SM 980E-4 A40003-UP CEBM031000 (Ingles)

CEBM031000
Shop
Manual
DUMP TRUCK
SERIAL NUMBERS A40003 & UP
®
CEN00023-00
DUMP TRUCK 1SHOP MANUAL
980E
Machine model Serial number

980E-4 A40003 and up
00 Index and foreword

Index
Composition of shop manual ................................................................................................................................ 2
Table of contents................................................................................................................................................... 4
1
CEN00023-00 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 CEBM031000

Index CEN00023-00
Foreword, safety and general information CEN00002-07
Operating instructions CEN00032-00
01 Specification
Specification and technical data CEN01014-00
10 Structure, function and maintenance standard

Steering circuit CEN10062-00
Hoist circuit CEN10067-00
Brake circuits CEN10068-00
Electrical system, 24 volt CEN10070-00
Electrical system, AC drive CEN10055-01
Cab air conditioning CEN10008-02
Reserve engine oil system CEN10022-02
20 Standard value table

Standard service value table CEN20005-00
30 Testing and adjusting

Steering, brake cooling and hoist hydraulic system CEN30071-00
Brake system CEN30072-00
Accumulators and suspensions CEN30073-00
Interface module (IM) CEN30068-00
KOMTRAX Plus CEN30069-00
Payload meter IV CEN30070-00
Electrical system, AC Drive CEN30053-01
2
00 Index and foreword CEN00023-00
40 Troubleshooting
Fuse and circuit breaker locations CEN40161-00
AC drive system fault codes CEN40114-01
Troubleshooting by failure code, Part 1 CEN40163-00
Orbcomm CEN40162-00
90 Diagrams and drawings

Hydraulic circuit diagrams CEN90014-00
Electrical circuit diagrams CEN90015-00
3
Table of contents

Index CEN00023-00
Composition of shop manual ....................................................................................................2
Table of contents .......................................................................................................................4
Foreword, safety and general information CEN00002-07
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......................................................................................19
Tires ........................................................................................................................................21
Precautions for performing repairs ..........................................................................................22
Precautions for welding on the truck .......................................................................................23
Capacitor discharge system ....................................................................................................24
Handling electrical equipment and hydraulic components ......................................................32
Standard tightening torques ....................................................................................................40
Conversion tables....................................................................................................................45
Operating instructions CEN00032-00
Preparing for operation..............................................................................................................3
Retractable ladder system.........................................................................................................8
Engine start-up ........................................................................................................................13
After engine start-up ................................................................................................................14
Pre-shift brake check...............................................................................................................14
Emergency steering system ....................................................................................................18
Precautions during truck operation..........................................................................................19
Operating on a haul road.........................................................................................................20
Starting on a grade with a loaded truck ...................................................................................21
Sudden loss of engine power or loss of drive system function................................................21
Fuel depletion..........................................................................................................................22
Towing .....................................................................................................................................22
Loading the dump body...........................................................................................................24
Dumping a load .......................................................................................................................25
Disabled truck dumping procedure..........................................................................................27
Safe parking procedure ...........................................................................................................29
Normal engine shutdown procedure .......................................................................................29
4
01 Specification
Specification and technical data CEN01014-00
Specification drawing ................................................................................................................ 3
Specifications ............................................................................................................................ 4
Weight table .............................................................................................................................. 6
Fuel, coolant and lubricants ...................................................................................................... 7
10 Structure, function and maintenance standard

Steering circuit CEN10062-00
Steering circuit operation........................................................................................................... 3
Steering circuit components ...................................................................................................... 8
Flow amplifier operation .......................................................................................................... 10
Steering/brake pump operation ............................................................................................... 19
Steering cylinder wear data ..................................................................................................... 22
Hoist circuit CEN10067-00
Hoist circuit operation................................................................................................................ 3
Hoist circuit components ........................................................................................................... 4
Hoist pilot valve operation ......................................................................................................... 8
Hoist cylinder wear data .......................................................................................................... 18
Brake circuits CEN10068-00
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
Electrical system, 24V CEN10070-00
Battery supply system ............................................................................................................... 3
Engine starting system with prelube ......................................................................................... 5
Auxiliary control cabinet components........................................................................................ 7
Body-up switch.......................................................................................................................... 9
Hoist limit switch...................................................................................................................... 10
General system operation ......................................................................................................... 2
System components.................................................................................................................. 4
DSC software functions............................................................................................................. 5
Alternator field control ............................................................................................................. 10
Event detection and processing .............................................................................................. 12
Event logging and storage ......................................................................................................13
Abnormal conditions/overriding functions ............................................................................... 15
AC drive system component table .......................................................................................... 16
Electronic accelerator and retarder pedals ............................................................................. 23
5

General information...................................................................................................................2
Principles of refrigeration...........................................................................................................3
Air conditioning system components.........................................................................................5
Air conditioning system electrical circuit....................................................................................9
Reserve engine oil system CEN10022-02
General information...................................................................................................................3
Operation...................................................................................................................................4
Service ......................................................................................................................................7
Troubleshooting.........................................................................................................................8
Auto fill system electrical schematic..........................................................................................9

Standard value table CEN20005-00
Standard value table for truck....................................................................................................3

Steering, brake cooling and hoist hydraulic system CEN30071-00
General information on system checkout ..................................................................................3
Hydraulic system checkout procedures.....................................................................................4
Hydraulic system checkout data sheet....................................................................................15
Toe-in adjustment ....................................................................................................................18
Hoist cylinder leakage test ......................................................................................................19
Brake system CEN30072-00
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
Bearing seal pressure test.......................................................................................................22
Wet disc brake bleeding procedure .........................................................................................23
Parking brake bleeding procedure ..........................................................................................23
Brake disc wear inspection......................................................................................................24
Brake valve bench test and adjustment ..................................................................................26
Dual relay valve bench test and adjustment............................................................................29
Accumulators and suspensions CEN30073-00
Accumulator charging precautions ............................................................................................2
Bladder accumulator charging procedure .................................................................................3
Bladder accumulator storage ....................................................................................................7
Bladder accumulator leak testing ..............................................................................................8
Piston accumulator charging procedure....................................................................................9
Piston accumulator storage..................................................................................................... 11
Piston accumulator leak testing............................................................................................... 11
Suspension oiling and charging procedures ...........................................................................12
Suspension pressure test........................................................................................................19
6
Interface module (IM) CEN30068-00

Interface module software ......................................................................................................... 3
Interface module checkout procedures ..................................................................................... 5
KOMTRAX Plus CEN30069-00
KOMTRAX Plus software and tools .......................................................................................... 3
KOMTRAX Plus controller setup procedure.............................................................................. 3
KOMTRAX Plus initialization form............................................................................................. 7
Precautions when replacing the KOMTRAX Plus controller ..................................................... 8
KOMTRAX Plus controller checkout procedure ...................................................................... 10
Payload meter IV CEN30070-00
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
Checks prior to self load engine test (loadbox) ....................................................................... 20
Engine running tests ............................................................................................................... 22
Diagnostic information display (DID) panel ............................................................................. 34
Viewing event and statistical data ........................................................................................... 64
Logic screens .......................................................................................................................... 68
Datalogger function ................................................................................................................. 70
Uploading data ........................................................................................................................ 74
Service tools and equipment..................................................................................................... 3
Detecting leaks.......................................................................................................................... 6
System performance test .......................................................................................................... 7
Checking system oil .................................................................................................................. 8
System flushing......................................................................................................................... 9
Installing the manifold gauge set............................................................................................. 10
Recovering and recycling refrigerant ...................................................................................... 11
Evacuating the air conditioning system................................................................................... 13
Charging the air conditioning system ...................................................................................... 14
40 Troubleshooting
Fuse and circuit breaker locations CEN40161-00
Fuse and circuit breaker locations ............................................................................................ 3
AC drive system fault codes CEN40114-01
DID panel fault code tables ....................................................................................................... 3
Troubleshooting by fault code, Part 1 CEN40163-00
Fault Code A001: Left front suspension pressure sensor signal high ....................................... 3
Fault Code A002: Left front suspension pressure sensor signal low ........................................ 4
Fault Code A003: Right front suspension pressure sensor signal high .................................... 5
Fault Code A004: Right front suspension pressure sensor signal low ...................................... 6
7
Fault Code A005: Left rear suspension pressure sensor signal high ........................................7
Fault Code A006: Left rear suspension pressure sensor signal low .........................................8
Fault Code A007: Right rear suspension pressure sensor signal high .....................................9
Fault Code A008: Right rear suspension pressure sensor signal low.....................................10
Fault Code A009: Incline sensor signal high ........................................................................... 11
Fault Code A010: Incline sensor signal low ............................................................................12
Fault Code A011: Payload meter speed sensor signal has failed ...........................................13
Fault Code A013: Body up switch has failed...........................................................................14
Fault Code A014: Payload meter checksum computation has failed ......................................15
Fault Code A016: Payload meter write to flash memory has failed.........................................16
Fault Code A017: Payload meter flash memory read has failed .............................................17
Fault Code A018: Right rear flat suspension cylinder warning................................................18
Fault Code A019: Left rear flat suspension cylinder warning ..................................................19
Fault Code A022: Carryback load excessive ..........................................................................20
Fault Code A101: High pressure detected across an hydraulic pump filter ............................21
Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level .......23
Fault Code A107: GE has generated a propel system caution ...............................................24
Fault Code A108: GE has generated a propel system temperature caution...........................25
Fault Code A109: GE has generated a propel system reduced level signal ...........................26
Fault Code A111: Low steering pressure warning ...................................................................27
Fault Code A115: Low steering precharge pressure detected ................................................28
Fault Code A117: Low brake accumulator pressure warning ..................................................29
Fault Code A118: Brake pressure is low while in brake lock ...................................................30
Fault Code A123: GE has generated a reduced retarding caution .........................................31
Fault Code A124: GE has generated a no propel / no retard warning ....................................32
Fault Code A125: GE has generated a no propel warning......................................................33
Fault Code A126: Oil level in the hydraulic tank is low............................................................34
Fault Code A127: IM-furnished +5 volt output for sensors is low ............................................35
Fault Code A128: IM-furnished +5 volt output for sensors is high ..........................................36
Fault Code A139: Low fuel warning ........................................................................................37
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................................................................................5
Fault Code A152: Starter failure ................................................................................................6
Fault Code A153: Battery voltage is low with the truck in operation .........................................8
Fault Code A154: Battery charging voltage is excessive ........................................................10
Fault Code A155: Battery charging voltage is low................................................................... 11
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low
fuel level ..................................................................................................................................12
Fault Code A166: Left rear hydraulic oil temperature sensor is low ........................................14
Fault Code A167: Right rear hydraulic oil temperature sensor is low .....................................16
Fault Code A168: Left front hydraulic oil temperature sensor is low .......................................18
Fault Code A169: Right front hydraulic oil temperature sensor is low.....................................20
Fault Code A170: Left rear hydraulic oil temperature sensor is high ......................................22
Fault Code A171: Right rear hydraulic oil temperature sensor is high ....................................23
8
Fault Code A172: Left front hydraulic oil temperature sensor is high ..................................... 24
Fault Code A173: Right front hydraulic oil temperature sensor is high ................................... 25
Fault Code A184: J1939 data link is not connected ................................................................ 26
Fault Code A190: Auto lube control has detected an incomplete lube cycle .......................... 28
Fault Code A194: Left front hydraulic oil temperature is high ................................................. 30
Fault Code A195: Right front hydraulic oil temperature is high............................................... 31
Fault Code A196: Left rear hydraulic oil temperature is high .................................................. 32
Fault Code A197: Right rear hydraulic oil temperature is high................................................ 33
Fault Code A198: Hoist pressure 1 sensor is high.................................................................. 34
Fault Code A199: Hoist pressure 2 sensor is high.................................................................. 35
Fault Code A200: Steering pressure sensor is high................................................................ 36
Fault Code A201: Brake pressure sensor is high.................................................................... 37
Fault Code A202: Hoist pressure 1 sensor is low ................................................................... 38
Fault Code A203: Hoist pressure 2 sensor is low ................................................................... 40
Fault Code A204: Steering pressure sensor is low ................................................................. 42
Fault Code A205: Brake pressure sensor is low ..................................................................... 44
Fault Code A206: Ambient temperature sensor is high .......................................................... 46
Fault Code A207: Ambient temperature sensor is low............................................................ 47
Fault Code A212: Bad truck speed signal................................................................................. 3
Fault Code A213: Parking brake should have applied but is detected as not having
applied....................................................................................................................................... 4
Fault Code A214: Parking brake should have released but is detected as not having
released .................................................................................................................................... 6
Fault Code A215: Brake auto apply valve circuit is defective ................................................... 8
Fault Code A216: An open or short to ground has been detected in the parking brake
command valve circuit............................................................................................................. 10
Fault Code A223: Excessive engine cranking has occurred or a jump start has been
attempted ................................................................................................................................ 11
Fault Code A230: Parking brake has been requested while truck still moving ....................... 12
Fault Code A231: The body is up with engine running and brakes not on.............................. 13
Fault Code A235: Steering accumulator is in the process of being bled down ....................... 14
Fault Code A236: The steering accumulator has not properly bled down after
90 seconds.............................................................................................................................. 15
Fault Code A237: The CAN/RPC connection to the display is open....................................... 16
Fault Code A240: The key switch input to the interface module is open ................................ 17
Fault Code A242: Fuel gauge within the dash display panel is defective ............................... 18
Fault Code A243: Engine coolant temperature gauge within the dash display panel is
defective.................................................................................................................................. 19
Fault Code A244: Drive system temperature gauge within the dash display panel is
defective.................................................................................................................................. 20
Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is
defective.................................................................................................................................. 21
Fault Code A246: Payload meter reports truck overload ........................................................22
Fault Code A247: Low steering pressure warning .................................................................. 23
Fault Code A248: Status module within the dash display panel is defective........................... 24
Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted ......... 25
9
Fault Code A250: Battery voltage is low with the truck parked ...............................................26
Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted
to ground .................................................................................................................................28
Fault Code A252: Start enable output circuit is either open or shorted to ground...................29
Fault Code A253: Steering bleed circuit is not open while running .........................................30
Fault Code A256: Red warning lamp in the dash display (driven by IM) is open ....................31
Fault Code A257: Payload CAN/RPC is not connected ..........................................................32
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective ................33
Fault Code A260: Parking brake failure ....................................................................................3
Fault Code A261: Low brake accumulator pressure warning....................................................4
Fault Code A262: Steering bleed valve circuit open during shutdown ......................................5
Fault Code A264: Parking brake relay circuit is defective .........................................................6
Fault Code A265: Service brake failure.....................................................................................7
Fault Code A266: Shift lever was not in park while attempting to crank engine........................8
Fault Code A267: Parking brake was not set while attempting to crank engine .......................9
Fault Code A268: Secondary engine shutdown while cranking ..............................................10
Fault Code A270: Brake lock switch power supply is not on when required ........................... 11
Fault Code A271: Shift lever not in gear .................................................................................13
Fault Code A272: Brake lock switch power supply is not off when required ...........................14
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure
switch circuit ............................................................................................................................16
Fault Code A274: A brake setting fault has been detected .....................................................17
Fault Code A275: A starter has been detected as engaged without a cranking attempt ........18
Fault Code A276: The drive system data link is not connected ..............................................19
Fault Code A277: Parking brake applied while loading...........................................................20
Fault Code A278: Service brake applied while loading ...........................................................21
Fault Code A279: Low steering pressure switch is defective ..................................................22
Fault Code A280: Steering accumulator bleed down switch is defective ................................23
Fault Code A281: Brake lock degrade switch is defective ......................................................24
Fault Code A282: The number of excessive cranking counts and jump starts without the
engine running has reached 7.................................................................................................25
Fault Code A283: An engine shutdown delay was aborted because the parking brake
was not set ..............................................................................................................................26
Fault Code A284: An engine shutdown delay was aborted because the secondary
shutdown switch was operated ...............................................................................................27
Fault Code A285: The parking brake was not set when the keyswitch was turned off............28
Fault Code A286: A fault was detected in the shutdown delay relay circuit ............................29
Fault Code A292: The shutdown delay relay has remained on after the latched key switch
circuit is off ..............................................................................................................................31
Fault Code A303: Shift lever is defective ..................................................................................3
Fault Code A304: Auto lube grease level fault ..........................................................................4
Fault Code A305: Auto lube circuit is defective.........................................................................5
Fault Code A307: Both GE inverters are disabled ....................................................................6
Fault Code A309: No brakes applied when expected ...............................................................7
Fault Code A310: Low fuel warning ..........................................................................................8
10
Fault Code A311: Brake lock switch is on when it should not be .............................................. 9
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings........... 10
Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings .......... 11
Fault Code A315: DCDC converter 12 volt circuit is low......................................................... 12
Fault Code A316: Starter engagement has been attempted with engine running................... 13
Fault Code A317: Operation of brake auto apply valve without a detected response ............ 14
Fault Code A318: Unexpected power loss to interface module .............................................. 16
Fault Code A320: Data link reports GE propel system caution fault but wired input
does not .................................................................................................................................. 17
Fault Code A321: Data link reports GE propel system temperature caution fault but
wired input does not ................................................................................................................ 18
Fault Code A322: Data link reports GE propel system reduced level fault but
wired input does not ................................................................................................................ 19
Fault Code A323: Data link reports GE reduced retard level fault but wired input
does not .................................................................................................................................. 20
Fault Code A324: Data link reports DC link voltage but wired input does not......................... 21
Fault Code A325: Data link reports GE no propel/retard fault but wired input does not.......... 22
Fault Code A326: Data link reports GE no propel fault but wired input does not .................... 23
Fault Code A327: Data link reports GE at rest but wired input does not................................. 25
Fault Code A328: Drive system not powered up..................................................................... 27
Fault Code A329: Data link reports the body is not down but wired input says it is ................ 29
Fault Code A330: Data link reports dynamic retard operating state but wired input
does not .................................................................................................................................. 31
Fault Code A350: Overload on output 1B ................................................................................. 3
Fault Code A351: Overload on output 1E ................................................................................. 4
Fault Code A352: Overload on output 1H ................................................................................. 5
Fault Code A353: Overload on output 1J.................................................................................. 6
Fault Code A354: Overload on output 1K ................................................................................. 7
Fault Code A355: Overload on output 1L.................................................................................. 8
Fault Code A356: Overload on output 1M................................................................................. 9
Fault Code A357: Overload on output 1N ............................................................................... 10
Fault Code A358: Overload on output 1P ............................................................................... 11
Fault Code A359: Overload on output 1R ............................................................................... 12
Fault Code A360: Overload on output 1S ............................................................................... 13
Fault Code A361: Overload on output 1T ............................................................................... 14
Fault Code A362: Overload on output 1U ............................................................................... 15
Fault Code A363: Overload on output 1X ............................................................................... 16
Fault Code A364: Overload on output 1Y ............................................................................... 17
Fault Code A365: Overload on output 1Z ............................................................................... 18
Orbcomm CEN40162-00
Orbcomm satellite connection...................................................................................................3
Preliminary checks .................................................................................................................... 3
Diagnosis of gauge readings and system performance ............................................................ 3
Troubleshooting by manifold gauge set readings...................................................................... 4
11

Hydraulic circuit diagrams CEN90014-00
Steering, hoist and brake cooling hydraulic circuit diagram ................................. 58B-60-21400
Brake hydraulic circuit diagram ............................................................................ 58B-33-00030
Auxiliary system hydraulic circuit schematic ........................................................ 58E-60-01680
Electrical circuit diagrams CEN90015-00
Electrical circuit diagram ...................................................................................... 58B-06-02261
Electrical sub-system circuit diagram ................................................................... 58B-06-02230
12
NOTES
13
980E Dump truck

Form No. CEN00023-00
© 2016 KOMATSU
All Rights Reserved
Printed in USA 03-16
14
CEN00002-07
730E
960E
980E

730E-8 A40003 and up
960E-1 A30003 - A30026
960E-2 A30027 and up
980E-4 A40003 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 ................................................................................................................. 19
Tires .................................................................................................................................................................... 21
Precautions for performing repairs...................................................................................................................... 22
Precautions for welding on the truck................................................................................................................... 23
Capacitor discharge system................................................................................................................................ 24
Handling electrical equipment and hydraulic components .................................................................................. 32
Standard tightening torques ................................................................................................................................ 40
Conversion tables ............................................................................................................................................... 45
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. (See Operating Instructions -
“Preparing For Operation”.)
• 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 Index and foreword section Operating
truck.
instructions.
• Stop the truck in the desired location. Check
again for persons or objects behind the truck. • Use a towing device with ample strength for the
Give the determined signal, then slowly operate weight of this truck.
the dump body. If necessary, use blocks for the • Towing vehicle must have adequate pulling and
wheels or position a flagman. braking capacity to both move and stop the towed
• When dumping on slopes, truck stability is poor truck under all conditions, including towing on a
and there is danger of tipping over. Always use grade.
extreme care when performing such operations. • Inspect towing components, such as tow bars
• Never travel with the dump body raised. and couplings, for any signs of damage. Never
use damaged or worn components to tow a
When loading disabled vehicle.
• Make sure that the surrounding area is safe. Stop • Keep a safe distance from the trucks and towing
the truck in the correct loading position, then load apparatus while towing a vehicle.
the body uniformly. • When connecting a truck that is to be towed, do
• Do not leave the operator seat during the loading not allow anyone to go between the tow vehicle
operation. and the disabled vehicle.
• Set the coupling of the truck being towed in a
straight line with the towing portion of the tow
truck, and secure it in position.
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: 09963-03001
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-
Stopping the engine
ness and attach it to a
• Before performing inspections or maintenance, tie-off anchor or tie-off
stop the truck on firm flat ground, lower the dump point.
body, move the directional control lever to PARK,
and stop the engine. Komatsu anchor (58B-98-75190) is available for use
with fall protection harnesses. Carefully read and
• If the engine must be run during service, such as understand the harness maker’s instructions before
when cleaning the radiator, the directional control
using any fall protection harness.
lever must be in PARK. Always perform this work
with two people. One person must sit in the NOTE: The anchor must not be used for lifting.
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
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.
19
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.
20
Tires Refer to the Society of Automotive Engineers (SAE),

SAE J1337, Off-Road Rim Maintenance Procedures
Handling tires and Service Precautions, Section 4.2 for additional
If tires are not used under the specified conditions, information on demounting the tires and rim assem-
they may overheat and burst, or be cut and burst by blies. Also, refer to Section 4.4 of SAE J1337 for
sharp stones on rough road surfaces. This may lead assembly and inflation recommendations.
to serious injury or damage. The U.S. Department of Labor Mine Safety and Health
To maintain tire safety, always use the specified tires. Administration (MSHA) addresses tire repairs in its Title
Inflate the tires to the specified pressure. An 30 Code of Federal Regulations, 30 CFR 57.14104.
abnormal level of heat is generated when the inflation
pressure is too low.
The tire inflation pressure and permissible speeds are
general values. The actual values may differ DO NOT stand in front of a rim and locking ring
depending on the type of tire and the condition under when inflating a tire mounted on the machine.
which they are used. For details, please consult the Observers must not be permitted in the area.
tire manufacturer.
DO NOT weld or heat the rim assembly with the tire
When tires become hot, a flammable gas is produced mounted on the rim. Resulting gases inside the tire
and may ignite. It is particularly dangerous if the tires may ignite, causing explosion of the tire and rim.
become overheated while the tires are pressurized. If
the gas generated inside the tire ignites, the internal
pressure will suddenly rise and the tire will explode,
resulting in danger to personnel in the area. Storing tires after removal
Explosions differ from punctures or tire bursts • As a basic rule, store the tires in a warehouse in
because the destructive force is extremely large. which unauthorized persons cannot enter. If the
Therefore, the following operations are strictly tires are stored outside, always erect a fence
prohibited when the tire is pressurized: around the tires and put up “No Entry” signs and
other warning signs that even young children can
• Welding the rim understand.
• Welding near the wheel or tire • Stand the tire on level ground and block it
• Smoking or creating open flames securely so that it cannot roll or fall over.
If the proper procedure for performing maintenance or • If the tire falls over, flee the area quickly. The tires
replacement of the wheel or tire is not used, the for dump trucks are extremely heavy. Never
attempt to hold or support the tire. Attempting to
wheel or tire may burst and cause serious injury or
hold or support a tire may lead to serious injury.
damage. When performing such maintenance,
consult your authorized regional Komatsu distributor
or the tire manufacturer.
Mounted tires stored as spares must be inflated to

the minimum inflation pressure necessary to keep the
tire beads properly seated. Maximum inflation
pressure of the stored tire must, in no instance,
exceed 15% of the tire’s cold inflation pressure.
21
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 Index and foreword section Operating
refrigerants. Refer to Testing and adjusting instructions.
section Cab air conditioning.
3. After the engine has been stopped for at least
• Follow package directions carefully when using
five minutes, inspect the link voltage lights on
cleaning solvents.
the exterior of the main control cabinet and the
• If an auxiliary battery assist is needed, refer to DID panel on the rear wall of the operator cab.
"Starting with jumper cables" or "Jump starting
with receptacles" earlier in this section. a. If all lights are off, it is safe to work on the
retarding grids, wheel motors, alternator and
• If the truck must be towed, use a rigid tow bar. related power cables. Proceed to Step 5.
Check the truck frame for a decal recommending
special towing precautions. Also refer to the b. If any red lights continue to be illuminated
towing instructions in Index and foreword section after following the above procedure, a fault
Operating instructions. has occurred. Leave all cabinet doors in
• Relieve hydraulic pressure before disconnecting place. Do not touch the retarding grid ele-
any lines or hoses. Hydraulic oil escaping under ments. Do not disconnect any power cables
pressure can have sufficient force to enter a or use them as hand or foot holds. Notify
person's body by penetrating the skin, resulting in your Komatsu service representative immedi-
serious injury and possibly death. ately.
• After adjustments or repairs, replace all shields, 4. Locate the generator field contactor (GF) switch
screens and clamps. in the access panel on the left side of the main
control cabinet. Place the switch in the
CUTOUT position. This will prevent the
alternator from re-energizing and creating
system voltage until the switch is returned to its
former position.
5. Leave the drive system in the rest mode until
the truck is to be moved.
22
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.
23
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 00-2. VOLT METER ASSEMBLY
Figure 00-2, the grounding sticks in Figure 00-3
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 00-3. GROUNDING STICKS
24
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.
25
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 00-4. INFORMATION DISPLAY PANEL
switch (2, Figure 00-4) 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 00-5.
FIGURE 00-5. DISCHARGE PATHS
26
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 00-6. 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 00-6. CAPACITOR CHARGE LIGHTS

1. Exterior Capacitor Charge Light (CCL2) 3. Information Display Panel
2. Interior Capacitor Charge Light (CCL1) 4. DC Link Capacitors
27
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 00-7 and Figure 00-8. 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 00-7. DC METER ON CAPACITOR
FIGURE 00-8. CAPACITOR TERMINAL POLARITY
28
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 00-8 and Figure 00-10. Attempt
2. Verify the ground connection and grounding
to minimize the time between application of the
stick resistance levels. Measure the resistance
positive stick and the negative stick so that the
between each individual grounding stick tip to
current flow will be positive to negative rather
either the GND1 or GND2 ground block in the
than either to ground. Leave sticks in place until
low voltage compartment of the control cabinet
capacitors are discharged. Refer to Figure 00-
using a multimeter (Figure 00-9). Ensure that
10.
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 00-9. GROUNDING STICK LEAD CONNECTION AND CHECK
29
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 00-9). 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 00-10. APPLICATION OF GROUNDING STICKS TO

CAPACITOR TERMINALS
30
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 00-11. 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 00-11. JUMPER ALL TERMINALS ON

ISOLATED CAPACITOR
31
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.
32
• 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.
33
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.
34
• 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.
35
• 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.
36
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.
37
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.
38
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.
39
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.
40
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
41
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
42
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
43
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
44
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
45
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)
46
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
47
730E Dump truck

960E Dump truck
980E Dump truck
© 2016 KOMATSU
All Rights Reserved
48
CEN00032-00
980E

980E-4 A40003 and up

Operating instructions
Preparing for operation ......................................................................................................................................... 3
Retractable ladder system .................................................................................................................................... 7
Engine start-up.................................................................................................................................................... 13
After engine start-up............................................................................................................................................ 14
Pre-shift brake check .......................................................................................................................................... 14
Emergency steering system................................................................................................................................ 18
Precautions during truck operation ..................................................................................................................... 19
Operating on a haul road .................................................................................................................................... 20
Starting on a grade with a loaded truck............................................................................................................... 21
Sudden loss of engine power or loss of drive system function ........................................................................... 21
Fuel depletion ..................................................................................................................................................... 22
Towing................................................................................................................................................................. 22
Loading the dump body ...................................................................................................................................... 24
Dumping a load................................................................................................................................................... 25
Disabled truck dumping procedure ..................................................................................................................... 27
Safe parking procedure....................................................................................................................................... 29
Normal engine shutdown procedure ................................................................................................................... 29
1
NOTES
2
Preparing for operation

The safest trucks are those which have been properly
prepared for operation. At the beginning of each shift,
a careful check of the truck should be made before
attempting to start the engine. High voltage may be present on this truck! DO
NOT open any electrical cabinet doors on this
Safety is thinking ahead. Prevention is the best safety truck while the engine is running. Never climb on
program. Prevent a potential accident by knowing the any power cables or use power cables for
employer's safety requirements, all necessary job site handholds or footholds unless the engine has
regulations, and use and care of the safety equipment been shut down and the system has been verified
on the truck. Only qualified operators or technicians to be at “rest”.
should attempt to operate or maintain a Komatsu
1. Start at left front of truck. Visually inspect all
truck.
lights and safety equipment for damage. Ensure
Safe practices start before the operator gets to the that the lenses are clean and unbroken. Ensure
equipment. that the battery box covers are in place and
secure.
• Wear the proper clothing. Loose fitting clothing,
unbuttoned sleeves and jackets, jewelry, etc., 2. Move in front of the left front tire. Inspect the
can catch on a protrusion and cause a potential hub and brake assemblies for leaks and any
hazard. abnormal conditions.
• Always use the personal safety equipment 3. Ensure that all suspension mounting hardware
provided for the operator such as hard hats, is secure. Inspect the mounting key area for
safety shoes, safety glasses or goggles. There evidence of wear. Ensure that the suspension
are some conditions when protective hearing extension (exposed piston rod) is correct and
devices should also be worn for operator safety. that there are no leaks.
• When walking to and from the truck, maintain a 4. Ensure that the anchor end of the steering
safe distance from all machines, even if the cylinder is secure and properly greased.
operator is visible.
5. With the engine stopped, check the engine oil
Walk around inspection level. Use the service light if necessary.
6. Inspect the air conditioner belts for correct
At the beginning of each shift, a careful walk around
tension, obvious wear, and tracking. Ensure that
inspection should be performed before attempting to
the fan guard is secure and in good condition.
start the engine. A walk around inspection is a
When leaving this point, turn off the service light
systematic ground level inspection of the truck and its
if used.
components to ensure that the truck is safe to operate
before entering the operator's cab. 7. Move outside of the front wheel. Ensure that all
of the mounting nuts/studs are in place and
Start at the left front corner of the truck (see the tight. Check the tires for cuts, damage, or
illustration on the next page) and move in a bubbles. Check for evidence of incorrect tire
counterclockwise direction. Move front-to-rear, across inflation.
the rear, and continue forward up the opposite side of
8. Move in behind the front wheel. Ensure that the
the truck to the original starting point.
steering cylinder is properly greased and the
If these steps are performed in sequence and are mounting hardware is tight. Check the
repeated from the same point and in the same suspension mounting hardware and suspension
direction before every shift, many potential problems extension. Ensure that the suspension
may be avoided or scheduled for maintenance. protective boot is in good condition. Inspect the
Unscheduled downtime and loss of production can be hub and brakes for any unusual conditions.
reduced as a result. Check the entire area for leaks.
Local work practices may prevent an operator from
performing all tasks suggested here. To the extent
permitted, the operator should follow this routine.
3
START HERE
4
13. Move around the left side dual tires. Ensure that
FIGURE 00-2. TOP VIEW all wheel nuts/studs are in place and tight.
Inspect the wheel for any oil that would indicate
1. Operator Cab brake leakage or wheel motor leakage.
2. Auto Lubrication
3. Radiator 14. Check the dual tires for cuts, damage, and
4. Reserve Oil System bubbles. Verify that tire inflation is correct. If the
5. Engine truck has been run on a “flat”, the tire must be
6. Fuel Filters cooled before moving the truck inside. Check for
7. Suspension any rocks that might be lodged between the
8. Wet Disc Brake dual tires.
9. Brake Accumulators
10. Hoist Filters 15. Inspect the left rear suspension for damage,
11. Steering Filter correct rod exposure, and leaks. Ensure that the
12. Fuel Tank covers over the chrome piston rod are in good
13. Hoist Cylinder condition.
14. Rear Axle Housing 16. Open the rear axle hatch. Inspect for leaks
15. Wet Disc Brake around the parking brakes. Ensure the cooling
16. Wheel Motor Transmission air exhaust ductwork is intact and there are no
17. Rear Tires obstructions.
18. Rear Suspension
19. Rear Axle Hatch 17. While standing at the rear axle hatch, look up to
20. AC Electric Motor check that the rear lights and back-up alarms
21. Hydraulic Tank are in good condition. Look up at panhard rod to
22. Steering Pump check that it is properly greased. Also check
23. Hoist Pump both body hinge pins for proper greasing and
24. Steering Accumulators any abnormal condition. Check the hoist limit
25. Alternator switch and clear any mud or debris from the
contacts.
18. Inspect the right rear suspension for damage,
correct rod exposure, and leaks. Ensure that the
covers over the chrome piston rod are in good
9. Inspect the sight glass on the hydraulic tank. condition.
With the engine stopped and the body down,
the hydraulic oil level must be visible in the 19. Move around the right side dual tires. Inspect
center of the upper sight glass. between the tires for rocks. Inspect the tires for
cuts, damage and proper inflation.
10. Verify that all hydraulic tank shut-off valves (if
equipped) are locked in their fully open posi- 20. Ensure that all wheel nuts/studs are in place and
tions. tight. Inspect the wheel for any oil that would
indicate brake leakage or wheel motor leakage.
11. Move around the hydraulic tank and in front of
the rear dual tires. Inspect the hoist cylinder for 21. Move in front of right dual tires. Inspect the hoist
any damage and leaks. Ensure that both upper cylinder in the same manner as the left side.
and lower hoist cylinder pins are secure and Ensure that the body-up limit switch is secure
properly greased. and in good condition. Remove any mud or dirt
accumulation from the switch.
12. Look under the lower edge of the chassis to
ensure that the flexible duct that carries the air 22. Move around the fuel tank. Inspect the mounting
from the main blower to the final drive housing is hardware for the fuel tank at the upper saddles
in good condition. Also, look up at the main and at the lower back side of the tank. Check
hydraulic pumps to see if there is any leakage or the hoist filters and steering filter for leaks.
any other unusual condition with the pumps or
pump drive shafts.
5
23. Move in behind the right front wheel. Ensure

that the steering cylinder is properly greased
and the mounting hardware is secure. Check
the suspension mounting hardware and
suspension extension. Ensure that the
suspension protective boot is in good condition. If the engine has been running, allow the coolant
Inspect the hub and brakes for any unusual to cool before removing the fill cap or draining
conditions. Check the entire area for leaks. the radiator. Serious burns may result if skin
comes in contact with hot coolant.
24. Move out and around the right front wheel.
Ensure that all wheel nuts/studs are in place 30. Use the coolant level sight gauge to check the
and tight. coolant level in the radiator. If it is necessary to
remove the radiator cap, ensure that the engine
25. Move behind the front of the right front wheel. is off, then relieve the coolant pressure by
Check the hub and brakes for leaks and any slowly removing the radiator cap.
unusual conditions. Ensure that the steering
cylinder is secure and properly greased. Inspect 31. Inspect the retarding grid covers. Ensure that
the engine compartment for any leaks and the latches are in place and secure. Inspect the
unusual conditions. Inspect the fan guard and main air inlet to ensure that it is clear. Ensure
belts. Check for any debris behind the radiator. that all cabinet door latches are secure.
26. Inspect the automatic lubrication system. See 32. Move around to the rear of the cab. Open the
the Operation and Maintenance Manual for doors of the brake cabinet and check inside the
more information about the automatic cabinet for leaks.
lubrication system. 33. Clean the cab windows and mirrors. Clean out
27. Move around to the right front of the truck. As the cab floor, if necessary. Ensure that the
you move in front of the radiator, remove any steering wheel, operator controls, and pedals
debris that is stuck in front of the radiator. Check are free of any grease or mud.
for any coolant leaks. Inspect the headlights and 34. Stow any personal gear in the cab so that it
fog lights. does not interfere with any operation of the
28. Before climbing the ladder to first level, ensure truck. Dirt or trash buildup, specifically in the
that the ground level engine shutdown switch is operator cab, should be cleared. Do not carry
ON. Inspect the fire control actuator. Ensure that tools or supplies in the cab or on the deck.
the safety pin and the plastic tie that prevents 35. Adjust the seat and the steering wheel for the
accidental actuation are in place and in good most operator comfort.
condition. Ensure that the battery disconnect
36. Before operating the truck, read the Operation
switches are activated.
and Maintenance Manual to understand the
29. Always use handrails and ladders when locations and functions of all operator controls.
mounting or dismounting the truck. Clean any
foreign material such as ice, snow, oil or mud
from the ladders and handrails.
6
Retractable ladder system During normal operation, a person can lower or raise
the RLS by using the in-cab control panel, the ground
The retractable ladder system (RLS) is an electro-
level control box located next to the ground level
hydraulic ladder powered by the truck’s 24VDC
ladder light switch, or the control switches in the
electrical system. The RLS provides a safe means to
power pack.
mount and dismount the truck under normal and
emergency conditions. The RLS consists of two main NOTE: The master disconnect switch located on the
control components: battery disconnect box and the isolation switch in the
power pack must both be in the ON position for the
• The in-cab control panel is a microprocessor that
controls, monitors, stores and reports ladder RLS to operate.
system operational data. As an added safety measure, the RLS uses a parking
• The electro-hydraulic power pack is in a ground brake interlock that requires the parking brake to be
level stainless steel cabinet. It houses the main set before the ladder can be operated under normal
control hydraulics and electrical components that conditions. The RLS will automatically raise the
lower and raise the ladder. ladder if the operator moves the directional control
The RLS also contains wiring harnesses, hydraulic lever out of PARK and fails to press the [UP] button
hoses and an emergency down valve. on the in-cab control panel before attempting to drive
the truck.
The following safety precautions must be

followed to ensure safe operation and use of the
RLS.
• DO NOT run or jump on the ladder.
• DO NOT overload the ladder. Use the ladder
one person at a time.
• Hold onto the handrail when using the ladder.
• Always face the ladder when ascending or
descending.
• DO NOT attempt to ride on the ladder while it
is being raised or lowered or while the truck is
in motion.
• Always visually check the ladder before use
to ensure that the unit has not been damaged.
• Ensure that the ladder is in the fully down
position before boarding.
• Keep hands and fingers away from pinch
points while the ladder is in motion.
• Always check to ensure no personnel are on
or in the immediate vicinity of the ladder while
it is in motion.
FIGURE 00-3. RETRACTABLE LADDER SYSTEM
• The ladder must be kept clean and free of
moisture, grease and oil
• When in the truck’s cab, always use the in-cab
control panel to raise the ladder.
• Report defects to maintenance personnel
immediately.
7
Using the in-cab control panel In-cab control panel display screen (1, Figure 00-5)
provides the user with system status, error/fault
In-cab control panel (1, Figure 00-4) is located on the
messages and a visual indicator of the ladder’s
left side of the dash and contains a microprocessor
position (lowered, raised, in motion).
that controls, displays, monitors, stores and reports
ladder system operational data. The in-cab control [UP] button (2) is a dual function control that is used
panel provides real time position of the ladder to the to raise the ladder during normal operation and scroll
operator. through the menu displays. Pressing this button and
holding it briefly will cause the ladder to raise.
The in-cab control panel features a digital display
Pressing and releasing this button one time will scroll
screen, command buttons ([UP], [DOWN], [ENTER],
up one line of menu display, and holding it will result
[EXIT], [LEFT], [RIGHT]) for operating the ladder and
in continuous menu scrolling.
navigating through the various menu display screens,
a USB key port and RS 232 port for downloading [DOWN] button (3) is a dual function control that is
ladder system operational data to a laptop computer used to lower the ladder during normal operation and
for troubleshooting. Refer to Figure 00-5. scroll through the menu displays. Pressing this button
and holding it briefly will cause the ladder to lower.
down one line of menu display, and holding it will
result in continuous menu scrolling.
[DOWN] button (3) is a dual function control that is
used to lower the ladder during normal operation and
scroll through the menu displays. Pressing this button
and holding it briefly will cause the ladder to lower.
down one line of menu display, and holding it will
result in continuous menu scrolling.
[LEFT] button (4) is for scrolling left when entering a
password.
[RIGHT] button (5) is for scrolling right when entering
a password.
[ENTER] button (6) is a multi-function button used for
ladder system alarm acknowledgment and menu
access when in Display Mode. This button is also
used to confirm or accept changes shown on the
display screen. Press this button to confirm or accept
FIGURE 00-4. CAB CONTROLS changes listed on the display screen.
(OPERATOR VIEW)
[EXIT] button (7) is a multi-function button used for
1. In-Cab Control Panel ladder system alarm acknowledgment and menu
access when in Display Mode. This button is also
used to exit from the menu screens. Press this button
to exit from menu screens.
8
FIGURE 00-5. IN-CAB CONTROL PANEL

1. Display Screen 4. [LEFT] Button 7. [EXIT] Button
2. [UP] Button 5. [RIGHT] Button 8. USB Port
3. [DOWN] Button 6. [ENTER] Button 9. 15-Pin Harness Plug
While the ladder is in motion, the direction (up or The ladder will typically be in the lowered position on
down) can be changed by pressing the opposite a stationary truck. The in-cab control panel will
direction ([UP] or [DOWN]) button on the control indicate that the access is DOWN, as shown here:
panel.
If the IN CAB LOCKOUT message is displayed on
the control panel screen, then the RLS can only be
operated from the ground level control box mounted
next to the ground level ladder light switch. All other
control panel functionality is still available including
fault indication and audible alarms.
When in the operator’s cab, always use the [UP]

button on the control panel to raise the ladder
instead of moving the directional control lever
out of PARK. The automatic operation of the
ladder when the parking brake is released is an
emergency feature only. DO NOT move the
directional control lever out of PARK to raise the
ladder as part of normal operation.
9
To raise the ladder, press and hold (temporarily) the NOTE: The directional control lever must be in PARK
[UP] button located on the in-cab control panel. The before the ladder can be lowered.
illustrated ladder on the screen will animate and
To lower the ladder, press and hold (temporarily) the
begin to rise to the UP position and the UP arrow (on
[DOWN] button located on the in-cab control panel.
the control panel button) will flash. When the ladder is
The illustrated ladder on the screen will animate and
completely raised, the [UP] button will remain
begin to lower to the DOWN position and the
illuminated continuously.
[DOWN] button will flash.
When the ladder has reached its raised travel posi-
When the ladder has reached its lowered travel
tion and strikes the limit switch, the control panel will
position, the control panel will indicate that the
indicate that the access is UP, as shown here:
access is DOWN, as shown here:
The RLS power pack will continue to operate for

three more seconds to charge hydraulic accumulator. When the ladder is completely lowered, the [DOWN]
During this time, the UP arrow will continue to flash button will remain illuminated continuously.
until the cycle is complete.
The RLS uses a limit switch to monitor ladder travel
to the UP position. If the ladder fails to strike the limit
switch or the limit switch fails to close, a fault alarm
will activate after a short delay and the in-cab control
panel will display this message, as shown here:
NOTE: The fault alarm must be acknowledged by

pressing the [EXIT] or [ENTER] buttons on the
control panel. Once the alarm has been
acknowledged, the fault message will be replaced by
a FAULT IN SYSTEM message. A defective limit
switch will prevent normal RLS operation and must
be corrected immediately.
10
Using the ground level control box To raise the ladder, push toggle switch (2) to the
LADDER UP position and release. Ladder operation
Ground level control box (1, Figure 00-6) is located
via this switch is the same as using the in-cab control
next to the ground level ladder light switch. Toggle
panel. Any ladder movement will be shown on the in-
switch (2) lowers and raises the ladder.
cab control panel.
The parking brake must be applied before the ladder
To lower the ladder, push toggle switch (2) to the
can be lowered. If toggle switch (2) is held in either
LADDER DOWN position and release. Ladder
position for more than ten seconds, a fault will be
operation via this switch is the same as using the in-
activated and will need to be acknowledged by
cab control panel. Any ladder movement will be
pressing either the [EXIT] or [ENTER] buttons
shown on the in-cab control panel.
located on the in-cab control panel.
FIGURE 00-6. GROUND LEVEL CONTROL BOX
1. Ground Level Control Box 2. Toggle Switch
11
Emergency operation
In an emergency, the retractable ladder can be
lowered by using emergency down valve (1, Figure
00-7) mounted on the grille above the left hand
headlight assembly. The emergency down valve
relieves ladder system hydraulic pressure and allows
the ladder to smoothly lower to the ground.
To lower the ladder, rotate the handle on the
emergency down valve clockwise. The ladder will
lower smoothly until it reaches the ground.
To reset the ladder, rotate the handle
counterclockwise to its original position and, with
power restored to the power pack, press the [UP]
button to raise the ladder.
NOTE: The handle on the emergency down valve
must be in the original position before re-activating
the ladder.
FIGURE 00-7. EMERGENCY DOWN VALVE

1. Emergency Down Valve
2. Grille
12
Engine start-up
Do not crank an electric starter for more than 30

Never attempt to start the engine by shorting seconds. Allow two minutes for cooling before
across the starter terminals. This may cause fire, attempting to start the engine again. Severe
or serious injury or death to anyone in the damage to the starter motors can result from
machine’s path. Start the engine from the overheating.
operator seat only. 4. The key switch is a three-position switch
(OFF, RUN, START).
a. Turn the key switch one position clockwise to
the RUN position. All electrical circuits except
the start circuit are activated.
If the truck is in an enclosure, make sure that
there is adequate ventilation before start-up. b. Turn the key switch fully clockwise to the
Exhaust fumes are dangerous! START position and hold this position until
the engine starts. The START position is
spring-loaded and will return the switch to the
RUN position when the key is released.
NOTE: This truck is equipped with an engine prelube
If the truck is equipped with an auxiliary cold system. With this feature, a noticeable time delay
weather heater system, do not attempt to start the may occur before engine cranking begins as the
engine while the heaters are in operation. engine lube oil passages are being filled and
Damage to the coolant heaters will result. pressurized.
5. After the engine has started, place the rest
1. Ensure that all personnel are clear of the truck
switch in the OFF position to deactivate the rest
before starting the engine. Always sound the
mode.
horn as a warning before moving any controls.
2. Ensure that the directional control lever is in NOTE: In cold ambient conditions and when the
PARK before starting. engine is cold, the engine rpm will not increase above
low idle speed until the engine controller determines
3. Place the rest switch in the ON position to put
it is safe to do so. This time delay will vary from 30
drive system in rest mode. For more
seconds to 11 minutes which allows the coolant and
information, refer to the Operation and
engine oil to warm up.
Maintenance Manual.
13
After engine start-up Pre-shift brake check

NOTE: Komatsu recommends that operators perform
static brake tests to verify that the braking systems
are adequate at the beginning of each shift before
operating the truck.
Do not leave the truck unattended while the The static brake test allows the operator to check the
engine is running. Move the directional control service brake, parking brake and the dynamic
lever to PARK and turn off the engine before retarder. The purpose of these tests is to verify the
leaving the truck. functionality of the service brake, parking brake and
retarder systems at the time they are tested.
1. Become thoroughly familiar with steering and
emergency controls. After the engine has been After performing each test, it is the operator’s
started, DO NOT accelerate the engine speed responsibility to determine whether the truck passed
or drive the truck until the low pressure and each test and if the truck is safe for operation.
warning systems are normal and the coolant The order in which the brake tests are performed
temperature is at least 71°C (160°F). does not matter. Each brake test is a separate test,
2. Test the truck steering in extreme right and left and one brake system or all three can be tested at
directions. If the steering system is not any time.
operating properly, turn off the engine
immediately. Determine the steering system If an operator has questions during brake testing,
problem and have it repaired before resuming refer to the drive system Diagnostic Information
operation. Display (DID) panel, located on the back wall of the
cab, for guidance.
3. Operate each of the truck's brake circuits at
least twice before operating and moving the
truck. These circuits include the service brake,
parking brake, and brake lock. With the engine
running and the hydraulic circuit fully charged,
activate each circuit individually from the
operator cab. If the truck fails any brake test, notify
maintenance personnel immediately. Do not
If any application or release of any brake circuit resume operation unless the truck passes all
appears sluggish or improper, or if warning brake tests.
alarms are activated, turn off the engine and
notify maintenance personnel immediately. Do
not operate the truck until the brake circuit in The following events have been added to the drive
question is fully operational. system software to support the brake test feature.
4. Check the gauges, indicator lights, and other • 645-1 Service Brake test Performed
instruments before moving the truck to ensure • 645-2 Parking Brake Test Performed
proper system operation and proper instrument
functionality. Pay special attention to any • 645-3 Retard Test Performed
braking and steering hydraulic circuit warnings. • 645-4 Brake Test Switch stuck closed
If a warning is activated, turn off the engine
immediately and determine the cause.
5. Ensure that the headlights, worklights, and The Events Log will record which brake tests have
taillights are in proper working order. Check the been performed and when they were performed.
operation of windshield wiper. Good visibility
may help prevent an accident.
6. After engine startup, allow the reserve engine oil
pumping unit to run for 5 minutes before
operating the truck. Check the operation of the
pumping unit. Refer to “LED Monitor Lights” in
Section 10, Reserve Engine Oil System.
14
Operation If the brake check light does not illuminate

immediately after pressing the brake test switch,
The static brake test utilizes a momentary switch
there is most likely a problem with the test setup.
equipped with an amber light located in the instru-
Refer to the setup conditions and take action to
ment panel.
prepare the truck for a brake test.
The brake test switch is used to
If there is a problem with the setup, the DID panel will
initiate a brake test. Press on the
display the problem.
momentary switch to enter the
brake test mode. If certain For example if the engine is off:
conditions are met, the operator
ERROR Entering Brake Test
can enter a brake test sequence.
Engine not running
The amber light in the top of the
switch is used to indicate when If the truck is loaded:
the truck is in the brake test
mode. It is referred to as the ERROR Entering Brake Test
brake check light. When Truck is NOT Empty
illuminated, a brake test is ready. When flashing, the
brake test is at the validation point, or the retard If all of the conditions are correct, except the brakes
system test is finished. are not set correctly, an error message will be
displayed. For example, if the service brake and
parking brake are both applied together:
The operator can choose which brake test to perform,
ERROR Entering Brake Test
and will set the truck controls based on the settings in Set Brakes for Test
Table 1. The drive system will detect the position of
the directional control lever, and will prepare for the
appropriate test. The operator will then press the Numerous conditions can occur which may interrupt
brake test switch. a brake test, including the following:
If the brake check light is illuminated solid after press- • Any of the setup conditions becoming false
ing the brake test switch, the system is in brake test
mode and is ready for the chosen test to be initiated • Drive system fault which restricts the LINK or
by the operator. After testing, the operator will then Propel mode
determine whether the truck passed the brake tests • Truck speed greater than 3.2 kph (2.0 mph)
and if it is safe for operation.
• Drive system at torque level for more than 30
seconds
• Brake test requested, but not initiated by the
operator within 60 seconds after pressing the
brake test switch
Table 1: BRAKE TEST SETTINGS

Wheel Brake Service Brake Directional
Test Type Lock Pedal Control Lever
Service Brake OFF FULLY APPLIED NEUTRAL
Parking Brake OFF RELEASED PARK
Retard Test OFF RELEASED PARK
15
Brake test setup Service brake test
Before performing any brake test, the truck must be 1. Firmly depress the retard/brake pedal.
located outside on a flat area where truck movement 2. Place the directional control lever in the
is allowed. The dump body must also be empty. NEUTRAL position. Ensure that the wheel
brake lock switch is OFF.
NOTE: The drive system will not enter any brake test
if the truck is loaded. 3. Press the brake test switch and wait for the
brake check light to be on solid.
4. Fully depress the retard/brake pedal. Ensure
that full brake application is reached. Failure to
reach full brake application will affect the service
brake test results.
Ensure that the area around the truck is free of 5. The DID panel will display:
personnel and objects. Some truck movement
Service Brake Test READY
could occur during brake testing.
Press Accel Pedal to Start
The drive system is unable to determine whether
the truck is on a hill or in a parking ditch. Testing 6. With the retard/brake pedal fully applied, fully
during these conditions will affect test results. depress the accelerator pedal. The drive system
controller will enter propel mode and generate
torque up to the service brake limit. Maintain full
Before performing any brake test, the truck must be service brake pressure during the test.
in the following state: NOTE: The drive system can only detect whether the
• Engine on (low idle) service brakes are applied. It can not detect the
percentage of application. It is up to the operator to
• Drive system ready (Ready Mode) press hard enough on the service brake pedal to
• Dump body down achieve a full brake application.
• No drive system warnings active
(Cannot be in "limp" mode) 7. The DID panel will display:
• Zero ground speed
Service Brake Test ACTIVE
Check Truck Movement when Light Flashes
8. Once torque has reached the limit for the

service brake test, the brake check light will
begin to flash. This is the indication for the
operator to make a determination as to the
status of the service brake system.
• If the truck did not move:
The service brake system passed the test.
• If the truck moved during the test:
The service brake system failed the test.
16
9. Release the accelerator pedal. The torque will Parking brake test
be reduced, the test will stop and the brake
1. Place the directional control lever in the PARK
check light will turn off.
position.
10. Place the directional control lever in the PARK 2. Press the brake test switch and wait for the
position. Release the service brake pedal. brake check light to be on solid.
3. The DID panel will display:
Parking Brake or Retard Test READY
Press Accel or Retard Pedal to Start
4. Fully depress the accelerator pedal. The drive

If the truck fails the service brake test, notify
system controller will enter propel mode and
generate torque up to the parking brake limit.
resume operation unless the truck passes all
brake tests. 5. The DID panel will display:
NOTE: If the operator partially or fully releases the Park Brake Test ACTIVE
accelerator pedal during the test, torque will be Check Truck Movement when Light Flashes
reduced and the brake check light will go back on
solid when torque falls below the test set point. The 6. Once the torque has reached the limit for the
operator can re-apply the accelerator pedal to parking brake test, the brake check light will
increase torque and the brake check light will again begin to flash. This is the indication for the
flash when the torque is at the test limit. operator to make a determination as to the
status of the parking brake system.
If the test exits abnormally, or if the operator simply
does not press the accelerator pedal far enough to • If the truck did not move:
achieve the torque level for the service brake test, the The park brake system passed the test.
DID panel will display: • If the truck moved during the test:
Brake Test ERROR The parking brake test has failed. Release the
Test did NOT complete accelerator pedal. If the truck starts to roll, apply
the service brakes to hold the truck stationary.
If the truck fails the parking brake test, notify

brake tests.
7. Release the accelerator pedal. The torque will

be reduced, the test will stop and the brake
check light will turn off.
17
Retard system test Emergency steering system

1. Place the directional control lever in the PARK Operation
position.
2. Press the brake test switch and wait for the This truck is equipped with an emergency steering
brake check light to be on solid. system. This system is a backup in the event of loss
of oil supply to the main steering system. The
3. The DID panel will display: emergency steering system was designed to meet or
Parking Brake or Retard Test READY exceed SAE J1511 and ISO 5010 standards.
Press Accel or Retard Pedal to Start If the low steering system pressure warning and
alarm are activated, a failure in the hydraulic oil
4. Depress the retard/brake pedal far enough to supply to the steering and brake system exists. When
engage retard, but not far enough to engage the the alarm is activated, typically there is enough
service brakes. Depressing the retard/brake hydraulic pressure stored in the brake and steering
pedal too far will cancel the retarder test. accumulators to allow brief operation of the steering
The drive system controller will ramp up the and brake functions. However, this oil supply is
engine speed, close RP1, close RP2, close limited. Therefore, it is important to stop the truck as
RP3 (if present), turn on the choppers, and test quickly and safely as possible after the alarm is first
the retarding system. The system will verify activated.
current flow through each grid leg and the grid If the oil supply pressure drops to a predetermined
blower motor. level, the low brake pressure warning light will also
5. The DID panel will display the current status of illuminate. If the oil pressure continues to decrease,
the test. the brake auto-apply feature will activate the service
brakes to stop the truck.
Retard System Test ACTIVE
RP1 RP2 RP3 CHOP Pre-operation testing
(Elements are added as the test progresses.)
NOTE: Komatsu recommends that operators perform
6. Upon successful completion of the test, the light
this test to verify that the steering accumulator
will flash for 10 seconds, indicating a successful
precharge pressure is adequate at the beginning of
test. The DID panel will display:
each shift before operating the truck.
Retard System Test PASSED 1. Park the empty truck on flat, level ground.
or Lower the dump body onto the frame and stop
the engine. Ensure that the key switch is in the
Retard System Test FAILED or Incomplete OFF position.
NOTE: If the brake check light never flashes, but 2. Wait at least 90 seconds to verify that all
turns off, the test has failed. hydraulic pressure has been relieved from the
steering accumulators. Turn the steering wheel
from stop to stop. If the front wheels do not
move, there is no hydraulic pressure.
3. Check the hydraulic tank oil level. The oil level
must be visible in the center of the upper sight
If the truck fails the retard system test, notify glass but must not cover the entire upper sight
maintenance personnel immediately. Do not glass. Add oil if necessary. Do not overfill.
brake tests.
7. Release the accelerator pedal. The test will stop

and the brake check light will turn off.
18
4. Turn the key switch to the ON position, but do Precautions during truck operation
not start the engine.
After the engine is started and all systems are
a. Steering system pressure: Verify that the functioning properly, the operator must follow all local
warning light, alarm and low steering safety rules to ensure safe machine operation.
pressure warning message are activated. If
they are not, immediately notify maintenance
personnel. Do not operate the truck until the
problem is corrected.
b. Steering accumulator precharge: Verify that
the warning light, alarm and low steering If a warning is activated or any gauge reads in the
precharge warning message are not red area during truck operation, a malfunction is
activated. If they are activated, immediately indicated. Stop the truck as soon as possible and
notify maintenance personnel. Do not turn off the engine. Have the problem corrected
operate the truck until the problem is before resuming truck operation.
corrected.
5. Start the engine and allow the steering
accumulators to fully charge. Turn the steering
wheel so that the front wheels are straight.
6. Check the hydraulic tank oil level while the
The truck is equipped with “slip/slide” control. If
engine is on.
this function becomes inoperative, operating the
a. If the oil level is visible in center of the lower truck with stalled or free spinning wheel motors
sight glass and does not cover the entire may cause serious damage to the wheel motors.
lower sight glass, the steering accumulators If the truck does not begin to move within 10
are adequately charged. Proceed to Step 7. seconds after depressing the throttle pedal with
b. If the oil level is below the lower sight glass, the directional control lever in a F or R position,
the steering accumulators are not adequately release the throttle pedal and allow the wheels to
charged. Stop the engine and turn the key regain traction before accelerating again.
switch to the OFF position. Immediately • Operate the truck only while properly seated with
notify maintenance personnel. Do not seat belt fastened. Keep hands and feet inside
operate the truck until the problem is the cab while the truck is in operation.
corrected. • DO NOT allow unauthorized personnel to ride in
7. If the steering accumulators are adequately the truck. DO NOT allow anyone to ride on the
charged, stop the engine by pulling up the ladder or outside of the truck cab. Passengers
engine shutdown switch. Leave the key switch must be belted into the passenger seat during
in the ON position. This allows the steering travel.
accumulators to retain their hydraulic charge. • Always look to the rear before backing up the
The red warning light, alarm and warning truck. Watch for and obey the ground spotter's
messages should not be active. hand signals before making any reverse
movements. The spotter should have a clear view
8. Turn the steering wheel from stop to stop. The of the entire area at the rear of the truck.
front wheels should turn fully to the left and to
the right. Also, the warning light, alarm and low • When backing up the truck, give a back-up signal
steering pressure warning message should of three blasts on the horn. When starting
forward, give two blasts on the horn. These
activate.
signals must be given each time the truck is
If the front wheels cannot be turned fully to the moved forward or backward.
left and right, or if the warning light, alarm and
warning message do not activate, immediately • Truck operation requires concentrated effort by
the driver. Avoid distractions of any kind while
notify maintenance personnel. Do not operate
operating the truck.
the truck until the problem is corrected.
• Check the gauges and instruments frequently
If the truck passes this test, the emergency steering during operation for proper readings.
system is functioning properly.
19
• Observe all regulations pertaining to the job site's Operating on a haul road
traffic pattern. Be alert to any unusual traffic
pattern. Obey the spotter's signals. • Always stay alert! If you are unfamiliar with the
haul road, drive with extreme caution. The cab
• Match the truck speed to haul road conditions. doors should remain closed at all times if the
Slow down the truck in congested areas. Keep a truck is in motion or unattended.
firm grip on the steering wheel at all times.
• Obey all road signs. Keep the truck under control
• Do not allow the engine to run at idle for extended at all times. Govern the truck speed according to
periods of time. the road conditions, weather, and visibility. Report
poor haul road conditions immediately. Muddy or
• When the dump body is raised, do not allow
icy roads, pot holes, or other obstructions can
anyone beneath it unless the body-up retaining
present hazards.
cable is in place.
• Initial propulsion with a loaded truck should begin
from a level surface whenever possible. If starting
on a hill or grade cannot be avoided, refer to
"Starting on a grade with a loaded truck".
Do not use the brake lock for parking. With the • Use extreme caution when approaching a haul
engine stopped, hydraulic pressure will bleed road intersection. Maintain a safe distance from
oncoming vehicles.
down, allowing the brakes to release.
• Maintain a safe distance when following another
• Check the brake lock performance periodically for vehicle. Never follow another vehicle in the same
safe loading and dump operation. lane closer than 15 m (50 ft), or 30 m (100 ft) on a
• Proceed slowly on rough terrain to avoid deep downgrade.
ruts or large obstacles. Avoid traveling close to • Do not pass another truck on a hill or blind curve.
soft edges or the edge of a fill area. Only use areas designated for passing. Before
• Do not drive over unprotected power cables. passing, make sure that the road ahead is clear. If
a disabled truck is blocking your lane, slow down
• Check the tires for proper inflation periodically and pass with extreme caution.
during your shift. If the truck has been run on a
“flat” or under-inflated tire, it must not be parked • Do not stop or park on a haul road unless it is
in a building until the tire cools. unavoidable. If you must stop, move the truck to a
safe place, move the directional control lever to
• Do not leave the truck unattended while the PARK and turn off the engine before leaving the
engine is running. Move the directional control cab. Chock the wheels securely and notify
lever to PARK, then shut the engine off before maintenance personnel for assistance.
getting out of the cab.
• Before driving uphill or downhill, maintain a speed
that will ensure safe driving and provide effective
retarding under all conditions. Refer to the grade/
speed chart in the operator cab to determine the
maximum safe truck speeds for descending
various grades with a loaded truck.
• When operating the truck in darkness, or when
visibility is poor, do not move the truck unless all
headlights, clearance lights, and tail lights are on.
Do not back up the truck if the backup alarms or
lights are inoperative. Always dim the headlights
when meeting oncoming vehicles.
• If low steering pressure or low brake pressure
warning is activated during operation, steer the
truck immediately to a safe area away from other
traffic, if possible, and stop the truck.
20
Starting on a grade with a loaded truck If the brake supply pressure drops to a pre-
Initial propulsion with a loaded truck should begin determined level, the red warning light will illuminate
from a level surface whenever possible. If the truck and a buzzer will sound. If the brake pressure
must be started on a hill or grade, use the following continues to decrease, the auto-apply feature will
procedure: activate and the service brakes will apply
automatically to stop the truck.
1. Apply the wheel brake lock.
When loss of engine power or drive system function
2. Release the service brake pedal. Do not use the
occurs, perform the following:
retarder to hold the truck on the grade.
3. With the brake lock applied, move the direc- 1. Bring the truck to a safe stop as quickly as
tional control lever to a drive position (FOR- possible by using the foot pedal to apply the
WARD or REVERSE) and increase the engine service brakes. If possible, safely steer the truck
rpm with the throttle pedal. to the side of the road while braking.
4. As the engine rpm approaches maximum RPM, 2. As soon as the truck has stopped moving, park
and the operator senses the propulsion effort the truck.
working against the wheel brake lock, release 3. Slowly release the service brakes to check the
the brake lock and let truck movement start. As capacity of the parking brake. If the parking
the truck speed increases above 5-8 kph (3-5 brake cannot hold the truck stationary, apply the
mph), the Drive System Controller (DSC) will service brakes and hold them ON. DO NOT turn
drop the propulsion if the retarder is applied. the key switch OFF, and DO NOT release the
NOTE: Releasing and re-applying dynamic retarding service brakes.
during a hill start operation will result in loss of 4. Notify maintenance personnel immediately.
propulsion. 5. If the truck is on level ground, or if the parking
brake can hold the truck stationary and the truck
Sudden loss of engine power or loss of is in a stable condition, it is then OK to turn the
drive system function key switch OFF.
The loss of engine power and/or drive system will 6. If safe to do so, have maintenance personnel
result in loss of retard/propel functions on the truck. place wheel chocks or other mechanisms in
front or behind the wheels, depending on the
Under loss of retard/propel conditions, the truck
slope, to reduce the risk of the truck rolling.
should be immediately stopped using the service
brakes. In all cases, the service brakes should be 7. If traffic is heavy near the disabled machine,
utilized to stop the truck. mark the truck with warning flags during daylight
hours or use.
Dynamic retarding will not be available. Do not

use the service brakes for continuous retarding
purposes.
If the engine and/or drive system functionality is lost,
there is enough hydraulic pressure stored in the
brake and steering accumulators to allow the
operation of the steering and brake functions.
However, this oil supply is limited so it is important to
stop the truck as quickly and safely as possible.
21
Fuel depletion Towing

