18ga ) N PROPEL LOCKOUT INTERRUPT2
LEVEL SHUTDOWN F18 VEC-90
(ESDS) 3C
C 71GH-002-AA1 (ORG 16ga ) 1 L1 L2 1 71GH-003-AA3 (ORG 18ga ) M PROPEL LOCKOUT INTERRUPT1
(OPTIONAL LEFT AND 15 F15
71CK BUSS 86 85 3G
RIGHT LOCATIONS) VEC90-P3 G 73S1-000-AA1 (DBL 18ga ) SH5:H-16 P303
58E-06-20050 5 TB25
87 R PARK BRAKE RELEASED
A B 3H 1 N1 N2 1 510E-001-AA3 (DGR 18ga )
30 H
87a 510E-000-AA1 (DGR 18ga )
SWITCH CAB SECONDARY ENGINE SHUTDOWN (ESS) P304
1 1-1 1-2 1 11S-004-JJ5 (RED 16ga ) A A 11S-003-AR2 (RED 16ga ) 9 9 11S-000-AA1 (RED 16ga ) VEC90-P3
PARK BRAKE SH11:J-8 49-003-CC3 (TAN 18ga ) 1 1 0-310-CC3 (BLK 18ga ) SH14:P-11
A B
1-3 1-4 B B 10 10 STATUS RELAY 28
11KS-001-AR2 (BRN 16ga ) 11KS-002-AA1 (BRN 16ga ) 4C
C TB27
2-1 2-2 C C 1-1 1-2
72ES-000-CC3 (YEL 16ga ) 35 35 72ES-001-AC3 (YEL 16ga ) R1 R2 72ES-002-AA3 (YEL 18ga ) w ENG IGNITION
0 BUSS 85 86
J536 P536 P46 J46
2-3 2-4 1 1-3 1-4 1 R3 R4 P302
1D 87 TB22 J03 P03
11KS-003-AA1 (BRN 16ga ) D
PC1375 30 4G 58E-06-50070
G 23FA-000-AA1 (YEL 16ga ) 23F-000-AA1 (TAN 16ga ) 1 L1 L2 1 23F-001-AC3 (TAN 16ga ) 34 34 23F-002-CC3 (TAN 16ga )
87a
J702
11KS-005-JJ5 (BRN 16ga )
VEC90-P4 P03 J03 SH7:A-8 72ES-003-AE1 (YEL 16ga )
19 19
20 20
ENGINE AHT
SH5:H-9 72ES-005-AA1 (YEL 20ga )
D1 INTERLOCK RELAY 19 AUXBOX CONNECTOR
P702
1H
H (OPT)
SH6:F-12 712-001-AA3 (ORG 18ga ) r KEY SW +24V TO CNTRL PWR SW
TB24 86 85 1C
VEC90-P1 C
11KS-002-AA1 (BRN 16ga ) 1 H1 H2 1 1A P305
87 A
30
87a
VEC90-P1
TIMED ENGINE
11KS-004-AC3 (BRN 16ga ) SHUTDOWN RELAY 20
SH6:F-6 11-035-AA25 (RED 1/0 ) 1 GE BATT +
58E-06-20050
BATFU
712K-002-AA1 (LBL 16ga )
GB31-B
SWITCH KEY (KEYSW) A4
1 1 GE GROUND
712K-004-CC3 (LBL 16ga ) SH14:B-8 0-757-AA24 (BLK 1/0 )
OFF
TB23 RTN
BATT ON
48 48 11KS-006-CC3 (BRN 16ga ) 1 1 712K-000-CC3 (LBL 16ga ) 49 49 712K-001-AC3 (LBL 16ga ) N1 N2
START 1 23 23
P03 J03 21S-000-CC3 (YEL 16ga ) N4 712K-003-AA1 (LBL 20ga )
08086-10000
J03 P03
TB22
RELAY KEY SWITCH (KSWPR)
21S-001-AC3 (YEL 16ga ) 1 H1 H2 1 21S-003-AA1 (YEL 20ga )
1 85
86 1
SH6:G-10 0-006-AA2 (BLK 16ga ) 712IM-000-AA1 (ORG 16ga )
H4 1 21S-002-AA1 (YEL 16ga )
SH11:K-9 0-014-AA2 (BLK 16ga )
KEY SWITCH / ENGINE SHUTDOWN SH6:F-9 712-000-AA2 (ORG 8ga ) 1 88A 88 1

11-004-AA2 (RED 8ga ) SH6:F-6
58E-06-04150
INTERFACE MODULE
TB22
73S-002-AB1 (LBL 14ga )
SECONDARY ENGINE SHUT DOWN E 72ES-005-AA1 (YEL 20ga ) SH5:D-18 SH19:B-17 73S-004-AA1 (LBL 16ga ) 1 J1 J2 1 73S-000-AB1 (LBL 14ga )
PARK BRAKE RELEASED M

IM3
TB32 D72 HYD BRAKE CABINET
73S1-001-AA1 (DBL 20ga )
2 1 SWITCH PARK BRAKE RELEASE PRESSURE
SH5:C-13 73S1-000-AA1 (DBL 18ga ) M1 M2 73S1-002-AB1 (DBL 14ga )
IM2 E E 73S-003-BB1 (LBL 14ga ) C NO
N2 PC2834 C B 0-051-BB1 (BLK 16ga )
52A-001-AB1 (DBL 14ga ) F F 52A-000-BB1 (DBL 14ga ) A NC
PBRPS
ENGINE SHUTDOWN DELAY F 58E-06-30300
21NSL-003-AA1 (LTG 20ga ) SH7:D-8 PBRPS
IM3
H H
SP408
0-225-AB1 (BLK 14ga ) 0-456-BB1 (BLK 16ga ) 0-337-BB1 (BLK 16ga ) SH16:F-16
ENGINE SHUTDOWN DELAY RELAY H 712M-000-AA1 (PNK 20ga ) 0-338-BB1 (BLK 16ga ) SH16:F-16
0-339-BB1 (BLK 16ga ) SH16:G-16
GB31-B
IM1
D4
1 P P
SP407
0-226-AB1 (BLK 14ga ) 0-457-BB1 (BLK 16ga ) 0-444-BB1 (BLK 16ga ) SH14:P-14
0-445-BB1 (BLK 16ga ) SH14:P-14
KEY SW DIRECT P 712K-003-AA1 (LBL 20ga )
O O
SP406
0-472-AB1 (BLK 14ga ) 0-454-BB1 (BLK 16ga ) 0-455-BB1 (BLK 16ga ) SH10:M-18
0-024-BB1 (BLK 16ga ) SH19:L-13
CRANK REQUEST j 21S-003-AA1 (YEL 20ga ) P240 J240
IM2
SH16:I-15 24VIM-008-AA1 (LBL 16ga ) TB32 24VIM-002-AA1 (LBL 18ga ) SH16:B-20
+24V OUT W 24VIM-000-AA1 (LBL 20ga ) H2 H1 24VIM-001-AA1 (LBL 18ga )
H4
EB7418
G2 G1 24VIM-005-AC1 (LBL 16ga ) SH11:F-12
SH11:E-16 24VIM-006-AC4 (LBL 16ga ) G4
VEC-91
4F 85 86 2D
START ENABLE B 21SL-000-AA1 (TAN 20ga ) F D
87
VEC91-P4
TB28 30 2C
IM1 C
3H 87a
SH4:M-17 21PS-001-AE2 (BRN 14ga ) H2 H1 21PS-000-AA1 (BRN 18ga ) H
TB28
VEC91-P2
START ENABLE
START MOTOR 1 R 11SM1-002-AA1 (GRY 20ga ) F2 F1 11SM1-001-AE2 (GRY 14ga ) SH4:M-17 VEC91-P3 RELAY 30
START MOTOR 2 S F27

11SM2-002-AA1 (DGR 20ga ) G2 G1 11SM2-001-AE2 (DGR 14ga ) SH4:M-17 11 BUSS
G 3G
10
IM3 VEC91-P3
F28
4E 11 BUSS
E
VBATT A 10
11INT-000-AA1 (PNK 20ga )
VEC91-P4
58E-06-20061
VBATT2 F 11IM2-000-AA1 (WHT 20ga )
IM1 INTERFACE MODULE
58B-06-02390-00 APR 16
980E-5
A50005 & UP
Sheet 5 of 27
11B1-002-AA1 (LBL 10ga ) SH6:I-9
VEC-91
712 BUSS
0 BUSS 85 86
TB24
F23 87 12F F 4 4
65A-000-AA1 (WHT 16ga ) 1 F1 F2 1 65A-003-AC4 (WHT 16ga ) 65A-004-CC4 (WHT 18ga )
10E 30
E
10 87a 16 16
VEC91-P10 65-000-AA1 (TAN 16ga ) 1 D1 D2 1 65-002-AC4 (TAN 16ga ) 65-003-CC4 (TAN 18ga )
ENTERTAINMENT
RADIO RELAY 37 12E E P04 J04_CP
VEC91-P12 PC3010
DL1
F22 TB21 VEC-91 0-018-AA2 (BLK 16ga ) B
11G G 34 34 3 F55
12VREG-000-AA1 (LBL 12ga ) B1 B2 12VREG-001-AC2 (LBL 14ga ) 12VREG-003-CC2 (LBL 14ga ) 12VREG-005-CC2 (LBL 12ga ) 712 BUSS
20 F 9F
SP156 CUSTOMER OP-CAB 712L-001-AA2 (DBL 16ga ) A
35 35 5
VEC91-P11 B3 12VREG-002-AC2 (LBL 14ga ) 12VREG-004-CC2 (LBL 14ga ) COMMUNICATION
F40 TB22 DL1
VEC91-P9
11 BUSS 11C
C 36 36 1 RADIO CONNECTION 58E-06-20061
11ER-000-AA1 (RED 12ga ) 1 D1 D2 1 11ER-001-AC2 (RED 14ga ) 11ER-003-CC2 (RED 14ga ) 11ER-005-CC2 (RED 12ga )
20
F41
VEC91-P11
TB22
D3 1 11ER-002-AC2 (RED 14ga ) 37 37 11ER-004-CC2 (RED 14ga )
SP155
CAB ENTERTAINMENT RADIO SWITCH AUX BOX DOME LIGHT (DLS)
0-019-AA2 (BLK 16ga )
DL2
B
PC3010
SP104
11 BUSS 11B
B 1 2 3 1
SP100
11FS-000-AA1 (RED 16ga ) 1 F1 F2 1 P02 J02 SH17:E-10 0-202-CC4 (BLK 18ga ) 712A-000-AA1 (WHT 16ga ) 712L-000-AA2 (DBL 16ga ) 712L-002-AA2 (DBL 16ga ) A
5
GB31-A GB12 ENTERTAINMENT RADIO SR8325 DL2
VEC91-P11
C1
1 0-203-AC4 (BLK 8ga ) 1 1 0-204-CC4 (BLK 8ga ) 1 F4 A4 1 0-211-CC2 (BLK 12ga ) 2
A A 65-001-CC5 (ORG 18ga ) 7 (+) 12V SUPPLY
4 B B 13 SPEAKER LEFT FRONT (+) DL3 PC3010
P04 J04_CP 0-212-CC2 (BLK 12ga ) ENTERTAINMENT RIGHT FRT SPEAKER LF(+)-000-CC5 (WHT 18ga )
C C RF(+)-000-CC5 (WHT 18ga ) 11 SPEAKER RIGHT FRONT (+) 0-097-AA2 (BLK 16ga ) 0-020-AA2 (BLK 16ga ) B
J601_CP A D D 4 IGNITION
+ RF(+)-001-CC4 (WHT 18ga ) 65A-001-CC5 (TAN 18ga )
65A-002-CC5 (TAN 18ga ) 6 DIMMER 712L-007-AA2 (DBL 16ga ) 712L-003-AA2 (DBL 16ga ) A
- B RF(-)-001-CC4 (BLK 18ga ) E E
42 42 A F F DL3
11FS-001-AC2 (RED 16ga ) 11FS-002-CC2 (RED 16ga ) RFSPK
CUSTOMER
GB12 B OP-CAB FIRE P211 J211 12 SPEAKER RIGHT FRONT (-) DL4 PC3010
P02 J02 0-213-CC2 (BLK 16ga ) ENTERTAINMENT LEFT FRT SPEAKER RF(-)-000-CC5 (BLK 18ga )
B1
1 0-384-CC2 (BLK 14ga ) SUPPRESSION LF(-)-000-CC5 (BLK 18ga ) 14 SPEAKER LEFT FRONT (-) 0-021-AA2 (BLK 16ga ) B
0-383-CC2 (BLK 14ga ) C CONNECTION + A LF(+)-001-CC4 (WHT 18ga )
A A 0-099-CC5 (BLK 18ga ) 8 GROUND 712L-004-AA2 (DBL 16ga ) A
J602_CP - B B B 15 SPEAKER LEFT REAR (+)
LF(-)-001-CC4 (BLK 18ga ) LR(+)-000-CC5 (WHT 18ga ) DL4
LFSPK C C RR(+)-000-CC5 (WHT 18ga ) 9 SPEAKER RIGHT REAR (+)
D D RR(-)-000-CC5 (BLK 18ga ) 10 SPEAKER RIGHT REAR (-)
VEC-91 16 GB31-A DL5 PC3010
12VDC POWER PORT #1 ENTERTAINMENT LEFT REAR SPEAKER E E LR(-)-000-CC5 (BLK 18ga ) SPEAKER LEFT REAR (-)
F63 TB24 F F B3
12V BUSS 0-017-AA2 (BLK 16ga ) 0-022-AA2 (BLK 16ga ) B
9H 1 1 2 1
H 67C-000-AA1 (BRN 12ga ) 1 V1 V2 1 67C-001-AC2 (BRN 14ga ) 66 66 67C-003-CC2 (BRN 14ga ) + A LR(+)-001-CC4 (WHT 18ga ) P737 SP257
20 J210 P210
VEC91-P9 712L-005-AA2 (DBL 16ga ) A
- B PC2172 SP256
V4 1 PC1374 LR(-)-001-CC4 (BLK 18ga )
58E-06-20061 DL5
LRSPK 0-010-AA2 (BLK 16ga ) SH10:N-12
12VDC POWER PORT #2
DL6 PC3010
68 68 1 1 2 1
67C-002-AC2 (BRN 14ga ) 67C-004-CC2 (BRN 14ga ) ENTERTAINMENT RIGHT REAR SPEAKER 0-023-AA2 (BLK 16ga ) B
P02 J02 PC1374 + A RR(+)-001-CC4 (WHT 18ga ) AUX BOX DOME LIGHTS 712L-006-AA2 (DBL 16ga ) A
- B DL6
RR(-)-001-CC4 (BLK 18ga )
12VDC SUPPLY & CUSTOMER OPTIONAL ACCESSORY POWER RRSPK
24VDC BUS
SH4:G-9 1 SH5:E-19
AUXBOX FRAME GROUND CONNECTIONS
11-007-AK1 (RED 2/0 ) A1 F1 11-035-AA25 (RED 1/0 ) TB24
0-401-AA1 (BLK 14ga ) SH17:D-7
GB31-B
SH21:K-21 11-014-AA2 (RED 14ga ) C1 C2 11-004-AA2 (RED 8ga ) SH5:F-10 SH5:F-6 712-000-AA2 (ORG 8ga ) 1 J1 J2 1 712-001-AA3 (ORG 18ga ) SH5:D-19 C2
SP08 0-421-AA1 (BLK 14ga ) SH13:F-17
SH19:B-21 11-017-AA1 (RED 18ga ) 0-416-AA1 (BLK 6ga ) 0-135-AA1 (BLK 16ga ) SH12:M-15
SH5:B-9 11-010-AA1 (RED 16ga ) B1 C4 11-005-AA2 (RED 8ga ) 1 J3 0-129-AA1 (BLK 14ga ) SH11:L-11 0-255-AA1 (BLK 14ga ) SH14:E-7
EB7418 GB31-A
SH8:L-11 11-000-AA1 (RED 14ga ) SP12 0-128-AA1 (BLK 14ga ) SH11:L-11 0-403-AA1 (BLK 14ga ) SH17:B-8
1 VEC-89 C2
B2 11-012-AA2 (RED 8ga ) K1 K2 1 712-003-AA2 (ORG 10ga ) 0-413-AA1 (BLK 6ga ) 0-055-AA1 (BLK 14ga ) SH11:N-10
SH9:H-10 11-018-AA1 (RED 14ga ) SH17:C-16 712-002-AA1 (ORG 18ga ) 712 BUSS
0-094-AA1 (BLK 14ga ) SH11:P-10
SH8:K-11 11-031-AA1 (RED 14ga ) B3 B4 11-011-AA2 (RED 8ga ) 712-005-AA1 (ORG 16ga ) 1 K3 K4 1 712-004-AA2 (ORG 10ga ) 1 0-425-AA1 (BLK 14ga ) SH12:C-16
S5A
SH8:P-11 11-032-AA1 (RED 16ga ) SP037 VEC89-S5A 0-424-AA1 (BLK 14ga ) SH13:G-16 0-222-AA1 (BLK 14ga ) SH7:P-8
1 GB31-B
SH15:E-3 11-015-AA3 (RED 16ga ) D1 C3 11-006-AA2 (RED 8ga ) SH10:C-2 712-008-AA1 (ORG 14ga ) 712-007-AA1 (ORG 10ga ) S5B D2
SP09 0-104-AA1 (BLK 14ga ) SH12:B-16
SH7:K-6 712-009-AA1 (ORG 10ga ) VEC89-S5B 0 BUSS 0-417-AA1 (BLK 6ga ) 0-127-AA1 (BLK 14ga ) SH11:M-11
SH9:D-6 11-016-AA1 (RED 4ga ) D4 D2 11-033-AE1 (RED 12ga ) SH7:C-10 0-005-AA2 (BLK 10ga ) 1 0-219-AA1 (BLK 14ga ) SH7:M-8 0-008-AA1 (BLK 14ga ) SH11:O-10
S7A GB31-A
VEC89-S7A D2
SP13 0-162-AA1 (BLK 14ga ) SH12:G-13 0-223-AA1 (BLK 14ga ) SH7:P-8
D3 11-034-AE1 (RED 12ga ) SH7:C-10 1 0-414-AA1 (BLK 6ga ) 0-163-AA1 (BLK 14ga ) SH12:G-13 0-420-AA1 (BLK 14ga ) SH13:G-17
S7B
71CK BUSS 0-216-AA1 (BLK 14ga ) SH7:M-8
71CK-001-AA2 (PNK 8ga ) 1 0-080-AA1 (BLK 16ga ) SH7:E-14
S6A
GE CONTROL INTERFACE 11-012-AA2 (RED 8ga ) VEC89-S6A 0-050-AA1 (BLK 14ga ) SH4:I-3
1
S6B
CNTRL PWR ON SIG Q 71GE-000-AA3 (BRN 16ga ) 0-084-AA1 (BLK 14ga ) SH11:P-10
VEC-91 RELAY KEY/GE CNTRL 11 BUSS
11-012-AA2 (RED 8ga ) 1 0-423-AA1 (BLK 18ga ) SH16:I-15 0-165-AA1 (BLK 14ga ) SH12:D-13
D14 PWR (KCNPR) S8A GB31-A
P302 0-006-AA2 (BLK 16ga ) SH5:F-6 VEC89-S8A 0-270-AA1 (BLK 14ga ) SH13:C-16 SP10 0-164-AA1 (BLK 14ga ) SH12:E-13
712 BUSS 10H H 86 85 GB31-B A2
71C-000-AA1 (ORG 16ga ) 1 1 1 SH12:L-15 SH11:N-11
S8B A2
SP14 0-147-AA1 (BLK 16ga ) 0-130-AA1 (BLK 6ga ) 0-126-AA1 (BLK 14ga )
1 G3 0-160-AA1 (BLK 6ga ) 0-161-AA1 (BLK 14ga ) SH12:H-13 0-344-AA1 (BLK 16ga ) SH16:O-17
INTERFACE MODULE D15 58E-06-02042
VEC91-P10 TB24 0-334-AA1 (BLK 16ga ) SH16:O-6 0-075-AA1 (BLK 16ga ) SH7:D-16
GE CNTRL PWR ON SIG M 71GE-002-AA1 (BRN 20ga ) 1 G1 G2 1 71GE-001-AA1 (BRN 16ga ) G 10G 0-333-AA1 (BLK 16ga ) SH16:N-6
11-005-AA2 (RED 8ga ) 1 88 88A 1
71CK-000-AA2 (PNK 8ga ) 1 N1 N2 1 71CK-002-AA2 (PNK 8ga ) 0-341-AA1 (BLK 16ga ) SH16:I-15
TB24 58E-06-20061
VEC91-P10
+12V LOADS h 11B1-003-AA1 (LBL 20ga ) SH21:K-21 71CK-004-AA2 (PNK 14ga ) 1 N4 N3 1 71CK-003-AA1 (PNK 12ga ) SH7:O-2
CRANK SENSE U 58E-06-04150 VEC-90
21PT-010-AA1 (DBL 20ga ) 0-422-AA1 (BLK 14ga ) SH14:M-13
TB28 GB31-A
71CK BUSS 0-242-AA1 (BLK 14ga ) SH14:C-10 SP11 0-263-AA1 (BLK 14ga ) SH14:F-7
IM3 1 GB31-B B2
SH4:I-3 21PT-001-AA1 (DBL 14ga ) 1 J1
S8A B2
SP15 0-240-AA1 (BLK 14ga ) SH14:B-10 0-131-AA1 (BLK 6ga ) 0-134-AA1 (BLK 16ga ) SH12:J-15
0-007-AA2 (BLK 16ga ) VEC90-S8A 0-415-AA1 (BLK 6ga ) 0-146-AA1 (BLK 16ga ) SH12:M-15 0-426-AA1 (BLK 14ga ) SH13:F-16
SH4:M-17 21PT-007-AE2 (DBL 14ga ) 1 J3 1 0-241-AA1 (BLK 14ga ) SH14:B-10 0-402-AA1 (BLK 14ga ) SH17:D-7
12VDC S8B
CONVERTER VEC90-S8B 0 BUSS 0-521-AA1 (BLK 14ga ) SH7:O-8 0-407-AA1 (BLK 14ga ) SH17:C-8
(12VCN) 0-005-AA2 (BLK 10ga ) 1 0-523-AA1 (BLK 18ga ) SH7:O-7 0-484-AA1 (BLK 14ga ) SH7:P-8
CB60 12V POWER RELAY (12VPR) S7A
24Va 1 86 85 1 VEC90-S7A
11B5-000-AA2 (DBL 8ga ) 1 50A 1 11-006-AA2 (RED 8ga ) 712-005-AA1 (ORG 16ga ) 1 0-007-AA2 (BLK 16ga ) 1
S7B
24Vb VEC90-S7B
PB8460
58E-06-20050
12Va 1 1 88 88A 1
11B1-001-AA2 (LBL 8ga ) 11B1-001-AA2 (LBL 8ga ) 12V-000-AA2 (ORG 8ga )
AUXBOX TB POINT GROUNDS
TB24
12Vb 1
11B1-000-AA2 (LBL 10ga ) 1 L1 L2 1 11B1-004-AA2 (LBL 14ga ) SH21:J-21
58E-06-04150
GNDa 1 VEC-91
0-009-AA2 (BLK 8ga ) 1 L3 L4 1 11B1-002-AA1 (LBL 10ga ) SH6:A-3
GNDb 12V BUSS GB31-A
1
TB35 S7A C3
VEC91-S7A 0-234-AA2 (BLK 16ga ) SH17:M-15
PC1110 1 1
SH15:M-20 12V-001-AA16 (ORG 18ga ) X3 X1 12V-002-AA2 (ORG 16ga ) S7B
GB31-A
A3
MC090 VEC91-S7B 0 BUSS
0-012-AA2 (BLK 10ga ) 1
S6A
B1 VEC91-S6A
0-011-AA2 (BLK 10ga ) 1
S6B
VEC91-S6B 712 BUSS
1
S8A
VEC91-S8A
1
S8B
11 BUSS
11-011-AA2 (RED 8ga ) 1
S5A
VEC91-S5A
1
S5B
58E-06-20061
VEC BLOCK / GROUND / POWER DISTRIBUTION
58B-06-02390-00 APR 16
980E-5
A50005 & UP
Sheet 6 of 27
ENGINE INTERFACE CIRCUITS
ENGINE QSK78 INTERFACE
SH5:D-18
VEC-91
KEYSWITCH H 5 5 TB27 F36
439-006-EE3 (YEL 14ga ) 72ES-003-AE1 (YEL 16ga ) 11 BUSS
1 1 A1 A2 A 2A
SP112 11E1-003-EE3 (YEL 14ga ) 11E1-001-AE1 (YEL 14ga ) 11E1-000-AA1 (YEL 12ga )
UNSWITCHED BATT 24V PARENT A 7 7 20
11E1-005-EE3 (YEL 12ga ) 11E1-004-EE3 (YEL 14ga ) 11E1-002-AE1 (YEL 14ga )
2 2 VEC91-P2 VEC-91
SP113 11E2-003-EE3 (LBL 14ga ) 11E2-001-AE1 (LBL 14ga ) A3
F37
UNSWITCHED BATT 24V CHILD 1 C 11E2-005-EE3 (LBL 12ga ) 11E2-004-EE3 (LBL 14ga ) 8 8 11E2-002-AE1 (LBL 14ga ) 2B 11 BUSS
11E3-003-EE3 (DBL 14ga ) 3 3 11E3-001-AE1 (DBL 14ga ) B1 B2 11E2-000-AA1 (LBL 12ga ) B
SP114 20
UNSWITCHED BATT 24V CHILD 2 D 11E3-005-EE3 (DBL 12ga ) 11E3-004-EE3 (DBL 14ga ) 9 9 11E3-002-AE1 (DBL 14ga )
B3 VEC91-P2 VEC-91
SP111 F38
UNSWITCHED BATT 24V SERVICE F 11E4-002-EE3 (BRN 12ga ) 11E4-004-EE3 (BRN 14ga ) 4 4 11E4-001-AE1 (BRN 14ga )
2H 11 BUSS
11E4-005-EE3 (BRN 14ga ) 6 6 11E4-003-AE1 (BRN 14ga ) C1 C2 11E3-000-AA1 (DBL 12ga ) H
SP310 20
UNSWITCHED BATT 24V NOX SENSORS B 11E5-000-EE3 (PNK 12ga ) 11E5-001-EE3 (PNK 14ga ) 40 40 11E5-005-AE1 (PNK 14ga )
41 41 SP312 C3 VEC91-P2 VEC-91
SP311 11E5-002-EE3 (PNK 14ga ) 11E5-006-AE1 (PNK 14ga )
UNSWITCHED BATT 24V CHILD 3 G 42 42 F39
11E6-000-EE3 (PUR 12ga ) 11E6-001-EE3 (PUR 14ga ) 11E6-005-AE1 (PUR 14ga ) SP313 2G 11 BUSS
11E6-002-EE3 (PUR 14ga ) 43 43 11E6-006-AE1 (PUR 14ga ) D1 D2 11E4-000-AA1 (BRN 14ga ) G
20
64 64 GB31-B
SP115 0-063-EE3 (BLK 14ga ) 0-069-AE1 (BLK 14ga ) D3 VEC91-P2
BATT RETURN PARENT J 65 65 C1 58E-06-20061
0-060-EE3 (BLK 12ga ) 0-064-EE3 (BLK 14ga ) 0-070-AE1 (BLK 14ga )
0-065-EE3 (BLK 14ga ) 66 66 0-071-AE1 (BLK 14ga ) FH1
SP116 B4 08041-02000
BATT RETURN CHILD 1/SERVICE K 0-061-EE3 (BLK 12ga ) 0-066-EE3 (BLK 14ga ) 67 67 0-072-AE1 (BLK 14ga )
0-067-EE3 (BLK 14ga ) 68 68 0-073-AE1 (BLK 14ga ) 11E5-007-AE1 (PNK 12ga ) B A 11-033-AE1 (RED 12ga ) SH6:G-6
SP117 D1 20A
BATT RETURN CHILD 2 L 0-062-EE3 (BLK 12ga ) 0-068-EE3 (BLK 14ga ) 69 69 0-074-AE1 (BLK 14ga )
BATT RETURN NOX SENSORS E 0-638-EE3 (BLK 12ga ) 0-639-EE3 (BLK 14ga ) 62 62 0-641-AE1 (BLK 14ga ) FH2
ENGINE SHUTTERS / ETHER START OPTIONS
SP109 F1 08041-02000
0-640-EE3 (BLK 14ga ) 63 63 0-148-AE1 (BLK 14ga )
BATT RETURN CHILD 3 N 0-601-EE3 (BLK 12ga ) 0-661-EE3 (BLK 14ga ) 38 38 0-109-AE1 (BLK 14ga ) 11E6-007-AE1 (PUR 12ga ) B A 11-034-AE1 (RED 12ga ) SH6:G-6
SP309 39 39 20A VEC RTMR1
0-662-EE3 (BLK 14ga ) 0-154-AE1 (BLK 14ga ) RELAY - R1
P804 VEC-91
65S-000-AA1 (BRN 16ga ) G 12G VEC RTMR1-R1 GB31-A
86(+) 85(-)
SH7:K-9 65T-000-AA1 (DBL 16ga ) 1 A1 C2 1
0-079-AA1 (BLK 18ga )
D1
0 BUSS 85 86
VEC91-P12 RTMR1-A1 RTMR1-C2
87 A2
SH19:D-18 0-690-AA1 (BLK 16ga ) SOLENOID ENGINE SHUTTER (OPT)
F25 87 12H H 1 C1 30
712 BUSS 65SR-000-AA1 (ORG 16ga )
TB27 30 87a B2 1 58 58 15 15 1 1 2 1
10 87a RTMR1-C1 65SS-000-AA1 (LBL 16ga ) 65SS-001-AH1 (LBL 16ga ) 65SS-002-HL1 (LBL 16ga ) 65SS-003-HL2 (LBL 16ga ) 65SS-004-HL2 (LBL 16ga ) 0-480-HL2 (BLK 16ga )
SHUTTER CONTROL A 65S-003-EE3 (BRN 16ga ) 25 25 65S-001-AE1 (BRN 16ga ) M1 M2 VEC91-P12 RTMR1-B2 SH6:G-21 0-075-AA1 (BLK 16ga ) 59 59 0-076-AH1 (BLK 14ga ) 16 16 0-077-HL1 (BLK 14ga ) 2 2 SP3825
PC3414 PC0436
SHUTTER CONTROL 58E-65-00061 P520_CP J520 ESSOL ESSOL
ENGINE DELAY SHUTDOWN (3 MIN) E 21NSL-002-EE3 (LTG 16ga ) 12 12 21NSL-001-AE1 (LTG 16ga ) E1 E2 21NSL-003-AA1 (LTG 20ga ) SH5:H-9 58B-06-00130 VEC91-P12 (OPT) RELAY 39 J11 P11 J543 P543 D14
COOLANT LEVEL SWITCH SP3824
E4 21NSL-004-AA2 (LTG 18ga ) 2 1 0-388-AA2 (BLK 18ga ) D 12D 65SS-005-HL2 (LBL 16ga ) 1 2 0-481-HL2 (BLK 16ga )
COOLANT LEVEL SW +5VDC J 924-001-EE3 (PNK 16ga ) A + V SUPPLY 1KΩ 2W
R51 0 BUSS 85 86
COOLANT LEVEL SIGNAL W 926-001-EE3 (WHT 16ga ) B SIGNAL LOW
COOLANT LEVEL RETURN X 925-001-EE3 (TAN 16ga ) C GROUND 0-078-HL2 (BLK 16ga )
F21 87 12C C
P802 XA4486 TB27 11 BUSS 30
SOLENOID ETHER START (OPT)
ENGINE ETHER START OUTPUT C 18 18 10 87a
28EC-003-EE3 (DBL 16ga ) 28EC-002-AE1 (DBL 16ga ) H1 H2 28EC-000-AA1 (DBL 18ga ) VEC91-P12 SP3826
28E-000-AA1 (DBL 16ga ) 51 51 28E-001-AJ1 (DBL 16ga ) 15 15 28E-002-JL1 (DBL 16ga ) 1 1 28E-003-JL2 (DBL 16ga ) 28E-004-JL2 (DBL 16ga ) 2 1 0-431-JL2 (BLK 16ga )
ETHER START
RESERVE OIL LEVEL LOW SIGNAL K 21OR-000-EE3 (YEL 16ga ) 16 16
21OR-001-AE1 (YEL 16ga ) K1 K3 21OR-005-AA1 (LBL 16ga ) SH7:N-8 52 52 0-081-AJ1 (BLK 16ga ) 0-449-AJ1 (BLK 14ga ) 16 16 0-082-JL1 (BLK 14ga ) 2 2
(OPT) RELAY 36
21OR-002-AA1 (LBL 16ga ) SH7:P-8 SP796 PC0436
11A ETHER1_CP ETHER ESOL ESOL
K2 A
J542 P542 D13
EB7418 CONNECTION FOR LOW LEVEL SENSOR J12 P12 SP3827
RESERVE OIL LEVEL SENSOR RETURN N 11 11 58E-06-20061 VEC91-P11 1 2 0-430-JL2 (BLK 16ga )
21ORR-000-EE3 (WHT 16ga ) 21ORR-001-AE1 (WHT 16ga ) L1 L2 FOR RESERVE OIL TANK OPTION 28E-005-JL2 (DBL 16ga )
SH6:G-18 0-080-AA1 (BLK 16ga ) 0-342-AJ1 (BLK 16ga ) SH16:N-18
P805 L3 21ORR-005-AA1 (DGR 16ga ) SH7:N-8
TB27
21ORR-003-AA1 (DGR 16ga ) SH7:P-8 0-482-AA2 (BLK 16ga ) SH16:D-3 0-429-JL2 (BLK 16ga )
W4 W3 0-235-AA2 (BLK 16ga ) SH17:M-15
TB26 GE CONTROL INTERFACE

ALTERNATE IDLE 1180 RPM 25 74X1K-000-EE3 (LTG 16ga ) 13 13 74X1K-001-AE1 (LTG 16ga ) 1 E1 E2 1 74X1K-003-AA3 (LTG 18ga ) c ENGINE MEDIUM RPM SPEED SET
TB26
ALTERNATE SPEED 1910 RPM 27 531SC-000-EE3 (DGR 16ga ) 14 14 531SC-001-AE1 (DGR 16ga ) 1 F1 F2 1 531SC-003-AA3 (DGR 18ga ) d ENGINE HI RPM SPEED SET
P302
TB31
FAN ON FULL
ENGINE TEST MODE FAN CLUTCH (LOW) 2 22FO-002-EE3 (TAN 16ga ) 17 17 22FO-001-AE1 (TAN 16ga ) 1 X1
ENGINE TEST
GB31-B
D3
BATTERY GROUND 1 22 0-356-EE3 (BLK 14ga ) 70 70 0-086-AE1 (BLK 14ga )
FAN CLUTCH ON FULL 5 22C-009-EE3 (GRY 16ga )

FAN CLUTCH 5VDC SUPPLY 26 22C-008-EE3 (GRY 16ga )
P806
JB41
1
TB27
2 FAN ON FULL
3 22C-006-EE3 (GRY 16ga ) 31 31 22C-005-AE1 (GRY 16ga ) G1 TEST POINT
4 22C-007-EE3 (GRY 16ga )
PC1150
MC683 MC258
CAN J1939 HIGH A 939YE-003-EE3 (YEL 18ga ) 57 57 939YE-001-AE1 (YEL 18ga ) SH18:D-1
CAN J1939 LOW B 939GE-003-EE3 (GRN 18ga ) 58 58 939GE-001-AE1 (GRN 18ga ) SH18:E-1
CAN J1939 SHLD C 59 59
SHIELD-775 SHIELD-775 SHIELD-270
P820
J808 P808
WIF
WATER IN FUEL SENSOR SIGNAL 1 27WS-000-EE3 (WHT 16ga ) 1 1
ENGINE
WATER IN
WATER IN FUEL SENSOR RETURN 2 27WR-000-EE3 (BLK 16ga ) 2 2
FUEL SENSOR
FUEL FILTER SENSOR SIGNAL 3 27LPS-000-EE3 (WHT 16ga ) 1 1
PRE-ENGINE
FUEL SENSOR SIGNAL RETURN 4 27LPR-000-EE3 (BLK 16ga ) 2 2 FUEL SENSOR
P826 LP
22C-007-EE3 (GRY 16ga )

GB3 ENG
SWITCH A/C RECIEVER DRYER GND BLOCK VEC-91
3
NO2
4 1 A1 SOLENOID A/C F59 TB22 HVAC MODULE
C2 0-358-EE3 (BLK 16ga ) 1A 1B
COMPRESSOR CLUTCH SH6:F-11 712-009-AA1 (ORG 10ga ) A B 12H-006-AA1 (YEL 10ga ) 1 G1 G2 1 12H-005-AC3 (YEL 14ga ) 2 2 12H-000-CC3 (YEL 14ga ) 1 +24V SUPPLY 1
25 3 3 2 +24V SUPPLY 2
12H-007-AC3 (YEL 14ga ) 12H-008-CC3 (YEL 14ga )
1 2 65C-003-EE3 (DBL 14ga ) 1 2 VEC91-P1 VEC91-P1
C1 NC1 58E-06-20061
RECDR PC1804 RECDR P803 XB7317 P803
0-357-EE3 (BLK 14ga ) TB30
65T-005-EE3 (DBL 14ga ) 32 32 65T-002-AE1 (DBL 14ga ) X1 X4 1 65T-003-AC3 (DBL 18ga ) 1 1 65T-004-CC3 (DBL 18ga ) 3 A/C COMPRESSOR CLUTCH
SWITCH ENGINE RUN OIL
PRESSURE (EOPSW)
GB31-B
X2 65T-000-AA1 (DBL 16ga ) SH7:C-13 P03 J03
1 1 2 2 34 34 A1
4 GROUND 1
0-293-EE3 (BLK 14ga ) 0-215-AE1 (BLK 14ga ) SH14:P-11 0-703-CC3 (BLK 14ga )
TB28 5 GROUND 2
SH15:E-16 0-888-CC3 (BLK 14ga )
8 PSI 33 33
EOPS PC2979 EOPS 36-003-EE3 (YEL 14ga ) 36-001-AE1 (YEL 14ga ) A1 A2 36-002-AA1 (YEL 18ga ) SH10:H-3
P137
A3
J808 P808
OPERATOR CAB HVAC
ORS RELAY
1
86 85 1
11HH-002-AA1 (PNK 18ga ) 36-004-AA1 (YEL 18ga )
ORS-86 ORS-85
TB28
1 88 88A 1
11POR-001-AA1 (GRY 14ga ) E1 E2 11POR-003-AA1 (GRY 14ga ) 55 55
SH6:G-18 56 56
ORS-88 ORS-88A 0-216-AA1 (BLK 14ga )
D1 D2 CONTROL BOX (LH OPTION)
58E-06-04150 OIL RESERVE SYS
57 57 1 POS (WHT) LO (BLK) SP000
L1 11RCNT-001-AA1 (TAN 14ga ) 11RCNT-002-AJ1 (TAN 14ga ) A LSW-H-000-RR1 (WHT 14ga )
VEC-91 58 58 2 NEG (BLK) COM (WHT) SP001
SH6:G-18 0-219-AA1 (BLK 14ga ) 0-218-AJ1 (BLK 14ga ) B LSW-C-000-RR1 (BLK 14ga )
F32 HI (GRN) SP002
11ORS-001-AA1 (LBL 14ga ) P505_CP C LSW-L-000-RR1 (LTG 14ga )
11 BUSS 4A A
15
11RCNT-000-AA1 (TAN 14ga ) CM1_LSW_CP
SH7:D-8 21OR-005-AA1 (LBL 16ga ) 59 59
60 60 NEG2 (BLK) SP003
VEC91-P4 SH7:E-8 21ORR-005-AA1 (DGR 16ga ) 1 FVAL-000-RR1 (WHT 14ga )
F31 VAL (WHT) SP455
2 0-524-RR1 (BLK 14ga )
11 BUSS 4C C
15
11ORS-002-AA1 (LBL 14ga ) CM1_FVAL_CP
VEC91-P4 65TS-006-AA1 (DBL 16ga ) 65TS-009-AA1 (DBL 16ga ) 69 69

58E-06-20061 SP781
TANK
OIL RESERVE SYS
11POR-009-AH1 (GRY 14ga ) 1 PUMP (WHT) FLOAT SW NC (BLK) A LSW-H-002-RR1 (WHT 14ga )
0-518-AH1 (BLK 14ga ) 2 PUMP (BLK) FLOAT SW COM (WHT) B LSW-C-002-RR1 (BLK 14ga )
P506_CP FLOAT SW NO (GRN) C LSW-L-002-RR1 (LTG 14ga )
11PHH-000-AA1 (RED 14ga ) 66 66 11POR-007-AH1 (GRY 16ga ) 1 TEMP SW COM (BLK)
ORS_LSW_CP
SH6:H-18 0-521-AA1 (BLK 14ga ) 65 65 65TS-007-AH1 (DBL 16ga ) 2 TEMP SW NO (BLK) FILL VALVE (BLK) 1 FVAL-002-RR1 (WHT 14ga )
P503_CP FILL VALVE (WHT) 2 0-526-RR1 (BLK 14ga )
11PHH-002-AH1 (RED 14ga ) 1 RETURN HEATED LINE (RED)
J12 P12 ORS_FVAL_CP
0-503-AH1 (BLK 14ga ) 2 RETURN HEATED LINE (BLK)
P502_CP
HEATED HOSE RELAY 1 SUCTION HEATED LINE (RED)
11PHH-005-AH1 (RED 14ga )
1
86 85 1 2 SUCTION HEATED LINE (BLK)
0-523-AA1 (BLK 18ga ) SH6:H-18 0-527-AH1 (BLK 14ga )
TSW-86 TSW-85 P501_CP
VEC RTMR1 1 88 88A 1 CONTROL BOX (RH OPTION)

FUSE - F4 11PHH-001-AA1 (RED 14ga )
SP780 OIL RESERVE SYS
SH6:H-12 71CK-003-AA1 (PNK 12ga )
RTMR1-A9
1 A9
20A
B9 1
RTMR1-B9
11HH-000-AA1 (PNK 12ga ) TSW-88
58E-06-04150
TSW-88A
SH6:G-21
11RCNT-003-AA1 (TAN 14ga )
0-223-AA1 (BLK 14ga )
29 29
30 30
11RCNT-004-AH1 (TAN 14ga )
0-220-AH1 (BLK 14ga )
1
2
POS (WHT)
NEG (BLK)
LO (BLK)
COM (WHT)
A
B
LSW-H-001-RR1 (WHT 14ga )
LSW-C-001-RR1 (BLK 14ga )
58B-06-02390-00 APR 16
58E-06-02610 HI (GRN)
P180_CP C LSW-L-001-RR1 (LTG 14ga )
58E-65-00061 28 28
SH6:F-21 0-222-AA1 (BLK 14ga ) 0-518-AH1 (BLK 14ga ) CM2_LSW_CP
11POR-002-AA1 (GRY 14ga ) 27 27 11POR-005-AH1 (GRY 14ga )
SP776
980E-5
65TS-008-AA1 (DBL 16ga ) 69 69 65TS-007-AH1 (DBL 16ga ) NEG2 (BLK) 1 FVAL-001-RR1 (WHT 14ga )
SH6:H-21 0-484-AA1 (BLK 14ga ) 65 65 0-513-AH1 (BLK 14ga ) VAL (WHT) 2 0-525-RR1 (BLK 14ga )
66 66 SP801
ENGINE OIL RESERVE SYSTEM

11PHH-004-AA1 (RED 14ga ) 11PHH-003-AH1 (RED 14ga ) CM2_FVAL_CP
25 25
SP805 1 OIL RESERVE
SH7:E-8 21OR-002-AA1 (LBL 16ga ) 21OR-004-AH1 (LBL 16ga )
SH7:E-8 21ORR-003-AA1 (DGR 16ga ) 26 26 21ORR-004-AH1 (DGR 16ga )
P170_CP
2 LEVEL SW
(OPT) A50005 & UP
J11 P11
Sheet 7 of 27
TIER IV AFTERTREATMENT INTERFACE
QSK60 - ENGINE INTERFACE TIER IV SENSOR AMBIENT TEMP (AT)
SP299
AMBIENT TEMP SIGNAL 38 80AT-000-EE3 (WHT 20ga ) 1 1 80AT-001-EH1 (WHT 18ga ) 1 2 0-653-EH1 (BLK 18ga ) 0-704-EH1 (BLK 18ga ) SH9:J-17
1 2
58E-06-03490
SOLENOID DEF TANK COOLANT (TC)
DEF TANK COOLANT VALVE DRIVER 37 80TC-000-EE3 (LTG 20ga ) 2 2 80TC-001-EH1 (LTG 18ga ) 4 1 0-652-EH1 (BLK 18ga )
58E-03-00180
TERM6 TERM#6
MC1000 MC1008 SP262 MC1001 SP265 MC1010 SP268 MC944
J1939 (AT PARENT) HI 8 939YE4-001-EE3 (YEL 18ga ) 4 4 939YE4-005-EH1 (YEL 18ga ) 939YE4-002-EH1 (YEL 18ga ) 939YE4-007-EH1 (YEL 18ga ) 939YE4-006-EH1 (YEL 18ga ) A A
SP263 SP266 SP269
J1939 (AT PARENT) LO 9 939GE4-001-EE3 (GRN 18ga ) 5 5 939GE4-005-EH1 (GRN 18ga ) 939GE4-002-EH1 (GRN 18ga ) 939GE4-007-EH1 (GRN 18ga ) 939GE4-006-EH1 (GRN 18ga ) B B PC0618
J1939 (AT PARENT) SHIELD 10 6 6 SP264 SP267 SP270 C C
SHIELD-102 SHIELD-102 SHIELD-108 SHIELD-108 SHIELD-104 SHIELD-104 SHIELD-010 SHIELD-010 SHIELD-082 SHIELD-082
SHIELD-107
P809 MC1007
SHIELD-105 MC1006 939GE4-004-EH1 (GRN 18ga ) SH8:M-9
939GE4-003-EH1 (GRN 18ga ) SH8:M-10 939YE4-004-EH1 (YEL 18ga ) SH8:M-9
939YE4-003-EH1 (YEL 18ga ) SH8:L-10
SENSOR SCR 1
SCR1
SH9:K-17 0-029-EH1 (BLK 18ga ) 1 1
SHIELD-011 MC1011
2 2
AFTERTREATMENT J1939
939GE4-008-EH1 (GRN 18ga )
939YE4-008-EH1 (YEL 18ga ) 3 3
SH8:N-11 11NOX1-002-EH1 (ORG 18ga ) 4 4 PARENT NETWORK (CLEAR)

