KOMATSU CHECKOUT PROCEDURE 58E-06-20203

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NAME: MACHINE & MODEL:

IM Checkout 830E With Actia 830E With Actia Display (Unit TBD, Interim Cab)
WRITTEN BY: DATE:
Helge Mollhagen 10/19/16

CHECKED BY: DATE:

T. Imig 10/19/16

APPROVED BY: DATE: 0 NEW RELEASE

G. Horst 10/19/16 DASH DESCRIPTION OF CHANGE DATE ECN BY CK’D
A SIZE MICROFILM

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, 300 to 332 ohm
resistor
6. Connector back-probes.

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.

Go to the Komatsu America Extranet: https://www.komatsuamerica.net/northamerica/

to get the necessary files and instructions.

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
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same.

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How to use the IM Realtime Data Monitor softw are:

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 pow ered to communicate w ith 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.

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).
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Reconnect CN730.

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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.
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 13, 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 (IM3-F) --- Disconnect wire 21NSL from the Cummins 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 (IM3-E) --- Actuate the Secondary Engine
Shutdown switch and confirm state change (one to zero).
18. Keyswitch (IM3-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).
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20. Mode sw2 (IM3-J) --- Actuate the ‘‘OK’’ LCD screen navigation switch and
confirm state change (one to zero).

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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).
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 (IM2-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 68 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 71F 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).
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. Accessory Drive Pump Filter Switch (IM3-X) --- Disconnect Connector HAFSW. Short
wire 39HP1 to ground momentarily at connector HAFSW pin A and confirm
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state change (one to zero). Reconnect connector HAFSW.

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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-g,h): Use GE DID to simulate vehicle speed and confirm
reported speed matches vehicle speed set using GE DID + /- 2 kph.
2. Steering Pressure [kPa] (IM3-d): Disconnect steering pressure sensor, identified by
circuit 33SP, and confirm fault A204, Steering Pressure Sensor Low, is active.
Reconnect sensor.
3. Ambient Air Temp [C] (IM3-e): confirm reported temperature matches ambient
temperature within 3 C.
4. Fuel Level [% ] (IM3-g): confirm reported % level matches actual fuel level in tank
+ /- 5% .
5. 12V Converter [V] (IM3-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. Hyd Tank Oil Temp [C] (IM3-m): Disconnect hydraulic tank oil temp sensor and
confirm fault A103, Hydraulic Oil Temp - Tank Sensor Low, is active. Reconnect
sensor.
8. Hoist Pressure 2 [kPa] (IM3-q): Short wire 33HP2 to ground at TB28-K momentarily
and confirm fault A203, Hoist Pressure 2 Sensor Low, is active.
9. Hoist Pressure 1 [kPa] (IM3-s): Short wire 33HP1 to ground at TB30-N momentarily
and confirm fault A202, Hoist Pressure 1 Sensor Low, is active.
10. Battery Voltage 24V [V] (IMint): confirm reported voltage is + /- 1 volt of actual
measured battery voltage.

CHECK SERIAL INTERFACES TO THE IM

1. Proper operation of the serial interfaces to the IM is assured if faults A184, A233,
A237, and A257 are not active.

CHECK OUTPUTS FROM THE INTERFACE MODULE

Note: Before performing these next steps, the key switch must be turned off for
at least 7 minutes to allow the IM to completely shutdown. Confirm that the
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IM has shutdown by verifying that the green LED on the IM controller has
stopped flashing. While performing the following IM output checks, ensure

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that no output short circuit fault codes are reported by the IM Realtime Data
Monitor software.

