ALTERNATOR TO ENGINE ASSEMBLY CHECKOUT PROCEDURE

Care must be exercised when mounting alternator to probe on the face of the flywheel housing
engine on electric drive vehicles to avoid early adaptor plate.
crankshaft bearing failures. 3. Using the engine barring device, slowly rotate
the engine crank through 2 full revolutions.
Attaching GE Alternator to Cummins QSK50, 60
When complete insure dial indicator returns to
& 78 Engines
0. Record high and low readings for each
NOTE: The following instructions must be followed revolution and average.
for new or repower installations or whenever the 4. The difference between the highest and lowest
engine and/or alternator is serviced. values for each revolution is the TIR (Total
Indicated Runout). If the average of the two
General Instructions: measurements exceeds tolerance limits below,
1. Loosen or remove fan belts prior to measuring contact engineering for next steps.
crankshaft end play to ensure that it moves
Highest Reading – Lowest Reading = TIR
easily back and forth.
2. When taking measurements always clean TIR =_______
mating surfaces and take four equally spaced Limits are shown below:
readings, then average all four.
Max Value mm (in)
3. Clockwise (CW) or counterclockwise (CCW) is
while looking at front or damper end of engine. Cummins “0” Flywheel Housing: 0.25 mm
4. All measurements are set to three decimal (0.010”) used on QSK50/60’s
places. Cummins “00” Flywheel Housing: 0.30 mm
5. Be sure that a surface reference (ie.flat steel (0.012”) used on QSK78
bar) used for dial indicating is calibrated
periodically for flatness and dimensional
accuracy to within +/-.0009”. Also, be sure all
instruments used for measurements are
calibrated on a periodic basis.
6. Do not pry or hammer on engine vibration
damper.
7. Forward is defined as the front of truck and
rearward is defined as the rear of the truck.
8. Refer to Appendix 1 for Summary of Radial and
Axial Runout Limits.
9. Additional Measurements (page 9): It is
assumed that these dimensions are within
specification from the supplier and are therefore
not required for new installations. However,
these measurements must be used for service
rebuilds and/or troubleshooting to confirm these
dimensions are within tolerance specification of
the engine manufacturer.
Engine Flywheel Adaptor Plate Face
Runout (Figure 1-1)
1. Thoroughly clean all mounting surfaces; the
alternator housing, rotor, flywheel, and flywheel
housing.
2. Locate the dial indicator base on the machined
face of the flywheel/flexplate hub and zero the FIGURE 1-1. MEASURING FLYWHEEL HOUSING
ADAPTOR PLATE FACE RUNOUT

58B-01-20100_06 2/20 Alternator to Engine Assembly Checkout Procedure 1

Cummins Crankshaft End Play (Figure 1-2
and Figure 1-3)
5. Mount a magnetic base on the front of the
engine and a dial indicator on the front of the
crankshaft. Measure total crankshaft endplay.
Move crankshaft forward and rearwards as far
as possible. This is accomplished by removing
a hand-hole cover and prying gently on a
crankshaft counter weight or using a rubber
mallet on the crankshaft hub. Confirm the
measurement is equal in both forward and rear
directions. Record values and confirm end play
is within Cummins limits.
NOTE: Do not pry or hammer on engine vibration
damper. FIGURE 1-3. USING PRY BAR ON CRANKSHAFT
COUNTER WEIGHT
Total Crankshaft Endplay: _______
Endplay limits: 0.13 - 0.52 mm (0.005 - 0.020 Engine Flywheel to Flywheel Mating
in.) Surface - Measurement “C” (Figure 1-4)
6. Move the crankshaft rearward to its end travel.
7. Bolt a flat calibrated steel bar across the
flywheel housing as a surface reference to
measure the distance between the flywheel
housing to flywheel Adaptor Plate (CR1).