TERM#7
MC1002 MC1012 SP271 MC1009 SP274 MC945 TERM7
J1939 (AT CHILD) HI 8 939YE5-001-EE3 (YEL 18ga ) 7 7 939YE5-004-EH1 (YEL 18ga ) 939YE5-003-EH1 (YEL 18ga ) 939YE5-006-EH1 (YEL 18ga ) A A
J1939 (AT CHILD) LO 9 8 8
SP272 SP275 B B PC0618
939GE5-001-EE3 (GRN 18ga ) 939GE5-004-EH1 (GRN 18ga ) SP273 939GE5-003-EH1 (GRN 18ga ) SP276 939GE5-006-EH1 (GRN 18ga )
J1939 (AT CHILD) SHIELD 10 9 9 C C
SHIELD-103 SHIELD-103 SHIELD-012 SHIELD-012 SHIELD-109 SHIELD-109 SHIELD724 SHIELD724
P810 SHIELD-106
MC1003
939GE5-002-EH1 (GRN 18ga ) SH8:O-9
939YE5-002-EH1 (YEL 18ga ) SH8:O-9
SENSOR SCR 2
SH9:K-17 0-470-EH1 (BLK 18ga ) 1 1

SHIELD-013
MC1013
939GE5-005-EH1 (GRN 18ga ) 2 2
MC1013
939YE5-005-EH1 (YEL 18ga ) 3 3 AFTERTREATMENT J1939
SH8:O-12 12NOX1-002-EH1 (ORG 18ga ) 4
SCR2
4
CHILD NETWORK (BLACK)
#1 PUMP VOLTAGE SUPPLY 21 81PV-001-EE3 (YEL 20ga ) 16 16 81PV-000-EH1 (YEL 14ga ) 1 1 81PV-002-HH1 (YEL 18ga )
#1 PUMP VOLTAGE RETURN 22 81PR-001-EE3 (GRY 20ga ) 17 17 81PR-000-EH1 (GRY 14ga )
RTMR4
RELAY - R2
RTMR4-R2
85(-) 86(+)
2 2 81PR-002-HH1 (GRY 18ga ) F2 F2 D1 D1
81PV-002-HH1 (YEL 18ga )
DEF SUPPLY PUMP #1 (DSP1)
#1 PUMP RPM FEEDBACK 20 81PF-000-EE3 (LBL 20ga ) 18 18 81PF-001-EH1 (LBL 18ga ) 1 RPM FEEDBACK GROUND 4 0-655-EH1 (BLK 18ga ) SH9:K-17 4 4 11DFP1-001-HH1 (ORG 16ga ) D2 D2 87
#1 PUMP RPM CONTROL 19 19 19 3 RPM CONTROL SUPPLY 2 30 F1 F1
81PS-000-EE3 (LTG 20ga ) 81PS-001-EH1 (LTG 18ga ) 11DFP1-000-EH1 (ORG 18ga ) 11DFP-008-HH1 (PNK 16ga )
E2 E2 87a
58E-01-00070
P809 RTMR4
RTMR4 58E-06-01940
RELAY DEF SUPPLY PUMP 1
XC2989
RTMR4
#2 PUMP VOLTAGE RETURN 22 21 21 7 7 RELAY - R3
82PR-001-EE3 (GRY 20ga ) 82PR-000-EH1 (GRY 14ga ) 82PR-002-HH1 (GRY 18ga )
RTMR4-R3
85(-) 86(+)
C4 C4 A3 A3
82PV-002-HH1 (YEL 18ga )
#2 PUMP RPM FEEDBACK 20 82PF-000-EE3 (LBL 20ga ) 22 22 82PF-001-EH1 (LBL 18ga ) 1 RPM FEEDBACK GROUND 4 0-666-EH1 (BLK 18ga ) SH9:K-17 9 9 12DFP1-001-HH1 (ORG 16ga ) A4 A4 87
#2 PUMP RPM CONTROL 19 23 23 3 RPM CONTROL SUPPLY 2 30 C3 C3
82PS-000-EE3 (LTG 20ga ) 82PS-001-EH1 (LTG 18ga ) 12DFP1-000-EH1 (ORG 18ga ) 11DFP-007-HH1 (PNK 16ga )
B4 B4 87a
58E-01-00070
P810 J807 P807 RTMR4
RTMR4 58E-06-01940
XC2989
RTMR4
RTMR4-R4
85(-) 86(+)
F4 F4 D3 D3
83PV-002-HH1 (YEL 18ga )
#3 PUMP RPM FEEDBACK 26 83PF-000-EE3 (LBL 20ga ) 11 11 83PF-001-EH1 (LBL 18ga ) 1 RPM FEEDBACK GROUND 4 0-670-EH1 (BLK 18ga ) SH9:K-17 60 60 13DFP1-001-HH1 (ORG 16ga ) D4 D4 87
#3 PUMP RPM CONTROL 25 12 12 3 RPM CONTROL SUPPLY 2 30 F3 F3
83PS-000-EE3 (LTG 20ga ) 83PS-001-EH1 (LTG 18ga ) 13DFP1-000-EH1 (ORG 18ga ) 11DFP2-008-HH1 (PNK 16ga )
E4 E4 87a
P809 58E-01-00070
RTMR4
RTMR4 58E-06-01940
XC2989
RTMR4
RTMR4-R5
85(-) 86(+)
C6 C6 A5 A5
84PV-002-HH1 (YEL 18ga )
#4 PUMP RPM FEEDBACK 26 84PF-000-EE3 (LBL 20ga ) 15 15 84PF-001-EH1 (LBL 18ga ) 1 RPM FEEDBACK GROUND 4 0-678-EH1 (BLK 18ga ) SH9:K-17 65 65 14DFP1-001-HH1 (ORG 16ga ) A6 A6 87
#4 PUMP RPM CONTROL 25 16 16 3 RPM CONTROL SUPPLY 2 30 C5 C5
84PS-000-EE3 (LTG 20ga ) 84PS-001-EH1 (LTG 18ga ) 14DFP1-000-EH1 (ORG 18ga ) 11DFP2-007-HH1 (PNK 16ga )
B6 B6 87a
58E-01-00070
P810 J811 P811 RTMR4
RTMR4 58E-06-01940
XC2989
62 62
SP231 11DFP2-003-EH1 (PNK 16ga ) 11DFP2-007-HH1 (PNK 16ga )
11DFP2-001-EE3 (PNK 14ga ) 24 24 11DFP2-005-EH1 (PNK 14ga ) 11DFP2-002-EH1 (PNK 16ga ) 61 61 11DFP2-008-HH1 (PNK 16ga )
8 8
SP229 11DFP-003-EH1 (PNK 16ga ) 11DFP-007-HH1 (PNK 16ga )
11DFP-001-EE3 (PNK 14ga ) 25 25 11DFP-005-EH1 (PNK 14ga ) 11DFP-002-EH1 (PNK 16ga ) 3 3 11DFP-008-HH1 (PNK 16ga )
J807 P807 P49 J49

VEC RTMR1
TB26 FUSE - F5
11DFP-001-EE3 (PNK 14ga ) 10 10 11DFP-000-AE1 (PNK 14ga ) 1 A1 A2 1 11DFP-006-AA1 (PNK 14ga ) 1 C9 D9 1

11-031-AA1 (RED 14ga ) SH6:F-3
15A
RTMR1-C9 58E-06-02390 RTMR1-D9
58E-65-00061
VEC RTMR1
TB26 FUSE - F9
11DFP2-001-EE3 (PNK 14ga ) 19 19 11DFP2-000-AE1 (PNK 14ga ) 1 H1 H2 1 11DFP2-006-AA1 (PNK 14ga ) 1 E8 F8 1

11-000-AA1 (RED 14ga ) SH6:F-3
15A
RTMR1-E8 58E-06-02390 RTMR1-F8
J808 P808 58E-65-00061
MFHU SENSORS (MFHU)

DEF QUALITY, LEVEL,
AND TEMPERATURE
MC1006
83G-002-EH1 (BLK 16ga ) 4 GROUND CAN HI 1 939YE4-003-EH1 (YEL 18ga ) SH8:C-11
83P-002-EH1 (PNK 16ga ) 3 POWER CAN LO 2 939GE4-003-EH1 (GRN 18ga ) SH8:C-11

58B-02-00230
NOx ECU#1 POWER 4 26 26

SP296 12 12
83P-001-EE3 (PNK 16ga ) 83P-003-EH1 (PNK 14ga ) 83P-000-EH1 (PNK 14ga ) 83P-004-HH1 (PNK 18ga )
RTMR4
NOx ECU#1 GROUND 1 27 27
SP295 RELAY - R6
83G-001-EE3 (BLK 16ga ) 83G-003-EH1 (BLK 14ga )
RTMR4-R6
NOX ECU #1 (NOX1) 85(-) 86(+)
14 14 F6 F6 D5 D5
P809 MC1007 83G-000-EH1 (BLK 14ga ) 83G-004-HH1 (BLK 18ga )
CAN HI 3 939YE4-004-EH1 (YEL 18ga ) SH8:C-16
CAN LO 2 SH8:C-16 25 25 D6 D6 87
939GE4-004-EH1 (GRN 18ga ) SP241 11NOX1-003-HH1 (ORG 16ga )
F5 F5
POWER 1 30
11NOX1-000-EH1 (ORG 18ga ) 11NOX1-001-EH1 (ORG 14ga )
GROUND 4 0-667-EH1 (BLK 18ga ) E6 E6 87a
11NOX1-002-EH1 (ORG 18ga ) SH8:D-14 RTMR4

RTMR4 58E-06-01940
RELAY NOX ECU 1
SP237 XC2989
0-669-EH1 (BLK 14ga ) SH9:L-17
NOx ECU#2 POWER 11 84P-001-EE3 (PNK 16ga ) 28 28 84P-000-EH1 (PNK 14ga ) 16 16 84P-002-HH1 (PNK 18ga )
RTMR4
RELAY - R7
NOx ECU#2 GROUND 7 29 29 RTMR4-R7
84G-001-EE3 (BLK 16ga ) 84G-000-EH1 (BLK 14ga ) 85(-) 86(+)
17 17 84G-002-HH1 (BLK 18ga ) C8 C8 A7 A7
NOX ECU #2 (NOX2)
P810 J807 P807
GROUND 4 0-668-EH1 (BLK 18ga ) SP242 19 19 12NOX1-003-HH1 (ORG 16ga ) A8 A8 87
POWER 1 30 C7 C7
MC1003 12NOX1-000-EH1 (ORG 18ga ) 12NOX1-001-EH1 (ORG 14ga )
CAN HI 3 939YE5-002-EH1 (YEL 18ga ) SH8:E-13 B8 B8 87a
CAN LO 2 939GE5-002-EH1 (GRN 18ga ) SH8:E-13 12NOX1-002-EH1 (ORG 18ga ) SH8:F-14 RTMR4
RTMR4 58E-06-01940
RELAY NOX ECU 2
XC2989
11NOX-004-EE3 (PNK 16ga ) 30 30 11NOX-003-EH1 (PNK 14ga ) 18 18 11NOX-007-HH1 (PNK 16ga )

11NOX-002-EE3 (PNK 16ga ) 31 31 11NOX-005-EH1 (PNK 14ga ) 15 15 11NOX-008-HH1 (PNK 16ga )
58B-06-02390-00 APR 16
J807 P807 P49 J49
VEC RTMR1
TB26 FUSE - F6
SP230
1 E9
980E-5
15 15 1 1 F9 1
11NOX-001-EE3 (PNK 16ga ) 11NOX-000-AE1 (PNK 16ga ) B1 B2 11NOX-006-AA1 (PNK 16ga ) 11-032-AA1 (RED 16ga ) SH6:F-3
15A
RTMR1-E9 58E-06-02390 RTMR1-F9
J808 P808 58E-65-00061
A50005 & UP
Sheet 8 of 27
TIER IV AFTERTREATMENT INTERFACE 81LH1-002-EH1 (BRN 14ga )
LINE HEATER DEF PRESSURE 1 (LH1)
2 1 0-695-EH1 (BLK 14ga )
LH1 LH1
QSK60 - ENGINE INTERFACE TIER IV 58B-02-01680
LINE HEATER POWER FEEDBACK 1 31 LINE HEATER DEF RETURN 1 (LH2)
SP289
81LH1-003-EH1 (BRN 14ga ) 2 1 0-696-EH1 (BLK 14ga ) 0-645-EH1 (BLK 14ga ) 54 54 0-723-EE3 (BLK 14ga ) 44 44
P810 LH2 LH2
52 52
81LH-012-EE3 (RED 20ga ) 81LH-011-EH1 (RED 14ga ) 58E-02-02240
LINE HEATER POWER FEEDBACK 2 31 81LH-004-EE3 (RED 20ga ) 53 53 81LH-003-EH1 (RED 14ga )
LINE HEATER DEF PRESSURE 2 (LH3)
81LH2-002-EH1 (DBL 14ga ) 2 1 0-697-EH1 (BLK 14ga )
RELAY LINE HEATER (LHR) - K7 LH3 LH3
SP500 0-778-HH1 (BLK 18ga ) SH9:G-10 58B-02-01680
LINE HEATER RELAY DRIVER #1 30 32 32 24 24 86 85 34 34
80LHR-001-EE3 (DBL 20ga ) 80LHR-002-EE3 (DBL 14ga ) 80LHR-000-EH1 (DBL 14ga ) 80LHR-004-HH1 (DBL 18ga ) 0-675-HH1 (BLK 18ga ) 0-643-EH1 (BLK 14ga ) SH9:K-17
22 22 LINE HEATER DEF RETURN 2 (LH4)
81LH-013-HH1 (RED 18ga ) 81LH-003-EH1 (RED 14ga ) SP288 0-743-AE1 (BLK 14ga )
P809 32 32 2 1 55 55 45 45 GB31-A
CB1 P49 J49 RTMR3
81LH-014-HH1 (RED 18ga ) 81LH-011-EH1 (RED 14ga ) 81LH2-003-EH1 (DBL 14ga ) 0-702-EH1 (BLK 14ga ) 0-646-EH1 (BLK 14ga ) 0-724-EE3 (BLK 14ga ) 0-744-AE1 (BLK 14ga ) F1
LH4 LH4 0-745-AE1 (BLK 14ga ) 1
88 88A 58B-06-02570
LINE HEATER RELAY DRIVER #2 30 SH6:G-3 11LH-001-AH3 (RED 4ga ) 0-746-AE1 (BLK 14ga )
80LHR-003-EE3 (DBL 20ga ) 11-016-AA1 (RED 4ga )
90A PWR BUS FUSE - F1 58B-02-01770 F2
0-747-AE1 (BLK 14ga ) 1
58B-06-02700 88(2) RTMR3-S2 L1 PWR A1 A1 11 11 LINE HEATER DEF PRESSURE 3 (LH5)
P810 11LH-007-HH1 (RED 12ga ) BUS 81LH1-000-HH1 (BRN 14ga ) 81LH1-001-EH1 (BRN 14ga ) 0-748-AE1 (BLK 14ga ) F3
81LH-000-HH2 (RED 4ga ) 15A SP809 2 1 1
58E-06-02390 81LH3-002-EH1 (DGR 14ga ) 0-705-EH1 (BLK 14ga ) 0-749-AE1 (BLK 14ga )
58E-06-04150 LH5 LH5
RTMR3-S1 FUSE - F2 0-750-AE1 (BLK 14ga ) F4
0-751-AE1 (BLK 14ga ) 1
PWR A2 A2 58B-02-01680
81LH2-000-HH1 (DBL 14ga ) 21 21 81LH2-001-EH1 (DBL 14ga ) 0-752-AE1 (BLK 14ga )
BUS 15A LINE HEATER DEF RETURN 3 (LH6)
SP810 SP287
58E-06-02390 2 1 56 56 46 46
FUSE - F3 81LH3-003-EH1 (DGR 14ga ) 0-706-EH1 (BLK 14ga ) 0-647-EH1 (BLK 14ga ) 0-725-EE3 (BLK 14ga )
PWR
LH6 LH6
A3 A3 31 31
BUS 81LH3-000-HH1 (DGR 14ga ) 81LH3-001-EH1 (DGR 14ga ) 58B-02-00670
15A SP811
58E-06-02390 LINE HEATER DEF PRESSURE 4 (LH7)
FUSE - F4
81LH4-002-EH1 (LBL 14ga ) 2 1 0-708-EH1 (BLK 14ga )
PWR A4 A4 41 41
BUS 81LH4-000-HH1 (LBL 14ga ) 81LH4-001-EH1 (LBL 14ga ) LH7 LH7
15A SP812
58E-06-02390 58B-02-01690
FUSE - F5 LINE HEATER DEF RETURN 4 (LH8)
PWR A5 A5 SP813 SP284
81LH5-000-HH1 (LTG 14ga ) 43 43 81LH5-001-EH1 (LTG 14ga ) 81LH4-003-EH1 (LBL 14ga ) 2 1 0-709-EH1 (BLK 14ga ) 0-648-EH1 (BLK 14ga ) 57 57 0-726-EE3 (BLK 14ga ) 47 47
BUS 15A
58E-06-02390 LH8 LH8
FUSE - F6 58B-02-00660
PWR A6 A6 47 47 SP814 LINE HEATER DEF SUCTION 1 (LH9)
BUS 81LH6-000-HH1 (PNK 14ga ) 81LH6-001-EH1 (PNK 14ga )
15A 81LH5-002-EH1 (LTG 14ga ) 2 1
58E-06-02390 0-681-EH1 (BLK 14ga )
RTMR3
LH9 LH9
58B-02-01750
LINE HEATER DEF SUCTION 2 (LH10)
SP293
RTMR4 81LH5-003-EH1 (LTG 14ga ) 2 1 58 58 48 48
0-682-EH1 (BLK 14ga ) 0-710-EH1 (BLK 14ga ) 0-649-EH1 (BLK 14ga ) 0-727-EE3 (BLK 14ga )
RELAY - R1
LH10 LH10 SP282
86(+) 85(-) RTMR4 58B-02-01760
SUPPLY MODULE COOLANT VALVE 29 80SMC-000-EE3 (DGR 20ga ) 3 3 80SMC-001-EH1 (DGR 16ga ) 35 35 80SMC-002-HH1 (DGR 18ga ) A1 A1 C2C2
0-778-HH1 (BLK 18ga ) SH9:D-11 FUSE - F1 LINE HEATER DEF SUCTION 3 (LH11)
A2 SP297 SP290
87 A2 11DHP-001-HH1 (ORG 12ga ) 11DHP-000-HH1 (ORG 14ga ) A9 A9 B9 B9
11DHP1-000-HH1 (PUR 14ga ) 20 20 11DHP1-001-EH1 (PUR 14ga ) 81LH5-004-EH1 (LTG 14ga ) 2 1 0-683-EH1 (BLK 14ga )
C1 C1 30 15A
LH11 LH11
87a B2 B2 58E-06-02390
RTMR4 RTMR4 58B-02-01750
XC2989
RTMR4
58E-06-01940 RTMR4 LINE HEATER DEF SUCTION 4 (LH12)
RTMR4 FUSE - F2
XC2989 81LH5-005-EH1 (LTG 14ga ) 2 1
SP298 0-684-EH1 (BLK 14ga )
DEF PUMP HEATER POWER FEEDBACK 7 11DHP-005-EE3 (ORG 20ga ) 12 12 11DHP-004-EH1 (ORG 16ga ) 13 13 11DHP-003-HH1 (ORG 20ga ) 11DHP-002-HH1 (ORG 14ga ) C9 C9 D9 D9
11DHP2-000-HH1 (TAN 14ga ) 5 5 11DHP2-001-EH1 (TAN 14ga ) LH12 LH12
15A
P809 58E-06-02390 58B-02-01760
J807 P807 P49 J49 RTMR4 RTMR4
XC2989 LINE HEATER DEF TRANSFER (LH13)
J49 P49
81LH6-002-EH1 (PNK 14ga ) 2 1 0-685-EH1 (BLK 14ga )
LH13 LH13
58E-02-02510
VEC RTMR1 HEATER DEF FAST FILL RECEIVER (DFFR)
FUSE - F7 SP283
28 28 TB22 1 2 0-711-EH1 (BLK 14ga )
80LH-002-EE3 (ORG 14ga ) 80LH-005-AE1 (ORG 14ga ) 81LH6-003-EH1 (PNK 14ga ) 0-686-EH1 (BLK 14ga )
27 27 1 1 1 A8 B8 1
11-018-AA1 (RED 14ga ) SH6:F-3
80LH-001-EE3 (ORG 14ga ) 80LH-004-AE1 (ORG 14ga ) V1 V2 80LH-007-AA1 (ORG 14ga ) DFFR DFFR
15A
RTMR1-A8 58E-06-02390 RTMR1-B8 58B-02-00650
J808 P808 58E-65-00061 HEATER DEF FAST FILL VALVE (DFFV)
81LH6-004-EH1 (PNK 14ga ) 1 2 0-687-EH1 (BLK 14ga )
DFFV DFFV
58B-02-00590
HEATER ELEC DEF PUMP 1 (DHP1)
HEATER GROUND FOR #1 INJECTOR 13 81H1-000-EE3 (DGR 20ga ) 38 38 81H1-002-EH1 (DGR 14ga ) 11DHP1-002-EH1 (PUR 16ga ) 1 2 0-689-EH1 (BLK 16ga )
RTMR3
RELAY - R1
86(+) 85(-) HEATER ELEC DEF PUMP 2 (DHP2)

HEATER FOR #1 INJECTOR 14 81H2-000-EE3 (LTG 20ga ) 39 39 81H2-001-EH1 (LTG 14ga ) 26 26 81H2-002-HH1 (LTG 18ga ) D1D1 B2 B2
81H1-003-HH1 (DGR 18ga ) 27 27
11DHP1-003-EH1 (PUR 16ga ) 1 2 0-691-EH1 (BLK 16ga )
87 D2D2 29 29
81H-001-HH1 (YEL 16ga )
35 35 80LH-011-EH1 (ORG 14ga ) 80LH-003-EH1 (ORG 16ga ) 28 28 80LH-015-HH1 (ORG 16ga ) B1 B1 30
87a C2 HEATER ELEC DEF PUMP 3 (DHP3)
C2 SP291
SP300 J49 P49
RTMR3 11DHP2-002-EH1 (TAN 16ga ) 1 2 0-692-EH1 (BLK 16ga ) 0-650-EH1 (BLK 14ga ) 59 59 0-728-EE3 (BLK 14ga ) 49 49
P49 J49 58E-06-01940 RTMR3
RELAY DOSING MODULE HEATER 1 DOSING MODULE 1 (DM1)
3 HEATER GROUND HEATER ELEC DEF PUMP 4 (DHP4)
SH9:K-17 0-672-EH1 (BLK 16ga )
81H-000-EH1 (YEL 16ga ) 4 HEATER SUPPLY 11DHP2-003-EH1 (TAN 16ga ) 1 2 0-693-EH1 (BLK 16ga )
INJECTOR #1 HI 11 81DMH-000-EE3 (DBL 20ga ) 36 36 81DMH-001-EH1 (DBL 16ga ) 1 INJECTOR HI
INJECTOR #1 LO 12 81DML-000-EE3 (LBL 20ga ) 37 37 81DML-001-EH1 (LBL 16ga ) 2 INJECTOR LO
DM#1 5V SENSOR SUPPLY 15 81S5V-000-EE3 (YEL 20ga ) 40 40 81S5V-001-EH1 (YEL 16ga ) 5 SENSOR SUPPLY 5V
TEMP SIGNAL FOR DM#1 16 81T-000-EE3 (PNK 20ga ) 41 41 81T-001-EH1 (PNK 16ga ) 6 TEMPERATURE SIGNAL
SENSOR GROUND FOR DM#1 17 81DMG-000-EE3 (GRY 20ga ) 42 42 81DMG-001-EH1 (GRY 16ga ) 7 SENSOR GROUND SH8:A-11 0-704-EH1 (BLK 18ga )
PRESSURE SIGNAL FOR DM#1 18 81P-000-EE3 (PUR 20ga ) 43 43 81P-001-EH1 (PUR 16ga ) 8 PRESSURE SIGNAL SH9:N-12 0-712-EH1 (BLK 16ga )
SH9:O-12 0-715-EH1 (BLK 16ga )
DM1 58E-01-00060 SP286
P809 SH9:L-12 0-673-EH1 (BLK 16ga )
SH9:J-12 0-672-EH1 (BLK 16ga ) 0-721-EH1 (BLK 14ga ) 60 60 0-729-EE3 (BLK 14ga ) 50 50
HEATER GROUND FOR #2 INJECTOR 13 82H1-000-EE3 (DGR 20ga ) 46 46 82H1-001-EH1 (DGR 14ga )
RTMR3
RELAY - R2 61 61 51 51
SH8:E-14 0-470-EH1 (BLK 18ga ) 0-722-EH1 (BLK 14ga ) 0-730-EE3 (BLK 14ga )
SH8:D-14 0-029-EH1 (BLK 18ga ) SP362
86(+) 85(-) B4 B4
HEATER FOR #2 INJECTOR 14 82H2-000-EE3 (LTG 20ga ) 47 47 82H2-001-EH1 (LTG 14ga ) 36 36 82H2-002-HH1 (LTG 18ga ) D3 D3 82H1-002-HH1 (DGR 18ga ) 37 37 SH9:D-14 0-643-EH1 (BLK 14ga )
87 D4 D4 39 39
82H-001-HH1 (YEL 16ga )
80LH-006-EH1 (ORG 16ga ) 38 38 80LH-016-HH1 (ORG 16ga ) B3 B3 30
SH8:I-11 0-670-EH1 (BLK 18ga ) SP292
87a C4 C4 62 62 52 52
J49 P49 SH8:G-11 0-655-EH1 (BLK 18ga ) 0-654-EH1 (BLK 14ga ) 0-731-EE3 (BLK 14ga )
RTMR3 SH8:J-11 0-678-EH1 (BLK 18ga )
58E-06-01940 RTMR3
P49 J49 SH8:H-11 0-666-EH1 (BLK 18ga )
DOSING MODULE 2 (DM2)
RELAY DOSING MODULE HEATER 2
SH9:J-17 0-673-EH1 (BLK 16ga ) 3 HEATER GROUND
82H-000-EH1 (YEL 16ga ) 4 HEATER SUPPLY SH8:N-11 0-669-EH1 (BLK 14ga ) 63 63 0-732-EE3 (BLK 14ga ) 53 53
P807 J807 J808 P808
SENSOR GROUND FOR DM#2 17 82DMG-000-EE3 (GRY 20ga ) 50 50 82DMG-001-EH1 (GRY 16ga ) 7 SENSOR GROUND
PRESSURE SIGNAL FOR DM#2 18 82P-000-EE3 (PUR 20ga ) 51 51 82P-001-EH1 (PUR 16ga ) 8 PRESSURE SIGNAL
P810 DM2 58E-01-00060
RTMR3
RELAY - R3
86(+) 85(-) B6 B6
HEATER FOR #3 INJECTOR 43 83H2-002-EE3 (LTG 20ga ) 11 11 83H2-001-EH1 (LTG 14ga ) 50 50 83H2-000-HH1 (LTG 18ga ) D5 D5 83H1-000-HH1 (DGR 18ga ) 52 52
87 D6 D6 53 53
83H-000-HH1 (YEL 16ga )
34 34 80LH-012-EH1 (ORG 14ga ) 80LH-008-EH1 (ORG 16ga ) 51 51 80LH-017-HH1 (ORG 16ga ) B5 B5 30
87a C6 C6
SP302 J49 P49
RTMR3
58E-06-01940 RTMR3
P49 J49 DOSING MODULE 3 (DM3)
83H-001-EH1 (YEL 16ga ) 4 HEATER SUPPLY
PRESSURE SIGNAL FOR DM#3 47 85P-000-EE3 (PUR 20ga ) 69 69 85P-001-EH1 (PUR 16ga ) 8 PRESSURE SIGNAL
DM3 58E-01-00060
P809
J807 P807
RTMR3
RELAY - R4
86(+) 85(-) B8 B8
HEATER FOR #4 INJECTOR 23 84H2-002-EE3 (LTG 20ga ) 8 8 84H2-001-EH1 (LTG 14ga ) 54 54 84H2-000-HH1 (LTG 18ga ) D7 D7 84H1-000-HH1 (DGR 18ga ) 56 56
87 D8 D8 57 57
84H-000-HH1 (YEL 16ga )
80LH-009-EH1 (ORG 16ga ) 55 55 80LH-018-HH1 (ORG 16ga ) B7 B7 30
87a C8 C8
J49 P49
P49 J49 RTMR3
58E-06-01940 RTMR3
DOSING MODULE 4 (DM4)
84H-001-EH1 (YEL 16ga ) 4 HEATER SUPPLY
INJECTOR #4 HI
INJECTOR #4 LO
5
6
84DMH-000-EE3 (DBL 20ga )
84DML-000-EE3 (LBL 20ga )
1
2
1
2
84DMH-001-EH1 (DBL 16ga )
84DML-001-EH1 (LBL 16ga )
1
2
INJECTOR HI
INJECTOR LO 58B-06-02390-00 APR 16
PRESSURE SIGNAL FOR DM#4 34 6 6 8 PRESSURE SIGNAL
980E-5
86P-000-EE3 (PUR 20ga ) 86P-001-EH1 (PUR 16ga )
P810 DM4 58E-01-00060
J811 P811
A50005 & UP
Sheet 9 of 27
OP-CAB WINDOW MOTOR SWITCH LEFT WINDOW
OPERATOR CAB SEATS VEC-91 GB12

0-192-CC4 (BLK 18ga ) 7 7 9 9
F60
MOTOR WINDOW LH
TB24 VEC-91 B2
0-275-CC4 (BLK 12ga ) 3 3
2F 3F F TB24 0-191-CC4 (BLK 12ga )
F 1 1 49 49 F56 2B 2 1 1
SH6:F-11 712-008-AA1 (ORG 14ga ) 712DS2-000-AA1 (BRN 14ga ) P1 P2 712DS2-001-AC2 (BRN 14ga ) SP806 SP009 67M-000-CC4 (GRY 14ga ) 67M-001-CC9 (GRY 14ga ) 2
15 712 BUSS 9E E 67P-000-AA1 (YEL 12ga ) 1 T2 T1 1 67P-001-AC4 (YEL 14ga ) 13 13 67P-012-CC4 (YEL 14ga ) 67P-005-CC4 (YEL 12ga ) 1 1 1 MOTOR
20 9 9 6
VEC91-P2 VEC91-P3 67P-002-AC4 (YEL 14ga ) 67P-010-CC4 (YEL 14ga ) 67P-006-CC4 (YEL 12ga ) 6
58E-06-20061 5B 5 2 2
P059
VEC91-P9 67L-001-CC4 (PNK 14ga ) 67L-002-CC9 (PNK 14ga )
VEC-89 58E-06-20061 4
0-195-CC4 (BLK 12ga ) 4
F56 TB24
712 BUSS 4B P50 J50
B 712DS-000-AA1 (ORG 14ga ) 1 C1 C2 1 712DS-001-AC2 (ORG 14ga ) 2 2
15 8 10
8 10
VEC89-P4
58E-06-02042
P02 J02 P072 P072
58F-06-60860
AIR SEAT DRIVER 67P-015-CC4 (YEL 18ga )

1 1 1 712DS-003-CC2 (ORG 14ga ) SWITCH RIGHT WINDOW
2 2 2 0-309-CC2 (BLK 14ga ) 0-197-CC4 (BLK 18ga ) 7 7 9 9

GB12
MOTOR WINDOW RH
VEC-91 C1
3 3
P227 J227 TB24 0-522-CC4 (BLK 12ga ) 0-198-CC4 (BLK 12ga )
F62 2B 2 1 1
SP006 SP007 67S-000-CC4 (DBL 14ga ) 67S-001-CC10 (DBL 14ga ) 2
712 BUSS 9G G 67R-000-AA1 (PUR 12ga ) 1 S2 S1 1 67R-011-AC4 (PUR 14ga ) 11 11 67R-013-CC4 (PUR 14ga ) 67R-005-CC4 (PUR 12ga ) 1 1 1 MOTOR
AIR SEAT PASSENGER 20 12 12 6
67R-012-AC4 (PUR 14ga ) 67R-029-CC4 (PUR 14ga ) 67R-006-CC4 (PUR 12ga ) 6 P058
1 1 1 5B 5 2 2
712DS2-002-CC2 (BRN 14ga ) VEC91-P9 67T-001-CC4 (LBL 14ga ) 67T-002-CC10 (LBL 14ga )
GB12 58E-06-20061 4
A3
0-200-CC4 (BLK 12ga ) 4
2 2 2 0-308-CC2 (BLK 14ga ) 1
P04 J04_CP P51 J51
P230 J230 8 10
8 10
SH10:G-16 0-266-CC2 (BLK 14ga )
P071 P071
58F-06-60860
67R-016-CC4 (PUR 18ga )
DIRECTIONAL SHIFTER / PARK BRAKE
P701
10
11
12
1
2
3
AHT
AUXBOX CONNECTOR
10
11
12
J701
1
2
3
(OPT) GE CONTROL INTERFACE
72AF-000-AA3 (GRY 18ga ) p FWD DIR REQ
TB23
72RA-001-AA3 (YEL 18ga ) X1 X2 72RA-002-AA1 (YEL 18ga ) SH14:C-2
SWITCH SERVICE BRAKE PSI

HYD BRAKE CABINET TB35
72RA-000-AA3 (YEL 18ga ) H SEL SW IN REVERSE
NO C K K TB24 P304
44R-004-BB1 (GRY 14ga ) 44R-005-AB1 (GRY 14ga ) F1 F3 44R-003-AA1 (GRY 18ga ) SH14:G-2
71BC-006-BB1 (DGR 14ga ) B C 72PA-001-AA3 (BRN 18ga ) 1 E1 E4 1 72PA-003-AA1 (BRN 20ga ) SH10:I-15
NC A F4 44R-001-AA1 (GRY 20ga ) SH10:I-15
SBPS VEC-89
58E-06-30320 F NEUTRAL REQUEST
TB23 F43
JB4A
SBPS 72N-003-AA3 (PNK 18ga ) 4A 71CK BUSS
3 3 71SS-001-AC2 (LBL 18ga ) T1 T2 71SS-000-AA1 (LBL 18ga ) A
1 TB25 5
P303
2 71BC-007-BB1 (DGR 14ga ) J J 71BC-003-AB1 (DGR 14ga ) 1 V2 V4 1 71BC-000-AA1 (DGR 16ga ) VEC89-P4
J02 P02 58E-06-02042
3 SOLENOID PARK BRAKE
4
DIRECTION SELECTOR
2 1 G G
SHIFTER CONTROLLER
PC1150
71BC-005-BB1 (DGR 14ga ) 52CS-004-BB1 (GRY 14ga ) 52CS-006-BB1 (GRY 14ga ) 52CS-003-AB1 (GRY 14ga ) SH10:J-8
SP161 VBATT 7 71SS-002-CC2 (LBL 20ga ) SH10:E-7 0-266-CC2 (BLK 14ga )
TB21
PBS XA3347 PBS SH10:L-15 0-450-CC2 (BLK 18ga )
72P-002-AA3 (BRN 18ga ) K1 K2 72P-001-AC2 (BRN 18ga ) 13 13 72P-000-CC2 (BRN 20ga ) 2 PARK GND 6 0-260-CC2 (BLK 20ga )
D2 J240 P240 SP365
71BC-004-BB1 (DGR 14ga ) 1 2 52CS-005-BB1 (GRY 14ga ) 72R-003-AA3 (YEL 18ga ) L1 L2 72R-001-AC2 (YEL 18ga ) 14 14 72R-000-CC2 (YEL 20ga ) 1 REVERSE
DIRECTION SELECTOR SHIFTER
PC2834 72R-002-AA1 (YEL 18ga ) L3 15 15 72N-000-CC2 (PNK 20ga ) 12 NEUTRAL PWM 4 72PWM-000-CC2 (TAN 20ga ) 4 PWM OUTPUT GND 5 0-418-CC2 (BLK 20ga )
72N-002-AA1 (PNK 18ga ) M1 M2 72N-001-AC2 (PNK 18ga ) 16 16 72F-000-CC2 (GRY 20ga ) 11 FORWARD VSHIFT 8 71SR-000-CC2 (LTG 20ga ) 6 VBATT DIMMER INPUT 9 49-004-CC2 (TAN 20ga ) SH11:K-9
VEC-90
F19 9 9 3 TROLLEY FAULT 10 SW A COM 1
M3 72T-000-CC2 (YEL 20ga ) P108 71H-002-CC2 (LBL 20ga ) SH13:K-7
71CK BUSS 9B
B
10 SW A NO 2
72F-003-AA3 (GRY 18ga ) N1
P02 J02 P109 P109 71P-003-CC2 (BRN 20ga ) SH13:J-11
D14
VEC90-P9
H 9H 85 86 58E-06-06390 58E-06-20420
SH7:L-9 36-002-AA1 (YEL 18ga ) 72F-002-AA1 (GRY 18ga ) N3 N2 72F-001-AC2 (GRY 18ga ) P108
87 D2 P2
TB26 INTERFACE MODULE
TO 1G 72T-001-AC2 (YEL 18ga )
30 G 47 47 1 C1 C2 1 m SHIFTER FAULT
72IM-000-CC2 (YEL 20ga ) 72IM-002-AC2 (YEL 20ga ) 72IM-001-AA1 (YEL 20ga )
87a VEC-90
RELAY 20 D3
IM2
1F J02 P02
ENGINE RUNNING (87a) F
RELAY 21
D4 C SERVICE BRAKE PRESS SW
1E SH10:G-7 44R-001-AA1 (GRY 20ga )
E 72R-002-AA1 (YEL 18ga )
D13
85 86 T SELECTOR SWITCH PARK
VEC90-P1 SH10:G-11 72PA-003-AA1 (BRN 20ga )
TB24
87 11B
B 52PB-000-AA1 (PUR 16ga ) 1 B1 B2 1 52PB-003-AA1 (PUR 20ga ) V PARK BRAKE RELEASE REQUEST
30 D6
87a 1 2 P HYD LADDER NOT UP
SH19:C-19 510E2-001-AA1 (DGR 20ga ) 510E2D-000-AA1 (DGR 20ga )
PARK BRAKE PC2834 IM3
REQUEST RELAY 22 TB21
SH16:B-13 0-229-AA2 (BLK 16ga ) X1 X2 0-230-AA1 (BLK 20ga ) C IM GROUND

TB32 58B-06-00290
0 BUSS 85 86
SH10:G-6 52CS-003-AB1 (GRY 14ga ) K1 K2 52CS-002-AA2 (GRY 18ga ) 1 2 0-231-AA2 (BLK 18ga ) X3
11A R18 SH16:M-17 0-345-AA2 (BLK 18ga )

87 A
0 BUSS 52CS-000-AA1 (GRY 16ga ) K3 SH16:D-3 0-238-AA2 (BLK 16ga ) X4
30
87a
VEC90-P11
52CS-001-AA1 (GRY 20ga ) 52CS-001-AA1 (GRY 20ga ) E PARK BRAKE SOLENOID
PARK BRAKE 12D
D
RELEASE RELAY 23
IM1
TB24
72FNR-000-AA1 (DBL 16ga ) 1 M1 M2 1 72FNR-001-AA1 (DBL 20ga ) N SELECTOR SW (NOT IN PARK)
0 BUSS 85 86
IM2
D5 TB23
87 12A
A 712BL-000-AA1 (DGR 16ga ) L1 L2 712BL-001-AA1 (DGR 20ga ) 712BL-001-AA1 (DGR 20ga ) L BRAKE LOCK SWITCH POWER SUPPLY
30
87a VEC90-P12
L4 70 70 712BL-003-CC2 (DGR 16ga ) IM3
712BL-002-AC2 (DGR 16ga )
PARK BRAKE TB32
SWITCH RELAY 24 P02 J02
S1 52ABA-000-AA1 (TAN 20ga ) R PARK BRAKE PROTECTION (OPT)
52ABA-000-AA1 (TAN 20ga )
0 BUSS IM1
i BRAKE LOCK
86 85 SWITCH BRAKE LOCK
D6 IM2
87 9 9 7 7
0-095-CC2 (BLK 16ga ) SH19:K-7
30
87a 3 3
9D
52B1-002-CC2 (PUR 16ga )
D 2B 2
52B-000-AA1 (PUR 16ga ) 712BL-003-CC2 (DGR 16ga )
TRUCK MOVING 1 1
RELAY 25 D7 44 44
52B1-001-AC2 (PUR 16ga )
39HA-001-AC2 (YEL 16ga ) 45 45 39HA-000-CC2 (YEL 16ga ) 6 6 0-450-CC2 (BLK 18ga ) SH10:G-16
5B
5
D8 TB23
39H-001-AC2 (YEL 16ga ) 46 46 39H-000-CC2 (YEL 16ga ) 4 4
0 BUSS 85 86 9C
C 52B1-000-AA1 (PUR 16ga ) B1 B2 52B1-001-AC2 (PUR 16ga )
10 10 8 8
0-059-CC2 (BLK 16ga )
87 P02 J02
VEC90-P9
30
P39 P39
87a 58F-06-60920
PARK BRAKE RELAY PARK BRAKE PROTECTION

D9 LATCH RELAY 26 (930 OPTION ONLY)
E 9E VEC RTMR1
RELAY - R2
D10 86 85 VEC RTMR1-R2
52B-001-AA1 (PUR 20ga )
86(+) 85(-) TB32
SOLENOID BRAKE LOCK
F 9F 1 D1 F2 1
71ABA-001-AA1 (YEL 16ga ) 52ABA-001-AA1 (TAN 20ga ) SP453
87 L L 2 1
RTMR1-D1 J4 SH5:I-21
D2 1 RTMR1-F2
J1 52B-003-AB1 (PUR 16ga ) 52B-004-BB1 (PUR 16ga ) 52B-005-BB1 (PUR 16ga ) 0-098-BB1 (BLK 16ga ) 0-455-BB1 (BLK 16ga )
30 87
VEC90-P9 VEC90-P11 52B-002-AA1 (PUR 16ga ) SP160
11D
87a D 1 F1 30
BLS XA3347 BLS
71ABA-000-AA1 (YEL 16ga ) E2 RTMR1-D2 P240 J240
87a
GE INTERFACE
RTMR1-F1 D3
RELAY 27 TB32 PC3414 1 2
52B-006-BB1 (PUR 16ga ) 0-239-BB1 (BLK 16ga )
T1
58E-65-00061
71ABA-002-AA1 (YEL 16ga ) 58B-06-02020
58E-06-20050 PC2834
T3 T2 71ABA-003-AA2 (YEL 16ga ) 1 2 0-010-AA2 (BLK 16ga ) SH6:D-20
6800.0
TB29 GE CONTROL INTERFACE R1
79RD-000-AA1 (BRN 18ga ) 1 S1 S2 79RD-001-AA3 (BRN 18ga ) b REVERSE OUT
72FD-000-AA1 (WHT 18ga ) 1 R1 R2 72FD-001-AA3 (WHT 18ga ) a FORWARD OUT

AHT
INTERFACE MODULE TB24
P702
AUXBOX CONNECTOR
GE CPU RUNNING n 72CPU-003-AA1 (BLK 20ga ) W3 W2 e SYS RUN TO ENG ECU
72CPU-001-AA3 (BLK 18ga ) (OPT)
1
TB23
1
IM2 P302
J702
V2 39HA-001-AC2 (YEL 16ga )

TB22
SH17:J-8 39H1-001-AA4 (YEL 20ga ) 1 X1 X2 1 39H1-000-AA1 (YEL 18ga ) 39H-002-AA1 (YEL 18ga ) A1 A2 39H-001-AC2 (YEL 16ga )
58B-06-02390-00 APR 16
980E-5
A50005 & UP
Sheet 10 of 27
ELECTRONIC GAUGE DISPLAY 0-180-CC3 (BLK 16ga )
VEC-89 SWITCH DISPLAY MODE #1

F44 TB23
71CK BUSS 4D
D 71LS-000-AA1 (DGR 16ga ) M1 M2 71LS-001-AC3 (DGR 16ga ) 36 36 71LS-003-CC3 (DGR 16ga ) 9 9 7 7
5 TB26 INTERFACE MODULE
VEC89-P4 3 3
55B-000-CC3 (DBL 16ga ) 42 42 55B-001-AC3 (DBL 16ga ) 1 P1 P2 1 55B-002-AA1 (DBL 20ga ) J OK
58E-06-02042 P03 J03
SH13:K-10 0-052-CC3 (BLK 16ga ) 2 2B
1 1 41 41 1 N1 N2 1 H LEFT ARROW
55A-000-CC3 (LBL 16ga ) 55A-001-AC3 (LBL 16ga ) 55A-002-AA1 (LBL 20ga )
6
6 IM3
5 5B
4
4
71LS-007-CC3 (DGR 16ga ) 10 8

10 8
P26 P26
58F-06-60850
ELECTRONIC GAUGE DISPLAY 58E-06-60000
0-182-CC3 (BLK 16ga )
0-183-CC3 (BLK 16ga )
1 +7.5V +7.5V 1
GND GND SWITCH DISPLAY MODE #2
2 2
3 LIN LIN 3
4 4 9 9 7 7
TB26
3 3 45 45 1 S1 S2 1 q UP ARROW
55D-000-CC3 (PUR 16ga ) 55D-001-AC3 (PUR 16ga ) 55D-002-AA1 (PUR 20ga )
2 2B
+7.5V +7.5V 1 1 44 44 1 1 IM2
1 1 55C-000-CC3 (YEL 16ga ) 55C-001-AC3 (YEL 16ga ) R1 R2 55C-002-AA1 (YEL 20ga )
GND 2 2 GND 6
LIN LIN 6
3 3 5 5B
1
2
3
4
5
6
7
8
4 4 4 K
PC1942
DOWN ARROW
4
1 2 3 4 1 2 3 4 1 2 3 4 J03 P03 IM3
NOT USED
HIGH BEAM
RIGHT TURN
HIGH BEAM
LEFT TURN
10 8
POWER 7.5V
COOLANT TEMP GAUGE SH17:A-2 SH17:B-2