1. Park Brake Solenoid output (IM1-E), Brake Auto Apply output (IM1-R). Short the
engine oil pressure switch wire circuit 36 to ground on TB28-A. Key on and shift
into neutral. Confirm that park brake solenoid is energized by verifying that coil is
magnetized. Use the GE DID panel to set the truck speed to a speed above 1 kph.
Shift into park. Confirm that the park brake solenoid remains energized. Reduce the
truck speed to 0 kph. Confirm that the park brake solenoid de-energizes. Remove
the ground from TB28-A.
2. Start Enable output (IM1-B). Disconnect all circuit 21PL wires from pre-lube timer
prior to performing this step. Place shifter in park and confirm that circuit 21PS on
TB28-H is 24 volts while cranking. Place shifter in neutral and confirm that circuit
21PS on TB28-H is 0 volts while cranking. Reconnect all circuit 21PL wires to pre-
lube timer.
3. IM On Signal (IM1-K). With keyswitch on, confirm voltage on circuit 110NS at
TB35-T is approximately 0 volts.
4. Red Warn output (IM1-G), Sonalert output (IM1-M). Disconnect the IM from the
CAN/RPC network by unplugging its T-connection to the network then confirm the
following on the dash panel:
a. all status panel indicators flash on/off
b. the red warning indicator flashes on/off
c. two separate audible alarms can be heard sounding on/off
d. a loss of communications message is displayed on the speedometer
e. the needles in all of the gauges are moving through their entire range of
motion
Reconnect the IM to the CAN/RPC network.
5. Steering Bleed Down Solenoid output (IM1-P). Confirm steering bleed down solenoid
is de-energized. Turn key switch off and confirm that steering bleed down solenoid
is energized by verifying that coil is magnetized.

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S/N ___________________
IM Installation Checkout Checklist

Software Validation Check

IM Realtime Display CRC Number Extranet Software CRC Number Comments

Function Description Expected Result Result (OK/Fail) Comments

DIGITAL INPUT CHECKS:
1 - Hydraulic Tank 1 to 0
Level input
2 - Low Steering 0 to 1
Precharge input
3 - Pump Filter Switches 1 to 0
input
4 - Park Brake Released 1 to 0
input
5 - Park Brake Request 1 to 0
input
6 - GE Batt + input 1

7 - Starter Motor 1 0 to 1
Energized input
8 - Starter Motor 2 0 to 1
Energized input
9 - Crank Sense input 0 to 1

10 - Selector Switch 1 to 0
(Park)

11 - Selector Switch 0 in Park, 1 in Forward,

(FNR) Neutral, and Reverse
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Function Description Expected Result Result (OK/Fail) Comments

12 - Steering Bleed 0 to 1
Pressure input
13 - Brake Lock Switch 0 to 1
Power Supply input

14 - Brake Lock input 0 to 1

15 - Service Brake Set 0 to 1

input
16 - Cummins 0 to 1
Shutdown Delay input
17 – Secondary Engine 1 to 0
Shutdown input
18 – Keyswitch input 1

19 - Mode switch 1 1 to 0
input
20 - Mode switch 2 1 to 0
input

21 - Mode switch 3 1 to 0
input

22 - Mode switch 4 1 to 0
input

23 - Crank Request 0 to 1
input
24 - Park Brake Set 0 to 1
input
25 – Seat Belt switch 0 to 1
26 - Snapshot input 1 to 0

27 - Low Steering 1 to 0
Pressure switch input
28 - Brake Accumulator 1 to 0
Pressure switch input
29 - Brake Lock 1 to 0
Degrade switch input
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Function Description Expected Result Result (OK/Fail) Comments

30 – Keyswitch Direct 1 to 0 to 1
input
31 - Auto Lube Level 1 to 0
switch input
32 - Auto Lube Pressure 1 to 0
switch input
33 – Body Up switch w/o body 0 to 1 to 0
input with body 1 to 0
34 – Dynamic Retard 1 to 0
input
35 – No Propel/Retard 0 to 1 to 0
input (GE CPU
Running)
36 – Accessory Drive 1 to 0
Pump Filter Switch
ANALOG INPUT
CHECKS:
1 - Truck Speed set speed +/- 2 kph

2 - Steering Pressure fault A204

3 - Ambient Air Temp ambient temp +/- 3C

4 - Fuel Level tank level +/- 5%

5 - Converter Voltage 13.5 +/- 0.5V

(12V)
6 - Brake Pressure fault A205

7 – Hyd Tank Oil Temp fault A103

8 - Hoist Pressure 2 fault A203

9 - Hoist Pressure 1 fault A202

10 - Battery Voltage measured battery voltage

24V +/- 1V
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SERIAL COMM
CHECKS:
1 - CAN/J1939, Drive no fault A184, A233,
System CAN/RPC, A237, A257
Display CAN/RPC,
Payload CAN/RPC,
OUTPUT CHECKS:
1 - Park Brake Solenoid energized/de-energized

2 - Start Enable output 24 V, 0 V

3- IM On Signal output 0V

4 - Electronic Dash Items 4a-e function as

Panel check described
5- Steering Bleed Solenoid de-energized then
Solenoid output energized

IM Software Version Number: _________________________________________

Completed By: _________________________________________ Date: _______________________

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