FIGURE 1-2. RUBBER MALLET USED TO MOVE

CRANKSHAFT REARWARD TO MEASURE
ENGINE END PLAY

FIGURE 1-4. FLAT BAR USED TO MEASURE

DISTANCE BETWEEN ENGINE FLYWHEEL AND
FLYWHEEL MATING SURFACE

2 Alternator to Engine Assembly Checkout Procedure 2/20 58B-01-20100_06

 8. Repeat the same procedure in three more
locations, 90 degrees apart from each other in
the perimeter, to find the values CR2, CR3, CR4.
1st measurement (12:00 O’clock): CR1
2nd measurement (6:00 O’clock): CR2
3rd measurement (3:00 O’clock): CR3
4th measurement (9:00 O’clock): CR4
Cavg.R = (CR1+CR2+CR3+CR4) / 4 =______
9. Move the crankshaft frontward to its end travel.
10. Repeat the same procedure, 90 degrees apart
from each other in the perimeter, to find the
values CF1, CF2, CF3, CF4.
1st measurement (12:00 O’clock): CF1
2nd measurement (6:00 O’clock): CF2
3rd measurement (3:00 O’clock): CF3
4th measurement (9:00 O’clock): CF4
Cavg.F = (CF1+CF2+CF4+CF4) / 4 = ______
11. The Total Engine Axial Play of the engine is
calculated as:
TEAP = | Cavg.F - Cavg.R | = ______
12. The mean absolute value of the relative location
of the flywheel with respect to flywheel housing
is:
C = TEAP/2 + Cavg.R = ______
Alternator Housing to Rotor Measurement
– Measurement “A” (Figure 1-5 through
Figure 1-8)
13. For GTA41 alternator use 5/8”-11 x 4.5 bolt or
rotor saddle to support the alternator adapter.
For GTA39 alternator place shims between
rotor and stator.
NOTE: Whenever alternator is removed from the
engine for extended storage or transportation of the
alternator, rotor shipping locks must be installed.
Refer to PSN AA12108 for rotor shipping locks.

FIGURE 1-5. BOLT OR ROTOR SADDLE USED AT 6 O’CLOCK POSITION TO SUPPORT ROTOR ON GTA41 

ALTERNATOR

58B-01-20100_06 2/20 Alternator to Engine Assembly Checkout Procedure 3

 FIGURE 1-6. SHIMMING OF GTA39 ALTERNATOR ROTOR

14. Position the Alternator Rotor Rearward by both ends. Alternately tighten each bolt until
placing a push bar across the center of rotor reaches end of travel. (Do not exceed 12
alternator rotor. Position the two 5/8” – 11 bolts ft-lbs). See Figure 1-7.
through the bar ends and fasten to housing on

FIGURE 1-7.FASTEN BAR TO ALTERNATOR

HOUSING TO MOVE THE ALTERNATOR ROTOR
AXIALLY TOWARD SLIP RING (REARWARD).
BOLTS ARE TIGHTENED TO NO MORE
THAN 12 FT-LB.

4 Alternator to Engine Assembly Checkout Procedure 2/20 58B-01-20100_06

 15. Push bar is to remain in position to hold the
rotor in rearward position. Bolt a calibrated flat
steel bar to the rotor as a reference to measure
the distance between the alternator housing
and rotor to determine the reading A1. Make
sure the bars are not contacting each other
affecting the readings. When taking the
measurements, make sure the readings are
taken from the mating surfaces. See Figure 1-8.

FIGURE 1-8.MEASURING DISTANCE BETWEEN ALTERNATOR HOUSING AND ROTOR

16. Repeat the same procedure in three more

locations, ~90 degrees apart from each other in
the perimeter, to find the values A2, A3, A4.

1st measurement (45°): A1

2nd measurement (135°): A2
3rd measurement (225°): A3
4th measurement (315°): A4

Aavg = (A1 +A2 +A3 +A4) / 4 = ______

17. Alternators will have a tag from GE indicating
rotor end play. See Figure 1-9 for example of
tag. Use ½ the End Play in the following
calculation from the tag.
88256
A = Aavg + ½ End Play(GE Tag) = ______

FIGURE 1-9.EXAMPLE OF TAG FROM GE

58B-01-20100_06 2/20 Alternator to Engine Assembly Checkout Procedure 5

 18. Refer to Figure 1-10 below. If measurement C is
greater than A, subtract A from C; the shim
pack is to be added between Rotor and
Flywheel (location B). If measurement A is
greater than C, subtract C from A; the shim
pack is to be added between the Alternator
Housing and Engine Flywheel Housing (location
D). Use a combination to shim within 0.1 mm
(0.004 in). See Table 1 below.
If C > A: shim = C – A; shim at Rotor
If A > C: shim = A – C; shim at Housing

FIGURE 1-10.
Table 1: SHIM COMBINATION DATA

SHIM LOCATION QSK78 (SAE 00) QSK50 & 60 (SAE 0)

P/N - Alt. Hsg. To FW Hsg. Adaptor (Location D) EJ1056 (.004") TM3466 (.004")
EJ1055 (.007") EJ1055 (.007")
TW6616 (.010")
P/N - Alt. Rotor to Flexdrive (Location B) EL3332 (.004") TM3467 (.004")
EL3331 (.007") TM3469 (.007")

19. Remove bolt or saddle bracket supporting rotor
on GTA41 alternator or remove shims placed
between rotor and stator on GTA39 alternator.
20. Carefully move the alternator into place and
engage the engine drive end and the alternator
rotor.
21. Fasten the flywheel housing adapter to the
alternator. Tighten bolts to 175 ft lbs. (240 Nm)
22. Install and torque the flywheel / flexplate
assembly to alternator rotor. Tighten bolts to
175 ft lbs. (240 Nm).