POWER
FUEL GAUGE 71LS-013-CC3 (DGR 16ga ) 10 8 0-179-CC3 (BLK 16ga )
+7.5V +7.5V 1 P27 P27 D9

1 58F-06-60840
GND
SPEEDOMETER & DISPLAY GND

LIN
2 GND 2 SONALERT
LIN (MASTER GAUGE) LIN 3 (SONA) 1 2 712G-001-AC4 (LTG 16ga ) SH11:F-13
3
4 4
+ 1 24SON-000-CC4 (LBL 16ga ) 18 18 24SON-004-AC4 (LBL 16ga ) SP364 PC2834
24SON-001-AC4 (LBL 16ga ) 24SON-002-AC4 (LBL 16ga )
D10
+7.5V +7.5V - 1 31IML-004-CC4 (BRN 16ga ) 17 17 31IML-002-AC4 (BRN 16ga )
1 1
+7.5V GND GND 1 2
1 2 2 24SON-003-AC4 (LBL 16ga ) 24VIM-006-AC4 (LBL 16ga ) SH5:J-9
GND LIN LIN
2 3 3 PB1951 J04_CP P04
LIN 58B-06-00190 PC2834
3 4 4
2 1 TB34
4 31IML-003-AC4 (BRN 16ga )
470Ω 2W
COMMUNICATION 31IML-001-AC4 (BRN 16ga ) N1 N2 31ILM-000-AA1 (BRN 20ga ) M SONALERT
TO SLAVE DEVICES
R16
SP252
CNP2
OIL TEMP GAUGE DEF LEVEL GAUGE 31IML-002-AC4 (BRN 16ga )
(BLACK)
RIGHT TURN 1 31 31
1 45LL-005-CC1 (BRN 16ga ) 45LL-006-AC1 (BRN 16ga ) SH12:L-13
LEFT TURN 2 30 30
2 45RL-005-CC1 (DBL 16ga ) 45RL-006-AC1 (DBL 16ga ) SH12:L-13
HIGH BEAM
HIGH BEAM TB23
3 3 41H-006-CC1 (TAN 16ga ) SH11:I-13
LEFT
TURN
RIGHT KEY SWITCH 4 4 712G-003-CC1 (LTG 16ga ) 6 6 712G-002-AC1 (LTG 16ga ) H1 H2 712G-000-AA1 (LTG 16ga )
5 5
6 6 H4 712G-001-AC4 (LTG 16ga ) SH11:D-16
WARNING LAMP 1 2 WARNING LAMP RETURN 7 7 3 3
1 2 11RWL-000-CC1 (PUR 16ga )
3 4 WARNING LAMP +24V 8 8 4 4
24VIM-004-CC1 (LBL 16ga )
LEFT TURN
HIGH BEAM
1
WARNING LAMP RETURN
RIGHT TURN
2 P902
POWER
TB35
WARNING LAMP +24V
3
DIMMER G RED WARNING LAMP
4 11RWL-001-AC1 (PUR 16ga ) P1 P2 11RWL-002-AA1 (PUR 20ga )
5
6 24VIM-005-AC1 (LBL 16ga ) SH5:J-13
7
8
9
10
11 KEY SWITCH
12 LEFT TURN VEC-91
13 RIGHT TURN F54
14 GB12 9C 712 BUSS
C
15 1 C4 5
IM ON SIGNAL 0-185-CC1 (BLK 16ga )
16
TB23 VEC91-P9
F26
CNP1 2E 11 BUSS
1 1 G1 G2 E
24V BATT+ (GRAY) 11DISP-003-CC1 (YEL 16ga ) 11DISP-001-AC1 (YEL 16ga ) 11DISP-000-AA1 (YEL 16ga )
1 15
2 GND 24V BATT+
CAN/RPC-H 1 1 VEC91-P2
3 DIMMER TB35 58E-06-20061
CAN/RPC-L 2 2 49-002-CC1 (TAN 16ga ) SH11:K-12
4
IM ON SIGNAL 3 2 2 1 K IM ON SIGNAL
5 3 11ONS-000-CC1 (LBL 16ga ) 11ONS-001-AC1 (LBL 16ga ) T1 T2 11ONS-002-AA1 (LBL 20ga )
6 GROUND BATT 4 4 SH16:M-9
MC254 11ONS-003-AA1 (LBL 18ga )
7 CAN/RPC-H 5 5 939YP-001-CC1 (YEL 20ga ) SH18:B-19 IM1
8
CAN TERMINATOR CAN/RPC-L SP326 J01 P01
6 6 939GP-014-CC1 (DGR 20ga ) 939GP-001-CC1 (GRN 20ga ) SH18:B-19
7 7
CAN TERMINATOR 8 SHIELD-263
8 939GP-015-CC1 (DGR 20ga )
P903
HEADLIGHT LAMP SWITCH

SPARE WIRES - AUX BOX TO CAB
SWITCH HEADLIGHTS 3 3
SH11:E-9 41H-006-CC1 (TAN 16ga ) 41H-007-CC3 (TAN 16ga )
7 7 9 9 1 59 59 1 OP-CAB
P60 J60 SPR_5 SPR1-000-AC3 (DGR 14ga ) SPR1-001-CC3 (DGR 14ga ) SPR_13
VEC-89 CENTER CONSL
3 SH11:K-2 41H-004-CC3 (TAN 16ga )
F64 TB22
71CK BUSS 2B
3 41L-002-CC3 (LBL 16ga ) SH11:L-2 SPR_6 1 SPR2-000-AC3 (DGR 14ga ) 60 60 SPR2-001-CC3 (DGR 14ga ) 1
SPR_14 SPARE WIRES
2D D 5 5 2
11D-000-AA1 (PNK 16ga ) 1 A1 A2 1 11D-001-AC3 (PNK 16ga ) 11D-002-CC3 (PNK 16ga )
5 1 1 SWITCH COMBO
6 6 SP016
VEC89-P2 41L-000-CC3 (LBL 16ga ) 41L-001-CC3 (LBL 16ga ) 4 3 41H-000-CC3 (TAN 16ga )
58E-06-02042 P03 J03 OP-CAB
5 5B SP004 1 61 61 1
11D-003-CC3 (PNK 16ga ) SPR_7 SPR3-000-AC3 (DGR 14ga ) SPR3-001-CC3 (DGR 14ga ) SPR_15
4 4
P121
DIMMER SW LOWER DASH
PC1709 P121 SPARE WIRES
1 62 62 1
SPR_8 SPR4-000-AC3 (DGR 14ga ) SPR4-001-CC3 (DGR 14ga ) SPR_16
SH12:B-3 0-159-CC3 (BLK 18ga ) 8 8 10 10
11L-010-CC3 (YEL 18ga ) SH12:L-4 AUX BOX
SPARE
P20 58F-06-60800 P20
WIRES 1 63 63 1 OP-CAB
TB34
SPR_9 SPR5-000-AC3 (DGR 14ga ) SPR5-001-CC3 (DGR 14ga ) SPR_17
SP301 LOWER FRT
SH12:I-8 41TS-005-AA1 (DGR 18ga ) A1 A2 41TS-003-AC3 (DGR 16ga ) 11 11 41TS-000-CC3 (DGR 16ga ) 41TS-002-CC3 (DGR 16ga ) SPR_10 1 SPR6-000-AC3 (DGR 14ga ) 64 64 SPR6-001-CC3 (DGR 14ga ) 1
SPR_18 SPARE WIRES
ACTIA DISPLAY PANEL DIMMER
41TS-011-CC3 (DGR 16ga ) 4 4 41TS-006-CC1 (DGR 16ga ) 1

P03 J03
50.0
SH5:C-16 49-003-CC3 (TAN 18ga ) 5 5 49-006-CC1 (TAN 18ga ) 49-001-CC1 (TAN 16ga ) 2
P03 J03
58B-06-00290 1 6 6 1 OP-CAB
3
J60 P60 SPR_11 SPR7-000-AC4 (DGR 14ga ) SPR7-001-CC4 (DGR 14ga ) SPR_19
49-005-CC1 (TAN 16ga ) 1 2
P18 569-06-61711 OVERHEAD
GB12 1 7 7 1 SPARE WIRES
R27 SPR_12 SPR8-000-AC4 (DGR 14ga ) SPR8-001-CC4 (DGR 14ga ) SPR_20
0-178-CC1 (BLK 16ga ) 1 A2
SH10:H-17 49-004-CC2 (TAN 20ga ) 1 1 49-008-CC1 (TAN 20ga ) 49-002-CC1 (TAN 16ga ) 0-187-CC1 (BLK 16ga )
SH11:G-9
SP285 P04 J04_CP
J61 P61
RELAY HI-BEAM 0-014-AA2 (BLK 16ga ) SH5:F-6

HEADLIGHT
TB34 (HBHR) GB31-B
18 18
86 85 B1
SH11:I-15 41H-004-CC3 (TAN 16ga ) 41H-001-AC3 (TAN 16ga ) B1 B2 41H-002-AA1 (TAN 18ga ) 0-015-AA2 (BLK 16ga )
LAMP HIGH MOUNT LEFT HI-BEAM
VEC-89 58D-06-10070
F6 TB34
11 BUSS 12F 88 88A
F 11HL-000-AA1 (BRN 10ga ) 41HB-000-AA2 (LTG 10ga ) F1 F2 41HB-001-AA1 (LTG 14ga ) 41 41 41HB-005-AJ1 (LTG 14ga ) 5 5 41HB-006-JL1 (LTG 14ga ) 1
25
VEC89-P12 F4 SH6:F-18 0-129-AA1 (BLK 14ga ) 42 42 0-110-AJ1 (BLK 14ga ) 6 6 0-111-JL1 (BLK 14ga ) 2
58E-06-02042 58E-06-04150
TB34 HMLHB
SH11:I-12 41L-002-CC3 (LBL 16ga ) 4 4 41L-004-AC3 (LBL 16ga ) C1 C2 41L-005-AA1 (LBL 16ga ) LAMP LOW MOUNT LEFT HI-BEAM
58D-06-10070
41HB-002-AA1 (LTG 14ga ) 43 43 41HB-007-AJ1 (LTG 14ga ) 7 7 41HB-008-JL1 (LTG 14ga ) 1

J03 P03
SH6:F-18 0-128-AA1 (BLK 14ga ) 44 44 0-112-AJ1 (BLK 14ga ) 8 8 0-121-JL1 (BLK 14ga ) 2
LMLHB
J12 P12 J542 P542
LAMP HIGH MOUNT RIGHT HI-BEAM
58D-06-10070
41HB-003-AA1 (LTG 14ga ) 41 41 41HB-009-AH1 (LTG 14ga ) 5 5 41HB-010-HL1 (LTG 14ga ) 1
SH6:F-21 0-127-AA1 (BLK 14ga ) 42 42 0-122-AH1 (BLK 14ga ) 6 6 0-123-HL1 (BLK 14ga ) 2
HMRHB
LAMP LOW MOUNT RIGHT HI-BEAM
58D-06-10070
RELAY HEADLIGHT 41HB-004-AA1 (LTG 14ga ) 43 43 41HB-011-AH1 (LTG 14ga ) 7 7 41HB-012-HL1 (LTG 14ga ) 1
LOW MOUNT
(HLMR) 0-016-AA2 (BLK 16ga ) SH12:F-12 SH6:G-21 0-126-AA1 (BLK 14ga ) 44 44 0-124-AH1 (BLK 14ga ) 8 8 0-125-HL1 (BLK 14ga ) 2
86 85 LMRHB
41L-006-AA1 (LBL 16ga ) 1 1 0-013-AA2 (BLK 16ga ) J11 P11 J543 P543 LAMP LOW MOUNT LEFT LOW-BEAM
VEC-89 58D-06-10080
F4
11 BUSS 9A
A 11LL-000-AA1 (GRY 10ga ) 1 88 88A 1
41LM-000-AA1 (GRY 14ga ) 39 39 41LM-002-AJ1 (GRY 14ga ) 3 3 41LM-003-JL1 (GRY 14ga ) 1
15
VEC89-P9 SH6:F-18 0-055-AA1 (BLK 14ga ) 40 40 0-114-AJ1 (BLK 14ga ) 4 4 0-113-JL1 (BLK 14ga ) 2
58E-06-02042 58E-06-04150
LMLLB
LAMP LOW MOUNT RIGHT LOW-BEAM
J542 P542 58D-06-10080
J12 P12
39 39 3 3 1
RELAY HEADLIGHT 41LM-001-AA1 (GRY 14ga ) 41LM-004-AH1 (GRY 14ga ) 41LM-005-HL1 (GRY 14ga )
HIGH MOUNT
SH6:G-21 40 40 4 4 2
(HHMR) 0-008-AA1 (BLK 14ga ) 0-116-AH1 (BLK 14ga ) 0-115-HL1 (BLK 14ga )
86 85 LMRLB
41L-006-AA1 (LBL 16ga ) 1 1 0-157-AA2 (BLK 16ga ) SH14:D-8
LAMP HIGH MOUNT LEFT LOW-BEAM
VEC-89 J11 P11 J543 P543 58D-06-10080
F5
11 BUSS 9G
G 11LR-000-AA1 (PNK 10ga ) 1 88 88A 1
41HM-000-AA1 (PNK 14ga ) 45 45 41HM-002-AJ1 (PNK 14ga ) 9 9 41HM-003-JL1 (PNK 14ga ) 1
15
VEC89-P9 SH6:F-18 0-094-AA1 (BLK 14ga ) 46 46 0-118-AJ1 (BLK 14ga ) 10 10 0-117-JL1 (BLK 14ga ) 2
58E-06-02042 58E-06-04150
HMLLB
LAMP HIGH MOUNT RIGHT LOW-BEAM
J12 P12 J542 P542 58D-06-10080
45 45 9 9 1
58B-06-02390-00 APR 16
41HM-001-AA1 (PNK 14ga ) 41HM-004-AH1 (PNK 14ga ) 41HM-005-HL1 (PNK 14ga )
HEADLIGHT LAMPS SH6:G-21 0-084-AA1 (BLK 14ga ) 46 46 0-119-AH1 (BLK 14ga ) 10 10 0-120-HL1 (BLK 14ga )
HMRLB
2
J11 P11 J543 P543

980E-5
A50005 & UP
Sheet 11 of 27
SWITCH FOG LAMP (OPT)
FOG LAMPS LAMP RIGHT FOG
58D-06-10061
7 7 9 9
SH11:J-8 0-159-CC3 (BLK 18ga )
TB34 VEC-89 37 37 1 1 1
48LF-001-AA1 (GRY 14ga ) 48LF-003-AH1 (GRY 14ga ) 48LF-005-HL1 (GRY 14ga )
3 3 55 55 B 1B
48F-000-CC3 (GRY 16ga ) 48F-001-AC3 (GRY 16ga ) E1 E2 48F-002-AA1 (GRY 18ga )
SH17:D-2 71LS-011-CC3 (DGR 16ga ) 2 2B SH6:F-21 0-104-AA1 (BLK 14ga ) 38 38 0-103-AH1 (BLK 14ga ) 2 2 0-102-HL1 (BLK 14ga ) 2
1 1 0 BUSS 85 86
J03 P03 VEC89-P1 RFLT
F62
6 6 11 BUSS 87 TB34 J11 P11 J543 P543
LAMP LEFT FOG
5B 15 30 1D 58D-06-10061
5 D 48LF-000-AA1 (GRY 12ga ) D1 D2
4 4 87a
VEC89-P1 48LF-002-AA1 (GRY 14ga ) 37 37 48LF-004-AJ1 (GRY 14ga ) 1 1 48LF-006-JL1 (GRY 14ga ) 1
8 8 10 10 FOG LAMP (OPT)
SH14:B-8 0-268-CC3 (BLK 18ga ) RELAY 40
SH6:F-18 0-425-AA1 (BLK 14ga ) 38 38 0-106-AJ1 (BLK 14ga ) 2 2 0-105-JL1 (BLK 14ga ) 2
P23 P23 58E-06-02042
58F-06-60830 LFLT
J12 P12 J542 P542
RIGHT DECK LAMPS

LAMP RH DIAGONAL LADDER
LADDER LAMPS 47 47 11 11 1
48-001-AA1 (DBL 14ga ) 48-006-AH1 (DBL 14ga ) 48-007-HL1 (DBL 14ga )
SH6:G-21 0-165-AA1 (BLK 14ga ) 48 48 0-166-AH1 (BLK 14ga ) 12 12 0-167-HL1 (BLK 14ga ) 2
RDLLT_CP
XA5780
LAMP RH DECK
SWITCH GROUND LEVEL
LADDER LIGHT(LLSW) SP245
48-002-AA1 (DBL 14ga ) 49 49 48-009-AH1 (DBL 14ga ) 48-019-AH1 (DBL 14ga ) 13 13 48-010-HL1 (DBL 14ga ) 1
(OPTIONAL LEFT AND
RIGHT LOCATIONS) SH6:G-21 0-164-AA1 (BLK 14ga ) 50 50 0-168-AH1 (BLK 14ga ) 0-493-AH1 (BLK 14ga ) 14 14 0-169-HL1 (BLK 14ga ) 2
A A
48C-007-JJ2 (ORG 16ga ) 48C-004-AR2 (ORG 16ga ) SP246 RDLT_CP
XA5780
2 J543 P543
1 48A-007-JJ2 (YEL 16ga ) B B
1 J11 P11
1
3
C C GB31-A LAMP RH DECK (OPT)
1 48B-007-JJ2 (PUR 16ga ) A4
0-237-AA2 (BLK 16ga )
P535 J535 14 14 O O
48-020-AH1 (DBL 14ga ) 48-021-FH1 (DBL 14ga ) 48-022-FF1 (DBL 14ga ) 1
SWITCH CAB LADDER LIGHT 0-494-AH1 (BLK 14ga ) 13 13 0-495-FH1 (BLK 14ga ) N N 0-496-FF1 (BLK 14ga ) 2
TB34
9 9 DLT_CP
SH14:C-8 0-056-CC3 (BLK 18ga ) 7 7 13 13 48C-001-AA1 (ORG 18ga ) L1 XA5780
TB34 J541 P541 P502 J502
RELAY ACCESS LADDER LIGHT (ALLR)
3 3 53 53 K1 K2 11 11
48B-000-CC3 (PUR 18ga ) 48B-001-AC3 (PUR 16ga ) 48B-002-AA1 (PUR 18ga ) 48B-003-AR2 (PUR 16ga ) P46 J46 86
SH12:L-4 11L-008-CC3 (YEL 18ga ) 2 2B 48C-000-AA1 (ORG 18ga ) 1 85 1 0-016-AA2 (BLK 16ga ) SH11:N-9
1 1 54 54 J1 J2 12 12
48A-000-CC3 (YEL 18ga ) 48A-001-AC3 (YEL 16ga ) 48A-002-AA1 (YEL 18ga ) 48A-003-AR2 (YEL 16ga )
6 6 TB26
5B J46 P46 LEFT DECK LAMPS
5 11DSL-000-AA1 (RED 12ga ) 1 88 88A 1
48-000-AA1 (DBL 8ga ) 1 T1 T2 1
4 4 J03 P03 VEC-89
F10 1 LAMP LH DIAGONAL LADDER
V2
10 10 11 BUSS 12G 58E-06-04150
SH17:D-2 0-320-CC3 (BLK 18ga ) 8 8 G
20 47 47 11 11 1
VEC89-P12 48-003-AA1 (DBL 14ga ) 48-011-AJ1 (DBL 14ga ) 48-012-JL1 (DBL 14ga )
P21 P21
58F-06-60810 58E-06-02042 48 48 12 12 2
SH6:G-18 0-163-AA1 (BLK 14ga ) 0-170-AJ1 (BLK 14ga ) 0-171-JL1 (BLK 14ga )
LDLLT_CP
XA5780
LAMP LH DECK (OPT)
48-004-AA1 (DBL 14ga ) 49 49 48-013-AJ1 (DBL 14ga ) 13 13 48-014-JL1 (DBL 14ga ) 1
SH6:G-18 0-162-AA1 (BLK 14ga ) 50 50 0-172-AJ1 (BLK 14ga ) 14 14 0-173-JL1 (BLK 14ga ) 2
LDLT_CP
XA5780
J542 P542
J12 P12
LAMP CONTROL CABINET WORK LIGHT #1

SP150
48-005-AA1 (DBL 14ga ) 16 16 48-015-AJ2 (DBL 14ga ) 1 1 48-016-JT1 (DBL 14ga ) 48-017-JT1 (DBL 14ga ) 1
SP151
SH6:G-18 0-161-AA1 (BLK 14ga ) 17 17 0-174-AJ2 (BLK 14ga ) 2 2 0-175-JT1 (BLK 14ga ) 0-478-JT1 (BLK 14ga ) 2
P565 J565 CDL1

XA5780
J14 P14 LAMP CONTROL CABINET WORK LIGHT #2
48-018-JT1 (DBL 14ga ) 1
0-155-JT1 (BLK 14ga ) 2
CDL2
XA5780
VEC-89
F 11F
SH11:J-4 41TS-005-AA1 (DGR 18ga )
FRONT TURN / CLEARANCE LAMPS / HAZARD SWITCH VEC89-P11
0 BUSS
F8
85 86
11 BUSS 87 TB35
15 30 11G G 41T-000-AA1 (TAN 14ga ) E1 E2
87a LAMP MARKER/TURN LEFT SIDE DECK
VEC89-P11 E4
SP144
MARKER LAMP A C
RELAY 8 45LL-004-GG1 (BRN 16ga ) 45LL-009-GG1 (BRN 16ga )
45LL-001-AA1 (BRN 16ga ) 1 1 45LL-002-AJ1 (BRN 16ga ) 1 1 45LL-003-GJ1 (BRN 16ga ) A A AMB
SP143 LCL1
0 BUSS
41T-001-AA1 (TAN 16ga ) 2 2 41T-003-AJ1 (TAN 16ga ) 2 2 41T-004-GJ1 (TAN 16ga ) B B 41T-005-GG1 (TAN 16ga ) 41T-006-GG1 (TAN 16ga ) B
AMB
F11 3 3 3 3 C C
PWR SH6:H-21 0-134-AA1 (BLK 16ga ) 0-476-AJ1 (BLK 16ga ) 0-477-GJ1 (BLK 16ga ) 0-138-GG1 (BLK 16ga ) LCL1 58D-06-00830
11 BUSS
15 GND SP142
LOAD 0-139-GG1 (BLK 16ga )
SWITCH COMBO TB22 J12 P12 J540 P540 P503 J503 LAMP MARKER/TURN LEFT FRT DECK
TURN SW SP035
9 45L-000-CC3 (DGR 16ga ) 45L-001-CC3 (DGR 18ga ) 17 17 45L-003-AC3 (DGR 16ga ) 1 P1 P2 1 SH17:H-21 0-363-GG1 (BLK 16ga )
56 56 10
FLASHER A C
712T-002-CC3 (BRN 16ga ) SP036 RELAY 13 45LL-010-GG1 (BRN 16ga )
11 45R-000-CC3 (LBL 16ga ) 45R-001-CC3 (LBL 18ga ) 19 19 45R-003-AC3 (LBL 16ga ) 1 R1 R2 1 AMB
12D
45L-004-AA1 (DGR 16ga ) D LCL2
P121 PC1709 B
P03 J03 P121 J03 P03 41T-007-GG1 (TAN 16ga )
0 BUSS 85 86
AMB
45R-002-CC3 (LBL 18ga ) LCL2 58D-06-00830
VEC-91 87 TB35 12 12 B
TB23 D13 F52 D4 30 12C 41T-013-AA1 (TAN 16ga ) 41T-014-AJ2 (TAN 16ga ) OPTIONAL
C 45LL-000-AA1 (BRN 14ga ) J1 J2 0-140-GG1 (BLK 16ga )
1 H 11H
712 BUSS
1 2
87a
24 24 A
LEFT SIDE
712T-001-AC3 (BRN 16ga ) R1 R2 712T-000-AA1 (BRN 16ga ) 45L-002-CC3 (DGR 18ga ) 45LR-002-CC3 (LTG 18ga ) 45LL-007-AA1 (BRN 16ga ) 45LL-011-AJ2 (BRN 16ga )
5 MARKER/
VEC91-P11 LEFT TURN SH11:E-12 45LL-006-AC1 (BRN 16ga ) J3 J4
PC2834
SH6:G-18 0-147-AA1 (BLK 16ga ) 1 1 0-149-AJ2 (BLK 16ga ) C TURN
F35 RELAY 11
3A 11 BUSS 12B P732_CP
11L-000-AA1 (YEL 14ga ) A 45R-004-AA1 (LBL 16ga ) B
15
VEC91-P3 0 BUSS 85 86 J14 P14 LAMP MARKER/TURN RIGHT FRT DECK
SWITCH HAZARD LIGHTS VEC89-P12
58E-06-20061
9 9 87 TB35 SP145
SH17:D-2 0-318-CC3 (BLK 18ga ) 7 7 45RL-004-FF1 (DBL 16ga ) 45RL-007-FF1 (DBL 16ga ) A C
30 12A
SH11:J-11 11L-010-CC3 (YEL 18ga ) A 45RL-000-AA1 (DBL 14ga ) K1 K2 45RL-001-AA1 (DBL 16ga ) 1 1 45RL-002-AH1 (DBL 16ga ) 1 1 45RL-003-FH1 (DBL 16ga ) A A AMB
3 3 87a
SH17:D-2 11L-003-CC3 (YEL 14ga ) SP146 RCL1
SH12:F-2 11L-008-CC3 (YEL 18ga ) 11L-009-CC3 (YEL 16ga ) 2 2B VEC89-P12 SH11:E-12 45RL-006-AC1 (DBL 16ga ) K3 K4 41T-002-AA1 (TAN 16ga ) 2 2 41T-008-AH1 (TAN 16ga ) 2 2 41T-009-FH1 (TAN 16ga ) B B 41T-010-FF1 (TAN 16ga ) 41T-011-FF1 (TAN 16ga ) B
TB22 1 1 RIGHT TURN
SP248 AMB
RELAY 12
1 C1 C2 1 11L-001-AC3 (YEL 14ga ) 9 9 11L-002-CC3 (YEL 14ga ) SH6:F-21 0-135-AA1 (BLK 16ga ) 3 3 0-141-AH1 (BLK 16ga ) 3 3 0-142-FH1 (BLK 16ga ) C C 0-143-FF1 (BLK 16ga ) RCL1 58D-06-00830
6 6 58E-06-02042
5B SP147
1 C3 11L-006-CC3 (YEL 18ga ) 5 0-144-FF1 (BLK 16ga )
4 4
P03 J03 J11 P11 J541 P541 P502 J502 LAMP MARKER/TURN RIGHT SIDE DECK
8 8 10 10
SH15:N-9 0-136-CC3 (BLK 18ga )
SH17:F-21 0-364-FF1 (BLK 16ga ) 45RL-009-FF1 (DBL 16ga ) A C
P33 P33 AMB
58F-06-60900
RCL2
LAMP CAB DOME DRIVER 41T-012-FF1 (TAN 16ga ) B
SH6:H-18 0-146-AA1 (BLK 16ga ) 14 14 0-156-AH2 (BLK 16ga ) C AMB
DOOR (-)
SP281
OPTIONAL RCL2 58D-06-00830
+ OFF
0DL-000-CC4 (GRY 18ga ) SP149
2 2 15 15 B RIGHT SIDE
11L-007-AC4 (YEL 16ga ) 11L-005-CC4 (YEL 18ga ) 11L-011-CC4 (YEL 18ga ) CDL1(D) 41T-015-AA1 (TAN 16ga ) 41T-016-AH2 (TAN 16ga ) 41T-017-AH2 (TAN 16ga )
GB12 MARKER/
CDL1(+) ON (-) 0-176-CC4 (BLK 18ga ) SP148 0-145-FF1 (BLK 16ga )
1 C2 45RL-008-AA1 (DBL 16ga ) 19 19 A TURN
P04 J04_CP CDL1(-) 45RL-010-AH2 (DBL 16ga ) 45RL-011-AH2 (DBL 16ga )
58E-06-11640 P731_CP
45LL-008-AA1 (BRN 16ga ) 18 18
41T-018-AH2 (TAN 16ga ) SH14:F-8 TO REAR AXLE

TURN /
J16 P16
LAMP CAB DOME CENTER LH 45RL-012-AH2 (DBL 16ga ) SH14:G-12 CLEARANCE
DOOR (-) LIGHTING
+ 0DL-001-CC4 (GRY 18ga ) 45LL-012-AH2 (BRN 16ga ) SH14:J-12
OFF
11L-012-CC4 (YEL 18ga ) CDL2(D)
CDL2(+) ON (-) 0-316-CC4 (BLK 18ga )
CDL2(-) SWITCH DOOR PIN (DPSW2)
58E-06-11640
1 2
0DL-005-CC4 (GRY 14ga ) 3 3 0DL-006-CC10 (GRY 14ga ) 0-897-CC10 (BLK 14ga ) 4 4 0-899-CC4 (BLK 14ga )
LAMP CAB DOME CENTER RH P51 J51 J51 P51

DOOR (-) SP294 SWITCH DOOR PIN (DPSW1) GB12
+ OFF
0DL-002-CC4 (GRY 18ga ) 1 2
3 3 4 4 1 C3
11L-013-CC4 (YEL 18ga ) CDL3(D) 0DL-004-CC4 (GRY 14ga ) 0DL-007-CC9 (GRY 14ga ) 0-359-CC9 (BLK 14ga ) 0-898-CC4 (BLK 14ga )
CDL3(+) ON (-) 0-360-CC4 (BLK 18ga )
CDL3(-)
58E-06-11640
P50 J50 J50 P50
58B-06-02390-00 APR 16
LAMP CAB DOME PASSENGER
DOOR (-)
0DL-003-CC4 (GRY 18ga )
980E-5
+ OFF
11L-014-CC4 (YEL 18ga ) CDL4(D)
CDL4(+) ON (-) 0-528-CC4 (BLK 18ga )
CDL4(-)
58E-06-11640
A50005 & UP
Sheet 12 of 27
GE CONTROL INTERFACE
P301 CONTINUITY CHECK2 y 71CNCK-000-AA3 (PNK 18ga ) GE INTERFACE AND WHEEL MOTOR SPEED SENSORS
P301 CONTINUITY CHECK1 z
TB33
15SRW-003-AA1 (RED 18ga ) 1 AHT RH WHEEL
MC242 MC242
RH FT WHEEL SP +15V Q 15SRW-002-AA3 (RED 18ga ) M1 M2 15SRW-001-AA1 (RED 18ga ) 2 SPD RESISTOR
SP728 (OPT) R56
P56_CP
L4 33RF-003-AA1 (WHT 18ga ) MC232 MC232 P501
MC239
15SRW-004-AA1 (RED 18ga ) 1 1 15SRW-005-AR1 (RED 16ga ) A +V SUPPLY
RH FT WHEEL SP SIGNAL X
MC239
33RF-002-AA3 (WHT 18ga ) L1 L2 33RF-001-AA1 (WHT 18ga )
33RF-001-AA1 (WHT 18ga ) 2 2 33RF-000-AR1 (WHT 16ga ) B SIGNAL
RH FT WHEEL SP COMM P 0RF-002-AA3 (BLK 18ga ) K1 K2 0RF-001-AA1 (BLK 18ga )
0RF-001-AA1 (BLK 18ga ) 3 3 0RF-000-AR1 (BLK 16ga ) C GROUND
RH FT WHEEL SP COMM 2 S 0RF-003-AA3 (BLK 18ga ) K3
4 4
SHIELD-240 SHIELD-230 SHIELD-230 D SHIELD
RH FT WHEEL SP SHIELD V J1 J2
SHIELD-245 SHIELD-245 SHIELD-240 SENSOR RIGHT FRONT WHEEL SPEED
AHT LH WHEEL
TB33
SPD RESISTOR
(OPT) R57 ENGINE AND PUMP MODULE SERVICE LAMPS
MC244 MC244
LH FT WHEEL SP +15V J 15SLW-002-AA3 (RED 18ga ) S1 S2 15SLW-001-AA1 (RED 18ga ) 15SLW-003-AA1 (RED 18ga ) 1
SP729 2
R4 33LF-003-AA1 (WHT 18ga ) P57_CP
MC238 TIMER (1HR) HYDRAULIC PUMP MOD (HPLT)
LH FT WHEEL SP SIGNAL W 33LF-002-AA3 (WHT 18ga ) R1 R2 33LF-001-AA1 (WHT 18ga ) LAMP HYD TANK SERVICE
MC238 MC234 MC234 P507
T 1 42PMS-000-AA1 (DBL 16ga ) 35 35 42PMS-001-AJ2 (DBL 16ga ) A A
LH FT WHEEL SP COMM H 0LF-002-AA3 (BLK 18ga ) P1 P2 0LF-001-AA1 (BLK 18ga ) 15SLW-005-AA1 (RED 18ga ) 5 5 15SLW-006-AR1 (RED 16ga ) A +V SUPPLY
42PML-003-FG2 (ORG 14ga ) 1
LH FT WHEEL SP COMM 2 L 0LF-003-AA3 (BLK 18ga ) P3 33LF-001-AA1 (WHT 18ga ) 6 6 33LF-000-AR1 (WHT 16ga ) B SIGNAL 1 42PML-000-AA1 (ORG 14ga ) 33 33 42PML-001-AJ2 (ORG 14ga ) B B B 42PML-002-FG2 (ORG 14ga ) 0-632-FG2 (BLK 14ga ) 2
11SL-002-AA1 (DBL 14ga ) 1 SP712
LH FT WHEEL SP SHIELD O N1 N2 0LF-001-AA1 (BLK 18ga ) 7 7 0LF-000-AR1 (BLK 16ga ) C GROUND HSL
LAMP FUEL TANK SERVICE
8 8 PC2644
SENSOR GE ALTERNATOR SPEED SHIELD-239 SHIELD-233 SHIELD-233 D SHIELD
TB33 SENSOR LEFT FRONT WHEEL SPEED 42PML-004-FG2 (ORG 14ga ) 1
MC250 MC250 MC252 MC252 J13 P13
ENG SP REF PASS MAG PICK-UP s 74X-002-AA3 (WHT 18ga ) T1 T2 74X-001-SS1 (WHT 16ga ) B REF VEC-91
SH6:G-18 0-270-AA1 (BLK 14ga ) 25 25 0-483-AJ2 (BLK 14ga ) C C C 0-631-FG2 (BLK 14ga ) 0-633-FG2 (BLK 14ga ) 2
F34 TB24
SP713
ENG SP COMM x 74Z-002-AA3 (BLK 18ga ) W1 W2 74Z-001-SS1 (BLK 16ga ) A COM 11 BUSS 4D D P563_CP J563_CP J563 FSL
11SL-000-AA1 (DBL 14ga ) 1 A1
15
ENG SP SHIELD w V1 V2 G SHIELD J14 P14
SHIELD-257 SHIELD-257 SHIELD-260 SHIELD-260 VEC91-P4
ALTSP 58E-06-20061
11SL-001-AA1 (DBL 14ga ) SWITCH LEFT ENGINE SWITCH RIGHT ENGINE
TIMER (1HR) ENGINE SERVICE LAMP SERVICE LAMP (LESLS) SERVICE LAMP (RESLS)
(ESLT) 2 2
42A-001-AJ1 (LTG 16ga ) 19 19 42A-002-AA1 (LTG 16ga ) 19 19 42A-003-AH1 (LTG 16ga )
DIG OUT (EXT RETARD LIGHT) t 74ZA-000-AA3 (DGR 18ga ) SH14:H-2 3 1 1
T 1 42SL-000-AA1 (ORG 16ga ) 22 22 42SL-001-AJ1 (ORG 16ga ) 3 3
42B-001-AJ1 (BRN 16ga ) 20 20 42B-002-AA1 (BRN 16ga ) 20 20 42B-003-AH1 (BRN 16ga )
SENSOR LEFT REAR WHEEL SPEED
TB29
MC228 MC228 MC217 MC217 MC205 MC205 NO 1 VA2828 VA2828
LH RR WHEEL SP +15V B 1 1 A A J12 P12
77P-003-AA3 (RED 18ga ) TW1 A1 A2 77P-002-AA1 (RED 18ga ) TW1 77P-004-AD1 (RED 18ga ) TW1 1 C
NC P12 J12 J11 P11
LH RR WHEEL SP COMM A 77G-003-AA3 (BLK 18ga ) TW1 B1 B2 77G-001-AA1 (BLK 18ga ) TW1 2 2 77G-000-AD1 (BLK 18ga ) TW1 B B
PC2644
LH RR WHEEL SP SIGNAL +V2 C 77C-003-AA3 (WHT 18ga ) TW2 C1 C2 77C-001-AA1 (WHT 18ga ) TW2 3 3 77C-000-AD1 (WHT 18ga ) TW2 C C
LH RR WHEEL SP SIGNAL -V2 D 77DP-003-AA3 (BLK 18ga ) TW2 D1 D2 77DP-001-AA1 (BLK 18ga ) TW2 4 4 77DP-000-AD1 (BLK 18ga ) TW2 F F
LH RR WHEEL SP SIGNAL +V1 E 77B-003-AA3 (GRN 18ga ) TW3 E1 E2 77B-001-AA1 (GRN 18ga ) TW3 5 5 77B-000-AD1 (GRN 18ga ) TW3 G G
LH RR WHEEL SP SIGNAL -V1 F 77DN-003-AA3 (BLK 18ga ) TW3 F1 F2 77DN-001-AA1 (BLK 18ga ) TW3 6 6 77DN-000-AD1 (BLK 18ga ) TW3 D D
SHIELD-217 SHIELD-211 SP767
SHIELD-227 SP766 7 7
SP768 SHIELD-211 E E
G1 G2 TB35
SHIELD-227 SHIELD-217
LH RR WHEEL SP SHIELD G SHIELD-002-AD1 (BLK 18ga ) SHIELD-003-AD1 (BLK 18ga )
SHIELD-008-AA3 (BLK 18ga ) SHIELD-006-AA1 (BLK 18ga ) P721 42-000-AA2 (BRN 12ga ) M1 M2 42-001-AA1 (BRN 14ga ) 0-288-AH1 (BLK 16ga )
SP742
MC221 42-002-AA1 (BRN 14ga )
42-008-AA1 (BRN 14ga ) M3
SENSOR RIGHT REAR WHEEL SPEED 42-007-AA1 (BRN 14ga )

MC221 TB29 LAMP LEFT UPPER LAMP RIGHT UPPER
MC213 MC209 MC209
RH RR WHEEL SP +15V k H1 H2 714P-001-AA1 (RED 18ga ) TW1 13 13 714P-002-AD1 (RED 18ga ) TW1 A A ENGINE SERVICE ENGINE SERVICE
714P-003-AA3 (RED 18ga ) TW1
RH RR WHEEL SP COMM j 714G-003-AA3 (BLK 18ga ) TW1 J1 J2 714G-001-AA1 (BLK 18ga ) TW1 14 14 714G-000-AD1 (BLK 18ga ) TW1 B B
1 42-012-GJ1 (BRN 14ga ) 15 15 42-009-AJ1 (BRN 14ga ) 15 15 15 15 42-003-AH1 (BRN 14ga ) 15 15 42-006-FH1 (BRN 14ga ) 1
RH RR WHEEL SP SIGNAL +V2 m 714A-003-AA3 (WHT 18ga ) TW2 K1 K2 714A-001-AA1 (WHT 18ga ) TW2 15 15 714A-000-AD1 (WHT 18ga ) TW2 C C
2 0-277-GJ1 (BLK 14ga ) 16 16 0-276-AJ1 (BLK 14ga ) 16 16 0-426-AA1 (BLK 14ga ) SH6:H-21 SH6:F-21 0-421-AA1 (BLK 14ga ) 16 16 0-282-AH1 (BLK 14ga ) 16 16 0-283-FH1 (BLK 14ga ) 2
RH RR WHEEL SP -V2 n 16 16 F F LUESL RUESL

714DP-003-AA3 (BLK 18ga ) TW2 L1 L2 714DP-001-AA1 (BLK 18ga ) TW2 714DP-000-AD1 (BLK 18ga ) TW2 XA5780 XA5780
RH RR WHEEL SP +V1 p 714B-003-AA3 (GRN 18ga ) TW3 M1 M2 714B-001-AA1 (GRN 18ga ) TW3 17 17 714B-000-AD1 (GRN 18ga ) TW3 G G LAMP LEFT LOWER LAMP RIGHT LOWER
ENGINE SERVICE ENGINE SERVICE
RH RR WHEEL SP -V1 q 714DN-003-AA3 (BLK 18ga ) TW3 N1 N2 714DN-001-AA1 (BLK 18ga ) TW3 18 18 714DN-000-AD1 (BLK 18ga ) TW3 D D
SP765 SP769 SP770 1 42-011-GJ1 (BRN 14ga ) 17 17 42-010-AJ1 (BRN 14ga ) 17 17 17 17 42-004-AH1 (BRN 14ga ) 17 17 42-005-FH1 (BRN 14ga ) 1
SHIELD-223 P1 P2 19 19 E E
SHIELD-213
RH RR WHEEL SP SHIELD r SHIELD-007-AA3 (BLK 18ga ) SHIELD-005-AA1 (BLK 18ga ) SHIELD-012-AD1 (BLK 18ga ) SHIELD-004-AD1 (BLK 18ga ) P720 2 0-280-GJ1 (BLK 14ga ) 18 18 0-279-AJ1 (BLK 14ga ) 18 18 0-424-AA1 (BLK 14ga ) SH6:F-18 SH6:G-21 0-420-AA1 (BLK 14ga ) 18 18 0-285-AH1 (BLK 14ga ) 0-286-AH1 (BLK 14ga ) 18 18 0-287-FH1 (BLK 14ga ) 2
SP741 J15 P15 SP165
LLESL RLESL
P301 XA5780 XA5780
P540 J540 P12 J12 J11 P11 J541 P541
TB33
MC246 MC246
BUFFERED RH RR SP SIG POS Q 714Z-000-AA3 (WHT 18ga ) C1
BUFFERED RH RR SP SIG RET R 714Y-000-AA3 (BLK 18ga ) D1
MC248 MC248
BUFFERED LH RR SP SIG RET X 77Y-000-AA3 (BLK 18ga ) E1
BUFFERED LH RR SP SIG POS W 77Z-000-AA3 (WHT 18ga ) F1
SHIELD-251
SHIELD-252 SP025 SHIELD-252
H1
EB7418
BUFFERED RR SP SIG SHIELD Y SHIELD-019-AA3 (BLK 18ga ) G1
SHIELD-251
TB31
SHIELD-253 1
A1
MC249 MC249
BUFFERED LH FT SP SIG RET S 0BLF-000-AA3 (BLK 20ga ) 1 B1
BUFFERED LH FT SP SIG POS V 33BLF-000-AA3 (WHT 20ga ) 1 C1
MC251 MC251
BUFFERED RH FT SP SIG POS T 33BRF-000-AA3 (WHT 20ga ) 1 J1
BUFFERED RH FT SP SIG RET P 0BRF-000-AA3 (BLK 20ga ) 1 K1
SHIELD-253 1 L1
71P-005-AA1 (BRN 16ga ) SH15:B-5
BUFFERED FT SP SIG SHIELD U SHIELD-992-AA3 (BLK 18ga ) SP026
TB23
VEC-89
SH13:K-12 71P-017-AC3 (BRN 16ga ) J1 J2
F45
2E 71CK BUSS
10 10 71P-001-AC2 (BRN 14ga ) J3 J4 71P-000-AA1 (BRN 14ga ) E
15
J02 P02 VEC89-P2

58E-06-02042
71P-003-CC2 (BRN 20ga ) SH10:H-17

71P-006-CC2 (BRN 14ga ) 71P-020-CC2 (BRN 18ga ) SH19:K-5
SP366
P305 CONN INSTALL CHECK z SWITCH
DATA STORE
P305 (DSSW)
P304 CONN INSTALL CHECK z

TB21
71CN1-000-AA3 (PNK 18ga ) NC
RESET/BODY UP OVERRIDE h 11 11 C 1
71H-000-AA3 (LBL 18ga ) R1 R2 71H-001-AC2 (LBL 16ga ) 71H-002-CC2 (LBL 20ga ) SH10:H-17 71P-002-CC2 (BRN 16ga )
NO
STORE DATA J 73DS-000-AA3 (TAN 18ga ) S1 S2 73DS-001-AC2 (TAN 16ga ) 12 12 73DS-002-CC2 (TAN 16ga ) 1
SWITCH SPEED CONTROL ROCKER
PB8624
S4 73DS-003-AC3 (TAN 16ga ) SH15:H-14 P02 J02
9 9 7 7
0-052-CC3 (BLK 16ga ) SH11:B-9
TB31
CRUISE CONTROL ON (+24V) P 31RR-002-AA3 (LTG 18ga ) 1 E1 E2 1 31RR-001-AC3 (LTG 16ga ) 40 40 31RR-000-CC3 (LTG 16ga ) 3 3 71P-004-CC3 (BRN 16ga ) SH15:L-9
2B 2 7 7
71P-016-CC3 (BRN 16ga ) 71P-017-AC3 (BRN 16ga ) SH13:I-8
SYSTEM BUSY Z 74SB1-005-AA3 (DBL 18ga ) SH21:J-17 1 1
P03 J03
TB31 J03 P03
P304 6 6
5B
1 5
MC263 SHIELD-276
H3
SPEED CONTROL REF + D 32RS-006-AA3 (RED 18ga ) 4 4
SPEED CONTROL REF - E SHIELD-275 1 H1 H2 1 SHIELD-274
32OR-006-AA3 (BLK 18ga )
MC263 10 10 8 8
0-151-CC3 (BLK 16ga ) SH15:L-9
P305
1 M3
SPEED CONTROL SHIELD J SHIELD-275
P29 P29
SPEED CONTROL SIGNAL + A 1 1 58F-06-60960
32RS-005-AA3 (RED 18ga ) M1 M2 32RS-002-AC1 (RED 18ga ) SWITCH SPEED CONTROL MODULE
32OR-002-AA3 (LTG 18ga ) 1 G3