The high pressure injection (HPI) fuel system uses
fuel to adjust fuel delivery timing by creating a
hydraulic link between the upper plunger and the tim-
ing plunger. Metered fuel is also used for lubricating
the injector plunger and barrel. The maximum Before towing a truck, many factors must be
demand for metered fuel is required during high carefully considered. Serious personal injury
speed / low load conditions. and/or significant property damage may result if
important safety practices, procedures and
preparation for moving heavy equipment are not
observed.
NOTE: Information about special towing attachments

Operating the truck to fuel depletion forces the is available from your Komatsu service
injector train into a no-follow condition. No fuel representative.
flow between the plungers may cause damage to
A disabled machine may be towed after the following
the injectors and the overhead due to adhesive
precautions have been taken.
wear, resulting in costly repairs and unnecessary
downtime. • Do not tow the truck any faster than 8 kph (5
mph).
• Tow with a solid tow bar. DO NOT tow with a
cable. Use a towing device with ample strength
for the weight of this truck.
• The towing vehicle must have adequate pulling
Allowing the Komatsu truck to operate until fuel and braking capacity to both move and stop the
depletion can lead to unsafe operating conditions towed truck under all conditions, including towing
possibly resulting in an uncontrollable vehicle on a grade.
and/or personal injury.
• Inspect towing components, such as tow bars
and couplings, for any signs of damage. Never
use damaged or worn components to tow a
disabled vehicle.
• Keep a safe distance from the trucks and towing
apparatus while towing a vehicle.
• When connecting a truck that is to be towed, do
not allow anyone to go between the tow vehicle
and the disabled vehicle.
• Set the coupling of the truck being towed in a
straight line with the towing portion of the tow
truck and secure it in position.
• An operator is to remain in the cab of the towed
vehicle at all times during the towing procedure.
22
Special Wiring Harness Towing Procedure

Before towing, a special wiring harness must be 1. Turn off the engine.
made in order to release the parking brake. The har- 2. Block the wheels on the disabled truck to pre-
ness will require approximately 9 meters (30 ft) of #14 vent movement while preparing the truck for
wire, one ON/OFF switch (capable of carrying 2 towing and while attaching the tow bar.
amps of current) and two ring terminals. 3. Ensure that the towing vehicle has adequate
Refer to Figure 00-8 for a diagram of the special wir- capacity to both move and stop the towed truck
ing harness circuit. under all conditions.
• Using a ring terminal, one end of the harness 4. Ensure that the tow bar has adequate strength
must connect to 24VDC terminal (1, Figure 00-8) (approximately 1.5 times the empty vehicle
in the auxiliary control cabinet to supply 24V to weight of truck being towed). Install the tow bar
the parking brake solenoid. between the two vehicles.
• Switch (2) must be connected to the other end of 5. If necessary, install quick disconnect fittings to
the harness so the operator can use the switch the bleed down manifold to allow the hydraulic
while seated in the cab. system to be operational. Install hydraulic con-
nections for steering/braking between the tow
• The harness must be fitted with connector (4) to
vehicle the and disabled vehicle. An auxiliary
allow it to be plugged into parking brake solenoid
(3) inside the brake cabinet. Ground wire (5) power unit can also be used.
leading from this connector must be long enough 6. After the hydraulic connections are made, check
to connect to a ground block using the second the disabled vehicle braking and steering sys-
ring terminal. tems for normal operation.
Connector (4) consists of: 7. If the truck is loaded, dump the entire load.
Never pull or tow a loaded truck. Refer to “Dis-
• one housing (PB8538)
abled Truck Dumping Procedure”.
• two sockets (08191-05430) 8. The parking brakes must be released before
• one wedge (PB8540) towing. To release the parking brakes, use the
following steps to install the special wiring har-
ness.
a. Ensure that the ON/OFF switch is in the OFF
position.
b. Connect one lead of the special wiring har-
ness to a 24VDC terminal in the auxiliary
control cabinet for the 24V supply power.
c. Disconnect the truck wiring harness from
parking brake solenoid (2, Figure 00-9). Con-
nect the special wiring harness to the parking
brake solenoid. Connect the ground wire
from the connector to a ground block in the
right side of the brake cabinet.
d. Open the window and place the other end of
the special wiring harness inside the cab so
the operator can control the ON/OFF switch.
9. When ready to tow the disabled truck, remove
FIGURE 00-8. PARKING BRAKE HARNESS
the blocking from the wheels.
1. 24VDC Terminal 4. Connector
2. Switch (ON/OFF) 5. Ground Wire
3. Parking Brake Solenoid
23
10. The operator in the disabled truck should now Loading the dump body
move the ON/OFF switch to the ON position. 1. Pull into the loading area with caution. Remain
This will release the parking brakes. at a safe distance while the truck ahead is being
11. Tow the disabled truck. Sudden movement may loaded.
cause tow bar failure. Smooth, gradual truck 2. When approaching or leaving a loading area,
movement is preferred. Do not tow the truck any watch out for other vehicles and personnel
faster than 8 kph (5 mph). working in the area.
12. Minimize the tow angle at all times. Never 3. When pulling in under a loader or shovel, follow
exceed 30 degrees. The towed truck must be the spotter or shovel operator’s signals. The
steered in the direction of the tow bar. truck operator may speed up loading operations
13. When the desired location has been reached, by observing the location and loading cycle of
the operator in the towed vehicle must apply the the truck being loaded ahead, then follow a
service brakes, then move the switch to the similar pattern.
OFF position. This will apply the parking brakes. 4. During loading, the operator must stay in the
cab with the engine running. Place the
14. Block the wheels to prevent movement.
directional control lever in NEUTRAL and apply
15. Turn off the engine in the towing vehicle. the brake lock.
16. If installed, disconnect the hydraulic hoses at 5. When loaded, pull away from shovel as quickly
the quick disconnect fittings on the bleed down as possible but with extreme caution.
manifold.
17. Disconnect the special wiring harness from the
truck. Connect the truck wiring harness to the
parking brake solenoid.
FIGURE 00-9. BRAKE CABINET

1. Brake Manifold 2. Parking Brake
Solenoid
24
Overload speed limit function Dumping a load

NOTE: This feature can be enabled or disabled at the Raising the dump body
discretion of site management. The setting for
payload trigger and speed limits are also adjustable 1. Pull into the dump area with extreme caution.
by local site preference. Ensure that the area is clear of persons and
obstructions, including overhead utility lines.
The overload speed limit function limits the speed of Obey signals directed by the spotter, if present.
the truck if a payload limit setting has been
2. Avoid unstable areas. Stay a safe distance from
exceeded. The overload signal becomes true (24
the edge of the dump area.
volts) when the payload meter system early estimate
of payload exceeds the preset payload ton threshold.
The payload meter system early estimate of payload
calculation occurs after 12 seconds of travel above 5
kph (3 mph) after being loaded. Once the overload
signal becomes true, it stays true until the payload is To prevent tipping or rolling, position the truck on
dumped. a solid, level surface before dumping. As the
body raises, the truck center of gravity will move.
By default, the overload speed limit is disabled 3. Carefully maneuver the truck into the dump
(option 0 in the configuration file). The configuration position. When backing the truck into the dump
file can be set to: position, use only the foot-operated brake pedal
Option 1 - Overload speed limit is imposed. to stop and hold the truck. Do not rely on the
wheel brake lock to stop the truck. This control
or
is not modulated and applies the rear service
Option 2 - No propel restriction is imposed and brakes only.
logged. The truck cannot move under its own 4. When the truck is stopped and in the dump
power when the overload signal becomes true.
position, apply the brake lock and move the
directional control lever to NEUTRAL.
The overload speed limit can be adjusted by
modifying the configuration file. Use the Payload
Service Software Lite Version (available for download
at www.KomatsuAmerica.net) to set the overload
threshold.
Dumping very large rocks (10% of payload or
When option 1 is selected, and the overload signal is greater) or sticky material (loads that do not flow
true, tractive effort is reduced to attempt to respect freely from the body) may allow the material to
the speed limit setting. The retard effort will not be move too fast and cause the body to move
engaged to lower the speed of the truck. Once the rapidly and suddenly. This sudden movement
truck speed matches that of the overload speed limit may jolt the truck violently, possibly causing
setting, limited propel efforts and retarding efforts will injury to the operator and/or damage to the hoist
be used as necessary. This feature maintains the cylinders, frame, and/or body hinge pins.
truck speed at the maximum of the overload speed
limit setting.
25
Lowering the dump body (on flat ground)

It is very likely when dumping on flat ground that the
dumped material will build up enough to prevent the
body from lowering. In this case, the truck will have to
be driven forward a short distance (just enough to
clear the material) before the body can be lowered.
1. Move the directional control lever to
FORWARD, release the brake lock, depress the
override button, and drive just far enough
forward for the body to clear the material.
2. Stop, move the directional control lever to
NEUTRAL, and apply the brake lock.
3. Move the hoist lever forward to the LOWER
position. Release the lever to place the hoist
control valve in the FLOAT position, which
allows the body to return to the frame.
If dumped material builds up at the rear of the
body and the body cannot be lowered, then
perform the following steps:
FIGURE 00-10. HOIST CONTROL
a. Move the hoist lever back to the RAISE posi-
1. Raise 3. Float tion to fully raise the dump body. Then
2. Hold 4. Lower release the hoist lever so it returns to the
HOLD position.
b. Move the directional control lever to FOR-
5. Pull the lever to the rear to actuate the hoist
WARD, release the brake lock, depress the
circuit. Releasing the lever anywhere during
override button, and drive forward to clear
“hoist up” will hold the body at that position.
the material.
6. Raise the engine rpm to accelerate the hoist
speed. c. Stop, move the directional control lever to
NEUTRAL, apply the brake lock, and lower
If dumping very large rocks or sticky material, the body.
slowly accelerate the engine to raise the body.
When the material starts to move, release the NOTE: Failure to hoist the body after making an
hoist lever to the HOLD position. If the material unsuccessful attempt at lowering the body may result
does not continue moving and clear the body, in the dump body suddenly lowering after the truck
repeat this procedure until the material has has pulled ahead of the material that was previously
cleared the body. preventing the body from lowering.
7. Reduce the engine rpm as the last stage of the
hoist cylinder begins to extend. Let the engine
go to low idle as the last stage reaches half-
extension.
8. Release the hoist lever as the last stage of the
hoist cylinder reaches full extension. Do not move the truck with the dump body raised
9. After the material being dumped clears the except in an emergency. Failure to lower body
body, lower the body to the frame. before moving truck may cause damage to hoist
cylinders, frame and/or body hinge pins.
NOTE: If the directional control lever is in REVERSE
when the dump body is raised, reverse propel is 4. With the body returned to frame, move the
inhibited. To deactivate, lower the dump body and directional control lever to FORWARD, release
move the directional control lever out of REVERSE. the brake lock, and leave the dump area
carefully.
26
Lowering the dump body Disabled truck dumping procedure

(over a berm or into a crusher)
It may be necessary to dump a load from the body of
1. Move the hoist lever forward to the DOWN a truck if the hoist system is inoperable. In the
position. Release the lever to place the hoist following instructions, two hoses (supply and return)
control valve in the FLOAT position, which must be connected to a hydraulic source such as an
allows the body to return to the frame. operational truck or an auxiliary power unit.
If dumped material builds up at the rear of the
body and the body cannot be lowered, perform
the following steps:
a. Move hoist lever back to the HOIST position 3
to fully raise the dump body. Release the
hoist lever so it returns to the HOLD position.
NOTE: Do not drive forward if the tail of body will not
clear the crusher wall in the fully raised position.
b. Move the directional control lever to FOR-
WARD, release the brake lock, depress the
Override button, and drive forward to clear
the material.
c. Stop, move the directional control lever to 1
NEUTRAL, apply the brake lock and lower
the body.
2
NOTE: Failure to hoist the body after making an
unsuccessful attempt at lowering the body may result
in the dump body suddenly lowering after the truck
has pulled ahead of the material that was previously
83615
preventing the body from lowering.
FIGURE 00-11. HOIST CONNECTIONS
1. Power Up Quick Disconnect Fitting
2. Power Down Quick Disconnect Fitting
3. Overcenter Valve
Do not move the truck with the dump body raised NOTE: The matching quick disconnect coupling for
except in an emergency. Failure to lower the body fittings (1) and (2) is PB4684.
before moving the truck may cause damage to
Quick disconnect fittings (1) and (2, Figure 00-11) are
the hoist cylinders, frame and/or body hinge pins.
provided on the overcenter valve to allow operation of
the hoist circuit for temporary truck operation if the
2. With the body returned to the frame, move the hoist pump, hoist valve or other hoist system
directional control lever to FORWARD, release component is not operational. This will allow
the brake lock, and leave the dump area maintenance personnel to raise the truck body to
carefully. dump the load before moving the disabled truck.
The hoist circuit relief valves are adjusted to 17 240
kPa (2,500 psi).
27
Hookup Lowering the body

1. Ensure that there is an adequate, clear area to 1. Place the hoist control lever of the operational
dump the loaded body. Park the operational truck in FLOAT to lower the body. If necessary,
truck as close as possible to the disabled truck. momentarily move the hoist control lever to
2. Turn off the engine and wait for two minutes to RAISE until the body is able to descend in
allow the hydraulic system to depressurize FLOAT. Do not accelerate the engine.
before connecting the hoses. Ensure that all 2. After the body is lowered, turn off the engine.
hydraulic pressure has bled off before Allow two minutes for the hydraulic system to
connecting the hoses. depressurize, then disconnect the hoses.
3. Attach a hose from power up quick disconnect 3. If necessary, reduce the power down relief valve
(1, Figure 00-11) to the power down circuit of pressure of the operational truck to normal by
the disabled truck. turning the adjustment screw counterclockwise
the same number of turns as required in Step 3
NOTE: The hose for the power up circuit must be
of "Raising the body".
rated for at least 17 000 kPa (2,500 psi). The power
down circuit will use a smaller diameter hose. 4. Check the power down relief pressure of the
operational truck. Refer to Testing and adjusting
4. Connect another hose from power down quick
section Steering, brake cooling and hoist
disconnect (2) to the power up circuit of the
hydraulic system.
disabled truck.
5. Check the hydraulic tank oil level. Add oil, if
NOTE: If both trucks are the same model, the hoses necessary.
will be installed at the quick disconnects shown in
Figure 00-11 and will be crossed when connected.
Raising the body

1. On the disabled truck, move the hoist control
lever to power up and then release it to place
the hoist pilot valve in the HOLD position. Leave
the lever in this position during the entire
procedure.
2. On the operational truck, start the engine, place
the hoist control lever in the LOWER position
and increase the engine rpm to high idle to raise
the disabled truck’s body.
3. If the body of the disabled truck fails to rise,
increase the power down relief pressure of the
operational truck as follows and repeat Step 2:
a. Turn off the engine and allow the hydraulic
system to depressurize.
b. Remove the cap from the hoist pilot valve
relief valve located in the hydraulic brake
cabinet. While counting the number of turns,
slowly turn the relief valve adjustment screw
clockwise until it bottoms.
28
Safe parking procedure Normal engine shutdown procedure

Continue to use safety precautions when preparing 1. Stop the truck out of the way of other traffic on a
for parking and engine shutdown. level surface. Ensure that there are no overhead
power lines or other obstructions in case the
If the truck is being used in consecutive shifts, any
dump body must be raised.
questionable truck performance the operator may
have noticed must be checked by maintenance 2. Reduce the engine speed to idle.
personnel before the truck is released to another 3. Place the directional control lever in PARK.
operator. Ensure that the parking brake indicator light is
1. Park the truck on level ground, if possible. If the illuminated.
truck must be parked on a grade, position the 4. Place the rest switch in the ON position to put
truck at a right angle to the grade. the AC drive system in the rest mode. Ensure
2. The directional control lever must be in PARK that the rest mode switch is illuminated.
and chocks must be placed in front of and
5. Turn the key switch to the OFF position. A
behind the wheels so the truck cannot roll. Each
shutdown timing sequence will be activated
truck should be parked at a reasonable distance
automatically to allow the engine to cool down
from one another.
before it is turned off. The timing sequence may
last up to three minutes.
If the engine does not shut down after the timing
sequence is done, use the engine shutdown
switch on the operator cab center console. Pull
this switch up until the engine stops.
Do not activate the wheel lock feature when the
6. With the key switch OFF and engine stopped,
parking brake is activated. Bleed down of
wait at least 90 seconds for the steering
hydraulic pressure may occur, causing the truck
accumulators to depressurize completely.
to roll away.
Ensure that the steering circuit is completely
depressurized by turning the steering wheel
3. Haul roads are not safe parking areas. In an back and forth several times. The front wheels
emergency, pick the safest spot that is most should not turn when the hydraulic pressure is
visible to other machines in the area. If the truck relieved. If the front wheels can still be turned,
becomes disabled where traffic is heavy, mark notify maintenance personnel.
the truck with warning flags in daylight or flares 7. Ensure that the link voltage light in the control
at night. cabinet is off. Notify maintenance personnel if
the light remains illuminated for longer than five
minutes after the engine is shut down.
8. Close and lock all windows. Remove the key
from the key switch and lock the cab to prevent
unauthorized truck operation. Dismount the
truck properly. Put wheel chocks in place behind
and in front of each tire.
29
980E Dump truck

© 2016 KOMATSU
All Rights Reserved
30
CEN01014-00
980E

980E-4 A40003 and up
01 Specification
Specification and technical data
Specification drawing ............................................................................................................................................ 3
Specifications ........................................................................................................................................................ 4
Weight table .......................................................................................................................................................... 6
Fuel, coolant and lubricants .................................................................................................................................. 7
1
CEN01014-00 01 Specification
NOTES
2
01 Specification CEN01014-00
Specification drawing
3
Specifications
Specification Value
Empty 262 403 kg (578,500 lb)
Nominal load 362 874 kg (800,000 lb)
Gross total 625 277 kg (1,378,500 lb)
Weight
front 122 662 kg (270,423 lb)

distribution
Empty
Weight
rear 139 741 kg (308,077 lb)

front 205 489 kg (453,025 lb)
Loaded
rear 419 788 kg (925,475 lb)
Struck 191 m3 (250 yd3)
Dump body capacity
Performance
Heaped (2:1) 250 m3 (327 yd3)

Max. travel speed 64.5 kph (40 mph)
Gradeability 22.3% at stall
Min. turning radius 32 m (105 ft)
Dumping angle 45°
Overall length 15.7 m (51 ft 6 in)
Dimensions
Overall width 10.0 m (32 ft 10 in)

Overall height 8 m (26 ft 3 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 1,900 rpm

Max. torque 13 771 N·m (10,157 ft lb)
Min. fuel consumption 0.323 lb/hp-hr
Cranking motor 24V, 7.5 kW X 2 units
Battery charging alternator 24V, 250A
Batteries 12V, 1400 CCA, 8D type X 4 units
Motorized wheels AC induction traction motors
AC Drive System
Standard gear ratio 35.03:1
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 type

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

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

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 type, 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 (w/sub-frame and grille) 22 000 kg (48,500 lb)
Engine assembly 11 840 kg (26,100 lb)
Radiator and shroud assembly 1 520 kg (3,350 lb)
Main traction alternator 6 900 kg (15,212 lb)
Fuel tank assembly 2 050 kg (4,520 lb)
Hydraulic tank assembly 590 kg (1,300 lb)
Front suspension cylinder assembly 4 373 kg (9,640 lb)
Rear suspension cylinder assembly 1 028 kg (2,266 lb)
Hoist cylinder assembly 1 175 kg (2,590 lb)
Steering cylinder assembly 260 kg (573 lb)
Tie rod 383 kg (845 lb)
Bleed down manifold 170 kg (375 lb)
Pump/hoist valve module 765 kg (1,686 lb)
Hoist pump 136 kg (300 lb)
Steering/brake pump 62 kg (137 lb)
Hoist valve 189 kg (417 lb)
Overcenter valve manifold 114 kg (250 lb)
Spindle, hub and brake assembly 5 935 kg (13,085 lb)
Front spindle and hub 3 957 kg (8,724 lb)
Steering arm 352 kg (776 lb)
Front brake assembly 1 588 kg (3,500 lb)
Anti-sway bar 160 kg (353 lb)
Axle housing 7 382 kg (16,275 lb)
Wheel motor assembly 16 700 kg (36,817 lb)
Electric wheel motor 1 740 (3,835 lb)
Transmission/rear brake assembly 14 952 kg (32,964 lb)
Parking brake 173 kg (381 lb)
Final frame structure 29 760 kg (65,610 lb)
Battery box assembly 560 kg (1,235 lb)
Alternator blower air duct 205 kg (452 lb)
Wheel motor blower air duct 345 kg (760 lb)
Cab assembly 3 442 kg (7,590 lb)
Hydraulic brake cabinet 182 kg (400 lb)
Main electrical control cabinet 3 176 kg (7,000 lb)
Auxiliary control cabinet 532 kg (1173 lb)
Retarding grid 760 kg (1,675 lb)
Right deck 1 000 kg (2,205 lb)
Left deck 720 kg (1,587 lb)
Center deck 275 kg (606 lb)
6
Fuel, coolant and lubricants

Reservoir Fluid type Recommended fluids
Engine oil pan See engine manufacturer’s
Engine oil
Engine oil reserve tank service manual.
Hydraulic tank Hydraulic oil C-4 type (SAE 10W)
Suspension oil with friction See "Suspension cylinder oil and
Suspension cylinders
modifier nitrogen specifications".
Grease fitting Multi-purpose extreme pressure
NLGI No. 2
Auto lube tank grease
See drive system manufacturer’s
Wheel motor Heavy duty synthetic gear oil
service manual.
See engine manufacturer’s
Cooling system Coolant
service manual.
See engine manufacturer’s
Fuel tank Diesel fuel
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

© 2016 KOMATSU
All Rights Reserved
10
CEN10062-00
980E

980E-4 A40003 and up
10 Structure, functions and

maintenance standard
Steering circuit
Steering circuit operation ...................................................................................................................................... 3
Steering circuit components.................................................................................................................................. 7
Steering/brake pump operation............................................................................................................................. 9
1
CEN10062-00 10 Structure, functions and maintenance standard
NOTES
2
10 Structure, functions and maintenance standard CEN10062-00
Steering circuit operation Two nitrogen precharged steering accumulators (4,

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 suffi-
pressure filter (9). This oil supply is then distributed to cient to allow the operator to steer the truck off the
the various circuits. haul road and park in a safe area if a loss of steering
circuit oil occurs. Steering accumulator bleeddown
The bleeddown manifold performs many functions, solenoid (2, Figure 10-3) on the bleeddown manifold
including distribution of the steering circuit oil supply is electrically activated to bleed the pressurized
to steering accumulators (3) and flow amplifier (4). Oil hydraulic oil from inside the accumulators back to the
is also provided to the brake apply circuit, the hoist hydraulic tank whenever the key switch is turned to
pilot circuit, the auxiliary system manifold, and the the OFF position. Approximately 90 seconds is
optional radiator shutters, if installed. required for the accumulator to bleed down fully.
NOTE: The hoist pilot circuit passes through the The bleeddown manifold and steering accumulators
bleeddown manifold, but is not supplied by the supply oil to flow amplifier (4, Figure 10-1). The flow
steering/brake pump. It is supplied by the hoist pump. amplifier directs oil flow to the appropriate ports on
Oil pressure from the bleeddown manifold is routed the steering cylinders as determined by inputs from
back to the steering/brake pump and sensed by the steering control unit (as the operator steers the
“ACC” port (7, Figure 10-5) on the unloader valve truck.
located on the steering/brake pump case. The Oil entering the steering control unit is blocked until
unloader valve regulates the system pressure the steering wheel is turned in a desired direction.
between 22 065 kPa (3,200 psi) and 24 130 kPa The steering control unit then directs oil to the flow
(3,500 psi). Steering system pressure switch (10, Fig- amplifier, which in turn provides a high volume of oil
ure 10-3) on the bleeddown manifold activates a to steering cylinders (1, Figure 10-1). Hydraulic oil at
warning if the steering system pressure drops below the opposite ends of the steering cylinders flows back
15 858 kPa (2,300 psi). 517 kPa (75 psi) pressure through the flow amplifier and bleeddown manifold to
sensor (1, Figure 10-3) confirms that hydraulic pres- hydraulic tank (6).
sure is fully relieved at the completion of the bleed-
Oil flow to the brake apply circuit flows through a
down cycle.
check valve, preventing loss of oil in the brake circuit
Auxiliary system pressure switch (18, Figure 10-3) if a loss of oil occurs in the steering circuit. Refer to
controls a solenoid valve in the auxiliary system man- Section 10, Structure, functions and maintenance
ifold. When the steering system pressure is above standard, Brake circuit for more information.
18,960 kPa (2,750 psi), the switch sends a signal cur-
rent to the solenoid valve to open. When the steering
system pressure drops below 17,580 kPa (2,550 psi), NOTE: Refer to Section 90, Diagrams and drawings,
the signal current is removed, causing the solenoid Steering, hoist and brake cooling hydraulic
valve to close, and all steering/brake pump supply circuit schematic for more details on the hydraulic
returns to the steering and brake circuits. circuit operation.
3
5
2
10
6
7
8
9 86245
FIGURE 10-1. STEERING CIRCUIT COMPONENTS - TYPICAL

1. Steering Cylinders 6. Hydraulic Tank
2. Steering Accumulator Bleeddown Manifold 7. Shutoff Valve
3. Steering Accumulators (Piston Type) 8. Steering/Brake Pump
4. Flow Amplifier 9. High Pressure Filter
5. Bleeddown Manifold 10. Hoist Pump
4
5
6
7
8
3 4
10 11 12
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. Auto Lube Pump Supply Port 15. To Hoist Valve, Power Down
8. Return to Tank 16. To Brake System
5
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
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 10-4) 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. pure dry nitrogen.
Operation of the steering control unit is both manual Oil entering the accumulators compresses the piston
and hydraulic in effect. This component incorporates against the nitrogen. The nitrogen pressure increases
a hydraulic control valve. Steering effort applied to directly with steering circuit pressure. When steering
the steering wheel by the operator actuates the valve, circuit pressure reaches 24 305 kPa (3,525 psi), the
which in turn directs hydraulic oil through flow ampli- unloader valve will unload the pump. The accumula-
fier valve (2) to the steering cylinders to provide the tors will contain a quantity of oil, under pressure and
operator with power steering. held by check valves in the bleeddown manifold, that
will be available for steering the truck. When system
1 pressure drops to 22 065 kPa (3,200 psi), the pump
2 output will again increase to refill the accumulators
T and increase the steering system pressure. The
L LS accumulators also provide oil for a limited period of
P
R time to be used in case the steering/brake pump
becomes inoperative.
LS
A pressure switch located in the top of each accumu-
T PP
L lator monitors the precharge pressure when the key
switch is turned ON before the engine is started. If
L P the nitrogen pressure drops below 7 600 kPa (1,100
psi), a warning is activated. A latching circuit prevents
the warning from turning off when the engine is
started and steering system pressure compresses
R 86257 the remaining nitrogen in the accumulator.
FIGURE 10-4. STEERING CONTROL UNIT /
FLOW AMPLIFIER VALVE CIRCUIT
1. Steering Control Unit “T”: Tank Port
2. Flow Amplifier Valve “L”: Left Steer Port
“P”: Pressure Supply Port Do not operate the truck with a precharge
“R”: Right Steer Port pressure of less than 7 600 kPa (1,100 psi) in the
“LS”: Load Sense Port
accumulator. Low nitrogen pressure may not
provide an adequate supply of steering system
High pressure filter oil in some emergency conditions.
High pressure filter (9, Figure 10-1), located on the If the low precharge warning remains active, wait
back of the fuel tank, filters oil for the steering and approximately three minutes after the steering
brake apply circuits. accumulators are completely depressurized to
If the filter element becomes restricted, a warning is check the accumulator precharge pressure and
activated at 241 kPa (35 psi) differential. Oil will start recharge the accumulator, if necessary.
to bypass the element when the pressure differential
exceeds 345 kPa (50 psi).
7
Bleeddown manifold Hoist up limit solenoid

Bleeddown manifold (5, Figure 10-1) is located on the Hoist up limit solenoid (6, Figure 10-3) is a 3-way
outside of the left frame rail just behind the valve that is activated by the hoist limit switch when
accumulators. the hoist cylinders approach the maximum extension
The bleeddown manifold receives oil from the limit. When activated, the solenoid will close the
steering/brake pump through a high pressure filter power up pilot line to the hoist valve from the hoist
and directs oil to the steering accumulators, flow pilot valve mounted in the hydraulic cabinet.
amplifier, brake apply circuit, and the auxiliary Pilot operated check valve (7) is opened by the
system. The manifold also provides hoist circuit power down pilot pressure line to allow oil in the raise
control when the body is raised. port to bypass hoist up limit solenoid (6) for the initial
power down operation while the solenoid is activated
Relief valve (4, Figure 10-3) limits the hydraulic
by the hoist limit switch.
supply pressure to the steering and brake circuits to
27 500 kPa (4,000 psi). Relief valve (3) provides Refer to Section 10, Structure, functions and mainte-
maximum pressure protection of 4 100 kPa (600 psi) nance standard section, Hoist circuit for more infor-
for the oil returning to the hydraulic tank. mation.
NOTE: The relief valves, steering accumulator Quick disconnect ports
bleeddown solenoid, and hoist up limit solenoid are
factory preset and cannot be individually rebuilt. Two quick disconnect ports on the bleeddown mani-
fold allow service personnel to connect an external
Steering accumulator bleeddown solenoid hydraulic supply to allow operation of the truck steer-
ing and service brakes if the steering/brake pump or
Each time the key switch is turned OFF with the truck
engine is not operational.
stopped, steering accumulator bleeddown solenoid
(2, Figure 10-3) is energized. When the solenoid is The external supply is connected to port (5, Figure
energized, all hydraulic steering pressure (including 10-2) and the return is connected to port (6) on top of
the accumulators) is bled back to the hydraulic tank. the bleeddown manifold. This feature should only be
Brake pressure, however, will not bleeddown due to used for an emergency to allow operation of the truck
internal check valves in the brake manifold and to return to the shop for service or to move the truck
bleeddown manifold. out of haul road traffic.
After approximately 90 seconds, the solenoid will de- Flow amplifier
energize to close the return port to the hydraulic tank.
By this time, all the oil in the accumulators should be Flow amplifier (3, Figure 10-1), located on the left
returned to the hydraulic tank. At startup, the steering frame rail in front of the accumulators, provides the
circuit and brake circuit will be charged. Steering sys- steering circuit with the high volume of oil required for
tem pressure switch (10, Figure 10-3) will activate a the steering cylinders.
low steering pressure warning until steering pressure The flow amplifier uses the amount of flow from the
reaches 15 858 kPa (2,300 psi). steering control unit to determine a proportional
If steering pressure falls below 15 858 kPa (2,300 amount of flow to send from the bleeddown manifold
psi) during operation, the low steering pressure warn- to the steering cylinders.
ing 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 inter- 1 2 3
nally 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 pres-
sure 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.
7 6 5 4
84753
FIGURE 10-5. PUMP ASSEMBLY
1. Case Drain 5. Case Drain (Plugged)
2. Inlet 6. Unloader Adjuster
3. Outlet 7. "ACC" Port
4. GPA Test Port
9
980E Dump truck

© 2016 KOMATSU
All Rights Reserved
10
CEN10067-00
980E

980E-4 A40003 and up

Hoist circuit
Hoist circuit operation ........................................................................................................................................... 3
Hoist circuit components ....................................................................................................................................... 4
Hoist pilot valve operation..................................................................................................................................... 8
Hoist cylinder wear data...................................................................................................................................... 18
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
Refer to Figure 10-8.
The pilot valve spool is positioned to allow the pilot
supply oil entering pilot supply port (12) to return to
the hydraulic tank through head end work port (10).
Pilot supply pressure in pilot supply ports (12) then
decreases to no pressure, allowing flow control valve
(2) to open and route the incoming pump oil through
brake cooling circuit port (23) and back to the
hydraulic tank.
Both raise pilot port (14) and down pilot port (15) in
the pilot valve are closed by the pilot valve spool. In
this condition, pressure is equalized on each end of
each rod end spool (7) and head end spool (8),
allowing the springs to center the spools and close all
ports to trap the oil in hoist cylinders (6) and hold the
body in its current position.
12
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
© 2016 KOMATSU
All Rights Reserved
18
CEN10068-00
980E

980E-4 A40003 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 isolate each circuit from each other.
pressure will be applied to an internal piston that is
Each check valve allows each circuit to retain
incorporated into the brake treadle valve. This
pressurized oil and energy in case the other circuit
pressure moves the piston to depress the treadle
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

© 2016 KOMATSU
All Rights Reserved
12
CEN10070-00
980E

980E-4 A40003 and up

Electrical system, 24 volt
Battery supply system........................................................................................................................................... 3
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 During operation, the batteries function as an

electrochemical device that converts chemical energy
Batteries into the electrical energy that is required for operating
The truck uses a 24VDC electrical system to supply the accessories when the engine is off.
power for the engine starting circuits and most non-
24VDC auxiliary battery receptacles
propulsion related electrical components. The 24VDC
engine starting circuit is supplied by four heavy duty, Two receptacles (7) are provided to attach battery
type 8D, 12-volt storage batteries (2, Figure 10-1) charger leads for charging the batteries. These
located in the battery box on the platform in front of receptacles can also be used for connecting external
the radiator. The batteries are of the lead-acid type, batteries to aid engine starting during cold weather.
each containing six 2-volt cells.
When external batteries are used, they should be of
While the engine is off, power is supplied by the the same type (8D) as the batteries installed on the
batteries. During engine cranking, power is supplied truck. Two pairs of batteries should be used. Each
by the batteries. When the engine is running, pair should be connected in series to provide 24VDC,
however, power is supplied by a high capacity with one pair connected to the each receptacle.
alternator that is driven by the engine.
FIGURE 10-1. BATTERY BOX COMPONENTS
1. Battery Box 4. 24VDC Bus Bar 7. Auxiliary Battery Receptacles

2. Batteries 5. Engine Start Relay 8. Battery Pallet
3. Battery Control Box 6. Negative Bus Bar 9. Mounting Hardware
3
Engine shutdown switch Propel lockout lever

Engine shutdown switch (1, Figure 10-2) is a push- Propel lockout lever (5) provides a convenient
pull type switch and is located on top of isolation box method of disconnecting the AC electric drive system
(6). This switch provides a ground level means to while the engine is in operation. This ensures the
shut the engine off in an emergency. Push the button truck will remain stationary without the need to check
in to stop the engine. the GF cutout switch. When the propel lockout lever
is in the OFF position, the drive system is locked out
Battery disconnect switches and the truck will not propel. When the propel lockout
Battery disconnect switches (3) and (4) provide a lever is in the ON position, the drive system is active
convenient method of disconnecting the truck and the truck can be driven.
batteries from the truck electrical circuits without
System busy light
having to remove any battery cables. Starter
disconnect switch (4) opens the cranking motor If green LED light (6) is illuminated, do not turn of 24V
battery circuit only, preventing engine startup while power to the truck. Electrical system components are
still allowing battery power to the 24VDC control still in operation and must be shut down.
system circuits, if desired. Master disconnect switch
(3) disconnects the 24VDC system circuit. When the LED lights
battery disconnect switches are in the OFF positions, LED lights (7) provide a positive, visual indicator
the 24VDC electrical system and start system are when a selected switch is in the ON position. LED
disabled. When the battery disconnect switches are lights (8) provide a positive, visual indicator when a
ON, the 24VDC electrical system is active and the selected switch is in the OFF position.
engine can be operated.
1 7
8 7
8 8
2 5
3 6 4 86262
FIGURE 10-2. ISOLATION BOX COMPONENTS

1. Engine 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 motor motors to engage the
cranking motor pinion gears at this time. The prelube
pump supplies oil from the engine oil pan to fill the
85377
engine 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), engine oil pressure switch (1, Figure 1. Engine Prelube Pump 3. Engine Prelube
10-4) supplies signal current to engine start relays (2, 2. Engine Prelube Relay Solenoid
Figure 10-1). When the engine start relays are
activated, current is provided to the solenoids of both
cranking motors (1, Figure 10-5). The cranking
motors will then be activated and the pinion gears will 1
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.
85378
FIGURE 10-4. ENGINE PRELUBE SYSTEM

1. Engine Oil Pressure Switch
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, engine
start relays (2, Figure 10-1) provide current to the
solenoids of both cranking motors (1, Figure 10-5).
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, engine oil pressure switch
(1, Figure 10-4) senses the engine oil pressure and
opens the electrical circuit to prevent actuation of the
cranking motor(s) after the engine has started.
FIGURE 10-5. 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, engine related
devices, 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.
24VDC to 12VDC converter

24VDC to 12VDC converter (7, Figure 10-6) is used
to convert the 24 volt battery system voltage to 12
volts for various truck components such as the radio/ 3
CD player, cab power windows, and the auxiliary
power receptacles in the cab.
The converter output circuits are protected by 50 amp
circuit breaker (2).
Interface module (IM)

Interface module (3, Figure 10-6) collects data from
various sensors and sends this information to the
KOMTRAX Plus controller through the main wiring
harness.
NOTE: New IM controllers come unprogrammed and 1
must have the correct software installed in order to
function. Refer to Testing and adjusting section
Interface module (IM) for the correct software 2
installation procedures.
86255
Temperature sensors monitor the ambient air
temperature and the hydraulic oil temperature. An FIGURE 10-6. AUXILIARY CONTROL CABINET
ambient air temperature sensor is located on the left 24VDC COMPONENTS - RH WALL
side of the air blower inlet duct for the traction 1. 24VDC to 12 VDC Converter
alternator. The hydraulic oil temperature sensors are 2. Circuit Breaker (50 amp)
located at each wheel to measure the oil temperature 3. Interface Module (IM)
as it leaves each brake assembly.
Four pressure sensors have been added to the truck
to monitor the following hydraulic circuits:
• both inlets to the hoist valve
• steering supply circuit
• front brake apply circuit
The hoist pressure sensors are both located at the
inlet of the hoist valve. The front brake apply
pressure sensor is located in the brake circuit
junction block in the hydraulic brake cabinet. The
steering pressure sensor is located on the bleeddown
manifold in the port labeled “TP2”.
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. 86256
• 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 RTMR1
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 10-7) 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 10-7. 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 10-8) 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, located in the hydraulic brake
cabinet, to prevent further oil flow to the hoist
cylinders.
Dimension "A"................................ 45 mm (1.77 in.) FIGURE 10-8. HOIST LIMIT SWITCH

Dimension "B"............................. 83.1 mm (3.27 in.)
1. Hoist Limit Switch 3. Magnet Assembly
2. Switch Mounting Plate 4. Actuator Arm
10
NOTES
11
980E Dump truck

© 2016 KOMATSU
All Rights Reserved
12
CEN10055-01
960E
980E

960E-2 A30074 and up
980E-4 A40003 and up

Electrical system, AC drive
General system operation..................................................................................................................................... 2
System components ............................................................................................................................................. 4
DSC software functions ........................................................................................................................................ 5
Alternator field control ......................................................................................................................................... 10
Event detection and processing.......................................................................................................................... 12
Event logging and storage .................................................................................................................................. 13
Abnormal conditions/overriding functions ........................................................................................................... 15
AC drive system component table ...................................................................................................................... 16
Electronic accelerator and retarder pedals ......................................................................................................... 23
1
General system operation The alternator field is supplied from a tertiary winding
on the alternator and is controlled by a silicon
NOTE: The following information provides a brief
controlled rectifier (SCR) bridge. A starting boost
description of system operation and major
circuit initially energizes the alternator from the truck
components of the AC propulsion system. Refer to
batteries until the flux builds up enough to sustain
the appropriate GE publication for detailed
excitation.
information and theory of operation.
Cooling air for the alternator, control cabinet and
A list of commonly used propulsion system
traction motors is supplied by a dual in-line fan
component abbreviations is listed in Table 1. Figure
assembly mounted on the rear of the alternator. This
10-3 through Figure 10-6 illustrate the physical
blower provides cooling air to the traction motors,
location of these components where applicable.
propulsion inverters, dynamic retarding choppers,
The AC drive system consists of the following major and control system.
components:
A resistor grid package is used to dissipate power
• Alternator (coupled to a diesel engine) from the traction motors (operating as generators)
• In-line cooling blower when in dynamic retarding mode. The total retard
power produced by the traction motors is controlled
• Gate drive power converters by the two motor inverters. The amount of retard
• Rectifier diode modules power dissipated by the grid package is controlled by
an IGBT chopper circuit and stage-controlled
• AC power inverters contactors.
• AC induction traction motors
The drive system controller (DSC), which is mounted
NOTE: Refer to Figure 10-1 for the following in the main control cabinet, determines the optimum
description. engine operating speeds based on what the operator
requests, propulsion system requirements, and
The alternator supplies three phase AC power for the
efficient fuel usage. Interfaces between the DSC and
rectifier diode modules. The rectifier diode modules
the truck brake system allow the DSC to provide
convert the AC power to DC power, then supply that
proper retarding, braking and wheel slide control.
DC power to two AC power inverters via the DC link.
Each AC power inverter inverts the rectified DC Engine and propulsion system data that is processed
voltage, delivering variable voltage, variable and stored in the DSC is displayed on the diagnostic
frequency power to each of the AC induction traction information display (DID) panel located in the cab
motors. behind the operator seat.
The two AC induction traction motors, each with its
own inverter, are connected in parallel across the
rectified output of the alternator. The inverters
change the rectified voltage back to AC by turning on
and off (chopping) the applied DC voltage.
The output AC voltage and frequency are controlled
to produce optimum slip and efficiency in the traction
motors. At low speeds, the rectified alternator output
(DC link or DC bus) voltage is chopped with patterns
called pulse width modulation (PWM) inverter
operation. At higher speeds, the DC link voltage is
applied to the traction motors using square wave
inverter operation. The voltage of the DC link is
dependent upon the drive system controller (DSC)
and engine RPM during propulsion. The DC link
voltage will vary between 600 and 1600 volts.
2
FIGURE 10-1. PROPULSION SYSTEM DIAGRAM
3
System components
Drive system controller (DSC) The DSC contains the following internal, removable
printed circuit boards and two fiber optic boards:
The DSC is the main controller for the AC drive
system. The DSC panel receives input signals from System CPU Card: Provides serial
speed sensors mounted on the alternator and communications and control functions, RS232
traction motors, as well as voltage and current communications to PTU, and microprocessor
feedback signals from various control devices. Using controls for internal panel circuits.
these inputs, the DSC controls the two inverters, Digital I/O Card: Receives digital inputs and
retarding circuits, relays, contactors, and other feedback information from various propulsion and
external devices to provide the following functions: control system components. Digital outputs drive
propulsion system contactors, relays and provide
• Propulsion and wheel slip control equipment enable commands.
• Retarding and wheel slide control System Analog I/O Card: Receives engine,
• Engine speed control voltage and current signals for the main
alternator, link voltage and current, retard pedal
• Event detection input, and retard lever input. Controls retard
• Initialization of the necessary operating effort, engine speed request, and AFSE firing
restrictions, including the shut down of the truck if pulses.
a serious system fault (event) is detected. If the Inverter 1 and 2 CPU and I/O Cards (2 each):
fault is not serious, a status indicator alerting the Receives motor speed signals, link voltage,
operator to the problem will illuminate. All event phase voltages, and phase currents for
data is recorded for future review by maintenance microprocessor control for inverters 1 and 2.
personnel. Controls IGBT phase modules through the fiber
• Log event data optic assembly. Phase module status is returned
via a separate fiber optic assembly.
• Store statistical data of the history of various
component and system function operations. Ethernet Switch Card:
• Communicate directly with the Portable Test Unit Fiber Optic Assembly: Provides electrical
(PTU) to test and monitor propulsion system isolation for control and feedback signals for
status, upload system data, and to receive phase modules and chopper modules.
system software updates.
• Drive the operator cab status indicators and
warning messages.
4
Diagnostic information display (DID) panel DSC software functions

The DID panel (Figure 10-2) is located in the cab The operation of the AC drive system is regulated by
behind the operator seat. The display provides a software program which resides in the propulsion
service personnel with a means of communicating system control panel's memory. The software
with the DSC. program also contains instructions to test and fault
isolate the system.
The panel has two display lines. Each line is 40
characters long. The top line is the “message” line This section describes the DSC software program
and is used by the DSC to inform service personnel and its functions without regard to hardware.
of the truck systems and components status.
The bottom display line provides information in
addition to the top line or relates to the keypad, Input processing
displaying possible selection options and display This function reads in all external inputs for use by
functions. The keypad, located below the display the DSC. The input processing function performs any
lines, is used by service personnel to direct the signal conditioning that is required and computes the
activity of the DSC. required derived inputs.
The display provides service and status information
on the various truck systems and the propulsion
system by displaying system status information or State machine
fault codes, as well as a description of the system
status or a problem on the top display line. As part of the total software package, a particular
Information on the second display line may change to group of regulatory software commands is included
indicate which functions are available by pressing called a “state machine”. The state machine controls
keys [F1] through [F5]. the various functions of truck operation.
The DID panel can also be used to perform the self- The software implements the state machine by
load test. keeping track of which state the truck is in and which
state the truck is allowed to move into if the operator
Refer to Troubleshooting section AC drive system requests a different mode of operation. Each
fault codes for a list of fault codes that could be software state is defined as follows:
displayed on the DID panel.
Startup/Shutdown state: The purpose of this state

is to ensure the system is in a desired known state
upon startup or shutdown. This is an unpowered
state.
NOTE: “Powered” and “unpowered” refer to the state
of the DC link. 600 volts or more equals “powered”.
FIGURE 10-2. DIAGNOSTIC INFORMATION

DISPLAY
NOTE: In addition to displaying English text, the DID
panel can also display messages in Russian or
Spanish.
5
Test state: The purpose of this state is to provide an Transitions between states under normal operational
environment for the verification of system conditions (no failures) are described as follows:
functionality. The test state will support a variety of
activities, including:
Transition to Startup/Shutdown state
• Waiting for the engine to start (if needed).
(for Startup): The system will transition to the
• Automatic testing on initial system startup or Startup/Shutdown state for the purpose of “startup”
following rest state. whenever execution control is initially transferred to
• Application of power to the DC link. the application program (after application of power,
system reset, etc).
• Externally initiated testing to clear a fault, set
temporary variables, or for maintenance
purposes.
Transition to Startup/Shutdown state
NOTE: The test state may be either powered or (for shutdown): The system will transition to the
unpowered at a given point in time, depending on Startup/Shutdown state for the purpose of “shutdown”
which activities are being performed. from the Test, Rest, Ready, or Startup/Shutdown (if
previously entered for the purpose of startup) state if
all of the following conditions are true:
Ready state: This is the default powered state. The
system will be in this state whenever the engine and • System power is removed, or the control power
switch or key switch is turned off.
control system are ready to provide power, but none
is requested. • The truck is not moving.
Ready state is also the state where the DC link is • There is essentially no voltage on the DC link.
discharged in preparation for shutdown, rest, or in • Any testing in progress is complete.
reaction to certain event conditions. Therefore, the
ready state should not be considered strictly a NOTE: Testing in progress does not have to be
powered state (as are propel and retard). successful, but for the purpose of ensuring an orderly
shutdown it must be complete before the current
state is exited.
Rest state: The purpose of this state is to conserve
fuel while the truck idles for an extended period of
time. The rest state also provides an environment Transition from Startup/Shutdown state to Test
where maintenance personnel can control the engine state: This transition will occur automatically once
without causing power to be applied to the DC link. initialization is complete (functions performed while in
The rest state is an unpowered state. Startup/Shutdown state for the purpose of startup
have been completed).
Propel state: The purpose of this state is to provide

the power system configuration and overall Transition from Test state to Ready state: This
environment for engine-powered propulsion. This is a transition will occur upon completion of any required
powered state. The system will not be allowed to testing if the Rest state request is not active and
maintain the propel state without sufficient power on there is sufficient voltage on the DC link.
the DC link.
Retard state: This state provides the power system

configuration and overall environment for retard
functions, where energy from vehicle movement is
dissipated in the retarding grid resistors in an effort to
slow the truck. The retard state is a powered state.
6
Transition to Rest state: This transition will occur Transition from Ready state to Retard state: This
automatically from the Test or Ready state if a transition will occur if truck speed is such that retard
request for Rest state is received and all of the is allowed and at least one of the following conditions
following conditions are true: exists:
• Any testing in progress is complete. • Truck speed is greater than or equal to motor
overspeed limit. Overspeed will not be engaged
• The system temperatures are cool enough to such that it prevents the truck from propelling at
allow the Rest state (function of IGBT phase
64 kph (40 mph).
module, chopper module, and motor
temperatures). • The retard pedal or lever is pressed such that a
significant amount of retarding effort is requested.
• The AFSE panel is disconnected and there is
essentially no voltage on the DC link. • All of the following conditions are true:
• The truck is not moving. a. Retard speed control is selected.
b. Truck speed exceeds the set retard speed, or
the truck is accelerating such that the truck
Transition from Ready state to Test state: This
speed will soon exceed the set retard speed
transition will occur if the truck is not moving and a
if no action is taken.
request for testing is received.
c. The accel pedal is not pressed and/or the
truck is configured such that accelerator
Transition from Ready state to Propel state: This pedal signal does not override retard speed
transition will occur if all of the following conditions control.
are true:
• The accel pedal is pressed. Transition from Rest state to Test state: This
• A direction has been chosen (the truck is either in transition will occur upon release of the Rest request.
FORWARD or REVERSE).
NOTE: A transition directly from Rest state to Ready
• There is sufficient voltage on the DC link. state is not allowed because the system is essentially
• At least one of the following conditions is true: off and should be brought back on-line and checked
out before Ready state is entered.
a. The retard pedal or lever is not pressed or is
pressed such that an insignificant amount of
retarding effort is requested. Transition from Propel state to Ready state: This
b. Truck speed is such that retard is not transition will occur if all of the following conditions
allowed. exist:
c. Truck speed is less than the motor • The accelerator pedal is not pressed.
overspeed limit.
• The retard pedal or lever is not pressed or is
d. The accel inhibit is not active. pressed such that an insignificant amount of
retarding effort is requested.
• Truck speed is less than the motor overspeed
limit.
• At least one of the following conditions is true:
a. Retard speed control is not selected.
b. Truck speed is below the set retard speed,
and acceleration is such that no retard effort
is (currently) required to maintain this
condition.
7
Transition from Propel state to Retard state: This DC link state

transition will occur if at least one of the following
Power is provided to the inverters and motors via the
conditions exists:
DC link. The DC link has two associated states:
• Truck speed is such that retard is allowed, and powered and unpowered. The following defines the
the retard pedal or lever is pressed such that a conditions necessary to establish each state, as well
significant amount of retarding effort is requested. as the transitional conditions between the two states:
• Truck speed exceeds the motor speed limit.
Overspeed will not be engaged such that it
prevents the truck from propelling at 64 kph (40 Powering the DC link: The DSC software will
mph). attempt to power the DC link (command the system
• All of the following conditions are true: configuration defined below) if all of the following
conditions are true:
a. Retard speed control is selected.
• Event restrictions do not prohibit power on the DC
b. Truck speed exceeds the set retard speed, or link.
the truck is accelerating such that the truck
speed will soon exceed the set retard speed • The system is in Test state and any initiated
if no action is taken. testing is complete.
• The engine is running.
c. The truck is configured such that accelerator
pedal signal does not override the retard • The gate drive power converters have been
speed control. enabled.
• Neither inverter is requesting that a low voltage
test be run.
Transition from Retard state to Ready state: This
transition will occur if all of the following conditions
exist: In attempting to power the DC link, the DSC software
• Overspeed is not active. will establish the necessary system configuration as
follows:
1. GF is closed and GFR is picked up.
a. The retard pedal or lever is not pressed or is
2. AFSE is enabled.
pressed such that an insignificant amount of
retarding effort is requested. 3. Alternator field reference is commanded so that
the desired DC link voltage or three-phase
b. Truck speed is such that retarding is not
voltage is maintained.
allowed.
4. RP contactors open.
5. Chopper turn-on voltage is set above 600 volts.
a. Retard speed control is not selected.
NOTE: Before the AFSE is allowed to output firing
b. Truck speed is low enough such that retard pulses, the RP contactors will be commanded to
speed control is not active. open and the GF contactor will be verified to be
c. The accelerator pedal is pressed, and the closed. The AFSE will not output firing pulses if it is
truck is configured such that the accelerator disabled, if GFR is dropped out, or if the alternator
pedal overrides the retard speed control. reference signal is 0.
This allows the configuration constant to
determine if pressing on the accelerator
pedal kicks the truck out of retard, even if the
retard speed control is still active.
• The retard torque control logic exit sequence is
complete.
8
De-powering the DC link: The DSC software will Engine control

attempt to de-power the DC link (command the
This software function generates the engine speed
system configuration defined below) if the system is
command. The engine electronic fuel control is
in Test or Ready state and any of the following
responsible for maintaining that speed.
conditions are true:
The desired engine speed is determined according to
• Event restrictions prohibit power on the DC link.
the system state:
• The system is preparing to transition to Startup/
Shutdown state for the purpose of shutdown (all Propel state: The engine speed is commanded such
the non-link-related conditions for Startup/ that the engine supplies only as much horsepower as
Shutdown state have been satisfied). is required to achieve the desired torque.
• The system is preparing to transition to Rest state All other states: The engine speed is a direct
(all the non-link-related conditions for Rest state function of the accelerator pedal. Additional
have been satisfied). constraints on the engine speed command are as
• The engine is being shut down. follows:
• If the truck is in NEUTRAL, the commanded
engine speed at full scale accelerator pedal will
To accomplish this, the DSC software will establish be the engine's high idle. If the truck is not in
the necessary system configuration as follows: NEUTRAL, the maximum commanded engine
speed will be the engine's rated horsepower rpm.
1. Alternator field reference is set to zero.
This allows faster hoisting of the truck bed, if
2. AFSE is disabled. desired.
3. GF is open and GFR is dropped out. • During retard state the engine speed command
4. Chopper turn-on voltage is set below 600 volts. will not be increased to support the DC link when
retard is being ramped out at low truck speeds.
5. RP2 is closed.
However, engine speed may be increased if
needed to support the DC link during normal
retard when wheel slides are occurring.
The following constraints are applied to generating

the engine speed command during all operating
states:
• The engine speed command will always be
greater or equal to the minimum idle signal. The
DSC can request that the engine speed
command be increased by setting minimum idle.
• The engine speed command will be increased if
more alternator cooling is needed.
9
Alternator field control Propel torque control

The alternator is controlled by controlling the This software function commands the appropriate
alternator field reference sent to the AFSE panel. motor torque to the inverters during propel. The
torque command is primarily a function of the accel
The desired alternator output voltage is dependent
pedal position and is limited by the physical
on the system state. The DSC will command an
constraints of the system.
alternator field reference such that the desired DC
link voltage or three-phase voltage is maintained. Each wheel torque is computed independently
because the wheels may be operating at different
Desired DC link voltage speeds. Each torque command is adjusted to
The desired link voltage is controlled by the alternator account for the following constraints:
during all powered states except retard. The desired • Speed override
voltage is based on:
The propulsion system will attempt to limit truck
1. During propel, the desired DC link voltage will speed to the design envelope of the wheel
be adjusted based on motor speed and motors. The torque command will be modulated
horsepower commanded to the inverters. as the truck speed approaches the motor
2. During retard, the DC link voltage may rise overspeed limit so that this limit is not exceeded
above the rectified three-phase voltage. When if possible. Note, however, that steady state
this occurs, the DC link voltage is controlled by operation is kept as close to the overspeed limit
the retard torque command, grid resistor as possible without exceeding it.
command and chopper start. If conditions occur
• Motor torque limits
which prevent the motors from producing power
to support the resistor grids, the alternator may The torque command will be constrained to the
be required to supply some power. In this case, operating envelope of the inverters and the
the alternator field control will maintain at least traction motors. The maximum torque that can
600 volts on the DC link. be commanded is dependent on motor speed
3. During all powered states, the DC link voltage and DC link voltage.
will not be allowed to drop below 600 volts. • Gear stress
4. While the DC link is being powered up, the The torque commanded will not exceed that
voltage will be controlled to the levels necessary which will produce excess gear stress.
to support the inverter self-tests.
• Horsepower available
The horsepower available will be estimated
Self-load from the engine speed. Parasitic loads are
taken into account. The torque will be limited so
During self-load, the alternator provides power to the that the engine does not overload.
resistor grids. The rectifying diodes will be forward
biased, and DC link voltage will be controlled by the • Jerk limit
alternator. The alternator field control will be based The torque command will be slew-rate limited to
on the following: prevent jerking motion.
• The DC link voltage will not be allowed to drop • Wheel spin
below 600 volts.
In the event that the inverters detect a wheel
• One mode of self-load will require the alternator spin condition and reduce torque in the slipping
output to be controlled to maintain a set desired
wheel, the motor torque in the other wheel may
horsepower dissipation in the resistor grids.
be increased within the above constraints such
• Another mode of self-load will require the that as much of the total desired torque as
alternator output to be controlled to maintain a set possible is maintained.
desired link voltage between 600 and 1500 volts.
10
Retard torque control Wheel slide control