6 Alternator to Engine Assembly Checkout Procedure 2/20 58B-01-20100_06

Measurements after Joining the Alternator 24. Total Crankshaft End Play: ________
and Engine 25. Rotate the crankshaft one full revolution and
23. With the Magnetic base, or similar device, listen for any unusual noise caused by moving
mounted on the front of the engine and the components contacting stationary parts.
indicator on the front of the crankshaft, measure
26. Reset and record Engine Fan Belt Tension.
the total crankshaft endplay.
NOTE: **The total engine crankshaft endplay must
match the original measurement before the alternator
was installed. If the endplay after the alternator and
engine are assembled is less than the original
measurement, re-shimming is required.

58B-01-20100_06 2/20 Alternator to Engine Assembly Checkout Procedure 7

 Engine / Alternator Attachment Checkout Data Sheet
ENGINE MEASUREMENTS
STEP 4 ______Total indicated runout of flywheel STEP 10______CF1 (12:00 o'clock position)
adapter housing face ______CF2 (3:00 o'clock position)
STEP 5 ______Total Crankshaft Endplay ______CF3 (6:00 o'clock position)
______CF4 (9:00 o'clock position)
STEP 8 ______CR1 (12:00 o'clock position)
______Cavg.F = (CF1+CF2+CF3+CF4) / 4
______CR2 (3:00 o'clock position)
______CR3 (6:00 o'clock position) STEP 11 ______TEAP= (Cavg.F - Cavg.R)
______CR4 (9:00 o'clock position)
STEP 12______C = TEAP/2 + Cavg.R
______Cavg.R = (CR1+CR2+CR3+CR4) / 4

Summary of Axial & Radial Run out Limits

SAE 0 Flywheel SAE 0 Flywheel SAE 00 Flywheel
Description
(QSK50) (QSK60) (QSK78)
0.005” (.13 mm) - 0.005” (.13 mm) - 0.005” (.13 mm) -
Crankshaft Endplay
0.020” (.51 mm) 0.020” (.51 mm) 0.020” (.52 mm)
Alternator Endplay (Non SRB) 0.0273” (0.69 mm) 0.0273” (0.69 mm) 0.0273” (0.69 mm)
FW Housing Radial Runout 0.010” (0.25 mm) 0.010” (0.25 mm) 0.012” (0.30 mm)
FW Housing Face Runout 0.0273” (0.69 mm) 0.0273” (0.69 mm) 0.0273” (0.69 mm)
FW Housing Radial Runout 0.010” (0.25 mm) 0.010” (0.25 mm) 0.012” (0.30 mm)
FW (Flywheel) Radial Runout 0.0273” (0.69 mm) 0.0273” (0.69 mm) 0.0273” (0.69 mm)
FW (Flywheel) Face Runout 0.010” (0.25 mm) 0.010” (0.25 mm) 0.012” (0.30 mm)

ALTERNATOR MEASUREMENTS
STEP 16______A1 (45°)
______A2 (135°)
______A3 (225°)
______A4 (315°)
______Aavg = (A1+A2+A3+A4) / 4
STEP 17______A = Aavg + ½ End Play(GE Tag)

8 Alternator to Engine Assembly Checkout Procedure 2/20 58B-01-20100_06

SHIM CALCULATION
STEP 18______If C > A: shim = C – A;
shim at Rotor
______If A > C: shim = A – C;
shim at Housing

ENGINE MEASUREMENT (AFTER ADDITIONAL ENGINE MEASUREMENTS

ALTERNATOR ATTACHMENT) It is assumed that these following dimensions are
STEP 23______Total Crankshaft Endplay within specification from the supplier and are
therefore not required for new installations. However,
The total engine crankshaft endplay must match the
these measurements must be used for service
original measurement taken before the alternator
rebuilds and/or troubleshooting to confirm these
was installed. If the endplay after the alternator and
dimensions are within tolerance specification of the
engine are assembled is less than the original
engine manufacturer.
measurement, re-shimming is required.
Reference Cummins AEB 24.46 and Cummins
Service Bulletin 4021669
1. Engine Flywheel Housing Face Runout
(Appendix 2)
2. Engine Flywheel Housing Radial Runout
(Appendix 3)
3. Engine Flywheel/Flexplate Face Runout
(Appendix 4)
4. Engine Flywheel/Flexplate Radial Runout
(Appendix 5)

58B-01-20100_06 2/20 Alternator to Engine Assembly Checkout Procedure 9

References Appendices
1. Cummins AEB 24.46 1. Summary of Axial & Radial Runout Limits
2. Cummins Service Bulletin #4021669 2. Engine Flywheel Housing Face Runout
3. Komatsu Check Out Procedure EJ1062-2 3. Engine Flywheel Housing Radial Runout
(QSK78, 930E-SE, 960E) 4. Engine Flywheel/Flexplate Face Runout
4. Komatsu Check Out Procedure EH0586 5. Engine Flywheel/Flexplate Radial Runout
(QSK60, 830E & 930E)