SET
SPEED CONTROL SIGNAL - K 32OR-005-AA3 (BLK 18ga ) 1 G1 G2 1 32OR-003-AC1 (BLK 18ga )
MC262 MC262
P303 R21
32RR-000-AA3 (LTG 18ga ) 1 F1 F2 1 32RR-001-AC1 (WHT 18ga ) 18 18 CANCEL
SHIELD-274 SHIELD-256 MC256
1 2 MC261 32RS-002-AC1 (RED 18ga ) 15 15 32RS-003-CC1 (RED 18ga ) A EP
2 KΩ 1W 16 16
32OR-003-AC1 (BLK 18ga ) 32OR-004-CC1 (BLK 18ga )
17 17 220.0
58B-06-00280 32RR-001-AC1 (WHT 18ga ) 32RR-002-CC1 (WHT 18ga ) DOWN
MC261 MC256
ACCEL/RETARD POT SUPPLY 1 G TB31
10V-001-AA3 (RED 18ga ) 130.0
ACCEL/RETARD POT SUPPLY 2 H 10V-002-AA3 (RED 18ga ) 1 N1 N3 1 10V-008-AC1 (RED 18ga ) UP
N2 1 10V-009-AC1 (RED 18ga ) 68.0

TB31 CCS
ACCEL/RETARD POT RETURN 1 F 0ACL-004-AA3 (BLK 18ga ) C
ACCEL/RETARD POT RETURN 2 J 0ACL-005-AA3 (BLK 18ga ) 1 W3 W2 1 0ACL-001-AC1 (BLK 18ga )
B CMS
P305
V2 1 0RET-001-AC1 (BLK 18ga )
GB31-A P022
58E-06-60200
V4 1 0-546-AA2 (BLK 18ga ) 1 D4
10 10
MC269 MC269 SHIELD-286 SHIELD-282 ACCELERATOR PEDAL
ACCEL PEDAL COMMON y 1 W1 W4
0ACL-003-AA3 (BLK 18ga ) MC266
EB7418 10V-008-AC1 (RED 18ga ) 7 7 10V-000-CC1 (RED 18ga ) A A C +VDC SUPPLY
1 V1 V3
0ACL-001-AC1 (BLK 18ga ) 9 9 0ACL-002-CC1 (BLK 18ga ) C C A GROUND

TB31
ACCEL PEDAL SIGNAL t 525A-000-AA3 (WHT 18ga ) 525A-001-AA3 (WHT 18ga ) 525-002-AA3 (WHT 18ga ) 1 T1 T2 1 525-001-AC1 (WHT 18ga ) 8 8 525-000-CC1 (WHT 18ga ) B B B PEDAL SIGNAL
SP738 MC266 MC265
J701
P236 J236 58F-06-20390

ACCEL SHIELD u 1 S1 S2 1
SHIELD-295 AHT SHIELD-286
4
AUXBOX CONNECTOR
4
P701
P304 (OPT)
14 14
SHIELD-295 SHIELD-287 SHIELD-281 RETARD CONTROL PEDAL
MC267
RETARD PEDAL SHIELD W 10V-009-AC1 (RED 18ga ) 11 11 10V-004-CC1 (RED 18ga ) C +VDC SUPPLY
SHIELD-296
MC270
RETARD PEDAL COMMON V 0RET-002-AA3 (BLK 18ga ) 0RET-001-AC1 (BLK 18ga ) 13 13 0RET-008-CC1 (BLK 18ga ) A GROUND
TB31
RETARD PEDAL SIG P 74NA-000-AA3 (WHT 18ga ) 74NA-001-AA3 (WHT 18ga ) 74N-002-AA3 (WHT 16ga ) 1 R1 R2 1 74N-001-AC1 (WHT 18ga ) 12 12 74N-000-CC1 (WHT 18ga ) B PEDAL SIGNAL
SP739 MC267 MC264
J701
MC270 P235
AHT 1 P1 P2 1 58F-61-00000
SHIELD-287
6
AUXBOX CONNECTOR
(OPT) P01 J01
58B-06-02390-00 APR 16
6
P701
SHIELD-296 ELECTRICAL SCHEMATIC

P302 CONN INSTALL CHECK Z
P302 980E-5
P303 CONN INSTALL CHECK Z 71CN2-000-AA3 (PNK 18ga )
A50005 & UP
P303
Sheet 13 of 27
SP344 SH14:D-17
BACKUP LAMPS
0-251-DD2 (BLK 16ga )
SH6:H-18 0-240-AA1 (BLK 14ga ) 1 1 0-243-AH2 (BLK 14ga ) 6 6 0-694-DD2 (BLK 14ga ) 0-252-DD2 (BLK 16ga ) SH14:E-17
0-248-DD2 (BLK 16ga ) SH14:D-20
0-249-DD2 (BLK 16ga ) SH14:C-20
SWITCH MANUAL BACKUP LIGHT SP347
SH6:H-18 0-241-AA1 (BLK 14ga ) 2 2 0-244-AH2 (BLK 14ga ) 7 7 0-698-DD2 (BLK 16ga ) 0-265-DD2 (BLK 16ga ) SH14:F-16
9 9 7 7
0-268-CC3 (BLK 18ga ) SH12:C-3 0-264-DD2 (BLK 16ga ) SH14:E-16
TB22
47S-002-AA1 (LBL 16ga ) 1 T2 T1 1 47S-001-AC3 (LBL 16ga ) 51 51 47S-000-CC3 (LBL 16ga ) 3 3

2B 2
712K-004-CC3 (LBL 16ga ) SH5:E-11 SP076 0-289-AH2 (BLK 14ga ) SH16:L-21 SP350
1 1 SH6:H-18 0-242-AA1 (BLK 14ga ) 3 3 0-245-AH2 (BLK 14ga ) 0-680-AH2 (BLK 14ga ) 8 8 0-311-DD2 (BLK 14ga ) 0-254-DD2 (BLK 16ga ) SH14:I-13
P03 J03
0-300-AH2 (BLK 16ga ) SH14:H-12 0-253-DD2 (BLK 16ga ) SH14:I-13
6 6 0-301-AH2 (BLK 16ga ) SH14:J-12
5B
5
4 4 HORN BACKUP LEFT
10 10 8 8
0-056-CC3 (BLK 18ga ) SH12:F-2
79A-003-DD2 (DBL 16ga ) 1 - 1 0-249-DD2 (BLK 16ga ) SH14:B-18
+
P22 P22 SP343 LRBH-(+) LRBH-(-)
VEC-89 58F-06-60820 29 29 4 4
79A-000-AA1 (DBL 14ga ) 79A-001-AH2 (DBL 14ga ) 79A-004-DD2 (DBL 16ga )
B
11B
SH10:F-11 72RA-002-AA1 (YEL 18ga ) HORN BACKUP RIGHT
0 BUSS 85 86
F3 1 1
79A-002-DD2 (DBL 16ga ) - 0-248-DD2 (BLK 16ga ) SH14:B-18
+
11 BUSS 87
15 30 11C RRBH-(+) RRBH-(-)
C
87a
D14
11D RELAY BACKUP LIGHT LAMP BACKUP RIGHT REAR
BACKUP HORN D 47A-000-AA1 (PNK 16ga ) (BULR) TB35
RELAY 3
D15 86 85 SP346
VEC89-P11 1 1 0-157-AA2 (BLK 16ga ) SH11:O-9 47-000-AA2 (GRY 10ga ) L1 L2 47-002-AA1 (GRY 14ga ) 13 13 47-004-AH2 (GRY 14ga ) 5 5 47-016-DD2 (GRY 16ga ) 47-006-DD2 (GRY 16ga ) 1
11E
47S-002-AA1 (LBL 16ga ) E
47-008-AA1 (GRY 14ga ) L3 SH14:B-18 0-251-DD2 (BLK 16ga ) 2
F2
VEC89-P11 9C J16 P16 P73 J73 HIDBLR
11 BUSS
C 47B-000-AA1 (TAN 10ga ) 1 88 88A 1
47-000-AA2 (GRY 10ga ) 47-012-AA1 (GRY 14ga ) 58D-06-10350
25
VEC89-P9 LAMP BACKUP LEFT REAR
LAMP BACKUP RIGHT 58E-06-02042 58E-06-04150
DECK (OPT) 1
47-007-DD2 (GRY 16ga )
1 47-011-FF1 (GRY 14ga ) H H 47-010-FH1 (GRY 14ga ) 8 8 47-009-AH1 (GRY 14ga ) 8 8 47-008-AA1 (GRY 14ga ) SH14:B-18 0-252-DD2 (BLK 16ga ) 2
HIDBLL
2 0-258-FF1 (BLK 14ga ) J J 0-257-FH1 (BLK 14ga ) 9 9 0-256-AH1 (BLK 14ga ) 9 9 0-255-AA1 (BLK 14ga ) SH6:F-21 58D-06-10350
RBUL_CP
XA6208
LAMP STOP/TAIL LEFT
J502 P502 P541 J541 P11 J11
A C
44-004-DD2 (GRY 16ga ) A C 0-264-DD2 (BLK 16ga ) SH14:B-18
RED
LAMP BACKUP LEFT DECK
LRSTL
(OPT) B
B
41T-019-DD2 (TAN 16ga )
RED
1 H H 8 8 8 8 47-012-AA1 (GRY 14ga ) LRSTL 58D-06-00820
47-015-GG1 (GRY 14ga ) 47-014-GJ1 (GRY 14ga ) 47-013-AJ1 (GRY 14ga ) SP345
41T-035-AH2 (TAN 16ga ) 3 3 41T-029-DD2 (TAN 16ga )
2 0-259-GG1 (BLK 14ga ) J J 0-261-GJ1 (BLK 14ga ) 9 9 0-262-AJ1 (BLK 14ga ) 9 9 0-263-AA1 (BLK 14ga ) SH6:H-21 LAMP STOP/TAIL RIGHT
LBUL_CP P73 J73
XA6208
SP348 A C
44-007-DD2 (GRY 16ga ) 44-005-DD2 (GRY 16ga ) A C 0-265-DD2 (BLK 16ga ) SH14:B-18
J503 P503 P540 J540 P12 J12
RED
B
RRSTL
41T-020-DD2 (TAN 16ga ) B
SP220
SH12:N-19 41T-018-AH2 (TAN 16ga ) 41T-022-AH2 (TAN 16ga ) RED
41T-021-AH2 (TAN 16ga ) RRSTL 58D-06-00820
LAMP BODY RIGHT SIDE TURN
VEC-89 A
A C
C
11H 45RL-017-MM1 (DBL 16ga )
SH10:G-7 44R-003-AA1 (GRY 18ga ) H AMB
RSTL
0 BUSS 85 86 B
VEC89-P11 SH12:N-19 45RL-012-AH2 (DBL 16ga ) A A 45RL-017-MM1 (DBL 16ga ) B
TB35
AMB
F9 87 12E E 16 16 1 1 B B RSTL
11 BUSS 44-000-AA1 (GRY 14ga ) G1 G2 44-001-AA1 (GRY 14ga ) 44-003-AH2 (GRY 14ga ) 44-007-DD2 (GRY 16ga ) 41T-022-AH2 (TAN 16ga ) 41T-036-MM1 (TAN 16ga ) 58D-06-00830
30
10 87a C C
74ZA-000-AA3 (DGR 18ga ) SH13:D-3 VEC89-P12 G4
J73 SH14:C-13 0-300-AH2 (BLK 16ga ) 0-460-MM1 (BLK 16ga ) 0-463-MM1 (BLK 16ga )
P73
J16 P16 P55 J55 LAMP BODY RIGHT SIDE MARKER
SERVICE BRAKE
LAMP RELAY 9
TB21 LAMP RETARD LEFT REAR A C
1C
D1 D2 74ZA-001-AA1 (DGR 18ga ) C RED
A C
44D-005-DD2 (LBL 16ga ) A C SP716 RSCL1
71CK BUSS 86 85
D4 VEC89-P1 AMB 41T-030-MM1 (TAN 16ga ) B
TB35
LRL RED
F13 87 1F B
F 44D-000-AA1 (LBL 16ga ) H1 H2 44D-001-AA1 (LBL 16ga ) 17 17 44D-003-AH2 (LBL 14ga ) 2 2 44D-007-DD2 (LBL 16ga ) B RSCL1 58D-06-00820
11 BUSS 30
SP349 AMB SP717
10 87a
VEC89-P1 H4
J73 LRL 58D-06-00830 0-461-MM1 (BLK 16ga )
P73
RETARD LAMPS J16 P16 LAMP BODY RIGHT REAR MARKER
RELAY 15 LAMP RETARD RIGHT REAR
58E-06-02042 A C
A C
44D-006-DD2 (LBL 16ga ) A C RED
AMB RSCL2
RRL 41T-031-MM1 (TAN 16ga ) B
INTERFACE MODULE LAMP SERVICE BRAKE B
B RED
OP-CAB (SBL)
74ZA-002-AA1 (DGR 20ga ) Z RETARD SWITCH INPUT AMB RSCL2 58D-06-00820
RRL 58D-06-00830 0-462-MM1 (BLK 16ga )
IM3 44-002-AC4 (GRY 16ga ) 10 10 44-006-CC4 (GRY 16ga )
SH14:C-18 0-254-DD2 (BLK 16ga ) LAMP BODY LEFT SIDE TURN
GB12 0-091-CC4 (BLK 16ga ) SH14:C-18 0-253-DD2 (BLK 16ga )
E1
1 RED
0-137-CC4 (BLK 16ga ) A C
58E-06-06041 45LL-017-MM2 (BRN 16ga ) A C
LAMP RETARD OP-CAB (DRL) AMB
LSTL
B
B
44D-002-AC4 (LBL 16ga ) 5 5 44D-004-CC4 (LBL 16ga ) AMB
LSTL
58D-06-00830
SH12:N-19 45LL-012-AH2 (BRN 16ga ) A A 45LL-017-MM2 (BRN 16ga ) 0-465-MM2 (BLK 16ga )
AMB SP719
P04 J04_CP
58E-06-06051 41T-021-AH2 (TAN 16ga ) B B 41T-032-MM2 (TAN 16ga )
LAMP BODY LEFT SIDE MARKER
REAR TURN / TAIL / STOP LAMPS SH14:C-13 0-301-AH2 (BLK 16ga ) C
J54
C
P54
0-464-MM2 (BLK 16ga )
SP720 A C
RED
LSCL1
41T-033-MM2 (TAN 16ga ) B
RED
VEC-91 LSCL1 58D-06-00820
F50 TB24
712 BUSS 10C C
63-009-AA1 (PNK 14ga ) 1 R1 R2 1 63-000-AC3 (PNK 14ga ) 0-466-MM2 (BLK 16ga )
10
LAMP BODY LEFT REAR MARKER
VEC91-P10
58E-06-20061
A C
63-002-CC3 (PNK 16ga ) 63-001-CC3 (PNK 14ga ) 58 58 RED
SP030 LSCL2
JB6G B
J03 P03 41T-034-MM2 (TAN 16ga )
1 63-003-CC3 (PNK 14ga ) RED
2 63-004-CC3 (PNK 16ga ) LSCL2 58D-06-00820
3 63-005-CC3 (PNK 16ga ) 0-467-MM2 (BLK 16ga )
4 63-006-CC3 (PNK 16ga )
5 63-007-CC3 (PNK 16ga )
6 63-008-CC3 (PNK 16ga )
56B-06-11510
SWITCH HORN BUTTON
RELAY VEHICLE TB22
JB4C TIMER WASHER DELAY MOD (WADT) HORN POWER
11H-000-AA1 (DGR 16ga ) 1 B1 B2 1 50 50 5 A B
(HPR) 11H-001-AC3 (DGR 16ga ) 11H-002-CC3 (DGR 16ga )
1 63W-000-CC3 (GRY 16ga ) 63L1-002-CC3 (BRN 16ga ) 1
TIMER WIPER DELAY MOD 86 85
2 63W-001-CC3 (GRY 16ga ) 11A-011-AA1 (TAN 16ga ) 1 1 P121
P03 J03
3 63W-002-CC3 (GRY 16ga ) 63-008-CC3 (PNK 16ga ) 86 63-007-CC3 (PNK 16ga ) 2
X
4 HORN FRONT VEHICLE

3
T
63T1-000-CC3 (PUR 16ga ) 87 0-380-CC3 (BLK 16ga )

P
PC1150 1 88 88A 1 13 13 13 13 N N
11A-001-AA1 (TAN 12ga ) 11HS-000-AA1 (DBL 14ga ) 11HS-001-AJ1 (DBL 14ga ) 11HS-002-GJ1 (DBL 14ga ) 11HS-003-GG1 (DBL 14ga ) 1 1
4
L
63L1-003-CC3 (BRN 16ga ) 85

P10 0-422-AA1 (BLK 14ga ) 14 14 0-290-AJ1 (BLK 14ga ) 14 14 0-291-GJ1 (BLK 14ga ) O O 0-292-GG1 (BLK 14ga ) 2 2
PC0566 5 58E-06-04150
AHS
SH6:H-21
SWITCH COMBO 63W-002-CC3 (GRY 16ga ) 6
63W-002-CC3 (GRY 16ga ) J12 P12 J540 P540 P503 J503
WASHER SW
8 7 PC1838
63-002-CC3 (PNK 16ga ) 63W-001-CC3 (GRY 16ga ) 63W-000-CC3 (GRY 16ga )
WIPER CONT
SW
P121 12 MOTOR WINDSHIELD WASHER
INT 63T1-000-CC3 (PUR 16ga )
LO 2 TB35
PARK 63L2-000-CC3 (LBL 16ga ) PUMP REAR AXLE
HI 1 63H1-000-CC3 (LTG 16ga ) 63H1-000-CC3 (LTG 16ga ) 63W-000-CC3 (GRY 16ga ) A A 63W-003-BC1 (GRY 16ga ) + - 11A-001-AA1 (TAN 12ga ) A1 A2 11A-002-AA1 (TAN 16ga ) 4 4
SERVICE LAMP
6 63P-000-CC3 (DBL 16ga )
WW+ WW- POWER
1 A3
PC1709 XA4584 J16 P16
P121 C C
D15 VEC-91 EB7418
1 B1 B4 1 11A-004-AC3 (TAN 18ga ) SH18:F-19
2 1 F33
63L2-000-CC3 (LBL 16ga ) 11 BUSS 4B
SH14:P-11 0-811-CC3 (BLK 16ga ) B B 0-377-BC1 (BLK 16ga ) B 11A-000-AA1 (TAN 12ga ) B3 B2
PC2834 15
JWW PWW
VEC91-P4
58E-06-20061
JB4H
RELAY WIPER MOTOR LOW
86
(+) (-)
85 MOTOR WINDSHIELD WIPER
11A-003-AB1 (TAN 16ga ) FRONT VEHICLE HORN
5 4 4
1 63L1-000-CC3 (BRN 16ga ) 63L-000-CC3 (DGR 16ga ) 5
SWITCH HYDRAULIC LAMP
2 63L1-001-CC3 (BRN 16ga )
(NO) 6 1
3 63L1-002-CC3 (BRN 16ga ) 87 6 MOTOR 1 C C 11A-008-BB1 (TAN 16ga ) 1 2 1 1
4 63L1-003-CC3 (BRN 16ga ) 30 (C) HLSW-2 HLSW-1
(NC) 87A SR8325
PC1150 P240 J240
63P-000-CC3 (DBL 16ga ) 2 2
P09_K PC1730 3
3 11A1-000-BB1 (LBL 16ga )
P09_K
63P-000-CC3 (DBL 16ga ) P07 LAMP HYDRAULIC CABINET #1
PB9923
P07
A
RELAY WIPER MOTOR HIGH 11A1-001-BB1 (LBL 16ga )
SP171
86
(+) (-)
85 0-378-CC3 (BLK 16ga )
0-390-CC3 (BLK 16ga )
SP363
0-315-CC3 (BLK 18ga ) SH18:I-14
SH5:I-21 0-445-BB1 (BLK 16ga )
HL1
B
PC3010
58B-06-02390-00 APR 16
30 (C)
(NO)
(NC) 87A
87 63H-000-CC3 (TAN 16ga )
LAMP HYDRAULIC CABINET #2
980E-5
0-346-CC3 (BLK 14ga )
GB12 A
P08_K PC1730 E2 0-811-CC3 (BLK 16ga ) SH14:N-8 11A1-002-BB1 (LBL 16ga )
1 0-278-CC3 (BLK 18ga ) SH18:F-15
P08_K
SH5:C-18 SH5:I-21 B
HYD CABINET LAMP

0-310-CC3 (BLK 18ga ) 0-444-BB1 (BLK 16ga )
WINDSHIELD WIPER / WASHER

B3
1 0-382-CC3 (BLK 16ga )
0-703-CC3 (BLK 14ga ) SH7:K-12
HL2 PC3010 A50005 & UP
Sheet 14 of 27
GE CONTROL INTERFACE
GE INTERFACE SWITCH TRACTION MOTOR PRESSURE
(BPSW)
NO C C
1 75A2-002-DD4 (WHT 18ga )
C
1
NC A A
1 75A1-000-DD4 (RED 18ga )
PB4673
71P-014-DD4 (BLK 18ga ) B B
TB35 J703 P703

MC122
N.O. AXLE BOX AIR PRESS SW c 75A2-000-AA3 (BRN 18ga ) V1 V2 75A2-001-AA1 (BRN 16ga ) 28 28 75A2-003-AH2 (BRN 16ga ) 1 1 75A2-004-DD1 (GRN 14ga )
SH13:I-12 71P-005-AA1 (BRN 16ga ) 26 26 71P-010-AH2 (BRN 14ga )

SP180
71P-011-AH2 (BRN 16ga ) 2 2 71P-013-DD1 (WHT 14ga ) GPS ANTENNA
KOMTRAX PLUS MODULE / ORBCOMM MODULE
P72 J72
71P-012-AH2 (BRN 16ga ) KOMTRAX PLUS MODULE
TB35 SWITCH BODY-UP PROXIMITY

3 1
DIG IN (BODY DOWN) v 71F-000-AA3 (LTG 18ga ) S1 S2 71F-001-AA1 (LTG 18ga ) 25 25 71F-004-AH2 (LTG 16ga ) 3 1
4 2
4 2
SH17:J-8 71F-002-AA4 (LTG 20ga ) S3
PC2818 MC695 MC695
J16 P16 BUSW BUSW COMM_CAN_H_1 32 939YP-010-CC3 (YEL 20ga ) SH18:C-17
P301
SH16:G-6 71F-003-AA1 (LTG 20ga ) S4 COMM_CAN_L_1 31 939GP-010-CC3 (GRN 20ga ) SH18:C-17
MC696 MC696
COMM_CAN_H_0 42 939YE-010-CC3 (YEL 20ga ) SH18:E-16
COMM_CAN_L_0 41 939GE-010-CC3 (GRN 20ga ) SH18:E-16
MC098 MC100 MC100
EN2 TX DATA+ F 94ET1-000-AA6 (W-OR 24ga ) SH15:N-16 COMM_CAN_H_2 22 939YK-006-CC3 (YEL 20ga ) SH18:H-12
EN2 TX DATA - E 94ET2-000-AA6 (ORG 24ga ) SH15:N-16 COMM_CAN_L_2 21 939GK-006-CC3 (GRN 20ga ) SH18:H-12
EN2 RX DATA+ C 94ER1-000-AA6 (W-GR 24ga ) SH15:N-16
EN2 RX DATA- B 94ER2-000-AA6 (GRN 24ga ) SH15:N-16
ETC2
F47
TB28 1B 71CK BUSS
71VHM-000-AA1 (DGR 16ga ) B
VID ETHERNET SHIELD G VID PANEL 5 VEC-90
SHIELD-133 SHIELD-133 SHIELD-134 SHIELD-134 SHIELD-135 71VHM-002-CC3 (DGR 16ga ) 10 10 71VHM-001-AC3 (DGR 16ga ) 1 B1 B2 1
EN4 TX DATA+ F 97ET1-000-AA28 (W-OR 24ga ) 6 6 97ET1-001-AC51 (W-OR 24ga ) 6 6 97ET1-002-CC24 (W-OR 24ga ) 1 TX(+) DOS_L_UPDATE 27
58E-06-20050
76-000-CC3 (LBL 18ga ) SH18:F-17 VEC90-P1
EN4 TX DATA - E 97ET2-000-AA28 (ORG 24ga ) 4 4 97ET2-001-AC51 (ORG 24ga ) 4 4 97ET2-002-CC24 (ORG 24ga ) 2 TX(-) 14 14 1 F30
85-002-CC3 (GRY 14ga ) 85-001-AC3 (GRY 14ga ) C1 C2
EN4 RX DATA+ C 97ER1-000-AA28 (W-GR 24ga ) 5 5 5 5 3 RX(+) 4G 11 BUSS
97ER1-001-AC51 (W-GR 24ga ) 97ER1-002-CC24 (W-GR 24ga ) 85-000-AA1 (GRY 14ga ) G
EN4 RX DATA- B 97ER2-000-AA28 (GRN 24ga ) 8 8 97ER2-001-AC51 (GRN 24ga ) 8 8 97ER2-002-CC24 (GRN 24ga ) 6 RX(-) 20 VEC-91
MC1080 MC1080 MC1081 MC1081 MC1082 SP187 J03 P03 58E-06-20061
PWR_CTR_KEY_1 4 71VHM-003-CC3 (DGR 18ga ) VEC91-P4
ETC4 PENET7 JENET7 JENET8 PENET8 VID_ENET
PWR_CTR_KEY_2 5 71VHM-004-CC3 (DGR 18ga )
JB8A
85-002-CC3 (GRY 14ga ) 1
VEC RTMR1 PWR_IN_BATT_1 8 85-003-CC3 (GRY 18ga ) 85-003-CC3 (GRY 18ga ) 2
FUSE - F8 85-004-CC3 (GRY 18ga ) 3
TB22
PWR_IN_BATT_2 9 85-004-CC3 (GRY 18ga ) 85-005-CC3 (GRY 18ga ) 4
SH6:F-3 11-015-AA3 (RED 16ga ) 1 C8 D8 1
11DID-000-AA3 (PNK 16ga ) 1 W1 W2 1 11DID-001-AC2 (PNK 16ga ) 1 1 11DID-002-CC2 (PNK 16ga ) 1 24VDC + 5
10A 85-006-CC3 (GRY 18ga )
RTMR1-C8 RTMR1-D8 VID(+) PWR_IN_BATT_3 18 85-005-CC3 (GRY 18ga ) 85-007-CC3 (GRY 18ga ) 6
58E-06-20110 ORBCOMM ANTENNA
P02 J02 71VHM-005-CC3 (DGR 18ga ) 85-008-CC3 (GRY 18ga ) 7
58E-65-00061 1 24VDC -
SH16:B-12 0-812-CC2 (BLK 16ga ) PWR_IN_BATT_4 19 85-008-CC3 (GRY 18ga ) 8
VID(-)
58E-06-20990 GB12 56B-06-11530
B4
0-412-CC3 (BLK 16ga ) SH15:P-6
1 0-888-CC3 (BLK 14ga ) SH7:L-12
JB8D ORBCOMM MODEM (OPT)
DID POWER SUPPLY 0-347-CC3 (BLK 14ga )
1
11DID-003-AA3 (PNK 18ga ) 7 +24VDC SUPPLY POWER GND_PWR_1 6 2 6 PWR_IN_BATT1
0-348-CC3 (BLK 18ga ) 85-007-CC3 (GRY 18ga )
GND_PWR_2 7 0-349-CC3 (BLK 18ga ) 3
SH15:N-3 0-614-AA3 (BLK 18ga ) 6 +24VDC SUPPLY GROUND GND_PWR_3 16 4 7 PWR_IN_BATT2
0-350-CC3 (BLK 18ga ) 85-006-CC3 (GRY 18ga )
GND_PWR_4 17 0-351-CC3 (BLK 18ga ) 5
15VDI-000-AA3 (WHT 18ga ) 8 OUTPUT ENABLE SIGNAL (INPUT) 6 3 POWER_CTR_KEY
71VHM-005-CC3 (DGR 18ga )
7
+15VDC GROUND RETURN KP-B
0COM-010-AA3 (BLK 18ga ) 1 8
5VDI-005-AA3 (YEL 18ga ) 10 +5VDC OUTPUT (2) 56B-06-11530 1 GROUND2

0-353-CC3 (BLK 18ga )
0-352-CC3 (BLK 18ga ) 2 GROUND1
-15VDI-003-AA3 (LTG 18ga ) 11 -15VDC OUTPUT
TB22 CNB
1 K1 K2 1 15DID-002-AA3 (BRN 18ga ) 12 +15VDC OUTPUT
58B-06-08000 DIS_HL_7 5 7KTS-000-CC3 (PUR 18ga ) 9 DOS_L_0

TB21 P500_CP
SNSR & CNTRL +15V SUPP1 G 15VDI-002-AA3 (WHT 18ga ) T1 T2
GE DID PANEL KP-A
SP280 7KTWU-001-CC3 (YEL 18ga ) SH18:F-17
SNSR & CNTRL +15V SUPP2 J 15VDI-003-AA3 (WHT 18ga ) T3 T4 1 15DID-001-AC2 (BRN 14ga ) 22 22 15DID-000-CC2 (BRN 14ga ) 6 6 PWR_CTR_EXT 3 14 PWR_CTR_EXT
7KTWU-000-CC3 (YEL 18ga ) 7KTWU-002-CC3 (YEL 18ga )
TB21
P302 KOMTRAX STARTUP 26 7MSU-000-CC3 (ORG 18ga ) 6 KOMTRAX MODEM STARTUP
1 V1 V2 -15VDI-001-AC2 (LTG 14ga ) 23 23 -15VDI-000-CC2 (LTG 14ga ) 9 9 SYS_BUSY 10
SP807 15 SYS_BUSY
74SB1-012-CC3 (DBL 18ga ) 74SB1-013-CC3 (DBL 18ga )
TB21 MC112
SNAPSHOT IN PROGRESS 29 74DS-000-CC3 (GRY 18ga ) SH16:F-3 SH18:E-14 939YE-016-CC3 (YEL 20ga ) 10 COMM_CAN_H
1 W1 W2 5VDI-001-AC2 (YEL 14ga ) 25 25 5VDI-000-CC2 (YEL 14ga ) 5 5 11 COMM_CAN_L
SH18:E-14 939GE-016-CC3 (GRN 20ga )
KP-B CNA
TB22
1 S1 S2 1 0COM-001-AC2 (BLK 14ga ) 24 24 0COM-000-CC2 (BLK 14ga ) 10 10 47 47

74SB1-011-CC3 (DBL 18ga ) 74SB1-000-AC3 (DBL 18ga ) SH21:J-17
MC279 MC279 TB25 MC277 MC277 J03 P03

MC278 DIS_HL_0 19 73DS-005-CC3 (TAN 18ga ) 12 12 73DS-003-AC3 (TAN 16ga ) SH13:K-5
DID PANEL RS232 GND H 90DIG-000-AA3 (BLK 18ga ) 1 A1 A2 1 90DIG-001-AC2 (BLK 18ga ) 32 32 90DIG-002-CC2 (BLK 18ga ) 3 3
DID PANEL RS232 RECEIVE D 31 31 2 2 KP-A J03 P03

90DIR-000-AA3 (WHT 18ga ) 1 B1 B2 1 90DIR-001-AC2 (WHT 18ga ) 90DIR-002-CC2 (WHT 18ga )
DID PANEL RS232 TRANSMIT C 90DIT-000-AA3 (RED 18ga ) 1 C1 C2 1 90DIT-001-AC2 (RED 18ga ) 30 30 90DIT-002-CC2 (RED 18ga ) 1 1
SHIELD-131 SHIELD-124 SHIELD-124 SHIELD-125
TX(+) 1 93ET1-000-CC22 (W-OR 24ga ) 1 1 93ET1-002-AC51 (W-OR 24ga ) 1 1 93ET1-001-AA22 (W-OR 24ga )
DID PANEL COMM RS232 SHIELD O 33 33 DID 58B-06-00110
SHIELD-625 1 1 SHIELD-620
D1 D2
TX(-) 3 93ET2-000-CC22 (ORG 24ga ) 3 3 93ET2-002-AC51 (ORG 24ga ) 3 3 93ET2-001-AA22 (ORG 24ga )
P02 J02
RX(+) 2 93ER1-000-CC22 (W-GR 24ga ) 2 2 93ER1-002-AC51 (W-GR 24ga ) 2 2 93ER1-001-AA22 (W-GR 24ga )
RX(-) 6 93ER2-000-CC22 (GRN 24ga ) 4 4 93ER2-002-AC51 (GRN 24ga ) 4 4 93ER2-001-AA22 (GRN 24ga )
MC096 MC093 MC093 MC121
KP-ENET JENET6 KOMTRAX ANTENNA
KOMTRAX1 JENET3
WIRELESS (OPT)
WIRELESS ACCESS
+12VDC 2 5 100-000-CC23 (W-BL 24ga ) 1 1 100-001-CG3 (W-BL 24ga ) 1 1 100-002-GG4 (W-BL 24ga ) 5 +12VDC2
+12VDC 1 4 101-000-CC23 (BLU 24ga ) 7 7 101-001-CG3 (BLU 24ga ) 7 7 101-002-GG4 (BLU 24ga ) 4 +12VDC
T3
GND 8 0-777-CC23 (BRN 24ga ) 3 3 0-779-CG3 (BRN 24ga ) 3 3 0-193-GG4 (BRN 24ga ) 8 GND
GND 2 7 0-771-CC23 (W-BR 24ga ) 2 2 0-780-CG3 (W-BR 24ga ) 2 2 0-236-GG4 (W-BR 24ga ) 7 GND2
TB25
MC280 MC280 MC286 MC286 MC2470
DSC RS232 RECEIVE V 90CAR-000-AA3 (WHT 18ga ) 1 E1 E2 1 90CAR-001-AC2 (WHT 18ga ) 57 57 90CAR-003-CC2 (WHT 20ga ) 3 TX (+) 1 6 6 6 6 1 TX(+)
90ET1-003-CC23 (W-OR 24ga ) 90ET1-002-CG3 (W-OR 24ga ) 90ET1-001-GG4 (W-OR 24ga )
GE - DSC TX (-) 2 4 4 4 4 2 TX(-)
90ET2-003-CC23 (ORG 24ga ) 90ET2-002-CG3 (ORG 24ga ) 90ET2-001-GG4 (ORG 24ga )
E3 1 90CAT-001-AC2 (RED 18ga ) 58 58 90CAT-003-CC2 (RED 20ga ) 2 DIAGNOSTIC RX (+) 3 90ER1-003-CC23 (W-GR 24ga ) 5 5 90ER1-002-CG3 (W-GR 24ga ) 5 5 90ER1-001-GG4 (W-GR 24ga ) 3 RX(+)
CONNECTOR RX (-) 6 90ER2-003-CC23 (GRN 24ga ) 8 8 90ER2-002-CG3 (GRN 24ga ) 8 8 90ER2-001-GG4 (GRN 24ga ) 6 RX(-)
DSC RS232 TRANSMIT W 1 F1 F2 1 90CAG-001-AC2 (BLK 18ga ) 56 56 5 MC600 MC599 MC599
90CAT-000-AA3 (RED 18ga ) 90CAG-003-CC2 (BLK 20ga ) MC097
J608 P608 P607 J607
1 59 59 DIAG6 CN5 KWB 58F-06-01210
F3
DSC RS232 GND d 90CAG-000-AA3 (BLK 18ga ) 1 G1 G2 1 P02 J02
ETHERNET SWITCH WIRING

G3 1
DSC RS232 SHIELD X

SHIELD-628 1 1
H1 H2
MC1085
H3 1 90CAR-002-AA3 (WHT 20ga ) 3
SHIELD-196 GE - DSC ETHERNET SWITCH
90CAT-002-AA3 (RED 20ga ) 2 DIAGNOSTIC
MODULAR MINING DISPLAY
CONNECTOR
(PTX-C)
90CAG-002-AA3 (BLK 20ga ) 5
SHIELD-125
DIAG5 SHIELD-128 SHIELD-121 SHIELD-121 SHIELD-123 SHIELD-123 MC121
TX(+) 6 91ET1-000-CC11 (W-OR 24ga ) 1 1 91ET1-002-AC51 (W-OR 24ga ) 1 1 91ET1-001-AA26 (W-OR 24ga ) 1 MMS TX(+) KOMTRAX RX(-) 4 93ER2-001-AA22 (GRN 24ga )
TB36
MC282 MC289 TX(-) 4 91ET2-000-CC11 (ORG 24ga ) 3 3 91ET2-002-AC51 (ORG 24ga ) 3 3 91ET2-001-AA26 (ORG 24ga ) 3 MMS TX(-) KOMTRAX RX(+) 2 93ER1-001-AA22 (W-GR 24ga )
MMS RS232 RECEIVE y MC282
90MMR-000-AA3 (WHT 18ga ) G1 G4 90MMR-003-AA1 (WHT 20ga ) SH16:L-5 RX(+) 5 91ER1-000-CC11 (W-GR 24ga ) 2 2 91ER1-002-AC51 (W-GR 24ga ) 2 2 91ER1-001-AA26 (W-GR 24ga ) 2 MMS RX(+) KOMTRAX TX(-) 3 93ET2-001-AA22 (ORG 24ga )
RX(-) 8 91ER2-000-CC11 (GRN 24ga ) 4 4 91ER2-002-AC51 (GRN 24ga ) 4 4 91ER2-001-AA26 (GRN 24ga ) 4 MMS RX(-) KOMTRAX TX(+) 1 93ET1-001-AA22 (W-OR 24ga )
MMS RS232 TRANSMIT w 90MMT-000-AA3 (RED 18ga ) F1 F4 90MMT-003-AA1 (RED 20ga ) SH16:L-5 MC094 MC091 MC091 MC119 MC119
MMS_ENET JENET4 MMSI MMSI1 JENET1 PORT1 PORT3
MMS RS232 GND z 90MMG-000-AA3 (BLK 18ga ) H1 H4 90MMG-003-AA1 (BLK 20ga ) SH16:L-5
USER PC
MMS RS232 SHIELD x J1 J5
SHIELD-630 SHIELD-630 SHIELD-654 SHIELD-129 SHIELD-122 SHIELD-122 SHIELD-120 SHIELD-120
TX(+) 1 92ET1-000-CC21 (W-OR 24ga ) 1 1 92ET1-002-AC51 (W-OR 24ga ) 1 1 92ET1-001-AA21 (W-OR 24ga ) 1 PC TX(+)
P303 TERMINAL BLOCK TX(-) 2 92ET2-000-CC21 (ORG 24ga ) 3 3 92ET2-002-AC51 (ORG 24ga ) 3 3 92ET2-001-AA21 (ORG 24ga ) 3 PC TX(-)
SPLIT UP. SEE RX(+) 3 92ER1-000-CC21 (W-GR 24ga ) 2 2 92ER1-002-AC51 (W-GR 24ga ) 2 2 92ER1-001-AA21 (W-GR 24ga ) 2 PC RX(+)
CONNECTOR CHART RX(-) 6 92ER2-000-CC21 (GRN 24ga ) 4 4 92ER2-002-AC51 (GRN 24ga ) 4 4 92ER2-001-AA21 (GRN 24ga ) 4 PC RX(-)
SWITCH TRACTION CONTROL MC092 MC092 MC120 MC120
FOR LOCATIONS PC_ENET MC095 PORT2
JENET5 PC PC1 JENET2
9 9 7 7
0-151-CC3 (BLK 16ga ) SH13:L-10
TB26
WHEEL SPIN/SLIDE A 72TC-000-AA3 (YEL 18ga ) 1 G1 G2 1 72TC-001-AC3 (YEL 18ga ) 6 6 72TC-002-CC3 (YEL 18ga ) 3 3
2B 2
71P-004-CC3 (BRN 16ga ) SH13:K-10
OPERATOR CAB
P305 1 1 71P-009-CC3 (BRN 16ga )
6 6
5B
5
4 4
TB23 10 10 8 8 SHIELD-127
0-132-CC3 (BLK 16ga ) SH15:P-6
REST REQUEST O MC099
72RQ-003-AA3 (GRY 18ga ) K1 K4 72RQ-002-AA1 (GRY 14ga ) SH4:C-22 PAYLOAD TX(+) 1 95ET1-000-AA15 (W-OR 24ga ) SH17:N-16
P30 P30 PAYLOAD TX(-) 3 95ET2-000-AA15 (ORG 24ga ) SH17:N-16
58F-06-60880
PAYLOAD RX(+) 2 95ER1-000-AA15 (W-GR 24ga ) SH17:N-16
P304 PAYLOAD RX(-) 4 95ER2-000-AA15 (GRN 24ga ) SH17:O-16
PORT6
SHIELD-126 MC090
V(+) 4 12V-001-AA16 (ORG 18ga ) SH6:I-10
SWITCH ENGINE WARMING MC098 1 GE EN2 TX(+) GB31-A
SH15:C-4 94ET1-000-AA6 (W-OR 24ga )
SH15:C-4 94ET2-000-AA6 (ORG 24ga ) 3 GE EN2 TX(-) V(-) 2 0-177-AA16 (BLK 18ga ) 1 B4
9 9 7 7
0-136-CC3 (BLK 18ga ) SH12:M-6 2 GE EN2 RX(+)
TB23 SH15:C-4 94ER1-000-AA6 (W-GR 24ga ) ENET_PWR
SH15:C-4 94ER2-000-AA6 (GRN 24ga ) 4 GE EN2 RX(-)
ENG WARMUP REQ b 72GD-000-AA3 (DBL 18ga ) S1 S2 72GD-001-AC3 (TAN 16ga ) 8 8 72GD-002-CC3 (TAN 18ga ) 3 3 GB31-B
2B 2 PORT5
71P-009-CC3 (BRN 16ga ) GND SCREW 0-550-AA1 (BLK 16ga ) 1 C4
1 1
AUX BOX
GND-SWITCH
SH16:H-13 0-361-AA1 (BLK 18ga )
6 6
5B
5
4 4
GB31-B
SH15:E-8 0-614-AA3 (BLK 18ga )
BATT CHG SYS FAIL IND RTN h 0-322-AA3 (BLK 18ga ) 1
B3
10 10 8 8
0-446-CC3 (BLK 16ga ) SH17:A-2
DIG OUT RET-CONN TO GND k 0-323-AA3 (BLK 18ga ) SHIELDS ARE
P31 P31
58F-06-60930 GROUNDED TO THE
72SBT-002-CC3 (DBL 18ga )
SHELL OF THE M12
712P-003-CC3 (YEL 18ga ) PLUGS AT THE
TB25
SWITCH BRAKE TEST ETHERNET SWITCH
PRESHIFT BK TEST LIGHT DRIVER j 37 37 7 7 9 9
33SBA-000-AA3 (YEL 18ga ) 1 W1 W2 1 33SBA-001-AC3 (YEL 16ga ) 33SBA-002-CC3 (YEL 18ga )
PRESHIFT BRAKE TEST a 72SBT-000-AA3 (WHT 18ga ) 43 43 72SBT-002-CC3 (DBL 18ga ) 3 3
1 X1 X2 1 72SBT-001-AC3 (DBL 16ga )
712P-002-CC3 (YEL 16ga ) 2 2B
1 1
P305
6 6
58B-06-02390-00 APR 16
5B
5
4 4
SH15:M-9 0-132-CC3 (BLK 16ga )
10 10
980E-5
SH15:E-16 0-412-CC3 (BLK 16ga ) 8 8
VEC-89
F57 TB35
712 BUSS 4G
P25 P25
G D1 D2 15 15 58F-06-60910
10
VEC89-P4
712P-000-AA1 (YEL 16ga ) 712P-001-AC3 (YEL 16ga )
A50005 & UP
58E-06-02042 P03 J03
Sheet 15 of 27
INTERFACE MODULE
AIR RESTRICTION SWITCH 2 AIR RESTRICTION SWITCH 1
NC C C TB28 SWITCH DRIVERS SEAT BELT

SH16:N-3 0-085-AR1 (BLK 16ga ) 2 1 25AF1-000-AR1 (WHT 16ga ) 2 NC 1 25AF-000-AR1 (TAN 16ga ) 9 9 25AF-001-AA1 (TAN 20ga ) X ENGINE AIR FILTER INPUT
OPERATOR SEAT BELT SWITCH g 4 4 3 3 2 2 1 1
62SB-000-AA1 (ORG 20ga ) X1 X2 62SB-001-AC2 (ORG 18ga ) 62SB-002-CC2 (ORG 18ga ) 62SB-003-CC7 (ORG 18ga )
ARS2 ARS2 ARS1 ARS1 P13 J13 IM2 XK1267
58E-06-05290 58E-06-05290 IM2 P02 J02 P212 P212
GB12
A1
1 0-329-CC2 (BLK 18ga ) 4 4 0-284-CC7 (BLK 18ga )
0-812-CC2 (BLK 16ga ) SH15:E-8 J227 P227

VEC-89
SEAT BELT ALARM OPTION J A 2A 85 86 2G G
62A-000-AA1 (YEL 20ga ) 24VIM-002-AA1 (LBL 18ga ) SH5:J-13
TB30 58B-06-00290 H 2H 87 F63
62SBA-000-AA1 (ORG 14ga ) VEC89-P2
30 71CK BUSS
STEERING BLEED SOLENOID P 33JB-000-AA1 (LTG 20ga ) D1 D2 33JB-005-AA2 (LTG 18ga ) 1 2 0-229-AA2 (BLK 16ga ) SH10:J-12 VEC89-P2 87a 15
R19
IM1 D4
R2 SEAT BELT ALARM
58B-06-02020 GB31-B (OPT) RELAY 41
TB32 E3
SEAT BELT ALARM 1 2 0-547-AA1 (BLK 16ga )
6800.0 71CK BUSS
CUSTOMER ATTACHMENT L2
(OPT) 86 85 0 BUSS
33JB-001-AA1 (LTG 16ga ) 33J-005-AA1 (GRY 16ga )