The retard system converts braking torque from the The inverters prevent wheel slide by limiting torque to
wheel motors to energy dissipated in the resistor grid. maintain wheel speeds above preset limits. These
The requested retard torque is based on the following preset limits are a function of truck speed and the
three sources: allowable creep. Additional compensation will be
applied to provide for differences between wheel
• Retard foot pedal or lever
speeds during turns.
The maximum short time retard torque (at any
speed, hence the constant torque level) will be
scaled (linearly) by the retard foot pedal input Resistor grid control
(RPINHI) to produce the foot pedal retard torque
call. The first resistor grid (RG1) will always be engaged
when retard is active since the grid blower motors are
• Overspeed
wired across it.
While overspeed is active, the full available
The second fixed resistor grids (controlled by RP2)
retard torque will be requested.
will be engaged as needed to dissipate the energy
• Retard speed control (RSC) produced in retard state.
While RSC is active, the RSC retard torque call
will be adjusted to control truck speed to the
RSC set point. Retard speed control will not Chopper voltage control
request any retard torque if RSC is not active. Chopper turn-on voltage will be set to give the motors
The maximum torque call from the above three as much of the retard envelope as possible (i.e., keep
sources will be selected as the retard torque call. the voltage as close to the maximum value as
Retard torque limits are as follows: possible) and to keep the DC link voltage at or below
the maximum link voltage value.
• The retard torque call will be limited to the
maximum torque level based on speed.
• The retard torque call will be limited to the
maximum torque level available within the
thermal constraints of the motors.
• The retard torque call will be limited as needed to
prevent overvoltage on the DC link.
• While in retard, the minimum retard torque call
will provide enough power to support at least one
grid with 600 volts on the DC link. Retard will be
dropped if the torque call falls below this value.
• At low speed, the available retard torque will be
ramped to zero.
11
Event detection and processing 2. Low Voltage Test - A given inverter will
automatically perform its low voltage test if
The DSC contains very powerful troubleshooting
needed once inverter powerup testing is
software. The DSC software constantly monitors the
enabled per the above requirements. The DSC
AC drive system for any abnormal conditions
will declare the test failed and log an event if the
(events).
test does not successfully complete within an
Automatic self-tests are performed periodically on expected time period.
various parts of the system to ensure its integrity. 3. High Voltage Test - If the low voltage testing
Additionally, there are some elaborate tests which defined above is successful for a given inverter,
may be run by an electrician with the use of DID the inverter will automatically perform its high
screens. Predictive analysis is used in some areas to voltage test if needed once there is sufficient
report potential problems before they occur. power on the DC link. The DSC will declare the
The event detection function of the software is test failed and log an event if the test does not
responsible for verifying the integrity of the DSC successfully complete within an expected time
hardware and the systems to which the DSC after the DC link is sufficiently powered.
interfaces by detecting an “event” (abnormal • DC link capacitance test - This test will run once
condition). The events fall into three detection every 24 hours when conditions allow, normally
categories: after a VI-test during the normal power-up
sequence. This test can also be run from the DID
Power-on tests panel to aid in troubleshooting. During test
execution, engine speed is set to 1500 rpm and
Three power-on tests are executed once every time
the DC link is charged to 120 VDC. The engine is
power is applied to the DSC. A fourth power-on test is then returned to idle while the DC link is allowed
executed once every 24 hours. to discharge to 100 VDC. Total link capacitance is
• CPU card checks - Upon power-up, the DSC will then calculated using the time it took to
confirm the integrity of its CPU card hardware discharge.
before transferring execution control to the If capacitance is getting low, but is still OK, event
application program residing in its flash memory. 70 is logged. If capacitance is below the minimum
• Inverter powerup tests - The purpose of these allowable level, event 71 is logged and the truck
tests is to verify that each inverter sub-system is is restricted to 16 kph (10 mph). If the test is not
functional: able to be completed after numerous attempts,
event 72 is logged, indicating a problem in the
1. Enabling Inverter Powerup Tests - The power- truck's ground detection circuit, and truck speed
up tests for a given inverter will be enabled if all is limited to 10 mph.
of the following conditions are true:
a. The system is in Test state for the purpose of
power-up.
b. The associated gate drive power converter
has been enabled.
c. The engine is running.
d. Battery voltage is at least 25 VDC.
e. The inverter is requesting that the low
voltage and/or high voltage powerup tests be
performed.
f. The inverter has not been physically cut out
of the system.
g. Active event restrictions do not preclude
powering the DC link or running the inverter.
12
Initiated tests Event logging and storage

These tests are performed when requested by This software function is responsible for the recording
maintenance personnel. The truck must be in the of event information. There are two basic levels of
Test state for these tests to run. event storage: event history buffer and data packs.
The event history buffer provides a minimum set of
• Maintenance Tests - The purpose of these tests is
information for a large number of events, while data
to facilitate verification of system installation and
wiring, particularly the “digital” interfaces (relays, packs provide extensive information for a limited
contactors, etc). number of events.
• Self-Load Test - Self-load testing is a means by The following requirements apply to both data packs
which the truck’s diesel engine can be checked and the event history buffer:
for rated horsepower output.
• Fault information is maintained until overwritten; it
Periodic tests is not cleared out following a reset. This allows
the user to examine data associated with events
These automatic tests are run continuously during that have been reset, as long as there have not
the operation of the truck to verify certain equipment. been so many new events as to necessitate
reuse of the storage space.
Event restrictions • If a given event is active (logged and not reset),
The DSC software will not override an event logging of duplicate events (same event and sub-
restriction as long as the “limp home” mode is not ID numbers) will not be allowed. If the event is
active. Transitions to restricted states will not be reset and subsequently reoccurs, it may be
logged again. Likewise, if an event reoccurs with
allowed. If the system is in a state which becomes
a different sub-ID from the original occurrence,
restricted, it will transition down to the highest the event may be logged again.
unrestricted state. The order of the states, from
lowest to highest, is Startup/Shutdown, Rest, Test,
Ready, Retard, Propel.
Transitions to the Test state or lower states in
reaction to event restrictions will not be allowed until
the truck is not moving. The “limp home” mode is a
state which is entered when the truck has suffered a
failure and is not able to continue normal operation,
but is still capable of getting back to the maintenance
area, or at least out of the way of other trucks.
13
Data packs However, in the default case, faults will be stored as

they come until all data packs are frozen (holding
A data pack is defined as an extended collection of
fault data). When all data packs are frozen, the data
information relevant to a given event.
pack with the fault that was RESET first (either
NOTE: The concepts of lockout, soft reset, and automatically or by the DID or PTU), if any, will be
accept limit do not apply to data packs. unfrozen and will start storing new data in case a new
fault occurs.
1000 data packs are stored with each containing 120
frames of real time snapshot data. Snapshot data is Event reset
defined as a collection of key data parameter values
for a single point in time). The purpose of each data There are two basic types of event resets: soft and
pack is to show a little “movie” of what happened hard. The difference between the soft and hard reset
before and after a fault. is that a soft reset only affects events that have not
been locked out and a hard reset affects events
The time interval between snapshots is default to 50 regardless of lockout status.
ms, but each data pack may be programmed via the
DID or PTU from 10 ms to 1 sec. (In multiples of 10 Events will be reset:
ms). The “TIME 0:00 frame #” at which the fault is • On power-up - A soft reset will be issued against
logged is default to frame #60, but each data pack is all events at power-up.
programmable from 1 to 100.
• By DID commands - The DSC can issue both
In the above default cases, data is stored for 3 hard and soft resets.
seconds (2.95 second actual) before the fault and 2
• By PTU commands - The PTU can issue both
seconds after the fault.
hard and soft resets.
A data pack status structure is assigned to each data
pack plus any programmable settings. This status
structure is used by the DSC or PTU to check for
available data (event number, ID, and status should
be set to zero if the data pack is not frozen), as well
as for control of the data packs.
If a data pack is unfrozen (not holding any particular
fault data), it is continually updated each 100 frames,
organized in a circular queue, with new real time
snapshot data. When a fault occurs, the frame
number at which the event occurred is used as a
reference to mark the end of the data pack, and data
is collected until the data pack is full. Only when the
data pack is full will the event number, ID and status
be updated in the status structure.
All logic control variables are saved in battery backed
RAM in case a fault occurs and battery power is
cycled before the data pack is filled with data. The
software allows for proper recovery and then
continues to fill the data pack. Maintenance
personnel, by way of the DID or PTU, can assign the
data pack to hold only certain event numbers if it is
desired to collect data on a particular fault.
14
Abnormal conditions/overriding functions Limp home mode

The software functions discussed up to this point The purpose of limp home mode is to address the
have assumed that the truck is operating under situation where the truck has suffered a failure and is
typical circumstances. The following information not able to continue normal operation but is still
defines system operation under abnormal or capable of “limping” (getting back to the maintenance
exceptional circumstances. In the event of conflict area or at least out of the way of other trucks). The
between these functions and those given for normal intent is that the limp home mode will be used by
operation, the following functions will take maintenance personnel operating the truck at low
precedence. speeds with the truck unloaded. Maximum truck
speed will be limited to a reduced value while in limp
Engine shutdown/Engine not running home mode.
The engine must be running to maintain power on the If the DSC requests limp home mode, the state
DC link. Typically, the DSC will be given advanced machine will ignore the restrictions associated with
warning that the engine is about to be shut off. any fault for which limp home mode is possible.
However, if the engine stalls or stops because of a
mechanical malfunction, the system will most likely The DSC will enter limp home mode if all of the
have no advance warning. following conditions are true:
The system reaction to an engine not running • The truck is not moving.
condition will be the same as an event carrying a “no • The DSC is in Ready or Test state and there is no
power” restriction. The “no power” restriction will be initiated testing in progress.
automatically lifted as soon as the engine starts
• At least one inverter is functional.
running.
• There are no events active for which limp home
If the system is given warning of an impending mode is not possible.
engine shutdown, the existing torque commands will
be command to zero. If no warning is given and the • If there are any events active for which an inverter
engine stops running, the existing torque commands must be turned off or cut out before limp home
mode is allowed, those actions have been taken
will be command to zero over a “short” ramp time (0.1
(inverter is turned off or cut out as required).
to 0.5 second).
NOTE: The DID panel can be used to cut out an
inverter. In some cases, certain DC link bus bars/
cables within the inverter also may need to be
removed. The DID will prompt maintenance
personnel if any of the above actions need to be
accomplished.
The DSC will exit limp home mode if an event occurs

for which limp home mode is not possible.
15
AC drive system component table

Table 1 lists component abbreviations that are used in schematics and system function information. Refer to
Figure 10-3 through Figure 10-6 for the location of the components.
Table 1: AC drive system component descriptions

Fig.
Abbreviation Component Function
No.
Regulates current in the alternator field based on
AFSE 10-4 Alternator Field Static Exciter Panel firing pulses from the DSC.
AFSER 10-4 Resistor AFSE Battery boost command pull up resistor.
ALT Alternator Main alternator, propulsion and control system.

Provides ambient air temperature input to the control
AMBTS 10-6 Ambient Temperature Sensor group.
Provides signal conditioning for analog signals to
ANALOG I/O CARD System analog input/output card and from the DSC.
BAROP 10-4 Barometric Pressure Sensor Provides altitude input for control electronics.
BATFU1, 2 10-4 System Fuse Provides overload protection for control equipment.
Connects and disconnects the 24 VDC truck
BATTSW Battery Disconnect Switch batteries.
Works in conjunction with BFC and BLFP to
BDI 10-4 Battery Blocking Diode maintain battery voltage to CPU.
Additional capacitance for BLFP to prevent nuisance
BFC 10-4 Battery Line Filter Capacitor CPU resets.
Added to replace Battery line filter that was
BFCR 10-4 Battery Filter Resistor removed.
DC motors driving blowers to provide cooling air for
BM1, 2 Grid Blower Motors 1 and 2 the retarding grids.
Monitors current flowing through grid blower motors
BM1I / BM2I 10-3 Current Sensing Modules #1 and #2.
Absorbs and releases current to the DC link for the
CCF1, 2 10-3 DC Link Filter Capacitors grid resistors when a current spike occurs.
Connected across the DC link to provide a voltage
Capacitor Charge Resistor Panels
CCLR1, 2 10-3 attenuated sample of the DC link voltage to the
1 and 2 Capacitor Charge Indicating lights.
Illuminated when 50 volts or more is present on the
Capacitor Charge Indicating Lights DC link (the DC bus connecting the Alternator
CCL1, 2 10-4
1 and 2 output, Chopper Module/Resistor Grid circuits and
traction Inverters).
Controls the DC voltage applied to the grids during
CD1, 2 10-3 Chopper Diodes 1 and 2 retarding.
Absorbs and releases current to the DC link for the
CF11, 22, 21, 22 10-3 DC Link Filter Capacitors Traction Motors when a current spike occurs.
Limit the rate of current increase when starting to
CGBM1, 2 10-3 Blower Motor Capacitors optimize motor commutation.
Alternator Field Current Sensing Detects amount of current flowing through the
CMAF 10-4
Module Alternator field winding.
Alternator Tertiary Current Sensing Detects amount of current flowing through the
CMT 10-4
Module Alternator tertiary winding.
Chopper IGBT Phase Module 1 Controls the DC voltage applied to the grids during
CM1, 2 10-3
and 2 retarding.
16

Fig.
No.
Current Sensing Modules, Phase Detects amount of current flow through the A, B and
CM11A - 12C
1A, 1B and 1C C phases of Traction Motor 1.
Current Sensing Modules, Phase Detects amount of current flow through the A, B and
CM21A - 22C
2A, 2B and 2C C phases of Traction Motor 2.
Picks up when the Key Switch and Control Power
CPR 10-4 Control Power Relay Switch are closed.
CPRD 10-4 Dual Diode Module Allows two separate voltages to control the CPR coil.
Control Power Relay Suppression Suppresses voltage spike when CPR coil is de-
CPRS 10-4
Module energized.
CPS 10-4 Control Power Switch Energizes CPR coil.

The DC bus connects the Alternator output, Chopper
DCN BUS/DCP BUS DC Link (-) and (+) Bus Module/Resistor Grid circuits, and Traction inverters.
Provides maintenance personnel with the ability to
DID Diagnostic Information Display monitor the operational status of certain truck
systems and perform system diagnostic test.
Receives contactor, relay and switch feedback
DIGITAL I/O CARD Digital Input/Output Card signals and provides drive signals to relays,
contactors, indicator lamps, etc. Located in DSC.
The DSC is the main controller for the AC drive sys-
tem. All propulsion and retarding functions are con-
DSC Drive System Controller trolled by the DSC based on internally stored
software instructions.
DSC Link DSC Link State of the LINK charging machine.
Resistor divider network connected across the DC
FDR 10-6 Filter Discharge Resistor link, provides secondary discharge link for the DC
link. Normal discharge is through RP1.
Provides voltage and electrical noise isolation for
FIBER OPTIC
Fiber Optic Assembly control and feedback signals between the DSC and
ASSEMBLY Phase/Chopper Modules.
Filters electrical noise on 3 phases of Alternator
FP 10-6 Filter Panel output.
Converts 19 to 95 VDC from the Gate Drive Power
GDPC1 10-4 Gate Driver Power Converter 1 Supply to 25 kHz, 100 VRMS, square wave power to
drive Inverter 1 IGBT Phase and Chopper Modules.
Converts 19 to 95 VDC from the Gate Drive Power
GDPC2 10-4 Gate Driver Power Converter 2 Supply to 25 kHz, 100 VRMS, square wave power to
drive Inverter 2 IGBT Phase and Chopper Modules.
GF 10-5 Alternator Field Contactor Connects the AFSE to the Alternator field.
Provides a small load across the contactor
GFBR 10-4 Resistor feedbacks to help keep the contactors clean.
Generator Field Contactor Cutout
GFCO 10-4 Disables Alternator output.
Switch
Receives pulses from the Analog I/O card in the
DSC, amplifies the pulses, and then splits the pulses
GFM1, 2 Gate Firing Module to drive two SCR circuits in the AFSE. Located on
AFSE panel.
Picks up with GF contactor and applies B+ to the
GFR 10-5 Alternator Field Relay AFSE (battery boost) during initial acceleration
phase.
17

Fig.
No.
Alternator Field Relay Coil Suppresses voltage spikes when GF coil is de-
GFRS
Suppression Module energized.
Suppresses voltage spikes in coil circuit when GF

GFS Suppression Module contactor is de-energized.
GRR 10-6 Ground Resistor Panel Detects power circuit grounds.
GRR9, 10 10-4 Resistors Used with GRR to detect power circuit grounds.
Generates Phase Module turn-on/turn-off
Inverter 1 Central Processing Unit commands for the Inverter 1.
INV1 TMC CARD Card and Input/Output Card Monitors voltages and currents from various areas
for Inverter 1. Monitors Traction Motor 1 speed.
Generates Phase Module turn-on/turn-off
Inverter 2 Central Processing Unit commands for the Inverter 2.
INV2 TMC CARD Card and Input/Output Card Monitors voltages and currents from various areas
for Inverter 2. Monitors Traction Motor 2 speed.
Connects battery voltage to CPR and control circuits
KEYSW Key Switch when closed. (Located on instrument panel.)
LINK1 Link Current Sensing Module Detects amount of current flow through the DC link.
L1, 2 Cabinet Lights Provide interior cabinet illumination.

Each Motorized Wheel consists of a Traction Motor
and a Transmission Assembly. The 3-phase
asynchronous Traction Motors convert electrical
M1, 2 Motorized Wheels energy into mechanical energy. This mechanical
energy is transmitted to the wheel hub through a
double reduction gear train (Transmission).
Provide positive driving voltages (PWM or square
P11A+, 11B+, 11C+
10-3 IGBT Phase Modules wave, depending on truck speed) for each of the
P12A+, 12B+, 12C+ three windings of Traction Motor 1.
Provide negative driving voltages (PWM or square
P11A-, 11B-, 11C-
P12A-, 12B-, 12C- three windings of Traction Motor 1.
Provide positive driving voltages (PWM or square
P21A+, 21B+, 21C+
P22A+, 22B+, 22C+ three windings of Traction Motor 2.
Provide negative driving voltages (PWM or square
P21A-, 21B-, 21C-
P22A-, 22B-, 22C- three windings of Traction Motor 2.
A DC to DC converter which provides regulated ± 24
VDC outputs from the unfiltered battery supply.
PS 10-4 Power Supply Supplies power to DSC & LEMS.
Converts Alternator 3-phase, AC voltage to DC
RD 10-6 Rectifier Diode Panel voltage to power the two Inverters.
Dissipate power from the DC link during retarding,
RG1A - 5C Retard Grid Resistors load box testing, and Inverter Filter Capacitor
discharge operations.
When closed, connects Grid Resistors to the DC link
during retarding, load box testing, and Inverter Filter
RP1, 2 10-5 Retard Contactors 1and 2 discharge operations.
Note: Some trucks do not have RP3 installed.
Suppresses voltage spikes in coil circuit when RP
RP1S, RP2S Suppression Modules contactors are de-energized.
18

Fig.
No.
Provides a small load across the contactor
RP1BR \ RP2BR 10-4 Resistor feedbacks to help keep the contactors clean.
Limits surge current in the Alternator field circuit
R1 10-5 Battery Boost Resistor when GFR contacts first close.
Each speed sensor provides two output speed
SS1, 2 Traction Motor Speed Sensors signals, proportional to the Traction Motor's rotor
shaft speed.
Provides control of propulsion and dynamic retarding
System Central Processing Unit functions, battery backed RAM, real-time clock,
SYS CPU Card
Card downloadable code storage, and an RS422 serial
link.
Discharges the Alternator field when the AFSE is
TH1 10-5 Alternator Field Thyrite (Varistor) first turned off.
Attenuates the three high voltage outputs applied to
VAM1 10-3 Voltage Attenuation Module each phase winding of Traction Motor 1 to a level
acceptable for use by the Analog I/O card in the ICP.
Attenuates the three high voltage outputs applied to
VAM2 10-3 Voltage Attenuation Module each phase winding of Traction Motor 2 to a level
Attenuates the high voltage outputs between the
main alternator and the rectifier panel, and between
VAM3 10-5 Voltage Attenuation Module the rectifier panel and the inverters to a level
Attenuates the high voltage outputs between the
VAM4 10-5 Voltage Attenuation Module AFSE and the main alternator to a level acceptable
for use by the Analog I/O card in the ICP.
19
FIGURE 10-3. CONTROL CABINET COMPONENTS - HIGH VOLTAGE INVERTER AREA
20
FIGURE 10-4. CONTROL CABINET COMPONENTS - LOW VOLTAGE CONTROL AREA
21
R1 GFR GF RP1 RP3 RP2
VAM3
VAM4
TH1
86283
FIGURE 10-5. CONTROL CABINET COMPONENTS - CONTACTOR COMPARTMENT
FIGURE 10-6. CONTROL CABINET COMPONENTS - REAR VIEW (TYPICAL)
22
Electronic accelerator and retarder pedals

The drive system controller (DSC) is internally
partitioned into separate propulsion system controller
(PSC) and truck control interface (TCI) functions. 2
Accelerator pedal (2, Figure 10-7) provides a signal
to the TCI partition when the operator requests
1
power. Retarder pedal (1) provides a signal to the
PSC partition when the operator requests retarding.
The pedal signals are processed by the analog card
in the panel for use by the system controllers to
provide the desired mode of operation.
As the operator depresses the pedal, the internal
potentiometer's wiper is rotated by a lever. The output
voltage signal increases in proportion to the angle of
depression of the pedal.
86231
FIGURE 10-7. OPERATOR CAB PEDALS

1. Service Brake/Retarder Pedal
2. Accelerator Pedal
23
960E Dump truck

980E Dump truck
© 2016 KOMATSU
All Rights Reserved
24
CEN10008-02
730E
860E
960E
980E
730E-8 A40004 and up 960E-2K A50011 and up
860E-1K A30003 and up 960E-2KT A50028 and up
860E-1KT A30003 and up 980E-4 A40003 and up
960E-1 A30003 - A30026
960E-1K A50003 - A50010
960E-2 A30027 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.
Relays
Three relays (9, Figure 10-3) control 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 the position of the fan
speed control knob on control panel (40, Figure 10-
3).
If blower assembly (3) 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
assembly is probably defective and should be FIGURE 10-2. CAB FILTER LOCATION
removed and replaced.
1. Access Cover 2. Cab Filter
Cab air filter
Recirculation air filter (5, Figure 10-3) and the cab air Actuators
filter behind access panel (2, Figure 10-2) at the front
of the cab need periodic cleaning to prevent Two rotary actuators (9, Figure 10-3) are installed
restrictions in air circulation. Restricted filters will inside the heater housing and are used to actuate the
decrease the performance of the heater and air damper doors for the following:
conditioner. The recommended interval for cleaning • Defroster outlet
and inspection is 250 hours, but in extremely dusty
conditions the filters may need daily service and • Bi-level or floor outlets
inspection, especially the outer panel filter on the cab A failure to switch one of the above modes of
shell. The filter elements should be cleaned with operation may be caused by a faulty actuator.
water and dried in a dust free environment before
Visually inspect damper doors (35) and (36) and the
reinstallation. Replace the filter element every 2,000
linkage for the function being diagnosed. Ensure that
hours, or sooner if inspection indicates a clogged or
the damper door is not binding or obstructed,
damaged filter.
preventing movement from one mode to the other.
Heater core Verify that 24 VDC is present at the actuator when air
flow directional knob on control panel (40, Figure 10-
Heater core (2, Figure 10-3) receives engine coolant 3) is moved through its various positions of operation.
through water valve (33) when heat is selected. If the
temperature control knob on control panel (40) is If the correct voltages are present during operation of
placed in between the red and blue area, or turned the air flow knob, disconnect the actuator from the
counterclockwise to the blue area, coolant flow damper door and verify that actuator force is
should be blocked. comparable to a known (new) actuator. If it is not,
install a new actuator.
If the temperature control knob and water valve (33)
appear to be working properly, yet no heat is
apparent in the heater core, the core may be
restricted. Remove and clean or replace the core.
5
36
31
14
22
16
13 31 15
24 35
30 38 25 40
16 30
DETAIL A
9 28 34
39
8 16
12 20 41
3 26 2
A
33
27
37
21
23 18
32
11 21
1 18
29 6 4 19 17
5 10
16 42
N040086
FIGURE 10-3. HEATER/AIR CONDITIONER ASSEMBLY
1. Evaporator Core 10. Louver 21. Foam 32. Punched Setup

2. Heater Core 11. Thermostat 22. Bracket 33. Water Valve
3. Blower Assembly 12. LH Seal 23. Case 34. Drive Adapter
4. Outer Recirculation 13. Front Seal 24. Bracket 35. Damper Door (Up)
Grille 14. Top Seal 25. Control Panel Harness 36. Damper Door (Side)
5. Recirculation Filter 15. Screw 26. Main Unit Harness 37. Punched Strip
6. Inner Recirculation 16. Screw 27. Seal 38. Punched Strip
Grille 17. Cover 28. Screw 39. Blower Retainer
7. Expansion Valve 18. Knob 29. Screw 40. Control Panel
8. Relay 19. Seal 30. Bulb 41. Grommet
9. Actuator 20. Foam 31. Pivot Bushing 42. Duct Adapter
6
Compressor (refrigerant pump) Condensing of the refrigerant is the change of state

of the refrigerant from a vapor to a liquid. The action
Compressor (11, Figure 10-1) is where the low
is affected by the pressure of the refrigerant in the
pressure side of the system changes to high
coil and air flow through the condenser. Condensing
pressure. It concentrates the refrigerant returning
pressure in an air conditioning system is the
from the evaporator (low side), creating high
controlled pressure of the refrigerant which affects
pressure and a temperature much higher than the
the temperature at which it condenses to liquid,
outside air temperature. The high temperature
giving off large quantities of heat in the process. The
differential between the refrigerant and the outside air
condensing point is sufficiently high to create a wide
is necessary to aid rapid heat flow in the condenser
temperature differential between the hot refrigerant
from the hot refrigerant gas to much cooler outside
vapor and the air passing over the condenser fins
air.
and tubes. This difference permits rapid heat transfer
To create high pressure concentration, the from the refrigerant to ambient air.
compressor draws in refrigerant from the evaporator
through the suction valve and, during compression Receiver-drier
strokes, forces it out through the discharge valve to Receiver-drier (15, Figure 10-1) is an important part
the condenser. The pressure from the compressor of the air conditioning system. The drier receives the
action moves the refrigerant through the condenser, liquid refrigerant from the condenser and removes
receiver-drier and connecting hoses to the expansion any moisture and foreign matter present which may
valve. have entered the system. The receiver section of the
The compressor is driven by the engine through a tank is designed to store extra refrigerant until it is
drive belt driving an electrically operated clutch needed by the evaporator. The storage of this
mounted on the compressor drive shaft. refrigerant is temporary and is dependent on the
demand of the expansion valve.
Service valves
A desiccant is a solid substance capable of removing
Quick-connect hose end fittings with integral service moisture from gas, liquid or solid. It is held in place
valves attach to system service ports for servicing the within the receiver between two screens, which also
unit. A manifold gauge set is connected into the act as strainers.
system at the service valve ports and all procedures,
The receiver-drier is also equipped with a sight glass
such as discharging, evacuating and charging the
and a moisture indicator. The sight glass can give a
system, are performed through the service valves.
good indication of the charge of the system. If the
Condenser sight glass is not clear, the system is low on
refrigerant.
Condenser (17, Figure 10-1) receives the high
pressure, high-temperature refrigerant vapor from the The moisture indicator is a device to notify service
compressor and condenses it to high pressure, hot personnel that the drier is full of moisture and must
liquid. be replaced. The indicator is blue when the
component is free from moisture. When the indicator
It is designed to allow heat movement from the hot turns beige or tan, the drier must be replaced.
refrigerant vapor to the cooler outside air. The cooling
of the refrigerant changes the vapor to liquid. Heat
exchange is accomplished using cooler air flowing
through the condenser. Condenser cooling is
achieved by air flowing from the radiator fan along
with ram air provided by vehicle movement. The
radiator fan moves more than 50% of condenser air
flow unless travel speed is at least 40 kph (25 mph).
Ram air condensers depend upon the vehicle
movement to force a large volume of air past the fins
and tubes of the condenser. The condenser is usually
located in front of the radiator or on the roof of the
truck.
7
Expansion valve The storage of the liquid refrigerant is temporary.

When the liquid vaporizes into a gas it will be pulled
Expansion valve (8, Figure 10-1) controls the amount
from the bottom of the accumulator into the
of refrigerant entering the evaporator core. Both
compressor. This process not only allows the
internally and externally equalized valves are used.
accumulator to act as a storage device, but also
The expansion valve is located near the inlet of the protects the compressor from liquid slugging.
evaporator and provides the functions of throttling,
The low side service port is also located on the
modulating, and controlling the liquid refrigerant to
accumulator.
the evaporator coil.
The refrigerant flows through a restriction creating a
pressure drop across the valve. Since the expansion Evaporator core
valve also separates the high side of the system from
the low side, the state of the refrigerant entering the Evaporator core (9, Figure 10-3) cools and
valve is warm to hot high pressure liquid; exiting it is dehumidifies the air before it enters the cab. Cooling
low pressure liquid and gas. The change to low a large area requires that large volumes of air be
pressure allows the flowing refrigerant to immediately passed through the evaporator coil for heat
begin changing to gas as it moves toward the exchange. Therefore, a blower becomes a vital part
evaporator. This produces the desired cooling effect. of the evaporator assembly. It not only draws heat
laden air into the evaporator, but also forces this air
The amount of refrigerant metered into the over the evaporator fins and coils where the heat is
evaporator varies with different heat loads. The valve surrendered to the refrigerant. The blower forces the
modulates from wide open to the nearly closed cooled air out of the evaporator into the cab.
position, seeking a point between for proper metering
of the refrigerant. Heat exchange, as explained under condenser
operation, depends upon a temperature differential of
As the load increases, the valve responds by opening the air and the refrigerant. The greater the
wider to allow more refrigerant to pass into the temperature differential, the greater will be the
evaporator. As the load decreases, the valve reacts amount of heat exchanged between the air and the
and allows less refrigerant into the evaporator. It is refrigerant. A high heat load condition, as is generally
this controlling action that provides the proper encountered when the air conditioning system is
pressure and temperature control in the evaporator. turned on, will allow rapid heat transfer between the
This system uses an internally equalized, block type air and the cooler refrigerant.
expansion valve. With this type valve, the refrigerant The change of state of the refrigerant in and going
leaving the evaporator coil is also directed back through the evaporator coil is as important as that of
through the valve so the temperature of the the air flow over the coil.
refrigerant is monitored internally rather than by a
remote sensing bulb. The expansion valve is All or most of the liquid that did not change to vapor in
controlled by both the temperature of the power the expansion valve or connecting tubes boils
element bulb and the pressure of the liquid in the (expands) and vaporizes immediately in the
evaporator. evaporator, becoming very cold. As the process of
heat loss from the air to the evaporator coil surface is
NOTE: It is important that the sensing bulb, if taking place, any moisture (humidity) in the air
present, is tight against the output line and protected condenses on the cool outside surface of the
from ambient temperatures with insulation tape. evaporator coil and is drained off as water.
At atmospheric pressure, refrigerant boils at a point
lower than water freezes. Therefore, the temperature
Accumulator
in the evaporator must be controlled so that the water
Accumulator (18, Figure 10-1) receives vaporized collecting on the coil surface does not freeze on and
refrigerant from the evaporator, moisture and/or any between the fins and restrict air flow. The evaporator
residual liquid refrigerant is collected at the bottom of temperature is controlled through pressure inside the
the component. The moisture is absorbed by the evaporator, and temperature and pressure at the
desiccant where it is safely isolated from the rest of outlet of the evaporator.
the system.
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 blower control is a switch which provides a range
blower is turned off.
of blower speeds from fast to slow. When the blower
switch is turned on, current is available at the The stationary field clutch is the most desirable type
compressor clutch. Once the blower is turned on, fan since it has fewer parts to wear. The field is mounted
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
730E Dump truck

860E Dump truck
960E Dump truck
980E Dump truck
© 2013 KOMATSU
All Rights Reserved
Printed in U.S.A. 08-13
12
CEN10022-02
860E
960E
980E

860E-1K A30003 and up 980E-4 A40003 and up
860E-1KT A30003 and up
960E-1 A30003 - A30026
960E-1K A50003 - A50010
960E-2 A30027 and up
960E-2K A50011 and up
960E-2KT A50028 and up

Reserve engine oil system
Operation .............................................................................................................................................................. 4
Service .................................................................................................................................................................. 7
Troubleshooting .................................................................................................................................................... 8
Auto fill system electrical schematic ..................................................................................................................... 9
1
NOTES
2
General information
The reserve engine oil system works by constantly 10
circulating the engine oil between the engine oil pan 9
and a supplementary external reserve tank while 11
maintaining the appropriate running oil level. The
intent is that a larger volume of engine oil slows the 8
oil deterioration, allowing longer periods between oil
changes.
The normal reserve system capacity of oil carried in

the tank can be one half or nearly the same
(depending on tank size) volume inside the engine. In
the process of continuous adjustment of the engine 12
oil level, there is a constant circulation of oil between
the engine and the reserve tank. The volume of oil in 1
the tank becomes part of the working oil for the
engine. Oil change intervals may usually be extended 7
in proportion to the increased working oil volume.
Extension beyond a proportional increase is often
possible, but should be undertaken only as 6
determined by oil sampling and analysis. Local
conditions such as engine application, climate, and
fuel quality should be taken into consideration before
determining permissible oil life.
For trucks operating in cold weather applications with 2

a minimum ambient temperature of -30°C (-22°F), a
heated suction line is installed between the reserve
3
oil pump and engine oil pan. Engine oil becomes 5
more viscous in lower temperatures, causing the
4
pumps to work harder and wear more quickly. 84882
Heating the oil keeps the oil less viscous, thus FIGURE 10-1. RESERVE TANK COMPONENTS
maintaining the corresponding flow rate at the inlet of
the reserve pump. 1. Reserve Tank 7. Inline Screen
An optional heated return line is available which 2. Sight Gauge 8. Fill Cap
extends the minimum ambient temperature to -40°C 3. Thermostat Switch 9. Oil Level Switch
(-40°F). 4. Suction Line from 10. Air Relief Valve
Engine Oil Pan 11. Return Line to
5. Pumping Unit Engine Oil Pan
6. Remote Fill Line 12. Fill Valve
3
Operation Pump 1 and pump 2 are interlocked. Once the engine

is started, the pumps run continuously. This action
Pumping unit returns oil from the reserve tank and raises the
The oil level is controlled and circulated between engine oil level until air is no longer drawn by pump 1.
engine oil pan (1, Figure 10-2) and reserve tank (2) The oil level is continuously adjusted at the control
by two electrically driven pumps within single point by alternating between the withdrawal and
pumping unit (4). The pumping unit, which is return of oil in the engine oil pan. Pump 1 draws oil
mounted on the side of the reserve tank, is equipped from the engine oil pan at a preset control point
with two LED monitor lights: red on one side, green determined by the height of the suction tube. Pump 2
on the other side. returns oil back to the engine oil pan. Oil above this
point is withdrawn and transferred to the reserve
tank. This lowers the level in the engine oil pan until
air is drawn.
3
A 4
1 B 2
84884
FIGURE 10-2. RESERVE ENGINE OIL SYSTEM SCHEMATIC

1. Engine Oil Pan 4. Pumping Unit A. Oil Suction Line
2. Oil Tank 5. Air Relief Valve B. Oil Return Line
3. Suction Tube
4
LED monitor lights

After engine startup, allow the pumping unit to run for
1 4
5 minutes before operating the truck. Green LED (3,
Figure 10-3) should remain solid and red LED (4)
should be off. This verifies that the system is working
properly, pumps 1 and 2 are synchronized and
pumping oil, and the engine oil level is correct.
If the green LED is flashing, the pump is receiving air
from the engine oil pan (the oil level is below the
withdrawal point of the pickup tube). The reserve oil
pump should return oil back to the engine oil pan,
continuously adjusting the oil level until air is no
longer drawn by the reserve oil pump.
Over a period of time, both signals (solid / flashing
LED lights) should be observed. This verifies that the 3 2 84883
system is operating properly and the engine oil level
is correct. FIGURE 10-3. PUMPING UNIT
A solid red LED signal indicates that the pump is not 1. Pump 1 3. Green LED
able to return oil to the engine oil pan because the 2. Pump 2 4. Red LED
pump is not working properly, the line is frozen, or the
reserve tank is empty. Shut down the engine and
allow adequate time for the oil to drain into the engine
oil pan. Check the oil level. It should be between the
normal marks, not above the high static mark.
Table 2: LED Monitor Light Functions
Pumps, LED Action Green LED Red LED
Unit is operating with no oil pumping through pumps 1 or 2.

Flashing Flashing
(Low oil level in engine oil pan and reserve tank.)
Unit is running oil through pump 1.

Solid Flashing
(Withdrawing oil from engine oil pan. Reserve tank is low on oil.)
Pump 1 is receiving air from the engine oil pan.

Pump 2 is pumping oil from the reserve tank to the engine oil pan.
Flashing Off
(Pump is returning oil from reserve tank to engine oil pan. Low oil
level in reserve tank.)
Unit is running oil through pumps 1 and 2 simultaneously.

Solid Off
(Oil level is correct. Normal operation.)
5
Tank auto fill control 3. Pull out on power button (1, Figure 10-5) to turn
on the auto fill system.
With the reserve oil system, the engine oil level is
held constant. Only the reserve tank needs routine 4. Press and release start button (2). If the oil
filling. The auto fill system automatically controls the reserve tank is not full, the float will be in a low
filling of the remote tank from a convenient ground position and the relay in the auto fill control
level position. Filling of the tank to the proper “full” (AFC) box will close. This will cause the fill valve
level is fast and accurate and accomplished in 2 to 3 to open. Yellow light (4) should illuminate and
minutes. the filling process will begin.
5. When the tank is full, the float will be in a high
Power button (1, Figure 10-5) is an illuminated, push-
position. The relay in the AFC box will open and
pull POWER-ON switch that powers the auto fill
the filling process will terminate. Yellow light (4)
system. Start button (2) is a momentary push button
will turn off and red light (3) will illuminate.
switch that opens the fill valve mounted on the
reserve tank to begin the automatic filling of the 6. Close the oil supply valve in the fill hose.
reserve tank. Supply oil under pressure flows through 7. Press and hold start button (2) for 2 - 3 seconds
the fill valve and into the tank. to relieve oil pressure in the line.
8. Disconnect the new oil supply hose. Reattach
the cap to the reserve oil tank.
Filling procedure (remote fill feature) 9. Push power button (1) to turn off the auto fill
NOTE: This procedure adds oil to the reserve tank. system.
1. Remove fill cap (8, Figure 10-1) from the

reserve oil tank.
2. Connect the pressure supply hose from the new
oil supply to quick fill coupler on the truck. Open
the valve on the supply hose to apply pressure.
1 3
HYD OIL
2 1
RAD COOL
T ENGINE OIL
4
GREASE
84475
FIGURE 10-4. PUMPING UNIT
1. Engine Oil Quick Fill Coupler
84881
FIGURE 10-5. AUTO FILL CONTROL BOX
1. Power Button 4. Yellow Light

2. Start Button (Valve Open)
3. Red Light (Full)
6
Service Every 10 hours (each shift)

Between oil changes, the only normal servicing that 1. Before starting the engine, check the oil level by
is required is routine replenishment of oil at the using the engine oil dipstick. The oil level should
reserve tank. Running levels in the engine oil pan and be in the normal operating range. If it is not,
reserve tank must be checked before starting the check the reserve engine oil system for proper
engine and by observing the LED monitor lights on operation.
the reserve tank pumping unit when the engine is 2. The engine oil quality will be best if the reserve
running. tank is kept reasonably full. Check the oil level
There is also an in-line filter (screen) installed at the in the reserve tank. If the oil is not visible in the
inlet of the fill valve (3, Figure 10-1). This filter upper sight gauges, fill the tank by using the
requires no periodic maintenance, but it can be automatic fill control method. Refer to the topic
cleaned by removing it from the system and back “Tank Auto Fill Control” earlier in this chapter.
flushing through the filter. NOTE: DO NOT use fill cap (8, Figure 10-1) on top of
the tank to add oil to the reserve tank.
3. After the engine has been started and warmed
up for 5 minutes, check the LED monitor lights
to verify that the engine is being maintained at
the correct running oil level. Refer to the topic
To avoid potential engine damage due to low oil “LED Monitor Lights” earlier in this chapter.
level, always use the engine oil dipstick to check
the oil level in the engine oil pan before starting NOTE: Oil should always be visible in lower sight
the engine. gauge (2, Figure 10-1).
The reserve tank is designed to add more oil capacity Every 500 hours
to the engine to reduce the frequency of servicing the 1. Change all engine oil filters.
engine oil. The engine oil level must still be checked
before every shift by using the dipstick on the engine. 2. Check the electrical system connections for
The oil level in the reserve tank must also be visible tightness, corrosion and damage. Check the
in the upper sight gauges on the tank. battery, alternator, engine oil pressure switches,
junction boxes, auto fill control box and circuit
NOTE: DO NOT use the dipstick on fill cap (8, breakers.
Figure 31-1) to check the oil level in the reserve tank. 3. Examine all electrical cables over their entire
If the engine oil has been drained from the engine oil length for possible damage.
pan, the new oil must be added through the engine fill 4. Hose leaks can cause a system to malfunction.
tube. After an oil change, the oil in both the engine Examine all reserve tank hoses for leaks, cracks
and reserve tank must be at the full level before and damage. Check all fittings for tightness,
starting the engine. leaks and damage.
NOTE: DO NOT use the oil in the reserve tank to fill
the engine oil pan.
Changing oil
1. Drain both the engine oil pan and the reserve
tank.
2. Refill both the engine oil pan and reserve tank
with new oil to proper levels.
3. Change the engine oil filters.
4. Start the engine and check for proper operation.
NOTE: Do not use the oil in the reserve tank to fill the
engine oil pan. Both must be at their proper levels
before starting the engine.
7
Troubleshooting Circuit fuses

It is important to understand the LED monitor light The auto fill control box is protected by a 15 amp fuse
signals for the pumping unit. It is used primarily to located in the auxiliary control cabinet.
verify that the system is maintaining the oil at the cor-
The pumping unit is protected by a 15 amp fuse
rect level in the engine oil pan. The signal is also a
located in the auxiliary control cabinet.
valuable tool in troubleshooting the system.
The heated suction line is protected by a 20 amp fuse
Refer to the topic "LED monitor lights" earlier in this
located in the auxiliary control cabinet.
chapter.
For fuse locations and circuit information, refer to

There is a condition that would show a level higher
Troubleshooting section Fuse and circuit breaker
than the controlled point. If both the engine and
locations or the fuse label located on the door inside
reserve tank are overfilled, there is no room in the
the auxiliary control cabinet.
tank to draw the oil level down in the engine. In this
case, pump 1 is never receiving air. It will continue to
pump oil from the engine to the tank, but because the
tank is full, the oil will be routed back to the engine via
the air relief valve on top of the tank.
There are two explanations for an overfilled tank and
engine:
• When the reserve tank is filled to “FULL” and the
engine is overfilled.
• When oil is added directly to the engine between
oil changes. The system transfers the oil to the
reserve tank until it can not receive any more and
the engine remains overfilled. It is, therefore,
important that oil should be added only to the
reserve tank between oil changes (except if the
engine oil level is extremely low).
8
Auto fill system electrical schematic
FIGURE 10-6. AUTO FILL SYSTEM SCHEMATIC

1. Fill Valve 4. Auxiliary Control Cabinet
2. Oil Level Switch (top of reserve tank) 5. Ground Wire
3. 15 Amp Fuse 6. Auto Fill Control Box
9
860E Dump truck

960E Dump truck
980E Dump truck
© 2016 KOMATSU
All Rights Reserved
10
CEN20005-00
980E

980E-4 A40003 and up

Standard value table
Standard value table for truck ............................................................................................................................... 3
1
CEN20005-00 20 Standard value table
NOTES
2
20 Standard value table CEN20005-00
Standard value table for truck
Truck model 980E-4

Measurement
Check item Unit Standard value
conditions
• Flat dry road surface
0% grade 64
• Engine coolant
Travel speed
(empty) temperature within (40)

Maximum speed in operating range kph
forward gear 12% grade • Travel resistance: 2.0% (mph) 10.8
(empty) (6.7)
• Standard tires
12% grade 24
(loaded) (15)
• Engine coolant
temperature within
Rated operating range 1,900
Engine speed
Idle rpm 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
Truck model 980E-4

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
Truck model 980E-4

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 % Max. 15
specified grade
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
Truck model 980E-4

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

© 2016 KOMATSU
All Rights Reserved
8
CEN30071-00
980E

980E-4 A40003 and up

Steering, brake cooling and hoist
hydraulic system
General information on system checkout.............................................................................................................. 3
Hydraulic system checkout procedures ................................................................................................................ 4
Hydraulic system checkout data sheet ............................................................................................................... 15
Toe-in adjustment................................................................................................................................................ 18
Hoist cylinder leakage test .................................................................................................................................. 19
1
CEN30071-00 30 Testing and adjusting
NOTES
2
30 Testing and adjusting CEN30071-00
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.
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
by a physician familiar with this type of injury is
not received immediately. If the steering pump has just been installed, it is
essential that the pump case is full of oil before
Relieve pressure before disconnecting any
starting the engine.
hydraulic lines. Tighten all connections securely
before applying pressure.
NOTE: The interface module (IM) checkout

procedure must be successfully completed and
engine startup must be possible before beginning the
checkout procedures.
3
Hydraulic system checkout procedures 4. Chock the rear tires.
Required equipment 5. Ensure that all personnel and equipment are

clear of the tires.
• Steering, hoist and brake cooling hydraulic circuit
schematic 6. Turn the steering wheel back and forth until it
can no longer be turned by hand.
• Service PC with Interface Module Realtime Data
Monitor software 7. Turn both brake accumulator bleed valves (1,
Figure 30-1) clockwise to bleed down the brake
• Five 35 000 kPa (5,000 psi) calibrated pressure accumulators.
gauges
8. Depress the brake pedal. The service brakes
• Three 24 000 kPa (3,500 psi) calibrated pressure should not apply and the service brake status
gauges
indicator should not illuminate.
• Two 690 kPa (100 psi) calibrated pressure
gauges
• A graduated container marked to measure liquid
volume in cubic inches or milliliters
Bleeddown procedure
Ensure that all pressure is removed from the
steering, brake and auxiliary hydraulic circuits before
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
frame. 2
1 1 83138
The steering accumulator bleeddown solenoid is
energized by the interface module (IM) after the 1. Accumulator Bleed Valves
truck is stopped, the key switch is OFF, and the 2. Brake Manifold
engine is not running. The solenoid will remain
energized until the IM is shut 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
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
9. Install 35 000 kPa (5,000 psi) pressure gauges 11. To verify that the auxiliary accumulator is bled
in test ports "BR" (1, Figure 30-2) and "BF" (2) down, press override switch (3, Figure 30-4) on
on the junction manifold to the right of the brake automatic lubrication pump (1). The automatic
manifold. With the brake pedal depressed, the lubrication pump will not operate if the auxiliary
pressure at each test port should be at 103 kPa accumulator is bled down.
(15 psi) or less after the brake system has been
bled down.
1 2
2 1
3
86250
FIGURE 30-2. JUNCTION MANIFOLD

1. Test Port "BR"
2. Test Port "BF"
10. Open bleed valve (2, Figure 30-3) on auxiliary 86183

hydraulic manifold (3) to bleed down auxiliary
FIGURE 30-4. AUTOMATIC LUBRICATION
accumulator (1).
SYSTEM
1. Automatic Lubrication 3. Override Switch
Pump 4. Hydraulic Motor
2. Manifold
1
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
3 bleeddown manifold. The pressure should be at
103 kPa (15 psi) or less after the steering
2 system has been bled down.
14. After the service work is completed, tighten all
hydraulic connections and close all bleed
valves.
86259
FIGURE 30-3. AUXILIARY HYDRAULIC MANIFOLD
1. Auxiliary Accumulator
2. Accumulator Bleed Valve
3. Auxiliary Hydraulic Manifold
5
Preliminary steps 6. An optional hose/needle assembly for manually

1. The steering accumulators, brake accumulators bleeding down the steering accumulators can
and auxiliary system accumulator must have the be used. This hose/needle valve assembly is
correct precharge and must be at normal only for convenience and is not required. It
operating temperature. Refer to Testing and provides a way to manually bleed down both
adjusting section Accumulators and steering accumulators any time during the
suspensions for the accumulator charging checkout procedure.
procedures. The assembly will consist of two 1/4” diameter
* Record on Data Sheet hoses connected to a needle valve. The hose
material can be 1/4” diameter SAE 100R2,
NOTE: For best performance, charge the which has 35 000 kPa (5000 psi) rating. The
accumulators in the ambient conditions in which the needle valve will allow simple opening/closing
machine will be operating. and must be rated for 27 500 kPa (4,000 psi) or
2. Install 35 000 kPa (5,000 psi) calibrated above. The length of the hoses is not critical and
pressure gauges at the following locations: can be selected to provide the best accessibility
to the needle valve. Connect the opposite ends
a. steering pump test port "GPA"
of the hose/needle valve assembly as follows.
b. bleeddown manifold test port "TP3"
a. Ensure that both steering accumulators and
c. bleeddown manifold test port "TP2" both brake accumulators are bled down.
d. both steering cylinder manifold test ports b. Remove the plug from #10 SAE boss port (1,
3. Install 24 000 kPa (3,500 psi) calibrated Figure 30-5) located near bleeddown
pressure gauges at the following locations: manifold port "TP3" (2). This port has the
same pressure as the steering supply port
a. both hoist filter test ports and ACC2 port and will allow both steering
b. overcenter manifold test port "TPD" accumulators to bleed down when the needle
valve is opened.
Also, install 690 kPa (100 psi) calibrated pres-

sure gauges at the following locations:
a. front brake cooling test port on the hoist 1
valve outlet
b. rear brake cooling test port on the brake
cooling/hoist return manifold
Hydraulic system flushing procedure

4. Install a jumper hose between the "QD Supply"
and "QD Return" ports on the bleeddown 2
manifold. The hose must be rated for at least
24 000 kPa (3,500 psi) in case the steering
system becomes fully pressurized. However,
the pressure a 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.
84722
FIGURE 30-5. BLEEDDOWN MANIFOLD

1. #10 SAE Boss Port
2. Port "TP3"
6
c. Connect one end of the hose/needle valve 7. If brakes are not installed, connect brake
assembly to the #10 SAE boss port. cooling supply and return hoses together for this
d. Remove the plug in brake manifold port "T3" entire checkout procedure. Service brake and
(2, Figure 30-6). This port will return oil that is parking brake hoses must be fitted with steel
bled from the steering accumulators to the plugs rated for 27 500 kPa (4000 psi) or higher
hydraulic tank. during this checkout procedure.
8. Disconnect or disable all auxiliary hydraulic
systems (auto lube, retractable ladder, radiator
shutters, etc) that may be present on the truck.
9. Fill the steering pump case through case drain
port with clean hydraulic oil.
An alternate method to filling the pump case
with oil is by leaving case drain hose connected
and removing small SEA #6 plug marked "PRG"
near the case drain port on top of the pump.
This will vent air from the pump case if the
hydraulic tank is filled with oil. Install and tighten
the plug when oil appears.
1
NOTE: Filling the pump case with oil does not
eliminate the need for bleeding air from the pump
84723 suction line as described in step 11. Both must be
done.
10. Fully open all pump suction line shutoff valves.
1. Port T3 Valves are fully open when the handle is in line
with the hose.
e. Connect hose/needle valve assembly to port

"T3".
f. Retain the plugs that were removed from the
manifolds for replacement when the hose/ Serious pump damage will occur if any shutoff
needle valve assembly is removed. valve is not fully open when the engine is started.
NOTE: Use of optional bleeddown hose/needle valve
assembly does not substitute for the use of jumper 11. Fill hydraulic tank with hydraulic oil to upper
hose installed in step 4. sight glass.
12. Bleed the air from all pump suction lines by
loosening each suction hose at the pump inlet.
Ensure that the O-ring does not fall out of the
groove. When oil appears, retighten the
capscrews.
This hose/valve assembly cannot be connected
or disconnected if the steering accumulators are NOTE: Bleeding the piston pump suction line does
pressurized. 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
The hose/needle valve assembly must be removed still visible in the upper sight glass. Add oil if
when the checkout procedure is completed. The necessary.
original plugs must be installed in the manifold ports
and tightened to the proper torque. 14. Place the hoist control lever in the FLOAT
position.
7
15. It may be necessary at any time during this Start the engine and operate at low idle for no
checkout procedure to stop the engine and more than 30 seconds. At low idle with 21°C
allow the steering accumulators to bleed down. (70° F) oil, pressure at the hoist filters should be
Steering pressure at bleeddown manifold test approximately 552 kPa (80 psi). Pressure at
port "TP3" will be 103 kPa (15 psi) or less after a steering pump test port "GPA" should be
successful bleed down. The pressure gauge approximately 689 kPa (100 psi). Pressure at
installed in bleeddown manifold port "TP3" will the front and rear brake cooling test ports
show the steering accumulator pressure. should be approximately 172 kPa (25 psi) or
less.
Refer to step 6 if an optional manual method of
bleeding down the steering accumulators is
desired when performing this checkout proce-
dure.
Do not operate at low idle for more than 30
seconds. Steering pump pressure at test port
"GPA" needs to be at or above 1 724 kPa (250 psi)
during the flushing process to provide adequate
If the warning indicator is illuminated, the buzzer pump internal lubrication. Steering pump damage
is sounding and the steering pressure status will result if pressure is below 1 724 kPa (250 psi).
indicator is flashing, do not attempt to remove This also applies to steps 17-20.
any hydraulic hose, fitting, plug, switch, etc.
Hydraulic pressure may be trapped.
NOTE: Do not turn the steering wheel until step 21.
Do not apply the brakes at any time during this
If fault code A236 is shown on the message
checkout procedure.
display, the steering accumulators did not
properly bleed down. 17. With engine at a speed that is fast enough to
provide at least 1 724 kPa (250 psi) at steering
Locate and correct any steering accumulator pump test port "GPA", move the hoist lever to
bleeddown problem before proceeding. the POWER UP or POWER DOWN position.
The front and rear brake cooling oil supply
pressures should be 0 kPa (0 psi) when the
16. Turn the key switch to ON but do not start the
hoist lever is in POWER UP or POWER DOWN,
engine. Verify that the low steering accumulator
This confirms that the hoist valve is functioning
precharge warning (fault A115) is not displayed.
properly.
If the warning is displayed, correct the problem
before starting engine. If the pressures do not drop to 0 kPa (0 psi), the
* Record on Data Sheet hoist valve may be plumbed incorrectly. Stop the
checkout procedure and check all plumbing,
NOTE: The brake accumulators and the auxiliary including all pilot lines. If there is a plumbing
system accumulator do not have pressure switches error, repeat this step again. If no plumbing error
to warn for low precharge, but they must be was found or if the pressures still do not drop to
precharged to 9 653 kPa (1,400 psi) before starting 0 kPa (0 psi), replace the hoist valve and repeat
the engine. Do not start the engine without ensuring this step again.
that all accumulators are precharged to 9 653 kPa
(1,400 psi).
8
18. If all pump pressures and brake cooling oil If the pressure reaches 24 300 kPa (3,525 psi):
supply pressures are as stated in steps 16 and
a. The first time through this step:
17, increase engine to 1500 rpm and flush the
system for 20 minutes. During this time, move • Stop engine by leaving the key switch ON
the hoist lever to POWER UP for 30 seconds. and pulling up the engine shutdown switch
Then move the hoist lever to POWER DOWN on the center console. Confirm that
for 30 seconds. Continue to monitor the brake steering accumulator bleed down does not
occur and that no bleeddown faults are
cooling oil supply pressures. The oil supply
generated.
pressure should be 345 kPa (50 psi) or less
when the hoist lever is in HOLD or FLOAT and * Record on Data Sheet
drop to 0 kPa (0 psi) when the hoist lever is in • Turn the key switch OFF and confirm that
POWER UP or POWER DOWN. steering accumulator bleed down begins.
Confirm that bleed down is completed
Cycle the hoist lever as stated above five times.
normally within 90 seconds and that fault
A236 “Steering Bleed Fault” is not active.
Steering pressure at bleeddown manifold
19. After flushing is complete, stop the engine and test port "TP3" will be 103 kPa (15 psi) or
allow steering accumulators to completely less after a successful bleed down.
discharge. Remove the special flushing
* Record on Data Sheet
plumbing. If the optional steering accumulator
hose/needle valve assembly was installed in Continue to step 20c.
step 6, leave it installed. Reconnect all original
b. For the second and all other times through
plumbing. Check that oil is visible in upper sight
step 20, turn the key switch OFF and allow
glass on hydraulic tank. Add oil if necessary.
the steering accumulators to bleed down.
NOTE: If the brakes are not installed, leave the brake The steering pressure at bleeddown manifold
cooling supply and return hoses connected together test port "TP3" will be 103 kPa (15 psi) or
during this entire checkout procedure. less after a successful bleed down.
NOTE: Step 20 cannot be combined with the flushing c. Open the brake accumulator bleed valves on
procedure in steps 16-18. This flushing procedure the brake manifold and allow the brake
must be performed after step 19 is completed. accumulators to fully bleed down. Open the
bleed valve on the auxiliary hydraulic
NOTE: Do not steer or apply the brakes at any time manifold to bleed down the auxiliary
during step 20. accumulator. Close the bleed valves.
20. Flush the accumulators by starting the engine d. Perform step 20 five times.
and operating until the accumulator pressure is
approximately 24 300 kPa (3,525 psi) when the
unloader valve shifts and unloads the steering 21. After flushing all of the accumulator, the steering
pump. If the pressure will not reach 24 300 kPa system must be flushed. Start the engine. Allow
(3,525 psi), refer to the pump adjustment the accumulators to fully charge and the
procedure in step 26. steering pump to unload. turn the steering wheel
fully to the left and right at least 10 times. Stop
the engine and allow the steering accumulators
to bleed down completely. Add oil to the
hydraulic tank if necessary.
9
Flow amplifier adjustment Steering pump unloader valve adjustment