Appendix 1

Summary of Axial & Radial Runout Limits

SAE 0 Flywheel SAE 0 Flywheel SAE 00 Flywheel
Description
(QSK50) (QSK60) (QSK78)
0.005” (0.13 mm) - 0.005” (0.13 mm)- 0.005" (0.13 mm) -
Crankshaft Endplay
0.020” (0.51 mm) 0.020” (0.51 mm) 0.020” (0.52 mm)
FW Housing Radial Runout 0.010” (0.25 mm) 0.010” (0.25 mm) 0.012" (0.30 mm)
FW Housing Face Runout 0.010” (0.25 mm) 0.010” (0.25 mm) 0.012" (0.30 mm)
FW (Flywheel) Radial Runout 0.003” (0.08 mm) 0.003” (0.08 mm) 0.005" (0.13 mm)
FW (Flywheel) Face Runout 0.035” (0.89 mm) 0.035” (0.89 mm) 0.040" (1.0 mm)

10 Alternator to Engine Assembly Checkout Procedure 2/20 58B-01-20100_06

Appendix 2
FIGURE 1-11. FLYWHEEL HOUSING FACE
RUNOUT MEASUREMENT
Flywheel Housing Face Runout
Locate the dial indicator base on the machined face
of the flywheel/flexplate hub and 0 the probe on the
flywheel housing face. Using the engine barring
device, slowly rotate the engine crank through 2 full
revolutions. When complete insure dial indicator
returns to 0. The difference between the highest
and lowest values is the face runout TIR (Total
Indicated Reading). Limits are shown in the table
below:
Max Value mm (in)
Cummins “0” Flywheel Housing 0.25 (0.010)
Cummins “00” Flywheel Housing 0.30 (0.012)
SAE Standard J617 0.48 (0.019)
58B-01-20100_06 2/20 Alternator to Engine Assembly Checkout Procedure
Appendix 3
FIGURE 1-12. FLYWHEEL HOUSING RADIAL
RUNOUT MEASUREMENT
Flywheel Housing Radial Runout
Locate the dial indicator base on the machined face
of the flywheel/flexplate hub and 0 the probe on the
ID of the pilot bore of the flywheel housing. Using the
engine barring device, slowly rotate the engine crank
through 2 full revolutions. When complete insure dial
indicator returns to 0. The difference between the
highest and lowest value is the radial runout TIR.
Limits are shown in the table below:
Max Value mm (in)
Cummins “0” Flywheel Housing 0.25 (0.010)
Cummins “00” Flywheel Housing 0.30 (0.012)
SAE Standard J617 0.48 (0.019)
11
Appendix 4
85628
FIGURE 1-13. FLYWHEEL/FLEXPLATE FACE
RUNOUT MEASUREMENT
Flywheel/Flexplate Face Runout
Locate the dial indicator base on the machined face
of the flywheel housing and 0 the probe on the face
of the flywheel/flexplate. Using the engine barring
device, slowly rotate the engine crank through 2 full
revolutions. When complete insure dial indicator
returns to 0. The difference between the highest and
lowest value is the face runout TIR. Limits are shown
in the table below:
Max Value
Cummins “0” Flywheel 0.001" x Measured Radius
(0.25 mm type)
Cummins “00” Flywheel 0.001" x Measured Radius
(0.30 mm type)
SAE Standard J620 0.0005" x Measured Radius
Max Value mm (in)
Cummins “0” Flexplate 0.89 (0.035)
Cummins “00” Flexplate 0.89 (0.035)
SAE Standard J620
12 Alternator to Engine Assembly Checkout Procedure
Appendix 5
85629
FIGURE 1-14. FLYWHEEI/FLEXPLATE RADIAL
RUNOUT MEASUREMENT
Flywheel/Flexplate Radial Runout
Locate the dial indicator base on the machined face
of the flywheel housing and 0 the probe on the face
of the flywheel/flexplate. Using the engine barring
device, slowly rotate the engine crank through 2 full
revolutions. When complete insure dial indicator
returns to 0. The difference between the highest and
lowest value is the face runout TIR. Limits are shown
in the table below:
Max Value mm (in)
Cummins “0” Flywheel/Flexplate 0.13 (0.005)/0.08
(0.003)
Cummins “00” Flywheel/Flexplate 0.13 (0.005)
SAE Standard J620 0.13 (0.005)
2/20 58B-01-20100_06
 ALTERNATOR LOCK CHECKOUT PROCEDURE
Remove Alternator Shipping Bracket placed on the NOTE: These bolts are reused at the end of
Engine end of adapter plate. Refer to Figure 1-1. assembly line for installation before shipping the
truck.
NOTE: Alternator has (4) 375-16 x 12.00 grade 8 hex
head bolts as ship loose these are used in Step 3.