87 F12
SOLENOID STEERING BLEED DOWN 11 BUSS
30
1E 87a 10
10 10 33JB-002-AJ2 (LTG 16ga ) 33JB-003-AJ2 (LTG 16ga ) 2 1 33J-002-AJ2 (GRY 16ga ) 33J-001-AJ2 (GRY 16ga ) 7 7 33J-000-AA1 (GRY 16ga ) 33J-004-AA1 (GRY 16ga ) E
SP183 SP184 SP800
ACCBD BF4493 ACCBD VEC89-P1 STEERING BLEED
J14 P14 PWR RELAY 14
D26 P14 J14
2 1 F42
33JB-004-AJ2 (LTG 16ga ) 33J-003-AJ2 (GRY 16ga ) 4H 71CK BUSS
87-000-AA1 (TAN 18ga ) H
PC2834 TB21 5
KEYSWITCH OR INPUT G 87-001-AA1 (TAN 20ga ) J1 J2 VEC89-P4
58E-06-02042
87-002-AA2 (TAN 18ga ) J3
TB35 58B-06-00160
FUEL LEVEL SENSOR g C1 C2 1 2 SENSOR FUEL LEVEL
38G-000-AA1 (GRY 20ga ) 38G-002-AA2 (GRY 18ga )
MC703 560Ω 3W
38G-004-HH4 (GRY 16ga ) 1 + VDC SIGNAL
j CAN-RPC-HI
R15
SH18:B-6 939YP-008-AA1 (YEL 20ga ) IM3 AHT C4
AUXBOX CONNECTOR
SH18:C-6 939GP-008-AA1 (GRN 20ga ) k CAN-RPC-LOW 38G-001-AA1 (GRY 16ga ) 11 11 38G-003-AH2 (GRY 14ga ) 3 3 0-324-HH4 (BLK 16ga ) 2 GROUND
(OPT)
SP198 FLS 58B-06-03300
SHIELD-011-AA1 (BLK 20ga ) i CAN/RPC-SHLD MANUAL MODE AUTO APPLY PRESSURE SWITCH d 52AA2-000-AA1 (BRN 20ga ) 21 21
TB24 SHIELD-834
SH7:E-11 0-482-AA2 (BLK 16ga ) HYDRAULIC PUMP FILTERS PRESSURE Y 39-000-AA1 (TAN 20ga ) 15 15 J9-AA8 (BLK 18ga ) SH18:O-2 0-324-HH4 (BLK 16ga )
J16 P16 J730 P730 SWITCH STEERING FILTER #1
SH10:J-12 0-238-AA2 (BLK 16ga ) 1 X1 X3 1 0-387-AA1 (BLK 20ga ) 16 16 J27-AA8 (BLK 18ga ) SH18:O-2
SWITCH HYDRAULIC FILTER #2 C NO
IM2
SWITCH HYDRAULIC FILTER #1 C NO C B
SH17:M-13 0-701-AA4 (BLK 20ga ) 1 X2
J702 P702 0-328-HH4 (BLK 16ga )
C NO C B A NC
39SP-000-HH4 (BRN 16ga ) SP185
C B A NC
39HP-000-HH4 (LBL 16ga ) SFSW
12 12 1 1 A NC 58B-06-30000
39AP-000-AA1 (YEL 16ga ) 39AP-001-AH2 (YEL 16ga ) 39AP-002-HH4 (YEL 16ga ) HFSW2 SFSW
58B-06-30000
HFSW1 HFSW2
58B-06-30000
HFSW1
GB31-B
MC705 E2 SP008
SH18:E-5 939YE-008-AA1 (YEL 20ga ) r CAN/J1939-HI 0-325-AA1 (BLK 16ga ) 21 21 0-326-AH2 (BLK 16ga ) 0-699-AH2 (BLK 16ga ) 4 4 0-327-HH4 (BLK 16ga )
0-152-AH2 (BLK 16ga ) SH19:L-9
SH18:E-5 939GE-008-AA1 (GRN 20ga ) s CAN/J1939-LO 0-153-AH2 (BLK 16ga ) SH19:M-9
J16 P16 J730 P730
q CAN/J1939-SHLD
SHIELD-836
SWITCH PARK BRAKE SET
IM1
TB32
C NO
C B 0-337-BB1 (BLK 16ga ) SH5:I-21
HYD BRAKE CABINET
PARK BRAKE APPLY PSW f 33-002-AA1 (BRN 20ga ) D1 D2 33-001-AB1 (BRN 16ga ) D D 33-000-BB1 (BRN 16ga ) A NC
PBPSW
58E-06-30320
PBPSW
TB32 SWITCH LOW BRAKE ACCUM PRESSURE
TB25 BRAKE ACCUMULATOR PRESSURE U S S C NO
33BP-002-AA1 (WHT 20ga ) E1 E2 33BP-001-AB1 (WHT 16ga ) 33BP-000-BB1 (WHT 16ga )
13 13 L SNAPSHOT IN PROGRESS C B
SH15:G-13 74DS-000-CC3 (GRY 18ga ) 74DS-001-AC3 (GRY 18ga ) 1 M2 M1 1 74DS-002-AA1 (GRY 20ga ) 0-338-BB1 (BLK 16ga ) SH5:I-21
A NC
J03 P03 LBPS

58E-06-30400
LBPS
TB32 SWITCH SERVICE BRAKE DEGRADE PRESSURE
SH15:C-3 71F-003-AA1 (LTG 20ga ) R BODY DOWN SWITCH
BRAKE PRESSURE DEGRADATION V 33T-002-AA1 (DBL 20ga ) F1 F2 33T-001-AB1 (DBL 16ga ) N N 33T-000-BB1 (DBL 16ga ) C NO
C B
IM2 0-339-BB1 (BLK 16ga ) SH5:I-21
A NC
1175A/1000R
P240 J240 BDS
BDS PC1678
SENSOR STEERING PRESSURE 33SP-000-AA1 (WHT 20ga ) d STEERING PRESSURE

TB28
MC653 MC720 MC718 MC718 MC717
1 27 27 MC654 DIAGNOSTIC RS232/TRANSM A 52 52 2
1 18VIM-002-AJ2 (BLK 18ga ) 18VIM-001-AA1 (BLK 18ga ) 90IMT-000-AA1 (RED 20ga ) M1 M4 90IMT-002-AC2 (RED 18ga ) 90IMT-003-CC2 (RED 20ga )
TB30
2
OP-CAB IM
2 33SP-002-AJ2 (WHT 18ga ) 26 26 33SP-001-AA1 (WHT 18ga ) T1 DIAGNOSTIC RS232/RECIEV B 90IMR-000-AA1 (WHT 20ga ) N1 N4 90IMR-002-AC2 (WHT 18ga ) 53 53 90IMR-003-CC2 (WHT 20ga ) 3
DIAGNOSTIC
PC1538 SPS CONNECTOR
28 28 DIAGNOSTIC RS232/GND C 90IMG-000-AA1 (BLK 20ga ) P1 P4 90IMG-002-AC2 (BLK 18ga ) 54 54 90IMG-003-CC2 (BLK 20ga ) 5
SHIELD-733 SHIELD-001-AA1 (BLK 16ga ) SH16:K-10
SP737 55 55 DIAG1
IM2 R1 R4
b +18V SENSOR
SHIELD-896
P14 J14 18VIM-000-AA1 (WHT 20ga ) SHIELD-130
R2 0-361-AA1 (BLK 18ga ) SH15:N-20 P02 J02
TB30
SENSOR HOIST PRESSURE #1 0-447-AA1 (BLK 18ga ) SH16:J-12
W1
MC651 MC652
1 1 18VIM-004-AH2 (BLK 18ga ) 31 31 18VIM-003-AA1 (BLK 18ga )
W2 90IMT-001-AA1 (RED 20ga ) 2
2
2 33HP1-002-AH2 (WHT 18ga ) 32 32 33HP1-001-AA1 (WHT 18ga ) AUXBOX IM
3
PC1537 HPS1 W4 90IMR-001-AA1 (WHT 20ga ) DIAGNOSTIC
33 33
SHIELD-732 SHIELD-733 CONNECTOR
N1 90IMG-001-AA1 (BLK 20ga ) 5
MC719
s HOIST PRESSURE 1 J372
33HP1-000-AA1 (WHT 20ga )
SHIELD-013-AA1 (BLK 18ga ) SH16:K-10 SENSOR HYDRAULIC TANK LEVEL

SHIELD-731
SP773 MC635
SH5:J-9 29 29 A +VDC SUPPLY
SENSOR HOIST PRESSURE #2 24VIM-008-AA1 (LBL 16ga ) 24VIM-009-AJ2 (RED 16ga )
33HP2-000-AA1 (WHT 20ga ) q HOIST PRESSURE 2 SH6:H-18 0-341-AA1 (BLK 16ga ) 31 31 0-340-AJ2 (BLK 16ga ) B GROUND
1
MC649 5 5 MC650 LOW HYD TANK LEVEL k 30 30 C SIGNAL
1 18VIM-006-AH2 (BLK 18ga ) 18VIM-005-AA1 (BLK 18ga ) 34LL-001-AA1 (BRN 20ga ) 34LL-001-AA1 (BRN 20ga ) 34LL-002-AJ2 (WHT 16ga )
TB28 32 32
IM3 SH6:G-18 0-423-AA1 (BLK 18ga ) SHIELD-701 P712
2
2 6 6 EK8243
33HP2-002-AH2 (WHT 18ga ) 33HP2-001-AA1 (WHT 18ga ) K1 IM2
TB30
PC1537 HPS2 MC639 MC634
7 7 RIGHT REAR BRAKE TEMP SENSOR m 34BT4-002-AA1 (WHT 20ga ) A1 A2 34BT4-001-AA1 (WHT 18ga ) 18 18 34BT4-000-AJ2 (WHT 16ga ) 1 1
SHIELD-730 SHIELD-731 SENSOR BRAKE TEMP RH REAR
MC639 7861923320
2
L1 L2 5VIM-006-AA1 (BLK 18ga ) 20 20 5VIM-005-AJ2 (BLK 16ga ) 2
P16 J16 EB7418
SHIELD-709 SHIELD-700 P710
K1
+5V SENSOR MONITOR j SHIELD-709 19 19
5VIM-001-AA1 (ORG 20ga ) SP790 SHIELD-999-AA1 (BLK 16ga ) SHIELD-998-AJ2 (BLK 16ga ) SP791
+5V SENSOR c 5VIM-000-AA1 (ORG 20ga ) B2 0-447-AA1 (BLK 18ga ) SH16:H-13 1 1
SHIELD-710 SHIELD-974 SENSOR BRAKE TEMP LH REAR
HYD BRAKE CABINET LEFT REAR BRAKE TEMP SENSOR i 34BT3-001-AA1 (WHT 20ga ) C1 C2
SHIELD-710
MC640
34BT3-000-AA1 (WHT 18ga )
MC640
15 15 MC755
34BT3-002-AJ2 (WHT 16ga ) 2
2
7861923320
P709
K2 5VIM-002-AA1 (BLK 18ga ) 14 14 5VIM-009-AJ2 (BLK 16ga )
RIGHT FRONT BRAKE TEMPERATURE r 40 40 MC757 34BT2-002-AJ2 (WHT 16ga )
34BT2-001-AA1 (WHT 20ga ) H1 H2 34BT2-000-AA1 (WHT 18ga ) 1 1
SENSOR BRAKE TEMP RH FRONT
SENSOR BRAKE PRESSURE MC641 MC641 7861923320
2
K3 5VIM-004-AA1 (BLK 18ga ) 39 39 5VIM-010-AJ2 (BLK 16ga ) 2
1 MC647 A A MC648 SHIELD-977
1 18VIM-008-BB1 (BLK 14ga ) 18VIM-007-AB1 (BLK 14ga ) SH16:H-6 SHIELD-001-AA1 (BLK 16ga ) SHIELD-711 SHIELD-711 P708
SH16:I-6 SHIELD-013-AA1 (BLK 18ga ) B4 B3 SP792 SHIELD-997-AA1 (BLK 16ga ) 38 38 SHIELD-996-AJ2 (BLK 16ga ) SP789
2 SHIELD-725
2 33BPS-002-BB1 (WHT 14ga ) B B 33BPS-001-AB1 (WHT 14ga ) SH16:K-12 SHIELD-712 SHIELD-712 SHIELD-976
BPS SHIELD-728 SHIELD-729 LEFT FRONT BRAKE TEMPERATURE t 34BT1-001-AA1 (WHT 20ga ) G1 G2 34BT1-000-AA1 (WHT 18ga ) 37 37 34BT1-002-AJ2 (WHT 16ga ) 1 1 SENSOR BRAKE TEMP LH FRONT
PC1537 M M 7861923320
SP774 SP775 K4 5VIM-003-AA1 (BLK 18ga ) 36 36 5VIM-011-AJ2 (BLK 16ga ) 2
2
MC642 MC642 MC756

P707
BRAKE PRESSURE p 33BPS-000-AA1 (WHT 20ga ) M2 M1 33BPS-001-AB1 (WHT 14ga ) SH16:K-5
J240 P240 MC648
B1
23 23 SENSOR DUCT AIR TEMPERATURE
AMBIENT AIR TEMPERATURE e 34AT-002-AA1 (WHT 20ga ) J1 J2 34AT-001-AA1 (WHT 18ga ) 21 21 34AT-000-AJ2 (WHT 16ga ) A 1
MC289 2
SH15:K-7 90MMR-003-AA1 (WHT 20ga ) D MMS RS232/RECIEV L4 5VIM-008-AA1 (BLK 18ga ) 22 22 5VIM-007-AJ2 (BLK 16ga ) B
MC646 MC646 MC645
ATS AK7339
SH15:K-7 90MMT-003-AA1 (RED 20ga ) E MMS RS232/TRANSM
J14 P14
SH15:K-7 90MMG-003-AA1 (BLK 20ga ) F MMS RS232/GND
SWITCH AUTOLUBE PRESSURE

SWITCH ACCUMULATOR NO C 0-289-AH2 (BLK 14ga ) SH14:B-13
PRECHARGE PRESS #1 AUTOLUBE PRESSURE SWITCH Y 23 23 B C
68P-003-AA1 (PUR 20ga ) 68P-001-AH2 (PUR 14ga )
NC A
1 NO C 1 19 19 W LOW STEERING PRE-CHARGE
51A2-000-AR1 (BRN 16ga ) 51A1-001-AR1 (LBL 16ga ) 51A1-000-AA1 (LBL 20ga ) IM3 J16 P16 LLPS
58E-06-30700
ACCP1-NO ACCP1-C LLPS
1202A/1100R TB35 58B-06-00290
PC0909
AUTOLUBE SOLENOID T 68-001-AA1 (TAN 20ga ) R1 R4 68-000-AA2 (TAN 18ga ) 1 2 0-345-AA2 (BLK 18ga ) SH10:J-12
R30
IM1 R3 R2
SWITCH ACCUMULATOR
PRECHARGE PRESS #2
AUTOLUBE SYSTEM
GB31-B
SP077 SOLENOID AUTO LUBE
1 NO C 1 20 20
E4 VEC-89
0-087-AR1 (BLK 16ga ) 0-335-AR1 (BLK 16ga ) 0-336-AA1 (BLK 16ga ) 2B
B 32 32 E E 2 1
ACCP2-NO 1202A/1100R
ACCP2-C F20
68ES-003-AA1 (DBL 16ga ) 68ES-004-AA1 (DBL 16ga ) 68ES-001-AJ1 (DBL 14ga ) 68ES-002-JJ1 (DBL 14ga )
SP785
PC0909 4C 85 86 71CK BUSS
SH11:G-14 11ONS-003-AA1 (LBL 18ga ) C VEC89-P2 ALSOL PC2436 ALSOL
P13 J13 10
SH16:A-1 0-085-AR1 (BLK 16ga ) 68-005-AA1 (TAN 16ga ) 33 33 68-003-AJ1 (TAN 14ga ) B B 68-004-JJ1 (TAN 14ga )
87
30 4F SWITCH AUTOLUBE LEVEL (OPT)
F 74SB1-010-AA1 (DBL 18ga ) SH21:J-17
SWITCH LOW STEERING PRESSURE E
4E 87a 34 34 C C C NO
68LS-003-AA1 (DGR 20ga ) 68LS-001-AJ1 (DGR 16ga ) 68LS-000-JJ1 (DGR 16ga ) C
C NO VEC89-P4 B
C B 6 6 S LOW STEERING PRESSURE AUTO BUSY
IM SYSTEM LUBE RELAY A NC
33F-000-AJ2 (DBL 16ga ) 33F-001-AA1 (DBL 20ga ) VEC89-P4 J12 P12
NC RELAY 29
A P512
58E-06-02042 XA3247
ACPSW P512
58E-06-30330 A A
ACPSW SH7:E-17 0-342-AJ1 (BLK 16ga ) 0-343-JJ1 (BLK 16ga )
2 2 J511 P511
0-331-AJ2 (BLK 16ga ) 0-333-AA1 (BLK 16ga ) SH6:H-18
SWITCH STEERING BLEED PRESSURE 68ES-000-AA1 (DBL 16ga ) 57 57
NO C 9 9 Z STEERING BLEED PRESSURE SW
33JA-001-AA1 (YEL 20ga )
B C
NC A 33JA-000-AJ2 (YEL 16ga ) 68-002-AA1 (TAN 16ga ) 54 54 AUTOLUBE SYSTEM
SABS
58E-06-11900 AUTOLUBE GREASE LEVEL W 56 56
SABS 68LS-002-AA1 (DGR 20ga ) 68LS-004-AA1 (DGR 20ga )
34 34 SH6:G-18
0-385-AJ2 (BLK 16ga ) 0-332-AJ2 (BLK 16ga ) 0-334-AA1 (BLK 16ga ) SP786
SP799 IM3
SH6:G-21 0-344-AA1 (BLK 16ga ) 55 55
SH19:N-6 0-386-AJ2 (BLK 16ga ) P14 J14 J11 P11

SH19:N-6 0-419-AJ2 (BLK 16ga )
58B-06-02390-00 APR 16
TB33
A2 72AT-000-AA1 (PNK 20ga ) e AUTO MODE OPERATION REQUEST

B2 72MAN-000-AA1 (LTG 20ga ) s MANUAL MODE OPERATOR REQUEST
980E-5
INTERFACE MODULE IM2
A50005 & UP
Sheet 16 of 27
SWITCH HEATED MIRROR
SH15:N-9 0-446-CC3 (BLK 16ga ) 7 7 9 9

TB28
HEATED MIRROR
3 3 39 39
SH11:D-9 71LS-013-CC3 (DGR 16ga ) 69MA-000-CC3 (YEL 16ga ) 69MA-001-AC3 (YEL 16ga ) W1 W2
SH17:D-2 71LS-005-CC3 (DGR 16ga ) 2 2B

1 1
J03 P03
6 6
5B
5
4 4
8 8 10 10
SH11:D-11 0-179-CC3 (BLK 16ga ) MIRROR HEATED RIGHT DECK
P28 P28 69M-001-AA1 (YEL 14ga ) 6 6 69M-003-AH1 (YEL 14ga ) 6 6 69M-005-FH1 (YEL 14ga ) F F 69M-007-FF1 (YEL 14ga ) 1 1
58F-06-60940 7 7 7 7 G G
SH6:F-21 0-403-AA1 (BLK 14ga ) 0-404-AH1 (BLK 14ga ) 0-405-FH1 (BLK 14ga ) 0-406-FF1 (BLK 14ga )
69MA-002-AA1 (YEL 18ga ) 2 2
VEC-89
J11 P11 J541 P541 P502 J502
MIRROR1_CP
PC2930 OPERATOR CAB FANS
G 1G VEC-89
F61 TB26
0 BUSS 85 86 2F 2C C
VEC89-P1 SH6:F-9 712-002-AA1 (ORG 18ga ) F 712F-000-AA1 (LBL 18ga ) 1 D1 D2 1 712F-001-AC4 (LBL 18ga )
TB23 5
F53 87 1H
H 69M-000-AA1 (YEL 12ga ) F1 F2 VEC89-P2 VEC89-P2
11 BUSS 30 MIRROR HEATED LEFT DECK 58E-06-02042
20 87a 6 6 6 6 F F 1 1
VEC89-P1 69M-002-AA1 (YEL 14ga ) 69M-004-AJ1 (YEL 14ga ) 69M-006-GJ1 (YEL 14ga ) 69M-008-GG1 (YEL 14ga )
SH6:H-21 0-407-AA1 (BLK 14ga ) 7 7 0-408-AJ1 (BLK 14ga ) 7 7 0-409-GJ1 (BLK 14ga ) G G 0-410-GG1 (BLK 14ga )
HEATED MIRROR 2 2
RELAY 39
MIRROR2_CP
58E-06-02042 PC2930
J12 P12 J540 P540 P503 J503
CAB FAN THERMOSTAT FAN
COM NO
1 1 712F1-000-CC4 (LTG 18ga ) C B 712F-002-CC4 (LBL 18ga ) 15 15
NC A
SWITCH ROTATING BEACON (OPT) 4 4 4 4 D D 1 1
RIGHT DECK 2 2
11RB-002-AA1 (DGR 14ga ) 11RB-005-AH1 (DGR 14ga ) 11RB-007-FH1 (DGR 14ga ) 11RB-009-FF1 (DGR 14ga ) 0-267-CC4 (BLK 18ga ) SH17:E-10 P170 J04_CP P04
5 5 5 5 E E 2 2 ROTATING BEACON 58E-06-20910
P170
SH6:F-21 0-401-AA1 (BLK 14ga ) 0-395-AH1 (BLK 14ga ) 0-396-FH1 (BLK 14ga ) 0-397-FF1 (BLK 14ga ) FAN1
7 7 9 9 OPTION 58E-06-11091
SH12:G-2 0-320-CC3 (BLK 18ga )
P548_CP
3 3
SH12:B-3 71LS-011-CC3 (DGR 16ga ) J11 P11 J541 P541 P502 J502
SH17:A-2 71LS-005-CC3 (DGR 16ga ) 2 2B TB22
1 1 E2 1
6 6 38 38 4 4 4 4 D D 1 1
LEFT DECK
5B 11RB-000-CC3 (DGR 14ga ) 11RB-001-AC3 (DGR 14ga ) 1 E1 E4 1 11RB-003-AA1 (DGR 14ga ) 11RB-006-AJ1 (DGR 14ga ) 11RB-008-GJ1 (DGR 14ga ) 11RB-010-GG1 (DGR 14ga )
5 5 5 5 5 E E 2 2 ROTATING BEACON
SH12:L-4 11L-003-CC3 (YEL 14ga ) SH6:H-21 0-402-AA1 (BLK 14ga ) 0-398-AJ1 (BLK 14ga ) 0-399-GJ1 (BLK 14ga ) 0-400-GG1 (BLK 14ga )
4 4 E3 1
OPTION
J03 P03 P549_CP
8 8 10 10
SH12:L-6 0-318-CC3 (BLK 18ga ) J12 P12 J540 P540 P503 J503
P24 P24
58F-06-60950
11RB-004-AC4 (DGR 14ga ) 14 14 11RB-011-CC4 (DGR 14ga ) 1
CAB MOUNT
RRBB1
GB12 ROTATING BEACON
ROTATING BEACON OPTION

P04 J04_CP F1
1 0-428-CC4 (BLK 14ga ) 1 OPTION
RRBB2
0-267-CC4 (BLK 18ga ) SH17:D-17

0-202-CC4 (BLK 18ga ) SH6:C-13
LAMP RED PAYLOAD RIGHT
PAYLOAD METER IV VEC-90

39AA-001-AA1 (DGR 16ga ) 10 10 39AA-002-AH1 (DGR 16ga ) 10 10 39AA-004-FH1 (DGR 16ga ) K K 39AA-005-FF1 (DGR 16ga ) 1 2 0-189-FF1 (BLK 16ga )
2G
39A-001-AA1 (LTG 18ga ) G RPLR_CP RPLR_CP
EK9380
0 BUSS 85 86
TB23 LAMP AMBER PAYLOAD RIGHT
F14 87 3A
A 39AA-000-AA1 (DGR 16ga ) C1
71CK BUSS 30
39BA-001-AA1 (LBL 16ga ) 11 11 39BA-002-AH1 (LBL 16ga ) 11 11 39BA-004-FH1 (LBL 16ga ) L L 39BA-005-FF1 (LBL 16ga ) 1 2 0-199-FF1 (BLK 16ga ) 0-364-FF1 (BLK 16ga ) SH12:M-18
5 87a
SP195
RPLA_CP EK9381 RPLA_CP
TB34 PAYLOAD RED
LAMP RELAY 16
39A-000-AA4 (LTG 20ga ) S1 S2
3B LAMP GREEN PAYLOAD RIGHT
B
2D
R1 R2 D
39B-000-AA4 (BRN 20ga ) 39B-001-AA1 (BRN 18ga ) VEC90-P3
39CA-001-AA1 (YEL 16ga ) 12 12 39CA-002-AH1 (YEL 16ga ) 12 12 39CA-004-FH1 (YEL 16ga ) M M 39CA-005-FF1 (YEL 16ga ) 1 2 0-158-FF1 (BLK 16ga )
0 BUSS 85 86
39C-000-AA4 (DBL 20ga ) P1 P2
TB23 RPLG_CP RPLG_CP
2C EK9382
87 C 39BA-000-AA1 (LBL 16ga ) D1
30
87a J11 P11 J541 P541 P502 J502
LAMP RED PAYLOAD LEFT
PAYLOAD AMBER
LAMP RELAY 17 10 10 10 10 K K 1 2
2B 39AA-006-AA1 (DGR 16ga ) 39AA-007-AJ1 (DGR 16ga ) 39AA-008-GJ1 (DGR 16ga ) 39AA-009-GG1 (DGR 16ga ) 0-367-GG1 (BLK 16ga )
39C-001-AA1 (DBL 18ga ) B
LPLR_CP EK9380 LPLR_CP
0 BUSS 85 86
VEC90-P2
TB23
87 2A
A 39CA-000-AA1 (YEL 16ga ) E1 LAMP AMBER PAYLOAD LEFT
30
87a 11 11 11 11 L L 1 2
VEC90-P2 39BA-006-AA1 (LBL 16ga ) 39BA-007-AJ1 (LBL 16ga ) 39BA-008-GJ1 (LBL 16ga ) 39BA-009-GG1 (LBL 16ga ) 0-368-GG1 (BLK 16ga ) 0-363-GG1 (BLK 16ga ) SH12:K-18
SP196
PAYLOAD GREEN
LPLA_CP EK9381 LPLA_CP
LAMP RELAY 18
58E-06-20050
LAMP GREEN PAYLOAD LEFT
39CA-006-AA1 (YEL 16ga ) 12 12 39CA-007-AJ1 (YEL 16ga ) 12 12 39CA-008-GJ1 (YEL 16ga ) M M 39CA-009-GG1 (YEL 16ga ) 1 2 0-369-GG1 (BLK 16ga )
LPLG_CP EK9382 LPLG_CP

PAY LOAD METER 4
J12 P12 J540 P540 GB LEFT DECK P503 J503
39C-000-AA4 (DBL 20ga ) 44 GREEN LAMP DRIVE
1
39B-000-AA4 (BRN 20ga ) 45 AMBER LAMP DRIVE 1
43 RED LAMP DRIVE SHIELD-929
39A-000-AA4 (LTG 20ga )
31 +24VDC POWER SCORE BOARD RIGHT (OPT) SCORE BOARD LEFT (OPT)
SH5:B-3 39G-001-AA4 (DBL 20ga )
VEC-90 PWR & COMM GND 1 A A PWR & COMM GND 2
0-370-FG1 (BLK 16ga )
F46 TB34 N/C 1 B B PWR & COMM GND 3
71CK BUSS 4D
D 712PL-000-AA1 (LTG 16ga ) V1 V2 712PL-001-AA4 (LTG 20ga ) 50 KEYSWITCH SIGN TX C C N/C 2
5 SIGN RX D D SIGN TX2 REBROADCAST
VEC90-P4 35L10-000-FG1 (WHT 16ga )
24 VDC PWR IN E 712SL-002-FG1 (RED 16ga ) E 24 VDC PWR OUT
58E-06-20050 GB31-B MC606
A3 PC1137 CNRIN CNLO
0-365-AA4 (BLK 20ga ) 37 PLM4 GROUND
0-375-AA4 (BLK 18ga ) SH17:K-15 B N/C 1
TB36
MC607 MC607
712SL-000-AA1 (DGR 16ga ) P1 P2 712SL-001-AF1 (RED 16ga ) E 24 VDC PWR IN
SH10:O-5 39H1-001-AA4 (YEL 20ga ) 49 BRAKE LOCK
RS232 T2 25 MC605 S1 S2 D SIGN RX
35L8-000-AA4 (WHT 18ga ) 35L8-001-AF1 (WHT 16ga )
RS232 R2 24 35L9-000-AA4 (RED 18ga ) T1 T2 35L9-001-AF1 (BRN 16ga ) C SIGN TX
SH15:B-3 71F-002-AA4 (LTG 20ga ) 46 BODY UP
RS232 GND 2 34 35L7-000-AA4 (BLK 18ga ) R1 R2 35L7-001-AF1 (BLK 16ga ) A PWR & COMM GND 1
CNLIN
R4 0-375-AA4 (BLK 18ga ) SH17:J-9
PC1137
SHIELD-671
SHIELD-673
TB36
MC601 MC290
RS232 GND 1 23 35L2-000-AA4 (BLK 18ga ) L1 L2 35L2-001-AA4 (BLK 20ga ) 5
TB36 AUXBOX PLM

RS232 R1 15 35L3-000-AA4 (RED 18ga ) M1 M2 35L3-001-AA4 (RED 20ga ) 3 DIAGNOSTIC
CONNECTOR
SENSOR PAYLOAD PRESSURE RIGHT FRONT TB36
MC712 MC295 MC295
1 1 39F-007-AR1 (BLK 16ga ) 14 14 39F-001-AA1 (BLK 16ga ) RS232 T1 21 35L4-000-AA4 (WHT 18ga ) N1 N2 35L4-001-AA4 (WHT 20ga ) 2
TB36
MC603 MC603
2
2 15 15 A1 A2 2 SUSPENSION PRESSURE - RF K3
J362
39FC-003-AR1 (WHT 16ga ) 39FC-001-AA1 (WHT 16ga ) 39FC-000-AA4 (BLK 18ga ) SHIELD-667
P150 SHIELD-671
58E-06-10051 13 13 B1 B2 39FD-000-AA4 (WHT 18ga ) 1 SUSPENSION PRESSURE - LF K4 K2
C1 C2 39F-000-AA4 (RED 18ga ) 40 18VDC SENSOR SUPPLY K1
SHIELD-669 MC711
CAN HI1 5 TO RPC
SENSOR PAYLOAD PRESSURE LEFT FRONT
C3 939YP-007-AA4 (YEL 20ga ) SH18:B-9
MC294 CAN LO1 11 939GP-007-AA4 (GRN 20ga ) SH18:C-9
NETWORK
MC713 SHIELD-661 SHIELD-663
1 1 39F-008-AR1 (BLK 16ga ) 17 17 39F-002-AA1 (BLK 16ga ) J3 J4 CAN GND 1 14 CONNECTOR
SHIELD-860
2
2 39FD-003-AR1 (WHT 16ga ) 16 16 39FD-001-AA1 (WHT 16ga ) TO THIRD
TERMINAL BLOCK MC785
CAN HI 2 12 SH18:H-6 PARTY SH6:I-16
P151 MC294 SHIELD-660 SPLIT UP. SEE 939YK-001-AA4 (YEL 20ga ) 0-234-AA2 (BLK 16ga )
58E-06-10051 18 18 CAN LO2 13 939GK-001-AA4 (GRN 20ga ) SH18:H-6 NETWORK 0-235-AA2 (BLK 16ga ) SH7:E-11
SHIELD-878 SHIELD-660 CONNECTOR CHART CAN GND 2 22
SENSOR PAYLOAD FOR LOCATIONS SHIELD-858 CONNECTOR
PRESSURE LEFT REAR
58E-06-10051 P13 J13 0-700-AA4 (BLK 20ga ) 0-701-AA4 (BLK 20ga ) SH16:E-3
SHIELD-883
MC850 MC743 MC743 SP199

1 1 7 7 PLM4 COMMUNICATION BOX
39F-005-DD1 (BLK 16ga ) 39F-003-AH2 (BLK 16ga ) MC777 MC777
USB_PS_2 26 5VUSB-000-AA4 (BLU 24ga ) 1 USB_PS_2
2
2 39FB-005-DD1 (WHT 16ga ) 8 8 39FB-003-AH2 (WHT 16ga ) USB_PS_1 36 USBV-000-AA4 (BRN 24ga ) 2 USB_PS_1
9 9 USB_PORT2--DM 29 3 USB_PORT2--DM
P152 SHIELD-952 SHIELD-950 USBDMH-000-AA4 (GRN 24ga )
SHIELD-950 USB_PORT2--DP 39 4 USB_PORT2--DP
USBDPH-000-AA4 (W-GR 24ga )
USB_PORT1--DM 27 USBDMD-000-AA4 (ORG 24ga ) 5 USB_PORT1--DM
J72 P72
USB_PORT1--DP 28 USBDPD-000-AA4 (W-OR 24ga ) 6 USB_PORT1--DP
SHIELD-884 SHIELD-884 40 40 SHIELD-883
SENSOR PAYLOAD SHIELD-951 TB36 COMMA
SP233
PRESSURE RIGHT REAR 37 37 3 SUSPENSION PRESSURE - LR
39FB-002-AH2 (BLK 16ga ) 39FB-001-AA1 (BLK 18ga ) D1 D2 39FB-000-AA4 (BLK 18ga )
58E-06-10051 HEARTBEAT 8 1 HEARTBEAT
SP234 72HC-000-AA4 (ORG 20ga )
1 1 39F-004-AH2 (BLK 16ga ) 39F-011-AH2 (RED 16ga ) 38 38 39F-009-AA1 (RED 18ga ) HAUL CYCLE 10 74HB-000-AA4 (PNK 20ga ) 2 HAUL CYCLE
TB36 ETHERNET LINK 9 3 ETHERNET LINK
SP235 74LA-000-AA4 (LTG 20ga )
2
2 39FA-004-AH2 (WHT 16ga ) 39FA-002-AH2 (WHT 16ga ) 39 39 39FA-001-AA1 (WHT 18ga ) E1 E2 39FA-000-AA4 (WHT 18ga ) 4 SUSPENSION PRESSURE - RR MC778 MC099
P153 MC744 SP236 MC715 MC297 ETHERNET TX1 20 ENTX1-000-AA4 (W-OR 24ga ) 4 ETHERNET TX1 TX(+) 1 95ET1-000-AA15 (W-OR 24ga ) SH15:M-21
MC714
ETHERNET TX2 19 ENTX2-000-AA4 (ORG 24ga ) 5 ETHERNET TX2 TX(-) 2 95ET2-000-AA15 (ORG 24ga ) SH15:M-21
ETHERNET RX2 17 ENRX2-000-AA4 (GRN 24ga ) 8 ETHERNET RX2 RX(+) 3 95ER1-000-AA15 (W-GR 24ga ) SH15:M-21
P16 J16
ETHERNET RX1 18 ENRX1-000-AA4 (W-GR 24ga ) 9 ETHERNET RX1 RX(-) 6 95ER2-000-AA15 (GRN 24ga ) SH15:M-21
PLM4_ENET
5V 7 5VPL-000-AA4 (RED 20ga ) 6 5V
GND 30 0-520-AA4 (BLK 20ga ) 7 GND
COMMB
P264 P264
58B-06-02390-00 APR 16
980E-5
A50005 & UP
Sheet 17 of 27
GE CAN TEE IM CAN TEE PLM4 CAN TEE KOMVISION RPC TEE
CAN TEE RPC # 1 CAN TEE RPC # 2 CAN TEE RPC # 3 T4
MC704 MC704 MC748 MC748 MC706 MC706 MC707 MC707 P20T4B2 MC709 MC709 SP323 MC737 MC737 MC254
A A1 A2 A1 A2 A1 A2 A 20 20 A A1 A2 A 6 6
TERM#2
A 939YP-000-AA5 (YEL 18ga ) A A 939YP-012-AA9 (YEL 18ga ) A 939YP-002-AC3 (YEL 18ga ) 939YP-003-CC3 (YEL 20ga ) 939YP-005-CC3 (YEL 20ga ) 939YP-013-CC3 (YEL 20ga ) 939YP-001-CC1 (YEL 20ga ) SH11:H-10
B B1 B2 B1 B2 B1 B2 B 21 21 B B1 B2 B SP324 7 7 TO ACTIA PANEL
PC0618 B 939GP-000-AA5 (GRN 18ga ) B B 939GP-012-AA9 (GRN 18ga ) B 939GP-002-AC3 (GRN 18ga ) 939GP-003-CC3 (GRN 20ga ) 939GP-005-CC3 (GRN 20ga ) SP325 939GP-009-CC3 (GRN 20ga ) 939GP-001-CC1 (GRN 20ga ) SH11:H-10
C C1 C2 C1 C2 C1 C2 C 22 22 C C1 C2 C 8 8
C SHIELD-835 SHIELD-835 C C SHIELD-959 SHIELD-959 C SHIELD-842 SHIELD-842 SHIELD-843 SHIELD-843 SHIELD-845 SHIELD-042 SHIELD-042 SHIELD-263
SHIELD-845
P205B MC750 P204B P215B MC703 MC703 P216B P203B MC711 MC711 P20T4B1 MC753
SEE NOTE #1 A3 A A3 A3 A3 A
A 939YP-009-AA11 (YEL 18ga ) A 939YP-008-AA1 (YEL 20ga ) SH16:D-5 A 939YP-007-AA4 (YEL 20ga ) SH17:L-13 P03 J03 J60 P60
FOR AHT OPT B3 B GE CAN RPC B3 B3 B3 B
B 939GP-013-AA11 (GRN 18ga ) B 939GP-008-AA1 (GRN 20ga ) SH16:D-5 B 939GP-007-AA4 (GRN 20ga ) SH17:L-13
C3 C CONNECTION C3 C3 C3 C
C SHIELD-965 SHIELD-965 C SHIELD-834 C SHIELD-860 SHIELD-820 MC695
P218D P219D P206D P202D 939YP-010-CC3 (YEL 20ga ) SH15:C-14 TO KOMTRAX PLUS
PC0616 PC0616 PC0616 PC0616 P20T4D
939GP-010-CC3 (GRN 20ga ) SH15:C-14
SHIELD-816
NOTE: MC753
1) OPTIONAL AHT CONNECTION TO CAN RPC REMOVES 939YP-011-CC12 (YEL 18ga ) SH21:G-5
TERM#2 RESISTOR FROM RPC CAN TEE #1 AND AHT 939GP-011-CC12 (GRN 18ga ) SH21:G-5
CONNECTOR P216B CONNECTS TO RPC CAN TEE #1
OPERATOR CAB CAN RPC

CAN RPC NETWORK
(YELLOW)
IM CAN TEE GE CAN TEE KOMVISION J1939 TEE PTX-C J1939 TEE
CAN TEE J1939 # 1 CAN TEE J1939 # 2 T17 T5
P30T17B2 MC109 MC109 MC111 MC111 MC734 MC995 MC997 P30T5B1
FROM MC258 A1 A2 MC749 A1 A2 A MC691 MC691 MC692 MC692 SP327 SP330 MC734 SP333 MC995 SP336 MC997 A2 A
SH7:H-7 939YE-001-AE1 (YEL 18ga ) A A 939YE-011-AA10 (YEL 18ga ) A 939YE-004-AC3 (YEL 18ga ) 24 24 939YE-005-CC3 (YEL 20ga ) A A1 A2 A
939YE-009-CC3 (YEL 20ga ) 939YE-015-CC3 (YEL 20ga ) 939YE-002-CC3 (YEL 20ga ) 939YE-017-CC3 (YEL 20ga ) 939YE-019-CC3 (YEL 20ga ) A A1
ENGINE B1 B2 B1 B2 B SP328 SP331 SP334 SP337 TERM#8
SH7:H-7 B B B 25 25 B B1 B2 B
939GE-019-CC3 (GRN 20ga ) B B1 B2 B
939GE-001-AE1 (GRN 18ga )
C1 C2
939GE-011-AA10 (GRN 18ga )
C1 C2 C SHIELD-802
939GE-004-AC3 (GRN 18ga ) 939GE-005-CC3 (GRN 20ga ) 939GE-009-CC3 (GRN 20ga )
SP329
939GE-015-CC3 (GRN 20ga )
SP332
939GE-002-CC3 (GRN 20ga ) SP335 939GE-017-CC3 (GRN 20ga ) SP338 PC0618
CAN J1939 26 26 C C1 C2 C C C1 C2 C
SHIELD-270 C C SHIELD-962 SHIELD-962 C SHIELD-802 SHIELD-805 SHIELD-805 SHIELD-242 SHIELD-242 SHIELD-262 SHIELD-262 SHIELD-043 SHIELD-043 SHIELD-272 SHIELD-272 SHIELD-274 SHIELD-274
P301B P315B MC705 P316B P305B MC751 P30T17B1 MC752 SHIELD-273
A3 A3 A A3 A A3 A
A 939YE-008-AA1 (YEL 20ga ) SH16:E-5 A 939YE-012-AA12 (YEL 18ga ) P03 J03 939YE-018-CC3 (YEL 20ga )
B3 B3 B GE CAN J1939 B3 B B3 B
B 939GE-008-AA1 (GRN 20ga ) SH16:E-5 B 939GE-012-AA12 (GRN 18ga ) SHIELD-264 939GE-018-CC3 (GRN 20ga )
C3 C3 SHIELD-966 C CONNECTION C3 C MC996 C3 C
C SHIELD-836 C SHIELD-966 SHIELD-819 MC112 MC112 SHIELD-244
P306D P317D P318D 939GE-016-CC3 (GRN 20ga ) SH15:G-17 MC110 MC110
PC0616 PC0616 PC0616 P30T17D 10 PC0616
939YE-016-CC3 (YEL 20ga ) SH15:G-17 939GE-014-CC3 (GRN 20ga ) MC996
SHIELD-817 939YE-018-CC3 (YEL 20ga ) C
TO ORBCOMM MODEM 939YE-014-CC3 (YEL 20ga ) 3 939GE-018-CC3 (GRN 20ga ) D
939GE-010-CC3 (GRN 20ga ) SH15:C-14 E
MC752 SHIELD-273
939YE-020-CC12 (YEL 18ga ) SH21:G-5 939YE-010-CC3 (YEL 20ga ) SH15:C-14 SH18:I-12 11TP-004-CC3 (YEL 18ga ) 1 OP-CAB
KOM-NET
939GE-020-CC12 (GRN 18ga ) SH21:G-5 MC696 CONNECTOR
TO KOMTRAX PLUS SERVICE
0-271-CC3 (BLK 18ga ) 9 ENGINE DATALINK
CONNECTOR
TIER 4
SH18:I-12 2 SH14:N-17 33 33 B
712TP-004-CC3 (RED 18ga ) 11A-004-AC3 (TAN 18ga ) 11A-012-CC3 (TAN 18ga ) DIAGNOSTIC
SP191 12
DIAG4
SH14:P-11 0-278-CC3 (BLK 18ga ) 0-272-CC3 (BLK 18ga ) P03 J03
SH15:G-16 7KTWU-001-CC3 (YEL 18ga ) 6
CAN J1939 NETWORK SH15:D-14 76-000-CC3 (LBL 18ga ) 7 SH18:I-14 0-362-CC3 (BLK 18ga ) A
OPERATOR CAB CAN J1939 DIAG3 DIAG4
(RED)
OPERATOR CAB CAN THIRD

GE CAN TEE
PARTY
PLM4 CAN TEE MODULAR MINING THIRD PARTY TEE
CAN TEE 3RD PARTY #1 KOMTRAX PLUS THIRD PARTY TEE
CAN TEE 3RD PARTY #2
T14 T16 TERM#5
MC782 P40T14B2 MC105 MC108 MC108
A A1 A2 A1 A2 MC784 MC106 MC106 MC105 SP339 A2 A
A 939YK-000-AA14 (YEL 18ga ) A A 939YK-002-AC3 (YEL 18ga ) 28 28 939YK-004-CC3 (YEL 20ga ) A A1 A2 A
939YK-005-CC3 (YEL 20ga ) 939YK-008-CC3 (YEL 20ga ) A A1
PC0618 B B1 B2 B1 B2 29 29 B B1 B2 B SP340 B B1 B2 B PC0618
B 939GK-000-AA14 (GRN 18ga ) B B 939GK-002-AC3 (GRN 18ga ) 939GK-004-CC3 (GRN 20ga ) 939GK-005-CC3 (GRN 20ga ) 939GK-008-CC3 (GRN 20ga )
TERM#4 C C1 C2 C1 C2 30 30 C C1 C2 C SP341 C C1 C2 C
C SHIELD-859 SHIELD-859 C C SHIELD-862 SHIELD-862 SHIELD-247 SHIELD-247 SHIELD-248 SHIELD-241 SHIELD-241
SHIELD-248
P402B MC781 P401B P400B MC785 MC100
A3 A A3 P40T14B1 A3 A P40T16B1 A3 A
A 939YK-003-AA13 (YEL 18ga ) A 939YK-001-AA4 (YEL 20ga ) SH17:M-13 939YK-006-CC3 (YEL 20ga ) SH15:C-14
B3 B GE CAN THIRD B3 B3 B B3 B
B 939GK-003-AA13 (GRN 18ga ) B 939GK-001-AA4 (GRN 20ga ) SH17:M-13 939GK-006-CC3 (GRN 20ga ) SH15:C-14
C3 C PARTY C3 C3 C C3 C
C SHIELD-861 SHIELD-861 C SHIELD-858 SHIELD-250
CONNECTION
P403D P404D P402D P40T14D P40T16D
PC0616 PC0616 PC0616 PC0616
SHIELD-271
MC107 MC107
939GK-007-CC3 (GRN 20ga ) 10
939YK-007-CC3 (YEL 20ga ) 3