22. In preparation for the steering shock valve 26. The steering pump unloader valve should
checkout, adjust the unloader valve on the unload the pump at a nominal pressure of
steering pump by turning the unloader valve 24 300 kPa (3,525 psi) and reload the
adjustment screw clockwise until a minimum accumulators when the pressure at bleeddown
reload pressure of 25 325 ± 172 kPa (3675 ± 25 manifold port "TP2" falls to 22 240 ± 172 kPa
psi) is measured at bleeddown manifold port (3225 ± 25 psi). The reload pressure is the
"TP2". The unload pressure will be critical pressure to obtain.
approximately 27 400 kPa (3975 psi).
If the pump operates as described, proceed to
Turn the steering wheel to verify that at least the end of this step to record pressures. If not,
25 150 kPa (3650 psi) is maintained. This is adjust the unloader valve as follows:
acceptable pump performance for this part of
a. Install a calibrated multiple range pressure
the checkout procedure.
gauge capable of 35 000 kPa (5,000 psi) at
NOTE: The pump adjustment in this step is to be steering pump test port "GPA".
used only for checking the steering shock valves. It is b. Install a calibrated pressure gauge capable
not intended for normal truck operation. Refer to step of 35 000 kPa (5,000 psi) in bleeddown
26 when adjusting the pump for normal truck manifold test port "TP2".
operation.
c. Fully open all pump suction shutoff valves.
23. Before checking the steering shock valves, raise
the steering relief valve pressure setting. d. Remove the unloader valve adjuster cap and
Remove the external access plug on the flow completely back out the adjustment screw.
amplifier, then turn the internal adjustment e. Start the engine and allow the steering pump
screw clockwise to gently bottom out the relief to unload. When unloaded, the pressure at
valve. steering pump test port "GPA" will be 1 380 -
24. To check the steering shock valve pressure 2 760 kPa (200 - 400 psi).
settings, turn the steering wheel away from the f. Adjust the unloader valve to reload the
cylinder stops, then turn the steering wheel fully accumulators when the pressure at
into a stop and continue to turn the steering bleeddown manifold test port "TP2" falls to
wheel. One gauge on the steering cylinder 19 133 ± 172 kPa (2,775 ± 25 psi). The
manifold should read 24 000 ± 1000 kPa (3480 unload pressure will be approximately
± 145 psi). 21 200 kPa (3,075 psi), but the reload
Turn the steering wheel into opposite stop. The pressure is the critical pressure to obtain.
other gauge on the steering cylinder manifold NOTE: If adjusting after step 20, do not turn the
should read 24 000 ± 1000 kPa (3480 ± 145 steering wheel to make the accumulator pressure fall.
psi). The bleed valves on the brake manifold can be
* Record on Data Sheet opened partially to slowly bleed down the steering
accumulator pressure to allow the pump to cycle
25. After checking the steering shock valve
every 20-30 seconds while adjusting the unloader
pressure settings, lower the steering relief valve
valve.
pressure setting to 20 685 -207/+827 kPa (3000
-30/+120 psi). Turn the steering wheel fully to g. Tighten the adjustment cap and verify that
the left or right into a stop, then adjust the the pressures remain as adjusted. If the
steering pressure at the flow amplifier while reload pressure is 22 065 - 22 400 kPa
slowly turning the steering wheel into the stop. (3,200 - 3,250 psi) as the pump is cycling, the
When the appropriate gauge at the steering pump is properly adjusted. Close the bleed
cylinder manifold reads the correct pressure, valves.
replace the external access plug on the flow * Record on Data Sheet
amplifier. Tighten the plug to the proper torque.
h. If the pump is being adjusted from step 20,
* Record on Data Sheet return to step 20 now and flush the
accumulators without turning the steering
wheel.
10
Auxiliary accumulator pressure verification f. With the auxiliary accumulator bleed valve
27. The auxiliary accumulator supply valve closes open, verify that the pressures at test ports
when the steering system supply pressure falls "TP2" and "TP3" remain above 16 550 kPa
below the minimum required for proper system (2400 psi) for at least five minutes after the
operation. Oil that is consumed by any auxiliary auxiliary accumulator is bled down to 103
systems is not replaced below this pressure. kPa (15 psi) or less. If either of the steering
The supply valve closing pressure is the critical accumulator pressures at test port "TP2" or
pressure to verify. Maximum auxiliary pressure "TP3" falls or the pressure at auxiliary
is equal to the steering pump unload pressure hydraulic manifold test port “GA” rises,
and is not independently adjustable. correct the problem and return to step 27b.
The auxiliary accumulator supply valve is
located on the auxiliary hydraulic manifold. It is g. Close the bleed valve on the auxiliary
controlled by a non-adjustable pressure switch hydraulic manifold.
in the steering bleeddown manifold. Verify the
auxiliary accumulator supply valve closing pres- System diagnostics
sure as follows: 28. Start the engine to charge the steering
a. Install calibrated 35 000 kPa (5,000 psi) accumulators to at least 22 065 kPa (3200 psi).
pressure gauges in auxiliary hydraulic To prevent the accumulators from bleeding
manifold test ports “GA” and "GP1". down, leave the key switch ON and pull up the
engine shutdown switch on the center console
NOTE: Test port “GP1" is connected directly to to stop the engine.
steering bleeddown manifold test port "TP2". For the
sake of convenience, "GP1" pressure readings may 29. Set the wheel speed on the DID panel to 1.0
be used instead of "TP2" pressure readings. kPa. Slowly open the brake accumulator bleed
valve on the brake manifold. Observe the
b. Start the engine and allow the steering pump pressure at steering bleeddown manifold test
to unload. Continue to operate the engine at port "TP2" when the buzzer sounds and low
low idle for at least three minutes to allow the steering pressure fault code A247 appears on
accumulator temperatures to stabilize. The the dash panel message display. The fault
pressures at steering bleeddown manifold should occur at a falling pressure of 15 860 ±
test ports "TP2" and "TP3" and auxiliary 420 kPa (2300 ± 61 psi). If outside this range,
hydraulic manifold test port “GA” should be at correct the problem.
least 22 065 kPa (3,200 psi).
c. To prevent the accumulators from bleeding
down, leave the key switch ON and pull up NOTE: Step 30 may be skipped if no excessive
the engine shutdown switch on the center leakage in the steering system is suspected.
console to stop the engine. 30. To check for leakage in the steering system:
d. Slowly open the bleed valve on the auxiliary a. Disconnect the flow amplifier return hose at
hydraulic manifold. the steering bleeddown manifold and plug
e. Observe the pressure at steering bleeddown the fitting on the manifold. Disconnect the
manifold test port "TP2" at which the supply steering control unit return hose at the flow
valve closes and the pressure at auxiliary amplifier and plug the port.
hydraulic manifold test port “GA” falls below b. Start the engine. Allow the steering
the pressure at "TP2". The supply valve accumulators to fully charge and the steering
should close at a falling pressure of 17 580 pump to unload. Do not turn the steering
+690/-345 kPa (2550 +100/-50 psi). If wheel while the return hoses are
outside this range, correct the problem and disconnected.
return to step 27b.
11
c. Measure the leakage from the flow amplifier

and the steering control unit.
• Leakage from the flow amplifier should not
exceed 820 mL (50 in.3) per minute. If
leakage is excessive, replace the flow In the next step, DO NOT use the key switch to
amplifier. shut off the engine. If the key switch is turned
• Leakage from the steering control unit OFF, all accumulator oil will be discharged
should not exceed 164 mL (10 in.3) per through the open port on the bleeddown
minute. If leakage is excessive, replace the manifold. If the hose/needle valve assembly was
steering control unit. installed in step 6, use this method to bleed down
the steering accumulators after leakage is
measured. If not, the same hose/needle valve
NOTE: Step 31 may be skipped if no excessive assembly can be made and connected between
leakage in the steering bleeddown manifold is bleeddown manifold test port "TP3" and the
suspected. hydraulic tank fill tube. Both steering
31. To check for leakage in the steering bleeddown accumulators will be bled down when test port
manifold: "TP3" is opened to the tank.
a. Disconnect the flow amplifier return hose at c. Start the engine and allow the steering pump
the steering bleeddown manifold and plug to unload. Measure the leakage from the tank
the fitting on the manifold. Disconnect the return port in the steering bleeddown
steering control unit return hose at the flow manifold. Leakage from the tank return port
amplifier and plug the port. Disconnect the should not exceed 541 mL (33 in.3) per
tank return hose at the steering bleeddown minute.
manifold. * Record on Data Sheet
32. Reconnect all hoses to the steering bleeddown
manifold.
NOTE: Step 33 may be skipped if no excessive
The hydraulic tank oil level is above the level of leakage in the brake system or auxiliary hydraulic
the tank return line. It is necessary to draw a system is suspected.
vacuum on the hydraulic tank to prevent a large 33. To check for leakage in the brake system and
amount of oil from draining from the tank with the auxiliary hydraulic system:
return line disconnected from the bleeddown
manifold. a. Install pressure gauges at brake manifold
ports "AF3" and "AR3" and at auxiliary
b. Disconnect the hoist pilot valve return hose hydraulic manifold test port “GA”.
at the steering bleeddown manifold and plug
the port. Connect the tank return hose to the b. Start the engine and allow the steering pump
hoist pilot valve return hose, or plug the tank to unload. Continue to operate the engine at
return hose and vent the hoist pilot valve low idle for at least three minutes to allow the
return hose to the tank. Do not plug the accumulator temperatures to stabilize. Do
hoist pilot valve return hose. 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).
12
e. Wait 20 minutes, then record each Hoist counterbalance valve adjustment

accumulator pressure again. Note any
NOTE: Skip step 38 if the dump body is not installed.
changes.
• Each pressure gauge at brake manifold
ports "AF3" and "AR3" must be less than 38. To adjust the hoist counterbalance valve on the
2 275 kPa (330 psi). This is a loss of 6 900 overcenter manifold, the dump body must be
kPa (1,000 psi) per hour. empty and the hoist cylinder hoses must be
• The pressure gauge at auxiliary hydraulic connected to the hoist valve.
manifold test port “GA” must be less than a. Move the hoist lever to the FLOAT position
207 kPa (30 psi). This is a loss of 690 kPa and lower the body to the frame, or secure
(100 psi) per hour. the raised body with the proper body
* Record on Data Sheet retention cable or sling. Stop the engine.
f. Remove the pressure gauges from ports b. Loosen the locknut on the needle valve
"AF3", "AR3" and "GA". adjustment stem, then turn the adjustment
34. Disconnect and cap the four hoses from the stem inward. This will block the hoist cylinder
hoist cylinders. head pressure from the counterbalance
valve pilot.
35. Start the engine and raise the engine speed to
high idle. Move the hoist lever to POWER UP. c. Remove the plug from the "PILOT VENT"
The pressure gauges at the hoist filters should port on the overcenter manifold. This will
read 18 960 ± 690 kPa (2 750 ± 100 psi) at high vent the counterbalance valve pilot to
idle. atmosphere.
* Record on Data Sheet NOTE: Do not allow dirt or debris to enter the open
pilot vent port. A clean SAE # 4, 1/4" hydraulic hose
36. Move the hoist lever to POWER DOWN. The can be installed in the port and pointed downward to
pressure gauge at overcenter manifold test port help prevent entry of contaminants.
"TPD" should read 10 340 ± 515 kPa (1 500 ±
75 psi) at high idle. d. Install a calibrated pressure gauge at
overcenter manifold test port "TR". The
gauge will measure hoist cylinder rod end
37. Move the hoist lever to FLOAT to reduce the pressure, which is the pressure controlled by
pressure in the hoist cylinder hoses. Turn the the counterbalance valve.
key switch OFF to stop the engine. Vent the
NOTE: If adjustment of the counterbalance valve is
residual hoist cylinder hose pressure and
anticipated, skip verification step 38e and proceed to
remove the caps from the hoses. Reconnect the
step 38f.
four hoses to the hoist cylinder.
NOTE: If the dump body is secured in the raised
position, remove the body retention cable or sling.
e. Start the engine and operate at low idle.
Move the hoist lever to POWER UP until the
hoist cylinders are in the third stage and
observe the pressure gauge at overcenter
manifold test port "TR".
• If the pressure is 20 685 kPa (3,000 psi) or
higher, stop raising the dump body
immediately. The pressure setting is too
high and must be lowered. Repeat step
38a, then go to step 38f.
13
• If the pressure is below 20 685 kPa (3,000 Final steps

psi), increase the engine speed by
approximately 300 rpm and repeat step 39. Reconnect or enable any auxiliary hydraulic
38e. Continue testing the pressure setting systems on the truck (auto lube, hydraulic
at increasing 300 rpm intervals until high ladder, radiator shutters, etc).
idle is reached. 40. Perform the individual checkout procedures for
The counterbalance valve pressure must be any auxiliary hydraulic systems.
20 685 kPa (3,000 psi) when the hoist lever is in 41. If the optional hose/needle valve assembly was
POWER UP, the engine is at high idle and the installed in steps 6 or 31, bleed down all of the
hoist cylinder is in the third stage. accumulators, then remove the hose/needle
• If the pressure is correct, repeat step 38a, valve assembly and any associated fittings.
then go to step 38i. Install the port plugs and tighten them to the
proper torques.
• If the pressure does not reach 20 685 kPa
(3,000 psi), step 38a, then go to step 38f. 42. Remove all pressure gauges that were installed
during the checkout procedure.
f. Loosen the locknut on the counterbalance
valve adjustment stem. Turn the adjustment
Oil cleanliness check
step fully clockwise to lower the pressure as
much as possible. 43. Before the truck can be put into service, the
cleanliness of the hydraulic oil must be checked.
NOTE: If the dump body is secured in the raised Use the quick disconnect coupling at either hoist
position, remove the body retention cable or sling. filter test port to attach a hose and obtain an oil
g. Start the engine and operate at high idle. sample. Do not use the steering filter test
Move the hoist lever to POWER UP until the port. Do not use a hose that has been
hoist cylinders are in the third stage. Adjust previously used for system flushing.
the counterbalance valve adjustment stem a. The hydraulic system checkout procedure
as needed to obtain a reading of 20 685 kPa must be completed before taking an oil
(3,000 psi) at overcenter manifold test port sample.
"TR".
b. Start the engine and operate at high idle for
NOTE: Turning the adjustment stem clockwise at least ten minutes. Do not operate the
decreases the pressure. Turning the adjustment stem steering, hoist, brakes or any other hydraulic
counterclockwise increases the pressure. The entire function during the oil sampling procedure.
range of the adjustment stem is three turns.
c. Take particle count readings for at least 20
* Record on Data Sheet minutes without changing the engine speed.
h. Repeat step 38a. d. When the particle count level is at or below
i. Install the plug in the "PILOT VENT" port on ISO 21/18/15 standard and is showing a
the overcenter manifold and tighten it to the trend of improving cleanliness or at least
proper torque. maintaining the ISO 21/18/15 standard, the
hydraulic oil meets the acceptable criteria for
j. Turn the needle valve adjustment stem fully
cleanliness.
outward, then tighten the locknut. This
needle valve must be fully open for normal e. If the particle count level of the ISO 21/18/15
hoist operation. standard is not achieved within 20 minutes,
continue operating the engine at high idle
k. Remove the pressure gauge from overcenter
until the conditions in step 43d are achieved.
manifold test port "TR".
44. Replace all hydraulic filter elements before the
truck is put into service. Note the service hour
meter reading.
14
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) ___________
15
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) ___________
16
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: __________________
17
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
18
Hoist cylinder leakage test

After the hoist cylinder is assembled, perform the
following tests to verify that performance is within
acceptable limits.
1. With the rod fully extended, piston leakage must
not exceed 164 cm3/min. (10 in3/min.) at 17 237
kPa (2,500 psi), port to port.
2. With the rod fully retracted, piston leakage must
not exceed 328 cm3/min. (20 in3/min.) at 17 237
kPa (2,500 psi), port to port.
3. Rod seal leakage must not exceed one drop of
oil in eight cycles of operation.
19
980E Dump truck

© 2016 KOMATSU
All Rights Reserved
20
CEN30072-00
980E

980E-4 A40003 and up

Brake system
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
Bearing seal pressure test .................................................................................................................................. 22
Wet disc brake bleeding procedure .................................................................................................................... 23
Parking brake bleeding procedure ...................................................................................................................... 23
Brake disc wear inspection ................................................................................................................................. 24
Brake valve bench test and adjustment .............................................................................................................. 26
Dual relay valve bench test and adjustment ....................................................................................................... 29
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.
hydraulic lines. Tighten all connections securely
Required equipment
before applying pressure.
• Brake hydraulic circuit schematic
• Service PC with Interface Module Realtime Data
NOTE: The interface module (IM) checkout 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
adjusting section Accumulators and
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
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).
• 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 Brake seal pressure test

1. Remove the dust cap on test port (1, Figure 30- Check the integrity of the seals before installing the
4) on the brake backplate. brakes on the truck.
2. Remove the capnut on bleed port (2). Attach a 1. Cap the cooling oil ports and pressurize the
hydraulic pressure test device to the fitting. brake to a maximum of 103 kPa (15 psi).
3. Slowly apply pressure to bleed air from the 2. Close off the air supply and monitor the interior
piston cavity. brake pressure for 15 minutes.
4. Cycle the piston to full stroke ten times by 3. If the air pressure decreases rapidly, a
applying 2 070 kPa (300 psi) of hydraulic displaced or damaged brake seal is indicated.
pressure at bleed port (2). Observe the piston Disassemble the brake and reinstall or replace
for leakage. the seal.
5. Minor oil seepage (non-measurable) is
permissible. If the leakage is greater,
disassemble the piston assembly and determine Bearing seal pressure test
the cause.
Check the integrity of the seals before installing the
seal between the hub and spindle.
1. Connect a hose to the drain port in the hub
cover plate. Ensure that all other ports are
plugged.
2. Pressurize the hub cavity to a maximum of 103
kPa (15 psi).
FIGURE 30-4. FRONT BRAKES

Do not overpressurize the cavity. Excessive
1. Test Port - "LFBP" and "RFBP" pressure may cause damage to the seals.
2. Bleed Port
3. Close off the air supply and monitor the hub

cavity pressure for 15 minutes.
a. If the pressure decreases slowly, the integrity
of the seals is verified.
b. If the pressure decreases rapidly, repeat this
procedure using 12 L (3 gal) or TO-50 oil.
NOTE: The hub must be positioned vertically with the
hub facing upward.
c. If the air pressure still decreases rapidly, a
displaced or damaged seal is indicated.
Disassemble the hub and reinstall or replace
the seal.
22
Wet disc brake bleeding procedure Parking brake bleeding procedure

NOTE: Rear wheel brakes must be bled before rear 1. Securely block the wheels to prevent the truck
tire installation. from rolling away.
1. Make sure that the hydraulic brake supply 2. Open bleed down valves (1, Figure 30-5) on
(steering circuit) is operating properly. brake manifold (2) to depressurize the brake
2. If necessary, charge the brake accumulators. accumulators.
Refer to Refer to Testing and adjusting section 3. To verify that the brake accumulators are
Accumulators and suspensions for the depressurized, turn the key switch ON, but do
accumulator charging procedure. not start the engine. Press the brake lock switch
3. Make sure that the bleed down valves on brake and apply the service brake pedal. The service
manifold are closed. brake light should not come on.
4. Check the hydraulic tank oil level and fill if 4. Close the accumulator bleed down valves.
necessary. 5. Open the rear axle housing hatch.
5. With the wheels securely blocked, start the 6. Start the engine and allow the steering system
engine and allow the accumulators to fill. to fully charge (pump unloads). Then move the
6. Slowly depress the brake pedal until the service directional control lever to NEUTRAL to
brake is partially applied. disengage the parking brake.
7. Connect a clear plastic hose to the bleeder
Rear wheel brakes: valve at the top of the parking brake. Place the
7. Crack open the O-ring plug located next to the other end of hose into a container.
cooling oil port and brake apply port on the 8. Slowly open the bleeder valve and allow
brake backplate. Close the plug after the oil runs hydraulic oil to run until it is clear and free of
clear and free of bubbles. Repeat for the other bubbles. Close the bleeder valve securely.
rear wheel brake.
9. Repeat Steps 5 and 6 for the other parking
NOTE: The other cooling line has a single hex plug brake.
located adjacent. DO NOT use this plug for bleeding
brake. 10. Shut off the engine. Remove the bleed
equipment and close the rear axle housing
Front wheel brakes: hatch.
NOTE: The front wheel brakes are equipped with a

diagnostic coupler on the brake backplate. A hose
with a mating fitting can be attached to direct the oil
into a container during the bleeding process.
8. Attach a hose to diagnostic coupler (1, Figure
30-3) on the brake backplate (brake apply
pressure circuit).
9. Slowly depress the brake pedal until the service
brake is partially applied.
10. After the oil stream is clear of air, remove the
hose from the coupler. Release the brake pedal.
11. Repeat Steps 8 - 10 for the other front wheel
brake. 1. Accumulator Bleed Down Valves
2. Brake Manifold
12. Shut off the engine and allow 90 seconds for the
steering accumulators to depressurize
completely. Check the hydraulic tank oil level.
23
Brake disc wear inspection

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

1. Cover 5. O-Ring
2. Indicator Pin End Face 6. Housing
3. Housing Face 7. O-Ring
4. O-Ring 8. Indicator Pin
25
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 30-8. 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
26
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 30-8. 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 30-8.
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 30-8. All ports must be adjustment collar contacting the actuator base
used and connected. (fully actuated). Fine adjustment will require
turning the collar only in 1/8 turn increments.
5. “B2” Adjustment: Adjust the adjustment collar
up (counterclockwise), starting with one-turn
increments until the output pressure at port “B2”
is 17 235 ± 517 kPa (2,500 ± 75 psi) with the
All ports must be used. Relieve pressure before adjustment collar contacting the actuator base
disconnecting hydraulic and other lines. Tighten (fully actuated). Fine adjustment will require
all connections before applying pressure. turning the collar only in 1/8 turn increments.
Avoid spillage and contamination! Avoid contact 6. Tighten the set screws in the adjustment collars
with hot oil if the machine has been operating. 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
30-8) 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).
27
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.
28
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 30-9. 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
29
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 30-9. 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 30-9. All ports must be to cycle the valve from minimum to maximum
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).
30
NOTES
31
980E Dump truck

© 2016 KOMATSU
All Rights Reserved
32
CEN30073-00
DUMP TRUCK
980E

980E-4 A40003 and up

Accumulators and suspensions
Accumulator charging precautions........................................................................................................................ 2
Bladder accumulator charging procedure ............................................................................................................. 3
Bladder accumulator storage ................................................................................................................................ 7
Bladder accumulator leak testing.......................................................................................................................... 8
Piston accumulator charging procedure ............................................................................................................... 9
Piston accumulator storage .................................................................................................................................11
Piston accumulator leak testing ...........................................................................................................................11
Suspension oiling and charging procedures ....................................................................................................... 12
Suspension pressure test ................................................................................................................................... 19
1
Accumulator charging precautions Temperature during precharge

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

recommended to check and charge both Pressure and Ambient Temperature
accumulators at the same time. Correct precharge
Ambient Charging Pressure
pressure is the most important factor in prolonging
Temperature ± 70 kPa (10 psi)
accumulator life.
-23°C (-10°F) and below 8 232 kPa (1,194 psi)
NOTE: Use only nitrogen that meets or exceeds CGA -17°C (0°F) 8 412 kPa (1,220 psi)
(Compressed Gas Association) specification G-10.1 -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)
16°C (60°F) 9 473 kPa (1,374 psi)
21°C (70°F) 9 653 kPa (1,400 psi)
27°C (80°F) 9 832 kPa (1,426 psi)
32°C (90°F) 10 011 kPa (1,452 psi)
38°C (100°F) 10 184 kPa (1,477 psi)
43°C (110°F) 10 363 kPa (1,503 psi)
49°C (120°F) 10 542 kPa (1,529 psi)
NOTE: A precharge pressure below 8 232 kPa (1,194

psi) is not recommended because of low precharge
pressure warnings. The accumulator pressure switch
activates a warning at 7 584 ± 310 kPa (1,100 ± 45
psi).
2
Bladder accumulator charging procedure 5. Open bleed valve (2, Figure 30-2) on auxiliary
hydraulic manifold (3) to depressurize auxiliary
accumulator (1).
Do not loosen or disconnect any hydraulic line or

component until the engine is stopped and the
key switch has been OFF for at least 90 seconds.
1
Only precharge accumulators to 9 653 kPa (1,400
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. 3
1. Turn the key switch OFF and allow at least 90
seconds for the steering accumulators to 2
depressurize completely.
2. Open bleed valves (1, Figure 30-1) to
depressurize the brake accumulators.
3. To verify that the brake accumulators are
depressurized, press the brake lock switch (key 86259
switch ON, engine off) and apply the service FIGURE 30-2. AUXILIARY HYDRAULIC MANIFOLD
brake pedal. The service brake light should not
come on. 1. Auxiliary Accumulator
2. Accumulator Bleed Valve
4. Close bleed valves (1).
3. Auxiliary Hydraulic Manifold
1 1 83138
1. Accumulator Bleed Valves
2. Brake Manifold
3
6. To verify that the auxiliary accumulator is 9. Remove protective cap (1, Figure 30-4) from
depressurized, press override switch (3, Figure charging valve (2).
30-3) on automatic lubrication pump (1). The
automatic lubrication pump will not operate if the
auxiliary accumulator is depressurized.
1 2
FIGURE 30-4. GAS VALVE COMPONENTS -

BLADDER ACCUMULATOR
86183
1. Protective Cap 2. Charging Valve
FIGURE 30-3. AUTOMATIC LUBRICATION
SYSTEM
1. Automatic Lubrication 3. Override Switch
Pump 4. Hydraulic Motor
2. Manifold
7. Close auxiliary accumulator bleed valve (2,

Figure 30-2).
8. Ensure that hydraulic pressure has been
relieved from the hydraulic system. Remove the
bleed plug in the port valve at the bottom of
each accumulator to vent residual pressure.
NOTE: If a new or rebuilt accumulator (or any bladder
accumulator with all nitrogen discharged) is being
precharged while installed on the truck and
connected to the hydraulic system, the oil side of the
accumulator must be vented to allow proper bladder
expansion. Trapped air or oil on the hydraulic side of
the bladder will prevent the proper precharge
pressure to be obtained for safe operation.
4
10. Close inlet valve (4, Figure 30-5) on control

manifold (6).
11. Connect the nitrogen charging kit to nitrogen
container (8). Open the valve on the container.
12. Turn the “T” handle (1) on charging valve If the precharge is not added slowly, the bladder
adapter (2) all the way out (counterclockwise). may suffer permanent damage. A “starburst”
rupture in the lower end of the bladder is a
13. Close the bleed valve at the bottom of the characteristic failure caused by charging too
accumulator. quickly.
14. Attach the charging valve adapter (2) to the 16. If the precharge pressure inside the
charging valve on the accumulator. Ensure the accumulator is below 690 kPa (100 psi), set
hose does not loop or twist. Tighten the swivel regulator valve (5) for 172 kPa (25 psi) above
nut on the charging valve adapter finger-tight. the current pressure, then slightly open inlet
15. Turn the “T” handle on charging valve adapter valve (4) on control manifold (6) to slowly fill the
(2) clockwise to open the accumulator gas accumulator. It should take approximately three
valve. Do not turn the “T” handle all the way minutes to achieve the initial 172 kPa (25 psi)
down as it will damage the valve core. rise in pressure.
17. When the initial 172 kPa (25 psi) of pressure is
obtained, the bladder should be fully expanded.
Close the nitrogen container valve. Set the
regulator valve for the charging pressure based
on the current ambient temperature. Refer to
Table 1. Then, slowly open the nitrogen
container valve again and increase the fill rate to
fill the accumulator.
18. 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 control
manifold (6) to regulator valve (5).
NOTE: A small blast of pressure will escape.
FIGURE 30-5. HYDRAIR® CHARGING KIT
c. Open inlet valve (4) then slowly open each
NOTE: The arrangement of parts may vary from outlet valve (3) independently until the cor-
the illustration depending on the kit part number. rect precharge pressure is obtained in each
accumulator.
1. “T” Handle Valve
2. Charging Valve Adapter
3. Manifold Outlet Valves (from gauge)
4. Inlet Valve (from regulator)
5. Regulator Valve (Nitrogen Pressure) Do not reduce pressure by depressing the valve
6. Control Manifold core with a foreign object. High pressure may
7. Charging Pressure Gauge rupture the rubber valve seat.
8. Dry Nitrogen Gas Container
5
19. Turn the “T” handle (1) on the charging valve Precharge maintenance
adapters all the way out (counterclockwise) to
close the accumulator gas valve.
20. Hold the gas valve on the accumulator
stationary. Loosen the swivel nut on the If the low accumulator precharge warning is
charging valve adapter to remove the nitrogen active when the key switch is turned ON, do not
charging kit. attempt to start the engine. Permanent bladder
21. Use a common leak reactant to check for damage may result. Check the steering
nitrogen leaks. accumulator precharge pressure and adjust it if
necessary.
22. Install protective cap (1, Figure 30-4) on the gas
valve. 1. When starting the truck, turn the key switch to
the ON position and wait to confirm that the low
23. Operate the truck and check the steering
accumulator precharge warning does not stay
operation.
active after the system check is complete. If the
warning stays active, do not operate the truck.
Notify maintenance personnel.
2. Check the accumulator precharge pressure
every 500 hours. If the precharge pressure is
too low, the bladder will be crushed into the top
of the shell by hydraulic system pressure and
can extrude into the gas stem and become
punctured. This condition is known as "pick out".
One such cycle is sufficient to destroy a bladder.
3. Check all sealing areas on the nitrogen side of
the accumulator (charging valve, pressure
switch, manifold, etc) during every precharge
maintenance interval to ensure that the seals do
not leak. Replace all faulty or leaking seals,
valves, etc. Failure to repair leaking nitrogen
seals may result in a failed accumulator bladder
or low performance from the accumulator.
NOTE: If the precharge pressure continues to decline
frequently between precharge maintenance intervals,
and if all nitrogen sealing areas are free of leaks, then
the accumulator bladder most likely has a small hole
in it and must be replaced.
4. Check all heat shields and exhaust blankets, as
provided, during every precharge maintenance
interval to ensure that they are in place and
good condition.
NOTE: If the truck is equipped with cold weather
bladder accumulators, the precharge pressure must
be checked every 100 hours because the nitrogen
permeates this bladder material at a much greater
rate than the standard bladder material.
6
Bladder accumulator storage Installing a bladder accumulator from storage

Refer to "Bladder accumulator charging procedure"
to install the nitrogen charging kit on the accumulator
and to check the precharge pressure.
• If the precharge pressure is between 172 kPa (25
Always store bladder accumulators with 690 - 827 psi) and 690 kPa (100 psi), set the regulator to
kPa (100 - 120 psi) nitrogen precharge pressure. 690 kPa (100 psi) and slowly charge the
This amount of pressure fully expands the accumulator to 690 kPa (100 psi). Disconnect the
bladder and holds oil against the inner walls for nitrogen charging kit from the accumulator and
lubrication and rust prevention. Do not exceed install the accumulator on the truck. Charge the
827 kPa (120 psi). Storing accumulators with too accumulator to the correct operating precharge
much pressure is not safe due to possible pressure. Refer to Table 1.
leakage.
• If the precharge pressure is less than 172 kPa
Only precharge accumulators to 9 653 kPa (1,400 (25 psi), slowly drain off all of the precharge
psi) while installed on the truck. Never handle an pressure and use the following procedure:
accumulator with lifting equipment if the 1. Remove the nitrogen charging kit from the
precharge pressure is over 827 kPa (120 psi). accumulator.
Always set the precharge to 690 - 827 kPa (100 - 2. Lay the accumulator on a suitable work bench
120 psi) before removing or installing the so the valve port at the bottom of the
accumulators. accumulator is higher than the top end of the
1. If the accumulator was just rebuilt, ensure that accumulator. Remove the protective cap from
there is approximately 2 liters (64 oz.) of clean the valve port.
C-4 hydraulic oil inside the accumulator before 3. Pour approximately 2 liters (64 oz.) of clean C-4
adding a precharge pressure of 690 kPa (100 hydraulic oil into the accumulator through the
psi). valve port. Allow time for the oil to run down the
2. Store bladder accumulators with a precharge inside of the accumulator to reach the other
pressure of 690 - 827 kPa (100 - 120 psi). end.
3. Cover the hydraulic port with a plastic plug to 4. Lay the accumulator flat on the work bench (or
prevent contamination. Do not use a screw-in floor) and slowly roll the accumulator two
type plug. complete revolutions. This will thoroughly coat
4. Store the accumulator in an upright position. the accumulator walls with a film of oil that is
necessary for bladder lubrication during the
charging procedure.
Bladder storage 5. Stand the accumulator upright. Charge the
accumulator to 690 kPa (100 psi). Refer to
The shelf life of bladders under normal storage "Bladder accumulator charging procedure" for
conditions is one year. Normal storage conditions the proper charging procedure.
consist of the bladder being heat sealed in a black
6. Remove the nitrogen charging kit. Install the
plastic bag and placed in a cool dry place away from
protective cap on the valve port.
the sun, ultraviolet and fluorescent lights, and
electrical equipment. Direct sunlight or fluorescent 7. Install the accumulator on the truck.
light can cause the bladder to weather check and dry 8. Charge the accumulator to the correct operating
rot, which will appear on the bladder surface as precharge pressure listed in Table 1. Refer to
cracks. "Bladder accumulator charging procedure" for
the proper charging procedure.
7
Bladder accumulator leak testing 11. Submerge the accumulator assembly under
water and observe it for 20 minutes. No leakage
Leak testing entails checking for internal and external
(oil or bubbles) is permitted from the gas valve
leaks at high pressure. A source of 24 130 kPa
at the top or the valve port at the bottom. If
(3,500 psi) hydraulic pressure and nitrogen
leakage is present, proceed to Step 16.
precharge pressure of 9 653 kPa (1,400 psi) will be
required. A small water tank is necessary for a 12. Hold the gas valve on the accumulator
portion of the test. stationary. Loosen the swivel nut on the
charging valve adapter to remove the nitrogen
1. Remove protective cap (1, Figure 30-4) from the
charging kit.
gas valve.
2. Close inlet valve (4, Figure 30-5) on control 13. Install protective cap (1, Figure 30-4) on the gas
manifold (6). valve.
3. Connect the nitrogen charging kit to nitrogen 14. Ensure that the bleed valve at the bottom of the
container (8). Open the valve on the container. accumulator is closed. Connect a hydraulic
4. Turn the “T” handle on charging valve adapter power supply to the valve port at the bottom of
(2) all the way out (counterclockwise). the accumulator.
5. Close the bleed valve at the bottom of the 15. Pressurize the accumulator with oil to 24 130
accumulator. kPa (3,500 psi). This may take 6 to 8 gallons of
oil. No external oil leakage is permitted.
6. Attach the charging valve adapter (2) to the
charging valve on the accumulator. Ensure the 16. Slowly relieve oil pressure and remove the
hose does not loop or twist. Tighten the swivel hydraulic power supply. Install the protective
nut on the charging valve adapter finger-tight. cap on the valve port to prevent contamination.
7. Turn the “T” handle on charging valve adapter 17. Install the nitrogen charging kit.
(2) clockwise to open the accumulator gas
valve. Do not turn the “T” handle all the way • If any gas or oil leakage was present, discharge
down as it will damage the valve core. all nitrogen gas from the accumulator. Repair the
accumulator as necessary.
8. Set the regulator (5) for 690 kPa (100 psi), then
slightly open inlet valve (4) on control manifold • If there were no leaks, adjust the precharge
(6) to slowly fill the accumulator. After 690 kPa pressure to 690 - 827 kPa (100 - 120 psi).
(100 psi) is obtained, the charging rate can be
increased until the accumulator is fully charged
to 9 653 kPa (1,400 psi). 18. Verify that all warning and caution labels are
attached and legible. Install new labels as
10. Close inlet valve (4) on control manifold (6) then required.
turn the “T” handle on charging valve adapter
(2) fully counterclockwise to close the
accumulator gas valve.
8
Piston accumulator charging procedure

1
Do not loosen or disconnect any hydraulic line or

component until engine is stopped and the key
switch has been OFF for at least 90 seconds. 2 4
Pure dry nitrogen is the only gas approved for

use in the steering accumulator. The accidental
charging of oxygen or any other gas in this 3
compartment may cause an explosion. Ensure
that pure dry nitrogen gas is being used to
charge the accumulator.
When charging or discharging nitrogen gas in the

accumulator, ensure that the warning labels are
observed and the instructions regarding the
charging valve are carefully read and understood.
Only precharge accumulators that are installed

on the truck. Never use lifting equipment to 84476
handle an accumulator that has a nitrogen
precharge of more than 172 kPa (25 psi). Always FIGURE 30-6. TOP OF PISTON ACCUMULATOR
set the precharge to 172 kPa (25 psi) or less for 1. Valve Cover 3. Charging Valve
storage purposes and before removing or 2. Spacer 4. Switch Cover
installing accumulators.
NOTE: In piston-type accumulators, an increase in

precharge pressure (after allowing for any
appreciable temperature variation) indicates a
gradual leakage of fluid into the gas side. Conversely,
Nitrogen pressure may be present in the accumu-
a decrease in precharge pressure is indicative of
lator. Only turn the swivel nut (small hex nut)
nitrogen gas leakage into the fluid side.
during the next step. Turning the entire valve
NOTE: If one accumulator is low on nitrogen, both body may result in the valve assembly being
accumulators must be checked and charged at the forced out of the accumulator by the nitrogen
same time. pressure inside. Wear a protective face mask
1. Turn the key switch OFF and allow 90 seconds when discharging nitrogen gas.
for the accumulators to bleed down. Turn the 3. Turn “T” handle (1, Figure 30-5) on the charging
steering wheel in both directions, until resis- valve adapter all the way out (counterclock-
tance prevents the steering wheel from turning, wise).
to ensure that no oil pressure remains in the 4. Attach the charging valve adapter (2) to the
accumulators. charging valve on the accumulator. Ensure the
2. Remove valve cover (1, Figure 30-6) and hose does not loop or twist. Tighten the swivel
spacer (2). nut on the charging valve adapter finger-tight.
5. Close inlet valve (4) and outlet valves (3) on
control manifold (6).
9
13. If the precharge pressure inside the

accumulator is below 690 kPa (100 psi), set
1 regulator valve (5) for 172 kPa (25 psi) above
the current pressure, then slightly open inlet
valve (4) on control manifold (6) to slowly fill the
accumulator. It should take approximately three
2 minutes to achieve the initial 172 kPa (25 psi)
rise in pressure.
14. When the initial 172 kPa (25 psi) of pressure is
obtained, the piston should be bottomed. Close
3 the nitrogen container valve. Set the regulator
valve for the charging pressure based on the
current ambient temperature. Refer to Table 1.
84483
Then, slowly open the nitrogen container valve
again and increase the fill rate to fill the
FIGURE 30-7. PISTON ACCUMULATOR accumulator.
CHARGING VALVE
NOTE: If a loss in nitrogen pressure occurred during
1. Valve Cap 3. Valve Body operation, oil may still be present in the accumulator
2. Swivel Nut (Large Hex Nut) below the piston. This oil can be bled off during the
(Small Hex Nut) nitrogen charging procedure by turning the steering
wheel back and forth until resistance prevents the
steering wheel from turning.
NOTE: If a loss in nitrogen pressure is the reason for 15. After the accumulator is charged to the desired
recharging, inspect the charging valve and pressure, shut off the charging kit and wait 15
accumulator for damage. Replace or repair items, as minutes to allow the gas temperature to
necessary, before continuing the charging procedure. stabilize. If the desired pressure is maintained,
6. Hold the gas valve stationary at valve body (3, proceed to step 16. If the desired pressure is
Figure 30-7) with one wrench, then loosen exceeded:
swivel nut (2) with a second wrench. This will
a. close the nitrogen container valve, inlet valve
open the gas valve.
(4) and both outlet valves (3).
NOTE: Three turns will fully open the valve. b. Disconnect the hose that connects the mani-
7. Disconnect the hose that connects manifold (6) fold (6) to regulator valve (5).
to regulator valve (5).
NOTE: A small blast of pressure will escape.
NOTE: A small blast of pressure may escape.
c. Open the inlet valve (4) then slowly open
8. Open the inlet valve (4) then slowly open the each outlet valve (3) independently until the
outlet valve (3) connected to the accumulator correct precharge pressure is obtained in
until any stored pressure in the accumulator is each accumulator.
relieved.
10. Close inlet valve (4) and outlet valves (3) then
reconnect the hose that connects manifold (6) to
regulator valve (5).
Do not reduce pressure by depressing the valve
11. Connect the nitrogen charging kit to nitrogen
core with a foreign object. High pressure may
container (8). Open the valve on the container.
rupture the rubber valve seat.
12. Open outlet valve (3) connected to the
accumulator.
10
16. Tighten swivel nut (2, Figure 30-7) to 6-11 N·m Piston accumulator leak testing
(5-8 ft lb).
It will be necessary to check for internal and external
17. Use a common leak reactant to check for leaks at high pressure. A source of 24 132 kPa
nitrogen leaks. (3,500 psi) hydraulic pressure and nitrogen pressure
18. Install charging valve cap (1) finger tight. of 9 653 kPa (1,400 psi) will be required. A small
water tank with the necessary safety guards will be
19. Install valve cover (1, Figure 30-6) and tighten necessary for a portion of the test.
capscrews to 34 N·m (25 ft lb).
20. Operate the truck and check the steering opera-
tion.
Do not stand near the accumulator during test

Piston accumulator storage procedure. A box enclosure made of heavy steel
plate is recommended to contain the accumulator
during oil pressurization test.
1. Ensure that there is no pressure in either end of

the accumulator.
When storing a piston accumulator, do not
exceed the recommended storage pressure of 2. Fill each end of the accumulator with
172 kPa (25 psi) or less. Sudden loss of the approximately 22.7 L (6 gal) of clean type C-4
accumulator pressure can result in a projectile hydraulic oil. Install an adapter on the oil end to
hazard that can cause serious injury or death. connect to a hydraulic power source. Plug the
remaining ports.
Only precharge the accumulators to operating a. Apply 24 132 kPa (3,500 psi) of oil pressure.
pressure while installed on the truck. DO NOT
b. Verify that no external leakage exists.
handle an accumulator with a nitrogen precharge
greater than 172 kPa (25 psi). c. Verify that no structural damage exists.
3. Release the pressure and remove the oil side
fitting.
Apply a small nitrogen precharge of 172 kPa (25 psi) 4. Drain all the hydraulic oil from both ends of the
or less to prevent seal compression and corrosion accumulator. Leave the oil port open.
due to condensation.
5. Slowly pressurize the gas end of the accumula-
Store the accumulator in the upright position in a cool tor with approximately 690 kPa (100 psi) of
dry place away from the sun. The ideal temperature nitrogen to move the piston to the bottom of the
for storage is 21°C (70°F). housing.
Cover the oil port at the bottom of the accumulator 6. Submerge the oil end of the accumulator in the
with a plastic plug (without threads) to prevent con- water tank.
tamination. DO NOT install a threaded plug in the 7. Apply 9 653 kPa (1,400 psi) of nitrogen pres-
oil port. 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.
11
Suspension oiling and charging

procedures
The suspension system supports the weight of the
truck and absorbs the shock from uneven road
surfaces to provide a comfortable ride for the All HYDRAIR® II suspensions are charged with
operator. Also, the suspension system maintains the compressed nitrogen gas with sufficient pressure
stability of the truck by ensuring that all of the wheels to cause injury and/or damage if improperly
are always in contact with the ground. This allows the handled. Follow safety instructions, cautions,
truck to demonstrate its full performance in and warnings provided in the following
acceleration, braking, and turning, even when procedures to prevent accidents during oiling
traveling at high speeds. and charging.
The suspension system uses HYDRAIR® II hydro- Proper charging of HYDRAIR® II suspensions
pneumatic suspension cylinders, which are charged requires that three basic conditions be established in
with oil and nitrogen gas. The cylinder acts as a the following order:
shock absorber by contracting and expanding the
nitrogen gas and oil to absorb the load from the road 1. The oil level must be correct.
surface. 2. The suspension piston rod extension for
nitrogen charging must be correct.
Suspensions which have been properly charged will
provide improved handling and ride characteristics 3. The nitrogen charge pressure must be correct.
while also extending the fatigue life of the truck frame For best results, HYDRAIR® II suspensions should be
and improving tire wear. charged in pairs (fronts together and rears together).
NOTE: Inflation pressures and exposed piston If rear suspensions are to be charged, the front
lengths are calculated for a normal truck gross suspensions should be charged first.
vehicle weight (GVW). Additions to truck weight by NOTE: For longer life of suspension components, a
adding body liners, tailgates, water tanks, etc, should friction modifier should be added to the suspension
be considered part of the payload. Keeping the truck oil. See the oil and nitrogen specification charts in the
GVW within the specification shown on the Grade/ Specifications section.
Speed Retard chart in the operator cab will extend
the service life of the truck main frame and allow the NOTE: Setup dimensions must be maintained during
suspensions to produce a comfortable ride. oiling and charging procedures. However, after the
truck has been operated, these dimensions may vary.
12
Equipment list
• HYDRAIR® charging kit
• Jacks and/or overhead crane
• Support blocks (front and rear) for:
Oiling height dimensions
Charging height dimensions
• HYDRAIR® II oil
• Friction modifier
• Dry nitrogen
If both the front and rear suspensions are to be

serviced at the same time, service the front
suspensions first. Do not remove the front
suspension nitrogen charging blocks until after the
rear suspensions have been completely serviced.
FIGURE 30-8. HYDRAIR® CHARGING KIT

Installing the charging kit
NOTE: The arrangement of parts may vary from
1. Assemble the charging kit as shown in Figure the illustration depending on the kit part number.
30-8, and attach it to a container of pure dry
nitrogen (8). 1. “T” Handle Valve
2. Charging Valve Adapter
2. Remove the protective covers and charging
3. Manifold Outlet Valves (from gauge)
valve caps from the suspensions.
4. Inlet Valve (from regulator)
3. Turn the charging valve adapter’s (2) "T" handle 5. Regulator Valve (Nitrogen Pressure)
valves (1) completely counterclockwise. 6. Manifold
4. Ensure outlet valves (3) and inlet valve (4) are 7. Charging Pressure Gauge (Suspensions)
closed (turned completely clockwise). 8. Dry Nitrogen Gas Container
5. Turn the swivel nut (4, Figure 30-10) on the
charging valve three full turns counterclockwise Removing the charging kit
to unseat the valve.
1. Close both outlet valves (3).
6. Attach charging valve adapters (2, Figure 30-8)
2. Turn "T" handles (1) counterclockwise to
to each suspension charging valve stem.
release the charging valve cores.
7. Turn "T" handle valves (1) clockwise. This will
3. Remove charging valve adapters (2) from the
depress the core of the charging valve and open
charging valves.
the gas chamber of the suspension.
4. If charging valve is being reused tighten the
8. Open both outlet valves (3).
swivel nut (4, Figure 30-10) on the charging
NOTE: By selective opening and closing of outlet valve to 6 N·m (50 in lb). Install the valve cap
valves (3), and inlet valve (4), suspensions may be finger-tight.
charged separately or together.
If a new charging valve is being used, tighten
the swivel nut to 15 N·m (11 ft lb), then loosen
and tighten the swivel nut to 15 N·m (11 ft lb).
Loosen the swivel nut again and tighten to 6
N·m (50 in lb). Install the valve cap finger-tight.
5. Install the charging valve caps and protective
covers on both suspensions.
13
Support blocks for oiling and charging Front suspension oiling

dimensions
Before starting the oiling and charging procedures,
supports should be fabricated to maintain the correct
exposed piston rod extensions. All HYDRAIR® II suspensions are charged with
NOTE: Nitrogen charging support blocks for the rear compressed nitrogen gas with sufficient pressure
suspension are no longer necessary. However, oiling to cause injury and/or damage if improperly
blocks are necessary to properly set the oiling height. handled. Follow all the safety notes, cautions and
warnings in these procedures to help prevent
Exposed piston rod extensions are specified for both accidents during servicing and charging.
oil level and nitrogen charging for HYDRAIR® II
suspensions. These dimensions are listed in the
tables below. Measure the dimensions from the face
of the lower bearing retainer to the machined surface
on the spindle at the front suspension. At the rear Wear a face mask or goggles while relieving
suspension, measure from the face of the lower nitrogen pressure. Ensure all personnel are clear
bearing retainer to the piston flange. DO NOT of the area and support blocks are secure before
measure using the capscrews. Reference Figure 30- relieving nitrogen pressure from the suspension.
9 and Figure 30-12. An unsecured block could be ejected as weight is
applied, causing serious injury to nearby
Support blocks may be made in various forms. Mild
personnel and/or damage to the equipment.
steel materials are recommended. Square stock or
Overhead clearance may be reduced rapidly and
pipe segments at least 38.1 mm (1.5 in.) may be
suddenly when nitrogen pressure is released.
used. The blocks must be capable of supporting the
weight of the truck during oiling and charging NOTE: For longer life of suspension components, a
procedures while avoiding contact with plated friction modifier should be added to the suspension
surfaces and seals on the suspension. Refer to oil. See the oil and nitrogen specification charts in the
Figure 30-9 for front suspension support block specifications section of this shop manual.
placement and Figure 30-11 for rear support block
1. Park the unloaded truck on a hard, level
placement.
surface. Place the directional control lever in
PARK.
Table 1: Front Suspension Dimensions (Empty) 2. Place wheel chocks in front of and behind both
OILING CHARGING HEIGHT CHARGING sets of rear tires to prevent roll away.
HEIGHT PRESSURE NOTE: Do not place wheel chocks around the front
228.6 mm tires. The front tires will roll forward and backward a
Standard
25.4 mm (9.0 in.) *3 047 kPa small amount as the suspension travels up and down
(1.0 in.) 165.1 mm (442 psi) during the suspension charging process.
Oil Sands 3. Thoroughly clean the area around the charging
(6.5 in.)
* Charging pressures are for reference only and may vary depending on
valve on the suspensions. Remove the
body weights. protective covers from the charging valves.
4. Position and secure oiling height dimension
blocks 180° apart to provide stability (See
Table 2: Rear Suspension Dimensions (Empty) Figure 30-9). When nitrogen pressure is
OILING CHARGING CHARGING released, the suspensions will lower and rest on
HEIGHT HEIGHT PRESSURE the blocks.
47.2 mm 212.3 mm *1 455 kPa Ensure that the blocks do not mar or scratch the
(1.86 in.) (8.36 in.) (211 psi) plated surfaces of the pistons or damage wiper
* Charging pressures are for reference only and may vary depending on seals in the lower bearing retainer. Support
body weights. blocks must seat on the spindle and the cylinder
housing.
14
5. Remove charging valve cap (1, Figure 30-10). Front suspension nitrogen charging
Turn swivel nut (small hex) (4) counterclockwise
three full turns to unseat the valve seal. Do not
turn valve body (large hex) (6). The charging
valve body has a bleeder groove in its mounting
threads, but for safety of all personnel, the valve
Lifting equipment (crane or hydraulic jacks) must
body must not be loosened until all nitrogen
be of sufficient capacity to lift the truck weight.
pressure has been released from the
Ensure that all personnel are clear of the lift area
suspension.
before the lift begins. Clearances under the truck
6. Depress the charging valve core to release may be suddenly reduced.
nitrogen pressure from the suspension. When
all nitrogen pressure has been released, loosen 1. If removed, install the charging valve with new
and remove the fill plug. The suspension should O-ring (9, Figure 30-10). Lubricate the O-ring
have collapsed slowly as gas pressure was with clean HYDRAIR® oil.
released. The weight of the truck is now 2. Tighten valve body (large hex) (6) to 23 N·m (17
supported by the support blocks. ft lb). Swivel nut (small hex) (4) must be
7. Adjust oiling support blocks (Figure 30-9) to unseated by turning it counterclockwise three
obtain the oiling height dimension shown in full turns.
Table 1.
8. Fill the suspension with clean HYDRAIR® II oil
(with 6% friction modifier) until the cylinder is full
to the top of the fill plug bore. Use drip pans and
clean all spillage from the outside of the
suspension. Allow the suspension to settle to
clear any trapped nitrogen and bubbles from the
oil. Add more suspension oil if necessary. Install
a new O-ring on the fill plug and install the plug.
FIGURE 30-10. CHARGING VALVE

1. Valve Cap 6. Valve Body
2. Seal 7. O-Ring
3. Valve Core 8. Valve Stem
4. Swivel Nut 9. O-Ring
5. Rubber Washer
FIGURE 30-9. FRONT SUSPENSION
15
12. If the charging valve is being reused, tighten

swivel nut (4, Figure 30-10) to 6-11 N·m (5-8 ft
lb). Install the valve cap finger-tight.
13. If a new charging valve is being used, tighten
Dry nitrogen is the only gas approved for use in the swivel nut to 15 N·m (11 ft lb), then loosen
HYDRAIR® II suspensions. Charging of these and tighten the swivel nut to 15 N·m (11 ft lb).
components with oxygen or other gases may Loosen the swivel nut again and tighten to 6-11
result in an explosion which could cause N·m (5-8 ft lb). Install the valve cap finger-tight.
fatalities, serious injuries and/or major property 14. Install the protective guard over the charging
damage. Use only nitrogen gas meeting the valve.
specifications shown in the oil and nitrogen
specification charts in the Specifications section. NOTE: If the rear suspensions are to be serviced at
this time, leave the nitrogen charging blocks in place
3. Install the HYDRAIR® charging kit and a bottle on the front suspensions until after the rear
of pure dry nitrogen. Refer to "Installing the suspensions are completely serviced.
charging kit".
4. Charge the suspensions with nitrogen gas to
50.8 mm (2 in.) greater than the charging height
listed in Table 1. Close inlet valve (4, Figure 30-
8). Ensure there is adequate overhead clearance
NOTE: If the truck starts to lift off the blocks before before raising the body.
charging pressure is attained, stop charging. 15. Raise the truck body to extend the front
5. Remove the oiling blocks from the suspensions suspensions, allowing for removal of the
and install the nitrogen charging blocks. Secure nitrogen charging blocks. If the suspensions do
the blocks to prevent accidental dislodging. not extend enough to allow for removal of the
blocks, use a crane or floor jacks to raise the
NOTE: Use caution to prevent damage to plated
truck and remove the blocks.
cylinder surfaces and oil seals when installing the
blocks. Any time the suspensions are recharged, calibration
6. Remove the center hose from manifold (6). of the Payload Meter III® system is affected. Refer to
the Payload Meter III® information in the Operation
and Maintenance Manual and perform a “Clean Truck
Tare”. This will ensure accurate payload records.
The front HYDRAIR® II suspensions are now ready
Be aware when relieving nitrogen gas, the truck
for operation. Visually check piston extension with the
may lower suddenly.
truck both empty and loaded. Record the extension
7. Open inlet valve (4) until the pressure drops dimensions. Maximum downward travel is indicated
below the pressure listed in Table 1, then close by the dirt ring at the base of the piston. Operator
the valve. comments on steering response and suspension
8. Install the center hose to manifold (6). rebound should also be noted.
9. Charge the suspensions to the pressure listed NOTE: The empty ride height may be less than the
in Table 1. Do not use an overcharge of nitrogen charging ride height. Also, the suspension height
to lift the suspensions off the charging blocks. between the left and right suspensions may not
10. Close inlet valve (4). Leave outlet valves (3) always be the same due to the fuel level in the fuel
open for five minutes to allow the pressures in tank.
the suspensions to equalize.
11. Close outlet valves (3). Remove the charging kit
components. Refer to "Removing the charging
kit".
16
Rear suspension oiling 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.
All HYDRAIR® II suspensions are charged with
compressed nitrogen gas with sufficient pressure
to cause injury and/or damage if improperly
handled. Follow all the safety notes, cautions and
warnings in these procedures to help prevent
accidents during servicing and charging.
Wear a face mask or goggles while relieving

nitrogen pressure. Ensure all personnel are clear
of the area and support blocks are secure before
relieving nitrogen pressure from the suspension.
An unsecured block could be ejected as weight is
applied, causing serious injury to nearby
personnel and/or damage to the equipment.
Overhead clearance may be reduced rapidly and
suddenly when nitrogen pressure is released.
NOTE: For longer life of suspension components, a
friction modifier should be added to the suspension
oil. See the oil and nitrogen specification charts in the FIGURE 30-11. OILING BLOCK INSTALLATION
specifications section of this shop manual. 1. Main Frame 3. Rear Axle Housing
1. Park the unloaded truck on a hard, level 2. Oiling Support Block
surface. Place the directional control lever in
PARK.
2. Place wheel chocks in front of and behind both 5. Remove charging valve cap (1, Figure 30-10).
sets of rear tires to prevent roll away. Turn swivel nut (small hex) (4) counterclockwise
NOTE: Do not place wheel chocks around the front three full turns to unseat the valve seal. Do not
tires. The front tires will roll forward and backward a turn valve body (large hex) (6). The charging
small amount as the suspension travels up and down valve body has a bleeder groove in its mounting
during the suspension charging process. threads, but for safety of all personnel, the valve
3. Thoroughly clean the area around the charging body must not be loosened until all nitrogen
valve on the suspensions. Remove the pressure has been released from the
protective covers from the charging valves. suspension.
Remove the hose clamp and the rubber cover 6. Depress the charging valve core to release
from the suspension housing. nitrogen pressure from the suspension. When
all nitrogen pressure has been released, loosen
and remove the fill plug. The suspension should
have collapsed slowly as gas pressure was
released. The weight of the truck is now
supported by the support blocks.
7. Adjust oiling support blocks (2, Figure 30-11) to
obtain the oiling height dimension shown in
Table 2.
17
NOTE: A plastic tube can be used to help bleed off Rear suspension nitrogen charging
trapped air inside the piston.
8. Remove the vent plug, pressure sensor, and
charging valve (See Figure 30-12). Use one of
the open ports to fill the suspension with clean
HYDRAIR® oil (with 6% friction modifier). Fill Lifting equipment must be of sufficient capacity
until clean oil seeps from the open ports. Use to lift the truck weight. Ensure all personnel are
drip pans and clean all spillage from the outside clear of lift area before lifting begins. Clearances
of the suspension. Allow the suspension to under the truck may be suddenly reduced.
settle to clear any trapped nitrogen and bubbles
from the oil. Add more suspension oil if NOTE: Ensure the automatic apply circuit has not
necessary. applied the service brakes during truck maintenance.
9. Install the vent plug and pressure sensor onto If the front brakes are applied during rear suspension
the suspension. charging, the axle cannot pivot for frame raising/
lowering, and the rear suspension may be unable to
10. Install a new O-ring onto the charging valve. move up or down.
Lubricate the O-ring with clean HYDRAIR® II oil.
1. If removed, install charging valve with new O-
11. Install the charging valve onto the suspension. ring (9, Figure 30-10). Lubricate the O-ring with
Tighten valve body (6, Figure 30-10) to 23 N·m clean HYDRAIR® oil.
(17 ft lb). 2. Tighten valve body (large hex) (6) to 23 N·m (17
ft lb). Swivel nut (small hex) (4) must be
unseated by turning it counterclockwise three
full turns.
Dry nitrogen is the only gas approved for use in

HYDRAIR® II suspensions. Charging of these
components with oxygen or other gases may
result in an explosion which could cause
fatalities, serious injuries and/or major property
damage. Use only nitrogen gas meeting the
specifications shown in the Specifications Chart
at the end of this section.
3. Install the HYDRAIR® charging kit and a bottle
of pure dry nitrogen. Refer to "Installing the
charging kit".
4. Charge the suspensions with nitrogen gas to 38
mm (1.5 in.) greater than the charging height
listed in Table 2.
FIGURE 30-12. REAR SUSPENSION
18
Suspension pressure test

The suspension assembly should be tested for
leakage after rebuild procedures are completed. If
leakage occurs, the cause of the leakage must be
identified, and repaired before the suspension is
Be aware when relieving nitrogen gas, the truck
installed on the truck.
may lower suddenly.
5. Slowly release gas until the suspensions match
the charging height listed in Table 2.
6. Close inlet valve (4, Figure 30-8). Leave outlet
valves (3) open for five minutes to allow the The entire suspension assembly must be placed
pressures in the suspensions to equalize. in a containment device that will keep the
7. Ensure both of the suspension cylinders are suspension piston in the retracted position and
extended the same distance ± 10 mm (0.39 in.). prevent it from extending during pressurization.
If the difference in the extension from side to Ensure the containment device is capable of
side exceeds this amount, check the front withstanding the applied force.
suspensions for equal extension. Adjust the 1. Collapse the suspension until the piston is fully
front suspensions as necessary. retracted in the housing.
NOTE: A low left front suspension will cause the right 2. Ensure the charging valve and all plugs are
rear suspension to be high. A low right front installed. Attach the pressurization line to the
suspension will cause the left rear suspension to be charging valve.
high. 3. Place the suspension assembly in a
8. Close outlet valves (3). Remove the charging kit containment device and submerge the entire
components. Refer to "Removing the charging assembly in the water tank.
kit". 4. Pressurize the suspension with air or nitrogen to
9. If the charging valve is being reused, tighten 7 585 ± 1 380 kPa (1,100 ± 200 psi).
swivel nut (4, Figure 30-10) to 6-11 N·m (5-8 ft 5. Maintain pressure for a minimum of 20 minutes
lb). Install the valve cap finger-tight. and check for bubbles at the following locations:
10. If a new charging valve is being used, tighten
• Housing bearing/housing joint
the swivel nut to 15 N·m (11 ft lb), then loosen
and tighten the swivel nut to 15 N·m (11 ft lb). • Piston/piston seal area
Loosen the swivel nut again and tighten to 6-11
• Charging valve and plugs
N·m (5-8 ft lb). Install the valve cap finger-tight.
6. After the test is complete, remove the assembly
11. Install the protective guards over the charging from the water tank and release the air or
valves. Install the hose clamps with the rubber nitrogen pressure. Do not remove the charging
covers over the suspension housings. valve from the suspension.
Any time the suspensions are recharged, calibration 7. Remove the suspension from the containment
of the Payload Meter III® system is affected. Refer to device.
the Payload Meter III® information in the Operation 8. Coat any exposed, unpainted areas with rust
and Maintenance Manual and perform a “Clean Truck preventive grease.
Tare”. This will ensure accurate payload records. 9. Store the suspension in a collapsed position to
®
The rear HYDRAIR II suspensions are now ready for protect the piston chrome surface until it is
operation. Visually check piston extension with the installed on a truck.
truck both empty and loaded. Record the extension
dimensions. Maximum downward travel is indicated
by the dirt ring at the base of the piston. Operator
comments on steering response and suspension
rebound should also be noted.
19
20
980E Dump truck

© 2016 KOMATSU
All Rights Reserved
21
22
CEN30068-00
980E

980E-4 A40003 and up

Interface module (IM)
Interface module software..................................................................................................................................... 3
Interface module checkout procedures................................................................................................................. 5
1
NOTES
2
Interface module software NOTE: The data files, application code and
Flashburn software are only required if the interface
To work with the interface module (IM), several
module is being replaced. Replacement interface
special tools and software programs are required.
modules from Komatsu do not have any software
Refer to Table 1 and Table 2 for information on
installed in them. Be aware that the software and
software and tools.
data files are updated periodically. Check with the
local Komatsu distributor for the latest software
versions.
Table 1: Interface Module Software

Name Description Source
Interface Module
Realtime Data Monitor Use to watch inputs and outputs in the interface module Komatsu distributor
Software
Flashburn program To install application code in interface module Komatsu distributor
Application code Application code for interface module Komatsu distributor
Table 2: Interface Module Tools

Name Description Source
200 MHz or higher
64 MB RAM or more
Laptop computer Serial or USB Port Purchase locally
CD/DVD-Rom drive
Windows operating system
Male DB9 connector at one end
Serial cable (RS232 port) Purchase locally
Female DB9 connector at other end
USB port to RS232 serial port
Adaptor (If the laptop computer does not have an RS232 port, Purchase locally
this adaptor is required.)
Flashburn program installation

The Flashburn program is used to install the
application code into the interface module controller.
1. Save the Flashburn program file to a folder on a
local hard drive (such as C:\temp) on the laptop
computer.
2. Double-click on the Flashburn program file so it
will extract the file. Chose a folder on a local
hard drive to save the file into (such as
C:\temp).
3. Inside that directory, double click on Setup.exe
to install the Flashburn program.
4. Follow the on-screen prompts to install the
program.
3
Interface module application code installation Interface module realtime data monitor software
installation
The application code is truck specific software that is
installed into the interface module. Application code The interface module realtime data monitor software
is installed using the Flashburn program. is used to display the data going into and out of the
1. Using a laptop computer, save the application interface module.
code files to a folder on a local hard drive (such
To install:
as C:\temp).
2. Double-click on the correct application code file 1. Copy the file onto the hard drive of the laptop
so it will extract the file. Chose a folder on a computer.
local hard drive to save the file into (such as 2. Double-click on the file and follow the screen
C:\temp). prompts to install the software.
3. Using a serial cable, connect the laptop
To use:
computer to the IM-Diag connector located near
the interface module. 1. Start the Interface Module Realtime Data
4. Start the Flashburn program. Monitor program.
5. Select [Download Application to Product]. 2. Click on the [Select Serial Port] menu item.
Select the correct communication port. It will
usually be Com1.
3. Click on the [Start/Stop] menu item and choose
[Start].
4. Click on the [Units] menu to select the desired
units to display the information.
6. Make sure that the power to the interface

module is off. Then click [Next].
7. Select the correct COM port. Then click [Next].
8. Select the application code file. Then click
[Next].
Flashburn will now install the application code into
the interface module.
4
Interface module checkout procedures
If a new truck with KOMTRAX Plus is being

assembled, or a new KOMTRAX Plus system has
just been installed, refer to Testing and adjusting
section KOMTRAX Plus and payload meter for
instructions regarding the KOMTRAX Plus
Initialization Procedure. The initialization
procedure and form must be completed before
the truck can be put into service.
Necessary equipment
• System schematic
• Laptop computer
• Interface Module Realtime Data Monitor software
• Serial cable (RS232)
• Jumper wire 77 mm (3 in.) or longer
• Voltmeter
• 300 to 332 ohm resistor FIGURE 30-1. INTERFACE MODULE
• 3/8 in. nut driver
1. Interface Module 3. Connector IM2
2. Connector IM1 4. Connector IM3
NOTE: The interface module must already have the
application code installed.
5
Preliminary 7. Check for fault codes associated with the