FIGURE 1-1.

Care must be exercised when disassembling Cover

Str Top, Cover Str Bottom and Drive Shaft and instal-
lation. Refer to Table 1 below.
Table 1:
830E 930E 930E-SE 960E 980E
Drive Shaft XB1736 EL6424 EJ9748 EL6424 EL6424
Cover Top
Drive Shaft XB1737 EL6425 58F-60-00150 EL6425 EL6425
Cover Bottom
Drive Shaft PC0183 PC0183 PC0183 PC0183 PC0183

58E-01-00540 Alternator Lock Checkout Procedure 18-1

Disassembling Cover Str Top, Cover Str Bottom Part No. Description Quantity
and Drive Shaft
EK7573 SCREW CAPTIVE 2
The following instructions must be followed for new WINGED
or re-power installations. EK7907 RETAINER 2
1. Carefully remove assembly Cover Str Top and
Cover Str Bottom and mounting hardware. 2. Carefully remove Drive Shaft and mounting
Refer Figure 1-2. hardware. Refer to Figure 1-3.

FIGURE 1-2. FIGURE 1-3.

The following component should be packaged with

The following components should be packaged with
other shipped loose components:
other shipped loose components:

Part No. Description Quantity

Part No. Description Quantity
PC0183 SHAFT ASSY DRIVE 1
SEE CHART COVER STR BOTTOM 1
SEE CHART COVER STR TOP 1 The following hardware that was used to attach Drive
Shaft to Alternator and Hydraulic Pump should be
TD0791 C/S .375-16 X 1.25 5
discarded:
G5 ZINC
TC1231 L/W .375 5
Part No. Description Quantity
TG5720 C/S .375-16 X 1.00 2
G5 ZINC SG7814 C/S .375-24 X 1.25 G8 8
WA4726 F/W .375 ZINC 4 VN9037 C/S .375-16 X 1.25 G8 8
HE5611 NUT LOCK 2 WA0386 NUT HEX .375-16 UNC 8
.38-16 UNC G8 G8

18-2 Alternator Lock Checkout Procedure 58E-01-00540

 3. After completion of assembly of the truck and
checkout, complete the following:
• Rebar the engine to align the hub holes with
bearing cap holes.
• Only requires to align one hole, the other three
holes are 90 deg apart, they would line up
automatically.
• Insert the four (4) bolts 3/8-16X12.00 Grade 8
Hex Head bolts and torque them to 13ft-lbs (+/- 1
ft-lbs). Refer to Figure 1-4.
Assembly at Site-
1. Remove the tag attached to Hydraulic pump
hub.
2. Carefully remove four (4) .375-16 x 12.00 grade
8 hex head bolts from Alternator hub,
Installation of the Drive Shaft
Care must be exercised when assembling Drive
Shaft. Add a protective sheet inside the alternator
housing to protect the fiberglass housing from being
damaged.
The following components are in a container with the
truck:

Part No. Description Quantity

SEE CHART COVER STR BOTTOM 1
SEE CHART COVER STR TOP 1
TD0791 C/S .375-16 X 1.25 5
G5 ZINC
TC1231 L/W .375 5
TG5720 C/S .375-16 X 1.00 2
G5 ZINC
WA4726 F/W .375 ZINC 4
HE5611 NUT LOCK .38-16 2
UNC G8
FIGURE 1-4.
EK7573 SCREW CAPTIVE 2
WINGED
4. Add Tag, Warning (58E-98-02190) and Tyrap
EK7907 RETAINER 2
(vz4843) to Steering Wheel in cab and to
Hydraulic pump hub. PC0183 SHAFT ASSY DRIVE 1
SG7814 C/S .375-24 X 1.25 G8 8
VN9037 C/S .375-16 X 1.25 G8 8
WA0386 NUT HEX .375-16 8
UNC G8

58E-01-00540 Alternator Lock Checkout Procedure 18-3

 1. Assemble Drive Shaft with Female end (the end
will have two grease fittings on it) going first
between the Hydraulic Pump Mount and the
Fiberglass housing of the Alternator. Refer to
Figure 1-5 and Figure 1-6.
3. Attach Drive Shaft to Hydraulic Pump flange
using eight cap screws .375-16 x 1.25
(VN9037) and eight nut hex .375-16 (WA0386).

FIGURE 1-6.