VEC-91 11
58E-06-20061 SHIELD-271 DATA PORT
F29 TB32
11 BUSS SP249 11TP-004-CC3 (YEL 18ga ) SH18:E-17
4H H 1 P1 P2 1 16 16 1
11TP-000-AA1 (YEL 16ga ) 11TP-001-AC3 (YEL 16ga ) 11TP-002-CC3 (YEL 16ga ) 11TP-003-CC3 (YEL 18ga )
10 6
SP3813 712TP-006-CC3 (RED 18ga )
VEC91-P4 1 R1 R2 1 31 31 SP278 2
VEC-90
712TP-000-AA1 (RED 18ga ) 712TP-001-AC3 (RED 18ga ) 712TP-002-CC3 (RED 18ga ) 712TP-003-CC3 (RED 18ga ) 712TP-007-CC3 (RED 18ga )
58E-06-20050 712TP-004-CC3 (RED 18ga ) SH18:F-17
GB12 9
P03 J03 0-273-CC3 (BLK 18ga )
F48 D1
1 12
71CK BUSS 4E 0-274-CC3 (BLK 18ga )
E 0-362-CC3 (BLK 18ga ) SH18:F-20
5 DIAG2
VEC90-P4
B
CAN THIRD PARTY NETWORK SH14:P-10 0-315-CC3 (BLK 18ga )
712TP-005-CC3 (RED 18ga )
11TP-005-CC3 (YEL 18ga )
C
A
MODULAR MINING
DISPLAY PWR IN
CONNECTION
(GRAY) PTX_CP
HEATER COOLANT LH
46GA-005-AA1 (LBL 14ga ) 61 61 46GA-006-AH1 (LBL 14ga ) 24 24 46GA-007-FH1 (LBL 14ga ) P P 46GA-008-FF1 (LBL 14ga ) 1 1
HOT START OPTION 87-501-HH7 (WHT 14ga )
0-501-HH7 (DGR 14ga ) XB7268
GE ALTERNATOR & WHEEL MOTOR POWER CIRCUIT
46YA-005-AA1 (TAN 14ga ) 62 62 46YA-006-AH1 (TAN 14ga ) 25 25 46YA-007-FH1 (TAN 14ga ) Q Q 46YA-008-FF1 (TAN 14ga ) 2 2 AHT RIGHT DECK 86-501-HH7 (BLK 14ga )
AHT CONNECTIONS OPTION 46RA-005-AA1 (LTG 14ga )

0-438-AA1 (BLK 14ga )
63 63
64 64
46RA-006-AH1 (LTG 14ga )
0-439-AH1 (BLK 14ga )
26 26
27 27
46RA-007-FH1 (LTG 14ga )
0-440-FH1 (BLK 14ga )
R
S
R
S
46RA-008-FF1 (LTG 14ga )
0-441-FF1 (BLK 14ga )
3
4
3
4
MODE LAMPS
CONNECTOR (OPT) HEATER COOLANT RH THERMOSTAT OIL RESERVE TANK
GE CONTROL CABINET
1A1 1
MOTOR WHEEL DRIVE # 1
A1
1 7M1A1-DT1 (ORG 313-MCM )
RDML_CP A A
TB-HTST
87-502-JJ8 (WHT 14ga ) 90-510-JJ8 (BLK 14ga ) IPT1AX2 MTR1-TA1
XB7269 B B 1A2 1 A2
J11 P11 J541 P541 P502 J502 0-502-JJ8 (DGR 14ga ) 86-511-JJ8 (BLK 14ga ) EG1968 1 7M1A2-DT2 (ORG 313-MCM )
C1 C C
86-502-JJ8 (BLK 14ga ) IPT1AX3 MTR1-TA2
1B1 1 7M1B1-DT3 (ORG 313-MCM ) 1 B1
61 61 24 24 P P 1 1
46GA-004-AA1 (LBL 14ga ) 46GA-003-AJ1 (LBL 14ga ) 46GA-009-GJ1 (LBL 14ga ) 46GA-010-GG1 (LBL 14ga ) AHT LEFT DECK C2
IPT1BX2 MTR1-TB1
46YA-004-AA1 (TAN 14ga ) 62 62 46YA-003-AJ1 (TAN 14ga ) 25 25 46YA-009-GJ1 (TAN 14ga ) Q Q 46YA-010-GG1 (TAN 14ga ) 2 2 1 D4 1B2 1 7M1B2-DT4 (ORG 313-MCM ) 1 B2
GB31-A MODE LAMPS HEATER OIL RESERVE TANK
63 63 26 26 R R 3 3 D2
D3
46RA-004-AA1 (LTG 14ga ) 46RA-003-AJ1 (LTG 14ga ) 46RA-009-GJ1 (LTG 14ga ) 46RA-010-GG1 (LTG 14ga ) CONNECTOR (OPT) IPT1BX3 MTR1-TB2
0-434-AA1 (BLK 14ga ) 64 64 0-435-AJ1 (BLK 14ga ) 27 27 0-436-GJ1 (BLK 14ga ) S S 0-437-GG1 (BLK 14ga ) 4 4 87-510-JJ7 (PNK 14ga ) A A 87-511-JJ8 (BLK 14ga ) A A 1C1 1 7M1C1-DT5 (ORG 313-MCM ) 1 C1
B B B B EG1966
LDML_CP
E1 86-510-JJ7 (TAN 14ga ) 90-510-JJ8 (BLK 14ga ) IPT1CX2 MTR1-TC1
0-514-JJ7 (BLK 14ga ) C C 0-515-JJ8 (BLK 14ga ) C C 1C2 1 7M1C2-DT6 (ORG 313-MCM ) 1 C2
J12 P12 J540 P540 P503 J503

E2
CON3 IPT1CX3 MTR1-TC2
MOTOR WHEEL DRIVE # 2
TB32 SERIES 2A1 1 A1
1 7M2A1-DT7 (ORG 313-MCM )
A1
JUNCTION
A2 0-432-AA1 (BLK 14ga ) BLOCK THERMOSTAT ENGINE OIL IPT2AX2 MTR2-TA1
46GA-002-AA1 (LBL 14ga ) 2A2 1 7M2A2-DT8 (ORG 313-MCM ) 1 A2
87-503-EJ3 (BLK 14ga ) A A
TB32 IPT2AX3 MTR2-TA2
90-500-EJ3 (BLK 14ga ) B B 2B1 1 7M2B1-DT9 (ORG 313-MCM ) 1 B1
B1 B2 C C
0-505-EJ3 (BLK 14ga ) 0-504-EJ3 (BLK 14ga ) IPT2BX2 MTR2-TB1
SP706 2B2 1 1 B2
46RA-002-AA1 (LTG 14ga ) POWER RECEPTACLE ON EOTS HEATER ENGINE OIL LH 7M2B2-DT10 (ORG 313-MCM )
TB32 FRONT LH BUMPER IPT2BX3 MTR2-TB2
27 27 0-433-AH2 (BLK 14ga ) 3 3 0-442-DD1 (BLK 14ga ) 4 4 AHT REAR AXLE 86-504-EJ3 (BLK 14ga ) A A 2C1 1 7M2C1-DT11 (ORG 313-MCM ) 1 C1
TB-HTST B B
12 12 46GA-000-AA1 (LBL 14ga ) C1 C2 34 34 46GA-001-AH2 (LBL 14ga ) 4 4 46GA-011-DD1 (LBL 14ga ) 1 1 MODE LAMPS SUPPLY POWER 90-501-EJ3 (BLK 14ga ) PC0292 IPT2CX2 MTR2-TC1
13 13 46RA-000-AA1 (LTG 14ga ) 35 35 46RA-001-AH2 (LTG 14ga ) 5 5 46RA-011-DD1 (LTG 14ga ) 2 2 CONNECTOR G1 PARALLEL 0-507-EJ3 (BLK 14ga ) C C 2C2 1 7M2C2-DT12 (ORG 313-MCM ) 1 C2
SINGLE PHASE 240 VAC
14 14 46YA-002-AA1 (TAN 14ga ) 36 36 6 6 3 3 (OPT) JUNCTION
46YA-000-AA1 (TAN 14ga ) 46YA-001-AH2 (TAN 14ga ) 46YA-011-DD1 (TAN 14ga ) FULL LOAD AMPS: 35 EOH1 IPT2CX3 MTR2-TC2 ALTERNATOR PROPULSION DRIVE
G2 BLOCK HEATER ENGINE OIL RH
RBML2_CP CMTAFSE 1 1 A1
J16 P16 P72 J72 MC723 1 F4 71J-000-ST1 (ORG 1ga-MCM )
4 4 0 G3 86-503-EJ3 (BLK 14ga ) SP703 A A ALT1
SHIELD-918 0-500-JJ6 (GRN 8ga ) 86-505-EJ3 (BLK 14ga ) T19
2 90-500-EJ3 (BLK 14ga ) SP704 B B PC0292 AFSE 1 1 A2
MC728 MC726 86-500-JJ6 (BLK 8ga ) 90-502-EJ3 (BLK 14ga ) 74D-000-ST2 (ORG 1ga-MCM )
5 5 8 8 1 1 AHT 3 H1 SP705 C C ALT2
33PG-000-AA1 (BLK 18ga ) 33PG-001-AD1 (BLK 18ga ) 0-506-EJ3 (BLK 14ga ) 0-508-EJ3 (BLK 14ga ) T20
6 6 5VDI-009-AA1 (RED 18ga ) 9 9 5VDI-010-AD1 (RED 18ga ) 3 3 RIGHT REAR BRAKE 1 87-500-JJ6 (WHT 8ga ) EOH2
7 7 33PRR-000-AA1 (WHT 18ga ) 10 10 33PRR-001-AD1 (WHT 18ga ) 2 2 PRESSURE SENSOR H2
11 11 J712
SHIELD-918 SHIELD-914 RRBPS_CP
(OPT) THERMOSTAT HYDRAULIC OIL
AHT
A A
AUXBOX CONNECTOR MC727 MC725 90-503-JJ3 (BLK 14ga )
8 8 20 20 1 1 AHT TB-HTST B B
(OPT) 33PG-002-AA1 (BLK 18ga ) 33PG-003-AD1 (BLK 18ga ) 87-507-JJ3 (BLK 14ga ) EG1968
LEFT REAR BRAKE C C
9 9
10 10
5VDI-011-AA1 (RED 18ga )
33PLR-000-AA1 (WHT 18ga )
21 21
22 22
5VDI-012-AD1 (RED 18ga )
33PLR-001-AD1 (WHT 18ga )
3
2
3
2 PRESSURE SENSOR
J1
NOTE: USE GE SCHEMATIC FOR ADDITIONAL CABLES TO ALTERNATOR
23 23 (OPT) J2
SHIELD-917 SHIELD-913 LRBPS_CP
11 11 K4
SHIELD-917 HEATER HYDRAULIC OIL #1
J3
A A SP707 A A
J15 P15 86-506-JJ7 (PNK 14ga ) 86-507-JJ3 (BLK 14ga ) 86-508-JJ3 (BLK 14ga )
K1 B B SP708 B B EG1966
87-506-JJ7 (TAN 14ga ) 87-507-JJ3 (BLK 14ga ) 90-506-JJ3 (BLK 14ga )
C C SP709 C C
0-509-JJ7 (BLK 14ga ) 0-510-JJ3 (BLK 14ga ) 0-511-JJ3 (BLK 14ga )
58E-06-08830 K2
JUMPER PLUG AHT CON1
C C
18 18 11 11 B STEERING FILTER SWITCH
SH16:D-11 J9-AA8 (BLK 18ga ) 39-001-AA1 (TAN 16ga ) 39-002-AJ2 (TAN 16ga ) B
(OPT) HEATER HYDRAULIC OIL #2
39L-000-AJ2 (YEL 16ga ) A A J27-000-JJ20 (BLK 18ga )
SH16:D-11 J27-AA8 (BLK 18ga ) 17 17 39AP-003-AA1 (YEL 16ga ) 8 8 HOTSTART JUNCTION BOX 86-509-JJ3 (BLK 14ga ) A A
SFSW_JP B B
90-507-JJ3 (BLK 14ga ) EG1966
0-512-JJ3 (BLK 14ga ) C C
P702 J702
J14 P14 BRAKE FILTER PRESS
SW
C NO
B C
NC
58B-06-02390-00 APR 16
39AP-004-AJ2 (YEL 16ga ) A
BFSW
980E-5
A50005 & UP
Sheet 18 of 27
HYDRAULIC LADDER OPTION OPTIONAL HYD ACCESS LADDER F58
JUMPER PLUG NEEDED WHEN NO
11LAD-008-AA1 (BRN 18ga ) D 1D 1C C
11-017-AA1 (RED 18ga ) SH6:F-3
LADDER IS PRESENT 5
73S-006-JR1 (LBL 20ga ) 8 8 8 73S-005-AR2 (LBL 16ga ) 1 1 73S-004-AA1 (LBL 16ga ) SH5:H-16 VEC91-P1 VEC91-P1
POWER LADDER CONTROLLER JB8E 58E-06-20061
56B-06-11530
PARKING BRAKE SWITCH 10
SWITCH LADDER CONTROL
TB21
8
7
6
5
4
3
2
1
11LAD-009-JR1 (BRN 16ga ) 2 2 2 11LAD-004-AR2 (BRN 16ga ) 2 2 11LAD-007-AA1 (BRN 16ga ) F1 F2 11LAD-010-AC2 (BRN 16ga ) 21 21 11LAD-013-CC2 (BRN 18ga ) 9 9 7 7
0-768-CC2 (BLK 18ga ) SH19:K-7
VBAT 7 11LAD-000-JR1 (BRN 20ga )
3 3
11LAD-001-JR1 (BRN 16ga ) P02 J02
11LAD-002-JR1 (BRN 16ga ) 2 2B
1 1
11LAD-005-JR1 (BRN 16ga ) 6 12LU-005-CC2 (DBL 16ga )

6
11LAD-006-JR1 (BRN 16ga ) 11LAD-012-CC2 (BRN 16ga ) 5 5B
4 12LD-005-CC2 (LBL 16ga )
4
TB21
SP308
UP POSITION SENSOR 4 510E2-002-JR1 (DGR 20ga ) 510E2-006-JR1 (DGR 16ga ) 1 J9-000-JJ10 (BLK 18ga ) 1 1 510E2-000-AR2 (DGR 16ga ) 3 3 510E2-004-AA1 (DGR 18ga ) A4 A2 510E2-001-AA1 (DGR 20ga ) SH10:J-14 10 8
10 8
P35 P35
58F-06-60970
AHT
12DP-001-JR1 (BRN 16ga ) 9 9 9 12DP-004-AR2 (ORG 16ga ) 4 4 12DP-003-AA1 (ORG 18ga ) 3 3 AUXBOX CONNECTOR
(OPT)
SENSOR POWER LADDER UP J702 P702
A A
510E2-003-JR1 (DGR 16ga ) B B C C 0-304-JR1 (BLK 16ga )

56B-06-15610
UPS UPS
SENSOR POWER LADDER DOWN 3 3 3 8 8

0-688-JR1 (BLK 16ga ) 0-519-AR2 (BLK 16ga ) 0-690-AA1 (BLK 16ga ) SH7:C-16
A A
58E-06-02630
JB12D
DOWN POSITION SENSOR 5 12DP-000-JR1 (BRN 20ga ) 12DP-002-JR1 (BRN 16ga ) B B C C 0-473-JR1 (BLK 16ga )
SP454
12
11
10
56B-06-15610
9
8
7
6
5
4
3
2
1
DPS DPS
GND 6 0-089-JR1 (BLK 20ga )
0-474-JR1 (BLK 16ga )

0-058-JR1 (BLK 16ga )
0-093-JR1 (BLK 16ga ) 0-475-JR1 (BLK 16ga )
6
0-101-JR1 (BLK 16ga )
RELAY CAB LADDER ALARM
(+) (-) TB21
CAB ALARM 1 12CA-000-JR1 (YEL 20ga ) 86 85 0-474-JR1 (BLK 16ga ) C1
INTERFACE MODULE
(NO) 87 7 7 7 5 5 a HYDRAULIC LADDER ALARM
13CA-001-JR1 (YEL 16ga ) 13CA-002-AR2 (YEL 16ga ) 13CA-005-AA1 (YEL 16ga ) 13CA-003-AA1 (YEL 20ga )
30 (C)
(NC) 87A
IM2
CAR_K 58E-06-10020 SWITCH GROUND LEVEL
CAR_K LADDER OVERRIDE
(SWITCH SHOWN PULLED OUT)
RELAY LADDER UP
(+) (-)
SOLENOID 11 12HS-000-JR1 (LBL 20ga ) 86 85 0-058-JR1 (BLK 16ga )
4 3 SOLENOID HYDRAULIC LADDER
SP399
(NO) 87 1 2 1 2
13HS-000-JR1 (BRN 16ga ) 13LS-000-JR1 (LBL 16ga ) 13LS-002-JR1 (LBL 16ga ) 0-676-JR1 (BLK 16ga )
30 (C) SP400
(NC) 87A GLORS GLORS
58E-06-13190 LSOL LSOL
LUR_K 58E-06-10020
LUR_K ALARM GROUND
LEVEL LADDER
RELAY GROUND LEVEL ALARM D7
(+) (-)
GROUND ALARM 2 12GLA-000-JR1 (PNK 20ga ) 86 85 0-093-JR1 (BLK 16ga ) 1 + 13LS-001-JR1 (LBL 16ga ) 1 2 0-677-JR1 (BLK 16ga )
2 - PC2834
(NO) 87 13GLA-000-JR1 (LTG 16ga ) GLA
30 (C)
(NC) 87A 58E-06-08400
GLAR_K 58E-06-10020 0-100-JR1 (BLK 16ga ) TB21

GLAR_K
DN SWITCH 9 12LD-000-JR1 (LBL 20ga ) 4 4 4 12LD-001-AR2 (LBL 16ga ) 6 6 12LD-002-AA1 (LBL 16ga ) G1 G2 12LD-004-AC2 (LBL 16ga ) 28 28 12LD-005-CC2 (LBL 16ga )
UP SWITCH 8 12LU-000-JR1 (DBL 20ga ) 5 5 5 12LU-001-AR2 (DBL 16ga ) 7 7 12LU-002-AA1 (DBL 16ga ) H1 H2 12LU-004-AC2 (DBL 16ga ) 29 29 12LU-005-CC2 (DBL 16ga )
P7 J538 P538_JP P02 J02

P46 J46
58D-06-11100
D11
HOIST CONTROL 53BU-006-BB1 (PNK 16ga ) 1
PC2834
2 0-810-BB1 (BLK 16ga )
SWITCH HOIST UP/DN HOIST PILOT VALVE

UP
9 9 7 7 TB22 T T
0-768-CC2 (BLK 18ga ) SH19:B-22 53BU-001-AB1 (PNK 16ga ) 53BU-000-BB1 (PNK 16ga ) 53BU-005-BB1 (PNK 16ga ) 1 A1 A2 2 0-808-BB1 (BLK 16ga )
VEC-91 19 19 SP3837 SP3840
53BU-002-AC2 (PNK 16ga ) 1 M4 M3 1
F51 TB23 3 3 SOL_A
53BF-003-CC2 (LTG 16ga ) SOL_A DOWN
712 BUSS 10F F 26 26 2 2B 20 20 1 1 U U 1
B2 2
712H-003-AA1 (LBL 16ga ) W1 W2 712H-009-AC2 (LBL 16ga ) 712H-007-CC2 (LBL 16ga ) 53BF-002-AC2 (LTG 16ga ) N4 N3 53BF-001-AB1 (LTG 16ga ) 53BF-000-BB1 (LTG 16ga ) 53BF-005-BB1 (LTG 16ga ) 0-809-BB1 (BLK 16ga )
10 1 1 B1
53BU-003-CC2 (PNK 16ga ) SP3838
VEC91-P10 6 SOL_B SOL_B
58E-06-20061 P02 J02 6 J02 P02 P240 J240 PC2260
5 5B
4
4 D12
53BF-006-BB1 (LTG 16ga ) 1 2 0-096-BB1 (BLK 16ga )

SH13:J-11 71P-020-CC2 (BRN 18ga ) 10 8 0-095-CC2 (BLK 16ga ) SH10:L-15
10 8
PC2834
P36 P36
58F-06-60870
SH5:I-21 0-024-BB1 (BLK 16ga )
HYDRAULIC TAP
MANIFOLD SOLENOID
AUX HYD PRESS SWITCH
NO C 1 2
39SU-029-AH2 (TAN 16ga ) 39SU-030-AH2 (TAN 16ga ) 0-152-AH2 (BLK 16ga ) SH16:E-14
C
712H-004-AA1 (LBL 16ga ) 712H-005-AH2 (LBL 16ga ) B SP015
NC A
HTM HTM
AHPS
58E-06-30610 AHPS
D1
39SU-031-AH2 (TAN 16ga ) 1 2 0-153-AH2 (BLK 16ga ) SH16:E-14
SWITCH HOIST LIMIT PC2834
D1 D1
3 1
712H-004-AA1 (LBL 16ga ) 30 30 712H-001-AH2 (LBL 16ga ) 712H-002-AH2 (LBL 16ga ) 3 1
4 2
SP018 4 2
53H-001-AA1 (PNK 16ga ) 22 22 53H-002-AH2 (PNK 16ga ) PC2818
HLS HLS
J16 P16
TB35
N1 N2 R R 830E HOIST LIMIT
53H-003-AB1 (PNK 16ga )
SOLENOID POWER
P240 J240
SOLENOID HOIST LIMIT
53H-005-AA1 (PNK 16ga ) 3 3 53H-009-AJ2 (PNK 16ga ) 53H-010-AJ2 (PNK 16ga ) 1 2 0-386-AJ2 (BLK 16ga ) SH16:O-2
SP794
HS HS
J14 P14
D88
53H-008-AJ2 (PNK 16ga ) 1 2 0-419-AJ2 (BLK 16ga ) SH16:O-2

PC2834
58B-06-02390-00 APR 16
980E-5
A50005 & UP
Sheet 19 of 27
SWITCH KOMVISION DIM SWITCH KOMVISION CANCEL SWITCH KOMVISION BODY SWITCH KOMVISION GRIDLINE SWITCH KOMVISION MODE SWITCH KOMVISION REAR SWITCH KOMVISION RH REAR SWITCH KOMVISION RH FRONT
8X021-000-CC6 (YEL 20ga ) 3 3 8X035-000-CC6 (YEL 20ga ) 3 3 8X023-000-CC6 (YEL 20ga ) 3 3 8X025-000-CC6 (YEL 20ga ) 3 3 8X027-000-CC6 (YEL 20ga ) 3 3 8X029-000-CC6 (YEL 20ga ) 3 3 8X031-000-CC6 (YEL 20ga ) 3 3 8X033-000-CC6 (YEL 20ga ) 3 3
2
2 2
2 2
2 2
2 2
2 2
2 2
2 2
2
8X022-000-CC6 (PNK 20ga ) 6 8X036-000-CC6 (PNK 20ga ) 6 8X024-000-CC6 (PNK 20ga ) 6 8X026-000-CC6 (PNK 20ga ) 6 8X028-000-CC6 (PNK 20ga ) 6 8X030-000-CC6 (PNK 20ga ) 6 8X032-000-CC6 (PNK 20ga ) 6 8X034-000-CC6 (PNK 20ga ) 6
6 0-591-CC6 (BLK 20ga ) 6 0-594-CC6 (BLK 20ga ) 6 0-596-CC6 (BLK 20ga ) 6 0-599-CC6 (BLK 20ga ) 6 0-603-CC6 (BLK 20ga ) 6 0-605-CC6 (BLK 20ga ) 6 0-609-CC6 (BLK 20ga ) 6 0-611-CC6 (BLK 20ga )
SP022 SP122 SP032 SP042 SP052 SP062 SP072 SP082
12
12 12
12 12
12 12
12 12
12 12
12 12
12 12
12
8X022-001-CC6 (PNK 20ga ) 8X036-001-CC6 (PNK 20ga ) 8X024-001-CC6 (PNK 20ga ) 8X026-001-CC6 (PNK 20ga ) 8X028-001-CC6 (PNK 20ga ) 8X030-001-CC6 (PNK 20ga ) 8X032-001-CC6 (PNK 20ga ) 8X034-001-CC6 (PNK 20ga )
8X021-001-CC6 (YEL 20ga ) 11 11 8X035-001-CC6 (YEL 20ga ) 11 11 8X023-001-CC6 (YEL 20ga ) 11 11 8X025-001-CC6 (YEL 20ga ) 11 11 8X027-001-CC6 (YEL 20ga ) 11 11 8X029-001-CC6 (YEL 20ga ) 11 11 8X031-001-CC6 (YEL 20ga ) 11 11 8X033-001-CC6 (YEL 20ga ) 11 11
SP021 SP121 SP031 SP041 SP051 SP061 SP071 SP081
5
5 5
5 5
5 5
5 5
5 5
5 5
5 5
5
8X011-000-CC6 (ORG 20ga ) 8X010-000-CC6 (DBL 20ga ) 8X009-000-CC6 (WHT 20ga ) 8X008-000-CC6 (TAN 20ga ) 8X005-000-CC6 (BLK 20ga ) 8X004-000-CC6 (YEL 20ga ) 8X003-000-CC6 (PUR 20ga )
8 8
8 8
8 8
8 8
8 8
8 8
8 8
8 8
1 8X018-000-CC6 (LTG 20ga ) 1 0-593-CC6 (BLK 20ga ) 1 0-597-CC6 (BLK 20ga ) 1 0-600-CC6 (BLK 20ga ) 1 0-602-CC6 (BLK 20ga ) 1 0-606-CC6 (BLK 20ga ) 1 0-608-CC6 (BLK 20ga ) 1 0-612-CC6 (BLK 20ga )
8X017-000-CC6 (DBL 20ga ) 1 1 1 1 1 1 1 1
7
7 7
7 7
7 7
7 7
7 7
7 7
7 7
7
8X022-002-CC6 (PNK 20ga ) 8X036-002-CC6 (PNK 20ga ) 8X024-002-CC6 (PNK 20ga ) 8X026-002-CC6 (PNK 20ga ) 8X028-002-CC6 (PNK 20ga ) 8X030-002-CC6 (PNK 20ga ) 8X032-002-CC6 (PNK 20ga ) 8X034-002-CC6 (PNK 20ga )
1010 1010 1010 1010 1010 1010 1010 1010
4
8X013-001-CC6 (RED 20ga ) 4
8X013-003-CC6 (RED 20ga ) 4
8X013-005-CC6 (RED 20ga ) 4
8X013-007-CC6 (RED 20ga ) 4
8X013-009-CC6 (RED 20ga ) 4
8X013-013-CC6 (RED 20ga ) 4
8X013-015-CC6 (RED 20ga ) 4
8X013-017-CC6 (RED 20ga )
8X021-002-CC6 (YEL 20ga ) 4 9 9 8X035-002-CC6 (YEL 20ga ) 4 9 9 8X023-002-CC6 (YEL 20ga ) 4 9 9 8X025-002-CC6 (YEL 20ga ) 4 9 9 8X027-002-CC6 (YEL 20ga ) 4 9 9 8X029-002-CC6 (YEL 20ga ) 4 9 9 8X031-002-CC6 (YEL 20ga ) 4 9 9 8X033-002-CC6 (YEL 20ga ) 4 9 9
PC3712 PC3706 PC3705 PC3704 PC3703 PC3701 PC3702 PC3702

P0028X P0028X P0128X P0128X P0038X P0038X P0048X P0048X P0058X P0058X P0068X P0068X P0078X P0078X P0088X P0088X
0-592-CC6 (BLK 20ga ) 0-595-CC6 (BLK 20ga ) 0-598-CC6 (BLK 20ga ) 0-674-CC6 (BLK 20ga ) 0-604-CC6 (BLK 20ga ) 0-607-CC6 (BLK 20ga ) 0-610-CC6 (BLK 20ga ) SP083
SP023 SP123 SP033 SP043 SP053 SP063 SP073
SH21:F-11 8X018-000-CC6 (LTG 20ga ) 8X018-000-CC6 (LTG 20ga ) 8X018-000-CC6 (LTG 20ga ) 8X018-000-CC6 (LTG 20ga ) 8X018-000-CC6 (LTG 20ga ) 8X018-000-CC6 (LTG 20ga ) 8X018-000-CC6 (LTG 20ga ) SP084
8X013-002-CC6 (RED 20ga ) 8X013-004-CC6 (RED 20ga ) 8X013-006-CC6 (RED 20ga ) 8X013-008-CC6 (RED 20ga ) 8X013-012-CC6 (RED 20ga ) 8X013-014-CC6 (RED 20ga ) 8X013-016-CC6 (RED 20ga )
SP024 SP124 SP034 SP044 SP054 SP064 SP074
SH21:E-11
SH21:E-11
SH21:E-11
SH21:E-11 SH21:E-11
SH21:E-11 SH21:F-11
0-590-CC6 (BLK 20ga ) SH21:E-11
8X013-000-CC6 (RED 20ga ) SH21:E-11
SWITCH KOMVISION LH REAR SWITCH KOMVISION LH FRONT SWITCH KOMVISION FRONT SWITCH KOMVISION LOCK
SWITCH KOMVISION BRIGHT
3 3 3 3 3 3 3 3
8X043-000-CC6 (YEL 20ga ) 8X041-000-CC6 (YEL 20ga ) 8X039-000-CC6 (YEL 20ga ) 8X037-000-CC6 (YEL 20ga )
3 3
8X019-000-CC6 (YEL 20ga )
2 2 2 2 2 2 2 2
6 8X044-000-CC6 (PNK 20ga ) 6 8X042-000-CC6 (PNK 20ga ) 6 8X040-000-CC6 (PNK 20ga ) 6 8X038-000-CC6 (PNK 20ga ) INDICATOR KOMVISION POWER 2 2
0-629-CC6 (BLK 20ga ) 6 0-626-CC6 (BLK 20ga ) 6 0-623-CC6 (BLK 20ga ) 6 0-620-CC6 (BLK 20ga ) 6 8X020-000-CC6 (PNK 20ga )
6
6
12 12 SP162 12 12 SP152 12 12 SP200 12 12 SP132 0-615-CC6 (BLK 20ga )
8X044-001-CC6 (PNK 20ga ) 8X042-001-CC6 (PNK 20ga ) 8X040-001-CC6 (PNK 20ga ) 8X038-001-CC6 (PNK 20ga ) 0-618-CC6 (BLK 20ga ) 6 3 SP012
12 12
RED 8X020-001-CC6 (PNK 20ga )
11 11 11 11 11 11 11 11 P0098X
8X043-001-CC6 (YEL 20ga ) 8X041-001-CC6 (YEL 20ga ) 8X039-001-CC6 (YEL 20ga ) 8X037-001-CC6 (YEL 20ga ) 11
11 11
SP204 SP203 SP141 SP131 RED 8X019-001-CC6 (YEL 20ga )
5 5 5 5 5 5 5 5
8X006-000-CC6 (LBL 20ga ) 8X007-000-CC6 (GRY 20ga ) 8X002-000-CC6 (LTG 20ga ) PC3710 P0098X SP011
8
8 8
8 8
8 8
8 5 5
0-630-CC6 (BLK 20ga ) 1 1 0-627-CC6 (BLK 20ga ) 1 1 0-624-CC6 (BLK 20ga ) 1 1 0-621-CC6 (BLK 20ga ) 1 1 8 8X018-000-CC6 (LTG 20ga )
8X012-000-CC6 (BRN 20ga ) 8X013-027-CC6 (RED 20ga ) 8
1 1
7 7 7 7 7 7 7 7
8X016-000-CC6 (YEL 20ga )
8X044-002-CC6 (PNK 20ga ) 8X042-002-CC6 (PNK 20ga ) 8X040-002-CC6 (PNK 20ga ) 8X038-002-CC6 (PNK 20ga ) 7 7
8X013-033-CC6 (RED 20ga ) 1010 8X013-032-CC6 (RED 20ga ) 1010 8X013-024-CC6 (RED 20ga ) 1010 8X013-022-CC6 (RED 20ga ) 1010 8X020-002-CC6 (PNK 20ga )
9 9
4 4 9 9
4 4 9 9
4 4 9 9
4 4 1010
8X043-002-CC6 (YEL 20ga ) 8X041-002-CC6 (YEL 20ga ) 8X039-002-CC6 (YEL 20ga ) 8X037-002-CC6 (YEL 20ga ) 8X013-019-CC6 (RED 20ga ) 4 4
9 9 8X019-002-CC6 (YEL 20ga )
PC3702 PC3702 PC3701 PC3707
P0168X P0168X P0158X P0158X P0148X P0148X P0138X P0138X
P0018X PC3711 P0018X
0-628-CC6 (BLK 20ga ) 0-625-CC6 (BLK 20ga ) 0-622-CC6 (BLK 20ga ) 0-619-CC6 (BLK 20ga ) 0-617-CC6 (BLK 20ga ) 0-613-CC6 (BLK 20ga )
SP163 SP153 SP201 SP133 SP093 SP013
8X013-033-CC6 (RED 20ga ) 8X013-025-CC6 (RED 20ga ) 8X013-023-CC6 (RED 20ga ) 8X013-021-CC6 (RED 20ga ) 8X013-021-CC6 (RED 20ga ) 8X013-018-CC6 (RED 20ga )
SP154 SP202 SP134 SP014
SH21:F-11 SH21:F-11 SH21:F-11 SH21:F-11 SH21:F-11

8X045-000-CC6 (PUR 20ga ) SP091
8X045-001-CC6 (PUR 20ga ) 8X045-002-CC6 (PUR 20ga ) SH21:F-11
KOMVISION SWITCH PANEL
TERMX1 TX0
P21TX0B2 MC823 MC823 MC821 MC821 MC813 MC813 SP049 MC815 MC815 SP056 MC817
A A1 A2 A 9 9
SP046
939YX1-010-CC12 (YEL 18ga ) 939YX1-009-CR1 (YEL 18ga ) 939YX1-002-CR1 (YEL 18ga ) 939YX1-003-CR1 (YEL 18ga )
SP057 939YX1-005-CR1 (YEL 18ga ) SH21:C-19
PC0618 B B1 B2 B 10 10 SP047 SP050
939GX1-010-CC12 (GRN 18ga ) 939GX1-009-CR1 (GRN 18ga ) 939GX1-002-CR1 (GRN 18ga ) 939GX1-003-CR1 (GRN 18ga ) 939GX1-005-CR1 (GRN 18ga ) SH21:C-19
C C1 C2 C 11 11 SP048 SP055 SP058
SHIELD-024 SHIELD-024 SHIELD-023 SHIELD-023 SHIELD-030 SHIELD-030 SHIELD-028 SHIELD-028 SHIELD-026
A3 A
B3 B
C3 C J01X_CP P01X
SHIELD-039
PC0616 P21TX0D
MC803 MC818 MC816
939YX1-000-CC12 (YEL 18ga ) SH21:L-5 939GX1-008-CR1 (GRN 18ga ) SH21:E-19 939GX1-007-CR1 (GRN 18ga ) SH21:E-19 939GX1-006-CR1 (GRN 18ga ) SH21:D-19
939GX1-000-CC12 (GRN 18ga ) SH21:K-5 939YX1-008-CR1 (YEL 18ga ) SH21:E-19 939YX1-007-CR1 (YEL 18ga ) SH21:D-19 939YX1-006-CR1 (YEL 18ga ) SH21:D-19
MC818 MC816 MC814
OPERATOR CAB
AUTOLIV NETWORK (BLUE)
TERMX3 TX9 P22TX9B2

MC824 MC824 MC822 MC822 MC806 MC806 MC807 MC852 MC852 MC809 MC809
A A1 A2 A 9 9
SP059 SP066 MC807 5 5 SP069
939YX2-010-CC12 (YEL 18ga ) 939YX2-009-CD2 (YEL 18ga ) 939YX2-002-CD2 (YEL 18ga ) 939YX2-003-CD2 (YEL 18ga ) 939YX2-001-DD6 (YEL 18ga ) 939YX2-005-DD6 (YEL 18ga ) SH21:G-19
PC0618 B B1 B2 B 10 10 SP060 SP067 6 6 SP070
939GX2-010-CC12 (GRN 18ga ) 939GX2-009-CD2 (GRN 18ga ) 939GX2-002-CD2 (GRN 18ga )
SP068 939GX2-003-CD2 (GRN 18ga ) 939GX2-001-DD6 (GRN 18ga ) 939GX2-005-DD6 (GRN 18ga ) SH21:G-19
C C1 C2 C 11 11 SP065 7 7 SP075
SHIELD-035 SHIELD-035 SHIELD-022 SHIELD-022 SHIELD-037 SHIELD-037 SHIELD-036 SHIELD-036 SHIELD-000 SHIELD-000 SHIELD-034
A3 A
B3 B P16X J16X
C3 C J09X_CP P09X
SHIELD-038
PC0616 P22TX9D
MC804 MC812 MC811 MC810
939YX2-000-CC12 (YEL 18ga ) SH21:L-5 939GX2-008-CD2 (GRN 18ga ) SH21:I-19 939GX2-007-CD2 (GRN 18ga ) SH21:H-19 939GX2-006-DD6 (GRN 18ga ) SH21:H-19
939GX2-000-CC12 (GRN 18ga ) SH21:L-5 939YX2-008-CD2 (YEL 18ga ) SH21:I-19 939YX2-007-CD2 (YEL 18ga ) SH21:H-19 939YX2-006-DD6 (YEL 18ga ) SH21:H-19
MC812 MC811 MC810
OPERATOR CAB
AUTOLIV NETWORK (GREEN)
58B-06-02390-00 APR 16
980E-5
A50005 & UP
Sheet 20 of 27
OPERATOR CAB RADAR 1 KOMVISION
MC817
SH20:H-14 939YX1-005-CR1 (YEL 18ga ) 2 2
3 3 SHORT RANGE RADAR
SH21:G-10 8X013-028-CC12 (RED 20ga ) SH20:H-14 939GX1-005-CR1 (GRN 18ga )
4 4 LOCATED ON BUMPER
SH21:I-10 8X013-029-CC12 (RED 20ga ) 12VR-003-CR1 (RED 16ga )
1 1 FRONT FORWARD LH
SH21:K-10 8X013-030-CC12 (RED 14ga ) 0-565-CR1 (BLK 20ga )
5 5 (AIMING FRONT RH)
8X013-011-CC12 (RED 20ga ) 8X013-010-CC12 (RED 20ga ) 0-566-CR1 (BLK 20ga )
JB9X 6 6
8X013-026-CC12 (RED 20ga ) 0-567-CR1 (BLK 20ga )
SH21:I-13 0-716-CC2 (BLK 14ga ) 7 7 0-534-CC12 (BLK 14ga ) 1 12VR-020-CC12 (RED 16ga ) 1 1 SP3806
8
7
6
5
4
3
2
1
2 2 2 J119
12VR-000-CC12 (RED 16ga ) 12VR-021-CR1 (RED 16ga )
8X013-020-CC12 (RED 18ga ) 2 3 3 3 RADAR 2 KOMVISION
12VR-001-CC12 (RED 16ga ) 12VR-022-CR1 (RED 16ga ) MC814
SH21:K-6 11CAM-007-CC12 (YEL 18ga ) 1 4 12VR-002-CC12 (RED 16ga ) 4 4 SH20:I-14 939YX1-006-CR1 (YEL 18ga ) 2 2
PX07_CP JX07 JB8C
SH21:J-4 8X001-000-CC12 (ORG 18ga ) 6 5 12VR-004-CC12 (RED 16ga ) SH20:I-14 939GX1-006-CR1 (GRN 18ga ) 3 3
56B-06-11530 JB10X SHORT RANGE RADAR
KOMVISION 6 12VR-005-CC12 (RED 16ga ) 12VR-021-CR1 (RED 16ga ) 4 4
SERVICE LOCATED ON BUMPER
SH21:J-5 74SB1-009-CC12 (DBL 18ga ) 4 7 12VR-006-CC12 (RED 16ga ) 1 0-637-CC12 (BLK 16ga ) 5 5 0-035-CR1 (BLK 16ga ) 0-568-CR1 (BLK 16ga ) 1 1
CONNECTOR FRONT FORWARD RH
8 12VR-009-CC12 (RED 16ga ) 2 0-036-CC12 (BLK 16ga ) 6 6 0-589-CR1 (BLK 16ga ) 0-569-CR1 (BLK 16ga ) 5 5
KOMVISION CONTROLLER SP3807 (AIMING FRONT LH)
9 12VR-017-CC12 (RED 14ga ) SH21:J-10 3 0-037-CC12 (BLK 16ga ) 7 7
0-616-CR1 (BLK 16ga ) 6 6
SH21:I-3 0-536-CC12 (BLK 20ga ) 0-539-CC12 (BLK 18ga ) 9 10 4 0-038-CC12 (BLK 16ga ) 8 8
KEY SLG-1 4 12 11 5 J122
SH21:I-3 0-537-CC12 (BLK 20ga ) 0-540-CC12 (BLK 18ga ) 0-039-CC12 (BLK 16ga )
KEY SLG-2 5 12 6 RADAR 3 KOMVISION
SH21:I-10 0-538-CC12 (BLK 20ga ) 0-560-CC12 (BLK 16ga ) J01X_CP P01X MC816
GND PWR-1 6 J251X_CP 7 2 2
0-529-CC12 (BLK 20ga ) 0-044-CC12 (BLK 16ga ) SH20:I-12 939YX1-007-CR1 (YEL 18ga )
GND PWR-2 7 58E-06-02630 8 3 3 LONG RANGE RADAR
0-530-CC12 (BLK 20ga ) 0-045-CC12 (BLK 16ga ) SH20:I-12 939GX1-007-CR1 (GRN 18ga )
GND PWR-3 16 0-531-CC12 (BLK 20ga ) 9 12VR-022-CR1 (RED 16ga ) 4 4 LOCATED ON BUMPER
GND PWR-4 17 0-532-CC12 (BLK 20ga ) 0-533-CC12 (BLK 20ga ) 10 0-571-CR1 (BLK 16ga ) 1 1 FRONT RIGHT CORNER
11 SP3808 5 5
12
11
10
9
8
7
6
5
4
3
2
1
JB12A 12 0-573-CR1 (BLK 16ga ) 6 6
KVIS-B
58E-06-02630 13 13 8X013-000-CC6 (RED 20ga ) SH20:E-4
58E-06-02640 J123
1 1 0-590-CC6 (BLK 20ga ) SH20:D-4
SWITCH CANCEL 36 RADAR 4 KOMVISION
8X011-001-CC12 (ORG 20ga ) 11 11 8X011-000-CC6 (ORG 20ga ) SH20:D-4 MC818
SWITCH BODY 37 8X010-001-CC12 (DBL 20ga ) 10 10 8X010-000-CC6 (DBL 20ga ) SH20:D-7 SH20:I-9 939YX1-008-CR1 (YEL 18ga ) 2 2
SWITCH LINE 38 8X009-001-CC12 (WHT 20ga ) 9 9 8X009-000-CC6 (WHT 20ga ) SH20:D-9 SH20:I-9 939GX1-008-CR1 (GRN 18ga ) 3 3 SHORT RANGE RADAR
SWITCH MODE 39 8X008-001-CC12 (TAN 20ga ) 8 8 8X008-000-CC6 (TAN 20ga ) SH20:D-11 12VR-019-CR1 (RED 16ga ) 4 4 LOCATED ON RIGHT
SWITCH REAR 47 8X005-001-CC12 (BLK 20ga ) 5 5 8X005-000-CC6 (BLK 20ga ) SH20:D-14 0-636-CR1 (BLK 16ga ) 1 1 UPRIGHT REAR
SWITCH RH REAR 48 8X004-001-CC12 (YEL 20ga ) 4 4 8X004-000-CC6 (YEL 20ga ) SH20:D-17 5 5
SWITCH RH FRONT 49 8X003-001-CC12 (PUR 20ga ) 3 3 8X003-000-CC6 (PUR 20ga ) SH20:D-19 6 6
J124
KVIS-A 18 18 8X045-002-CC6 (PUR 20ga ) SH20:G-21
12 12 8X012-000-CC6 (BRN 20ga ) SH20:G-17
INDICATOR POWER 48 8X045-003-CC12 (PUR 20ga ) 2 2 8X002-000-CC6 (LTG 20ga ) SH20:G-14
7 7 8X007-000-CC6 (GRY 20ga ) SH20:G-12
KVIS-B 6 6 8X006-000-CC6 (LBL 20ga ) SH20:G-9
17 17 8X017-000-CC6 (DBL 20ga ) SH20:D-1 1 1 12VR-010-CD2 (RED 16ga ) 1 1 12VR-007-DD6 (RED 16ga )
SWITCH LOCK 30 8X012-001-CC12 (BRN 20ga ) 16 16 8X016-000-CC6 (YEL 20ga ) SH20:G-21 2 2 12VR-011-CD2 (RED 16ga ) 2 2 12VR-008-DD6 (RED 16ga )
SWITCH FRONT 50 8X002-001-CC12 (LTG 20ga ) 3 3 12VR-014-CD2 (RED 16ga )
SWITCH LH FRONT 40 8X007-001-CC12 (GRY 20ga ) P0178X J0178X 4 4 12VR-015-CD2 (RED 16ga )
SWITCH LH REAR 46 8X006-001-CC12 (LBL 20ga )
5 5 0-046-CD2 (BLK 16ga ) 3 3 0-541-DD6 (BLK 16ga )
6 6 0-047-CD2 (BLK 16ga ) 4 4 0-542-DD6 (BLK 16ga )
KVIS-A
7 7 0-544-CD2 (BLK 16ga )
8 8 0-545-CD2 (BLK 16ga )
MC753 MC753 P16X J16X RADAR 5 KOMVISION
VEHICLE CAN H 42 939YP-011-CC12 (YEL 18ga ) SH18:C-14 MC809
VEHICLE CAN L 41 939GP-011-CC12 (GRN 18ga ) SH18:C-14 SH20:J-15 939YX2-005-DD6 (YEL 18ga ) 2 2
KOMVISION DISPLAY MONITOR J09X_CP P09X
SH20:J-15 939GX2-005-DD6 (GRN 18ga ) 3 3
MC752 MC752 SHORT RANGE RADAR
J1939 CAN H 32 939YE-020-CC12 (YEL 18ga ) SH18:E-13 8X016-001-CC12 (YEL 20ga ) 3 BRIGHTNESS + 4 4
LOCATED ON REAR AXLE
J1939 CAN L 31 939GE-020-CC12 (GRN 18ga ) SH18:E-13 8X017-001-CC12 (DBL 20ga ) 4 BRIGHTNESS - SP3809 0-577-DD6 (BLK 20ga ) 1 1
RH (AIMING REAR LH)
0-578-DD6 (BLK 20ga ) 5 5
DISPLAY ON/OFF 38 8X046-000-CC12 (ORG 20ga ) 8X046-000-CC12 (ORG 20ga ) 2 DISPLAY ON/OFF 0-579-DD6 (BLK 20ga ) 6 6
SH21:C-4 8X013-028-CC12 (RED 20ga ) 6 LIGHT
J125
KVIS-B RADAR 6 KOMVISION
MC810
GND SLG D-2 8 0CAM-000-CC12 (BLK 20ga ) 0CAM-000-CC12 (BLK 20ga ) 5 SIGNAL GND SH20:K-15 939YX2-006-DD6 (YEL 18ga ) 2 2
SH20:K-15 939GX2-006-DD6 (GRN 18ga ) 3 3
P44 4 4
KVIS-A 12VR-008-DD6 (RED 16ga ) LONG RANGE RADAR
0-580-DD6 (BLK 16ga ) 1 1 LOCATED ON REAR AXLE
SP3810 5 5
SP164 MC838 MC838 SP213 0-581-DD6 (BLK 16ga ) LH (AIMING REAR RH)
HSYNC A 910-001-CC12 (WHT 20ga ) 910-000-CC12 (WHT 26ga ) MC838A 910-002-CC12 (WHT 20ga ) 4 HSYNC 6 6
SP205 SHIELD-100-CC12 (BARE SHLD_16ga ) MC838A SP214