1. Turn the key switch to the OFF position to stop interface module.
the engine. a. Perform a KOMTRAX Plus download with
2. Turn the key switch to the ON position, but DO the VHMS Technical Analysis Toolbox pro-
NOT start the engine. gram. Refer to Testing and adjusting section
KOMTRAX Plus and payload meter for
3. Allow the KOMTRAX Plus controller to start up.
detailed instructions on performing a down-
This should take about one minute. Verify that
load.
the red LED display starts counting up.
4. Attach the KOMTRAX Plus serial cable to b. In the download data, view the fault history
KOMTRAX Plus diagnostic port (2, Figure 30- and confirm that there are no fault codes
2), and the other end to the serial port on the associated with the interface module. If any
laptop computer. are found, these circuits should be analyzed
to determine the cause of the fault and
repaired.
c. Confirm that there are no fault codes
associated with the communications
between the PLM III controller, engine
controller, interface module, drive system
controller or the Orbcomm controller. If any
are found, these circuits should be analyzed
to determine the cause of the fault and
repaired.
8. Attach the KOMTRAX Plus serial cable to the
machine's IM diagnostic port (1, Figure 30-2),
and the other end to the serial port on the laptop
computer.
9. Start the Interface Module Real Time Data
FIGURE 30-2. DIAGNOSTIC PORTS Monitor program by double-clicking on the
1. KOMTRAX Plus 2. IM Diagnostic Port shortcut. The program begins with a blank
Diagnostic Port window. On the menu bar, there are five items:
Select Serial Port, Start/Stop, Logging,
Screenshot, and Units.
10. Click on [Select Serial Port] in the menu bar.
5. Double-click on the VHMS Technical Analysis
Select the correct communication port. It will
Tool Box icon on the computer's desktop.
usually be Com1.
6. Enter the appropriate User Name and Password
and click the [OK] button. 11. Click on [Start/Stop] in the menu bar and select
Start.
12. The program should display data as shown in
Figure 30-3 and Figure 30-4.
NOTE: If any fault codes associated with the
interface module are found, these circuits should be
analyzed to determine the cause of the fault, and
they should be repaired.
6
Check digital inputs to the interface module 5. Park Brake Request (IM3-V) - Short the engine
1. Hydraulic Tank Level (IM2-k) - Disconnect wire oil pressure switch wire circuit 36 on TB28-K to
34LL from connector CN 14 at TB21-T. Short ground. Move shift lever from neutral to park
TB21-T to ground momentarily and confirm position and confirm state change (one to zero).
state change (one to zero). Reconnect Remove the ground from TB28-K.
disconnected wire. 6. GE Batt + (IM3-M) -- confirm this is a one.
2. Low Steering Precharge (IM2-W) - Disconnect 7. Starter Motor 1 Energized (IM3-R) - Disconnect
wire 5 1A 1 from precharge pressure switch #1 wire 1 1SM1 from cranking motor to TB28-F at
at TB21-K. Short TB21 -K to ground TB28-F. Momentarily short TB28-F to 24V and
momentarily and confirm state change (one to confirm state change (zero to one). Reconnect
zero). Reconnect disconnected wire. disconnected wire.
3. Pump Filter Switches (IM2-Y) - disconnect wire 8. Starter Motor 2 Energized (IM3-S) - Disconnect
39 from TB35-C momentarily and confirm state wire 1 1SM2 from cranking motor to TB28-G at
change (zero to one). TB28-G. Momentarily short TB28-G to 24V and
4. Park Brake Released (IM2-M) - short wire 73S confirm state change (zero to one). Reconnect
to ground at TB32-M momentarily and confirm disconnected wire.
state change (one to zero).
FIGURE 30-3. INTERFACE MODULE REALTIME DATA MONITOR
7
9. Crank Sense (IM3-U) - Open the start battery 12. Steering Bleed Pressure switch (IM2-Z) -
disconnect switch so that there is no battery Disconnect the steering bleed down pressure
voltage to the starters. Momentarily short TB28- switch, identified by circuit 33JA, and confirm
J to 24V and confirm state change (zero to one). state change (zero to one). Reconnect the
After removing 24V short from TB28-J, close the switch.
start battery disconnect switch.
13. Brake Lock Switch Power Supply (IM3-L) -
10. Selector Switch (Park) (IM3-T) - Place shift lever Ensure that shift lever is in park position. Use
into park position and confirm 1 state then shift GE's wPTU software to turn on FWD True
into neutral and confirm 0 state. Return shift output signal. Confirm state change (zero to
lever to park position. one). Leave GE FWD True signal on until
11. Selector Switch (FNR) (IM2-N) - Place shift lever completion of step 14.
into park position and confirm 0 state then shift
into neutral, forward, and reverse and confirm 1
state for each of these positions. Return shift
lever to park position.
FIGURE 30-4. INTERFACE MODULE REALTIME DATA MONITOR
8
14. Brake Lock (IM2-i) -Actuate brake lock switch 27. Low Steering Pressure switch 1 (IM2-S) - Short
and confirm state change (zero to one). Turn off wire 33F to ground at TB30-A momentarily and
GE FWD True signal. Confirm input state confirm state change (one to zero).
remains at one. Turn off brake lock switch.
28. Brake Accumulator Pressure switch (IM2-U) -
Confirm input state returns to zero. (The Brake
Momentarily short wire 33BP to ground at TB32-
Lock Switch Power Supply test, item 13, must
E. Confirm state change (one to zero).
be completed before this test can be
successfully completed. Turn off GE FWD True 29. Brake Lock Degrade switch (IM2-V) - Short wire
signal. 33T to ground at TB3 2-F momentarily and
confirm state change (one to zero).
15. Service Brake Set switch (IM3-C) - Short wire
44R at TB31-P to 24 volts momentarily and 30. Keyswitch Direct (IM2-P) - Confirm state is a
confirm state change (zero to one). one. Turn key switch off for 1 second and then
back on. Confirm state changes to zero and
16. Engine Shutdown Delay (IM3-F) - Disconnect
then back to one.
wire 21 INS from the engine ECM at TB27-E
leaving wire 21 INS to IM connected at TB27-E. 31. Auto Lube Level (IM3-W) - Disconnect wire
Momentarily short TB27-E to 24V and confirm 68LS coming from lube level switch to TB34-R
state change (zero to one). Remove short, and at TB34-R while leaving the IM connected.
then reconnect 21 INS to TB27-E. Short wire 6 8LS to ground at TB34-R
momentarily and confirm state change (one to
17. Secondary Engine Shutdown switch (IM3-E) -
zero). Reconnect disconnected wire.
Actuate the Secondary Engine Shutdown switch
and confirm state change (one to zero). 32. Auto Lube Press Switch (IM3-Y) - Short wire
68P to ground at TB35-P momentarily and
18. Key switch (IM3-G) - confirm state is a one.
confirm state change (one to zero).
19. Mode switch 1 (IM3-H) - Actuate the "left arrow”
33. Body Up switch (IM2-R) - For trucks without a
LCD screen navigation switch and confirm state
body installed yet, place a washer on the body
change (one to zero).
proximity sensor, confirm state change, then
20. Mode switch 2 (IM3-J) - Actuate the "OK” LCD remove the washer and confirm state change
screen navigation switch and confirm state again.
change (one to zero).
For trucks with a body installed, make sure that
21. Mode switch 3 (IM3-K) - Actuate the "down the body is lowered all the way, then momentar-
arrow” LCD screen navigation switch and ily disconnect wire 71F at TB35-S and confirm
confirm state change (one to zero). state change (one to zero). Reconnect the wire.
22. Mode switch 4 (IM2-q) - Actuate the "up arrow” 34. Dynamic Retard (IM3-Z) - Momentarily short
LCD screen navigation switch and confirm state wire 74ZA to ground at TB21-D and confirm
change (one to zero). state change (one to zero).
23. Crank Request (IM2-j) - Open the Starter 35. No Propel/Retard (GE CPU Running) (IM2-n) -
Disconnect switch so that there is no battery Confirm the state is zero. Turn OFF the
voltage to the starters. Momentarily turn key keyswitch. Confirm the state changes to one.
switch to the crank position and confirm state Turn ON the keyswitch. Confirm the state
change (zero to one). changes to zero once the drive system is
24. Park Brake Set (IM2-f) - Momentarily disconnect booted up (see the DID panel). This could take
Park Brake Pressure switch, identified by circuit up to 45 seconds.
33, and confirm state change (zero to one).
25. Seat Belt switch (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).
9
Check analog inputs to the interface module 9. Right Front Brake Oil Temp [°C] (IM3-r) -
Disconnect right front brake oil temperature
NOTE: Instead of using a resister in place of a sensor
sensor (circuit 34BT2) and confirm fault A169,
for verifying pressure readings, a calibrated pressure
Hydraulic Oil Temp - Right Front Sensor Low, is
gauge can be installed in the hydraulic circuit to
active. Reconnect sensor.
compare system pressures with the pressures
displayed in the Interface Module Realtime Data 10. Left Front Brake Oil Temp [°C] (IM3-t) -
Monitor program. Disconnect left front brake oil temperature
Verify that the used analog inputs are in the range of
Hydraulic Oil Temp - Left Front Sensor Low, is
the values listed below.
1. Truck Speed [kph] (IM1-g, h) - Use the DID
11. Hoist Pressure 2 [kPa] (IM3-q) - Short wire
panel to simulate vehicle speed and confirm
33HP2 to ground at TB41-G momentarily and
reported speed matches simulated vehicle
confirm fault A203, Hoist Pressure 2 Sensor
speed +/- 2 kph.
Low, is active.
2. Steering Pressure [kPa] (IM3-d) - Disconnect
steering pressure sensor (circuit 33SP) and 12. Hoist Pressure 1 [kPa] (IM3-s) - Short wire
confirm fault A204, Steering Pressure Sensor 33HP1 to ground at TB41-A momentarily and
Low, is active. Reconnect sensor. confirm fault A202, Hoist Pressure 1 Sensor
Low, is active.
3. Ambient Air Temp [°C] (IM3-e) - Confirm
reported temperature matches ambient 13. Battery Voltage 24V [V] (IMint) - Confirm
temperature within 3 °C. reported voltage is +/- 1 volt of actual measured
battery voltage.
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 13.5 +/- 0.5 V. (24V battery voltage Check serial interfaces to the interface module
must be greater that 18 volts). 1. Proper operation of the serial interfaces to the
6. Brake Pressure [kPa] (IM3-p) - Disconnect IM is assured if faults A184, A233, A237, and
service brake pressure sensor located in brake A257 are not active.
cabinet (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 temperature
Hydraulic Oil Temp - Right Rear Sensor Low, is
8. Left Rear Brake Oil Temp [°C] (IM3-i) -
Disconnect left rear brake oil temperature
Hydraulic Oil Temp - Left Rear Sensor Low, is
10
Check outputs from the interface module 3. IM On Signal (IM 1-K) - With key switch on,
confirm voltage on circuit 11 ONS at TB41-B is
NOTE: Before performing these next steps, the key
approximately 0 volts.
switch must be turned off for at least 7 minutes to
allow the IM to completely shutdown. Confirm that the 4. Red Warn output (IM 1-G) and Sonalert output
IM has shutdown by verifying that the green LED on (IM 1-M) - Disconnect the IM from the CAN/RPC
the IM controller has stopped flashing. While network by unplugging its T-connection to the
performing the following IM output checks, ensure network then confirm the following on the dash
that no output short circuit fault codes are reported by panel:
the IM Realtime Data Monitor software. a. All status panel indicators flash on/off.
Verify that the used analog inputs are in the range of b. The red warning indicator flashes on/off.
the values listed below.
c. Two separate audible alarms can be heard
1. Park Brake Solenoid output (IM1-E) - Short the sounding on/off.
engine oil pressure switch wire circuit 36 to
d. A loss of communications message is dis-
ground on TB28-K. Key on and shift into neutral.
played on the speedometer.
Confirm that the park brake solenoid is
energized by verifying that the coil is e. The needles in all of the gauges are moving
magnetized. Use the GE DID panel to set the through their entire range of motion Recon-
truck speed to a speed above 1 kph. Shift into nect the IM to the CAN/RPC network.
park. Confirm that the park brake solenoid 5. Steering Bleeddown Solenoid output (IM 1-P) -
remains energized. Reduce the truck speed to 0 Confirm steering bleeddown solenoid is de-
kph. Confirm that after one second the park energized. Turn key switch off and confirm that
brake solenoid de-energizes. Remove the steering bleed down solenoid is energized by
ground from TB28-K. verifying that coil is magnetized.
2. Start Enable output (IM 1-B) - Disconnect circuit
21 PL from prelube timer prior to performing this
step. Place shift lever in park and confirm that
circuit 21 PS on TB28-H is 24 volts while
cranking. Place shift lever in neutral and confirm
that circuit 21 PS on TB28-H is 0 volts while
cranking. Reconnect circuit 21 PL to prelube
timer.
11
CHECKOUT PROCEDURE
S/N:_____________________
TABLE 1. INTERFACE MODULE INSTALLATION CHECKOUT CHECKLIST
Function Description Expected Result Result (OK/Fail) Comments
DIGITAL INPUT CHECKS:
1 - Hydraulic Tank Level input 1 to 0

2 - Low Steering Precharge input 1 to 0
3 - Pump Filter switches input 1 to 0
4 - Park Brake Released input 1 to 0
5 - Park Brake Request input 1 to 0
6 - GE Batt + input 1
7 - Starter Motor 1 Energized input 0 to 1
8 - Starter Motor 2 Energized input 0 to 1
9 - Crank Sense input 0 to 1
10 - Selector Switch (Park) 1 to 0
11 - Selector Switch (FNR) 0 in PARK,
1 in FORWARD,
NEUTRAL, and
REVERSE
12 - Steering Bleed Pressure input 0 to 1
13 - Brake Lock Switch Power 0 to 1
Supply input
14 - Brake Lock input 0 to 1
15 - Service Brake Set input 0 to 1
16 - Cummins Shutdown Delay 0 to 1
input
17 - Secondary Engine Shutdown 1 to 0
input
18 - Keyswitch input 1
19 - Mode switch 1 input 1 to 0
12
TABLE 1. (Continued)INTERFACE MODULE INSTALLATION CHECKOUT CHECKLIST

23 - Crank Request input 0 to 1
24 - Park Brake Set input 0 to 1
25 - Seat Belt switch 1 to 0
26 - Snapshot input 1 to 0
27 - Low Steering Pressure switch 1 to 0
input
28 - Brake Accumulator Pressure 1 to 0
switch input
29 - Brake Lock Degrade switch 1 to 0
input
30 - Keyswitch Direct input 1 to 0 to 1
31 - Auto Lube Level switch input 1 to 0
32 - Auto Lube Pressure switch 1 to 0
input
33 - Body Up switch input w/o body:1 to 0 to 1
with body: 1 to 0
34 - Dynamic Retard input 1 to 0
35 - No Propel/Retard input (GE 0 to 1 to 0
CPU Running)
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
13
TABLE 1. (Continued)INTERFACE MODULE INSTALLATION CHECKOUT CHECKLIST
9 - Right Front Brake Oil Temp fault A169

10 - Left Front Brake Oil Temp fault A168
11 - Hoist Pressure 2 fault A203
12 - Hoist Pressure 1 fault A202
13 - Battery Voltage (24V) measured battery
voltage +/- 1V
SERIAL COMM CHECKS:
1 - CAN/JI 939, no fault A184,

Drive System CAN/RPC, A233, 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 Panel check Items 4a-e function
as described
5 - Steering Bleeddown Solenoid Solenoid de-ener-
output gized then energized
Completed By: ______________________________ Date: _______________________
14
NOTES
15
980E Dump truck

© 2016 KOMATSU
All Rights Reserved
16
CEN30069-00
980E

980E-4 A40003 and up

KOMTRAX Plus
KOMTRAX Plus software...................................................................................................................................... 3
KOMTRAX Plus controller setup procedure ......................................................................................................... 3
KOMTRAX Plus initialization form ........................................................................................................................ 7
Precautions when replacing the KOMTRAX Plus controller ................................................................................. 8
KOMTRAX Plus controller checkout procedure.................................................................................................. 10
1
NOTES
2
KOMTRAX Plus software and tools KOMTRAX Plus controller setup procedure
Several software programs and tools are required for Preliminary steps
KOMTRAX Plus setup and checkout procedures.
1. The interface module (IM) checkout procedure
• VHMS Technical Analysis Tool Box must be successfully completed and engine
• VHMS Setting Tool startup must be possible before beginning this
setup procedure.
• Service PC with Windows® operating system
(200 MHz processor, 64 MB RAM minimum) 2. Check for KOMTRAX Plus system faults.
• RS232 serial cable (DB9 connector and female a. Connect the service PC to the RS232 port on
connector) the KOMTRAX Plus controller.
• USB port to RS232 serial port adaptor (if no b. Turn the keyswitch to ON but do not start the
RS232 port on service PC) engine.
NOTE: Be aware that the software and data files are c. Run the VHMS Technical Analysis Tool Box
updated periodically. Download the latest versions to confirm that there are no active faults
from the Komatsu extranet at: related to items which will be configured
during the setup procedure. Repair any such
https://www.komatsuamerica.net/northamerica faults before proceeding.
Setup procedure
1. Turn the keyswitch to OFF. Record the following
information on the KOMTRAX Plus initialization
form:
• Truck model
• Truck serial number
• Customer unit number
• Engine 1 serial number
• Engine 2 serial number (usually blank)
• Transmission or alternator serial number
• KOMTRAX Plus controller part number
• KOMTRAX Plus controller serial number
• Orbcomm controller part number
• Orbcomm Plus controller serial number
2. Verify that red LED display (2, Figure 30-1) on
the KOMTRAX Plus controller is off.
3. Disconnect the Orbcomm antenna. (WebCARE
must be ready to receive data before connecting
the antenna.)
4. Turn the keyswitch to ON, but do not start the
engine. Watch the red LED display on the
KOMTRAX Plus controller. After a short time,
the display should start counting upward.
FIGURE 30-1. KOMTRAX PLUS CONTROLLER 5. Connect the service PC to the RS232 port on
1. KOMTRAX Plus 7. Connector CN1 the KOMTRAX Plus controller.
Controller 8. Connector CN2A
2. LED Display 9. Connector CN2B
3. Connector CN3B 10. PLM Status LED
4. Connector CN3A 11. Orbcomm Status LED
5 C t CN4B
3
6. Start the VHMS Setting Tool program, then click 9. Enter the machine information, then click [Next].
[Next].
NOTE: Serial No. must be included and is case
7. Select VHMS Setting, then click [Next]. sensitive.
8. Select Set up & All clear if initializing a truck, 10. Enter the engine information, then click [Next].
then click [Next].
NOTE: Typically, Engine Serial No. 2 is left blank.
4
11. Enter the time zone, date and time. Check [DST 13. Verify that all the setting information is correct,
(Summer Time)] if the truck's location observes then click [Apply].
Daylight Savings Time. Then click [Next].
NOTE: The KOMTRAX Plus time clock is the
master time keeper. The Payload Meter time clock
is synchronized with the KOMTRAX Plus time
clock. Do not set the time in the Payload Meter
controller if the KOMTRAX Plus controller is
operational.
14. Click [YES] to record the old setting and fault

data.
12. Choose the correct GCC setting, then click

[Next].
NOTE: The GCC setting tells Orbcomm which 15. Click [OK]. The setup has been completed.
satellite ground station to use. KOMTRAX Plus will
not communicate with the satellite if this setting is
not correct for the area in which the truck is
operating.
16. Click [OK]. The VHMS Setting Tool program will

close and the KOMTRAX Plus controller will
reboot with the new settings.
5
17. Start the engine and wait for 30 seconds. Verify 25. Verify that the date and time on the download
that the red LED display on the KOMTRAX Plus screen are correct for the current local date and
controller starts counting upward. Press and time and that the displayed service meter hours
hold the data store switch for three seconds to are equal to the value entered previously.
trigger a manual snapshot.
26. Verify that a manual snapshot (MFAO) has been
NOTE: A snapshot taken through KOMTRAX Plus recorded. The display should show an item
records important data about different systems on named "Snapshot" with the code MFAO and the
the truck. Take snapshots on a periodic schedule text "Manual Trigger".
and store them as part of the truck history. These 27. Select the Select All option from the bottom right
snapshots can then be compared and trends can of the window. All items will become checked.
be analyzed to predict future repairs. A single Click the [Download] button.
snapshot records truck data for 7.5 minutes.
NOTE: The download may take one to ten
18. When the Data Store In Progress indicator light
minutes. Generally, if there are several snapshots
is done flashing, wait one additional minute,
in the download items, the download will take
then turn the keyswitch to OFF and stop the
longer.
engine. Verify that the red LED display on the
KOMTRAX Plus controller is off. 28. Verify that the Download Completed message is
displayed, then click [Exit].
19. Turn the keyswitch to ON, but do not start the
engine. Watch the red LED display on the 29. Select the [Machine History] option from the list
KOMTRAX Plus controller. After a short time, on the left side of the window.
the display should start counting upward. Start 30. Verify that the Key ON/OFF and Engine ON/
the VHMS Setting Tool program, then click OFF records are recorded correctly.
[Next].
31. Close the Technical Analysis Tool Box program.
20. Select Review Setting Information, then click
[Next]. 32. Fill in the remaining information on the
KOMTRAX Plus initialization form, then email
the form and the newly downloaded data files to
the address shown on the form.
When a download using VHMS Technical Anal-
ysis Tool Box is performed, several files are
downloaded onto the service PC. They are
organized in a specific way so that they can be
used by VHMS Technical Analysis Tool Box at a
later time. This structure is created automati-
cally when the data is downloaded from the
KOMTRAX Plus controller. The basic path is as
follows:
- Desktop
- My Computer
- Local Disk (C:)
- VHMS_Data
21. Verify that all of the setting information has been - Model
entered correctly, then close the VHMS Setting - Truck serial Number
Tool program. - Date of download (YYYYMMDD)
- Check Number
22. Start the Technical Analysis Tool Box program.
Enter the user name and password. 33. Reconnect the Orbcomm antenna after
WebCARE registration is confirmed by
23. Select the Download icon and the correct
accessing the vehicle data on the website.
communication port when prompted (usually
COM1).
24. Select Connection.
6
KOMTRAX Plus initialization form

This form is available in electronic “fill-in” format, which is preferred. Send request to ServicePrograms@KomatsuNA.com.
fter filling out the form, save the file using the Model Type, Serial Number and “KOMTRAX Plus Initialization” in the file name.
Example: 960E-1-A30003-KOMTRAX Plus Initialization.pdf)
E-mail the completed form to the Service Systems Support Team at ServicePrograms@KomatsuNA.com.
Customer Information
Company Name
Site Name
Customer Employee Contact
Mailing Address
Phone Number
Fax Number
E-mail
Distributor Information
Distributor Name
Distributor Service System Support Administrator Name and E-mail
Distributor Branch
Distributor Branch Employee Contact and E-mail
Distributor 4 + 2 Code
Machine Information
Machine Model And Type
Machine Serial Number
Customer Unit Number
Engine 1 Serial Number
Engine 2 Serial Number
Transmission or Alternator Serial Number
KOMTRAX Plus Controller Part Number
KOMTRAX Plus Controller Serial Number
Orbcomm Controller Part Number
Orbcomm Controller Serial Numbers (5-Digit & 11-Digit)
Setting Tool Information
Setting Date (MM/DD/YYYY)
Setting Time (HH:MM:SS)
GMT (Time Zone)
Daylight Savings Time (DST) (Yes/No)
Service Meter Reading (SMR)
GCC code (Orbcomm satellite)
Orbcomm Activation Date
New WebCARE & MyKomatsu.com User Information
Distributor Name, Branch And Code
Employee Name
Title
E-mail
Primary Area of Responsibility (circle one) Admin Sales Parts Service PSSR Other
Reason for Form Submittal (Check One)
Factory Installed KOMTRAX Plus Initialization
Retrofitted KOMTRAX Plus Initialization
KOMTRAX Plus Controller Replacement
Major Component (Engine/Transmission Replacement)
Customer or Distributor Change
Setting Tool Information Change
New WebCARE & MyKomatsu.com User Request
7
Precautions when replacing the 4. Click [Save].

KOMTRAX Plus controller
When replacing a KOMTRAX Plus controller, use the
following steps to save the data and settings so they
can be transferred from the old controller to the new
controller.
1. Start the VHMS Setting Tool program, then click
[Next].
2. Select When VHMS Needs To Be Replaced,
then click [Next].
5. Click [OK].
6. Replace the controller.

7. Select Use previous setting after replacement of
3. Select Save current setting before replacement
VHMS controller, then click [Next].
of VHMS controller, then click [Next].
8. Verify that the data is the correct data to be
8
loaded, then click [Next]. 10. Enter the correct Time Zone, Date and Time
information. Check [DST (Summer Time)] if the
truck's location uses Daylight Savings Time.
Click [Apply].
9. If the correct data is not shown, click [Select

File] and choose the correct data, then click
[Next].
10. Click [OK].
11. Click [OK]. The VHMS Setting Tool program will

close.
9
KOMTRAX Plus controller checkout 8. At the prompt >, type "ver". Something similar to
procedure the following will be displayed:
NOTE: In addition to the software and tools specified
in the topic "KOMTRAX Plus software", serial
communications software such as Tera Term Pro is >ver
required for the checkout procedure. VHMS OS Ver 1.6.5.1 Mar 01 2004 16:37:25
Preliminary steps >
1. The KOMTRAX Plus controller setup procedure

must be successfully completed and the 9. At the prompt, type "dispvhmsinf". Something
interface module most be fully functional before similar to the following will be displayed:
beginning this checkout procedure.
2. Check for KOMTRAX Plus system faults.
---- MACHINE INFORMATION --------
a. Connect the service PC to the RS232 port on PRODUCT GROUP: Dumptruck
the KOMTRAX Plus controller.
MACHINE_MODEL: 830AC-
b. Turn the keyswitch to ON but do not start the
MACHINE_SERIAL:
engine.
ENG_MODEL: QSK60
c. Run the VHMS Technical Analysis Tool Box
ENG_SERIAL_NO1:
to confirm that there are no active faults
related to items which will be configured ENG_SERIAL_NO2:
during the setup procedure. Repair any such PRG_NO1: 12000100100
faults before proceeding. PRG_NO2: 782613R290
Checkout procedure ---- DEVICES ------------------------
PLC NO CONNECTION
1. Turn the keyswitch to OFF position and stop the
engine. Verify that red LED display (2, PLM23 Disabled
Figure 30-1) on the KOMTRAX Plus controller is PLM3 CONNECTED
off. ---- Condition --------------------
2. Turn the keyswitch to ON, but do not start the SMR: 90.0 H
engine. Watch the red LED display on the DATE 04-10-25 TIME14:44:24
KOMTRAX Plus controller. After a short time, TIMEZONE: 0.0 H SUMMERTIME 0
the display should start counting upward.
----Controller Info -------------------
3. Connect the service PC to the RS232 port on PartNumber: 0000000000
the KOMTRAX Plus controller.
Serial No.: 000000
4. Start the Tera Term Pro serial communications Compo Name: KDE1010
program.
SilkyID: VA011740744
5. Setup the software by selecting the appropriate
COM port and a baud rate equal to 19200 in the
program window. Use the actual results of the displayed information to
6. Wait for five seconds, then hold down the CTRL confirm that the correct software is installed in the
key and type "VHMS". (No letters will appear on KOMTRAX Plus controller.
the screen while typing.)
7. After "VHMS" has been typed, some text
followed by a prompt > will be displayed. This
confirms that proper communication between
the service PC and KOMTRAX Plus controller
has been established.
10
10. Verify the Orbcomm connection status by

checking Orbcomm status LED (11, Figure 30-
1) on the KOMTRAX Plus controller. The
Orbcomm status LED is the “dot” following the
second seven-segment LED character.
• If the LED is OFF, the connection between
the KOMTRAX Plus controller and
Orbcomm is bad. Troubleshoot the
connection. Refer to the Troubleshooting
section Orbcomm.
• If the LED is ON solid, the connection
between the KOMTRAX Plus controller and
Orbcomm is good. This is OK.
• If the LED is FLASHING, the Orbcomm
satellite signal is established. This must be
verified and may take as long as 15 minutes
to occur.
11
980E Dump truck

© 2016 KOMATSU
All Rights Reserved
12
CEN30070-00
980E

980E-4 A40003 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 like 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".
FIGURE 30-1. PLM IV CONTROLLER 6. Click on "Internet Protocol Version 4 (TCP/
1. USB 2.0 Ports 3. RJ45 Ethernet Port IPv4)" to highlight the option.
2. Status Window 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 PLMIV controller.
For example, if PLMIV has an assigned IP

address of 192.168.3.123, set the IP address of
the service PC to 192.168.3.124. The last three
numbers can be any number between 1 and
254, but not 123 since that is already assigned
to the PLM IV in this example.
• Subnet Mask: 255.255.0.0
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 10 minutes to complete. Do not
turn off 24V truck power during this process.
The completion percentage will be shown and
periodically updated on the web page as the FIGURE 30-3. PLM IV HOME PAGE
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 • Truck Model: There are many different truck
models available for selection. The correct truck
1. Ensure that the PLM IV software is up-to-date.
model must be selected for the payload meter to
2. Install one resistor (58B-06-03100) in place of accurately estimate payloads.
each of the suspension pressure sensors. The
• PLM IV Mounting Orientation: It is important to
resistors will provide a test load between circuit
configure the payload meter according to its
39F and each of the sensor circuits 39FA, 39FB, mounted position in the auxiliary control cabinet.
39FC and 39FD. Refer to Figure 30-4 to identify which wall the
3. In the auxiliary control cabinet, use a voltmeter payload meter is mounted on in the auxiliary
to check the PLM IV controller input voltage control cabinet.
between circuit 39G and 0 (ground). This should
be 24VDC supplied by the batteries.
4. Turn the engine start switch to ON.
5. In the auxiliary control cabinet, use a voltmeter
to check the PLM IV sensor supply voltage
between circuit 39F and 0 (ground). This should
be 18 ± 1VDC.
6. Use a Cat5e ethernet cable to connect the FIGURE 30-4. PLM IV CONTROLLER
service PC to RJ45 ethernet port (3, Figure 30- MOUNTING ORIENTATION
1) on the PLM IV controller.
7. Log on to the PLM IV home page. Refer to
Figure 30-3. • Display Units: This parameter can be set to
8. Click on the "System Configurations" link. There display measurements in metric tons, short tons
are eight parameters that can be set from this or long tons.
web page. There is no need to reboot the • Pressure Sensor Units (Real Time Data):
payload meter after updating any of these Select kg/cm3 or psi for the values displayed on
parameters. the Real Time Data web page only.
NOTE: Some of the parameters require a password • Date and Time: If the truck is equipped with
to change. The password for all parameters except KOMTRAX Plus, this parameter of the will be
the Payload Gain is Kac2300. This password is case automatically updated when the truck is
sensitive. The password for the Payload Gain powered up. If not, the date and time must be
parameter is not included in this document. set. This parameter will be lost after
approximately 30 days without truck power up.
• Payload Load Light Test: Proceed to step 10
to perform this test.
• Payload Gain Factor: The default parameter is
100%, but it is adjustable between 90% and
110%. It is recommended that this parameter
not be changed. A change in this value will
affect all payload calculations, which may cause
errors.
• Truck Tare Reset: This function forces the
payload meter to reset the truck tare to its
default value. Do not use this function unless
the payload meter state machine is locked up or
has calculated an unusually low tare value.
Check the system for a Sensor Low Pressure
alarm.
5
10. To test the functionality of the payload meter Test the following combinations and confirm
lamps and wiring, turn on the brake lock. Click proper light function:
on the check box next to the light(s) to be
• Green ON, Amber OFF, Red OFF
tested. The lights can be set ON/OFF for five
minutes from this web page. After five minutes, • Green OFF, Amber ON, Red OFF
the lights will return to their default states. • Green OFF, Amber OFF, Red ON
• Green OFF, Amber OFF, Red OFF
FIGURE 30-5. PLM IV SYSTEM CONFIGURATIONS PAGE
6
11. Return to the PLM IV home page. Click on the 13. Return to the PLM IV home page. Click on the
"Truck Data Configuration" link to set the "View Real Time Data" link to check the current
following parameters: status of various PLM IV inputs and outputs.
• Frame Serial Number: This is located on a a. The sprung weight shown includes the
plate that is mounted to the truck frame. This weight of the truck. With the load provided by
field will hold up to 20 alpha-numeric characters. the resistors installed in step 2, the nominal
• Customer Unit: This is number assigned by value should be 113 metric tons (125 short
most mining operations to each truck in its fleet. tons).
This field will hold up to 20 alpha-numeric b. Confirm that all suspension pressures are
characters. within the acceptable range. The nominal
• Distributor: This is the name and/or number values should be 25.6 ± 6.4 kg/cm2 (364 ± 91
assigned to the distributor that installed the psi).
payload meter system. This will be used for
warranty claims. This field will hold up to 20 * Record on Data Sheet
alpha-numeric characters. c. Check the inclinometer reading. Calibrate if
• Customer: This is the name and/or number necessary.
assigned to the customer or mine site where the * Record on Data Sheet
truck is in service. This will be used for warranty
claims. This field will hold up to 20 alpha- d. To confirm that the body up input is function-
numeric characters. ing properly, place a steel washer on the
body up switch. The reading in the Real Time
Enter the password Kac2300 and click on the Data window should be "OFF". When the
"Save Truck Data" button to save these parame- washer is removed, the reading should be
ters. This password is case sensitive. "ON".
12. Check the PLM IV software version on the * Record on Data Sheet
"Truck Data Configuration" page.
e. To confirm that the brake lock input is func-
* Record on Data Sheet tioning properly, activate the brake lock
switch. The reading in the Real Time Data
window should be "ON". When the switch is
deactivated, the reading should be "OFF".
FIGURE 30-7. TRUCK DATA CONFIGURATION

FIGURE 30-6. TRUCK DATA CONFIGURATION PAGE
PAGE
7
f. Ensure that the brake lock is OFF. Use the 18. On the PLM IV home page, click on the "View
DID panel on the rear wall of the operator alarms" link to view the list of alarms.
cab to provide a speed signal of 40 kph (25
All active alarms will be saved within five sec-
mph). Confirm that the speed value is dis-
onds. Confirm that the four alarms occurred in
played on the speedometer and on the Real
the order in which the resistors were removed:
Time Data window.
* Record on Data Sheet • Left front suspension low
14. Remove the resistor from the left rear • Left rear suspension low
suspension pressure sensor. Wait for at least • Right rear suspension low
one minute.
• Right front suspension low
15. Remove the resistor from the left rear
19. Turn the engine start switch to OFF. Close all
suspension pressure sensor. Wait for at least
windows on the service PC, then disconnect the
one minute.
service PC from the PLM IV controller.
16. Remove the resistor from the right rear
one minute.
17. Remove the resistor from the right front
one minute.
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
980E Dump truck

© 2016 KOMATSU
All Rights Reserved
10
CEN30053-01
960E
980E

960E-2 A30074 and up
980E-4 A40003 and up

Electrical system, AC drive
Checks prior to self load engine test (loadbox)................................................................................................... 20
Engine running tests ........................................................................................................................................... 22
Diagnostic information display (DID) panel ......................................................................................................... 34
Viewing event and statistical data ....................................................................................................................... 64
Logic screens...................................................................................................................................................... 68
Datalogger function ............................................................................................................................................. 70
Uploading data .................................................................................................................................................... 74
1
General information
Test equipment
Test equipment that is required to fully test the AC
drive system include: Hazardous voltages may be present in this
• One or two Portable Test Units (PTU) or laptop equipment even if the engine and capacitor
computers charge lights are off. Use measurement and
protective equipment rated for 2000VDC
• One digital multimeter minimum to verify that no voltage is present
• One analog multimeter before touching any terminal. Verify functionality
of the measurement equipment using site-
• Several jumper wires
approved procedures both before and after
• One 500 volt megger performing control group measurements. Failure
The Portable Test Unit (PTU) (with wPTU Toolbox to observe these precautions may result in death
software) is used to: or serious personal injury.
• test and adjust system parameters on the truck

• view and download system information If a VOM reading is significantly different from the
value listed in the Table 2, consult the system
• upload software to the propulsion system. schematic and inspect the affected circuit, checking
NOTE: In this section, details on access and use of connections and replacing components and wiring as
specific wPTU Toolbox programs are described. For required.
a complete description of using the wPTU Toolbox,
NOTE: Link capacitance will cause the initial
refer to the appropriate GE manual.
resistance reading to be inaccurate. Wait for
There are four, 1 amp, blade style fuses located on resistance value to stop changing before taking a
the control panel for the speed sensors. Two fuses final reading. This may take several seconds.
are for the front wheels and the other two are for the
rear wheels. One green LED is located next to each Table 2: DC Link VOM Reading
fuse. These LEDs indicate whether the fuse is blown.
If the LED is not lit, the fuse needs to be replaced. VOM
+ VOM Lead - VOM Lead
Reading
Circuit continuity and resistance checks DC+ Link Bus Bar Cabinet Ground 1185 ohms 1
The following circuit continuity and resistance checks DC- Link Bus Bar Cabinet Ground 1185 ohms 1
must be performed prior to energizing the propulsion
DC+ Link Bus Bar DC- Link Bus Bar 1150 ohms 2
system equipment. These procedures require the use
of a volt ohmmeter (VOM) that is set for resistance DC- Link Bus Bar DC+ Link Bus Bar 5.5 ohms 2
measurements. 1
If GNDB1 (ground block) is disconnected from the Ground
Resistor Panel (GRR), both the DC + and DC - resistance to
ground readings will be higher.
2
Set the VOM on R1 scale to avoid charging capacitors.
2
Megger test for grounds

The control equipment circuitry is classified in two
major categories: main power circuit and alternator
field control. Both circuit categories must be
separately prepared for megger testing. Check the polarity of the suppression modules
across all coils: relays, contactors and reverser.
If any are reversed, output channels on the digital
input/output cards can be damaged during
attempts to energize.
Hazardous voltages may be present in this Do not use a bell ringer wiring tester. Use an
equipment even if the engine and capacitor ohmmeter or light continuity tester.
charge lights are off. Use measurement and Before removing any of the cards in the
protective equipment rated for 2000VDC electronics panels, turn battery power to the
minimum to verify that no voltage is present control system OFF.
before touching any terminal. Verify functionality Do not put a shorting wire on the terminal boards.
performing control group measurements. Failure
Preparation for megger test
to observe these precautions may result in death
or serious personal injury. Perform the following procedure to prepare for a
Electric shock can cause serious or fatal injury. megger test by either removing wiring connections,
To avoid such injury, personnel must take and insulating, jumping, or preparations indicated by the
observe proper precautions when making system instructions. Use shorting wire for jumping
adjustments or performing system or component procedures. However, be careful not to short devices
electrical tests. to ground or to the wrong devices.
Personnel must not touch and remain clear of all The truck must be grounded. Ensure that all earth
components, cables, or terminals during and ground connections and ground blocks are
after megger testing due to electrical hazard. connected and grounded.
Insulating gloves must be worn by personnel
performing the megger test.
Use a megger with a discharge setting. Failure to
do so may result in death or serious personal 1. Ensure that the truck directional control lever is
injury. in PARK and the rest switch is in the REST
position.
The DC link will hold a capacitor charge after
megger testing the main power circuit. Allow 2. Shut down the engine.
sufficient time for it to discharge. Failure to 3. Disable the 24VDC electrical system by moving
observe these precautions may result in death or the master disconnect switch to the OFF
serious personal injury. position.
A successful megger test must be performed on 4. To ensure that the link will not be energized
the power circuits before attempting a ground during test and repair procedures, move
circuit test. If a ground exists when the test generator field contractor (GF) switch (2, Figure
ground is introduced, the introduced ground wire 30-1) in the control cabinet to the CUTOUT
may melt. Always perform the megger test to position by pulling the switch out and moving
avoid introducing another ground in the power the switch downward.
circuit. Failure to observe these precautions may
result in death or serious personal injury. 5. For first commissioning, disconnect all DSC
connectors.
6. Remove CN1 connector from the power supply.
3
7. Disconnect the round connector from the top of 14. Install a jumper wire between the DC+ link and
the gate driver power converters (GDPC1 and DC- link power. The jumper wire maybe
GDPC2). installed inside the left control cabinet door at
10. Disconnect the CCLR1 and CCLR2 connectors. the top on cables DCP08 and DCN08. See
Figure 30-2.
11. Disconnect the round output connectors from all
VAMs (VAM1, VAM2, VAM3, and VAM4).
12. Remove the wires from ground block located
near the DSC panel. Ensure that all removed
ground wires are insulated from ground and
from other wires. A wire that makes contact with
ground or any other wire may affect the megger
test results.
13. Remove the arc chute from GF contactor (1,
Figure 30-1) and install a jumper between main
contactor tips (2).
FIGURE 30-2. JUMPERING THE DC BUS
2 1. Jumper Wire (DCP08 to DCN08)
86299
FIGURE 30-1. JUMPERING GF CONTACTOR TIPS

1. GF Contactor 2. Contactor Tips
4
Megger test procedure 5. Switch the megger to the DISCHARGE setting

and wait a minimum of 30 seconds before
The DC link, chopper modules, all inverters, rectifier,
proceeding.
main alternator three phase output, and
interconnecting power cables are checked in this 6. Use a 2000 VDC meter to verify that the DC link
portion of the megger test. is discharged.
Connected wheel motors will also be meggered 7. Carefully ground the DC link by connecting a
during the test through a diode path in the inverter ground wire to the GF main contactor tip
phase modules. The megohm reading will be the (megger connection point). Personnel must
same unless the wheel motor cables or wheel motors remain insulated from the circuit and the ground
are grounded. wire while grounding the GF main contactor tip.
To megger the main power circuit: 8. Remove DCP jumper to ground.

1. Jumper the GF main contactor tip to ground. 9. Disconnect the megger leads from the
connection points.
2. Connect megger leads between the DC+ link
DCP08 wire (located inside the left control
cabinet door at the top) and ground. Ensure that If no faults were found, remove the shorting wires
the ground connection (Figure 30-2) is a and reconnect all wires and cables previously
chassis ground. disconnected for this test as follows:
3. Set the megger for 1000 VDC and activate the 1. Remove the jumper wire between contactor tips
megger to apply 1000 VDC to the circuit. (2, Figure 30-1) and reinstall the arc chute to GF
4. The megger reading should exceed 1 megohm. contactor (1).
If the megohm reading is less, then discharge 2. Remove the jumper wire from the DC+ link to
the circuit, troubleshoot, and retest when the the DC- Link. The jumper wire is installed inside
problem is resolved. To aid in finding a fault, the left control cabinet door at the top on cables
refer to "Troubleshooting for grounds". DCP08 and DCN08. See Figure 30-2.
5. Switch the megger to the DISCHARGE setting 3. Connect the round output connectors from all
and wait a minimum of 30 seconds before VAMs (VAM1, VAM2, VAM3, and VAM4).
proceeding.
4. Connect the ground wires to the ground block
6. Use a 2000 VDC meter to verify that the DC link located near the DSC panel.
is discharged.
5. Connect the CCLR1 and CCLR2 connectors.
7. Remove the GF tip to ground jumper.
6. Connect all DSC connectors. For subsequent
8. Disconnect the megger leads from the megger testing, insert the control cards from the
connection points. backplane connections.
7. Reapply CN1 connector at the power supply.
The alternator field (rotor), tertiary, and associated 8. Connect the round connector on the top of the
cables and components are meggered from a single gate driver power converters (GDPC1 and
point. To megger these components and circuits: GDPC2.
1. Jumper DCP to ground. 9. Move generator field contractor (GF) switch (2,
2. Verify that the truck is set up to perform a Figure 30-3) in the control cabinet to the
megger test according to the "Preparation for NORMAL position by moving the switch
megger test". upward.
3. Connect a megger between the GF main 10. Enable the 24VDC electrical system by moving
contactor tip and ground. the master disconnect switch to the ON position.
4. Set the megger for 1000 VDC and activate the
megger to apply 1000 VDC to the circuit.
5
Troubleshooting for grounds Low voltage power supply checks

1. Visually inspect the truck for the following:
• Moisture, oil, or debris in or on motorized
wheels, alternator, grid resistors, main control
cabinet, and power cables
• Any wire or metal that might be touching It is important to note that printed circuit cards in
exposed connections the electronic control card panels are sensitive to
• Frayed or rubbing cables static electricity. Handling cards without proper
grounding precautions could damage electronic
2. If the visual inspection does not locate the components mounted on them. Also, when
cause, follow the megger procedures to isolate transporting or storing these cards, industry
the ground to one of the three major loops. recommended, special static electricity-proof
3. Once the ground has been isolated to a containers must be used.
particular loop, that loop should be broken down Always turn the control power switch (CPS) to
into smaller sections and megger tested again. OFF before removing or installing control cards
NOTE: Subdividing the grounded section should in electronic panels. Failure to do so will result in
continue until the ground is isolated in a particular card and/or panel equipment damage.
cable or piece of equipment. Then take the
appropriate measures.
Preparation for power supply checks
4. If the ground occurs in a motorized wheel or
alternator, check the unit by removing all 1. Open the door to the low voltage area on the
connections and megger test the circuit again. right side of the control cabinet.
5. Perform a detailed inspection of the unit 2. Remove control power by moving control power
following the guidelines of the inspection made switch (1, Figure 30-3) downward to the OFF
in step 1. position. Then move generator field contractor
(GF) switch (2) to the CUTOUT position by
6. If no reason for the ground can be determined, pulling the switch out and moving the switch
or if the problem cannot be corrected, removal downward.
of the unit for repair at an authorized shop will
be necessary.
7. If the ground is isolated to the dynamic retarding
assembly, disconnect all cables leading to it and
megger test the dynamic retarding assembly.
8. If the ground is still present, thoroughly inspect
the dynamic retarding assembly for any obvious
problems such as frayed or rubbing cables and
water or debris inside the dynamic retarding FIGURE 30-3. INFORMATION DISPLAY PANEL
assembly.
1. Control Power Switch
9. If the inspection does not locate the cause,
2. Generator Field Contractor (GF) Switch
isolate the two halves of the dynamic retarding
3. Capacitor Charge Light
assembly and megger test to localize the
ground to one side or the other.
10. If the ground occurs on the blower motor side of
3. Disable the 24VDC electrical system by moving
the dynamic retarding assembly, disconnect the
the master disconnect switch to the OFF
motor and check for grounds in the unit once
position.
again.
4. Remove the 50 amp control circuit system fuse
11. If the ground is still present in the dynamic
(BATFU) located on the upper left wall of the low
retarding assembly, it will be necessary to
voltage cabinet.
disconnect each resistor section until the
grounded section is found.
6
5. Disconnect the Drive System Controller (DSC) Drive System Controller (DSC) card checks
cards from their backplane connectors. Verify
that all DSC panel connectors are connected.
Power supply check procedure

NOTE: During the course of these checks, if a
reading is significantly different from the expected It is important to note that printed circuit cards in
value, consult the system schematics, inspect the the electronic control card panels are sensitive to
circuit, check connections, and replace components static electricity. Handling cards without proper
as required. grounding precautions could damage electronic
components mounted on them. Also, when
1. Enable the 24VDC electrical system by moving transporting or storing these cards, industry
the master disconnect switch to the ON position. recommended, special static electricity-proof
Check the polarity of the battery voltage at the containers must be used.
location where BATFU was removed.
Always turn the Control Power Switch (CPS) to
The BATFU input side should read positive bat- OFF before removing or installing control cards
tery voltage (less than 30 VDC) to ground (bat- in electronic panels. Failure to do so will result in
tery common or negative), and the other side card and/or panel equipment damage.
should read 0 VDC to ground (battery common
1. Remove control power by moving control power
or negative).
switch (1, Figure 30-3) downward to the OFF
2. Disable the 24VDC electrical system by moving position.
the master disconnect switch to the OFF
2. Verify that the DSC card is properly installed
position. Reinstall the BATFU fuse.
and connected.
3. Enable the 24VDC electrical system by moving
3. Locate the POWER and RESET LEDs at the
the master disconnect switch to the ON position.
bottom of the DSC CPU card.
Turn the key switch in the operator cab to ON to
enable control power availability to the 4. Move the control power switch upward to the
propulsion system. ON position. The LEDs on the card should
initially turn on. The RESET LED should turn off.
4. Move the control power switch upward to the
ON position. If the RESET or neither LED remains illumi-
5. On the FH41 power supply (located in the nated, it may indicate a faulty CPU card or a
control area of the cabinet to the left of the DSC problem with the +5V power supply in that
panel), check the green status LEDs. Verify that panel.
all five LEDs (+15V, –15V, +5V, +24V, –24V) are 5. Replace the card if it is faulty.
illuminated.
6. Verify that the DID panel in the operator cab is
illuminated and shows DISPLAY IS READY
message.
7
Propulsion system software installation 2. After connecting the ethernet cable and
determining the IP address, start a Telnet
Preparation for software installation session. Telnet is a utility that is provided in
Truck configuration can be completed through the most operating systems or other communication
console method as described in the following packages.
sections. 3. Go to START -> PROGRAMS ->
After the DSC CPU card has been properly set up, ACCESSORIES -> RUN. In the RUN window,
the user can choose to modify mine-specific type “telnet 192.168.x.x” with x.x being the
configuration options. Using the console method specific port to which the PC is connected.
requires using the methods for connecting to an CPU The connection is successful if a login prompt
card debug console first. appears.
NOTE: A password will be required before
proceeding. Passwords are supplied by your
To use the console method for configuring the
Komatsu representative.
software:
1. At the xxx> prompt, type “config” then press
To connect using the RS232 serial cable: ENTER.
1. Connect the cable from the PC to the front edge 2. A list of possible configuration screens will
DB9 on the CPU card. appear:
2. Set up the parameters fields as follows: • OEM Options (1)
• Bits per second: 115200 • OEM Options (2)
• Data bits: 8 • Engine Screen
• Parity: None • Set Overspeeds Screen
• Stop bits: 1 • Set Wheel Motor Types Screen
• Flow control: None • Display (Diagnostic Information Display, DID)
Screen
NOTE: The COM port number selected depends on
the setup of the PC. • OEM Custom Settings
3. To view or edit options from one of the screens,
type “config <screen #>”. For example, to
To connect using an ethernet cable: change OEM Options (1), type “config 1” for
1. Connect the cable from the PC to one of the access.
locations in Table 3. RJ45 to RJ45 is required. 4. A list of variables and their present settings
become available on the screen. Typing “config
Table 3: Ethernet Connection Options 1” would show the following options (listed in
order of appearance):
Slot RJ45 Location IP Address
2 Front edge 192.168.0.1 • 10.0 MPH OEM Speed Option 1 (1, 50)
6 Switch 1 192.168.1.1 • 25.0 MPH OEM Speed Option 2 (1, 50)
6 Switch 2 192.168.2.1 • 2100.0 Engine OEM Speed Option (500,
3000)
• 5.0 Dump Body Up Speed Limit (0, 20)
NOTE: The PTU or PC should obtain an IP address
automatically. A DHCP server is running on the CPU • 15.0 Dump Body Up Speed Limit (with
Override) (5, 20)
card and will issue an IP address to the PC.
• 1.0 Dump Body Up Retard enable at Max
NOTE: A login name and password will be supplied Speed (0, 1)
separately by your GE representative.
• 0.0 External OEM Accel Inhibit Enabled (0, 1)
8
5. To change one of these options, choose the

screen, option number, and new value:
config <screen><option><value>
For example, to change OEM Options (1),
option 4 “15.0 Dump Body Up Speed Limit (with Do not cycle power once application of software
Override) (5, 20)”, type the following: starts to download. Equipment damage may
result.
config 1 4 7.5
The user will see “15.0” change to “7.5” in the
numbered list of options.
NOTE: The user should verify the settings on all of
the screens. When finished modifying the Hazardous voltages are present in this
configuration parameters, cycle power to the control equipment. Use caution and avoid touching any
group. The card is now set up and configured for energized equipment when the door to the low
operation. voltage area is open. Failure to do so may result
NOTE: The UP arrow can be used in the console to in death or serious personal injury.
retrieve the previous commands.
3. Enable the 24VDC electrical system by moving

the master disconnect switch to the ON position.
Software installation procedure
Turn the engine start switch to the ON position.
Before new software can be loaded into a truck’s 4. Remove control power by moving control power
propulsion system, configuration files must be switch (1, Figure 30-3) downward to the OFF
created for each truck model, and truck model position.
specific parameters must be recorded using a USB
flash drive. 5. Insert the USB drive into the front edge USB
connector to the card that is being programmed.
1. Download the desired software versions to the Jumper the download pin and the ground pin on
PC. the top edge of the card, then move the control
To update the application software only, there power switch upward to the ON position.
will be a single file: When the STATUS 3 and STATUS 4 LEDs are
• ohv_xxx.bin (xxx is the version number) solidly illuminated, remove the jumper. If these
two LEDs do not illuminate, the jumper was not
recognized. Move the control power switch
To update the operating system and application downward to the OFF position, ensure that the
software, there will be two files: jumper is making a solid connection, and try
again.
• os_xxx.bin
• ohv_xxx.bin
2. Copy the files from the PC to a USB drive.
9
6. The CPU card will boot up and automatically DSC manual test procedures
find and copy the new software from the USB
Perform the following procedure to manually check
drive to the CPU card.
certain DSC controlled outputs and DSC monitored
7. Wait for the light sequence to be solid GREEN inputs to verify proper wiring and component
(operating system and application updates) or operation.
cycling RED (application only updates).
1. Ensure that the truck directional control lever is
8. Move the control power switch downward to the in PARK and the rest switch is in the REST
OFF position and remove the USB drive. position.
9. Move the control power switch upward to the 2. Shut down the engine.
ON position. Wait for the CPU card to boot up. If
3. Connect an RS232 serial cable or ethernet
all four STATUS LEDs begin to flash
cable to the DSC.
simultaneously, the software needs to be
configured. Refer to "Preparation for software 4. Move control power switch (1, Figure 30-3)
installation". upward to the ON position.
NOTE: If installing the application only update, the 5. Start the wPTU Toolbox program on the PTU or
card must be instructed to use the new software. If laptop computer. At the login screen, select
installing both operating system and application Normal mode, enter a password, and click on
updates, this is automatically done. LOGIN to wPTU Toolbox. See Figure 30-4. A
truck model will be automatically selected. The
To instruct the card to use the new software, start and PTU screens window will appear on the screen.
login to a console window. Refer to "Preparation for
software installation" for instructions on opening a
console window.
10. At the OHV-xxx> prompt, type “list_apps” to
display available application versions to run.
11. At the OHV-xxx> prompt, type “change_app
ohv_xxx.bin” where “ohv_xxx.bin” is the desired
application version to be run.
The card will reboot and launch the new soft-
ware version.
12. After reboot, verify the software version(s) by
using the wPTU, DID, or console.
FIGURE 30-4. wPTU TOOLBOX LOGIN SCREEN
10
6. In the PTU screens window, go to

Ptu_Screens -> Inverters -> Special_Tasks ->
Engine_Stopped_Tasks -> DSC Manual Test.
7. After clicking on DSC Manual Test, the DSC
Manual Test window will be displayed in the
activity portion of the wPTU program screen.
Perform the following digital output checks from
the DSC Manual Test window. See Figure 30-5.
a. In the Toggle Digital Outputs section of the
screen, click on GF to highlight it. The
generator field contractor (GF) switch must
be in the NORMAL position. Verify that the
GF contactor picks up and that GFFB is
highlighted in the Inputs section of this
screen. Click on GF again in the TDO section
of the screen to de-energize GF.
b. In the Toggle Digital Outputs section of the
screen, click on GFR to highlight it. Verify
visually that the GFR contactor picks up.
Click on GFR again to de-energize GFR.
c. In the Toggle Digital Outputs section of the
screen, click on RP1 to highlight it. Verify that
the RP1 contactor picks up and that RP1FB
is highlighted in the Inputs section of the
screen. Click on RP1 again to de-energize
RP1.
d. In the Toggle Digital Outputs section of the
screen, click on RP2 to highlight it. Verify that
the RP2 contactor picks up and that RP2FB
is highlighted in the Inputs section of this
screen. Click on RP2 again to de-energize
RP2.
e. If equipped, in the Toggle Digital Outputs
section of the screen, click on RP3 to
highlight it. Verify that the RP3 contactor
picks up and that RP3FB is highlighted in the
Inputs section of this screen. Click on RP3
again to de-energize RP3.
f. In the Toggle Digital Outputs section of the
screen, click on AFSE to highlight it. Verify
that there is 24VDC to ground on the AFSEL
wire to ground (+25 on the GFM). Click on
AFSE again to de-energize AFSE.
11
FIGURE 30-5. DSC MANUAL TEST WINDOW
8. Perform the following digital input checks 10. Click on the target icon above the wPTU
a. With the engine start switch and the control program activity portion of the screen to go back
power switch ON, verify that the following to the wPTU Toolbox Login screen. Close the
items in the Inputs section of the screen are wPTU program, shut down the PTU, and
illuminated: KEYSW, CPSFB, CNFB, and disconnect the cable from the DSC port on the
GFNCO. truck.
b. BRAKEON will be highlighted in the Inputs

section if the service brakes are applied.
Otherwise, it will be off.
9. Activate each available switch in the Toggle
Digital Outputs section one at a time by
clicking on the button. Monitor the indicator
lights in the operator cab and the DSC Manual
Test window command and feedbacks
associated with the button to ensure proper
operation. Any circuit that is not responding
properly requires troubleshooting and repair
before attempting the DSC Manual Test again.
12
Accelerator pedal, retarder pedal, and retarder 6. In the PTU screens window, go to
lever calibration and checks Ptu_Screens -> Inverters -> Normal_Operation -
> Configuration -> Pedal Calibration.
When installing software on a truck, the accelerator
pedal, retarder pedal, and retard lever must be 7. After clicking on Pedal Calibration, the DSC
calibrated. The calibration must be checked Pedal Calibration window will be displayed in
afterward to ensure proper operation. The following the activity portion of the wPTU program screen.
procedure is for recording and checking the Click on Run PTU Calibration. See Figure 30-
propulsion system for the specific truck pedals and 7.
the retard speed control (RSC) potentiometer values. 8. Fully depress the accelerator pedal and then
release.
9. Fully depress the retarder pedal and then
Calibration procedure for pedals and retarder
release.
lever
10. Fully move the retarder lever and then release.
NOTE: The DID panel is the recommended method
for pedal calibration. Use the following PTU The calibration process is complete.
procedure if the DID panel is not functional.
in PARK and the rest switch is in the REST
position.
2. Shut down the engine.
cable to the DSC.
4. Move control power switch (1, Figure 30-3)
upward to the ON position.
5. Start the wPTU Toolbox program on the PTU or
laptop computer. At the login screen, select
Normal mode, enter a password, and click on
LOGIN to wPTU Toolbox. See Figure 30-6. A
PTU screens window will appear on the screen.
13
FIGURE 30-7. DSC PEDAL CALIBRATION WINDOW
Pedals and retarder lever operation check

position.
cable to the DSC.
PTU screens window will appear on the screen. FIGURE 30-8. wPTU TOOLBOX LOGIN SCREEN
14
6. In the PTU screens window, go to e. Record the value for RETARD PEDAL with
Ptu_Screens -> Inverters -> Normal_Operation - the pedal FULL ON (typical value is 8.0
> Real_Time -> DSC - Analog Inputs. VDC).
7. After clicking on DSC - Analog Inputs, the DSC f. Record the value for RETARD LEVER FULL
Analog Inputs window will be displayed in the OFF (typical value is 1.25 VDC).
g. Record the value for RETARD LEVER FULL
See Figure 30-9. Perform the following
ON (typical value is 8.0 VDC).
procedure from the DSC Analog Inputs window.
h. Pull up on the retard speed control (RSC)
a. Record the value for POTREF (typical value
switch and record the value for RSC POT
is 10.8 VDC).
with the knob turned FULLY CLOCKWISE
b. Record the value for ACCEL PEDAL with the (typical value is 0.1 VDC).
pedal FULL OFF (typical value is 1.6 VDC).
i. Record the value for RSC POT with the knob
c. Record the value for ACCEL PEDAL with the turned FULLY COUNTERCLOCKWISE
pedal FULL ON (typical value is 8.5 VDC). (typical value is 10.7 VDC).
d. Record the value for RETARD PEDAL with j. Close the DSC Analog Inputs window by
the pedal FULL OFF (typical value is 1.25 clicking on the X in the upper right corner of
VDC). the window.
FIGURE 30-9. DSC ANALOG INPUTS WINDOW
15
8. In the PTU screens window, go to e. With retard lever (if equipped) FULLY OFF,
Ptu_Screens -> Inverters -> Normal_Operation - verify that RETRD-SEL = 0.00. If it is not,
> Real_Time -> DSC - Real Time Data. calibrate using the DID panel.
9. After clicking on DSC - Real Time Data, the f. With retard lever (if equipped) FULLY ON,
DSC Real Time Data window will be displayed verify that RETRD-SEL = 1.00. If it is not,
in the activity portion of the wPTU program calibrate using the DID panel.
screen. See Figure 30-10. Perform the following
g. With retard speed control knob PULLED
procedure from the DSC Real Time Data
OUT (Retard Speed Control ON) and knob
window.
turned FULLY CLOCKWISE (turned to
a. With accel pedal FULLY RELEASED, verify TURTLE icon), verify that RETSPD = <5.0.
that ACCEL-SEL = 0.00. If it is not, calibrate
h. With retard speed control knob PULLED
using the DID panel.
OUT (Retard Speed Control ON) and knob
b. With accel pedal FULLY PRESSED, verify turned FULLY CLOCKWISE (turned to
that ACCEL-SEL = 1.00. If it is not, calibrate RABBIT icon), verify that RETSPD > 36.
using the DID panel.
i. Close the DSC Real Time Data window by
c. c. With retard pedal FULLY RELEASED, clicking on the X in the upper right corner of
verify that RETRD-SEL = 0.00. If it is not, the window.
calibrate using the DID panel.
10. Click on the target icon above the wPTU
d. With retard pedal FULLY PRESSED, verify program activity portion of the screen to go back
that RETRD-SEL = 1.00. If it is not, calibrate to the wPTU Toolbox Login screen. Close the
using the DID panel. wPTU program, shut down the PTU, and
disconnect the cable from the DSC port on the
truck.
16
FIGURE 30-10. DSC REAL TIME DATA WINDOW
Set truck ID number