• Torque eight cap screws .375-16 x 1.25

FIGURE 1-5.
(VN9037) and eight nut hex .375-16 (WA0386) to
35 ft-lbs.
2. Attach Drive Shaft (female end) to Alternator 4. Assemble Cover Str Top to Housing Pump
Shaft using eight cap screws .375-24 x 1.25 Mount using five cap screws .375-16 x 1.25
(SG7814). (TD0791) and five lock washer .375 (TC1231).
• Torque eight cap screws .375-24 x 1.25 Refer to Figure 1-7.
(SG7814) to 40 ft-lbs.

FIGURE 1-7.

18-4 Alternator Lock Checkout Procedure 58E-01-00540

 5. Assemble Cover Str Top to Cover Str Bottom
using two cap screw .375-16 X 1.00 (TG5720,
two flat washers .375 (WA4726) and two nut
lock .38-16 (HE5611). Refer to Figure 1-7.
6. To lock Cover Str Top to Cover Str Bottom use
two Screw Captive Winged (EK7573) and two
Retainer (EK7907).
7. Remove Tag (Figure 1-8), Warning (58E-98-
02190) and Tyrap (vz4843) from Steering
Wheel in cab.

FIGURE 1-8.

58E-01-00540 Alternator Lock Checkout Procedure 18-5

 NOTES

18-6 Alternator Lock Checkout Procedure 58E-01-00540

 INTERFACE MODULE CHECKOUT PROCEDURE
Purpose
This procedure is used to checkout the IM
installation.
Necessary Equipment
1. This checkout procedure and vehicle wiring
schematic.
2. Laptop computer with GE's wPTU software
installed.
3. Laptop computer with IM Realtime Data Monitor
Software installed. This software can be found
on the Komatsu America Extranet:
https://www.komatsuamerica.net/northamerica/
4. RS232 serial cable with a male DB9 connector
on one end and a female connector on the other
end.
5. 3/8 inch nut driver, voltmeter, 3 inch (or longer)
jumper wire.
6. Connector back-probes.
7. Small flat screw driver. Use the screw driver to
gently push in the orange wire release buttons
when removing a wire from a terminal board.
How to Use the IM Realtime Data Monitor
Software
Connect a DB9 straight through cable from the serial
port on the laptop to the IM Diagnostic connector in
the cab or auxiliary cabinet. The IM must be powered
to communicate with the laptop.
Double click the shortcut to IM Realtime Monitor on
the Desktop screen. After the program runs, a blank
window shows up. On the menu select “Select Serial
Port” to pick the serial port used and then select
“Start/Stop” to view the data.
Check for Fault Codes Associated With the
Interface Module
Key on then run the IM Realtime Data Monitor
Software and confirm that there are no fault codes
associated with the Interface Module. If any are
found, these circuits should be analyzed to
determine the cause of the fault and they should be
repaired or if required the IM should be replaced.

Install the Application Code

Before the Interface Module can be put to work, the
application code must be installed. Application code
must be matched to the truck model that the
Interface Module is installed on.
To get the necessary files and instructions, go to the
Komatsu America Extranet:
https://www.komatsuamerica.net/northamerica/
Validate the correct IM software is installed by using
the IM Realtime Data Monitoring software to locate
the CRC number of installed IM software. Compare
the CRC number on the IM Realtime Data Monitoring
software to the CRC number on the text document
inside of the software zip file found on the extranet.
Confirm these numbers are the same.