GND SIG SYNC J 11 GND SIG SYNC J126
0GSS-000-CC12 (BLK 20ga ) SHIELD-101-CC12 (BARE SHLD_16ga ) MC838B SP215 0GSS-001-CC12 (BLK 20ga )
VSYNC B SP206 5 VSYNC RADAR 7 KOMVISION
911-001-CC12 (YEL 20ga ) 911-000-CC12 (YEL 26ga ) MC838B SP216 911-002-CC12 (YEL 20ga ) MC811
RGB R C SP207 9 RGB R 2 2
912-001-CC12 (RED 20ga ) 912-000-CC12 (RED 26ga ) MC838C SP217 912-002-CC12 (RED 20ga ) SH20:K-11 939YX2-007-CD2 (YEL 18ga )
GND R D SP208 10 GND R 3 3 SHORT RANGE RADAR
SHIELD-986-CC12 (BLK 20ga ) SHIELD-102-CC12 (BARE SHLD_16ga ) MC838C SHIELD-985-CC12 (BLK 20ga ) SH20:K-11 939GX2-007-CD2 (GRN 18ga )
RGB G E SP209 SP178 8 RGB G 4 4 LOCATED ON LH UPRIGHT
913-001-CC12 (DGR 20ga ) 913-000-CC12 (GRN 26ga ) MC838D SP179 913-002-CC12 (DGR 20ga ) 12VR-014-CD2 (RED 16ga )
GND G F SP210 3 GND G 1 1 REAR
SHIELD-990-CC12 (BLK 20ga ) SHIELD-199-CC12 (BARE SHLD_16ga ) MC838D SP218 SHIELD-989-CC12 (BLK 20ga ) 0-544-CD2 (BLK 16ga ) 0-583-CD2 (BLK 16ga )
RGB B G SP211 6 RGB B SP3811 5 5
914-001-CC12 (DBL 20ga ) 914-000-CC12 (BLU 26ga ) MC838E SP219 914-002-CC12 (DBL 20ga )
GND B H SP212 7 GND B 6 6
SHIELD-988-CC12 (BLK 20ga ) SHIELD-104-CC12 (BARE SHLD_16ga ) MC838E SHIELD-987-CC12 (BLK 20ga ) 0-585-CD2 (BLK 16ga )
11CAM-001-CC12 (YEL 20ga ) 1 PWR IN BATT
RGB 12 PWR CTR KEY J127
ALARM KOMVISION ERROR (ESON) SH21:C-4 8X013-029-CC12 (RED 20ga )
2 GND PWR GB12 RADAR 8 KOMVISION
SH21:D-4 0-538-CC12 (BLK 20ga ) MC812
INDICATOR ERROR 46 8X048-000-CC12 (LBL 20ga ) + 0-714-CC12 (BLK 14ga ) 1 D3 SH20:K-9 939YX2-008-CD2 (YEL 18ga ) 2 2
P45 7831476000 3 3
D4
SH20:K-9 939GX2-008-CD2 (GRN 18ga )
SH21:D-4 0-536-CC12 (BLK 20ga ) - SH21:D-1 0-716-CC2 (BLK 14ga ) 1 12VR-015-CD2 (RED 16ga ) 4 4 LONG RANGE RADAR
PC0251 LOCATED ON FRONT
0-545-CD2 (BLK 16ga ) 1 1
ALARM KOMVISION RADAR (RSON) 5 5 BUMPER LEFT CORNER
8X050-002-CC12 (DBL 14ga ) 2 2 8X050-001-CC2 (DBL 14ga ) 6 6
INDICATOR RADAR 47 8X047-000-CC12 (DBL 20ga ) +
J128
SH21:D-4 0-537-CC12 (BLK 20ga ) -
PB1951
RELAY RADAR POWER (RPR)
(+) (-)
RADAR POWER CTRL 39 8X049-002-CC12 (PNK 18ga ) 86 85
VEC RTMR1
FUSE - F2
AUX BOX
(NO) 87 TB25
12VR-017-CC12 (RED 14ga ) SH21:D-11
30 (C) 6 6 8X050-000-AC2 (DBL 14ga ) 1 P1 P2 1 8X050-003-AA2 (DBL 14ga ) 1 C10 D10 1
11B1-004-AA2 (LBL 14ga ) SH6:I-9
PWR CTR EXT 3 (NC) 87A SH16:N-14 20A
8X001-000-CC12 (ORG 18ga ) SH21:D-7 74SB1-010-AA1 (DBL 18ga ) RTMR1-C10 RTMR1-D10
5 5 38 38 1 58E-06-02610
RPR_K 74SB1-007-CC12 (DBL 18ga ) 74SB1-006-CC2 (DBL 18ga ) 74SB1-001-AC2 (DBL 14ga ) 1 T1 T2 74SB1-002-AA1 (DBL 18ga ) SH4:B-22
PC1730 58E-65-00061
SP005 RPR_K
SYSTEM BUSY 10 74SB1-008-CC12 (DBL 18ga ) 74SB1-007-CC12 (DBL 18ga ) T3 1 74SB1-000-AC3 (DBL 18ga ) SH15:H-16
74SB1-009-CC12 (DBL 18ga ) SH21:D-7 0-713-CC12 (BLK 18ga ) 4 4 0-535-CC2 (BLK 18ga )
PWR IN BATT-1 8 1
SWITCH KOMVISION ON/OFF VEC RTMR1
11CAM-002-CC12 (YEL 18ga ) T4 74SB1-005-AA3 (DBL 18ga ) SH13:K-3 FUSE - F1
PWR IN BATT-2 9 1
11CAM-003-CC12 (YEL 18ga )
PWR IN BATT-3 18 TB25 2 1 1 A10 B10 1
11CAM-004-CC12 (YEL 18ga ) 71CKM-000-AA2 (BRN 14ga ) 71CK-004-AA2 (PNK 14ga ) SH6:H-9
PWR IN BATT-4 19 1 1 8 8 1 3 15A
11CAM-005-CC12 (YEL 18ga ) 11CAM-000-CC12 (YEL 18ga ) SH21:C-4 8X013-030-CC12 (RED 14ga ) 8X013-031-CC2 (RED 14ga ) 8X013-034-AC2 (RED 14ga ) 1 S1 S2 1 8X013-035-AA2 (RED 14ga ) KOMV-2 RTMR1-A10 RTMR1-B10
58E-06-02390
11CAM-007-CC12 (YEL 18ga ) SH21:D-7 KOMV-3
4 58E-65-00061
8
7
6
5
4
3
2
1
TB25 5 1
11CMX-000-AA2 (TAN 14ga ) VEC RTMR1
3 3 7 7 1 R1 R2 1 1 6
JB12B JB12C
11CAM-006-CC2 (YEL 18ga ) 11CAM-008-AC2 (YEL 14ga ) 11CAM-009-AA2 (YEL 14ga ) KOMV-5 FUSE - F3
JB8B 58E-06-02630 58E-06-02640 KOMV-6 1258403H1
1 E10 F10 1
SH6:F-3
56B-06-11530 JX07 PX07_CP J02 P02 11-014-AA2 (RED 14ga )
15A
RTMR1-E10 58E-06-02390 RTMR1-F10
12
11
10
12
11
10
58E-65-00061
7
7
9
8
6
5
4
3
2
1
9
8
6
5
4
3
2
1
RADAR CAN1 L 11
MC803
939GX1-000-CC12 (GRN 18ga ) SH20:I-4
RADAR CAN1 H 12 939YX1-000-CC12 (YEL 18ga ) SH20:I-4
CAMERA 1
RADAR CAN2 H 2
MC804 1 1 1 1
939YX2-000-CC12 (YEL 18ga ) SH20:K-4 24CAM-009-CC13 (PNK 16ga ) 24CAM-001-CL1 (PNK 16ga )
RADAR CAN2 L 1 939GX2-000-CC12 (GRN 18ga ) SH20:K-4 0DOS-009-CC13 (BLK 16ga ) 3 3 0DOS-001-CL1 (BLK 16ga ) 3 3
SP244 2 2 SP110 SP087 2 2 LOCATED ON ACCESS LADDER
SP254 SHIELD-039 26AV-005-CC13 (DGR 18ga ) 26AV-001-CL1 (DGR 18ga ) 26AV-003-CL1 (WHT 25ga ) 26AV-002-CL1 (DGR 18ga )
GND COMM-3 35 MC835 SP243 4 4 SP105 MC844 SP090 4 4
0COMX-000-CC12 (BLK 18ga ) SHIELD-038 SHIELD-016 8X073-003-CC13 (BLK 16ga ) 8X073-001-CL1 (BLK 16ga ) SHIELD-006 SHIELD-006 8X073-002-CL1 (BLK 16ga )
JX10_CP PX10 CAM1 CAMERA 2
KVIS-B
24CAM-008-CC13 (PNK 16ga ) 1 1 24CAM-002-CF1 (PNK 16ga ) 1 1
0DOS-008-CC13 (BLK 16ga ) 3 3 0DOS-002-CF1 (BLK 16ga ) 3 3
SP120 SP101 SP089 LOCATED ON RIGHT DECK
26AV1-005-CC13 (DGR 18ga ) 2 2 26AV1-001-CF1 (DGR 18ga ) 26AV1-003-CF1 (WHT 25ga ) 26AV1-002-CF1 (DGR 18ga ) 2 2
MC830 SP240 SP099 SP088 FACING FORWARD
8X074-003-CC13 (BLK 16ga ) 4 4 8X074-001-CF1 (BLK 16ga ) MC845 8X074-002-CF1 (BLK 16ga ) 4 4
CAM2 CAMERA 3
24CAM-007-CC13 (PNK 16ga ) 5 5 24CAM-003-CF1 (PNK 16ga ) 1 1
0DOS-007-CC13 (BLK 16ga ) 6 6 0DOS-003-CF1 (BLK 16ga ) 3 3 LOCATED ON RIGHT DECK
SP238 7 7
SP098 SP086 2 2
26AV2-003-CC13 (DGR 18ga ) 26AV2-001-CF1 (DGR 18ga ) 26AV2-004-CF1 (WHT 25ga ) 26AV2-002-CF1 (DGR 18ga ) FACING RIGHT OF TRUCK
MC833 SP232 SP097 SP085
8X075-002-CC13 (BLK 16ga ) 8 8 8X075-001-CF1 (BLK 16ga ) MC846 8X075-003-CF1 (BLK 16ga ) 4 4
CAM3 CAMERA 4
POWER OUT CAMERA A 24CAM-000-CC13 (PNK 20ga ) 24CAM-006-CC13 (PNK 16ga ) 9 9 24CAM-010-CF1 (PNK 16ga ) 1 1
0DOS-006-CC13 (BLK 16ga ) 10 10 0DOS-010-CF1 (BLK 16ga ) 3 3
SP119 SP170 SP080 LOCATED ON REAR AXLE
DOS L MR B 0DOS-000-CC13 (BLK 20ga ) 26AV3-003-CC13 (DGR 18ga ) 11 11 26AV3-001-CF1 (DGR 18ga ) 26AV3-004-CF1 (WHT 25ga ) 26AV3-002-CF1 (DGR 18ga ) 2 2
MC834 SP103 8X076-002-CC13 (BLK 16ga ) 12 12 SP279 MC847 SP128 4 4
SP221 SHIELD-017 8X076-001-CF1 (BLK 16ga ) SHIELD-003 SHIELD-003 8X076-003-CF1 (BLK 16ga )
AV NTSC 0 C 26AV-000-CC13 (DGR 20ga ) 26AV-006-CC13 (WHT 25ga )
GND NTSC 0 D
SP222 MC835 JX11_CP PX11 CAM4 CAMERA 5
8X073-000-CC13 (BLK 20ga ) SP186 SHIELD-016
AV NTSC 1 E 26AV1-000-CC13 (DGR 20ga ) 26AV1-006-CC13 (WHT 25ga ) 24CAM-005-CC13 (PNK 16ga ) 5 5 24CAM-011-CL1 (PNK 16ga ) 1 1
GND NTSC 1 F
SP223 MC830 6 6 3 3 LOCATED ON LEFT DECK
8X074-000-CC13 (BLK 20ga ) SHIELD-021 0DOS-005-CC13 (BLK 16ga ) 0DOS-011-CL1 (BLK 16ga )
AV NTSC 2 G
SP188 SP255 7 7
SP159 SP079 2 2 FACING LEFT OF TRUCK
26AV2-000-CC13 (DGR 20ga ) 26AV2-006-CC13 (WHT 25ga ) 26AV4-003-CC13 (DGR 18ga ) 26AV4-001-CL1 (DGR 18ga ) 26AV4-004-CL1 (WHT 25ga ) 26AV4-002-CL1 (DGR 18ga )
GND NTSC 2 H
SP189 MC833 MC831 SP197 8 8
SP096 MC848 SP127 4 4
8X075-000-CC13 (BLK 20ga ) 8X077-002-CC13 (BLK 16ga ) 8X077-001-CL1 (BLK 16ga ) 8X077-003-CL1 (BLK 16ga )
SP190 SHIELD-018 SHIELD-020 SHIELD-002 SHIELD-002
AV NTSC 3 J 26AV3-000-CC13 (DGR 20ga ) 26AV3-006-CC13 (WHT 25ga )
GND NTSC 3 K SP224 MC834 CAM5 CAMERA 6
8X076-000-CC13 (BLK 20ga ) SP225 SHIELD-017
AV NTSC 4 L 26AV4-000-CC13 (DGR 20ga ) 26AV4-006-CC13 (WHT 25ga ) 24CAM-004-CC13 (PNK 16ga ) 9 9 24CAM-012-CL1 (PNK 16ga ) 1 1
GND NTSC 4 M
SP226 MC831 10 10 3 3
8X077-000-CC13 (BLK 20ga ) SHIELD-020 0DOS-004-CC13 (BLK 16ga ) 0DOS-012-CL1 (BLK 16ga ) LOCATED ON LEFT DECK
AV NTSC 5 N
SP227 SP102 11 11
SP095 SP126 2 2
26AV5-000-CC13 (DGR 20ga ) SP228 26AV5-006-CC13 (WHT 25ga ) 26AV5-003-CC13 (DGR 18ga ) 26AV5-001-CL1 (DGR 18ga ) 26AV5-004-CL1 (WHT 25ga ) 26AV5-002-CL1 (DGR 18ga ) FACING FORWARD
GND NTSC 5 P MC832 MC832 SP118 12 12
SP094 MC849 SP125 4 4
8X078-000-CC13 (BLK 20ga ) 8X078-002-CC13 (BLK 16ga ) 8X078-001-CL1 (BLK 16ga ) 8X078-003-CL1 (BLK 16ga )
CAM6
NTSC1 JX10_CP PX10
KOMVISION
58B-06-02390-00 APR 16
980E-5
A50005 & UP
Sheet 21 of 27
WIRE TABLE
CONTINUED ON SHEETS 23, 24, 25
NAME DEVICE FROM CONN FROM DEVICE TO CONN TO NAME DEVICE FROM CONN FROM DEVICE TO CONN TO NAME DEVICE FROM CONN FROM DEVICE TO CONN TO NAME DEVICE FROM CONN FROM DEVICE TO CONN TO NAME DEVICE FROM CONN FROM DEVICE TO CONN TO NAME DEVICE FROM CONN FROM DEVICE TO CONN TO
-15VDI-000 GE DID PANEL DID - J02 0-143 - J502 SP147 - 0-323 GE CONTROL INTERFACE P305 GB31-B GB31B-B3 0-484 - J11 SP11 - 0-669 - P807 SP237 - 5VDI-010 - P15 - RRBPS_CP
-15VDI-001 TB21 TB21-V2 - P02 0-144 SP147 - LAMP MARKER/TURN RIGHT FRT DEC... RCL1 0-324 SENSOR FUEL LEVEL FLS SP185 - 0-493 SP246 - - J543 0-670 SP292 - DEF SUPPLY PUMP #3 (DSP3) DSP3 5VDI-011 - J15 - J702
-15VDI-003 TB21 TB21-V1 DID POWER SUPPLY P500_CP 0-145 SP147 - LAMP MARKER/TURN RIGHT SIDE DE... RCL2 0-325 - J16 GB31-B GB31B-E2 0-494 SP246 - - J541 0-672 SP286 - DOSING MODULE 1 (DM1) DM1 5VDI-012 - P15 - LRBPS_CP
0-000 GB70 FRAME GND GB70-A2 BUSS_BAR_0 DISC(-)-5 0-146 - J16 SP15 - 0-326 SP008 - - P16 0-495 - P541 - P502 0-673 DOSING MODULE 2 (DM2) DM2 SP286 - 5VIM-000 TB30 TB30-K1 INTERFACE MODULE IM3
0-001 24VDC ALTERNATOR ALT(-) GB70 FRAME GND GB70-A1 0-147 - J14 SP14 - 0-327 SP185 - - P730 0-496 - J502 LAMP RH DECK (OPT) DLT_CP 0-674 SP043 - SP053 - 5VIM-001 TB30 TB30-K1 INTERFACE MODULE IM3
0-002 GB70 FRAME GND GB70-B2 GB31-B GB31B-E1 0-148 GB31-B GB31B-F1 - P808 0-328 SP185 - SWITCH STEERING FILTER #1 SFSW 0-500 - J712 TB-HTST TB-HTST-D4 0-675 RELAY LINE HEATER (LHR) - K7 LHR(85) - J49 5VIM-002 - J14 TB30 TB30-K2
0-003 BUSS_BAR_0 DISC(-)-4 MOTOR STARTER 1 (STRT1) STRT1-2A 0-149 - P14 - P732_CP 0-329 GB12 GB12-A1 - J227 0-501 HEATER COOLANT LH - TB-HTST TB-HTST-C1 0-676 SOLENOID HYDRAULIC LADDER LSOL SP400 - 5VIM-003 TB30 TB30-K4 - J14
0-004 BUSS_BAR_0 DISC(-)-3 MOTOR STARTER 2 (STRT2) STRT2-2A 0-151 SWITCH TRACTION CONTROL P30 SWITCH SPEED CONTROL ROCKER P29 0-331 - P14 SWITCH LOW STEERING PRESSURE ACPSW 0-502 HEATER COOLANT RH - TB-HTST TB-HTST-C2 0-677 D7 D7 SP400 - 5VIM-004 TB30 TB30-K3 - J14
0-005 VEC-90 VEC90-S7A VEC-89 VEC89-S7A 0-152 HYDRAULIC TAP MANIFOLD SOLENOI... HTM SP008 - 0-332 - P14 SP799 - 0-503 SP801 - OIL RESERVE SYS P502_CP 0-678 DEF SUPPLY PUMP #4 (DSP4) DSP4 SP292 - 5VIM-005 - P14 SENSOR BRAKE TEMP RH REAR P710
0-006 RELAY KEY/GE CNTRL PWR (KCNPR) KCNPR-85 RELAY KEY SWITCH (KSWPR) KSWPR-85 0-153 D1 D1 SP008 - 0-333 - J14 SP14 - 0-504 SP706 - THERMOSTAT ENGINE OIL EOTS 0-680 SP076 - - P73 5VIM-006 - J14 TB30 TB30-L2
0-007 RELAY KEY/GE CNTRL PWR (KCNPR) KCNPR-85 12V POWER RELAY (12VPR) 12VPR-85 0-154 - P808 GB31-B GB31B-F1 0-334 - J14 SP14 - 0-505 SP706 - TB-HTST TB-HTST-E1 0-681 LINE HEATER DEF SUCTION 1 (LH9... LH9 SP282 - 5VIM-007 - P14 SENSOR DUCT AIR TEMPERATURE ATS
0-008 - J11 SP09 - 0-155 LAMP CONTROL CABINET WORK LIGH... CDL2 SP151 - 0-335 SP077 - - P13 0-506 SP706 - SP705 - 0-682 LINE HEATER DEF SUCTION 2 (LH1... LH10 SP282 - 5VIM-008 - J14 TB30 TB30-L4
0-009 12VDC CONVERTER (12VCN) 12VCN-GND GB31-A GB31A-A3 0-156 - P16 - P731_CP 0-336 - J13 GB31-B GB31B-E4 0-507 HEATER ENGINE OIL LH EOH1 SP705 - 0-683 LINE HEATER DEF SUCTION 3 (LH1... LH11 SP282 - 5VIM-009 - P14 SENSOR BRAKE TEMP LH REAR P709
0-010 R1 R1 GB31-A GB31A-B3 0-157 RELAY HEADLIGHT HIGH MOUNT (HH... HHMR-85 RELAY BACKUP LIGHT (BULR) BULR-85 0-337 SWITCH PARK BRAKE SET PBPSW SP408 - 0-508 SP705 - HEATER ENGINE OIL RH EOH2 0-684 LINE HEATER DEF SUCTION 4 (LH1... LH12 SP282 - 5VIM-010 - P14 SENSOR BRAKE TEMP RH FRONT P708
0-011 VEC-91 VEC91-S6B GB31-A GB31A-B1 0-158 SP195 - LAMP GREEN PAYLOAD RIGHT RPLG_CP 0-338 SP408 - SWITCH LOW BRAKE ACCUM PRESSUR... LBPS 0-509 TB-HTST TB-HTST-D2 - CON1 0-685 LINE HEATER DEF TRANSFER (LH13... LH13 SP283 - 5VIM-011 - P14 SENSOR BRAKE TEMP LH FRONT P707
0-012 VEC-91 VEC91-S6A VEC-90 VEC90-S7B 0-159 SWITCH FOG LAMP (OPT) P23 SWITCH HEADLIGHTS P20 0-339 SP408 - SWITCH SERVICE BRAKE DEGRADE P... BDS 0-510 SP709 - - CON2 0-686 HEATER DEF FAST FILL RECEIVER ... DFFR SP283 - 5VPL-000 PAY LOAD METER 4 P264 PLM4 COMMUNICATION BOX COMMB
0-013 RELAY HEADLIGHT LOW MOUNT (HLM... HLMR-85 RELAY HEADLIGHT HIGH MOUNT (HH... HHMR-85 0-160 GB31-B GB31B-A2 SP14 - 0-340 - P14 SENSOR HYDRAULIC TANK LEVEL P712 0-511 HEATER HYDRAULIC OIL #1 HOHTR1 SP709 - 0-687 HEATER DEF FAST FILL VALVE (DF... DFFV SP283 - 5VUSB-000 PLM4 COMMUNICATION BOX COMMA PAY LOAD METER 4 P264
0-014 RELAY HI-BEAM HEADLIGHT (HBHR) HBHR-85 RELAY KEY SWITCH (KSWPR) KSWPR-85 0-161 - J14 SP14 - 0-341 - J14 SP14 - 0-512 SP709 - HEATER HYDRAULIC OIL #2 HOHTR2 0-688 JB12D JB12D - J538 7KTS-000 ORBCOMM MODEM (OPT) CNA KOMTRAX PLUS MODULE KP-A
0-015 RELAY HI-BEAM HEADLIGHT (HBHR) HBHR-85 GB31-B GB31B-B1 0-162 - J12 SP13 - 0-342 - J511 SP796 - 0-513 SP801 - - P11 0-689 HEATER ELEC DEF PUMP 1 (DHP1) DHP1 SP291 - 7KTWU-000 KOMTRAX PLUS MODULE KP-B SP280 -
0-016 RELAY HEADLIGHT LOW MOUNT (HLM... HLMR-85 RELAY ACCESS LADDER LIGHT (ALL... ALLR-85 0-163 - J12 SP13 - 0-343 - P511 SWITCH AUTOLUBE LEVEL (OPT) P512 0-514 - CON3 TB-HTST TB-HTST-E2 0-690 - J46 GB31-A GB31A-D1 7KTWU-001 - DIAG3 SP280 -
0-017 SP257 - GB31-A GB31A-B3 0-164 - J11 SP10 - 0-344 - J11 SP10 - 0-515 HEATER OIL RESERVE TANK ECHTR2 - CON4 0-691 HEATER ELEC DEF PUMP 2 (DHP2) DHP2 SP291 - 7KTWU-002 SP280 - ORBCOMM MODEM (OPT) CNA
0-018 DL1 DL1 SP104 - 0-165 - J11 SP10 - 0-345 R30 R30 TB21 TB21-X3 0-516 BATT1 BAT1(+) BATT2 BAT2(-) 0-692 HEATER ELEC DEF PUMP 3 (DHP3) DHP3 SP291 - 7M1A1 GE CONTROL CABINET IPT1AX2 MOTOR WHEEL DRIVE # 1 MTR1-TA1
0-019 SP104 - DL2 DL2 0-166 - P11 - J543 0-346 SP363 - GB12 GB12-E2 0-517 BATT3 BAT3(+) BATT4 BAT4(-) 0-693 HEATER ELEC DEF PUMP 4 (DHP4) DHP4 SP291 - 7M1A2 GE CONTROL CABINET IPT1AX3 MOTOR WHEEL DRIVE # 1 MTR1-TA2
0-020 DL3 DL3 SP104 - 0-167 - P543 LAMP RH DIAGONAL LADDER RDLLT_CP 0-347 JB8D JB8D GB12 GB12-B4 0-518 OIL RESERVE SYS P506_CP - P11 0-694 - J73 SP344 - 7M1B1 GE CONTROL CABINET IPT1BX2 MOTOR WHEEL DRIVE # 1 MTR1-TB1
0-021 DL4 DL4 SP257 - 0-168 SP246 - - P11 0-348 JB8D JB8D KOMTRAX PLUS MODULE KP-B 0-519 - P46 - P538_JP 0-695 LINE HEATER DEF PRESSURE 1 (LH... LH1 SP289 - 7M1B2 GE CONTROL CABINET IPT1BX3 MOTOR WHEEL DRIVE # 1 MTR1-TB2
0-022 DL5 DL5 SP257 - 0-169 LAMP RH DECK RDLT_CP - P543 0-349 JB8D JB8D KOMTRAX PLUS MODULE KP-B 0-520 PAY LOAD METER 4 P264 PLM4 COMMUNICATION BOX COMMB 0-696 LINE HEATER DEF RETURN 1 (LH2) LH2 SP289 - 7M1C1 GE CONTROL CABINET IPT1CX2 MOTOR WHEEL DRIVE # 1 MTR1-TC1
0-023 DL6 DL6 SP257 - 0-170 - J542 - P12 0-350 JB8D JB8D KOMTRAX PLUS MODULE KP-B 0-521 - J12 SP15 - 0-697 LINE HEATER DEF PRESSURE 2 (LH... LH3 SP288 - 7M1C2 GE CONTROL CABINET IPT1CX3 MOTOR WHEEL DRIVE # 1 MTR1-TC2
0-024 SP3840 - SP406 - 0-171 LAMP LH DIAGONAL LADDER LDLLT_CP - P542 0-351 JB8D JB8D KOMTRAX PLUS MODULE KP-B 0-522 SP007 - GB12 GB12-C1 0-698 - J73 SP347 - 7M2A1 GE CONTROL CABINET IPT2AX2 MOTOR WHEEL DRIVE # 2 MTR2-TA1
0-026 BUSS_BAR_0 DISC(-)-7 LAMP LED MASTER DISCONNECT CL... MLLON 0-172 - J542 - P12 0-352 ORBCOMM MODEM (OPT) CNB JB8D JB8D 0-523 HEATED HOSE RELAY TSW-85 SP15 - 0-699 SP008 - - J730 7M2A2 GE CONTROL CABINET IPT2AX3 MOTOR WHEEL DRIVE # 2 MTR2-TA2
0-027 BUSS_BAR_0 DISC(-)-7 JB1 JB1 0-173 - P542 LAMP LH DECK (OPT) LDLT_CP 0-353 ORBCOMM MODEM (OPT) CNB JB8D JB8D 0-524 SP455 - OIL RESERVE SYS CM1_FVAL_CP 0-700 SP199 - PAY LOAD METER 4 P264 7M2B1 GE CONTROL CABINET IPT2BX2 MOTOR WHEEL DRIVE # 2 MTR2-TB1
0-028 MOTOR STARTER 1 (STRT1) STRT1-2B MOTOR STARTER 2 (STRT2) STRT2-2B 0-174 - P565 - P14 0-356 - J808 ENGINE QSK78 INTERFACE P806 0-525 SP455 - OIL RESERVE SYS CM2_FVAL_CP 0-701 SP199 - TB24 TB24-X2 7M2B2 GE CONTROL CABINET IPT2BX3 MOTOR WHEEL DRIVE # 2 MTR2-TB2
0-029 SP362 - SENSOR SCR 1 SCR1 0-175 - J565 SP151 - 0-357 GB3 ENG GND BLOCK GB3-A1 SOLENOID A/C COMPRESSOR CLUTCH P803 0-526 SP455 - OIL RESERVE SYS ORS_FVAL_CP 0-702 LINE HEATER DEF RETURN 2 (LH4) LH4 SP288 - 7M2C1 GE CONTROL CABINET IPT2CX2 MOTOR WHEEL DRIVE # 2 MTR2-TC1
0-030 JB1 JB1 RELAY PROPEL LOCKOUT PLREL_K 0-176 LAMP CAB DOME DRIVER CDL1(-) GB12 GB12-C2 0-358 GB3 ENG GND BLOCK GB3-A1 SWITCH A/C RECIEVER DRYER RECDR 0-527 SP801 - OIL RESERVE SYS P501_CP 0-703 HVAC MODULE P137 GB12 GB12-B3 7M2C2 GE CONTROL CABINET IPT2CX3 MOTOR WHEEL DRIVE # 2 MTR2-TC2
0-031 JB1 JB1 RELAY STARTER LOCKOUT SLREL_K 0-177 ETHERNET SWITCH ENET_PWR GB31-A GB31A-B4 0-359 - J50 SWITCH DOOR PIN (DPSW1) DPSW1-2 0-528 LAMP CAB DOME PASSENGER CDL4(-) GB12 GB12-C3 0-704 SP299 - SP286 - 7MSU-000 KOMTRAX PLUS MODULE KP-B ORBCOMM MODEM (OPT) CNA
0-032 JB1 JB1 LAMP LED PROPEL LOCKOUT ON PLON 0-178 GB12 GB12-A2 ACTIA DISPLAY PANEL DIMMER P18 0-360 LAMP CAB DOME CENTER RH CDL3(-) GB12 GB12-C2 0-529 KOMVISION CONTROLLER KVIS-B JB12A JB12A 0-705 LINE HEATER DEF PRESSURE 3 (LH... LH5 SP287 - 8X001-000 KOMVISION CONTROLLER KVIS-B - J251X_CP
0-033 JB1 JB1 LAMP LED PROPEL LOCKOUT LOCKED... PLLO 0-179 SWITCH DISPLAY MODE #2 P27 SWITCH HEATED MIRROR P28 0-361 TB28 TB28-R2 GB31-B GB31B-C4 0-530 KOMVISION CONTROLLER KVIS-B JB12A JB12A 0-706 LINE HEATER DEF RETURN 3 (LH6) LH6 SP287 - 8X002-000 - J0178X SWITCH KOMVISION FRONT P0148X
0-034 LAMP LED STARTER LOCKOUT OPEN SLLO JB1 JB1 0-180 SWITCH DISPLAY MODE #1 P26 SWITCH DISPLAY MODE #1 P26 0-362 - DIAG4 GB12 GB12-D1 0-531 KOMVISION CONTROLLER KVIS-B JB12A JB12A 0-708 LINE HEATER DEF PRESSURE 4 (LH... LH7 SP284 - 8X002-001 KOMVISION CONTROLLER KVIS-A - P0178X
0-035 - P01X SP3806 - 0-182 SWITCH DISPLAY MODE #1 P26 SWITCH DISPLAY MODE #2 P27 0-363 SP142 - SP196 - 0-532 KOMVISION CONTROLLER KVIS-B JB12A JB12A 0-709 LINE HEATER DEF RETURN 4 (LH8) LH8 SP284 - 8X003-000 - J0178X SWITCH KOMVISION RH FRONT P0088X
0-036 - J01X_CP JB10X JB10X 0-183 SWITCH DISPLAY MODE #2 P27 SWITCH DISPLAY MODE #2 P27 0-364 SP147 - SP195 - 0-533 - P0178X JB12A JB12A 0-710 SP293 - SP282 - 8X003-001 KOMVISION CONTROLLER KVIS-A - P0178X
0-037 - J01X_CP JB10X JB10X 0-185 ELECTRONIC GAUGE DISPLAY P903 GB12 GB12-C4 0-365 PAY LOAD METER 4 P264 GB31-B GB31B-A3 0-534 JB12A JB12A - JX07 0-711 SP283 - SP293 - 8X004-000 - J0178X SWITCH KOMVISION RH REAR P0078X
0-038 - J01X_CP JB10X JB10X 0-187 R27 R27 GB12 GB12-A2 0-366 LAMP LED STARTER LOCKOUT CLOSE... SLON JB1 JB1 0-535 - PX07_CP GB12 GB12-D4 0-712 SP286 - DOSING MODULE 3 (DM3) DM3 8X004-001 KOMVISION CONTROLLER KVIS-A - P0178X
0-039 - J09X_CP JB10X JB10X 0-189 LAMP RED PAYLOAD RIGHT RPLR_CP SP195 - 0-367 SP196 - LAMP RED PAYLOAD LEFT LPLR_CP 0-536 ALARM KOMVISION ERROR (ESON) ESON(-) JB12A JB12A 0-713 - JX07 RELAY RADAR POWER (RPR) RPR_K 8X005-000 - J0178X SWITCH KOMVISION REAR P0068X
0-040 ENGINE PRELUBE HIGH VOLUME PUM... PLPM-(-) GB3 ENG GND BLOCK GB3-B3 0-191 SP009 - SWITCH LEFT WINDOW P072 0-368 SP196 - LAMP AMBER PAYLOAD LEFT LPLA_CP 0-537 ALARM KOMVISION RADAR (RSON) RSON(-) JB12A JB12A 0-714 GB12 GB12-D3 JB10X JB10X 8X005-001 KOMVISION CONTROLLER KVIS-A - P0178X
0-041 RELAY ENGINE PRELUBE MAG SWITC... PLMS-(-) GB3 ENG GND BLOCK GB3-B1 0-192 SP009 - SWITCH LEFT WINDOW P072 0-369 LAMP GREEN PAYLOAD LEFT LPLG_CP SP196 - 0-538 KOMVISION DISPLAY MONITOR P45 JB12A JB12A 0-715 SP286 - DOSING MODULE 4 (DM4) DM4 8X006-000 - J0178X SWITCH KOMVISION LH REAR P0168X
0-042 RELAY ENGINE PRELUBE P800 RELAY ENGINE PRELUBE MAG SWITC... PLMS-(-) 0-193 WIRELESS ACCESS KWB - J607 0-370 SCORE BOARD RIGHT (OPT) CNRIN SCORE BOARD LEFT (OPT) CNLO 0-539 JB12A JB12A - J251X_CP 0-716 GB12 GB12-D4 - PX07_CP 8X006-001 KOMVISION CONTROLLER KVIS-A - P0178X
0-043 24VDC ALTERNATOR 2 ALT2(-) GB70 FRAME GND GB70-B1 0-195 SP009 - SWITCH LEFT WINDOW P072 0-375 TB36 TB36-R4 GB31-B GB31B-A3 0-540 JB12A JB12A - J251X_CP 0-721 SP286 - - P807 8X007-000 - J0178X SWITCH KOMVISION LH FRONT P0158X
0-044 - J09X_CP JB10X JB10X 0-197 SP007 - SWITCH RIGHT WINDOW P071 0-377 MOTOR WINDSHIELD WASHER WW- - PWW 0-541 SP3809 - - J16X 0-722 SP362 - - P807 8X007-001 KOMVISION CONTROLLER KVIS-A - P0178X
0-045 - J09X_CP JB10X JB10X 0-198 SP007 - SWITCH RIGHT WINDOW P071 0-378 RELAY WIPER MOTOR HIGH P08_K RELAY WIPER MOTOR LOW P09_K 0-542 SP3810 - - J16X 0-723 - J807 - J808 8X008-000 - J0178X SWITCH KOMVISION MODE P0058X
0-046 - P09X - P16X 0-199 SP195 - LAMP AMBER PAYLOAD RIGHT RPLA_CP 0-380 RELAY WIPER MOTOR LOW P09_K TIMER WASHER DELAY MOD (WADT) WADT-3 0-544 SP3811 - - P09X 0-724 - J807 - J808 8X008-001 KOMVISION CONTROLLER KVIS-A - P0178X
0-047 - P09X - P16X 0-200 SWITCH RIGHT WINDOW P071 SP007 - 0-382 MOTOR WINDSHIELD WIPER P07 GB12 GB12-B3 0-545 RADAR 8 KOMVISION J128 - P09X 0-725 - J807 - J808 8X009-000 - J0178X SWITCH KOMVISION GRIDLINE P0048X
0-048 RELAY ENG STARTER 1 (ESREL1) ESREL1-85 RELAY ENG STARTER 2 (ESREL2) ESREL2-85 0-202 - J210 GB12 GB12-F1 0-383 12VDC POWER PORT #1 PWR1-2 GB12 GB12-B1 0-546 TB31 TB31-V4 GB31-A GB31A-D4 0-726 - J807 - J808 8X009-001 KOMVISION CONTROLLER KVIS-A - P0178X
0-049 - P12 RELAY ENG STARTER 1 (ESREL1) ESREL1-85 0-203 GB31-A GB31A-C1 - P04 0-384 12VDC POWER PORT #2 PWR2-2 GB12 GB12-B1 0-547 R2 R2 GB31-B GB31B-E3 0-727 - J807 - J808 8X010-000 - J0178X SWITCH KOMVISION BODY P0038X
0-050 - J12 SP13 - 0-204 - J04_CP GB12 GB12-F4 0-385 SP799 - SWITCH STEERING BLEED PRESSURE SABS 0-550 ETHERNET SWITCH GND-SWITCH GB31-B GB31B-C4 0-728 - J807 - J808 8X010-001 KOMVISION CONTROLLER KVIS-A - P0178X
0-051 SP408 - SWITCH PARK BRAKE RELEASE PRES... PBRPS 0-211 - J601_CP GB12 GB12-A4 0-386 SP799 - SOLENOID HOIST LIMIT HS 0-560 - J09X_CP JB10X JB10X 0-729 - J807 - J808 8X011-000 - J0178X SWITCH KOMVISION CANCEL P0128X
0-052 SWITCH SPEED CONTROL ROCKER P29 SWITCH DISPLAY MODE #1 P26 0-212 - J601_CP GB12 GB12-A4 0-387 SP198 - TB24 TB24-X3 0-565 SP3806 - RADAR 1 KOMVISION J119 0-730 - J807 - J808 8X011-001 KOMVISION CONTROLLER KVIS-A - P0178X
0-055 - J12 SP12 - 0-213 - J602_CP GB12 GB12-B1 0-388 R51 R51 TB27 TB27-W4 0-566 SP3806 - RADAR 1 KOMVISION J119 0-731 - J807 - J808 8X012-000 - J0178X SWITCH KOMVISION LOCK P0138X
0-056 SWITCH CAB LADDER LIGHT P21 SWITCH MANUAL BACKUP LIGHT P22 0-215 - P808 GB31-B GB31B-A1 0-390 SP363 - RELAY WIPER MOTOR HIGH P08_K 0-567 SP3806 - RADAR 1 KOMVISION J119 0-732 - J807 - J808 8X012-001 KOMVISION CONTROLLER KVIS-A - P0178X
0-058 RELAY LADDER UP LUR_K JB12D JB12D 0-216 - J12 SP13 - 0-395 - J541 - P11 0-568 SP3807 - RADAR 2 KOMVISION J122 0-743 - P808 GB31-A GB31A-F1 8X013-000 - J0178X SP024 -
0-059 SWITCH BRAKE LOCK P39 SWITCH BRAKE LOCK P39 0-218 - P12 OIL RESERVE SYS P505_CP 0-396 - P502 - P541 0-569 SP3807 - RADAR 2 KOMVISION J122 0-744 - P808 GB31-A GB31A-F1 8X013-001 SP024 - SWITCH KOMVISION DIM P0028X
0-060 SP115 - ENGINE QSK78 INTERFACE P804 0-219 - J12 SP13 - 0-397 - P548_CP - J502 0-571 SP3808 - RADAR 3 KOMVISION J123 0-745 - P808 GB31-A GB31A-F1 8X013-002 SP024 - SP124 -
0-061 SP116 - ENGINE QSK78 INTERFACE P804 0-220 - P11 OIL RESERVE SYS P180_CP 0-398 - J540 - P12 0-573 RADAR 3 KOMVISION J123 SP3808 - 0-746 - P808 GB31-A GB31A-F2 8X013-003 SP124 - SWITCH KOMVISION CANCEL P0128X
0-062 SP117 - ENGINE QSK78 INTERFACE P804 0-222 SP09 - - J11 0-399 - P503 - P540 0-577 SP3809 - RADAR 5 KOMVISION J125 0-747 - P808 GB31-A GB31A-F2 8X013-004 SP124 - SP034 -
0-063 SP115 - - J808 0-223 - J11 SP09 - 0-400 - P549_CP - J503 0-578 SP3809 - RADAR 5 KOMVISION J125 0-748 - P808 GB31-A GB31A-F2 8X013-005 SP034 - SWITCH KOMVISION BODY P0038X
0-064 SP115 - - J808 0-225 GB31-B GB31B-D4 - P240 0-401 - J11 SP08 - 0-579 SP3809 - RADAR 5 KOMVISION J125 0-749 - P808 GB31-A GB31A-F3 8X013-006 SP034 - SP044 -
0-065 SP116 - - J808 0-226 - P240 GB31-B GB31B-D4 0-402 - J12 SP11 - 0-580 SP3810 - RADAR 6 KOMVISION J126 0-750 - P808 GB31-A GB31A-F3 8X013-007 SP044 - SWITCH KOMVISION GRIDLINE P0048X
0-066 SP116 - - J808 0-229 TB21 TB21-X1 R19 R19 0-403 - J11 SP08 - 0-581 RADAR 6 KOMVISION J126 SP3810 - 0-751 - P808 GB31-A GB31A-F4 8X013-008 SP044 - SP054 -
0-067 SP117 - - J808 0-230 INTERFACE MODULE IM1 TB21 TB21-X2 0-404 - J541 - P11 0-583 SP3811 - RADAR 7 KOMVISION J127 0-752 - P808 GB31-A GB31A-F4 8X013-009 SP054 - SWITCH KOMVISION MODE P0058X
0-068 SP117 - - J808 0-231 R18 R18 TB21 TB21-X3 0-405 - P502 - P541 0-585 RADAR 7 KOMVISION J127 SP3811 - 0-757 GB31-B GB31B-A4 GE CONTROL INTERFACE RTN 8X013-010 - P0178X JB8C JB8C
0-069 - P808 GB31-B GB31B-C1 0-234 GB31-A GB31A-C3 TB36 TB36-K1 0-406 MIRROR HEATED RIGHT DECK MIRROR1_CP - J502 0-589 - P01X SP3807 - 0-768 SWITCH HOIST UP/DN P36 SWITCH LADDER CONTROL P35 8X013-011 KOMVISION CONTROLLER KVIS-B JB8C JB8C
0-070 - P808 GB31-B GB31B-C1 0-235 TB36 TB36-K1 TB27 TB27-W3 0-407 - J12 SP11 - 0-590 - J0178X SP023 - 0-771 KOMTRAX PLUS MODULE CN5 - J608 8X013-012 SP054 - SP064 -
0-071 - P808 GB31-B GB31B-C1 0-236 WIRELESS ACCESS KWB - J607 0-408 - J540 - P12 0-591 SP023 - SWITCH KOMVISION DIM P0028X 0-777 KOMTRAX PLUS MODULE CN5 - J608 8X013-013 SP064 - SWITCH KOMVISION REAR P0068X
0-072 - P808 GB31-B GB31B-B4 0-237 RELAY ACCESS LADDER LIGHT (ALL... ALLR-85 GB31-A GB31A-A4 0-409 - P503 - P540 0-592 SP023 - SP123 - 0-778 RTMR4 RTMR4 RELAY LINE HEATER (LHR) - K7 LHR(85) 8X013-014 SP064 - SP074 -
0-073 - P808 GB31-B GB31B-B4 0-238 TB24 TB24-X1 TB21 TB21-X4 0-410 MIRROR HEATED LEFT DECK MIRROR2_CP - J503 0-593 SP123 - SWITCH KOMVISION CANCEL P0128X 0-779 - P608 - P607 8X013-015 SP074 - SWITCH KOMVISION RH REAR P0078X
0-074 - P808 GB31-B GB31B-D1 0-239 SP453 - D3 D3 0-412 GB12 GB12-B4 SWITCH BRAKE TEST P25 0-594 SP123 - SWITCH KOMVISION CANCEL P0128X 0-780 - P608 - P607 8X013-016 SP074 - SP084 -
0-075 - J11 SP10 - 0-240 - J16 SP15 - 0-413 GB31-A GB31A-C2 SP12 - 0-595 SP123 - SP033 - 0-808 SP3840 - HOIST PILOT VALVE SOL_A 8X013-017 SP084 - SWITCH KOMVISION RH FRONT P0088X
0-076 - J543 - P11 0-241 - J16 SP15 - 0-414 GB31-A GB31A-D2 SP13 - 0-596 SP033 - SWITCH KOMVISION BODY P0038X 0-809 HOIST PILOT VALVE SOL_B SP3840 - 8X013-018 SP014 - SP084 -
0-077 - P520_CP - P543 0-242 SP15 - - J16 0-415 GB31-B GB31B-B2 SP15 - 0-597 SP033 - SWITCH KOMVISION BODY P0038X 0-810 SP3840 - D11 D11 8X013-019 SP014 - SWITCH KOMVISION BRIGHT P0018X
0-078 SP3824 - - J520 0-243 - P16 - P73 0-416 GB31-B GB31B-C2 SP08 - 0-598 SP033 - SP043 - 0-811 GB12 GB12-E2 - JWW 8X013-020 - J251X_CP JB8C JB8C
0-079 VEC RTMR1 RTMR1-C2 GB31-A GB31A-D1 0-244 - P16 - P73 0-417 GB31-B GB31B-D2 SP09 - 0-599 SP043 - SWITCH KOMVISION GRIDLINE P0048X 0-812 GB12 GB12-A1 VID PANEL VID(-) 8X013-021 SP134 - SP014 -
0-080 - J12 SP13 - 0-245 - P16 SP076 - 0-418 DIRECTION SELECTOR SHIFTER P108 SP365 - 0-600 SP043 - SWITCH KOMVISION GRIDLINE P0048X 0-888 HVAC MODULE P137 GB12 GB12-B4 8X013-022 SP134 - SWITCH KOMVISION LOCK P0138X
0-081 - P12 SP796 - 0-248 HORN BACKUP RIGHT RRBH-(-) SP344 - 0-419 SP799 - D88 D88 0-601 SP309 - ENGINE QSK78 INTERFACE P804 0-897 - J51 SWITCH DOOR PIN (DPSW2) DPSW2-2 8X013-023 SP202 - SP134 -
0-082 - P542 - ETHER1_CP 0-249 HORN BACKUP LEFT LRBH-(-) SP344 - 0-420 SP09 - - J11 0-602 SP053 - SWITCH KOMVISION MODE P0058X 0-898 - P50 GB12 GB12-C3 8X013-024 SP202 - SWITCH KOMVISION FRONT P0148X
0-084 - J11 SP10 - 0-251 LAMP BACKUP RIGHT REAR HIDBLR SP344 - 0-421 SP08 - - J11 0-603 SP053 - SWITCH KOMVISION MODE P0058X 0-899 - P51 GB12 GB12-C3 8X013-025 SP154 - SP202 -
0-085 SP077 - AIR RESTRICTION SWITCH 2 ARS2 0-252 LAMP BACKUP LEFT REAR HIDBLL SP344 - 0-422 SP11 - - J12 0-604 SP053 - SP063 - 0ACL-001 TB31 TB31-W2 - P01 8X013-026 KOMVISION CONTROLLER KVIS-B JB8C JB8C
0-086 - P808 GB31-B GB31B-D3 0-253 LAMP RETARD LEFT REAR LRL SP350 - 0-423 - J14 SP14 - 0-605 SP063 - SWITCH KOMVISION REAR P0068X 0ACL-002 - J01 - P236 8X013-027 SP014 - SWITCH KOMVISION BRIGHT P0018X
0-087 SP077 - SWITCH ACCUMULATOR PRECHARGE P... ACCP2-C 0-254 SP350 - LAMP RETARD RIGHT REAR RRL 0-424 - J12 SP12 - 0-606 SP063 - SWITCH KOMVISION REAR P0068X 0ACL-003 GE CONTROL INTERFACE P304 TB31 TB31-W1 8X013-028 KOMVISION DISPLAY MONITOR P44 JB8C JB8C
0-089 JB12D JB12D POWER LADDER CONTROLLER P7 0-255 - J11 SP08 - 0-425 - J12 SP12 - 0-607 SP063 - SP073 - 0ACL-004 TB31 TB31-W3 GE CONTROL INTERFACE P305 8X013-029 KOMVISION DISPLAY MONITOR P45 JB8C JB8C
0-091 LAMP SERVICE BRAKE OP-CAB (SBL... SBL(-) GB12 GB12-E1 0-256 - J541 - P11 0-426 - J12 SP11 - 0-608 SP073 - SWITCH KOMVISION RH REAR P0078X 0ACL-005 TB31 TB31-W3 GE CONTROL INTERFACE P305 8X013-030 - JX07 JB8C JB8C
0-093 RELAY GROUND LEVEL ALARM GLAR_K JB12D JB12D 0-257 - P502 - P541 0-428 GB12 GB12-F1 - RRBB2 0-609 SP073 - SWITCH KOMVISION RH REAR P0078X 0BLF-000 TB31 TB31-B1 GE CONTROL INTERFACE P305 8X013-031 - PX07_CP - J02
0-094 - J12 SP12 - 0-258 LAMP BACKUP RIGHT DECK (OPT) RBUL_CP - J502 0-429 SP3827 - - ETHER 0-610 SP083 - SP073 - 0BRF-000 TB31 TB31-K1 GE CONTROL INTERFACE P305 8X013-032 SP154 - SWITCH KOMVISION LH FRONT P0158X
0-095 SWITCH HOIST UP/DN P36 SWITCH BRAKE LOCK P39 0-259 LAMP BACKUP LEFT DECK (OPT) LBUL_CP - J503 0-430 D13 D13 SP3827 - 0-611 SP083 - SWITCH KOMVISION RH FRONT P0088X 0CAM-000 KOMVISION CONTROLLER KVIS-A KOMVISION DISPLAY MONITOR P44 8X013-033 SP154 - SWITCH KOMVISION LH REAR P0168X
0-096 D12 D12 SP3840 - 0-260 SP365 - DIRECTION SELECTOR SHIFTER CON... P109 0-431 SP3827 - SOLENOID ETHER START (OPT) ESOL 0-612 SP083 - SWITCH KOMVISION RH FRONT P0088X 0COM-000 GE DID PANEL DID - J02 8X013-034 - P02 TB25 TB25-S1
0-097 SP104 - SP257 - 0-261 - P503 - P540 0-432 - J16 GB31-A GB31A-D3 0-613 SP013 - SP083 - 0COM-001 TB22 TB22-S2 - P02 8X013-035 TB25 TB25-S2 SWITCH KOMVISION ON/OFF KOMV-3
0-098 SOLENOID BRAKE LOCK BLS SP453 - 0-262 - J540 - P12 0-433 - P16 - P72 0-614 DID POWER SUPPLY P500_CP GB31-B GB31B-B3 0COM-010 TB22 TB22-S1 DID POWER SUPPLY P500_CP 8X016-000 - J0178X SWITCH KOMVISION BRIGHT P0018X
0-099 - P210 ENTERTAINMENT RADIO P737 0-263 - J12 SP11 - 0-434 - J12 GB31-A GB31A-D3 0-615 SP013 - SWITCH KOMVISION BRIGHT P0018X 0COMX-000 KOMVISION CONTROLLER KVIS-B SP254 - 8X016-001 KOMVISION DISPLAY MONITOR P44 - P0178X
0-100 JB12D JB12D ALARM GROUND LEVEL LADDER GLA 0-264 SP347 - LAMP STOP/TAIL LEFT LRSTL 0-435 - P12 - J540 0-616 SP3808 - - P01X 0DL-000 SP294 - LAMP CAB DOME DRIVER CDL1(D) 8X017-000 - J0178X SWITCH KOMVISION DIM P0028X
0-101 RELAY CAB LADDER ALARM CAR_K RELAY CAB LADDER ALARM CAR_K 0-265 LAMP STOP/TAIL RIGHT RRSTL SP347 - 0-436 - P540 - P503 0-617 SP093 - SP013 - 0DL-001 SP294 - LAMP CAB DOME CENTER LH CDL2(D) 8X017-001 KOMVISION DISPLAY MONITOR P44 - P0178X
0-102 LAMP RIGHT FOG RFLT - P543 0-266 GB12 GB12-A3 SP365 - 0-437 - J503 - LDML_CP 0-618 SP093 - INDICATOR KOMVISION POWER P0098X 0DL-002 SP294 - LAMP CAB DOME CENTER RH CDL3(D) 8X018-000 SWITCH KOMVISION BRIGHT P0018X SWITCH KOMVISION DIM P0028X
0-103 - J543 - P11 0-267 CAB FAN FAN1 GB12 GB12-F1 0-438 - J11 GB31-A GB31A-D3 0-619 SP133 - SP093 - 0DL-003 LAMP CAB DOME PASSENGER CDL4(D) SP294 - 8X019-000 SP011 - SWITCH KOMVISION BRIGHT P0018X
0-104 - J11 SP09 - 0-268 SWITCH MANUAL BACKUP LIGHT P22 SWITCH FOG LAMP (OPT) P23 0-439 - J541 - P11 0-620 SP133 - SWITCH KOMVISION LOCK P0138X 0DL-004 SP294 - - P50 8X019-001 SP011 - SWITCH KOMVISION BRIGHT P0018X
0-105 LAMP LEFT FOG LFLT - P542 0-270 - J14 SP14 - 0-440 - P541 - P502 0-621 SP133 - SWITCH KOMVISION LOCK P0138X 0DL-005 SP294 - - P51 8X019-002 SWITCH KOMVISION BRIGHT P0018X SP011 -
0-106 - J542 - P12 0-271 SP191 - - DIAG3 0-441 - RDML_CP - J502 0-622 SP201 - SP133 - 0DL-006 - J51 SWITCH DOOR PIN (DPSW2) DPSW2-1 8X020-000 SP012 - SWITCH KOMVISION BRIGHT P0018X
0-109 - P808 GB31-B GB31B-F1 0-272 SP191 - - DIAG3 0-442 - J72 - RBML2_CP 0-623 SP201 - SWITCH KOMVISION FRONT P0148X 0DL-007 SWITCH DOOR PIN (DPSW1) DPSW1-1 - J50 8X020-001 SP012 - SWITCH KOMVISION BRIGHT P0018X
0-110 - J542 - P12 0-273 - DIAG2 GB12 GB12-D1 0-444 LAMP HYDRAULIC CABINET #2 HL2 SP407 - 0-624 SP201 - SWITCH KOMVISION FRONT P0148X 0DOS-000 KOMVISION CONTROLLER NTSC1 JB12C JB12C 8X020-002 SWITCH KOMVISION BRIGHT P0018X SP012 -
0-111 LAMP HIGH MOUNT LEFT HI-BEAM HMLHB - P542 0-274 - DIAG2 GB12 GB12-D1 0-445 SP407 - LAMP HYDRAULIC CABINET #1 HL1 0-625 SP153 - SP201 - 0DOS-001 - PX10 CAMERA 1 CAM1 8X021-000 SP021 - SWITCH KOMVISION DIM P0028X
0-112 - J542 - P12 0-275 SP009 - GB12 GB12-B2 0-446 SWITCH HEATED MIRROR P28 SWITCH ENGINE WARMING P31 0-626 SP153 - SWITCH KOMVISION LH FRONT P0158X 0DOS-002 - PX11 CAMERA 2 CAM2 8X021-001 SP021 - SWITCH KOMVISION DIM P0028X
0-113 LAMP LOW MOUNT LEFT LOW-BEAM LMLLB - P542 0-276 - J540 - P12 0-447 TB30 TB30-B2 TB28 TB28-R2 0-627 SP153 - SWITCH KOMVISION LH FRONT P0158X 0DOS-003 - PX11 CAMERA 3 CAM3 8X021-002 SWITCH KOMVISION DIM P0028X SP021 -
0-114 - J542 - P12 0-277 LAMP LEFT UPPER ENGINE SERVICE LUESL - P540 0-448 RELAY MASTER DISCONNECT MLREL_K JB1 JB1 0-628 SP163 - SP153 - 0DOS-004 JB12C JB12C - JX10_CP 8X022-000 SP022 - SWITCH KOMVISION DIM P0028X
0-115 - P543 LAMP LOW MOUNT RIGHT LOW-BEAM LMRLB 0-278 GB12 GB12-E2 SP191 - 0-449 SP796 - - J542 0-629 SP163 - SWITCH KOMVISION LH REAR P0168X 0DOS-005 JB12C JB12C - JX10_CP 8X022-001 SP022 - SWITCH KOMVISION DIM P0028X
0-116 - J543 - P11 0-279 - J540 - P12 0-450 SP365 - SWITCH BRAKE LOCK P39 0-630 SP163 - SWITCH KOMVISION LH REAR P0168X 0DOS-006 JB12C JB12C - JX11_CP 8X022-002 SWITCH KOMVISION DIM P0028X SP022 -
0-117 - P542 LAMP HIGH MOUNT LEFT LOW-BEAM HMLLB 0-280 LAMP LEFT LOWER ENGINE SERVICE LLESL - P540 0-454 SP406 - - J240 0-631 - J563 SP713 - 0DOS-007 - JX11_CP JB12C JB12C 8X023-000 SP031 - SWITCH KOMVISION BODY P0038X
0-118 - J542 - P12 0-282 - J541 - P11 0-455 SP453 - SP406 - 0-632 SP713 - LAMP HYD TANK SERVICE HSL 0DOS-008 - JX11_CP JB12C JB12C 8X023-001 SP031 - SWITCH KOMVISION BODY P0038X
0-119 - J543 - P11 0-283 LAMP RIGHT UPPER ENGINE SERVIC... RUESL - P541 0-456 SP408 - - J240 0-633 SP713 - LAMP FUEL TANK SERVICE FSL 0DOS-009 JB12C JB12C - JX10_CP 8X023-002 SWITCH KOMVISION BODY P0038X SP031 -
0-120 - P543 LAMP HIGH MOUNT RIGHT LOW-BEAM HMRLB 0-284 - P227 SWITCH DRIVERS SEAT BELT P212 0-457 SP407 - - J240 0-636 RADAR 4 KOMVISION J124 - P01X 0DOS-010 - PX11 CAMERA 4 CAM4 8X024-000 SP032 - SWITCH KOMVISION BODY P0038X
0-121 LAMP LOW MOUNT LEFT HI-BEAM LMLHB - P542 0-285 SP165 - - P11 0-460 SP717 - - J55 0-637 - J01X_CP JB10X JB10X 0DOS-011 - PX10 CAMERA 5 CAM5 8X024-001 SP032 - SWITCH KOMVISION BODY P0038X
0-122 - P11 - J543 0-286 - J541 SP165 - 0-461 SP717 - LAMP BODY RIGHT SIDE MARKER RSCL1 0-638 SP109 - ENGINE QSK78 INTERFACE P804 0DOS-012 - PX10 CAMERA 6 CAM6 8X024-002 SWITCH KOMVISION BODY P0038X SP032 -
0-123 - P543 LAMP HIGH MOUNT RIGHT HI-BEAM HMRHB 0-287 - P541 LAMP RIGHT LOWER ENGINE SERVIC... RLESL 0-462 LAMP BODY RIGHT REAR MARKER RSCL2 SP717 - 0-639 SP109 - - J808 0GSS-000 SP205 - KOMVISION CONTROLLER RGB 8X025-000 SP041 - SWITCH KOMVISION GRIDLINE P0048X
0-124 - P11 - J543 0-288 SWITCH RIGHT ENGINE SERVICE LA... RESLS-1 SP165 - 0-463 SP717 - LAMP BODY RIGHT SIDE TURN RSTL 0-640 SP109 - - J808 0GSS-001 SP214 - KOMVISION DISPLAY MONITOR P45 8X025-001 SP041 - SWITCH KOMVISION GRIDLINE P0048X
0-125 - P543 LAMP LOW MOUNT RIGHT HI-BEAM LMRHB 0-289 SWITCH AUTOLUBE PRESSURE LLPS SP076 - 0-464 SP720 - - P54 0-641 GB31-B GB31B-D1 - P808 0LF-000 - P13 SENSOR LEFT FRONT WHEEL SPEED P507 8X025-002 SWITCH KOMVISION GRIDLINE P0048X SP041 -
0-126 - J11 SP10 - 0-290 - J540 - P12 0-465 SP720 - LAMP BODY LEFT SIDE TURN LSTL 0-643 SP362 - - P49 0LF-001 TB33 TB33-P2 - J13 8X026-000 SP042 - SWITCH KOMVISION GRIDLINE P0048X
0-127 - J11 SP09 - 0-291 - P503 - P540 0-466 SP720 - LAMP BODY LEFT SIDE MARKER LSCL1 0-645 - P807 SP289 - 0LF-002 GE CONTROL INTERFACE P301 TB33 TB33-P1 8X026-001 SP042 - SWITCH KOMVISION GRIDLINE P0048X
0-128 - J12 SP12 - 0-292 - J503 HORN FRONT VEHICLE AHS 0-467 LAMP BODY LEFT REAR MARKER LSCL2 SP720 - 0-646 SP288 - - P807 0LF-003 GE CONTROL INTERFACE P301 TB33 TB33-P3 8X026-002 SWITCH KOMVISION GRIDLINE P0048X SP042 -
0-129 - J12 SP12 - 0-293 - J808 SWITCH ENGINE RUN OIL PRESSURE... EOPS 0-470 SP362 - SENSOR SCR 2 SCR2 0-647 SP287 - - P807 0RET-001 TB31 TB31-V2 - P01 8X027-000 SP051 - SWITCH KOMVISION MODE P0058X
0-130 SP10 - GB31-A GB31A-A2 0-300 SP076 - - P55 0-471 GB5 FRAME GND BLOCK GB5-1 GB4 ENG SUBFRAME GND BLOCK GB4-1 0-648 SP284 - - P807 0RET-002 GE CONTROL INTERFACE P302 TB31 TB31-V1 8X027-001 SP051 - SWITCH KOMVISION MODE P0058X
0-131 SP11 - GB31-A GB31A-B2 0-301 SP076 - - J54 0-472 - P240 GB31-B GB31B-D4 0-649 SP293 - - P807 0RET-008 - J01 RETARD CONTROL PEDAL P235 8X027-002 SWITCH KOMVISION MODE P0058X SP051 -
0-132 SWITCH BRAKE TEST P25 SWITCH TRACTION CONTROL P30 0-304 JB12D JB12D SENSOR POWER LADDER UP UPS 0-473 JB12D JB12D SENSOR POWER LADDER DOWN DPS 0-650 SP291 - - P807 0RF-000 - P13 SENSOR RIGHT FRONT WHEEL SPEED P501 8X028-000 SP052 - SWITCH KOMVISION MODE P0058X
0-134 - J12 SP11 - 0-308 - J230 GB12 GB12-A3 0-474 RELAY CAB LADDER ALARM CAR_K JB12D JB12D 0-652 SP299 - SOLENOID DEF TANK COOLANT (TC) TC 0RF-001 - J13 TB33 TB33-K2 8X028-001 SP052 - SWITCH KOMVISION MODE P0058X
0-135 - J11 SP08 - 0-309 - J227 GB12 GB12-A3 0-475 SP400 - JB12D JB12D 0-653 SP299 - SENSOR AMBIENT TEMP (AT) AT 0RF-002 GE CONTROL INTERFACE P301 TB33 TB33-K1 8X028-002 SP052 - SWITCH KOMVISION MODE P0058X
0-136 SWITCH ENGINE WARMING P31 SWITCH HAZARD LIGHTS P33 0-310 GB12 GB12-B3 SWITCH CAB SECONDARY ENGINE SH... ESS-B 0-476 - P12 - J540 0-654 - P807 SP292 - 0RF-003 GE CONTROL INTERFACE P301 TB33 TB33-K3 8X029-000 SP061 - SWITCH KOMVISION REAR P0068X
0-137 LAMP RETARD OP-CAB (DRL) DRL(-) GB12 GB12-E1 0-311 - J73 SP350 - 0-477 - P540 - P503 0-655 SP292 - DEF SUPPLY PUMP #1 (DSP1) DSP1 1M-000 LAMP LED MASTER DISCONNECT OPE... MLLO RELAY MASTER DISCONNECT MLREL_K 8X029-001 SP061 - SWITCH KOMVISION REAR P0068X
0-138 - J503 SP142 - 0-315 - PTX_CP SP363 - 0-478 LAMP CONTROL CABINET WORK LIGH... CDL1 SP151 - 0-661 SP309 - - J808 1S-000 LAMP LED STARTER LOCKOUT OPEN SLLO RELAY STARTER LOCKOUT SLREL_K 8X029-002 SWITCH KOMVISION REAR P0068X SP061 -
0-139 SP142 - LAMP MARKER/TURN LEFT SIDE DEC... LCL1 0-316 LAMP CAB DOME CENTER LH CDL2(-) GB12 GB12-C2 0-480 SP3824 - SOLENOID ENGINE SHUTTER (OPT) ESSOL 0-662 SP309 - - J808 5VDI-000 GE DID PANEL DID - J02 8X030-000 SP062 - SWITCH KOMVISION REAR P0068X
0-140 SP142 - LAMP MARKER/TURN LEFT FRT DECK LCL2 0-318 SWITCH HAZARD LIGHTS P33 SWITCH ROTATING BEACON (OPT) P24 0-481 D14 D14 SP3824 - 0-666 DEF SUPPLY PUMP #2 (DSP2) DSP2 SP292 - 5VDI-001 TB21 TB21-W2 - P02 8X030-001 SP062 - SWITCH KOMVISION REAR P0068X
0-141 - P11 - J541 0-320 SWITCH ROTATING BEACON (OPT) P24 SWITCH CAB LADDER LIGHT P21 0-482 TB24 TB24-X1 TB27 TB27-W3 0-667 SP237 - NOX ECU #1 (NOX1) NOX1 5VDI-005 DID POWER SUPPLY P500_CP TB21 TB21-W1 8X030-002 SWITCH KOMVISION REAR P0068X SP062 -
0-142 - P541 - P502 0-322 GE CONTROL INTERFACE P305 GB31-B GB31B-B3 0-483 - P563_CP - P14 0-668 NOX ECU #2 (NOX2) NOX2 SP237 - 5VDI-009 - J15 - J702 8X031-000 SP071 - SWITCH KOMVISION RH REAR P0078X
58B-06-02390-00 APR 16
980E-5
A50005 & UP
Sheet 22 of 27
WIRE TABLE
CONTINUED ON SHEETS 22, 24, 25
NAME DEVICE FROM CONN FROM DEVICE TO CONN TO NAME DEVICE FROM CONN FROM DEVICE TO CONN TO NAME DEVICE FROM CONN FROM DEVICE TO CONN TO NAME DEVICE FROM CONN FROM DEVICE TO CONN TO NAME DEVICE FROM CONN FROM DEVICE TO CONN TO NAME DEVICE FROM CONN FROM DEVICE TO CONN TO
8X031-001 SP071 - SWITCH KOMVISION RH REAR P0078X 11D-002 - J03 SWITCH HEADLIGHTS P20 11NOX-000 - P808 TB26 TB26-B1 13CA-002 - P538_JP - P46 26AV3-002 SP080 - CAMERA 4 CAM4 35L9-001 SCORE BOARD LEFT (OPT) CNLIN TB36 TB36-T2
8X031-002 SP071 - SWITCH KOMVISION RH REAR P0078X 11D-003 SWITCH HEADLIGHTS P20 SWITCH HEADLIGHTS P20 11NOX-001 SP230 - - J808 13CA-003 TB21 TB21-C1 INTERFACE MODULE IM2 26AV3-003 SP119 - - JX11_CP 35L10-000 SCORE BOARD RIGHT (OPT) CNRIN SCORE BOARD LEFT (OPT) CNLO
8X032-000 SP072 - SWITCH KOMVISION RH REAR P0078X 11DFP-000 - P808 TB26 TB26-A1 11NOX-002 - J807 SP230 - 13CA-005 - J46 TB21 TB21-C1 26AV3-004 SP170 - SP080 - 36-001 - P808 TB28 TB28-A1
8X032-001 SP072 - SWITCH KOMVISION RH REAR P0078X 11DFP-001 - J807 - J808 11NOX-003 - P807 - P49 13DFP1-000 DEF SUPPLY PUMP #3 (DSP3) DSP3 - P49 26AV3-006 SP190 - SP119 - 36-002 TB28 TB28-A2 VEC-90 VEC90-P9
8X032-002 SP072 - SWITCH KOMVISION RH REAR P0078X 11DFP-002 SP229 - - P49 11NOX-004 - J807 SP230 - 13DFP1-001 - J49 RTMR4 RTMR4 26AV4-000 KOMVISION CONTROLLER NTSC1 SP225 - 36-003 - J808 SWITCH ENGINE RUN OIL PRESSURE... EOPS
8X033-000 SP081 - SWITCH KOMVISION RH FRONT P0088X 11DFP-003 SP229 - - P49 11NOX-005 - P807 - P49 13GLA-000 RELAY GROUND LEVEL ALARM GLAR_K ALARM GROUND LEVEL LADDER GLA 26AV4-001 SP159 - - PX10 36-004 ORS RELAY ORS-85 TB28 TB28-A3
8X033-001 SP081 - SWITCH KOMVISION RH FRONT P0088X 11DFP-005 - P807 SP229 - 11NOX-006 TB26 TB26-B2 VEC RTMR1 RTMR1-E9 13HS-000 RELAY LADDER UP LUR_K SWITCH GROUND LEVEL LADDER OVE... GLORS 26AV4-002 SP079 - CAMERA 5 CAM5 38G-000 TB35 TB35-C1 INTERFACE MODULE IM3
8X033-002 SWITCH KOMVISION RH FRONT P0088X SP081 - 11DFP-006 TB26 TB26-A2 VEC RTMR1 RTMR1-C9 11NOX-007 - J49 RTMR4 RTMR4 13LS-000 SWITCH GROUND LEVEL LADDER OVE... GLORS SP399 - 26AV4-003 SP255 - - JX10_CP 38G-001 TB35 TB35-C4 - J16
8X034-000 SP082 - SWITCH KOMVISION RH FRONT P0088X 11DFP-007 - J49 RTMR4 RTMR4 11NOX-008 - J49 RTMR4 RTMR4 13LS-001 D7 D7 SP399 - 26AV4-004 SP159 - SP079 - 38G-002 R15 R15 TB35 TB35-C2
8X034-001 SP082 - SWITCH KOMVISION RH FRONT P0088X 11DFP-008 - J49 RTMR4 RTMR4 11NOX1-000 NOX ECU #1 (NOX1) NOX1 SP241 - 13LS-002 SP399 - SOLENOID HYDRAULIC LADDER LSOL 26AV4-006 SP225 - SP255 - 38G-003 - P16 - J730
8X034-002 SWITCH KOMVISION RH FRONT P0088X SP082 - 11DFP1-000 - P49 DEF SUPPLY PUMP #1 (DSP1) DSP1 11NOX1-001 SP241 - - P49 14DFP1-000 DEF SUPPLY PUMP #4 (DSP4) DSP4 - P49 26AV5-000 KOMVISION CONTROLLER NTSC1 SP227 - 38G-004 SENSOR FUEL LEVEL FLS - P730
8X035-000 SP121 - SWITCH KOMVISION CANCEL P0128X 11DFP1-001 - J49 RTMR4 RTMR4 11NOX1-002 SP241 - SENSOR SCR 1 SCR1 14DFP1-001 RTMR4 RTMR4 - J49 26AV5-001 SP095 - - PX10 39-000 - J702 INTERFACE MODULE IM2
8X035-001 SP121 - SWITCH KOMVISION CANCEL P0128X 11DFP2-000 TB26 TB26-H1 - P808 11NOX1-003 - J49 RTMR4 RTMR4 15DID-000 GE DID PANEL DID - J02 26AV5-002 SP126 - CAMERA 6 CAM6 39-001 - J702 - J14
8X035-002 SP121 - SWITCH KOMVISION CANCEL P0128X 11DFP2-001 - J808 - J807 11ONS-000 - J01 ELECTRONIC GAUGE DISPLAY P903 15DID-001 TB22 TB22-K1 - P02 26AV5-003 SP102 - - JX10_CP 39-002 - P14 - SFSW_JP
8X036-000 SP122 - SWITCH KOMVISION CANCEL P0128X 11DFP2-002 SP231 - - P49 11ONS-001 - P01 TB35 TB35-T1 15DID-002 TB22 TB22-K2 DID POWER SUPPLY P500_CP 26AV5-004 SP095 - SP126 - 39A-000 PAY LOAD METER 4 P264 TB34 TB34-S1
8X036-001 SP122 - SWITCH KOMVISION CANCEL P0128X 11DFP2-003 - P49 SP231 - 11ONS-002 TB35 TB35-T2 INTERFACE MODULE IM1 15SLW-001 TB33 TB33-S2 SP729 - 26AV5-006 SP227 - SP102 - 39A-001 VEC-90 VEC90-P2 TB34 TB34-S2
8X036-002 SWITCH KOMVISION CANCEL P0128X SP122 - 11DFP2-005 - P807 SP231 - 11ONS-003 TB35 TB35-T2 VEC-89 VEC89-P4 15SLW-002 GE CONTROL INTERFACE P301 TB33 TB33-S1 27LPR-000 PRE-ENGINE FUEL SENSOR LP ENGINE QSK78 INTERFACE P826 39AA-000 VEC-90 VEC90-P3 TB23 TB23-C1
8X037-000 SP131 - SWITCH KOMVISION LOCK P0138X 11DFP2-006 VEC RTMR1 RTMR1-E8 TB26 TB26-H2 11ORS-001 TB28 TB28-D1 ORS RELAY ORS-88 15SLW-003 SP729 - - P57_CP 27LPS-000 PRE-ENGINE FUEL SENSOR LP ENGINE QSK78 INTERFACE P826 39AA-001 TB23 TB23-C1 - J11
8X037-001 SWITCH KOMVISION LOCK P0138X SP131 - 11DFP2-007 - J49 RTMR4 RTMR4 11ORS-002 VEC-91 VEC91-P4 TB28 TB28-D2 15SLW-005 SP729 - - J13 27WR-000 ENGINE WATER IN FUEL SENSOR WIF ENGINE QSK78 INTERFACE P826 39AA-002 - P11 - J541
8X037-002 SWITCH KOMVISION LOCK P0138X SP131 - 11DFP2-008 - J49 RTMR4 RTMR4 11PF-000 RELAY ENGINE PRELUBE MAG SWITC... PLMS-2 ENGINE PRELUBE HIGH VOLUME PUM... PLPM-(+) 15SLW-006 - P13 SENSOR LEFT FRONT WHEEL SPEED P507 27WS-000 ENGINE WATER IN FUEL SENSOR WIF ENGINE QSK78 INTERFACE P826 39AA-004 - P541 - P502
8X038-000 SP132 - SWITCH KOMVISION LOCK P0138X 11DHP-000 SP297 - RTMR4 RTMR4 11PHH-000 - J12 SP780 - 15SRW-001 TB33 TB33-M2 SP728 - 28E-000 VEC-91 VEC91-P12 - J12 39AA-005 - J502 LAMP RED PAYLOAD RIGHT RPLR_CP
8X038-001 SP132 - SWITCH KOMVISION LOCK P0138X 11DHP-001 RTMR4 RTMR4 SP297 - 11PHH-001 HEATED HOSE RELAY TSW-88A SP780 - 15SRW-002 GE CONTROL INTERFACE P301 TB33 TB33-M1 28E-001 - P12 - J542 39AA-006 TB23 TB23-C1 - J12
8X038-002 SWITCH KOMVISION LOCK P0138X SP132 - 11DHP-002 SP297 - RTMR4 RTMR4 11PHH-002 SP805 - OIL RESERVE SYS P502_CP 15SRW-003 SP728 - - P56_CP 28E-002 - P542 - ETHER1_CP 39AA-007 - P12 - J540
8X039-000 SP141 - SWITCH KOMVISION FRONT P0148X 11DHP-003 - J49 SP297 - 11PHH-003 SP805 - - P11 15SRW-004 - J13 SP728 - 28E-003 - ETHER SP3826 - 39AA-008 - P540 - P503
8X039-001 SP141 - SWITCH KOMVISION FRONT P0148X 11DHP-004 - P49 - P807 11PHH-004 - J11 SP780 - 15SRW-005 - P13 SENSOR RIGHT FRONT WHEEL SPEED P501 28E-004 SP3826 - SOLENOID ETHER START (OPT) ESOL 39AA-009 - J503 LAMP RED PAYLOAD LEFT LPLR_CP
8X039-002 SWITCH KOMVISION FRONT P0148X SP141 - 11DHP-005 - J807 QSK60 - ENGINE INTERFACE TIER ... P809 11PHH-005 SP805 - OIL RESERVE SYS P501_CP 15VDI-000 TB21 TB21-T4 DID POWER SUPPLY P500_CP 28E-005 D13 D13 SP3826 - 39AP-000 - J16 - J702
8X040-000 SP200 - SWITCH KOMVISION FRONT P0148X 11DHP1-000 RTMR4 RTMR4 - J49 11PL-000 FUSE LINK1 (300A) FUS-2 RELAY ENGINE PRELUBE MAG SWITC... PLMS-1 15VDI-002 GE CONTROL INTERFACE P302 TB21 TB21-T1 28EC-000 VEC-91 VEC91-P12 TB27 TB27-H2 39AP-001 - P16 - J730
8X040-001 SP200 - SWITCH KOMVISION FRONT P0148X 11DHP1-001 - P49 SP290 - 11POR-001 ORS RELAY ORS-88A TB28 TB28-E1 15VDI-003 GE CONTROL INTERFACE P302 TB21 TB21-T3 28EC-002 - P808 TB27 TB27-H1 39AP-002 SWITCH HYDRAULIC FILTER #1 HFSW1 - P730
8X040-002 SWITCH KOMVISION FRONT P0148X SP200 - 11DHP1-002 SP290 - HEATER ELEC DEF PUMP 1 (DHP1) DHP1 11POR-002 TB28 TB28-E2 - J11 18VIM-000 INTERFACE MODULE IM3 TB30 TB30-W1 28EC-003 - J808 ENGINE QSK78 INTERFACE P805 39AP-003 - J702 - J14
8X041-000 SP203 - SWITCH KOMVISION LH FRONT P0158X 11DHP1-003 HEATER ELEC DEF PUMP 2 (DHP2) DHP2 SP290 - 11POR-003 TB28 TB28-E2 - J12 18VIM-001 TB30 TB30-W1 - J14 31ILM-000 INTERFACE MODULE IM1 TB34 TB34-N2 39AP-004 - P14 BRAKE FILTER PRESS SW BFSW
8X041-001 SP203 - SWITCH KOMVISION LH FRONT P0158X 11DHP2-000 RTMR4 RTMR4 - J49 11POR-005 SP776 - - P11 18VIM-002 - P14 SENSOR STEERING PRESSURE SPS 31IML-001 TB34 TB34-N1 SP252 - 39B-000 PAY LOAD METER 4 P264 TB34 TB34-R1
8X041-002 SWITCH KOMVISION LH FRONT P0158X SP203 - 11DHP2-001 SP298 - - P49 11POR-007 OIL RESERVE SYS P503_CP SP776 - 18VIM-003 - J16 TB30 TB30-W2 31IML-002 - P04 SP252 - 39B-001 VEC-90 VEC90-P2 TB34 TB34-R2
8X042-000 SP152 - SWITCH KOMVISION LH FRONT P0158X 11DHP2-002 SP298 - HEATER ELEC DEF PUMP 3 (DHP3) DHP3 11POR-009 OIL RESERVE SYS P506_CP SP776 - 18VIM-004 - P16 SENSOR HOIST PRESSURE #1 HPS1 31IML-003 SP252 - R16 R16 39BA-000 VEC-90 VEC90-P2 TB23 TB23-D1
8X042-001 SP152 - SWITCH KOMVISION LH FRONT P0158X 11DHP2-003 SP298 - HEATER ELEC DEF PUMP 4 (DHP4) DHP4 11RB-000 SWITCH ROTATING BEACON (OPT) P24 - J03 18VIM-005 - J16 TB30 TB30-W2 31IML-004 - J04_CP SONALERT (SONA) SONA(-) 39BA-001 TB23 TB23-D1 - J11
8X042-002 SWITCH KOMVISION LH FRONT P0158X SP152 - 11DID-000 VEC RTMR1 RTMR1-D8 TB22 TB22-W1 11RB-001 - P03 TB22 TB22-E1 18VIM-006 - P16 SENSOR HOIST PRESSURE #2 HPS2 31RR-000 SWITCH SPEED CONTROL ROCKER P29 - J03 39BA-002 - P11 - J541
8X043-000 SP204 - SWITCH KOMVISION LH REAR P0168X 11DID-001 TB22 TB22-W2 - P02 11RB-002 TB22 TB22-E2 - J11 18VIM-007 - P240 TB30 TB30-W4 31RR-001 - P03 TB31 TB31-E2 39BA-004 - P541 - P502
8X043-001 SP204 - SWITCH KOMVISION LH REAR P0168X 11DID-002 - J02 VID PANEL VID(+) 11RB-003 - J12 TB22 TB22-E4 18VIM-008 SENSOR BRAKE PRESSURE BPS - J240 31RR-002 GE CONTROL INTERFACE P304 TB31 TB31-E1 39BA-005 - J502 LAMP AMBER PAYLOAD RIGHT RPLA_CP
8X043-002 SWITCH KOMVISION LH REAR P0168X SP204 - 11DID-003 TB22 TB22-W1 DID POWER SUPPLY P500_CP 11RB-004 TB22 TB22-E3 - P04 21NSL-001 - P808 TB27 TB27-E1 32OR-002 R21 R21 TB31 TB31-G3 39BA-006 TB23 TB23-D1 - J12
8X044-000 SP162 - SWITCH KOMVISION LH REAR P0168X 11DISP-000 VEC-91 VEC91-P2 TB23 TB23-G2 11RB-005 - P11 - J541 21NSL-002 - J808 ENGINE QSK78 INTERFACE P805 32OR-003 - P01 TB31 TB31-G2 39BA-007 - P12 - J540
8X044-001 SP162 - SWITCH KOMVISION LH REAR P0168X 11DISP-001 TB23 TB23-G1 - P01 11RB-006 - J540 - P12 21NSL-003 TB27 TB27-E2 INTERFACE MODULE IM3 32OR-004 SWITCH SPEED CONTROL MODULE P022 - J01 39BA-008 - P540 - P503
8X044-002 SWITCH KOMVISION LH REAR P0168X SP162 - 11DISP-003 - J01 ELECTRONIC GAUGE DISPLAY P903 11RB-007 - P541 - P502 21NSL-004 TB27 TB27-E4 R51 R51 32OR-005 TB31 TB31-G1 GE CONTROL INTERFACE P303 39BA-009 - J503 LAMP AMBER PAYLOAD LEFT LPLA_CP
8X045-000 SP091 - INDICATOR KOMVISION POWER P0098X 11DSL-000 RELAY ACCESS LADDER LIGHT (ALL... ALLR-88 VEC-89 VEC89-P12 11RB-008 - P503 - P540 21OR-000 - J808 ENGINE QSK78 INTERFACE P805 32OR-006 TB31 TB31-G3 GE CONTROL INTERFACE P305 39C-000 PAY LOAD METER 4 P264 TB34 TB34-P1
8X045-001 SP091 - INDICATOR KOMVISION POWER P0098X 11E1-000 TB27 TB27-A2 VEC-91 VEC91-P2 11RB-009 - J502 - P548_CP 21OR-001 - P808 TB27 TB27-K1 32RR-000 R21 R21 TB31 TB31-F1 39C-001 VEC-90 VEC90-P2 TB34 TB34-P2
8X045-002 - J0178X SP091 - 11E1-001 TB27 TB27-A1 - P808 11RB-010 - P549_CP - J503 21OR-002 TB27 TB27-K3 - J11 32RR-001 - P01 TB31 TB31-F2 39CA-000 VEC-90 VEC90-P2 TB23 TB23-E1
8X045-003 KOMVISION CONTROLLER KVIS-B - P0178X 11E1-002 TB27 TB27-A3 - P808 11RB-011 - J04_CP - RRBB1 21OR-004 - P11 - P170_CP 32RR-002 SWITCH SPEED CONTROL MODULE P022 - J01 39CA-001 TB23 TB23-E1 - J11
8X046-000 KOMVISION CONTROLLER KVIS-B KOMVISION DISPLAY MONITOR P44 11E1-003 SP112 - - J808 11RCNT-000 VEC-91 VEC91-P4 TB28 TB28-L1 21OR-005 - J12 TB27 TB27-K3 32RS-002 - P01 TB31 TB31-M2 39CA-002 - P11 - J541
8X047-000 KOMVISION CONTROLLER KVIS-B ALARM KOMVISION RADAR (RSON) RSON(+) 11E1-004 SP112 - - J808 11RCNT-001 TB28 TB28-L1 - J12 21ORR-000 - J808 ENGINE QSK78 INTERFACE P805 32RS-003 SWITCH SPEED CONTROL MODULE P022 - J01 39CA-004 - P541 - P502
8X048-000 KOMVISION CONTROLLER KVIS-B ALARM KOMVISION ERROR (ESON) ESON(+) 11E1-005 SP112 - ENGINE QSK78 INTERFACE P804 11RCNT-002 - P12 OIL RESERVE SYS P505_CP 21ORR-001 - P808 TB27 TB27-L1 32RS-005 TB31 TB31-M1 GE CONTROL INTERFACE P303 39CA-005 - J502 LAMP GREEN PAYLOAD RIGHT RPLG_CP
8X049-002 KOMVISION CONTROLLER KVIS-B RELAY RADAR POWER (RPR) RPR_K 11E2-000 TB27 TB27-B2 VEC-91 VEC91-P2 11RCNT-003 - J11 TB28 TB28-L1 21ORR-003 TB27 TB27-L3 - J11 32RS-006 TB31 TB31-M3 GE CONTROL INTERFACE P305 39CA-006 TB23 TB23-E1 - J12
8X050-000 - P02 TB25 TB25-P1 11E2-001 - P808 TB27 TB27-B1 11RCNT-004 - P11 OIL RESERVE SYS P180_CP 21ORR-004 - P11 - P170_CP 33-000 - J240 SWITCH PARK BRAKE SET PBPSW 39CA-007 - P12 - J540
8X050-001 - PX07_CP - J02 11E2-002 - P808 TB27 TB27-B3 11RWL-000 ELECTRONIC GAUGE DISPLAY P902 - J01 21ORR-005 - J12 TB27 TB27-L3 33-001 TB32 TB32-D2 - P240 39CA-008 - P540 - P503
8X050-002 RELAY RADAR POWER (RPR) RPR_K - JX07 11E2-003 SP113 - - J808 11RWL-001 - P01 TB35 TB35-P1 21PL-000 RELAY ENGINE PRELUBE P800 RELAY ENGINE PRELUBE MAG SWITC... PLMS-(+) 33-002 TB32 TB32-D1 INTERFACE MODULE IM2 39CA-009 - J503 LAMP GREEN PAYLOAD LEFT LPLG_CP
8X050-003 TB25 TB25-P2 VEC RTMR1 RTMR1-C10 11E2-004 SP113 - - J808 11RWL-002 TB35 TB35-P2 INTERFACE MODULE IM1 21PL-001 D87 D87 RELAY ENGINE PRELUBE MAG SWITC... PLMS-(+) 33BLF-000 TB31 TB31-C1 GE CONTROL INTERFACE P305 39F-000 PAY LOAD METER 4 P264 TB36 TB36-C2
8X073-000 SP222 - KOMVISION CONTROLLER NTSC1 11E2-005 SP113 - ENGINE QSK78 INTERFACE P804 11S-000 VEC-90 VEC90-P3 - J46 21PS-000 VEC-91