The truck identification (ID) number may be set to
any number between 1 and 99,999.
NOTE: The DID panel is the recommended method
for setting the truck ID number. Use the following
PTU procedure if the DID panel is not functional.
position.
cable to the DSC.
upward to the ON position. FIGURE 30-11. wPTU TOOLBOX LOGIN SCREEN
17
6. In the PTU screens window, go to Control cabinet pressure switch check

Ptu_Screens -> Inverters -> Normal_Operation -
> Configuration -> Set Truck ID.
7. After clicking on Set Truck ID, the Set Truck ID
window will be displayed in the activity portion of
the wPTU program screen. Enter a truck ID
number in the New Truck ID field. See Hazardous voltages may be present in this
Figure 30-12. equipment even if the engine and capacitor
charge lights are off. Use measurement and
protective equipment rated for 2000VDC
minimum to verify that no voltage is present
before touching any terminal. Verify functionality
performing control group measurements. Failure
to observe these precautions may result in death
or serious personal injury.
FIGURE 30-12. SET TRUCK ID WINDOW
Before opening the cover to adjust the switch, the

system must be de-energized. Ensure that the
8. Close the Set Truck ID window by clicking on control power switch (CPS) is in the OFF position
the X in the upper right corner of the window. and that the generator field contactor (GF) switch
is in the CUTOUT position before attempting any
9. Click on the target icon above the wPTU work.
program activity portion of the screen to go back
to the wPTU Toolbox Login screen. Close the The control cabinet pressure switch provides
wPTU program, shut down the PTU, and protection from the loss of coolIng air in the control
disconnect the cable from the DSC port on the group.The control cabinet pressure switch is located
truck. in the motor cable connection area at the rear of the
control cabinet. See Figure 30-13.
FIGURE 30-13. PRESSURE SWITCH LOCATION

1. Control Cabinet Pressure Switch
18
Checking the software setting 6. In the PTU screens window, go to

1. Start and login to a console window. Refer to Ptu_Screens -> Inverters -> Normal_Operation -
"Preparation for software installation" for > Real_Time -> DSC - Real Time Data.
instructions on opening a console window. 7. After clicking on DSC - Real Time Data, the
2. Select the screen “View OEM Options (2)”. View DSC Real Time Data window will be displayed
the heading “Hardware Configuration Options” in the activity portion of the wPTU program
and verify that “Control Group Pressure Sensor screen. See Figure 30-10. Verify that CNTRLP
Present” is set to 1. in the Inputs section of the screen is not
illuminated.
Checking the pressure switch setting If pressure switch digital input CNTRLP illumi-
1. Ensure that the truck directional control lever is nates while the truck is off, verify that the wiring
in PARK and the rest switch is in the REST to the switch is correct.
position. 8. Start the engine.
2. Shut down the engine. If pressure switch digital input CNTRLP illumi-
3. Connect an RS232 serial cable or ethernet nates while the engine is at idle, turn the adjust-
cable to the DSC. ment screw clockwise by 1/4 turn. Close the
cover and retest.
upward to the ON position. 9. Perform a no load engine sweep and verify that
pressure switch digital input CNTRLP
illuminates between 950 and 1150 rpm.
Normal mode, enter a password, and click on • If pressure switch digital input CNTRLP
LOGIN to wPTU Toolbox. See Figure 30-14. A illuminates below 950 rpm, turn the
truck model will be automatically selected. The adjustment screw clockwise by 1/4 turn.
PTU screens window will appear on the screen. Close the cover and retest.
• If pressure switch digital input CNTRLP
illuminates above 1150 rpm and below 1500
rpm, turn the adjustment screw
counterclockwise by 1/4 turn. Close the cover
and retest.
• If pressure switch digital input CNTRLP
illuminates above 1500 rpm, verify that there
are no holes in the inlet duct and the rear
compartment cover is fully closed with an
intact gasket.
19
Checks prior to self load engine test 7. After clicking on SW Versions, the SW Versions
(loadbox) window will be displayed in the activity portion of
the wPTU program screen. See Figure 30-16.
Verifying DSC Software Version Ensure that all of the information is correct and
1. Ensure that the truck directional control lever is up-to-date.
position.
cable to the DSC.
Ptu_Screens -> Inverters -> Normal_Operation - FIGURE 30-15. wPTU TOOLBOX LOGIN SCREEN
> Configuration -> SW Versions.
FIGURE 30-16. DSC SOFTWARE VERSION WINDOW
20
Resetting and erasing DSC event data 3. Verify that there are no DSC events logged on
1. To reset the DSC Event data: the DID panel.
a. In the PTU screens window, go to 4. Click on the target icon above the wPTU
Ptu_Screens -> Inverters -> Special_Tasks - program activity portion of the screen to go back
> Event_Menu -> Reset DSC Events. to the wPTU Toolbox Login screen. Close the
wPTU program, shut down the PTU, and
b. After clicking on Reset DSC Events, a small disconnect the cable from the DSC port on the
window will be displayed in the activity truck.
portion of the wPTU program screen which
asks “Do you want to RESET the Active DSC
Events?”. Click on “Yes”.
2. To erase the DSC Event data:
a. In the PTU screens window, go to
Ptu_Screens -> Inverters -> Special_Tasks -
> Event_Menu -> Erase DSC Events.
b. After clicking on Erase DSC Events, a small
window will be displayed in the activity
portion of the wPTU program screen which
asks “Do you want to ERASE the Stored
DSC Events?”. Click on “Yes”.
21
Engine running tests 3. All foreign material, tools, and loose parts must
be removed from the control cabinets and the
The following tests are performed with the engine
retarding grid. Remove any material around the
running. The checks and setup procedures described
retarding grid that may be drawn in during the
in "General information" and "Checks prior to self
self load engine test (loadbox).
load engine test (loadbox)" must be successfully
completed immediately before performing these test 4. Ensure that all cables and wires are connected
procedures. in the control cabinet and retarding grid. Any
cables or wires that are not connected must be
Battery boost circuit verification insulated from the truck frame and clear of
personnel. Wheel motors are not required and
may not be mounted during this test. If wheel
motors are not mounted and wired, ensure that
the wheel motor power cables are insulated
form personnel and the truck frame.
equipment. Ensure that the control power switch 5. Move generator field contractor (GF) switch (2,
(CPS) is in the OFF position and the generator Figure 30-17) to the CUTOUT position by
field contactor (GF) switch is in the CUTOUT pulling the switch out and moving the switch
position before attempting any work on control downward. Verify that the capacitor charge
components. Check that the capacitor charge lights are off.
lights (CCL1 and CCL2) are not illuminated. Use a
VOM to verify that no voltage is present before
touching any terminal. Failure to do so may result
in personal injury, death, or equipment damage.
FIGURE 30-17. INFORMATION DISPLAY PANEL

Follow all local safety procedures and mine
procedures. Verify that personnel are clear of the 1. Control Power Switch
truck. Truck components must be prepared for 2. Generator Field Contractor (GF) Switch
engine start and self load engine test (loadbox). 3. Capacitor Charge Light
Failure to do so may result in injury, death, or
equipment damage.
6. Connect a voltmeter across battery boost

resistor R1 in the power portion in the control
cabinet. Connect the voltmeter positive lead to
the R1 resistor terminal with wire BAT
This procedure must be performed exactly as connected. Connect the voltmeter negative lead
written by trained personnel only. Failure to do so to the R1 resistor terminal with wire F101
may result in personal injury or death. The connected.
contactors in the contactor cabinet may be 7. After connecting the voltmeter, secure the
energized while the engine is running. cabinet door closed without cutting the
voltmeter wires.
1. Park the truck on level ground and chock the 8. Connect an RS232 serial cable or ethernet
tires. Ensure that the truck directional control cable to the DSC.
lever is in PARK and the rest switch is in the 9. Move control power switch (1) upward to the ON
REST position. position.
22
10. Start the wPTU Toolbox program on the PTU or 11. In the PTU screens window, go to
laptop computer. At the login screen, select Ptu_Screens -> Inverters -> Normal_Operation -
Normal mode, enter a password, and click on > Real_Time -> DSC - Real Time Data.
12. After clicking on DSC - Real Time Data, the
DSC Real Time Data window will be displayed
in the activity portion of the wPTU program
screen.
13. Start the engine, then move the generator field
contractor (GF) switch upward to the NORMAL
position.
14. Deactivate the rest switch to while monitoring
the voltmeter that is connected to the R1
resistor. When the rest switch is deactivated, the
control system changes from REST mode to
READY mode. Alternator excitation begins
when the control system changes to READY
mode.
15. The voltmeter will read approximately 18 volts
momentarily and drop to 0 volts during the
battery boost portion of alternator excitation.
The DSC Real Time Data window will show
FIGURE 30-18. wPTU TOOLBOX LOGIN SCREEN system initiation when DSCMODE changes
from REST to READY, SUBSTATE changes
from LINKOFF to LINKON, and LINKV displays
the voltage level on the DC link. See Figure 30-
19.
23
NOTE: It may be helpful to set the digital multimeter 18. Shut down the engine. The control system may
to max/min setting to be able to see the voltage be left powered while just shutting down the
during the brief time of battery boost. engine.
16. If the maximum voltmeter reading is If the control system is powered down also, shut
approximately 18 volts, continue to completion down the PTU by clicking on the X in the upper
of this procedure. right of the DSC Real Time Data window, then
If the maximum voltmeter reading is significantly the DSC screens window.
different (higher or lower) from 18 volts, or if it 19. Move the generator field contractor (GF) switch
does not drop back to zero, troubleshoot the to the CUTOUT position by pulling the switch
battery boost circuit (battery volts, wiring, and out and moving the switch downward. Verify that
R1 connections) until the problem is resolved. the capacitor charge lights are off.
Repeat the check after the problem has been
NOTE: A short time interval may be required to allow
addressed.
the capacitor charge level to come down to a safe
17. Move the rest switch to the REST position. The level.
DSCMODE will change from READY to REST
20. When capacitor charge lights are off, disconnect
and the control system will power down.
the voltmeter from the R1 resistor and close the
control cabinet door.
24
Selector switch check 6. In the PTU screens window, go to

1. Park the truck on level ground and chock the Ptu_Screens -> Inverters -> Normal_Operation -
tires. Ensure that the truck directional control > Real_Time -> DSC - Real Time Data.
lever is in PARK and the rest switch is in the 7. After clicking on DSC - Real Time Data, the
REST position. DSC Real Time Data window will be displayed
2. Shut down the engine. in the activity portion of the wPTU program
screen.
3. All foreign material, tools, and loose parts must
8. Apply the service brakes and move the
Deactivate the rest switch. When the rest switch
is deactivated, the control system changes from
REST mode to TEST mode, then to READY
4. Ensure that all cables and wires are connected mode within one minute.
in the control cabinet and retarding grid. Any
cables or wires that are not connected must be 9. With the service brakes applied, move the
insulated from the truck frame and clear of direction control lever to FORWARD and verify
personnel. Wheel motors are not required and that torque (command and feedback) is present
may not be mounted during this test. If wheel on each inverter (TQCMD1, TQCMD2, and
motors are not mounted and wired, ensure that TRQFB1, TRQFB2) shown in the Inverters
the wheel motor power cables are insulated section of the DSC - Real Time Data screen.
form personnel and the truck frame. See Figure 30-21.
10. With the service brakes applied, move the
direction control lever to REVERSE and verify
that torque (command and feedback) is present
on each inverter (TQCMD1, TQCMD2, and
TRQFB1, TRQFB2) shown in the Inverters
section of the DSC - Real Time Data screen.
See Figure 30-21.
Ptu_Screens -> Inverters -> Special_Tasks ->
Event_Menu -> DSC Event Summary.
12. After clicking on DSC Event Summary, the DSC
Event Summary window will be displayed in the
Verify that no events are logged, then close the
DSC Event Summary window by clicking on the
X in the upper right corner of the window.
13. Move the direction control lever to PARK and
move the rest switch to the REST position. Shut
down the engine.
25
26
Ground detection network tests

The ground detection network is tested by static test
to verify the ground detection feedback circuit or by
utilizing the self load engine test (loadbox) mode to
verify the function of the ground resistor circuit (GRR) Only trained personnel may perform ground
and feedback to DSC analog input card. detection network tests. Attempting these tests
without proper training may result in personal
The static test is performed with the engine not
injury or death.
running. The battery voltage is introduced into the
ground detection feedback circuit that will be read on
the PTU screens.
The test that utilizes the self load engine test
(loadbox) mode creates a ground connection on the
DC+ link bus bar, DC- link bus bar, traction alternator A successful megger test must be performed on
stator, traction alternator field (rotor), and associated the power circuits before attempting a ground
cables or leads. The engine is started and a self load circuit test. If a ground exists when the test
engine test (loadbox) is performed which will cause a ground is introduced, the ground wire may melt.
ground fault condition. Always perform the megger test to avoid
introducing another ground in the power circuit.
Failure to do so may result in equipment damage.
Refer to "Megger test for grounds" for
instructions.
equipment. Ensure that the control power switch
(CPS) is in the OFF position and the generator
field contactor (GF) switch is in the CUTOUT
position before attempting any work on control
components. Check that the capacitor charge
lights (CCL1 and CCL2) are not illuminated. Use a
VOM to verify that no voltage is present before
touching any terminal. Failure to do so may result
in personal injury, death, or equipment damage.
27
Ground detection feedback circuit static test 5. In the PTU screens window, go to
The ground detection circuit may be tested statically
> Real_Time -> DSC - Real Time Data.
(engine not running). The test verifies the ground
detection circuit feedback to the control system. To 6. After clicking on DSC - Real Time Data, the
statically test the ground detection feedback circuit: DSC Real Time Data window will be displayed
in the activity portion of the wPTU program
1. Discharge the capacitors. Refer to “Capacitor
screen.
Discharge System” in the Section A3, General
Safety and Operating Instructions. 7. In the Analogs section of the DSC Real Time
window, GFAULT is shown in milliamperes (ma).
2. Connect battery voltage (+24VDC) to the GRR9
With the battery voltage (+24VDC) connected to
resistor B terminal. GRR9 resistor is located in
GRR9 terminal B, GFAULT will read
the low voltage cabinet (right side access door)
approximately 400 ma. If GFAULT is
on the floor of the compartment (fifth resistor
significantly different from 400 ma, troubleshoot
from the front). Wire number FAULTP02 is
the ground detection feedback circuit. When the
connected to terminal B of GRR9.
issue is resolved, test the ground detection
3. Connect an RS232 serial cable or ethernet feedback circuit again. See Figure 30-23.
cable to the DSC.
8. Exit the wPTU program. Remove control power
4. Start the wPTU Toolbox program on the PTU or by moving control power switch (1, Figure 30-
laptop computer. At the login screen, select 17) downward to the OFF position.
9. Remove the battery voltage (+24VDC) from the
GRR9 resistor.
28
29
DC link positive side ground check 5. Initiate a self load engine test (loadbox). Refer
to "Self load engine test (loadbox) procedure".
This portion of the ground test will simulate a ground
occurring on the DC+ link bus bar. This will verify the 6. The Self Load Engine Test window (Figure 30-
ground detection network and control system 27) will display DC link voltage (LINKV) and
feedback displayed on the PTU. Figure 30-24 shows ground fault current (GFAULT) in milliamperes
the block electrical diagram with an intentional (ma). The PTU GFAULT display reads absolute
ground on the DC+ link bus bar and a digital value on GRR10 and is always displayed as a
voltmeter connected to ground detection resistor positive number. The ground fault current will
GRR10. rise with the DC link voltage until the control
system faults (due to a ground), shutting down
power generation. This should occur at 1000
VDC. If a fault does not occur, stop the self load
position.
engine test (loadbox) process and troubleshoot
2. All foreign material, tools, and loose parts must the ground detection network issue. After the
be removed from the control cabinets and the issue is resolved, perform the test again.
7. After verifying the voltage and milliampere
readings, shut down the engine and the PTU.
8. To determine the control system DC link voltage
3. Discharge the capacitors. Refer to “Capacitor
and the ground fault current at the time of the
Discharge System” in Section 10, Foreword,
fault, it may be necessary to access the DSC
safety and general information.
event logs Refer to "Viewing the DSC event
4. Install a jumper wire between the DC+ link bus summary, trigger data, and data packs". The DC
bar and ground (chassis ground). The jumper Link voltage and ground fault current will be
wire may be installed on cable DCP08. Close displayed in the fault event windows.
the control cabinet door.
FIGURE 30-24. DC+ LINK POSITIVE SIDE GROUND SETUP AND CURRENT PATH
30
DC link negative side ground check 4. The Self Load Engine Test window (Figure 30-
27) will display DC link voltage (LINKV) and
This portion of the ground test will simulate a ground
ground fault current (GFAULT) in milliamperes
occurring on the DC- link bus bar. This will verify the
(ma). The PTU GFAULT display reads absolute
ground detection network and control system
value on GRR10 and is always displayed as a
feedback displayed on the PTU. Figure 30-25 shows
positive number. The ground fault current will
the block electrical diagram with an intentional
rise with the DC link voltage until the control
ground on the DC- link bus bar and a digital voltmeter
system faults (due to a ground), shutting down
connected to ground detection resistor GRR10.
power generation. This should occur at 1000
NOTE: Prior to performing this test, the test for a VDC. If a fault does not occur, stop the self load
ground on the DC+ link bus bar must be performed. engine test (loadbox) process and troubleshoot
Refer to "DC link positive side ground check". the ground detection network issue. After the
1. Discharge the capacitors. Refer to “Capacitor issue is resolved, perform the test again.
Discharge System” in Section 10, Foreword, 5. After verifying the voltage and milliampere
safety and general information. readings, shut down the engine and the PTU.
2. Remove the jumper wire from the DC+ link bus 6. To determine the control system DC link voltage
bar on cable DCP08 and connect it to the DC- and the ground fault current at the time of the
link bus bar at cable DCN08. The jumper wire is fault, it may be necessary to access the DSC
still connected to ground (chassis ground). event logs. Refer to "Viewing the DSC event
Close the control cabinet door. summary, trigger data, and data packs". The DC
3. Initiate a self load engine test (loadbox). Refer Link voltage and ground fault current will be
to "Self load engine test (loadbox) procedure". displayed in the fault event windows.
7. Remove the jumper wire and close the control
cabinet door.
FIGURE 30-25. DC+ LINK NEGATIVE SIDE GROUND SETUP AND CURRENT PATH
31
Self load engine test (loadbox) procedure 7. Start the wPTU Toolbox program on the PTU or
The self load engine test (loadbox) verifies engine
operation/horsepower and drive system operation.
The checks and setup procedures described in truck model will be automatically selected. The
"General information" and "Checks prior to self load PTU screens window will appear on the screen.
engine test (loadbox)" must be successfully
completed immediately before performing a self load
engine test (loadbox).
NOTE: Self load engine testing can also be

accomplished through the DID panel. Refer to "DID
self load engine test (loadbox)". If a DID panel self
load engine test is to be initiated without the wPTU
Toolbox, disregard these instructions and follow the
DID panel self load engine test procedure.
1. Park the truck on level ground and chock the

tires. Ensure that the truck directional control
lever is in PARK and the rest switch is in the
REST position.
3. All foreign material, tools, and loose parts must
8. Start the engine and deactivate the rest switch.
retarding grid that may be drawn in during the 9. In the PTU screens window, go to
self load engine test (loadbox). Ptu_Screens -> Inverters -> Normal_Operation -
> Tests -> Self Load Engine Test.
4. Ensure that all cables and wires are connected
in the control cabinet and retarding grid. Any 10. After clicking on Self Load Engine Test, the Self
cables or wires that are not connected must be Load Engine Test window will be displayed in
insulated from the truck frame and clear of the activity portion of the wPTU program screen.
personnel. Wheel motors are not required and 11. Click on ENTER LDBX on the DSC Self Load
may not be mounted during this test. If wheel Engine Test window. Verify that the DSCMODE
motors are not mounted and wired, ensure that changes to TEST and the SUBSTATE changes
the wheel motor power cables are insulated to LOADBOX before proceeding. Refer to
form personnel and the truck frame. Figure 30-27.
5. Connect an RS232 serial cable or ethernet 12. Press down the accelerator pedal. Engine
cable to the DSC. speed must be above 1200 rpm in order for RP1
6. Ensure that the control power switch is in the resistor to pickup, connecting the retarding grids
ON position. across the alternator output. RP1 command and
feedback are displayed in the lower right corner
of the Self Load Engine Test window.
32
13. Monitor DC link parameters GFAULT and LINKV 17. Upon completion of a successful self load
as engine loading increases. Ensure that the engine test (loadbox), lower the engine speed to
GFAULT value increases as the LINKV value idle and move the rest switch in the REST
increases. This indicates that the ground position.
detection circuit is connected and operational. If
18. On the Self Load Engine Test window, click on
this does not occur, abort the test and
EXIT LDBX and close the Self Load Engine
troubleshoot the ground fault circuitry.
Test window by clicking the X in the upper right
14. Monitor the commands, feedbacks, volts, amp, corner of the window.
horsepower, and rpm values displayed on the
19. Click on the target icon above the wPTU
Self Load Engine Test as engine speed
program activity portion of the screen to go back
increases to maximum.
to the wPTU Toolbox Login screen. Close the
15. Maintain loadbox operation at full engine rpm for wPTU program, shut down the PTU, and
a minimum of two minutes and verify that full disconnect the cable from the DSC port on the
horsepower is developed. truck.
16. Monitor the HP ALT value in the Horsepower 20. Shut down the engine.
section of the Self Load Engine Test. If HP ALT
(gross) is within 5% of the engine rating, the
engine is running optimally. If HP ALT is below
or above the 5% range, contact your Komatsu
service representative for additional
investigation.
FIGURE 30-27. SELF LOAD ENGINE TEST WINDOW
33
Diagnostic information display (DID) panel DID panel display selection

The Diagnostic Information Display (DID) panel Pressing Menu (F4) from the Normal or Faults
indicates the operating condition of the truck and is a display accesses the first layer of menu selections for
primary troubleshooting aid for maintenance and Test, Info, and Inv cutout. Then pressing the desired
service personnel. function key (F1 through F5) accesses the menu for
that function key. Test, Info, or Inv cutout selection is
The propulsion system utilizes the message lines and
made by pressing the desired function key from this
the function keys on the DID panel. Message lines (1,
menu layer. Display selection function keys (soft
Figure 30-28) provide propulsion system operating
keys) are shown in Figure 30-28. Refer to Figure 30-
information, test status information, and function key
29 for an overview of the hierarchy of the displays
label information depending on the DID panel mode
that are available.
of the display. Function keys (2) assume different
functionality depending on the DID panel’s mode of
display.
FIGURE 30-28. DID PANEL ARRANGEMENT

1. Message Lines
2. Function Keys
34
FIGURE 30-29. DID PANEL HIERARCHY
35
DID modes display • TEST – The propulsion system is in a self-test

propulsion mode of operation.
The normal display (when there are no active faults
and no propulsion system tests commanded through • READY – The propulsion system is ready for
the DID panel) is shown in Figure 30-30. The display operation.
will indicate one of the following propulsion modes: • PROPEL – The propulsion system is powered up
and the direction control lever is either in
• REST – The parking brake is ON and the rest
FORWARD or REVERSE.
switch is in the REST position, and both the
propulsion system and the truck are in the • RETARD – The propulsion system is powered up
appropriate condition for the REST mode to be and retarding effort is commanded either from the
active. retarder pedal or retarder speed control (RSC)
switch.
FIGURE 30-30. DID PANEL NORMAL MODE DISPLAY (NO FAULTS)
36
Function key F1 - DID events or faults display

By pressing function key F1 (List) whenever there are Refer to Figure 30-29 for the fault hierarchy of the
active events or faults, the DID panel displays DID panel.
information similar to Figure 30-31. The DID panel
faults display will show the most recent active event
or fault, as well as the number of active events or
faults that are currently stored.
FIGURE 30-31. DID PANEL FAULT DISPLAY
37
The function keys in the DID panel’s faults display • Function key F4 (Reset) enables the user to
mode screen (Figure 30-32) provide the user with the subsequently perform fault reset functions
following capabilities: (Figure 30-33) as follows:
• Function key F1 (Up) scrolls up through the event Pressing function key F1 (Reset1) after having
or fault messages to the previous one. pressed function key F4 (Reset) above will reset
the currently displayed fault.
• Function key F2 (Down) scrolls down through the
event or fault messages to the next one. Pressing function key F2 (RESET*) after having
pressed function key F4 (Reset) above will reset
• Function key F3 (Return) returns the user to the
previous display. ALL of the currently active faults.
Pressing function key F5 (Cancel) exits the user
from the fault reset screen and returns the user
to the fault display screen.
• When viewing the fault display screen, function
key F5 (More) displays additional information
regarding the currently displayed fault.
FIGURE 30-32. DID PANEL FAULT DISPLAY FUNCTION KEYS
38
FIGURE 30-33. DID PANEL FAULT RESET FUNCTION KEYS
NOTE: Function keys F2 and F3 provide no functions at the main screen level.
39
Function key F4 - DID menu display The function keys in the DID panel’s menu display
mode allow selection of the next level of menus.
When the DID panel normal mode is active, the menu
Refer to Figure 30-29 for the menu selection
display mode will be displayed when function key F4
hierarchy after pressing function key F4 (MENU).
(MENU) is pressed. Refer to Figure 30-34.
FIGURE 30-34. DID PANEL MENU DISPLAY
40
DID self load engine test (loadbox) 1. Press function key F2 (Enter) to enter the Load
Box mode of operation (Figure 30-35).
Several tests can be performed after pressing
function key F1 (Test Menu) from the menu display With the engine running and the accelerator
mode. Pressing F1 (LOAD BOX) will initiate the DID pedal fully depressed, the engine net horse-
self load engine test (loadbox). power, the engine load signal, the propulsion
system horsepower adjust level, and the ground
The checks and setup procedures described in
fault current are displayed to the user. Refer to
"General information" and "Checks prior to self load
Figure 30-36.
engine test (loadbox)" must be successfully
completed immediately before performing this test 2. To manually adjust the engine horsepower,
procedure. press function key F1 (TURN MAN ON).
Horsepower can be increased or decreased by
using function keys F3 (ADD +) or F4 (SUB -) as
shown in Figure 30-37.
3. Press function key F5 (Return) to stop the self
load engine test and return to the DID panel
Test Menu mode.
FIGURE 30-35. DID PANEL LOADBOX MODE
41
FIGURE 30-36. DID PANEL LOADBOX TEST DATA
FIGURE 30-37. DID PANEL LOADBOX MODE
42
DID link capacitance test 1. Press function key F2 (Start) to start the link
capacitance test again.
function key F1 (Test Menu) from the menu display 2. Press function key F5 (Return) to return to the
mode. Pressing F2 (CAP TEST) will initiate the DID DID panel Test Menu mode.
link capacitance test. The results of the link 3. Press function key F5 (Return) again to return to
capacitance test will then be automatically displayed. the DID panel Test Menu mode.
FIGURE 30-38. DID PANEL LINK CAPACITANCE TEST MODE
NOTE: Function key F3 provides no functions at the Test Menu level.
43
DID speedometer test 1. Press function key F2 (Begin) to start the

speedometer test.
function key F1 (Test Menu) from the menu display 2. Press function keys F1 (DEC 5), F2 (DEC), F3
mode. Pressing F4 (SPEEDO) will initiate the DID (INC), or F4 (INC 5) as required to calibrate the
speedometer test. Refer to Figure 30-39. speedometer by increasing or decreasing the
speed. Refer to Figure 30-40.
The speedometer test generates a specific mph
reading so the speedometer can be tested or 3. Press function key F5 (Exit) to exit the
calibrated. The default is 20 mph. speedometer test and return to the DID panel
Test Menu mode.
FIGURE 30-39. DID PANEL SPEEDOMETER TEST MODE
44
FIGURE 30-40. DID PANEL SPEEDOMETER TEST IN PROGRESS
45
DID view software version 1. DSC software version

Several menus are available after pressing function 2. Inverter No. 1 software version
key F2 (Info Menu) from the menu display mode. 3. Inverter No. 2 software version
4. DSC software version
Pressing F1 (SW Vers) accesses the software
version display, which shows the software versions 5. DSC base configuration version
that are loaded in the propulsion system. Refer to Pressing function key F5 (Return) at any time while in
Figure 30-42. the software version display will return the user to the
Subsequent pressings of F2 (Next) will display the DID panel Info Menu mode.
following information in the order listed:
FIGURE 30-41. DID PANEL INFO MENU MODE
46
FIGURE 30-42. DID PANEL SOFTWARE VERSION DATA
47
DID view overspeed setting Press function key F2 (Next) to toggle through four
overspeed settings that can be viewed (but cannot be
Several menus are available after pressing function
changed) via the DID panel.
key F2 (Info Menu) from the menu display mode.
Refer to Figure 30-41. Press function key F5 (Return) to return to the DID
panel Info Menu mode. Pressing function key F5
Pressing F2 (Over Speed) accesses the overspeed
(Return) again will return the user to the DID panel
settings display, which shows the overspeed settings
Menus Display mode.
that are loaded in the propulsion system. Refer to
Figure 30-43.
FIGURE 30-43. DID PANEL OVERSPEED SETTING DISPLAY
48
DID view data menu Pressing F3 (Data Menu) accesses the data menu.
Several menus are available after pressing function
key F2 (Info Menu) from the menu display mode.
FIGURE 30-44. DID PANEL DATA MENU
49
Press F2 (Data Dump) to transfer data to a USB c. After the files are generated, a message
drive. indicating that the files are being transferred
1. Press function key F2 (All) to copy all data onto will appear on the screen.
USB drive or press function key F3 (Quick) to d. When the file transfer is successful, the
copy everything but the data packs to the USB message “Data Transfer Complete” will
drive. See Figure 30-45. appear on the screen.
a. If a USB drive is not attached, an error 2. Press function key F5 (Exit) to exit the data
message appears on the screen. dump mode and return to the DID panel Info
Menu mode.
b. If a USB drive is attached, the generating
files status will appear on the screen.
FIGURE 30-45. DID PANEL DATA DUMP DISPLAY
50
Press F3 (View Params) to view parameters. See 2. Press function key F2 (Prev) or F3 (Next) to
Figure 30-46. proceed sequentially through the parameter list.
1. Press function key F1 (New) to return to the 3. Press function key F5 (Exit) to exit the View
View Parameters display and enter a new Parameters display and return to the DID panel
parameter number directly. See Figure 30-47. Info Menu mode.
FIGURE 30-46. DID PANEL VIEW PARAMETERS DISPLAY
FIGURE 30-47. DID PANEL ENTER PARAMETER DISPLAY
51
Press F4 (View Stats) to view statistical information. • DID key 1 (Today) displays the statistics for
See Figure 30-48. today.
1. Press function key F1 (New) to return to the • DID key 2 (Yesterday) displays the statistics
View Stats display and enter a new statistical for yesterday.
number directly. • DID key 3 (This Month) displays the statistics
2. Press function key F2 (Prev) or F3 (Next) to for the current month.
proceed sequentially through the statistics list. • DID key 4 (Last Month) displays the statistics
3. Press function key F4 (Time) to proceed to the for the previous month.
Time Interval display and select the desired • DID key 5 (This Qtr) displays the statistics for
interval using the 1 through 7 numbered keys. this quarter.
See Figure 30-49. When the desired key is • DID key 6 (Last Qtr) displays the statistics for
pressed, that time interval will be selected and the previous quarter.
the View Stats display will appear again
automatically. • DID key 7 (Life) displays the statistics for the
life of this vehicle.
Function keys F1 through F5 are not active on
4. Press function key F5 (Exit) to exit the View
this display.
Parameters display and return to the DID panel
Info Menu mode.
FIGURE 30-48. DID PANEL VIEW STATS DISPLAY
52
FIGURE 30-49. DID PANEL TIME INTERVAL CHANGE DISPLAY
53
DID inverter cutout menu 2. Press function key F4 (Toggle) to change the
status of the selected inverter. See Figure 30-
Pressing function key F3 (Inv Cutout) from the Menu
51.
Display mode accesses the Inverter Cutout menu.
See Figure 30-50. 3. Press function key F5 (Return) to return to the
Inverter Cutout display.
NOTE: The truck must be parked in order to cut out
or cut in an inverter. 4. Repeat Steps 1 through 3 for the other inverter if
desired.
1. Press function key F1 (Inv # 1) or F2 (Inv # 2) to
select the inverter and proceed to the Inverter 5. Press function key F5 (Return) to exit the
Status display. Inverter Cutout display and return to the DID
panels Menu Display mode. See Figure 30-34.
FIGURE 30-50. DID PANEL INVERTER CUTOUT MENU
54
FIGURE 30-51. DID PANEL INVERTER CUTOUT STATUS DISPLAY
55
DID truck configuration menu 2. Fully depress the accelerator pedal and then
release.
Pressing function key F4 (Truck Cfg) from the Menu
Display mode accesses the Truck Configuration 3. Fully depress the retarder pedal and then
menu. See Figure 30-52. release.
Upon initial power-up after a software download, 4. Fully move the retarder lever and then release.
Event 650-4 will be logged indicating the accelerator 5. If the pedal calibration process was successful,
pedal, retarder pedal, and retarder lever must be the message “Pedals Calibrated Successfully”
calibrated. These components may be calibrated via will appear on the screen. If not, repeat Steps 1
the DID panel by pressing function key F1 (Pedal through 4. See Figure 30-54.
Cal).
Event 650-4 will automatically reset when a suc-
1. Press function key F2 (Begin) to perform the cessful calibration has occurred.
calibration process. See Figure 30-53. A
“Calibration in Process” message will appear on 6. Press function key F5 (OK) when the
the screen. calibrations are complete.
FIGURE 30-52. DID PANEL TRUCK CONFIGURATION MENU
56
FIGURE 30-53. DID PANEL PEDAL CALIBRATION DISPLAY
FIGURE 30-54. DID PANEL PEDAL CALIBRATION SUCCESSFUL DISPLAY
57
Upon initial power-up after a software download, 3. If an error was made while entering the truck ID,
Event 651-1 will be logged indicating that the truck ID press function key F5 (CANCEL) to clear the
is set to 0. The truck ID may be set via the DID panel truck ID. Press F5 (CANCEL) again to return to
by pressing function key F2 (Truck ID). the Truck Configuration menu without updating
1. Enter a unique truck ID between 1 and 99999 the truck ID.
by using the numbers on the DID keypad. See 4. To confirm the truck ID, press function key F5
Figure 30-55. (OK) to view updated number and return to the
2. Press function key F2 (FINISH) in order to Truck Configuration menu.
update the truck ID.
FIGURE 30-55. DID PANEL TRUCK ID DISPLAY
58
FIGURE 30-56. DID PANEL TRUCK ID UPDATE SUCCESSFUL DISPLAY
59
The engine idle speed setting can be viewed or set 3. If an error was made while entering the speed
via the DID panel by pressing function key F3 setting, press function key F5 (CANCEL) to
(Engine Idle). clear the speed setting. Press F5 (CANCEL)
1. Enter the Min Engine Speed by using the again to return to the Truck Configuration menu
numbers on the DID keypad. See Figure 30-57. without updating the speed setting.
2. Press function key F2 (FINISH) in order to save 4. To confirm the speed setting, press function key
the speed setting. F5 (OK) to view updated setting and return to
the Truck Configuration menu. See Figure 30-
58.
FIGURE 30-57. DID PANEL MINIMUM ENGINE SPEED DISPLAY
60
FIGURE 30-58. DID PANEL MINIMUM ENGINE SPEED SET DISPLAY
61
The system’s date and time can be viewed or set via 3. If an error was made while entering the new
the DID panel by pressing function key F4 (Set Time). date or time, press function key F2 (CANCEL)
1. Press function key F2 (CHANGE) to change the to return to the previous setting.
date and/or time. Press F5 (EXIT) to return to 4. To confirm the new date and time, press
the Truck Configuration menu without changing function key F1 (SET). The message “Setting
the date or time. See Figure 30-59. New Time” will appear on the screen.
2. To change the current date, press function key 5. When the new date and/or time is set, the
F3 (MM-DD-YY) and enter the new date by message “Time Set Successfully” will appear on
using the numbers on the DID keypad. See the screen. Press function key F5 (OK) to return
Figure 30-60. to the Current Time display. See Figure 30-54.
To change the current time, press function key 6. Press F5 (EXIT) to return to the Truck
F5 (HH:MM:SS) and enter the new time by Configuration menu
using the numbers on the DID keypad. See
Figure 30-60.
FIGURE 30-59. DID PANEL CURRENT DATE AND TIME DISPLAY
62
FIGURE 30-60. DID PANEL CHANGE DATE AND TIME DISPLAY
FIGURE 30-61. DID PANEL DATE AND TIME CHANGE SUCCESSFUL DISPLAY
Language selection
When a second language option is selected, pressing
F5 while in the menu display mode toggles between
the primary and secondary language.
63
Viewing event and statistical data

The DSC Events and Statistical Data (profiles and
parameters) may be viewed on the PTU screen when
accessing the appropriate system.
To reset all data, refer to "Resetting and erasing DSC
event data".
Viewing the DSC event summary, trigger data,

and data packs
cable to the DSC.
LOGIN to wPTU Toolbox. See Figure 30-62. A FIGURE 30-62. wPTU TOOLBOX LOGIN SCREEN
3. To view the DSC event summary:
> Event_Menu -> DSC Event Summary.
b. After clicking on DSC Event Summary, the
DSC Event Summary window will be
displayed in the activity portion of the wPTU
program screen. See Figure 30-63.
FIGURE 30-63. DSC EVENT SUMMARY WINDOW
64
4. To view the DSC Trigger Data:

> Event_Menu -> DSC Trigger Data.
b. After clicking on DSC Trigger Data, the DSC
Trigger Data window will be displayed in the
See Figure 30-64.
FIGURE 30-64. DSC TRIGGER DATA WINDOW
65
5. To view the DSC Data Packs:

> Event_Menu -> DSC Data Packs.
b. After clicking on DSC Data Packs, the DSC
Data Packs window will be displayed in the
See Figure 30-65.
c. To view an individual Data Pack, enter the
number of the desired data pack in the field
at the bottom of the screen and press
ENTER.
FIGURE 30-65. DSC DATA PACK WINDOW
66
Viewing the statistical data 3. In the PTU screens window, go to

1. Connect an RS232 serial cable or ethernet Ptu_Screens -> Inverters -> Special_Tasks ->
cable to the DSC. Stat_Menu -> View Counters.
2. Start the wPTU Toolbox program on the PTU or 4. After clicking on View Counters, the View
laptop computer. At the login screen, select Counters window will be displayed in the activity
Normal mode, enter a password, and click on portion of the wPTU program screen. See
LOGIN to wPTU Toolbox. See Figure 30-66. A Figure 30-67.
truck model will be automatically selected. The 5. Select the type of counter to be viewed. See
PTU screens window will appear on the screen. Figure 30-68 for an example of a typical mine
counter window.

FIGURE 30-67. VIEW COUNTERS WINDOW
FIGURE 30-68. MINE COUNTERS WINDOW
67
Logic screens 3. To view the ACCEL Inhibit Logic:

To aid in troubleshooting, logic screens are provided a. In the PTU screens window, go to
to determine issues when operation modes are Ptu_Screens -> Inverters ->
inhibited. Normal_Operation -> Logic -> ACCEL Inhibit
Logic.
cable to the DSC. b. After clicking on ACCEL Inhibit Logic, the
ACCEL Inhibit Logic window will be
displayed in the activity portion of the wPTU
program screen. See Figure 30-70.
LOGIN to wPTU Toolbox. See Figure 30-69. A This screen shows conditions from the engine
truck model will be automatically selected. The that prevent truck propulsion but allow dynamic
PTU screens window will appear on the screen. retarding.
FIGURE 30-70. ACCEL INHIBIT LOGIC WINDOW
68
4. To view the READY Logic: 6. To view the RETARD Logic:

a. In the PTU screens window, go to a. In the PTU screens window, go to
Ptu_Screens -> Inverters -> Ptu_Screens -> Inverters ->
Normal_Operation -> Logic -> READY Logic. Normal_Operation -> Logic -> RETARD
b. After clicking on READY Logic, the READY Logic.
Logic window will be displayed in the activity b. After clicking on RETARD Logic, the
portion of the wPTU program screen. See RETARD Logic window will be displayed in
Figure 30-71. the activity portion of the wPTU program
screen. See Figure 30-73.
This screen shows conditions that prevent the
control from entering the READY mode. This screen shows conditions that prevent the
control from entering the RETARD mode.
FIGURE 30-71. READY LOGIC WINDOW

FIGURE 30-73. RETARD LOGIC WINDOW
5. To view the PROPEL Logic:

Ptu_Screens -> Inverters ->
Normal_Operation -> Logic -> PROPEL
Logic.
b. After clicking on PROPEL Logic, the
PROPEL Logic window will be displayed in
the activity portion of the wPTU program
screen. See Figure 30-72.
This screen shows conditions that prevent the
control from entering the PROPEL mode.
FIGURE 30-72. PROPEL LOGIC WINDOW
69
Datalogger function
The datalogger function may be used to monitor
selected specific DSC parameters. The recorded
data can be retrieved for analysis. The parameters
must be preselected by the user prior to starting the
datalogger function.
Setting up the datalogger

cable to the DSC.
PTU screens window will appear on the screen. FIGURE 30-74. wPTU TOOLBOX LOGIN SCREEN
> Configuration -> DSC Datalog Setup.
4. After clicking on DSC Datalog Setup, the DSC
Datalog Setup window will be displayed in the
See Figure 30-75.
FIGURE 30-75. DSC DATALOG SETUP WINDOW
70
5. On the DSC Datalog Setup window, click on the 8. After selecting the variables on the Datalogger
Datalogger Setup button located below the Parameter Selection window, click on the Exit
variables listings. The Datalogger Parameter button. The DSC Datalog Setup window will
Selection window will appear. See Figure 30-76. remain open.
In this window, each variable is assigned a 9. The selected parameters must be activated on
parameter to monitor on the DSC Datalog Setup the DSC Datalog Setup window. A green
window. Each variable has a drop down menu numbered button is beside each variable that is
selection. listed. Select which parameters are to be
monitored during the datalogger process by
6. Click on the drop down arrow of the first
clicking on the green numbered button beside
parameter selection, scroll through the list and
the variable. If five variables are selected to be
select the first parameter to be monitored during
monitored, click on the first five green numbered
the datalogger process.
buttons. The buttons will invert the colors from a
7. Repeat the variable selection procedure for green background with a black number to a
each parameter until all the parameters that are black background with a green number when
being monitored have been selected. Write selected. Only the selected variables on the
down all the variables that are selected so that DSC Datalog Setup window will be monitored.
selected variables may be turned on or off
during later datalogger process operations. Up
to 32 parameters may be selected to be
monitored.
The time sample rate during the datalogger pro-
cess slows when more than 15 variables are
selected. Set the rate to 20 ms or slower for 15
or fewer selected variables and to 40 ms or
slower for more than 15 selected variables.
FIGURE 30-76. DATALOGGER PARAMETER SELECTION WINDOW
71
10. The datalog setup may be saved and recalled Starting the datalogger
for future monitoring activities. To save or recall
The parameters to be monitored must be setup
a datalog setup:
before starting datalogger function. Refer to "Setting
a. Click on the Save button at the bottom of the up the datalogger". To begin the datalogger function,
DSC Datalog Setup window. A Save Setup an RS232 serial cable or ethernet cable must be
window will open on top of the DSC Datalog connected to the DSC, the drive system must be
Setup window. powered up, and the truck must be ready to operate.
b. Enter a file name in the FILE NAME line of By default, the datalogger function is set up to
the Save Setup window. Use a name that will communicate with the COM1 serial port. If the port to
be recognizable when opened in the future. be used is not COM1, the AC_run.bat file must be
c. After a file name has been entered, click on edited first. This file is located in
the Save button on the Save Setup window. c:\GETrans\wPTU_70\datalog. To edit the file:
The file will be saved on the PTU at 1. Open any text editor program.
PROGRAMS/GEOHVPTU_501/data_ac.
2. Open file AC_run.bat file.
d. To recall a saved setup, click on the Recall
button at the bottom of the DSC Datalog 3. Change the /p= value to the desired port
Setup window. The previously saved datalog number.
setup files will be displayed. Select the saved In the following example, the port is changed to
setup and click on the Open button of the COM6.
Recall window.
@echo off
11. Close the DSC Datalog Setup window by
clicking on the X in the upper right corner of the # aclogXXX.csv
window. # /b = baud rate
12. Close the wPTU Toolbox program on the PTU. # /p = COMM port
The datalogger function is activated separately
from the wPTU Toolbox program monitoring and seqcap dlog /b=38400 /p=6
setup windows. NOTE: Change the end number in the last line to the
preferred port number.
4. Save the file and launch the datalogger.
72
To begin the datalogger function:

1. With the truck operating in the datalog test
conditions, click on Start AC Datalogger in the
wPTU Toolbox xx folder. See Figure 30-77.
2. The Start AC Datalogger window will appear on
the PTU screen. See Figure 30-78. This window
will show how long the recording can be
performed based on the number of variables
being recorded, the record rate, and the
available computer memory.
3. In the middle of the Start AC Datalogger window
in the Menu section, there are two commands
for the datalogger. The datalogger will already
be recording data on the preselected
parameters. The two commands are:
• (W) Write data & quit - Pressing the W key
stops data logging and saves a data file to the
location c:\program files\GEOH-VPTU 1xx
\datalog\dlogxxx.
• (A) Abort - Pressing the A key stops data
logging and does not create a data file.
FIGURE 30-77. STARTING THE DATALOGGER
FIGURE 30-78. START AC DATALOGGER WINDOW
73
Uploading data 3. Select UPLOAD from the menu bar at the top of
the screen. See Figure 30-80.
Consolidated truck data save
The Consolidated Truck Data Save icon may
To aid in retrieving the data from the CPU card for also be selected to load data. The icon (small
use on another computer, the Consolidated Truck black squares with red line above and below) is
Data Save function has been provided in the wPTU located above the activity portion of the DSC
Toolbox program. This function puts all the collected screen.
statistical, event, and entered data in a file which can
then be processed at a later time.
NOTE: This function may also be completed via the
DID panel. Refer to "DID view data menu".
cable to the DSC.
LOGIN to wPTU Toolbox. See Figure 30-79.
FIGURE 30-80. wPTU CONSOLIDATED TRUCK DATA SAVE FUNCTION
74
4. The Consolidated Truck Data Save window will USB drive

appear. See Figure 30-81. Select the type of
Data can also be uploading using a USB drive at the
data to be saved by clicking the box next to data
edge of the CPU card.
type description. If EVENT DATA PACKS is
selected, the data pack file numbers must be 1. Insert a USB drive with sufficient space into the
entered in the field below. USB port at the edge of the CPU card, then
jumper the ground and download pins.
5. After selecting the data type to be saved, the
Browse button can be used to change the 2. The STATUS LEDs will flash, indicating that files
location to save the file. The default save are being written to the USB drive. When
directory is complete, the STATUS 1GREEN LED will flash
for 5 seconds, then the STATUS LEDs will
C:\GE_TRANS\wPTU_xx\data_ac\
resume their normal sequence.
<truck id date time>
3. Once the LEDs resume normal sequencing, it is
6. To download the selected data, click on the
safe to remove the USB drive from the CPU
Begin button at the bottom of the window.
card.
NOTE: Removing the USB drive while the STATUS
LEDs are flashing may cause corruption of the files
on the USB drive.
FIGURE 30-81. CONSOLIDATED TRUCK DATA

SAVE WINDOW
75
960E Dump truck

980E Dump truck
© 2016 KOMATSU
All Rights Reserved
76
CEN30029-01
730E
860E
960E
980E
960E-1K A50009 - A50010
960E-2 A30027 and up

Service tools and equipment................................................................................................................................. 3
Detecting leaks ..................................................................................................................................................... 6
System performance test ...................................................................................................................................... 7
Checking system oil .............................................................................................................................................. 8
System flushing..................................................................................................................................................... 9
Installing the manifold gauge set ........................................................................................................................ 10
Recovering and recycling refrigerant ...................................................................................................................11
Evacuating the air conditioning system............................................................................................................... 13
Charging the air conditioning system.................................................................................................................. 14
1
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.
2
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
3
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).
4
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
5
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.
6
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.
7
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.
8
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".
9
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.
10
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.
11
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.
12
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.
13
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".
14
NOTES
15
730E Dump truck

860E Dump truck
960E Dump truck
980E Dump truck
© 2016 KOMATSU
All Rights Reserved
16
CEN40161-00
DUMP TRUCK
980E

980E-4 A40003 and up
40 Troubleshooting
Fuse and circuit breaker locations
Fuse and circuit breaker locations ........................................................................................................................ 2
1
CEN40161-00 40 Troubleshooting
Fuse and circuit breaker locations

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 10 Hi-Beam Headlights
F8 15 Marker & Tail Lights
F9 10 Brake Light
F10 20 Ladder Lights
F11 15 Turn Signal Hazard
F12 10 Steering Bleed Down
F13 10 Retard Lamps
F20 10 Auto Lube
F42 5 IM & Fuel Sensor
F43 1 Direction Selector Switch
F44 5 Display Mode Switch, Camera Switch and Switch LED Lights
F45 15 GE Drive Control & Feedback
2
40 Troubleshooting CEN40161-00
Table 1: VEC - 89

F53 20 Heated Mirror
F56 10 Operator Seat
F57 10 Pre-Shift Brake Test
F61 5 Spare
F62 15 Fog Lamp
F63 15 Seat Belt Alarm
F64 5 Headlight Switch
SP1 1 Spare
SP2 1 Spare
SP3 1 Spare
SP4 5 Spare
SP5 10 Spare
SP6 15 Spare
SP7 20 Spare
SP8 25 Spare
D14 3 Back-Up Diode 1
D15 3 Back-Up Diode 2
R3 Back-Up Horn Micro Relay
R8 Marker & Tail Light Micro Relay
R9 Brake Light Micro Relay
R11 Left Turn Micro Relay
R12 Right Turn Micro Relay
R13 Turn Signal Hazard Flasher Relay
R14 Steering Bleed Down Micro Relay
R15 Retard Lamps Micro Relay
R29 Auto Lube Micro Relay
R39 Heated Mirror Micro Relay
R40 Fog Lamp Micro Relay
R41 Seat Belt Alarm Micro Relay
3
VEC-90
84053
FIGURE 3-2. VEC-90
Table 2: VEC - 90

F14 25 Payload Lamps
F15 15 Park Brake Status
F17 5 Payload Meter
F18 15 Ground Level Shutdown Switch
F19 10 Park Brake Control
F46 15 Payload Meter Key Switch Power
F47 10 KOMTRAX Plus Key Switch Power
F48 20 Modular Mining Conn Key Switch Power
SP1 5 Spare
SP2 5 Spare
SP3 10 Spare
SP4 10 Spare
SP5 10 Spare
SP6 15 Spare
SP7 15 Spare
SP8 15 Spare
D1 3 Key Switch Run Diode
4
Table 2: VEC - 90

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
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
VEC-91
84054
FIGURE 3-3. VEC-91
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 Unswitched
F27 10 IM Unswitched # 1
F28 10 IM Unswitched # 2
F29 10 KOMTRAX Plus & Orbcomm
F30 20 Modular Mining Unswitched
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 Unswitched Power #1
6
Table 3: VEC - 91

F40 20 Operator Cab Communication Radio 24V
F41 5 Operator Cab Fire Suppression
F49 15 Operator Cab HVAC Key Switch
F50 10 Windshield Wipers
F51 10 Hoist Limit Switch
F52 5 Turn Signal Switch
F54 5 Electronic Gauge Display Key Switch
F55 5 Aux Box Dome Lamps
F56 20 Electric Window - Left
F58 20 ORS Heated Hose
F59 5 Hydraulic Ladder
F60 5 Spare
F62 20 Electric Window - Right
F63 20 Auxiliary Power Port 12V
SP1 5 Spare
SP2 5 Spare
SP3 10 Spare
SP4 10 Spare
SP5 15 Spare
SP6 15 Spare
SP7 20 Spare
SP8 20 Spare
D13 3 Turn Signal Switch Diode
D14 3 Key Switch Power Or Diode
D15 3 GE Control Power Or Diode
R30 Starter Enable Relay
R34 GE Payload 70% Signal Relay
R35 GE Payload 100% Signal Relay
R36 Ether Start Relay
R37 Entertainment Radio Relay
R38 A/C Compressor Relay
R39 Shutter Control Relay
7
RTMR1 - VEC Block
86254
FIGURE 3-4. RTMR1 VEC BLOCK
Table 4: RTMR1 VEC BLOCK

F1 15 KomVision
F2 20 KomVision
F3 15 KomVision
F4 10 DID Panel 24VDC Supply Power
F5 Spare
F6 Spare
R1 A/C Shutter Control Micro Relay
R2 Park Brake Protection Micro Relay
R3 Spare
R4 Spare
R5 Spare
R6 Spare
R7 Spare
R8 Spare
8
NOTES
9
980E Dump truck

© 2016 KOMATSU
All Rights Reserved
10
CEN40114-01
DUMP TRUCK
730E
960E
980E

730E-8 A40003 and up
960E-2 A30074 and up
980E-4 A40003 and up
40 Troubleshooting
AC drive system fault codes (DSC)
DID panel fault code tables ................................................................................................................................... 3
1
NOTES
2
DID panel fault code tables

The tables on the following pages list the possible
fault codes which may be displayed on the DID panel Table 1: Operational restrictions
when accessed. Table 1 defines the restrictions to
Restriction Definition
operation of the propulsion and retarding systems
when a particular fault occurs. The fault codes listed NO RETARD (red) light
in the tables may be updated in later software illuminates.
versions. No power No retarding allowed.
No propulsion allowed.
• Fault codes numbered 000 through 099 are No power on the link.
applicable to the propulsion control portion of the
drive system controller (DSC). See Table 2. NO PROPEL (red) light
illuminates.
• Fault codes numbered 100 through 199 are
No propel No propulsion allowed.
applicable to Inverter 1. Fault codes numbered
200 through 299 are applicable to Inverter 2. See Retarding allowed.
Table 3. Link power allowed.
• Fault codes numbered 600 through 699 are PROPEL SYSTEM

applicable to the truck control portion of the drive CAUTION<170> (amber) light
system controller (DSC). See Table 4. illuminates.
Speed limit Propel, retard and DC link power
still allowed.
Speed limited to 10 MPH (16
KPH).
Prohibits system from enabling
INV1 disable
inverter #1 drive signal.
Prohibits system from enabling
INV2 disable
inverter #2 drive signal.
Raises engine speed to account
Engine speed
for a possible stuck RP contactor.
No restrictions. Event is for
System event
information purposes only.
3
Table 2: DID panel fault codes

(received from DSC - propulsion control)
Fault
Description Restriction Cause of fault
code
000 NO FAULT None Displayed when all faults have been reset
002 GROUND FAULT A ground fault has been detected:
For voltage < 1000 V, detection threshold is 166 mA
No power For voltage >= 1000 V, detection threshold ramps from
166 mA at 1000 V down to approximately 70 mA at
approximately 1500 V.
003 EXCESSIVE ALT FIELD TRANSIENT No power AC ripple in alternator DC excitation power
004 GF CUTOUT FAULT Occurs while not in REST mode.
:01 GF cutout switch open
System event
:02 propel lockout switch open
:03 propel lockout switch error
005 DRIVE SYSTEM OVERTEMP
:01 AFSE panel
:02 auxiliary inverter
:03 auxiliary blower
:04 alternator
:05 left stator
:06 left rotor
:07 right stator
No propel Temperature exceeds a limit for a sufficient time.
:08 right rotor
:09 chopper IGBT
:10 chopper diode
:11 left IGBT module
:12 left diode
:13 right IGBT module
:14 right diode
:15 rectifier diode
006 BOTH INVERTERS COMMUNICATION FAILED No power Lost communication with both inverters
008 DC LINK OVERVOLTAGE DC link voltage exceeds limit for a sufficient time.
:01 not in retard Occurs while not in retard, exceeds propel voltage limit
:02 in retard No power Occurs while in retard, exceeds retard voltage limit
:03 instantaneous Occurs instantaneously in propel or retard, exceeds link
voltage limit
009 ALT FIELD OVERCURRENT Alternator field current exceeds limit.
:01 normal Exceeds current limit over time
:02 instantaneous Exceeds current limit with no persistence
No power
:03 normal Exceeds current limit over time due to low engine speed
:04 instantaneous Exceeds current limit with no persistence due to low
engine speed
011 RETARD LEVER BAD
:01 voltage too high System event Incorrect input from retard lever
:02 voltage too low
4

Fault
code
012 RETARD PEDAL BAD
:01 voltage too high System event Incorrect input from retard pedal
:02 voltage too low
013 LINKV TEST FAILED No power Incorrect link volts
014 ANALOG SENSOR FAULT
:01 alt field amps
:02 link amps
:03 load box amps
:04 3 phase alt volts
:05 alt field volts
:10 link volts
:11 inv1 link volts
Speed limit Incorrect input from a sensor
:12 inv2 link volts
:13 ground connection
:14 10VDC power
:15 ground fault amps
:16 alt tertiary amps
:21 grid blower motor 1
:22 grid blower motor 2
:23 Link I T2 - Range
015 ANALOG SENSOR FAULT (restrictive)
No power Incorrect input from a sensor
:02 link amps
016 DSC CPU CARD (FB187)
:01
:02
:03
:04
Problem has occurred in the system CPU card.
:05
:06 No power
:07
:08
:09
:10 communication Software or I/O communication problem
:11 initialization Failed to initialize
:12 BRAM On power up, the status of data in BRAM is invalid.
017 DIGITAL I/O CARD FAULT (FB104) No power System CPU cannot communicate with digital I/O card.
018 ANALOG I/O CARD FAULT (FB173) System CPU cannot communicate with analog I/O card.
:01 analog card no response Card missing or not seated
No power
:02 analog card timeout Read timeout
Accelerator and retard pedals both applied while truck
019 RIDING RETARD PEDAL System event
speed is above 11 kph (7 mph)
020 LO SPEED HI TORQUE TIMEOUT No propel Torque limit exceeded
5

Fault
code
Current in alternator field tertiary winding exceeds limit
023 TERTIARY OVERCURRENT No power
over time.
024 DSC CONFIG FILE INCORRECT
:01 Incorrect or missing DSC configuration file
:03
No power
:04 overspeeds incorrect Incorrect overspeed values
:05
Incorrect or missing DSC configuration file
:06
025 AUX BLOWER FAULT Auxiliary blower system fault
Auxiliary speed feedback indicates no or incorrect
:01 not OK or no speed feedback
No power blower speed.
Auxiliary OK goes low twice when speed command is
:02 numerous shutdowns
greater than running speed.
026 CAPACITOR OVERPRESSURE
:01 inv 1 No power Excessive filter capacitor pressure
:02 inv 2
027 ICP PANEL CONNECTOR
:01 CNA - CNF
No power A panel connector is not properly connected.
:02 CNX connector
:03 aux blower connector
Torque command polarity does not match direction
029 DIRECT SIGNAL MISMATCH No propel
request over time.
030 GF CONTACTOR Speed limit GF command/feedback do not agree.
031 BATTERY BOOST CIRCUIT
:01 GFR failed to open GF command/feedback do not agree.
Speed limit
:02 GFR failed to close
:03 SCR3 failed AFSE panel or SCR3 shorted
033 HP IMBALANCE
Speed limit &
:01 Chopper module shorted Chopper module has failed.
engine speed
:02 Chopper module on w/o CM2 closure
034 RETARD CIRCUIT
:01 high chopper % on
CM2 may be inoperable
:02 overvoltage protection on Speed limit
:03 link discharge error
:04 chopper module stuck on Chopper module has failed.
035 ENGINE SPEED SENSOR INPUT Speed limit Engine speed sensor is out of range.
036 RETARD GRID BLOWER FAILURE
:01 blower 1 stall
:02 blower 2 stall
:03 blower 1 open No power A grid blower has failed.
:04 blower 2 open
:05 blower 1 & 2 currents unequal
:07 loadbox current w/o blower operation
6

Fault
code
037 COMPUTER POWER SUPPLY
:01 VOLTS 5 POS +5V power supply is out of limits.
Speed limit
:03 VOLTS 15 NEG -15V power supply is out of limits.
038 LOGIC POWER SUPPLY (instantaneous)
Speed limit
Selector lever moved to FORWARD or REVERSE
042 DIRECTION SELECTED IN LOADBOX MODE No propel
during loadbox mode.
043 DRIVE SYSTEM BATTERY LOW
:01 engine off Speed limit Battery volts are below limit.
:02 engine on
044 DRIVE SYSTEM BATTERY HIGH None Battery volts are above limit.
045 CHOPPER OPEN CIRCUIT Open circuit in a chopper
:01 chopper 1 Open circuit in chopper 1
:02 chopper 2 Speed limit Open circuit in chopper 2
Failure during chopper self test. Link voltage decayed
Speed limit &
046 RETARD SHORT CIRCUIT too quickly when AFSE command set low, prior to
engine speed
starting test.
047 ENGINE STALL (restrictive) No power An engine stall condition has occurred.
048 DC LINK VOLTAGE
:01 restrictive No power DC link voltage low after startup
:02 AFSE command full AFSE command at full for too long
049 ENGINE CAN FAULT System event Engine CAN network communication lost
050 CAN NETWORK ERROR System event Truck CAN network communication lost
051 SPEED SENSOR - LEFT REAR Input from M1 sensor is out of tolerance.
Zero output from sensor with front wheels moving,
:01 zero output with truck moving
INV1 disable brake released.
High output from sensor with all other wheel speeds at
:02 high output with truck stopped
zero.
052 SPEED SENSOR - RIGHT REAR Input from M2 sensor is out of tolerance.
Zero output from sensor with front wheels moving,
INV2 disable brake released.
zero.
7