58B-06-03391-01 8/19 Interface Module Checkout Procedure 1

Interface Module I/O
Use the IM Realtime Data Monitor software to
confirm the functionality of all IM inputs and serial
connections. The key switch must be on for all tests
below.
Check Digital Inputs to the Interface Module
1. Hydraulic Tank Level (IM2-k) - Disconnect
connector CN712 at Hydraulic Tank Level
Sensor. Short pin C to ground momentarily and
confirm state change (one to zero). Reconnect
CN712.
2. Low Steering Precharge (IM2-W) - This step
requires properly pre-charged steering
accumulators. Disconnect one of the Low
Accumulator Precharge Switches momentarily
and confirm state change (zero to one).
Reconnect switch.
3. Pump Filter Switches (IM2-Y) - Disconnect
connector CN730 at Steering Filter Pressure
Switch momentarily and confirm state change
(zero to one). Reconnect CN730.
4. Park Brake Released (IM2-M) - Short wire 73S1
to ground at TB32-M momentarily and confirm
state change (one to zero).
5. Park Brake Request (IM3-V) - Short the engine
oil pressure switch wire circuit 36 on TB28-A to
ground. Move shift lever from neutral to park
position and confirm state change (one to zero).
Remove the ground from TB28-A.
6. GE Batt + (IM3-M) - confirm this is a one.
7. Starter Motor 1 Energized (IM3-R) - Disconnect
wire 11SM1 from cranking motor to TB28-F at
TB28-F. Momentarily short TB28-F to 24V and
confirm state change (zero to one). Reconnect
disconnected wire.
8. Starter Motor 2 Energized (IM3-S) - Disconnect
wire 11SM2 from cranking motor to TB28-G at
TB28-G. Momentarily short TB28-G to 24V and
confirm state change (zero to one). Reconnect
disconnected wire.
9. Crank Sense (IM3-U) - Open the Start Battery
Disconnect switch so that there is no battery
voltage to the starters. Momentarily short TB28-
J to 24V and confirm state change (zero to
one). After removing 24V short from TB28-J,
close the Start Battery Disconnect switch.
10. Selector Switch (Park) (IM3-T) - Place shifter
into park position and confirm 1 state then shift
into neutral and confirm 0 state. Return shifter
to park position.
2 Interface Module Checkout Procedure
11. Selector Switch (FNR) (IM2-N) - Place shifter
into park position and confirm 0 state then shift
into neutral, forward, and reverse and confirm 1
state for each of these positions. Return shifter
to park position.
12. Strg Bleed Pressure SW (IM2-Z) - Disconnect
connector SABS at the Steering Bleed Pressure
Switch and confirm state change (zero to one).
Reconnect SABS.
13. Brake Lock Switch Power Supply (IM3-L) -
Ensure that shifter is in park position. Use GE's
wPTU software to turn on FWD True output
signal. Confirm state change (zero to one).
Leave GE FWD True signal on until completion
of step 20.
14. Brake Lock (IM2-i) - Actuate brake lock switch
and confirm state change (zero to one). Turn off
GE FWD True signal. Confirm input state
remains at one. Turn off brake lock switch.
Confirm input state returns to zero. (The Brake
Lock Switch Power Supply test, item 19, must
be completed before this test can be
successfully completed). Turn off GE FWD True
signal.
15. Service Brake Set SW (IM3-C) - Short wire 44R
at TB35 - F to 24 volts momentarily and confirm
state change (zero to one).
16. Cummins Shutdown Delay (1M3-F) -
Disconnect wire 21 NSL from the Engine ECM
at TB27-E leaving wire 21NSL to IM connected
at TB27-E. Momentarily short TB27-E to 24V
and confirm state change (zero to one).
Reconnect disconnected wire.
17. Secondary Engine Shutdown SW (1M3-E) -
Actuate the Secondary Engine Shutdown
switch and confirm state change (one to zero).
18. Keyswitch (1M3-G) - confirm state is a one.
19. Mode sw1 (IM3-H) - Actuate the “left arrow”
LCD screen navigation switch and confirm state
change (one to zero).
20. Mode sw2 (IM3-J) - Actuate the “OK” LCD
screen navigation switch and confirm state
change (one to zero).
21. Mode sw3 (IM3-K) - Actuate the “down arrow”
LCD screen navigation switch and confirm state
change (one to zero)
22. Mode sw4 (IM2-q) - Actuate the “up arrow” LCD
screen navigation switch and confirm state
change (one to zero).
8/18 58B-06-03391-01
 23. Crank Request (IM2-j) - Open the Starter
Disconnect switch so that there is no battery
voltage to the starters. Momentarily turn
keyswitch to the crank position and confirm
state change (zero to one).
24. Park Brake Set (IM2-f) - Momentarily disconnect
Park Brake Pressure switch, identified by circuit
33, and confirm state change (zero to one).
25. Seat Belt SW (1M2-g) - Buckle seat belt. Then
unbuckle seat belt and confirm state change
(zero to one).
26. Snapshot In - Progress (IM2-L) - Actuate the
Data Store Switch. Confirm state change (one
to zero).
27. Low Steering Pressure sw1 (IM2-S) - Using a
back - probe, short wire 33F to ground at
connector CN14 pin 6 momentarily and confirm
state change (one to zero). Remove back -
probe.
28. Brake Accum Pressure SW (IM2-U) -
Momentarily short wire 33BP to ground at TB32