Shopmanual 980E5 - Unlocked

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Shopmanual 980E5 - Unlocked

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CEBM033000

SERIAL NUMBERS 980E-5 A50003 and up

Copyright 2018 Komatsu

DUMP TRUCK 1SHOP MANUAL

Machine model Serial number

00 Index and foreword

Composition of shop manual

Section Title Form Number

Shop Manual, contents binder, binder label and tabs CEBM033000

00 Index and foreword

10 Structure, function and maintenance standard

20 Standard value table

30 Testing and adjusting

50 Disassembly and assembly

90 Diagrams and drawings

00 Index and foreword

10 Structure, function and maintenance standard

Secondary braking .................................................................................................................... 6

20 Standard value table

30 Testing and adjusting

Brake valve bench test and adjustment ..................................................................................27

KomVision checkout data sheet ................................................................................................ 9

Fault Code A203: Hoist Pressure 2 Sensor Low..................................................................... 52

Fault Code A341: The shifter control circuit is defective ......................................................... 50

50 Disassembly and assembly

Removal and installation of piston steering accumulator ........................................................23

90 Diagrams and drawings

980E Dump truck

DUMP TRUCK 1SHOP MANUAL

Machine model Serial number

00 Index and foreword

This material is proprietary to Komatsu America

NON-OEM PARTS IN CRITICAL SYSTEMS

Replacement parts manufactured and supplied by unauthorized sources may not be

Foreword A product identification plate is located on the frame

How to read the shop manual

Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

90. Diagrams and drawings

Revision and distribution

This “ALERT” symbol is used with the signal words,

“DANGER” identifies a specific potential hazard WHICH WILL

“WARNING” identifies a specific potential hazard WHICH MAY

“CAUTION” is used for general reminders of proper safety

General safety Fire extinguisher and first aid kit

Read and follow all safety precautions. Failure to

Safety rules Clothing and personal items

Mounting and dismounting

Precautions with high temperature fluids Prevention of injury by work equipment

Precautions for attachments Precautions before operating the truck

Fire prevention Mirrors, windows and lights

In operator cab (before starting the engine)

Precautions while operating the truck

Traveling Traveling on slopes

Driving near high voltage cables Working on loose ground

Working near batteries • Batteries generate hydrogen gas. Hydrogen gas

Precautions before performing service Proper tools

Securing the dump body

To avoid serious personal injury or death, the