Fault
code
053 SPEED SENSOR - LEFT FRONT Input from left front wheel sensor is out of tolerance.
Zero output from sensor with rear wheels moving, brake
System event released.
zero.
:03 higher rate of speed change Higher rate of speed change than other sensors
054 SPEED SENSOR - RIGHT FRONT Input from right front wheel sensor is out of tolerance.
Zero output from sensor with rear wheels moving, brake
released.
System event
zero.
:03 higher rate of speed change Higher rate of speed change than other sensors
Zero speed from front sensors while rear sensors
055 FRONT WHEEL SPEED SENSORS System event
indicate speed
056 INVERTER SOFTWARE VERSION
:01 inv 1 System event Incorrect version of inverter software is installed.
:02 inv 2
057 INV 1 SOFTWARE MISMATCH INV1 disable Software type does not match expectation
058 INV 2 SOFTWARE MISMATCH INV2 disable Software type does not match expectation
061 MOTOR OVERSPEED
:01 speed sensor signals System event Truck is over the motor overspeed limit.
:02 speed control overspeed
063 ENGINE LOAD SIGNAL
:01 below minimum Engine load out of range.
:02 above maximum
:03 below minimum System event PWM signal failed low.
:04 above maximum PWM signal failed high.
:05 frequency incorrect PWM signal frequency incorrect
:06 frequency inconsistent PWM signal frequency inconsistent
065 COMPONENT TEMP
:01 AFSE temp
:04 alternator temp
:05 left stator temp
:06 left rotor temp
:07 right stator temp
:08 right rotor temp
Speed limit Temperature is out of range.
:09 chopper IGBT temp
:10 chopper diode temp
:11 left IGBT module temp
:12 left diode temp
:13 right IGBT module temp
:14 right diode temp
:15 rectifier diode temp
8

Fault
code
066 CM1 SELF TEST
:01 turn on failure
:02 grid current sensor
:03 link current sensor
:04 grid blower 1 sensor
No power Chopper module 1 self test failed.
:06 grid/link current delta between two sensors
:07 turn off failure
:08 grid resistance, turned on but readings off
:09 grid current sensor not at zero at test start
:10 link current sensor not at zero at test start
:11 generic event
067 CM2 SELF TEST
:01 turn on failure
No power Chopper module 2 self test failed.
:11 generic event
068 CM3 SELF TEST
:01 turn on failure
Chopper module 3 self test failed.
:11 generic event
068 CM4 SELF TEST
:01 turn on failure
Chopper module 4 self test failed.
:11 generic event
9

Fault
code
070 LINK CAPACITANCE LEVEL LOW System event Link capacitance level is low, but OK.
071 LINK CAPACITANCE LEVEL TOO LOW Speed limit Link capacitance level is too low.
072 GROUND CIRCUIT FAULT Speed limit Ground fault detected during DC link capacitance test.
073 SENSOR OFFSET ERROR System event Current detected in DC link but should be zero.
074 INV1 COMMUNICATION FAILED
:01 No communication Inverter 1 INV1 disable
:02 Inverter 1 customer option bit
075 INV2 COMMUNICATION FAILED
:01 No communication Inverter 2 INV2 disable
:02 Inverter 2 customer option bit
076 DSC CPU CARD FAILED
:01 software did not load properly at startup
:02 timeout issue after software download
:05 timeout issue after software download No power FB173 card failure
Inverter failed during switch from REST to READY
077 INVERTER FAILED VI TEST No power
mode.
078 INVERTER COMMUNICATION FAILURE
:01 inverter 1
:02 inverter 2
A failure in the inverter background communication was
:03 inverter 1 System event
detected.
:04 inverter 2
:05 inverter 1
:06 inverter 2
Alternator 3 phase voltage does not match expected
079 :09 DSC ANALOG I/O CARD FAULT No propel
DC link voltage.
081 QUAD CHOPPER FAILURE
:01 Grid current high value
:02 Link current high value
:03 Grid current sensor loadbox Speed Limit Quad Chopper Fault
:04 Link current sensor loadbox

Detected high chopper percent on - CM2 may
:05
not have closed
082 GRID PROTECTION Speed limit Chopper modules on excessively in Propel mode
084 CONTROL POWER SWITCH OFF System event Control power switch is turned off while truck is moving.
087 HP LOW System event Horsepower adjust is at negative limit for 30 seconds.
10

Fault
code
088 HP LIMIT
:01 Engine cold idle lock active System event Horsepower limit exceeded while in propulsion.
:02 Alternator speed sensor error
089 ENGINE SPEED FAULT Engine speed feedback does not match commanded
:02 engine speed does not match command speed.
System event
:03 cold idle lock Engine cold idle lock is active.
:04 alternator speed Alternator speed sensor failed.
091 INVERTER 1 CUTOUT System event Automatically generated when an inverter is manually
092 INVERTER 2 CUTOUT System event cut out
094 ILLEGAL LIMP REQUEST System event A “limp mode” request is received while truck is moving.
095 BAD BRAM BATTERY System event BRAM battery voltage is low.
096 UNEXPECTED DSC CPU RESET System event DSC CPU card reset without request.
098 DATA STORE System event PTU data store manual request
11

(received from inverters 1 and 2)
Fault
code
100/200 INV TMC CPU CARD (FB190)
:23 pat fail out 100 Pattern had bad A, B, C output 100%.
:29 no extvi TIC Extrapolation interrupt not running
:30 no vector TIC Vector interrupt not running
:31 no I TIC TIC I TIC interrupt not running
:32 NMI occurred Non-maskable interrupt occurred.
:34 no background TIC INV1 (INV2) Background not running
:35 PGA not programmed disable PGA could not be programmed.
:38 PGA init failed PGA initialization failed.
:39 PGA DP failed PGA D/P did not initialize.
:40 par not found Parameter not found
:41 multiple par Parameter multiply defined
:48 no cam TIC Cam ISR not running
:49 no peak samp TIC Peak sample ISR not running
101/201 INV TMC CPU CARD (FB190) (NR)
:01 Aup cmd not off Phase A up command not off
:02 Adn cmd not off Phase A down command not off
:03 Bup cmd not off Phase B up command not off
:04 Bdn cmd not off Phase B down command not off
:05 Cup cmd not off Phase C up command not off
:06 Cdn cmd not off Phase C down command not off
:07 Aup cmd not on Phase A up command not on
System event
:08 Adn cmd not on Phase A down command not on
:09 Bup cmd not on Phase B up command not on
:10 Bdn cmd not on Phase B down command not on
:11 Cup cmd not on Phase C up command not on
:12 Cdn cmd not on Phase C down command not on
:13 no chopper TIC1 Chopper 1 interrupt not running
:14 no chopper TIC2 Chopper 2 interrupt not running
:16 inv CPU reset Inverter CPU was reset.
12

Fault
code
102/202 INV I/O CARD (FB173)
:05 gnd not ok Logic ground not OK
:08 no I/O card Could not access I/O card
:09 eoc not working A/D conversion did not work.
:10 DB no brake Chopper module on too long while not braking
:11 ptf A signal Phase A overcurrent signal too long
:12 ptf B signal Phase B overcurrent signal too long
:13 ptf C signal Phase C overcurrent signal too long
:14 IC zero not ok Current IC not zero at startup
:15 IC not ok INV1 (INV2) C phase current too high
:16 ptl not ok disable Protective turn off circuit not OK
:17 cur measure not ok Phase A1 and B1 currents do not match.
:19 cur measure not ok Phase A2 and B2 currents do not match.
:20 cur measure not ok Phase A2 and C2 currents do not match.
:21 cur excessive Excessive current on A1, no devices on
:22 cur excessive Excessive current on B1, no devices on
:23 cur excessive Excessive current on C1, no devices on
:24 cur excessive Excessive current on A2, no devices on
:25 cur excessive Excessive current on B2, no devices on
:26 cur excessive Excessive current on C2, no devices on
103/203 INV I/O CARD (FB173) (NR)
:01 chop 1 cmd not off Chopper 1 command not off
:02 chop 2 cmd not off Chopper 2 command not off
:03 chop 1 cmd not on Chopper 1 command not on
:04 chop 2 cmd not on Chopper 2 command not on
:05 volt scale A flt Scale A volts out of range 70%, 100%
:06 volt scale B flt Scale B volts out of range 70%, 100%
:07 link V scale flt Link V scale out of range 70%, 100%
:08 current scale A flt Scale A current out of range 70%, 100%
:09 current scale B flt Scale B current out of range 70%, 100%
:10 input V scale fit Input V scale out of range 70%, 100%
System event
:11 V test VCO high High frequency on VCO Vtest channel
:12 V test VCO low Low frequency on VCO Vtest channel
:13 IA VCO hi High frequency on IA channel
:14 IB VCO hi High frequency on IB channel
:15 link V VCO hi High frequency on VCO link filter V channel
:16 infilV VCO hi High frequency on VCO in filter V channel
:17 IA too high IA current too high
:18 IA too low IA current too low
:19 IB too high IB current too high
:20 IB too low IB current too low
:21 link V too hi DC link voltage too high
13

Fault
code
103/203 INV I/O CARD (FB173) (NR)
:23 infilV too hi Input filter voltage too positive
:24 DB chopV too hi DB chopper voltage too positive
:25 VA VCO hi High frequency on VCO VA channel
:26 VB VCO hi High frequency on VCO VB channel
:27 VC VCO hi High frequency on VCO VC channel
:28 VA volts too hi System event VA voltage too high
:29 VB volts too hi VB voltage too high
:30 volt scale C flt Scale C volts out of range 70%, 120%
:31 VC volts too hi VC voltage too high
:32 Hep load volts too hi HEP load voltage too high
:33 Hep load volts scale fault HEP load volts scale fault
:66 gnd cal scale Ground calibration scale out of range
:67 gnd fault Ground fault detected
104/204 FIBER OPTIC CARD
:01 fo ps low INV1 (INV2) Fiber optic power supply monitor
:02 fo card disable disable Fiber optic card disabled
:03 fo card enable Fiber optic card enabled and no direction
105/205 POWER SUPPLY CARD
:01 P5V not ok +5 volt not in tolerance
:03 N15V not ok -15 volt not in tolerance
INV1 (INV2)
disable
:07 N24V not ok -24 volt not in tolerance
:10
:11 Power low
:12
106/206 DC WIRING
:01 DC pwr conn open INV1 (INV2) DC power connection is open.
:02 link V phase V mismatch disable DC link and phase voltage are mismatched.
:03 link V chopper V mismatch DC link and chopper voltage are mismatched.
107/207 GDPS FAILURE
:01 gate dr ps off No power to gate drive power supply or it failed
INV1 (INV2)
:02 gate dr ps off S disable No power to gate drive power supply or it failed with
enable/DC volts
:03 multiple IGBT not off S Multiple IGBTs not off with enable/DC volts
109/209 LINK VOLTS SENSOR INV1 (INV2)
:01 linkV sensor flt disable DC link voltage sensor failed
111/211 INPUT VOLTS SENSOR
:01 Vfil not ok Speed limit Filter voltage outside limits
:02 Vhep not ok HEP voltage outside limits
14

Fault
code
113/213 INVERTER, GENERAL
:01 Aup cur hi Phase A current out too high
:02 Adn cur hi Phase A current in too high
:03 Bup cur hi Phase B current out too high
:04 Bdn cur hi Phase B current in too high
:05 Cup cur hi Phase C current out too high
:06 Cdn cur hi Phase B current in too high
:07 Aup cur lo Phase A current out too low
:08 Adn cur lo Phase A current in too low
:09 Bup cur lo Phase B current out too low
:10 Bdn cur lo Phase B current in too low
:11 Cup cur lo Phase C current out too low
:12 Cdn cur lo Phase C current in too low
:13 A zero cur hi Phase A current out not zero
:15 B zero cur hi Phase B current out not zero
:17 A volt hi Adn Phase A volt too high while phase A down on
:18 A volt lo Aup Phase A volt too low while phase A up on
:19 A volt hi Bdn Phase A volt too high while phase B down on
:20 A volt lo Bup Phase A volt too low while phase B up on
:21 A volt hi Cdn Phase A volt too high while phase C down on
INV1 (INV2)
:22 A volt lo Cup Phase A volt too low while phase C up on
disable
:23 B volt hi Adn Phase B volt too high while phase A down on
:24 B volt lo Aup Phase B volt too low while phase A up on
:25 B volt hi Bdn Phase B volt too high while phase B down on
:26 B volt lo Bup Phase B volt too low while phase B up on
:27 B volt hi Cdn Phase B volt too high while phase C down on
:28 B volt lo Cup Phase B volt too low while phase C up on
:29 C volt hi Adn Phase C volt too high while phase A down on
:30 C volt lo Aup Phase C volt too low while phase A up on
:31 C volt hi Bdn Phase C volt too high while phase B down on
:32 C volt lo Bup Phase C volt too low while phase B up on
:33 C volt hi Cdn Phase C volt too high while phase C down on
:34 C volt lo Cup Phase C volt too low while phase C up on
:35 Aup fault cur Phase A fault current when phase A up on
:36 Adn fault cur Phase A fault current when phase A down on
:37 Bup fault cur Phase B fault current when phase B up on
:38 Bdn fault cur Phase B fault current when phase B down on
:39 Cup fault cur Phase C fault current when phase C up on
:40 Cdn fault cur Phase C fault current when phase C down on
:48 A volt hi off Phase A voltage high with all IGBTs off
:49 A volt lo off Phase A voltage low with all IGBTs off
15

Fault
code
113/213 INVERTER, GENERAL
:50 B volt hi off Phase B voltage high with all IGBTs off
:51 B volt lo off Phase B voltage high with all IGBTs off
:52 C volt hi off Phase C voltage high with all IGBTs off
:53 C volt lo off Phase C voltage high with all IGBTs off
:54 phase short pos Possible phase to DC+ short
:55 phase short neg Possible phase to DC- short
:60 linkV too hi PTL Link volts above PTL
:70 Aph neg I low Phase A negative current low (unbalance)
:71 Bph neg I low Phase B negative current low (unbalance)
:72 Cph neg I low Phase C negative current low (unbalance)
:73 Aph neg I hi INV1 (INV2) Phase A negative current high (unbalance)
disable
:74 Bph neg I hi Phase B negative current high (unbalance)
:75 Cph neg I hi Phase C negative current high (unbalance)
:76 Aph pos I low Phase A positive current low (unbalance)
:77 Bph pos I low Phase B positive current low (unbalance)
:78 Cph pos I low Phase C positive current low (unbalance)
:79 Aph pos I hi Phase A positive current high (unbalance)
:80 Bph pos I hi Phase B positive current high (unbalance)
:81 Cph pos I hi Phase C positive current high (unbalance)
:82 no current w run No current while running
:83 link volt hi High DC link voltage during propel with torque feedback
opposite polarity command
:88 link overvolt Instantaneous link overvoltage
114/214 INVERTER, GENERAL (NR)
:22 IA VCO lo Low frequency on IA channel
:24 IB VCO lo Low frequency on IB channel
:26 linkV VCO lo Low frequency on VCO link filter V channel
:28 infilV VCO lo Low frequency on VCO in filter V channel
:38 LinkV too lo Link voltage too low
:40 infilV too lo Input filter voltage too high
:46 DB chop VCO lo Low frequency on VCO DB chopper channel
:48 DB chopV too lo DB chopper voltage too low
System event
:50 VA VCO lo Low frequency on VCO VA channel
:52 VB VCO lo Low frequency on VCO VB channel
:54 VC VCO lo Low frequency on VCO VC channel
:56 VA volts too lo VA voltage too low
:58 VB volts too lo VB voltage too low
:61 VC volts too lo VC voltage too low
:63 HEP volts too lo HEP voltage too low
:65 hi neg dv/dt High negative DV/DT with PTF while braking
:66 out of sat cluster Out of sat cluster
16

Fault
code
115/215 INVERTER SYSTEM FAULT
:01 comm error
:02 comm error DSC direction request missing or opposite truck travel
:03 comm error
:04 input volt lo Input voltage is too low.
:05 dc link volt lo Run request from DSC is active while DC link voltage
INV1 (INV2) feedback is low.
:06 comm lost disable Communication with DSC has been lost.
:07 link volt not ok DC link voltage not in tolerance
:08 link current not ok DC link current not in tolerance
:09 comm lost Communication with DSC has been lost.
:10 CM temp hi Both chopper modules too hot

:11 PM temp hi One or more phase modules too hot
116/21 INVERTER, PHASE A+/A-
:01 alarm A Phase A IGBT did not turn off
INV1 (INV2)
:02 PTF A Overcurrent on phase A
disable
:04 IGBT_SAT_AP IGBT saturated
:05 IGBT_SAT_AP IGBT saturated
117/217 INVERTER, PHASE A+
:01 alarm AP Phase A positive IGBT did not turn off.
:02 Adp fb not off Phase A down feedback is not off.
:03 phase A modl pos Phase A positive module failed.
INV1 (INV2)
:04 hold AP disable Phase A positive and negative IGBTs are on (positive
turn on).
:05 Adp fb not on Phase A down feedback is not on.
:06 Adp IGBT not on Phase A positive IGBT did not turn on.
:07 IGBT_PS_AP IGBT protective shutoff
118/218 INVERTER, PHASE A+ (NR)
:02 Adp temp short Phase A down thermistor short
:03 Adp temp open Phase A down thermistor open
System event
:04 Adp temp warm Phase A down thermistor warm
:05 Adp temp hot Phase A down thermistor hot
:06 Adp fb not off S Phase A down not off with enable/DC volts
119/219 INVERTER, PHASE A-
:01 alarm AN Phase A negative IGBT did not turn off.
:02 Adn fb not off Phase A down feedback is not off.
:03 phase A modl neg Phase A negative module failed.
INV1 (INV2)
:04 hold AN disable Phase A positive and negative IGBTs are on (negative
turn on).
:05 Adn fb not on Phase A down feedback is not on.
:06 Adn IGBT not on Phase A negative IGBT did not turn on.
:07 IGBT_PS_AN IGBT protective shutoff
17

Fault
code
120/220 INVERTER, PHASE A- (NR)
:02 Adn temp short Phase A down thermistor short
:03 Adn temp open Phase A down thermistor open
System event
:04 Adn temp warm Phase A down thermistor warm
:05 Adn temp hot Phase A down thermistor hot
:06 Adn fb not off S Phase A down not off with enable/DC volts
121/221 INVERTER, PHASE A CURR
:01 I sensor ph A Phase A current sensor failed.
:02 IA zero not ok INV1 (INV2) Current IA not zero at startup
:03 IA not ok disable Phase A current too high
:04 I snsr ph A open Phase A current sensor open
:05 I snsr ph A short Phase A current sensor short
123/223 INVERTER, PHASE A VOLTS
INV1 (INV2)
:01 V sensor phase A Phase A voltage sensor failed.
disable
:02 VA not ok Phase A voltage too high
125/225 INVERTER, PHASE B+/B-
:01 alarm B Phase B IGBT did not turn off
INV1 (INV2)
:02 PTF B Overcurrent on phase B
disable
:04 IGBT_SAT_BP IGBT saturated
:05 IGBT_SAT_BP IGBT saturated
126/226 INVERTER, PHASE B+
:01 alarm BP Phase B IGBT did not turn off.
:02 Bup fb not off Phase B up feedback is not off.
:03 phase B modl pos Phase B positive module failed.
INV1 (INV2)
:04 hold BP disable Phase B positive and negative IGBTs are on (positive
turn on).
:05 Bup fb not on Phase B feedback is not on.
:06 Bup IGBT not on Phase B positive IGBT did not turn on.
:07 IGBT_PS_BP IGBT protective shutoff
127/227 INVERTER, PHASE B+
:02 Bup temp short Phase B up thermistor short
:03 Bup temp open Phase B up thermistor open
System event
:04 Bup temp warm Phase B up thermistor warm
:05 Bup temp hot Phase B up thermistor hot
:06 Bup fb not off S Phase B up not off with enable/DC volts
18

Fault
code
128/228 INVERTER, PHASE B-
:01 alarm BN Phase B negative IGBT did not turn off.
:02 Bdn fb not off Phase B down feedback is not off.
:03 phase B modl neg Phase B negative module failed.
INV1 (INV2)
:04 hold BN disable Phase B positive and negative IGBTs are on (negative
turn on).
:05 Bdn fb not on Phase B down feedback is not on.
:06 Bdn IGBT not on Phase B negative IGBT did not turn on.
:07 IGBT_PS_BN IGBT protective shutoff
129/229 INVERTER, PHASE B- (NR)
:02 Bdn temp short Phase B down thermistor short
:03 Bdn temp open Phase B down thermistor open
System event
:04 Bdn temp warm Phase B down thermistor warm
:05 Bdn temp hot Phase B down thermistor hot
:06 Bdn fb not off S Phase B down not off with enable/DC volts
130/230 INVERTER, PHASE B CURR
:01 I sensor ph B Phase B current sensor failed.
:02 IB zero not ok INV1 (INV2) Current IB not zero at startup
:03 IB not ok disable Phase B current too high
:04 I snsr ph B open Phase B current sensor open
:05 I sensr ph B short Phase B current sensor short
132/232 INVERTER, PHASE B VOLTS
INV1 (INV2)
:01 V sensor phase B Phase B voltage sensor failed.
disable
:02 VB not ok Phase B voltage too high
134/234 INVERTER, PHASE C+/C-
:01 alarm C Phase C IGBT did not turn off.
INV1 (INV2)
:02 PTF C Overcurrent on phase C
disable
:04 IGBT_SAT_CP IGBT saturated
:05 IGBT_SAT_CN IGBT saturated
135/235 INVERTER, PHASE C+
:01 alarm CP Phase C positive IGBT did not turn off.
:02 Cup fb not off Phase C up feedback is not off.
:03 phase C modl pos Phase C positive module failed.
INV1 (INV2)
:04 hold CP disable Phase C positive and negative IGBTs are on (positive
turn on).
:05 Cup fb not on Phase C up feedback is not on.
:06 Cup IGBT not on Phase C positive IGBT did not turn on.
:07 IGBT_PS_CP IGBT protective shutoff
19

Fault
code
136/236 INVERTER, PHASE C+
:02 Cup temp short Phase C up thermistor short
:03 Cup temp open Phase C up thermistor open
:04 Cup temp warm System event Phase C up thermistor warm
:05 Cup temp hot Phase C up thermistor hot
:06 Cup fb not off S Phase C up not off with enable/DC volts
:07 IGBT_PS_CP IGBT protective shutoff
137/237 INVERTER, PHASE C-
:01 alarm CN Phase C negative IGBT did not turn off.
:02 Cdn fb not off Phase C down feedback is not off.
:03 phase C modl neg Phase C negative module failed.
INV1 (INV2)
:04 hold CN disable Phase C positive and negative IGBTs are on (negative
turn on).
:05 Cdn fb not on Phase C down feedback is not on.
:06 Cdn IGBT not on Phase C negative IGBT did not turn on.
:07 IGBT_PS_CN IGBT protective shutoff
138/238 INVERTER, PHASE C- (NR)
:02 Cdn temp short Phase C down thermistor short
:03 Cdn temp open Phase C down thermistor open
System event
:04 Cdn temp warm Phase C down thermistor warm
:05 Cdn temp hot Phase C down thermistor hot
:06 Cdn fb not off S Phase C down not off with enable/DC volts
141/241 INVERTER, PHASE C VOLTS
INV1 (INV2)
:01 V sensor phase C Phase C voltage sensor failed.
disable
:02 VC not ok Phase C voltage too high
143/243 INVERTER, TM SPEED SENSOR
:01 ss rate hi Speed sensor high rate of change
INV1 (INV2)
:02 ss no input disable Speed sensor no frequency input
:03 SS_INTERMIT Speed sensor feedback signal intermittent
:04 phase A overcurrent Phase A current is too high.

:05 phase B overcurrent Phase B current is too high.
:06 phase B overcurrent Phase C current is too high.
:07 felt volts hi Felt voltage is above limit.
144/244 INVERTER, TM SPEED SENSOR (NR)
:01 ss one channel Speed sensor single channel operation
System event
:02 ss rate hi Speed sensor high rate of change
:03 ss no input Speed sensor no frequency input
20

Fault
code
147/247 INVERTER, CHOPPER 1
:01 chop1 not off Chopper 1 did not turn off.
:02 chop1 overcurrent Chopper 1 current too high.
:04 chop1 sat flt IGBT saturation filter on chopper 1
Speed limit
:05 chop1 ps flt IGBT power supply filter on chopper 1
:06 chop1 current hi Chopper 1 on-state current too high
:07 chop1 current lo Chopper 1 on-state current too low
:08 chop1 current OOR Chopper 1 on-state current out of range
148/248 INVERTER, CHOPPER 1 (NR)
:01 chop1 fb not off Chopper 1 feedback is not off.
:02 chop1 fb not on Chopper 1 feedback is not on.
:03 chopA temp short ChopA thermistor short
:04 chopA temp open Speed limit ChopA thermistor open
:05 chopA temp warm ChopA thermistor warm
:06 chopA temp hot ChopA thermistor hot
:07 DB1 fb not off S Chopper 1 not off with DC volts
:08 chop1 short Chopper 1 off-state shorted
149/249 INVERTER, CHOPPER 2
:01 chop2 not off Chopper 2 did not turn off.
:02 chop2 overcurrent Chopper 2 current too high.
:04 chop2 sat flt IGBT saturation filter on chopper 2
Speed limit
:05 chop2 ps flt IGBT power supply filter on chopper 2
:06 chop2 current hi Chopper 2 on-state current too high
:07 chop2 current lo Chopper 2 on-state current too low
:08 chop2 current OOR Chopper 2 on-state current out of range
150/250 INVERTER, CHOPPER 2 (NR)
:01 chop2 fb not off Chopper 2 feedback is not off.
:02 chop2 fb not on Chopper 2 feedback is not on.
:03 chop B temp short Chop B thermistor short
:04 chop B temp open Speed limit Chop B thermistor open
:05 chop B temp warm Chop B thermistor warm
:06 chop B temp hot Chop B thermistor hot
:07 DB2 fb not off S Chopper 2 not off with DC volts
:08 chop2 short Chopper 1 off-state shorted
151/251 MISCELLANEOUS
System event
:01 tach differential Too much speed difference
153/253 INVERTER, MOTOR
:01 motor open Motor connection open
INV1 (INV2)
:02 motor short Motor connection short
disable
:03 rtc current bad RTC current bad
:04 motor overload Motor overload
21

Fault
code
154/254 INVERTER MOTOR FAULTS (NR)
:01 rotor temp hi Motor rotor temperature is high.
:02 stator temp hi Motor stator temperature is high.
:03 motor type 1 Motor type 1 detected
System event
:04 motor type 2 Motor type 2 detected
:05 motor temp sensor bad Motor temp sensor failed
:06 current pullout Current approached pullout
:07 filtered slip pullout Filter slip approached pullout
155/255 INVERTER, SECOND LOAD
System event
:01 second load open Second load connection open
156/256 INVERTER, SECOND LOAD
:01 zero seq volts hi Zero seq voltage is too high.
:02 zero seq current hi Zero seq current is too high.
System event
:03 neg sys volts hi Negative system voltage is too high.
:04 neg seq current hi Negative seq current is too high.
:05 hep load current unbalanced HEP load current is unbalanced.
157/257 INVERTER, FILTER
:01 inv cap overpressure Inverter capacitor is over the pressure limit.
:02 line neutral volts hi System event Line-neutral voltage in the capacitor is too high.
:03 flt cap OOT Filter cap value is out of tolerance.
:04 flt ind OOT Filter inductance value is out of tolerance.
166/266 INVERTER, PHASE A+ (NR) System event
168/268 INVERTER, PHASE A- (NR) System event
175/275 INVERTER, PHASE B+ (NR) System event
177/277 INVERTER, PHASE B- (NR) System event
184/284 INVERTER, PHASE C+ (NR) System event
186/286 INVERTER, PHASE C- (NR) System event
191/291 INVERTER, GENERIC EVENT System event
22

(received from DSC - truck control)
Fault
code
601 TCI FB144 CPU CARD
:01 10ms task failed to init
:03 50ms task failed to init DSC CPU card problem
No propel
:06 flt manager task
:07 flash CRC
Flash CRC computation did not match expected value.
:09 main task failed to init
:10 excess timeouts Upon power-up, excessive bus timeouts occurred.
:11 BBRAM bad
:12 BBRAM CRC CRC on BBRAM did not match expected value.
602 FB104 DIGITAL I/O CARD FAULT Internal TCI self-test detected a digital I/O card prob-
No propel
lem.
603 FB160 ANALOG I/O CARD FAULT Internal TCI self-test detected an analog I/O card prob-
No propel
lem.
604 DSC FAULT
:01 missing message
:02 bad tick
:03 bad CRC Speed limit Lost RS422 communication with PSC.
:04 FIFO overflow
:05 bad start bit
:06 bad stop bit
607 POSITIVE 5 VOLTS Speed limit +5V power supply out of limits
608 POSITIVE 15 VOLTS Speed limit +15V power supply out of limits
609 NEGATIVE 15 VOLTS Speed limit -15V power supply out of limits
610 POT REFERENCE Speed limit Pot reference (10.8V) out of limits
613 ANALOG INPUT
:01 A2D gnd Speed limit Signal is outside the design range of valid values.
:02 A2D gainchk
616 DIRECTION MISMATCH Simultaneous FORWARD and REVERSE commands
No propel
were received.
617 ENGINE START REQUEST DENIED
:01 engine warn while cranking Engine warning occurs after engine crank command is
SYS Event given.
:02 engine kill while cranking Engine kill input occurs while engine crank command is
active.
618 Engine Warning Event None Engine Warning indication with engine above idle and
selected period of time transpires.
619 ENGINE WARNING RECEIVED Engine controller sends caution signal, rpm above low
No propel
idle.
620 ENGINE KILL WHILE VEHICLE MOVING Engine shutdown switch is activated while truck is
No propel
moving.
23

Fault
code
622 PARK BRAKE FAULT Error in parking brake operation has occurred.
:01 command/response failure Park brake command and feedback don't agree.
No propel
:02 set above maximum speed Parking brake set feedback is received while truck is
moving.
624 BODY UP AND PAYLOAD INDICATION Full payload and body up signal are received at the
Speed limit
same time.
625 EXTENDED BATTERY RECONNECT TIME Excessive time since battery separate and battery
System event
reconnection
628 CONNECTED BATTERY VOLTS One of the connected batteries' volts are incorrect with
engine speed above low idle.
System event
:01 control battery low Control battery voltage below minimum limit (20)
:02 control battery high Control battery voltage above maximum limit (34)
629 BAROMETRIC PRESSURE SIGNAL Barometric pressure signal is outside operational limits.
:01 low System event Voltage is below minimum operational limit.
:02 high Voltage is above maximum operational limit.
630 AXLE BOX PRESSURE Axle box pressure signal is outside operational limits.
:01 low Speed limit Sensor indicates low pressure with engine running.
:05 high Sensor indicates low pressure with engine running.
631 AMBIENT TEMPERATURE Ambient temperature signal is outside operational
limits.
System event
:01 low Sensor indicates low temperature.
:02 high Sensor indicates high temperature.
634 TRUCK OVERLOADED No propel The over-payload signal is on, operation restricted.
635 TRUCK OVERLOADED (NR) System event The over-payload signal is on, propulsion allowed.
639 ENGINE START REQUEST WHILE RUNNING Engine start request signal occurred while engine RPM
System event
greater than 600 RPM, and longer than 3 seconds.
640 ACCEL PEDAL TOO HIGH No propel Accelerator pedal voltage is high.
641 ACCEL PEDAL TOO LOW System event Accelerator pedal voltage is low.
642 ENGINE STARTED Engine cranking protection is on with an engine start
System event
request and reset/dump body override on.
643 CONTROL COOLING AIR PRESSURE Control cabinet pressure signal is outside operational
limits.
:01 low Pressure switch indicates low pressure with engine
running.
Speed limit
:02 high Pressure switch indicates high pressure with engine not
running.
:03 low / afse high Pressure switch indicates low pressure with engine
running and high AFSE temperature.
24

Fault
code
644 CONTROL CABINET HEATER EVENT
:01 Relay HCR commanded closed (ON) and feedback
indicates HCR is open (OFF).
:02 Relay HCR commanded open (OFF and feedback
indicates HCR is closed (ON).
:03 Relay HCR commanded closed (ON) and HR1
feedback indicates open (OFF).
:04 Relay HCR commanded open (OFF) and HR1
System event feedback indicates closed (ON).
:05 Relay HCR commanded closed (ON) and HR2
feedback indicates open (OFF).
:06 Relay HCR commanded open (OFF) and HR2
feedback indicates closed (ON).
:07 Relay HCR commanded closed (ON) and HR3 (if
equipped) feedback indicates open (OFF).
:08 Relay HCR commanded open (OFF) and HR3 (if
equipped) feedback indicates closed (ON).
645 PRE-SHIFT BRAKE TEST Events occurring during the pre-shift brake test initiated
by the operator.
:01 service brake Service brake test active, specified torque achieved
:02 parking brake Parking brake test active, specified torque achieved
System event
:03 retard ok Retarder test active, circuit OK
:04 retard fail Retarder test active, circuit failed
:05 brake stuck Pre-shift test switch input remained on more than 1
minute, brake is stuck.
646 RETARD REQUEST Dash Full Retard Request button pressed and truck
No propel
speed is more than 1.6 kph (1 mph).
647 SERVICE BRAKE Service bake is applied at a speed that is higher than
System event
the preset truck speed.
650 PEDAL CALIBRATION REQUIRED Indicate that pedals may need calibration.
:01 accel pedal Accelerator pedal values are outside preset values.
:02 retard pedal Retarder pedal values are outside preset values.
System event
:03 accel pedal not registering Accelerator pedal does not register 100% over a period
of time.
:04 calibration Both pedals must be calibrated after CPU card
replacement or software download.
651 TRUCK ID System event Truck ID has not been set.
652 DID PANEL CONFIG System event DID panel configuration incorrect.
696 UNEXPECTED CPU RESET EVENT
DSC CPU card reset while truck was in an operational
:01 System event
mode.
:10
698 DATA STORE SYS Event A data snapshot has been manually initiated.
25
730E Dump truck

980E Dump truck
980E Dump truck
© 2014 KOMATSU
All Rights Reserved
26
CEN40163-00
DUMP TRUCK
980E

980E-4 A40003 and up
40 Troubleshooting
Troubleshooting by fault code, Part 1
Fault Code A001: Left front suspension pressure sensor signal high................................................................... 3
Fault Code A002: Left front suspension pressure sensor signal low .................................................................... 4
Fault Code A003: Right front suspension pressure sensor signal high ................................................................ 5
Fault Code A004: Right front suspension pressure sensor signal low.................................................................. 6
Fault Code A005: Left rear suspension pressure sensor signal high ................................................................... 7
Fault Code A006: Left rear suspension pressure sensor signal low ..................................................................... 8
Fault Code A007: Right rear suspension pressure sensor signal high ................................................................. 9
Fault Code A008: Right rear suspension pressure sensor signal low ................................................................ 10
Fault Code A009: Incline sensor signal high........................................................................................................11
Fault Code A010: Incline sensor signal low ........................................................................................................ 12
Fault Code A011: Payload meter speed sensor signal has failed....................................................................... 13
Fault Code A013: Body up switch has failed ...................................................................................................... 14
Fault Code A014: Payload meter checksum computation has failed.................................................................. 15
Fault Code A016: Payload meter write to flash memory has failed .................................................................... 16
Fault Code A017: Payload meter flash memory read has failed......................................................................... 17
Fault Code A018: Right rear flat suspension cylinder warning ........................................................................... 18
1
Fault Code A019: Left rear flat suspension cylinder warning.............................................................................. 19

Fault Code A022: Carryback load excessive ...................................................................................................... 20
Fault Code A101: High pressure detected across an hydraulic pump filter ........................................................ 21
Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level ................................... 23
Fault Code A107: GE has generated a propel system caution ........................................................................... 24
Fault Code A108: GE has generated a propel system temperature caution....................................................... 25
Fault Code A109: GE has generated a propel system reduced level signal....................................................... 26
Fault Code A111: Low steering pressure warning............................................................................................... 27
Fault Code A115: Low steering precharge pressure detected ............................................................................ 28
Fault Code A117: Low brake accumulator pressure warning.............................................................................. 29
Fault Code A118: Brake pressure is low while in brake lock............................................................................... 30
Fault Code A123: GE has generated a reduced retarding caution ..................................................................... 31
Fault Code A124: GE has generated a no propel / no retard warning ................................................................ 32
Fault Code A125: GE has generated a no propel warning ................................................................................. 33
Fault Code A126: Oil level in the hydraulic tank is low ....................................................................................... 34
Fault Code A127: IM-furnished +5 volt output for sensors is low........................................................................ 35
Fault Code A128: IM-furnished +5 volt output for sensors is high ...................................................................... 36
Fault Code A139: Low fuel warning .................................................................................................................... 37
2
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, deter-
mine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data Monitor
program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the unex-
pected state. Troubleshoot these items.
3. If this fault is not currently active or if no parameters are currently in the unexpected state and the malfunc-
tion is still unresolved, then check each of the parameters in the Table for proper functionality. Troubleshoot all
item(s) related to the parameter(s) which are found to be malfunctioning.
Parameter Expected State and/or Related Fault(s)
Left Front Pressure Sensor current >22 ma: failed high
Sensor (PLM 36,39) Sensor current <2 ma: failed low
Sensor current >2 ma, but < 22 ma: valid readings
Fault(s): A002
3
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
4
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
5
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
6
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
7
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
8
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
9
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
10
Fault Code A009: Incline sensor signal high

Fault Code A009
Description Incline sensor signal is high.
Fault Conditions Sets if incline signal is out of range high (sensor voltage less than 0.565 volts).
Display Fault Description: INCLINE SENSOR HIGH
fault.
Table
parameter fault(s).
Incline Sensor Sensor voltage <0.565: failed high
(PLM 36, 29, 19) Sensor voltage >5.08: failed low
Sensor voltage >0.565, but < 5.08: valid readings
Fault(s): A010
11
Fault Code A010: Incline sensor signal low

Fault Code A010
Description Incline sensor signal is low.
Fault Conditions Sets if incline signal is out of range low (sensor voltage greater than 5.08 volts).
Display Fault Description: INCLINE SENSOR LOW
fault.
Table
parameter fault(s).
Fault(s): A009
12
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 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. The primary
correction is to correct the problem at the source. No other faults are available.
13
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
(PLM 18) 1: Body is down
14
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.
15
Fault Code A016: Payload meter write to flash memory has failed
Fault Code A016
Description A payload meter write to flash memory has failed.
Fault Conditions Payload meter reports a failure in write to flash memory.
System Response Display Fault Description: PLM FLASH MEM WRITE
fault.
Table
16
Fault Code A017: Payload meter flash memory read has failed
Fault Code A017
Description A payload meter flash memory read has failed.
Fault Conditions Payload meter reports a failure of flash memory read.
Operator Alerting Lamp or Buzzer: None - Maintenance Item
System Response Display Fault Description: PLM FLASH MEM READ
fault.
Table
17
Fault Code A018: Right rear flat suspension cylinder warning

Fault Code A018
Description Right rear suspension cylinder is flat.
Fault Conditions Sets if PLM detects a flat right rear suspension cylinder.
Resets if conditions 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 (PLM 36, 40) Sensor current <2 ma: failed low
Fault(s): A007, A008
18
Fault Code A019: Left rear flat suspension cylinder warning

Fault Code A019
Description Left rear suspension cylinder is flat.
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 PLM.
19
Fault Code A022: Carryback load excessive

Fault Code A022
Description Carryback load is 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.
20
Fault Code A101: High pressure detected across an hydraulic pump filter
Operator Action Go To Shop Now
Fault Code A101
Description High pressure detected across an hydraulic pump filter.
Fault Conditions Sets if switch is on, engine is running, and oil temperature is above 50ºC (122ºF) for
10 seconds.
Resets if any of these 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 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
21
Engine Speed [RPM] < 300 RPM: engine is not running

> 300 RPM for 4 seconds: engine is running
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
22
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 volt-
age 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)
Battery Voltage, >18 Volt: Good reading
24 Volt (IM1A) <18 Volt: Low battery voltage (while cranking) blocks this A105 fault code.
Fault(s): A240
Engine Speed [RPM] < 600 RPM: combined with low voltage means cranking is in process and fault is
blocked
> 600 RPM: engine is running normally
23
Fault Code A107: GE has generated a propel system caution

Operator Action Max Speed Limited
Fault Code A107
Description GE has generated a propel system caution.
Fault Conditions Sets if the GE controller generates a propel system caution event.
Operator Alerting Sound Buzzer - single burst
System Response Display Operator Action: MAX SPEED LIMITED
Display Fault Description: PROPEL SYS CAUTION
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 driving an input pin of IM to ground.
2. It may be necessary to use GE's PTU software to determine the actual cause of the propel system distress
Propel System 0: GE has generated a propel system caution
Caution (IM2t) 1: no propel system caution exists
24
Fault Code A108: GE has generated a propel system temperature caution

Fault Code A108
Description GE has generated a propel system temperature caution.
Fault Conditions Sets if the GE controller generates a propel system temperature caution event.
Resets when GE removes the propel system temperature caution event.
Operator Alerting The warning lamp integral to the drive system temperature gauge is turned on.
System Response
fault.
Table
2. It may be necessary to use GE's PTU software to determine the actual cause of the propel system distress.
Propel System 0: GE has generated a propel system caution
Temperature Caution 1: no propel system caution exists
(IM3A)
25
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.
System Response Display Operator Action: MAX SPEED LIMITED
Display Fault Description: REDUCED PROPEL
fault.
Table
2. It may be necessary to use GE's PTU software to determine the actual cause of the propel system distress
Propel System 0: GE has generated a propel system reduced level signal
Reduced Level (IM3B) 1: no propel system reduced level signal exists
26
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 run-
ning 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
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
27
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 key-
switch on and "Steering Precharge Mask" not on. The "Steering Precharge Mask" pre-
vents warnings that might occur from the beginning of steering bleed till 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.
Low Steering 0: Normal reading - full precharge pressure
Precharge Pressure 1: Steering precharge pressure is low
Switch (IM2W)
Fault(s): A240
Steering Bleed Valve 0: steering bleed valve is off
1: steering bleed valve is on
Steering Accumulator 0: Steering bleed is complete
Bleed Pressure Switch 1: Steering bleed is not complete
(IM2Z) Fault(s): A258, A280
28
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
29
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 if brake lock is on and brake lock degrade switch closes indicating low service
brake pressure for 3 seconds unless steering bleed has already started.
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
Switch (IM2V) 1: brake lock degrade is on
Fault(s): A281
30
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 will still be driveable.
fault.
Table
1. The primary correction for this fault is to descend the hill at a slower speed so that retarding capacity is not
exceeded.
Reduced Retarding 0: GE has generated a reduced retarding caution
(IM2r) 1: no reduced retarding caution exists
31
Fault Code A124: GE has generated a no propel / no retard warning

Fault Code A124
Description GE has generated a no propel / no retard warning.
Fault Conditions Sets 0.25 sec after GE controller generates a no propel / no retard event.
Resets 1.0 sec after GE removes the no propel / no retard event.
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
No Propel / Retard 0: GE has generated a no propel / retard warning.
(IM2n) 1: no propel / retard warning exists
32
Fault Code A125: GE has generated a no propel warning

Fault Code A125
Description GE has generated a no propel warning.
Fault Conditions Sets 0.25 sec after GE controller generates a no propel event.
Resets 1.0 sec after GE removes the no propel event.
Display Operator Action: STOP; PARK
Display Fault Description: NO PROPEL
Resulting Problem(s) The drive system is inoperable in propel.
fault.
Table
No Propel (IM2p) 0: GE has generated a no propel warning.
1: no propel warning exists.
33
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. The 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
34
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 active temperature sensors using the +5 volt supply will report low readings. Con-
trol of engine speed and warnings of high oil temperature will be compromised. Equip-
ment 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
35
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
36
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 A139 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.
A139 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.
voltage)
Fault(s): A240
blocked
37
980E Dump truck

© 2016 KOMATSU
All Rights Reserved
38
CEN40164-00
DUMP TRUCK
980E

980E-4 A40003 and up
40 Troubleshooting
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of
hydraulic oil.................................................................................................................................................... 3
Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of
hydraulic oil.................................................................................................................................................... 4
Fault Code A152: Starter failure............................................................................................................................ 5
Fault Code A153: Battery voltage is low with the truck in operation ..................................................................... 6
Fault Code A154: Battery charging voltage is excessive ...................................................................................... 7
Fault Code A155: Battery charging voltage is low ................................................................................................ 8
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level.............................. 9
Fault Code A166: Left rear hydraulic oil temperature sensor is low ................................................................... 10
Fault Code A167: Right rear hydraulic oil temperature sensor is low ..................................................................11
Fault Code A168: Left front hydraulic oil temperature sensor is low................................................................... 12
Fault Code A169: Right front hydraulic oil temperature sensor is low ................................................................ 13
Fault Code A170: Left rear hydraulic oil temperature sensor is high .................................................................. 14
Fault Code A171: Right rear hydraulic oil temperature sensor is high................................................................ 15
Fault Code A172: Left front hydraulic oil temperature sensor is high ................................................................. 16
1
Fault Code A173: Right front hydraulic oil temperature sensor is high ............................................................... 17
Fault Code A184: J1939 data link is not connected............................................................................................ 18
Fault Code A190: Auto lube control has detected an incomplete lube cycle ...................................................... 19
Fault Code A194: Left front hydraulic oil temperature is high ............................................................................. 20
Fault Code A195: Right front hydraulic oil temperature is high........................................................................... 21
Fault Code A196: Left rear hydraulic oil temperature is high .............................................................................. 22
Fault Code A197: Right rear hydraulic oil temperature is high............................................................................ 23
Fault Code A198: Hoist pressure 1 sensor is high.............................................................................................. 24
Fault Code A199: Hoist pressure 2 sensor is high.............................................................................................. 25
Fault Code A200: Steering pressure sensor is high............................................................................................ 26
Fault Code A201: Brake pressure sensor is high................................................................................................ 27
Fault Code A202: Hoist pressure 1 sensor is low ............................................................................................... 28
Fault Code A203: Hoist pressure 2 sensor is low ............................................................................................... 29
Fault Code A204: Steering pressure sensor is low ............................................................................................. 30
Fault Code A205: Brake pressure sensor is low ................................................................................................. 31
Fault Code A206: Ambient temperature sensor is high ...................................................................................... 32
Fault Code A207: Ambient temperature sensor is low........................................................................................ 33
2
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 equip-
ment damage.
fault.
Table
Brake Cooling RPM Status - Open Load: Unexpected. Troubleshoot.
Advance 1 - (IM1L) Status - Normal: Expected. No problem.
Status - Shorted to Ground: Unexpected. Troubleshoot.
Status - Overload: Unexpected. Troubleshoot.
0: brake cooling rpm advance to advance idle
1: brake cooling rpm advance to normal idle
Fault(s): A355
3
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 equip-
ment damage.
fault.
Table
Advance 2 - (IM1X) Status - Normal: Expected. No problem.
0: brake cooling rpm advance to advance idle
1: brake cooling rpm advance to normal idle
Fault(s): A363
4
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
Starter Motor 2 0: starter motor 2 not energized
Energized (IM3S) 1: starter motor 2 energized
Fault(s): A275
Crank Sense (IM3U) 0: no cranking in process
1: cranking in process
5
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 for 5 seconds or when steering bleed begins at
shutdown.
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.
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.
Truck Speed [kph] 0: truck is not moving
(IM1g,h) > 0: truck is moving
Fault(s): A212
Park Brake Set (IM2f) 0: parking brake pressure switch indicating low pressure and an applied parking brake
1: parking brake pressure switch indicating high pressure and an released 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
6
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): A155
7
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 dis-
charged 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.
Engine Speed [RPM] < 1400 RPM: engine is not running fast enough for battery charger test.
> 1400 RPM: engine is running fast enough for battery charger test.
8
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.
voltage)
blocked.
> 600 RPM: engine is running normally.
9
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
1. The primary correction for this fault is to correct any external wiring or replace the sensor.
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
10
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
tion is still unresolved then check each of the parameters in the Table for proper functionality. Troubleshoot all
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
11
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
12
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
13
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
14
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
fault.
Table
Fault(s): A167
15
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
16
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
fault.
Table
Fault(s): A169
17
Fault Code A184: J1939 data link is not connected

Fault Code A184
Description J1939 data link is not connected.
Fault Conditions Sets if no data received from the engine for 10 seconds after an initial 11 second delay
at key ON.
Resets immediately when communication is established.
Display Operator Action: STOP: PARK: PWR 
Display Fault Description: NO ENGINE DATA
Resulting Problem(s) Loss of engine data makes it impossible to operate truck in a normal manner without
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
(IM1q,r,s) connected.
Successful read of PGN 61444: J1939 is connected.
Keyswitch (IM3G) 0: keyswitch is off and the truck is not moving and the engine is not running.
1: keyswitch is on or the truck is moving or the engine is running.
NOTE: For this fault, the keyswitch function is delayed for 11 seconds internally after
initial turn on.
Fault(s): A240
18
Fault Code A190: Auto lube control has detected an incomplete lube cycle
Fault Code A190
Description Auto lube control has detected an incomplete lube cycle.
Fault Conditions Sets if lube cycle is terminated by timeout rather than pressure.
Resets when a lube cycle is properly terminated by pressure rather than timeout.
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.
Table
tion is still unresolved then, check each of the parameters in the Table for proper functionality. Troubleshoot all
Auto Lube Pressure 0: Pressure switch has transferred at 13 790 kPa (2000 psi).
Switch (IM3Y) 1: Pressure switch at low pressure or solenoid circuit not on.
Fault(s): A304, A305, A361
Low Steering Pressure 0: steering pressure is normal (required for lube cycle to proceed).
Switch (IM2S) 1: steering pressure is low.
Fault(s): A279
Truck Speed [kph] 0: truck is not moving.
(IM1g,h) > 0 for 10 seconds: truck is moving.
GE Batt+ Off (IM3M) 0: GE Batt+ is not off.
1: GE Batt+ is off and the truck is not moving and the engine is not running.
Auto Lube Solenoid 0: solenoid is energized and grease is in progress.
Sense (IM3X) 1: solenoid is not energized.
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.
19
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 Operator Action: STOP: PARK: RUN ENG
Display Fault Description: HOT HYD OIL LF
Resulting Problem(s) Excessively hot oil can cause equipment damage and even reduce service brake
effectiveness.
fault.
Table
Steering Bleed Valve 0: steering bleed valve is off.
1: steering bleed valve is on.
20
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
effectiveness.
fault.
Table
21
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
effectiveness.
fault.
Table
22
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
effectiveness.
fault.
Table
Steering Bleed Valve 0: steering bleed valve is off
1: steering bleed valve is on
23
Fault Code A198: Hoist pressure 1 sensor is high

Fault Code A198
Description Hoist pressure 1 sensor is high.
Fault Conditions Sets at 27 751 kPa (4025 psi) [20.1mA] for 5 seconds.
Resets at 25 166 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
24
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
25
Fault Code A200: Steering pressure sensor is high

Fault Code A200
Description Steering Pressure Sensor is 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
26
Fault Code A201: Brake pressure sensor is high

Fault Code A201
Description Brake pressure sensor is 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
27
Fault Code A202: Hoist pressure 1 sensor is low

Fault Code A202
Description Hoist pressure 1 sensor is 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
Battery Voltage, >18 Volts: Good reading
24 Volt (IM1A) <18 Volts: Low battery voltage (while cranking) blocks this fault.
blocked.
28
Fault Code A203: Hoist pressure 2 sensor is low

Fault Code A203
Description Hoist pressure 2 sensor is low.
System Response Display Fault Description: HOIST PRES 2 SENS LO
fault.
Table
1.The primary correction for this fault is to correct any external wiring or replace the sensor.
Sensor (IM3q) < 2.4 mA or > 20.1 mA: Defective sensor or circuit
Fault(s): A199
blocked.
29
Fault Code A204: Steering pressure sensor is low

Fault Code A204
Description Steering pressure sensor is 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
blocked.
30
Fault Code A205: Brake pressure sensor is low

Fault Code A205
Description Brake pressure sensor is 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
(IM3p) < 2.4 mA or > 20.1 mA: Defective sensor or circuit
Fault(s): A201
blocked.
31
Fault Code A206: Ambient temperature sensor is high

Fault Code A206
Description Ambient temperature sensor is high.
Fault Conditions Sets at 133º C (271º F) [4.89 Volts] for 3 seconds.
Resets at 107º C (225º F) [4.77 Volts] for 3 seconds.
System Response Display Fault Description: AMBIENT TEMP SENS HI
Resulting Problem(s) Monitoring of temperatures will be compromised without ambient temperature informa-
tion.
fault.
Table
Sensor (IM3e) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A207
32
Fault Code A207: Ambient temperature sensor is low

Fault Code A207
Description Ambient temperature Sensor is low.
Fault Conditions Sets at -62ºC (-80º F) [0.016 Volt] for 3 seconds.
Resets at -59ºC (-74º F) [0.032 Volt] for 3 seconds.
System Response Display Fault Description: AMBIENT TMP SENS LO
Resulting Problem(s) Monitoring of temperatures will be compromised without ambient information.
fault.
Table
Sensor (IM3e) <0.016 Volt or >4.89 Volts: Defective sensor or circuit
Fault(s): A206
33
980E Dump truck

© 2016 KOMATSU
All Rights Reserved
34
CEN40165-00
DUMP TRUCK
980E

980E-4 A40003 and up
40 Troubleshooting
Fault Code A212: Bad truck speed signal............................................................................................................. 3
Fault Code A213: Parking brake should have applied but is detected as not having applied .............................. 4
Fault Code A214: Parking brake should have released but is detected as not having released .......................... 6
Fault Code A215: Brake auto apply valve circuit is defective ............................................................................... 8
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 10
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted .......................11
Fault Code A230: Parking brake has been requested while truck still moving ................................................... 12
Fault Code A231: The body is up with engine running and brakes not on ......................................................... 13
Fault Code A235: Steering accumulator is in the process of being bled down ................................................... 14
Fault Code A236: The steering accumulator has not properly bled down after 90 seconds............................... 15
Fault Code A237: The CAN/RPC connection to the display is open .................................................................. 16
Fault Code A240: The key switch input to the interface module is open ............................................................ 17
Fault Code A242: Fuel gauge within the dash display panel is defective ........................................................... 18
Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective ...................... 19
Fault Code A244: Drive system temperature gauge within the dash display panel is defective ......................... 20
Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective .......................... 21
1
Fault Code A246: Payload meter reports truck overload .................................................................................... 22

Fault Code A247: Low steering pressure warning .............................................................................................. 23
Fault Code A248: Status module within the dash display panel is defective ...................................................... 24
Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted ..................................... 25
Fault Code A250: Battery voltage is low with the truck parked ........................................................................... 26
Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground.................. 28
Fault Code A252: Start enable output circuit is either open or shorted to ground............................................... 29
Fault Code A253: Steering bleed circuit is not open while running ..................................................................... 30
Fault Code A256: Red warning lamp in the dash display (driven by IM) is open................................................ 31
Fault Code A257: Payload CAN/RPC is not connected...................................................................................... 32
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective ............................................ 33
2
Fault Code A212: Bad truck speed signal

Operator Action Go to Shop Now
Fault Code A212
Description Bad truck speed signal
Fault Conditions Sets if truck speed timeout (frequency input does not produce 5 periods within 1 sec-
ond) persists for 12 seconds with GE powered up and engine not being cranked.
Resets if timeouts clear for 3 seconds.
Display Fault Description: BAD TRUCK SPEED SIG
Resulting Problem(s) Loss of truck speed signal caused loss of protection from mis-application of the park-
ing brake and loss of speedometer for the driver.
fault.
Table
1. The primary correction for this fault is to correct any external wiring or replace the GE signal source.
2. This fault's logic contains more than one parameter.
3. Since there are no active parameter fault codes, then based on the truck's setup while this fault is active,
determine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data Mon-
itor program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the
unexpected state. Troubleshoot these items.
Truck Speed [kph] 0: Truck is not moving.
(IM1g,h) > 0: Truck is moving.
GE Batt+ Off (IM3M) 0: Power to GE control is off.
1: Power to GE control is on.
Crank Sense (IM3U) 0: Engine not being cranked.
1: Engine is being cranked.
3
Fault Code A213: Parking brake should have applied but is detected as not having applied
Operator Action Secure Vehicle
Fault Code A213
Description Parking brake should have applied but is detected as not having applied.
Fault Conditions Sets if the parking brake does not apply within 3 seconds if the shift lever is not in For-
ward, Neutral or Reverse or the engine oil pressure is below the setpoint of the engine
oil pressure switch and either the speed of the truck has been 0.8kph or less for 1 sec-
ond or the service brakes are applied, or after the engine has been off for 15 seconds
with the J1939 link working, or within 2 seconds after the key switch has been turned
off, the drive system control power is off, the engine is not running, and the truck is not
moving. Parking brake set is defined as closure of the parking brake set pressure
switch and opening of the parking brake release pressure switch.
Resets after 3 seconds if the parking brake applies, or if the parking brake request is
canceled and the shift lever is not in Park and the shift lever is in Forward, Neutral or
Reverse 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.
Timed engine shutdown may be prevented.
fault.
Table
Selector Switch (FNR) 0: Shift lever is not in Forward, Neutral, or Reverse.
(IM2N) 1: Shift lever is in Forward, Neutral, or Reverse.
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
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.
4
Selector Switch (Park) 0: Shift lever is not in Park.

(IM3T) 1: Shift lever is in Park.
Park Brake Request 0: Shift lever is not in Forward, Neutral, or Reverse or the engine oil pressure is below
(IM3V) the setpoint of the engine oil pressure switch.
1: Shift lever is in Forward, Neutral, or Reverse and the engine oil pressure is above
the setpoint of the engine oil pressure switch.
Fault(s): A264
Engine Speed [RPM] 0: Engine is not running.
> 0: Engine is running.
(IM1g,h) > 0: Tuck is moving.
Fault(s): A212
CAN J1939 connec- Fault(s): A184
tion (IM1q,r,s)
Keyswitch (IM3G) 0: Keyswitch is OFF and the truck is not moving and the engine is not running.
1: Keyswitch is ON or the truck is moving or the engine is running.
Fault(s): A240
Park Brake Solenoid Status - Open Load: Unexpected. Troubleshoot.
(IM1E) Status - Normal: Expected. No Problem.
Status - Shorted to Ground: Expected if shift lever is in Forward, Neutral, or Reverse
and the engine oil pressure is above the setpoint of the engine oil pressure switch.
Otherwise unexpected and troubleshoot.
0: Shift lever is not in Forward, Neutral, or Reverse or the engine oil pressure is below
the setpoint 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.
Fault(s): A216
5
Fault Code A214: Parking brake should have released but is detected as not having
released
Operator Action Stop: Park
Fault Code A214
Description Parking brake should have released but is detected as not having released.
Fault Conditions Sets if the engine has been running 90 seconds or more with the keyswitch on and the
parking brake does not release in response to the shift lever being moved out of Park
or in response to truck speeds over 0.8 kph (0.5 mph) for 3 seconds. Parking brake
release is defined as the closure of the parking brake release pressure switch and the
opening of the parking brake set pressure switch.
Resets after 3 seconds if the parking brake releases, or engine stops running, or key-
switch and propel control power are both turned off, or shift lever is moved to Park.
System Response Parking brake status indicator 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.
Table
(IM2M) brake.
1: Parking brake pressure switch indicates high pressure and a released parking
brake.
Fault(s): A264
6
Engine Speed [RPM] < 300 RPM: Engine is not running.