- E. Confirm state change (one to zero).
29. Brake Lock Degrade SW (IM2-V) - Short wire
33T to ground at TB32 - F momentarily and
confirm state change (one to zero).
30. Keyswitch Direct (IM2 - P) - Confirm state is a
one. Turn keyswitch off for 1 second and then
back on. Confirm state changes to zero and
then back to one.
31. Auto Lube Level (IM3-W) - Disconnect
connector CN511 at the Auto Lube Low Level
Switch, short pin C to ground momentarily and
confirm state change (one to zero). Reconnect
connector CN511.
32. Auto Lube Press SW (IM3-Y) - Short wire 68P
to ground at TB60-B momentarily and confirm
state change (one to zero).
33. Body Up SW (IM2-R) - For trucks without a
body installed yet, place washer on body
proximity sensor, confirm state change, them
remove washer and confirm state change
again. For truck with body installed, make sure
that the body is lowered down all the way, and
then momentarily disconnect wire 71 F at TB35
- S and confirm state change (one to zero).
Reconnect disconnected wire.
34. Dynamic Retard (IM3-Z) - Momentarily short
wire 74ZA to ground at TB21-D and confirm
state change (one to zero).
58B-06-03391-01 8/19 Interface Module Checkout Procedure
35. No Propel/Retard (GE CPU Running) (IM2-n) -
Confirm state is a zero. Turn off the GE
keyswitch. Confirm state changes to a one.
Turn GE keyswitch back on. Confirm state
changes to a zero once GE is booted back up
(see DID panel), which can take up to 45
seconds.
36. Engine Air Filter (IM2-X) – Unplug Air
Restriction Switch 2 (located on top of the
engine air intake pipe) and confirm state
change (zero to one). Reconnect Air Restriction
Switch 2.
37. Shifter Fault (IM2-m) - Disconnect wire 72IM
from TB22-G and confirm state change (zero to
one). Reconnect wire 72IM.
*AUTONOMOUS TRUCKS ONLY*
Check Autonomous Inputs the Interface Module
Autonomous and Manual Mode SW (IM2-e, IM2-s) -
Put the autonomous/manual mode switch in manual
mode. The position is indicated by a 0. The position
that the mode switch is not in is indicated by a 1.
Only one of the inputs can be 1 at any given point,
the other one must be the opposite. Then switch to
autonomous mode and confirm opposite states on
the inputs and wait 30 seconds. Finally, switch back
to manual mode and confirm state change. Make
sure no fault codes are created when shifting
between modes.
Manual Mode Auto Apply Pressure switch (IM2-d) -
With the autonomous/manual mode switch in manual
mode, disconnect wire from TB51-E and confirm
change on (0 to 1). Fault A335 should show at that
point. Reconnect disconnected wire and confirm
state change (1 to 0).
3
Check Analog Inputs To The Interface Module
Verify that the used analog inputs are in the range of
the values listed below.
1. Truck Speed [kph] (IM1-gh) - Use GE DID to
simulate vehicle speed and confirm reported
speed matches vehicle speed set using GE
DID+/ - 2 kph.
2. Steering Pressure [kPa] (1M3-d) - Disconnect
steering pressure sensor, identified by circuit
33SP, and confirm fault A204, Steering
Pressure Sensor Low, is active. Reconnect
sensor.
3. Ambient Air Temp [C] (1M3-e) - confirm
reported temperature matches ambient
temperature within 3°C (5.4°F).
4. Fuel Level [%] (1M3-g) - confirm reported %
level matches actual fuel level in tank +/ - 5%.
5. 12V Converter [V] (1M3-h) - confirm reported
voltage is 13.5V +/ - 0.5V. (24V Battery voltage
must be greater than 18 volts.)
6. Brake Pressure [kPa] (IM3-p) - Disconnect
service brake pressure sensor located in brake
cabinet, identified by circuit 33BPS, and confirm
fault A205, Brake Pressure Sensor Low, is
active. Reconnect sensor.
7. Right Rear Brake Oil Temp [C] (IM3-m) -
Disconnect right rear brake oil temp sensor and
confirm fault A167, Hydraulic Oil Temp - Right
Rear Sensor Low, is active. Reconnect sensor.
4 Interface Module Checkout Procedure
8. Left Rear Brake Oil Temp [C] (IM3-i) -
Disconnect left rear brake oil temp sensor and
confirm fault A166, Hydraulic Oil Temp - Left
Rear Sensor Low, is active. Reconnect sensor.
9. Right Front Brake Oil Temp [C] (IM3-r) -
Disconnect right front brake oil temp sensor and
confirm fault A169, Hydraulic Oil Temp - Right
Front Sensor Low, is active. Reconnect sensor.
10. Left Front Brake Oil Temp [C] (IM3-t) -
Disconnect left front brake oil temp sensor and
confirm fault A168, Hydraulic Oil Temp - Left
Front Sensor Low is active. Reconnect sensor.
Hoist Pressure 2 [kPa] (IM3-q) - Short wire
33HP2 to ground at TB28-K momentarily and
confirm fault A203, Hoist Pressure 2 Sensor
Low, is active.
11. Hoist Pressure 2 [kPa] (IM3-q): Short wire
33HP2 to ground at TB28-K momentarily and
confirm fault A203, Hoist Pressure 2 Sensor
Low, is active.
12. Hoist Pressure 1 [kPa] (IM3-s) Short wire
33HP1 to ground at TB30 - N momentarily and
confirm fault A202, Hoist Pressure 1 Sensor
Low, is active.
13. Battery Voltage 24V [V] (IMint) confirm reported
voltage is +/ - 1 volt of actual measured battery
voltage.
8/18 58B-06-03391-01