> 300 RPM for 4 seconds: Engine is running.
Truck Speed [kph] < 0.8 kph: Parking brake can be applied.
(IM1g,h) > 0.8 kph: Parking brake cannot be applied.
Fault(s): A212
CAN J1939 connec- Fault(s): A184
tion (IM1q,r,s)
1: Keyswitch is ON or the truck is moving (GE power not yet off).
Fault(s): A240
Status - Shorted to Ground: Expected if shift lever is in Forward, Neutral, or Reverse
Otherwise unexpected and troubleshoot.
0: Shift lever is not in Forward, Neutral, or Reverse or the engine oil pressure is below
the setpoint 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.
7
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 key-
switch 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.
Table
Fault(s): A240
8
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
9
Fault Code A216: An open or short to ground has been detected in the parking brake
command valve circuit
Fault Code A216
Description An open or short to ground has been detected in the parking brake command valve cir-
cuit.
Fault Conditions Sets if valve circuit is open or short to ground with keyswitch and parking brake
request on, or if valve circuit is open without parking 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 con-
cerns.
fault.
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
Fault(s): A240
10
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 starter 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.
Table
1. The primary correction for this fault is not to excessively crank the engine. Starting problems must be cor-
rected, or starter failures will result.
Crank Sense (IM3U) 0: Engine is not being cranked.
1: Engine is being cranked.
Starter Motor 1 0: Starter motor 1 is not energized.
Energized (IM3R) 1: Starter motor 1 is energized.
Fault(s): A152, A275, A316
Energized (IM3S) 1: Starter motor 2 is energized.
Fault(s): A152, A275, A316
Start Enable (IM1B) Status - Open Load: Unexpected. Troubleshoot.
Status - Normal: Expected. No problem.
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
11
Fault Code A230: Parking brake has been requested while truck still moving
Operator Action Move shift lever out of PARK
Fault Code A230
Description Parking brake has been requested while truck still moving.
Fault Conditions Sets if parking brake is requested (shift lever moved from Forward, Neutral, or
Reverse) while moving 0.8 kph (0.5 mph) and with parking brake released.
Resets if any condition changes.
Display Operator Action: MOVE SHFTR FROM PRK
Display Fault Description: PRK BRK SETTING ERR
Resulting Problem(s) Parking brake could be damaged if protective circuitry did not work.
fault.
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: Truck is not moving.
(IM1g,h) > 0.8 kph: Truck is moving.
Fault(s): A212
1: Parking brake pressure switch indicates high pressure and a released parking.
brake.
Fault(s): A213
(IM2M) brake.
Fault(s): A214
12
Fault Code A231: The body is up with engine running and brakes not on
Operator Action Lower body
Fault Code A231
Description The body is up with engine running and brakes not on.
Fault Conditions Sets if body is up with engine running and brake lock not on and parking brake not set.
Resets if body is down, engine not running or brakes applied.
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.
Table
1. The primary correction for this fault is just not to move the truck while the body is up.
Body Up (IM3N) 0: Body is raised off the truck frame.
1: Body is down on the truck frame.
Fault(s): A276
Fault(s): A184
brake.
Fault(s): A213
(IM2M) brake.
Fault(s): A214
Brake Lock (IM2i) 0: Brake lock valve is not on.
1: Brake lock valve is on.
Fault(s): A118
13
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 bleeddown pres-
sure switch has yet to operate and 90 seconds have yet to elapse.
Resets either at 90 second timeout or when steering accumulator bleeddown pressure
switch indicates bleeding 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 when it is done.
fault.
Table
1. No correction is necessary for normal bleeding with the truck properly parked.
Steering Bleed Valve Status - Open Load: Expected with keyswitch ON. No problem. Otherwise, unex-
(IM1P) pected.Ttroubleshoot.
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): A236, A253, A262, A358
Steering Accumulator 0: Accumulator is bled down.
Bleeddown Pressure 1: Accumulator is not completely bled down.
Switch (IM2Z) Fault(s): A258, A280
14
Fault Code A236: The steering accumulator has not properly bled down 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 bleeddown pressure switch does not indicate bleed
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.
Table
(IM1P) pected. Troubleshoot.
1: Steering bleed valve is on. This is expected after key off initiates steering bleed
operation.
Fault(s): A253, A262, A358
Steering Accumulator 0: Accumulator is bled down.
Bleeddown Pressure 1: Accumulator is not completely bled down.
Switch (IM2Z) Fault(s): A258, A280
15
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 Operator Action: STOP: PARK: PWR
Display Fault Description: NO DISPLAY DATA
Resulting Problem(s) A multitude of operational and equipment warnings will not be available to the opera-
tor, 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 (IM).
CAN/RPC (I,M1jki) Fault(s): A257
16
Fault Code A240: The key switch input to the interface module is open
Operator Action Stop, Park, Repair
Fault Code A240
Description The keyswitch input to the interface module (IM) is open.
Fault Conditions Sets if both Keyswitch input and steering bleed valve are missing for 15 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. Steer-
ing will bleed down as soon as the 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.
1: keyswitch is on or the truck is moving or the engine is running
1: Steering bleed valve is on. This is expected after key off initiates steering bleed
operation.
Fault(s): A253, A262, A263, A358
17
Fault Code A242: Fuel gauge within the dash display panel is defective
Fault Code A242
Description Fuel gauge within the dash display panel is defective.
Fault Conditions Sets if a fuel gauge fault is reported.
Resets if the fault clears.
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 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.
18
Fault Code A243: Engine coolant temperature gauge within the dash display panel is
defective
Operator Action Go to Shop
Fault Code A243
Description Engine coolant temp gauge within the dash display panel is defective.
Fault Conditions Sets if an engine coolant temp gauge fault is reported.
Resets if the fault clears or steering bleed 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 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 neces-
sary.
Steering Bleed Valve 0: Steering bleed valve is off.
(IM1P) 1: Steering bleed valve is on.
19
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.
Display Fault Description: DRIVE SYS TEMP GAUGE
Resulting Problem(s) Drive system could overheat without warning.
fault.
Table
sary.
20
Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defec-
tive
Fault Code A245
Description Hydraulic oil temp gauge within the dash display panel is defective.
Fault Conditions Sets if an hydraulic oil temperature gauge fault is reported.
Display Fault Description: HYD OIL TEMP GAUGE
Resulting Problem(s) Hydraulic oil could overheat without warning.
fault.
Table
sary.
21
Fault Code A246: Payload meter reports truck overload

Operator Action Speed Limit
Fault Code A246
Description Payload meter reports truck overload.
Fault Conditions Sets if payload meter (PLM) reports an overloaded truck.
Resets if payload meter (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 payload meter (PLM). The panel and communication to it must be work-
ing in order for interface module (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
PLM.
22
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 sec-
ond.
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
> 1200: Engine is running fast enough to maintain steering pressure.
(IM1g,h) > 0.8kph: Truck is moving.
23
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.
Display Fault Description: STATUS MODULE FLT
Resulting Problem(s) Proper operation will be difficult without status information.
fault.
Table
sary.
24
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 dis-
play 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
25
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, park-
ing 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.
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.
< 18 volts: Cranking is sensed.
Fault(s): A155
Engine Speed [RPM] < 600 RPM: Engine not being cranked.
< 300 RPM: Engine is not running.
Fault(s): A212
26
brake.
Fault(s): A213
(IM2M) brake.
Fault(s): A214
27
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 is
not on.
Resets if the circuit is normal for 400 ms or if steering bleed 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
28
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 the interface module
(IM) provides for the start enable circuit (excessive cranking, shift lever position, J1939
OK, and engine speed 0 to start and not above 400 rpm at finish).
fault.
Table
history, shift lever in wrong position, engine red light, J1939 not OK, engine speed
either not 0 to begin cranking or over 400 rpm while cranking).
Fault(s): A350
29
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.
Operator Alerting Repair Status Light On
Display Fault Description: STG BLD CKT NOT OPN
Resulting Problem(s) Steering bleed will be possible during normal running if interface module (IM) or some
of its inputs also malfunction.
fault.
Table
Steering Bleed Valve Status - Open Load: Expected with key switch on. No problem. Otherwise, unex-
Troubleshoot if found with keyswitch ON.
Status - Overload: Unexpected.Troubleshoot.
bleed operation.
Fault(s): A240
30
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 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 operates for 1 sec. (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 < 3.75 volts for 400 ms with the lamp off: Open
Feedback (IM1G) > 3.75 volts for 400 ms with the lamp off: Normal
31
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
32
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 after 90 seconds of
engine running above 300 rpm.
Display Fault Description: STRG BLEED PRESS SW
Resulting Problem(s) Indication of steering bleed is unreliable.
fault.
Table
Steering Accumulator 0: Accumulator is bled.
Bleeddown Pressure 1: Accumulator is not completely bled.
Switch (IM2Z) Fault(s): A280
> 300 rpm: Engine is running.
33
980E Dump truck

© 2016 KOMATSU
All Rights Reserved
34
CEN40166-00
DUMP TRUCK
980E

980E-4 A40003 and up
40 Troubleshooting
Fault Code A260: Parking brake failure ................................................................................................................ 3
Fault Code A261: Low brake accumulator pressure warning ............................................................................... 4
Fault Code A262: Steering bleed valve circuit open during shutdown .................................................................. 5
Fault Code A264: Parking brake relay circuit is defective..................................................................................... 6
Fault Code A265: Service brake failure ................................................................................................................ 7
Fault Code A266: Shift lever was not in park while attempting to crank engine ................................................... 8
Fault Code A267: Parking brake was not set while attempting to crank engine ................................................... 9
Fault Code A268: Secondary engine shutdown while cranking .......................................................................... 10
Fault Code A270: Brake lock switch power supply is not on when required........................................................11
Fault Code A271: Shift lever not in gear ............................................................................................................. 13
Fault Code A272: Brake lock switch power supply is not off when required....................................................... 14
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit............ 16
Fault Code A274: A brake setting fault has been detected................................................................................. 17
Fault Code A275: A starter has been detected as engaged without a cranking attempt .................................... 18
Fault Code A276: The drive system data link is not connected .......................................................................... 19
Fault Code A277: Parking brake applied while loading ...................................................................................... 20
1
Fault Code A278: Service brake applied while loading....................................................................................... 21

Fault Code A279: Low steering pressure switch is defective.............................................................................. 22
Fault Code A280: Steering accumulator bleed down switch is defective ............................................................ 23
Fault Code A281: Brake lock degrade switch is defective .................................................................................. 24
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has
reached 7 ..................................................................................................................................................... 25
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set .................. 26
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was oper-
ated .............................................................................................................................................................. 27
Fault Code A285: The parking brake was not set when the keyswitch was turned off ....................................... 28
Fault Code A286: A fault was detected in the shutdown delay relay circuit........................................................ 29
Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off ........... 30
2
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:
1. Truck Rolling After Stop: Sets if truck rolls 2 kph (1.2 mph) for 1.5 seconds after the
truck is stopped completely (defined as parking brake set and truck not moving for 1.5
seconds and reset only by parking brake release). Resets if conditions change.
2. Parking Brake Applied While Moving: Sets if truck’s speed is 0.8 kph (0.5 mph) or
over for 1.5 seconds with parking brake not released (parking brake released is
defined as parking brake release switch being on and parking brake set switch being
off). Resets only at power down.
Display Fault Description: PARK BRAKE FAILURE
Resulting Problem(s) Parking brake may not hold truck.
fault.
Table
Pressure Switch brake (This input is ignored if keyswitch is OFF).
(IM2M) 1: Parking brake pressure switch indicates low pressure and an applied parking brake.
Park Brake Set 0: Parking brake pressure switch indicates low pressure and an applied parking brake.
Pressure Switch (IM2f) 1: Parking brake pressure switch indicates high pressure and a released parking
brake.
Truck Speed [kph] < 2.0 kph: Truck is not moving - Truck Rolling After Stop.
(IM1g,h) < 0.8 kph: Truck is not moving - Parking Brake Applied While Moving.
> 2.0 kph: Truck is moving - Truck Rolling After Stop.
> 0.8 kph: Truck is moving - Parking Brake Applied While Moving.
Fault(s): A212
1: Keyswitch is ON.
Fault(s): A240
3
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 sec-
ond.
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)
> 300 RPM: engine is running.
4
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 keyswitch has been
turned OFF, the engine is not running, and the truck is stopped (drive system control
power is 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.
Table
bleed operation.
Fault(s): A240
Fault(s): A212
5
Fault Code A264: Parking brake relay circuit is defective

Fault Code A264
Description Parking brake relay circuit is defective.
Fault Conditions - Sets if parking brake request is not on when shift lever is not in Forward, Neutral, or
Reverse, or engine has not been running for 15 seconds with the J1939 data link to
the engine OK.
- Sets if parking brake request is on when shift lever 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 - Shift lever is not in Forward, Neutral, or Reverse or
(IM3V) the engine oil pressure is below the setpoint of the engine oil pressure switch.
1: Park Brake Release is Requested - Shift lever is in Forward, Neutral, or Reverse
> 400 RPM: Engine is running.
6
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 1725 kPa (250 psi) for 2 sec-
onds 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
(IM3b,p) > 1724 kPa (250 psi): front brake applied
Service Brake 0: Service brake is not applied.
Pressure Switch 1: Service brake is applied.
(IM3C)
Fault(s): A184
7
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 shift lever is not in Park or is in Forward, Neutral, or Reverse while attempting to
crank engine.
Resets if shift lever 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) Interface module (IM) will not permit cranking if selector lever is not in Park.
fault.
Table
Selector Switch (Park) 0: Shift lever is not Park.
Crank Request (IM2j) 0: Cranking is not attempted.
1: Cranking is attempted.
8
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 parking brake is not set while attempting to crank engine. (Parking brake set is
defined as closure of the parking brake set pressure switch and opening of the parking
brake release pressure switch.)
Resets if parking brake sets or cranking attempt is stopped.
System Response Display Operator Action: SET PARK BRAKE
Resulting Problem(s) Interface module (IM) will not permit cranking if parking brake is not set.
fault.
Table
tion is still unresolved ,then check each of the parameters in the Table for proper functionality. Troubleshoot all
Crank Request (IM2j) 0: Cranking isnot attempted.
brake.
Fault(s): A213
(IM2M) brake.
Fault(s): A214
9
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) Interface module (IM) will not permit cranking if parking 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.
Crank Request (IM2j) 0: Cranking is not attempted.
Secondary Engine 0: Secondary engine shutdown is on.
Shutdown (IM3E) 1: Secondary engine shutdown is not on.
10
Fault Code A270: Brake lock switch power supply is not on when required
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 not in steering bleed, truck speed
above 0.8 kph (0.5 mph) and parking brake not set, or with parking brake not
requested and the engine running 400 rpm for 15 seconds and the delayed shutdown
relay not on.
Parking brake set is defined as closure of the parking brake set pressure switch and
opening of the parking brake release pressure switch.
Resets at beginning of steering bleeddown.
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.
Table
Brake Lock Switch 0: No power is available for brake lock switch.
Power Supply (IM3L) 1: Power is available for brake lock switch.
Fault(s): A272
Fault(s): A212
Fault(s): A184
brake.
Fault(s): A213
(IM2M) brake.
Fault(s): A214
11
Fault(s): A264
Shutdown Delay Relay 0: Shutdown delay is off.
(IM1H) 1: Shutdown delay is on.
12
Fault Code A271: Shift lever not in gear

Operator Action Adjust shift lever
Fault Code A271
Description shift lever not in gear.
Fault Conditions Sets if shift lever is not in park, forward, neutral, or reverse for 2 seconds with the key
switch on.
Resets if shift lever position is detected or the key switch is turned off.
System Response Display Operator Action: ADJUST shift lever
Display Fault Description: shift lever NOT IN GEAR
Resulting Problem(s) Driving is impossible; engine won't crank.
fault.
Table
1. The normal corrective measure for this fault is to return the shift lever to a true position. If this does not work,
verify that the input parameters are correct.
Selector Switch (Park) 0: Shift lever is not Park.
Fault(s): A303
Fault(s): A303
Fault(s): A240
13
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 parking brake request is on or engine speed has
been 0 for 15 seconds and J1939 data link is OK, or the shutdown relay is on or the
keyswitch is OFF, for 3 seconds.
Alternatively sets if brake lock switch power supply is not off when brake lock is on and
brake auto apply is not on and truck speed is less than 0.5 kph (0.3 mph) and parking
brake request is on or engine speed has been 0 for 15 seconds and J1939 data link is
OK, or the shutdown relay is on or the keyswitch is OFF, for 1 second.
Resets in 1 second if conditions change.
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 and dumping operations.
fault.
Table
Brake Lock Switch 0: No power is available for brake lock switch.
Power Supply (IM3L) 1: Power is available for brake lock switch.
Fault(s): A270
Brake Lock (IM2i) 0: Brake lock not on.
1: Brake lock is on.
Auto Brake Apply 0: Normal operation with parking brake either applied or released. This valve operates
Relay (IM1R) only transiently when the parking brake is applied.
ing brake is applied if the truck is stopped. If moving, it will not operate until truck
Fault(s): A359
Fault(s): A212
14
Engine Speed [RPM] 0 RPM for 15 seconds with J1939 working: Engine is not running.
> 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 0.
(IM1H) 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 volt-
age, not starter stuck on, not active engine red light, and engine speed above 300
rpm.
15
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 are open.
(IM2Y) 1: One or more hydraulic filter switches are open.
Fault(s): A101
16
Fault Code A274: A brake setting fault has been detected

Fault Code A274
Description A brake setting fault has been detected.
Fault Conditions Sets if both parking brake and brake lock are set and brake lock has not been set by
brake auto apply for 5 seconds. (Parking brake set is defined as closure of the parking
brake set pressure switch and opening of the parking brake release pressure switch.)
Resets after 5 seconds if conditions change.
Display Fault Description: BRAKE MALFUNCTION
Resulting Problem(s) Improperly controlled brakes are dangerous to equipment as well as operator.
fault.
Table
Park Brake Set (IM2f) 0: Parking brake pressure switch indicate low pressure and an applied parking brake.
1: Parking brake pressure switch indicate high pressure and a released 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
Brake Lock (IM2i) 0: Brake lock isnot on.
Brake Auto Apply 0: Normal operation with parking brake either applied or released. This valve operates
Relay (IM1R) only transiently when the parking brake is applied.
Fault(s): A359
17
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
not in steering bleed.
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.
Crank Sense (IM3U) 0: No cranking is in process.
1: Cranking is in process.
18
Fault Code A276: The drive system data link is not connected
Fault Code A276
Description The drive system data link is not connected.
Fault Conditions Sets after 60 seconds of no communication if battery voltage is above 23 volts and
control power is on.
Resets 5 seconds after communication is detected.
System Response Display Fault Description: NO DRIVE SYS DATA
Resulting Problem(s) Details of warnings not available to drivers or KOMTRAX Plus.
fault.
Table
Drive System Data Should operate 20 seconds after initial power up as long as GE control power is on.
Link (IM2D, E, F)
Fault(s): A240
19
Fault Code A277: Parking brake applied while loading

Operator Action Turn Off Parking Brake
Fault Code A277
Description Parking brake is applied while loading the dump body.
Fault Conditions Sets if parking brake is set and payload meter (PLM) reports a loading state. (Parking
brake set is defined as closure of the parking brake set pressure switch and opening of
the parking brake release pressure switch.)
Resets if loading state is cleared or parking brake is released.
Display Operator Action: MOVE SHFTR FROM PARK
Display Fault Description: IMPROPER BRK USAGE
Resulting Problem(s) Parking brake may be damaged and load weights may contain errors.
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 PLM3 system.
Parking Brake Set 0: Parking brake pressure switch indicates low pressure and an applied parking brake.
(IM2f) 1: Parking brake pressure switch indicates high pressure and a released parking
brake.
Fault(s): A213
Parking Brake 0: Parking brake pressure switch indicates high pressure and a released parking
Released (IM2M) brake.
Fault(s): A214
Loading State The loading state input is developed by PLM and communicated to interface module
(PLM CAN/RPC) (IM) via CAN/RPC.
20
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 payload meter (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 PLM3 system.
Loading State The loading state input is developed by PLM and communicated to interface module
(PLM CAN/RPC) (IM) via CAN/RPC.
Brake Pressure > 1207 kPa (175 psi) for 10 seconds: Front brakes are applied.
(IM3b,p) < 1034 kPa (150 psi) for 1 second; Front brakes are not applied.
Fault(s): 201, 205
21
Fault Code A279: Low steering pressure switch is defective

Operator Action Stop: Park: Power Down: Check
Fault Code A279
Description Low steering pressure switch is defective.
Fault Conditions Sets if low steering pressure switch fails to turn on by the time the steering accumula-
tor bleed down 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
Low Steering 0: Steering pressure is normal.
Pressure Switch 1: Steering pressure is low.
(IM2S)
Bleed Pressure Switch 1: Accumulator is not completely bled.
(IM2Z) Fault(s): A280
22
Fault Code A280: Steering accumulator bleed down switch is defective

Fault Code A280
Description Steering accumulator bleeddown 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
Low Steering 0: Steering pressure is normal.
Pressure Switch 1: Steering pressure is low.
(IM2S) Fault(s): A279
Bleed Pressure Switch 1: Accumulator is not completely bled.
(IM2Z)
23
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 is not on.
Switch (IM2V) 1: Brake lock degrade is on.
Brake Lock (IM2i) 0: Brake lock is not on.
(IM3C)
Brake Pressure < 1034 kPa (150 psi): Front brake is not applied.
(IM3b,p) > 1034 kPa (150 psi): Front brake is applied.
24
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.
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.
Start Enable (IM1B) 0: One of several interlocking situations exists to prevent cranking (excessive cranking
1: No interlocking situations exist to prevent cranking.
Fault(s): A152, A223, A275, A316
Fault(s): A152, A223, A275, A316
25
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 run-
ning 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 be damaged when shut down immediately rather than in a controlled
delay.
fault.
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
brake.
Fault(s): A213
Park Brake Released 0: Parking brake pressure switch indicates high pressure and a released parking.
(IM2M) brake
Fault(s): A214
26
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 run-
ning but secondary engine shutdown switch is operated.
Resets if keyswitch is turned back on, engine shutdown delay is off, and engine is run-
ning.
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
Engine Shutdown 0: Engine shutdown delay signal is off.
Delay (IM3F) 1: Engine shutdown delay signal is on.
Fault(s): A283
27
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
28
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 0.
1: Turns on when Keyswitch, Direct is off, engine shutdown delay is on, parking brake
rpm.
Fault(s): A292
Fault(s): A240
29
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 (GE latches the
circuit until the truck and engine have stopped completely) is off.
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
rpm.
Fault(s): A286
Fault(s): A240
30
NOTES
31
980E Dump truck

© 2016 KOMATSU
All Rights Reserved
32
CEN40167-00
DUMP TRUCK
980E

980E-4 A40003 and up
40 Troubleshooting
Fault Code A303: Shift lever is defective .............................................................................................................. 3
Fault Code A304: Auto lube grease level fault...................................................................................................... 4
Fault Code A305: Auto lube circuit is defective .................................................................................................... 5
Fault Code A307: Both GE inverters are disabled ................................................................................................ 6
Fault Code A309: No brakes applied when expected ........................................................................................... 7
Fault Code A310: Low fuel warning ...................................................................................................................... 8
Fault Code A311: Brake lock switch is on when it should not be .......................................................................... 9
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings ...................................... 10
Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings .......................................11
Fault Code A315: DCDC converter 12 volt circuit is low..................................................................................... 12
Fault Code A316: Starter engagement has been attempted with engine running .............................................. 13
Fault Code A317: Operation of brake auto apply valve without a detected response ........................................ 14
Fault Code A318: Unexpected power loss to interface module .......................................................................... 16
Fault Code A320: Data link reports GE propel system caution fault but wired input does not............................ 17
Fault Code A321: Data link reports GE propel system temperature caution fault but wired input does not ....... 18
Fault Code A322: Data link reports GE propel system reduced level fault but wired input does not .................. 19
1
Fault Code A323: Data link reports GE reduced retard level fault but wired input does not ............................... 20
Fault Code A324: Data link reports DC link voltage but wired input does not..................................................... 21
Fault Code A325: Data link reports GE no propel/retard fault but wired input does not...................................... 22
Fault Code A326: Data link reports GE no propel fault but wired input does not ................................................ 23
Fault Code A327: Data link reports GE at rest but wired input does not............................................................. 24
Fault Code A328: Drive system not powered up................................................................................................. 25
Fault Code A329: Data link reports the body is not down but wired input says it is ............................................ 26
Fault Code A330: Data link reports dynamic retard operating state but wired input does not ............................ 27
2
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: shift lever DEFECTIVE
Resulting Problem(s) Control of truck and parking brake will be defective.
fault.
Table
Fault(s): A271
Fault(s): A271
3
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)
4
Fault Code A305: Auto lube circuit is defective

Fault Code A305
Description Auto lube circuit is defective.
Fault Conditions Sets if solenoid sense occurs with lube output off, or does not occur with lube output
on, or pressure switch stays on, or circuit is open or short to ground, any of those for 5
seconds with GE control power on.
System Response Display Fault Description: AUTO LUBE CIRCUIT
Resulting Problem(s) Automatic lubrication may not work.
fault.
Table
Status - Shorted to Ground: Unexpected except momentarily at termination of a lube
Fault(s): A361
Switch (IM3Y) 1: Pressure switch is at low pressure or solenoid circuit is not on.
Fault(s): A361
Auto Lube Solenoid 0: Auto lube solenoid is energized.
Sense (IM3X) 1: Auto lube solenoid is not energized.
GE Control Power 0: GE control power is off and the truck is not moving.
(IM3M) 1: GE control power is on or the truck is moving.
5
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 RS232) with the keyswitch
ON.
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
GE INV1 Disabled - 0: INV1 is not disabled.
RS232 Input 1: INV1 is disabled.
GE INV2 Disabled - 0: INV2 is not disabled.
RS232 Input 1: INV2 is disabled.
Fault(s): A240
6
Fault Code A309: No brakes applied when expected

Operator Action Apply brake or travel
Fault Code A309
Description No brakes applied when expected.
Fault Conditions Sets if truck speed is 0, parking brake is not set, service brake is not set, and engine is
running for 2 seconds. (Parking brake set is defined as closure of the parking brake set
pressure switch and opening of the parking brake release pressure switch.)
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.
Table
brake.
Fault(s): A213
(IM2M) brake.
Fault(s): A214
(IM3C) Fault(s): A265, A274, A309, A317
Fault(s): A212
7
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.
voltage)
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.
8
Fault Code A311: Brake lock switch is on when it should not be

Operator Action Turn Off Brake Lock Switch
Fault Code A311
Description Brake lock switch is on when it should not be.
Fault Conditions Sets if parking brake is set and brake lock is on except not when applied brake auto
apply for 2 seconds. (Parking brake set is defined as closure of the parking brake set
pressure switch and opening of the parking brake release pressure switch.)
Resets 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 opera-
tion.
fault.
Table
brake.
Fault(s): A213
(IM2M) brake.
Fault(s): A214
Brake Lock (IM2i) 0: Brake lock not on.
Fault(s): A272
Auto Brake Apply 0: Normal operation with parking brake either applied or released. This valve operates
Relay (IM1R) only transiently when the parking brake is set.
ing brake is released if the truck is stopped. If moving, it will not operate until truck
Fault(s): A359
9
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 24VDC to 12VDC 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 volt to 16.1 volts: Normal measurement range
12 Volt (IM3h) <0.2 volt or >16.1 volts: Defective sensing circuit or external connection
Fault(s): A315
10
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 HIGH
Resulting Problem(s) Monitoring is lost for the 12 volt battery tap circuit.
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
11
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 volts are above 22, sets if voltage is below 12.5.
If battery voltage is below 22, sets if voltage is more than 1.5 volts lower than 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 con-
tinue 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.
12
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 during steering bleeddown, sets after 2 seconds if either starter engages with
engine speed above 500 rpm with crank sense on.
Display Operator Action: DO NOT CRANK
Display Fault Description: STARTER ENGAGE FLT
Resulting Problem(s) Damage to starter and engine flywheel may occur.
fault.
Table
1. The normal corrective measure for this fault is to not engage the starter with the engine already running.
> 500 RPM: Engine is running.
Crank Sense (IM3U) 0: Cranking is not in process.
13
Fault Code A317: Operation of brake auto apply valve without a detected response
Fault Code A317
Description Operation of brake auto apply valve without a detected response.
Fault Conditions Sets if operation of brake auto apply valve for 1 second does not cause the service
brake pressure switch to operate or the front brake pressure to increase. (Parking
brake release is defined as the closure of the parking brake release pressure switch
and the opening of the parking brake set pressure switch.)
Resets when parking brake is released for 5 seconds.
Resulting Problem(s) Failure of brake auto apply circuit could cause damage to parking brake.
fault.
Table
Auto Brake Apply Status - Open Load: Unexpected if parking brake request and keyswitch are on.
Relay (IM1R) Expected if parking brake request is off or keyswitch is off. Troubleshoot if inconsis-
tent.
Status - Normal: Expected if parking brake request and keyswitch are on. Trouble-
shoot if status is normal with parking brake request off or keyswitch off.
0: Normal operation with parking brake either applied or released. This valve operates
only transiently when the parking brake is set.
Fault(s): A215
(IM3C)
14
(IM2M) brake.
Fault(s): A214
brake.
Fault(s): A213
(IM3p) < 2.4 mA or > 20.1 mA: Defective sensor or circuit
Fault(s): A205
15
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.
16
Fault Code A320: Data link reports GE propel system caution fault but wired input does not
Fault Code A320
Description Data link reports GE propel system caution fault but wired input does not.
Fault Conditions Sets if data link version is on while wired version is off for 8 seconds (with data link
working).
Display Fault Description: PROPEL CAUT CKT FLT
Resulting Problem(s) Wired input may not be giving operator proper warning of a GE propel system caution
fault.
fault.
Table
1. The primary correction for this fault is to correct any wiring problem associated with the input signal from GE.
2. This fault's logic contains more than one parameter, each of which may have it's own related fault code(s).
3. If there are no active parameter fault codes then based on the truck's setup while this fault is active, deter-
Propel System 0: GE has declared a propel system caution fault.
Caution Input (IM2t) 1: No propel system caution fault exists.
Fault(s): A107
Propel System 0: Data link reports no fault.
Caution - RS232 Input 1: Data link reports a fault from GE.
Link (IM2D,E,F) Fault(s): A276
17
Fault Code A321: Data link reports GE propel system temperature caution fault but wired
input does not
Fault Code A321
Description Data link reports GE propel system temperature caution fault but wired input does not.
working).
Display Fault Description: PROP TEMP CAUT CKT
Resulting Problem(s) Wired input may not be giving operator proper warning of a GE propel system temp
caution fault.
fault.
Table
Propel System Temp 0: GE has declared a propel system temp caution fault.
Caution Input (IM3A) 1: No propel system temp caution fault exists.
Fault(s): A108
Propel System Temp 0: Data link reports no fault.
Caution - RS232 Input 1: Data link reports a fault from GE.
18
Fault Code A322: Data link reports GE propel system reduced level fault but wired input
does not
Operator Action Go to shop now
Fault Code A322
Description Data link reports GE propel system reduced level fault but wired input does not.
working).
Display Fault Description: REDUCED PROPEL CKT
Resulting Problem(s) Wired input may not be giving operator proper warning of a GE propel system reduced
level fault.
fault.
Table
Propel System 0: GE has declared a propel system reduced level fault.
Reduced Level Input 1: No propel system reduced level fault exists.
(IM3B) Fault(s): A109
Propel System 0: Data link reports no fault.
Reduced Level - 1: Data link reports a fault from GE.
RS232 Input
19
Fault Code A323: Data link reports GE reduced retard level fault but wired input does not
Operator Action Stop; Park; Repair
Fault Code A323
Description Data link reports GE reduced retard level fault but wired input does not.
working).
Display Operator Action: STOP: PARK: REPAIR
Display Fault Description: REDUCED RETARD CKT
Resulting Problem(s) Wired input may not be giving operator proper warning of a GE reduced retard level
fault.
fault.
Table
Reduced Retard Level 0: GE has declared a reduced retard level fault.
Input (IM2r) 1: No reduced retard level fault exists.
Fault(s): A123
Reduced Retard Level 0: Data link reports no fault.
- RS232 Input 1: Data link reports a fault from GE.
20
Fault Code A324: Data link reports DC link voltage but wired input does not
Fault Code A324
Description Data link reports DC link voltage but wired input does not.
working).
Display Fault Description: NO DC LINK VOLT CKT
Resulting Problem(s) Wired input may not be giving operator proper warning of DC link voltage.
fault.
Table
GE Link Voltage 0: GE reports that link voltage exists.
(IM2b) 1: GE reports that no link voltage exists.
GE Link Voltage - 0: Data link reports no link voltage exists.
RS232 Input 1: Data link reports link voltage exists.
21
Fault Code A325: Data link reports GE no propel/retard fault but wired input does not
Fault Code A325
Description Data link reports GE no propel/retard fault but wired input does not.
working).
Display Fault Description: NO PROP / RET CIRCUIT
Resulting Problem(s) Wired input may not be giving operator proper warning of GE no propel/retard fault.
fault.
Table
No Propel/Retard Input 0: GE has declared a no propel/retard fault.
(IM2n) 1: The no propel/retard fault does not exist.
Fault(s): A124
No Propel/Retard - 0: Data link reports no fault.
RS232 Input 1: Data link reports a fault from GE.
22
Fault Code A326: Data link reports GE no propel fault but wired input does not
Fault Code A326
Description Data link reports GE no propel fault but wired input does not.
working).
Display Fault Description: NO PROPEL CKT FLT
Resulting Problem(s) Wired input may not be giving operator proper warning of GE no propel fault.
fault.
Table
No Propel Input (IM2p) 0: GE has declared a no propel fault.
1: The no propel fault does not exist.
Fault(s): A125
No Propel - RS232 0: Data link reports no fault.
Input 1: Data link reports a fault from GE.
23
Fault Code A327: Data link reports GE at rest but wired input does not
Fault Code A327
Description Data link reports GE at rest but wired input does not.
working).
Display Fault Description: REST / NOT READY CKT
Resulting Problem(s) Wired input may not be giving operator proper warning of a GE rest state.
fault.
Table
GE Propel Sys at Rest 0: GE has declared the system to be at rest or not ready.
or Not Ready 1: The system is not at rest and not ready.
Propel System at Rest 0: Data link reports system not at rest.
- RS232 Input 1: Data link reports system at rest.
24
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.
25
Fault Code A329: Data link reports the body is not down but wired input says it is
Fault Code A329
Description Data link reports the body is not down but wired input says it is.
working).
Display Fault Description: BODY DOWN CIRCUIT
Resulting Problem(s) Wired input may not be giving operator proper warning of a body not down.
fault.
Table
Body Down Switch 0: Dump body is not down.
Input (IM 3N) 1: Dump body is down.
Dump Body Down - 0: Data link reports dump body is not down.
Drive System 1: Data link reports dump body is down.
26
Fault Code A330: Data link reports dynamic retard operating state but wired input does not
Fault Code A330
Description Data link reports dynamic retard operating state but wired input says it is.
working).
Display Fault Description: RETARD LAMP CIRCUIT
Resulting Problem(s) Wired input may not be giving operator proper warning of retard operating state.
fault.
Table
Dynamic Retard Input 0: GE reports dynamic retard state.
(IM3Z) 1: GE reports not in dynamic retard.
Dynamic Retard State - 0: Data link reports not in retard.
RS232 Input 1: Data link reports dynamic retard state.
27
980E Dump truck

© 2016 KOMATSU
All Rights Reserved
28
CEN40168-00
DUMP TRUCK
980E

980E-4 A40003 and up
40 Troubleshooting
Fault Code A350: Overload on output 1B ............................................................................................................. 3
Fault Code A351: Overload on output 1E ............................................................................................................. 4
Fault Code A352: Overload on output 1H............................................................................................................. 5
Fault Code A353: Overload on output 1J.............................................................................................................. 6
Fault Code A354: Overload on output 1K ............................................................................................................. 7
Fault Code A355: Overload on output 1L ............................................................................................................. 8
Fault Code A356: Overload on output 1M ............................................................................................................ 9
Fault Code A357: Overload on output 1N........................................................................................................... 10
Fault Code A358: Overload on output 1P ............................................................................................................11
Fault Code A359: Overload on output 1R........................................................................................................... 12
Fault Code A360: Overload on output 1S ........................................................................................................... 13
Fault Code A361: Overload on output 1T ........................................................................................................... 14
Fault Code A362: Overload on output 1U........................................................................................................... 15
Fault Code A363: Overload on output 1X ........................................................................................................... 16
Fault Code A364: Overload on output 1Y ........................................................................................................... 17
Fault Code A365: Overload on output 1Z ........................................................................................................... 18
1
NOTES
2
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): A252
3
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.
4
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 (5 minute idle latch or shutdown delay relay) circuit is disabled.
fault.
Table
rpm.
5
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: IM OUTPUT 1J FAULT
Resulting Problem(s) Unused outputs with short circuits on them might damage the driver chip if not cor-
rected.
fault.
Table
1. This fault's logic contains just one parameter. There are no additional fault codes to investigate.
2. Any spare wires connected to this output should be removed to prevent ultimate failure of the driver chip.
Spare IM Output Status - Open Load: Unexpected. Troubleshoot.
(IM1J) Status - Normal: Expected. No problem.
0: Off
1: On
6
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.
7
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
rected.
fault.
Table
Advance 1: (IM1L) Status - Normal: Expected. No problem.
0: Off.
1: On.
Fault(s): A145
8
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 that require buzzer action are active.
1: One or more faults that require buzzer action are active.
Fault(s): A251
9
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
rected.
fault.
Table
(IM1N) Status - Normal: Expected. No problem.
0: Off.
1: On.
10
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 bleeddown circuit might not work properly, therefore causing a threat to
operators and mechanics.
fault.
Table
bleed operation.
Fault(s): A235, A236, A253, A262
11
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 inconsis-
tent.
Status - Normal: Expected if parking brake request and keyswitch are on. Trouble-
shoot if status is normal with parking brake request off or keyswitch off.
0: Normal operation with parking brake either applied or released. This valve operates
only transiently when the parking brake is set.
12
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
rected.
fault.
Table
(IM1S) Status - Normal: Expected. No problem.
0: Off
1: On
13
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
Status - Shorted to Ground: Unexpected except momentarily at termination of a lube
Fault(s): A190
Switch (IM3Y) 1: Pressure switch at low pressure or solenoid circuit not on.
Auto Lube Solenoid 0: Auto lube solenoid is energized.
Sense (IM3X) 1: Auto lube solenoid is not energized.
14
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
rected.
fault.
Table
(IM1U) Status - Normal: Expected. No problem.
0: Off
1: On
15
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
rected.
fault.
Table
Advance 2: (IM1X) Status - Normal: Expected. No problem.
0: Off
1: On
Fault(s): A146
16
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
Resulting Problem(s) Unused outputs with short circuits on them might damage the driver chip if not
corrected.
fault.
Table
(IM1Y) Status - Normal: Expected. No problem.
0: Off
1: On
17
Fault Code A365: Overload on output 1Z

Fault Code A365
Description Overload on output 1Z.
Fault Conditions Sets if driver chip detects overcurrent or over temp on output 1Z. Output is turned off
System Response Display Fault Description: IM OUTPUT 1Z FAULT
Resulting Problem(s) Unused outputs with short circuits on them might damage the driver chip if not
corrected.
fault.
Table
(IM1Z) Status - Normal: Expected. No problem.
0: Off
1: On
18
NOTES
19
980E Dump truck

© 2016 KOMATSU
All Rights Reserved
20
CEN40162-00
DUMP TRUCK
980E

980E-4 A40003 and up
40 Troubleshooting
Orbcomm
Orbcomm satellite connection............................................................................................................................... 3
1
NOTES
2
Orbcomm satellite connection

Orbcomm is a third party satellite communication 1
system that allows trucks to send data, such as fault
codes, by satellite to the Komatsu WebCARE server.
Many mines have limited cellular and WiFi 2
infrastructure for data communication, so Orbcomm
offers an alternative. Orbcomm coverage varies by
location and time.
3
Communication problems between the Orbcomm
controller and the satellite may occur.
Troubleshooting procedures for the following
problems will be covered in this chapter:
• Truck has never communicated with Orbcomm
86185
• Poor connection or no connection to WebCARE FIGURE 40-1. ORBCOMM CONTROLLER LABEL
• Confirmed satellite communication but not
reporting correctly to WebCARE 1. Part Number 3. Modem Number
2. Serial Number (12-Digit)
(6-Digit)
Required equipment
• VHMS Setting Tool
2. Cause: The wrong GCC code (satellite
• Service PC with Windows® operating system
(200 MHz processor, 64 MB RAM minimum) information) is selected on the KOMTRAX Plus
controller.
• RS232 serial cable (DB9 connector and female
connector) Solution: Connect the service PC to the RS232
port on the KOMTRAX Plus controller. Use the
• USB port to RS232 serial port adaptor (if no
VHMS Setting Tool program to ensure that the
RS232 port on service PC)
GCC is set correctly. For example select GCC
• Multimeter Code = 1 (USA) if in North or South America.
• Access to WebCARE See Figure 40-2.
• Orbitron (Free software at http://www.stoff.pl/)
Truck has never communicated with Orbcomm

1. Cause: An incorrect serial number may have
been submitted during the initialization process.
Solution: The Orbcomm controller has two
serial numbers: One is for the Orbcomm modem
(11-12 digits), the other is for the controller/
terminal itself (5-6 digits). Both are located on a
sticker attached to the top of the controller. The
part number is also located on this sticker. After
writing down all three numbers, confirm with
KAC that the correct numbers where submitted
during the activation request. See Figure 40-1. 86186
FIGURE 40-2. GCC SETTING
3
Poor connection or no connection to WebCARE 3. Cause: One or more wiring harnesses have
1. Cause: The Orbcomm antenna is not properly been damaged or disconnected.
connected to the Orbcomm controller terminal. Solutions:
Solution: Check the connections on both the a. There are two connectors that feed into Orb-
back of the Orbcomm controller terminal and the comm from KOMTRAX Plus. First, visually
base of the antenna. Ensure that the coaxial check these two connectors feeding into Orb-
cable is securely fastened on both ends. comm. Ensure that the connectors are
2. Cause: The Orbcomm terminal has been securely fastened. Also ensure that there are
disabled by Orbcomm Corp. If the Orbcomm no damaged or frayed wires leading into any
terminal was not activated prior to power up, it of the connectors.
will be disabled by Orbcomm Corp via Over The b. If there are no visual signs of damage, use a
Air (OTA) signal. multimeter to check for continuity in the wires
Solution: Make sure that the truck’s KOMTRAX between the Orbcomm controller and the
Plus and Orbcomm controllers have been KOMTRAX Plus controller. Use the subsys-
initialized and activated. Then, confirm that the tem diagram in Figure 40-3 for the wires to
truck is outside with the clear view of the sky test. Also perform a continuity check on the
and has the key ON or the engine running. coaxial cable going to the Orbcomm
antenna. There should be no open circuits.
After confirmation, contact Komatsu America
Corp to request a re-enable command to be
sent to the Orbcomm terminal. It may take up to
an hour for re-enable signal transmission.
Email: Servicesystems@komatsuna.com
Phone: (847) 437-4118
86187
FIGURE 40-3. SUBSYSTEM DIAGRAM
4
c. It may be difficult to discover damaged wires. • On, but not flashing - It is able to
The KOMTRAX Plus controller has a status communicate with the Orbcomm controller
LED light that will show its communication on the truck.
status with the Orbcomm controller. See • Flashing at a rate of about one blink per
Figure 40-4 second - Satellite communication is
established, but no data is being sent.
On the top of the KOMTRAX Plus controller, • Flashing at a rate of about one blink every
there is a two-digit, seven-segment display. two seconds - Satellite communication is
When there are no faults occurring, this two- established and data is being sent.
digit number will be counting up at a rate of If the LED is off, it means that the KOMTRAX
about 10 counts per second. Plus controller cannot communicate with the
Orbcomm controller. If this happens, a harness
The Orbcomm status LED is the “dot” follow- may be damaged or one of the controllers is
ing the second seven-segment LED charac- malfunctioning.
ter It has three different status signals:
86184
FIGURE 40-4. KOMTRAX PLUS CONTROLLER
5
For machines that are equipped with a TC301 NOTE: If the seven-segment LED display is solid, the
Orbcomm terminal, check the Orbcomm LED status Orbcomm terminal can detect the satellite. If the
on the Orbcomm controller. See Figure 40-5. seven-segment LED display is blinking, the
Orbcomm terminal cannot detect the satellite.
86188
FIGURE 40-5. TC301 ORBCOMM TERMINAL
4. Cause: The Orbcomm satellite is not in the area The following are 15 GES worldwide locations:
or is out of the reach of Ground Earth Stations • Chandler, AZ (USA)
(GES).
• Tifton, GA (USA)
For communication to take place, the truck and • Arcade, NY (USA)
GES have to be inside the satellite footprint
• Wenatchee, WA (USA)
(See Figure 40-6). If the satellite cannot detect
both the truck and GES at the same time, there • Matera, Italy
is no transfer of data. • Kitaura, Japan
• Chong Ho Won, Korea
• San Luis, Argentina
• Rio De Jan, Brazil
• Kijal, Malaysia
• Curacao, Netherlands
• Maghreb, Morocco
• Almaty, Kazakhstan
• Albury, Australia
• Hartebeesthoek, South Africa
6
There are many tools that allow the tracking of a satellite’s position and footprint size as it orbits the earth.
Orbitron (http://www.stoff.pl/) is one free tool that allows tracking of satellites in real time down to the second. It
can also run predictions for months in the future for any given location on Earth.
86189
FIGURE 40-6. ORBCOMM SATELLITE FOOTPRINT (ORBITRON VIEW)
Satellite AR is another free tool that is available for Android™ smart phones and tablets that show satellite
locations in real time using augmented reality from the device’s camera (Figure 30-8).
86190
FIGURE 40-7. SATELLITE AR HOME SCREEN AND AUGMENTED CAMERA VIEW
7
Confirmed satellite communication but not Cause: is that there was a change in vital settings on
reporting correctly to WebCARE the KOMTRAX Plus controller (e.g., SMR, date/time,
or component serial number.
Data shows up in WebCARE. However, it says it
does not exist when attempting to download it from WebCARE is programmed to “hide” KOMTRAX Plus
the website. You receive an orange or red flag under data when something unexpected happens within the
the machine spec section in the Receiving Status settings. For example, if the SMR is increased or a
section on WebCARE. SeeFigure 40-8 and Table 1. component serial number is changed.
Solution: WebCARE needs to receive a new set of
downloaded files and an information sheet that
explains the change. This can be done through KAC.
86191
FIGURE 40-8. WebCARE EXAMPLE
8
TABLE 1: WebCARE RECEIVING STATUS

Indicated Status Action Required
Color
- Normal Taking data is normal.
Continue updating continuously.
Orange Data is not accepted to update If exchange of the component, inform serial
WebCARE. there is a change in number updated to KOMTRAX Plus/WebCARE
information on data. Support Center by registration form.
Case 1 - Component serial number, etc.
has been changed. If operators change the calendar in CGC monitor,
Case 2 - There are great gaps in the advise them not to change it.
progress of SMR and the calendar (date/
time).
Red Data is not accepted. A part of data may
be broken. Connect to WebCARE and send the original
Case 1 - It is preserved with Snap Shot download data by email.
data has not been concluded.
Case 2 - File format is wrong.
(No Data Download data after initial setting is not The data after initial setting is sent to support
Stored) received by email. center by email immediately. (Do not send data by
Red FTP or Orbcomm until initial work has been
completed.)
9
980E Dump truck

© 2016 KOMATSU
All Rights Reserved
10
CEN40008-02
DUMP TRUCK
730E
860E
960E
980E
960E-1 A30003 - A30026
960E-1K A50003 - A50010
960E-2 A30027 and up
40 Troubleshooting
Preliminary checks................................................................................................................................................ 3
Diagnosis of gauge readings and system performance........................................................................................ 3
Troubleshooting by manifold gauge set readings ................................................................................................. 4
1
NOTES
2
Preliminary checks • System ducts and doors - Check the ducts and
doors for proper function.
If the system indicates insufficient cooling, or no
cooling, the following points should be checked • Refrigerant charge - Make sure system is
before proceeding with the system diagnosis properly charged with the correct amount of
procedures. refrigerant.
• Cab filters - Ensure the outside air filter and inside
NOTE: Ensure that the rest switch in the cab is ON
recirculation filter are clean and free of restriction.
and the drive system is disabled.
• Condenser - Check the condenser for debris and
Some simple, but effective checks can be performed clogging. Air must be able to flow freely through
to help determine the cause of poor system the condenser.
performance. Check the following to ensure proper
system operation. • Evaporator - Check the evaporator for debris and
clogging. Air must be able to flow freely through
• Compressor belt - Must be tight, and aligned. the condenser.
• Compressor clutch - The clutch must engage. If it
does not, check fuses, wiring, and switches.
Diagnosis of gauge readings and system
performance
• Oil leaks - Inspect all connection or components
Successfully servicing an air conditioning system,
for refrigeration oil leaks (especially in the area of
the compressor shaft). A leak indicates a beyond the basic procedures outlined in the previous
refrigerant leak. section, requires additional knowledge of system
testing and diagnosis.
• Electrical check - Check all wires and
connections for possible open circuits or shorts. A good working knowledge of the manifold gauge set
Check all system fuses. is required to correctly test and diagnose an air
NOTE: Before replacing a fuse, determine the cause conditioning system. An accurate testing sequence is
of failure. Repair as necessary. Always replace a fuse usually the quickest way to diagnose an internal
with one of the same specified amperage. Never problem. When correctly done, diagnosis becomes
replace with one of greater amperage. an accurate procedure rather than guesswork.
• Cooling system - Check for correct cooling The following troubleshooting charts list typical
system operation. Inspect the radiator hoses, malfunctions encountered in air conditioning
heater hoses, clamps, belts, water pump, systems. Indications and or problems may differ from
thermostat and radiator for condition or proper one system to the next. Read all applicable
operation. situations, service procedures, and explanations to
gain a full understanding of the system malfunction.
• Radiator shutters - Inspect for correct operation
and controls, if equipped. Refer to information listed under “Suggested
Corrective Action” for service procedures.
• Fan and shroud - Check for proper operation of
fan clutch. Check installation of fan and shroud.
• Heater/water valve - Check for malfunction or
leaking. With the heat switch set to COLD, the
heater hoses should be cool.
3
Troubleshooting by manifold gauge set readings
PROBLEM: Insufficient Cooling

Indications:
Low side pressure - LOW.
High side pressure - LOW.
Discharge air is only slightly cool.
Possible Causes Suggested Corrective Actions

- Low refrigerant charge, causing pressures to be Check for leaks by performing leak test.
slightly lower than normal.
If No Leaks Are Found:
Recover the refrigerant and use a scale to
charge the proper amount into the system.
Check system performance.
If Leaks Are Found:

After locating the source of the leak, recover the
refrigerant, and repair the leak. Evacuate the
system and recharge using a scale. Add oil as
necessary. Check A/C operation and perform-
ance test the system.
PROBLEM: Little or No Cooling
Indications:
Low side pressure - VERY LOW
High side pressure - VERY LOW
Discharge air is warm.
No bubbles observed in sight glass, may show oil
streaks.
- Pressure sensing switch may have compressor Add refrigerant (make sure system has at least
clutch disengaged. 50% of its normal amount) and leak test system.
It may be necessary to use a jumper wire to
-
enable the compressor to operate, if the com-
- Refrigerant excessively low; leak in system. pressor has shut down due to faulty pressure
sensing switch. Repair any leaks and evacuate
the system if necessary, Replace the receiver-drier
if the system was opened. Recharge the system
using a scale and add oil as necessary. Check
A/C operation and do system performance test.
4
PROBLEM: Extremely Low Refrigerant Charge in the System
Indications:
Low side pressure - LOW.
High side pressure - LOW.
Discharge air is warm.
The low pressure switch may have
shut off the compressor clutch.

- Extremely low or no refrigerant in the system. Check for leaks by performing leak test.
Possible leak in the system.
No Leaks Found:
Recover refrigerant from the system. Recharge
using a scale to ensure correct charge. Check
A/C operation and performance.
Leaks Found:
Add refrigerant (make sure system has at least
50% of its normal amount) and leak test system.
It may be necessary to use a jumper wire to
enable the compressor to operate, if the com-
pressor has shut down due to faulty pressure
sensing switch. Repair any leaks and evacuate
the system if necessary, Replace the receiver-drier
if the system was opened. Recharge the system
using a scale and add oil as necessary. Check
A/C operation and do system performance test.
PROBLEM: Air and/or Moisture in the System
Indications:
Low side pressure - Normal
High side pressure - Normal
(In a cycling type system with a
thermostatic switch, the switch may not cycle
the clutch on and off, so the low pressure
gauge will not fluctuate.)

Leaks in the system. Test for leaks, especially around the compressor shaft
seal area. When the leak is found, recover refrigerant
from the system and repair the leak. Replace the
receiver-drier or accumulator because the desiccant
may be saturated with moisture. Check the compressor
and replace any refrigerant oil lost due to leakage.
Evacuate and recharge the system with refrigerant
using a scale. Check A/C operation and performance.
5
PROBLEM: Air and/or Moisture in the System
Indications:
Low side pressure - HIGH
High side pressure - HIGH
- Leaks in system. Test for leaks, especially around the compressor

shaft seal area. After leaks are found, recover
refrigerant from the system and repair leaks. Re-
place the receiver-drier. Check the compressor
and replace any oil lost due to leakage. Evacuate
and recharge the system using a scale to ensure
proper quantity. Check A/C operation and perform-
ance.
PROBLEM: Expansion Valve Stuck or Plugged
Indications:
Low side pressure - VERY LOW or in a Vacuum
High side pressure - HIGH
Discharge air only slightly cool.
Expansion valve body is frosted or sweaty.

An expansion valve malfunction could mean Test: Warm diaphragm and valve body with your
the valve is stuck in the closed position, the filter hand, or very carefully with a heat gun. Activate
screen is clogged (block expansion valves do not the system and watch to see if the low pressure
have filter screens), moisture in the system has gauge rises. Next, carefully spray a little nitrogen,
frozen at the expansion valve orifice, or the or any substance below 0° C (32° F), on the capillary
sensing bulb is not operating. If the sensing bulb coil (bulb) or valve diaphragm. The low side gauge
is accessible, perform the following test. If not, needle should drop and read at a lower (suction)
proceed to the Repair Procedure. pressure on the gauge. This indicates the valve was
partially open and that your action closed it. Repeat
the test, but first warm the valve diaphragm or
capillary with your hand. If the low side gauge
drops again, the valve is not stuck.
Repair Procedure: Inspect the expansion valve

screen (except block type valves). To do this,
remove all refrigerant from the system. Disconnect
the inlet hose fitting from the expansion valve.
Remove, clean, and replace the screen. Reconnect
the hose and replace the receiver-drier. Evacuate
and recharge the system with refrigerant using a
scale. Check A/C operation and performance. If the
expansion valve tests did not cause the low press-
ure gauge needle to rise and drop, and if the other
procedure described did not correct the problem,
the expansion valve is defective. Replace the valve.
6
PROBLEM: Expansion Valve Stuck Open
Indications:
Air from vents in the cab seems warm
or only slightly cool.

The expansion valve is stuck open and/or the Test: Operate the A/C system on its coldest
capillary tube (bulb) is not making proper contact setting for a few minutes. Carefully spray
with the evaporator outlet tube. Liquid refrigerant nitrogen or another cold substance on the cap-
may be flooding the evaporator making it imposs- illary tube coil (bulb) or head of the valve. The low
ible for the refrigerant to vaporize and absorb pressure (suction) side gauge needle should now
heat normally. In vehicles where the expansion drop on the gauge. This indicates the valve has
valve sensing bulb is accessible, check the closed and is not stuck open. Repeat the test,
capillary tube for proper mounting and contact but first warm the valve diaphragm by warming
with the evaporator outlet tube. Then perform the with hands. If the low side gauge shows a drop
following test if the valve is accessible. If it is not, again, the valve is not stuck. Clean the surfaces of
proceed to the Repair Procedure. the evaporator outlet and the capillary coil or bulb.
Make sure the coil or bulb is securely fastened to
the evaporator outlet and covered with insulation
material. Operate the system and check perform-
ance.
Repair Procedure: If the test did not result in
proper operation of the expansion valve, the valve
is defective and must be replaced. Recover all
refrigerant from the system and replace the expan-
sion valve and the receiver-drier. Evacuate and
recharge the system with refrigerant using a
scale. Check A/C operation and performance.
PROBLEM: High Pressure Side Restriction
Indications:
Low side pressure - LOW
High side pressure - Normal to HIGH
Look for sweat or frost on high side hoses
and tubing. The line will be cool to the touch
near the restriction.

Kink in a line, collapsed hose liners, plugged Repair Procedure: After you locate the defective
receiver-drier or condenser, etc. component containing the restriction, recover all
of the refrigerant. Replace the defective compo-
nent and the receiver-drier. Evacuate and recharge
the system with refrigerant, then check A/C
operation and performance.
7
PROBLEM: Compressor Malfunction
Indications:
High side pressure - LOW
Compressor operates noisily.

- Defective reed valves or other internal Repair Procedure: If the belt is worn or loose,
components. replace or tighten it and recheck system perform-
ance and gauge readings. If inspection of the
compressor is required, all of the refrigerant must
be recovered and the compressor disassembled
to the point that inspection can be performed.
Replace defective components or replace the
compressor. If particles of desiccant are found in
the compressor, flushing of the system will be
required. It will also be necessary to replace the
receiver-drier. Always check the oil level in the
compressor, even if a new unit has been installed.
Rotary compressors have a limited oil reservoir.
Extra oil must be added for all truck installations.
Tighten all connections and evacuate the system.
Recharge the system with refrigerant using a scale
Check system operation and performance.
PROBLEM: Thermostatic Switch Malfunction
Indications:
Low side pressure - Normal
Low side pressure may cycle within a smaller
range as the compressor clutch cycles
more frequently than normal. This may indicate
the thermostat is set too high.
- Thermostat malfunctioning possibly due to Replace the thermostatic switch. When removing
incorrect installation. the old thermostat, replace it with one of the same
type. Take care in removing and handling the
thermostat and the capillary tube that is attached
to it. Use care not to kink or break the tube.
Position the new thermostat capillary tube at or

close to the same location and seating depth
between the evaporator coil fins as the old one.
Connect the electrical leads.
8
PROBLEM: Condenser Malfunction or System Overcharge
Indications:
Low Side High
High Side High
Discharge air may be warm.
High pressure hoses and lines are very hot.

- Lack of air flow through the condenser fins Repair Procedure: Check the engine cooling
system components, fan and drive belt, fan clutch
operation, and the radiator shutter. Inspect
condenser for dirt, bugs, or other debris, and
clean if necessary. Be sure the condenser
is securely mounted and there is adequate
clearance (about 38 mm) between it and
the radiator. Check the radiator pressure cap and
cooling system, including the fan, fan clutch, drive
belts and radiator shutter assembly. Replace any
defective parts and then recheck A/C system
operation, gauge readings, and performance.
If the problem continues, the system may be over-
charged. Recover the system refrigerant. Use a
scale to recharge the system using the correct
amount. Recheck A/C system operation, gauge
readings and performance. If the gauge readings
do not change, all of the refrigerant should be
recovered and the system flushed. The condenser
may be partially blocked -replace condenser. The
receiver-drier must also be replaced. Evacuate the
system, recharge, and check operation and
performance.
9
730E Dump truck

860E Dump truck
980E Dump truck
980E Dump truck
© 2015 KOMATSU
All Rights Reserved
10
CEN90014-00
980E

980E-4 A40003 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
1 2 3 4 5 6 7 8 9 10
HOIST CYL (3 STAGE)

1st STAGE 384.2 mm X 358.7 mm X 945.9 mm
2nd STAGE 320.7 mm X 288.8 mm X 945.9 mm
A 3rd STADE 257.1 mm X 193.7 mm X 945.9 mm A
NOTE: 27,628 CU. IN. TOTAL VOLUME TO EXTEND CYLINDERS
STEERING CYL 190.5 mm X 95.3 mm X 665.7 mm
FROM INSTALLED LENGTH (3" CHROME SHOWING) TO FULL
EXTENSION
HEAD
STEERING CYLINDER MANIFOLD
ROD
QUICK DISCONNECT
TEST PORT "TR" SHOCK VALVES
FOR DUMPING
3480 145 PSI
DISABLED TRUCK
(CYLINDER HEAD END)
CAVITY PLUG
CL CR
COUNTERBALANCE VALVE
TEST PORT "TCBV"
4.5:1 PILOT RATIO
OVERCENTER MANIFOLD
FLOW AMP
10:1 AMPLIFICATION
FACTOR L
R
B NEEDLE VALVE
QUICK DISCONNECT B
CLOSED FOR ADJUSTMENT ONLY.
OPEN FOR TRUCK OPERATION. FOR DUMPING R L
TO ACC TAP
DISABLED TRUCK 1100 PSI
MANIFOLD
(CYLINDER ROD END) FALLING
(TYP)
P
PILOT VENT STEERING VALVE

ACCUMULATOR
PLUGGED FOR TRUCK OPERATION. 800cc/REV
1400 PSI
OPEN FOR ADJUSTMENT ONLY. NITROGEN PRECHARGE
16.5 GAL (TYP) 2300 PSI
HOIST PILOT VALVE FALLING
ACC1
TEST PORT "TPD" P.P. PORT

PLUGGED P T LS
HOIST VALVE
TEST PORT "TPU" 2750 PSI HOIST E.F. PORT
TEST PORT (PLUGGED)
RELIEF PRESSURE POWER DOWN RELIEF T
"TP2"
TEST PORT "TCBVP" 1500 PSI
LS
ACCUM BLD DWN SWITCH PORT

HP 3000 PSI HT
ACTUATION: 300 15 PSIG (RISING)
C PRESSURE FEEDBACK RESET: 45 PSIG MAX. BELOW ACTUATION
C
2550 PSI
01 STRG SUPPLY
FALLING
HIGH PRESSURE
FILTER (HOIST)
TO BRAKE MANIFOLD
ACC2
TEST PORT
"TP3"
HIGH PRESSURE PRESSURE 01
SP BRAKE
FILTER SENSOR
(STEERING) LOCATED IN BRAKE
PORT "TP1" PORT
APU PS
TP4 QD SUPPLY
SHUTTER
SP PR
PANTO
PORT FOR OPTIONAL
PRESSURE SENSOR PRESSURE SENSOR
QUICK DISCONNECT
PUMP FOR DISABLED TRUCK
STEERING SUPPLY
PUMP SPECIFICATIONS
4000 PSI
C-4 10 WT. OIL@ 120 F
STRG RETURN
35 5 PSID SWITCH 0 PSI INLET PRESSURE
HPD TP9
TYP PUMP THEO FLOW DELIVERY
D HPU
B/D VALVE
NO.
STYLE
@ 1900 RPM/@100 PSI @ 2500 PSI D
GEAR PUMP
P1 135 GPM 123 GPM
PUMP PORT "GPA" 16.38 IN 3 /REV
TANK
GEAR PUMP
P2 135 GPM 123 GPM
16.38 IN 3 /REV
TP10 PISTON PUMP
P3 75 GMP 67 GPM
STEERING PUMP 9.15 IN 3 /REV
600 PSI
WITH UNLOADER
VALVE
P1 P2 P3 RELOAD
3225 25 PSI
50 PSID BYPASS UNLOAD
TP8 TP7 TP6 TP5
TYP BLEEDOWN
3525 PSI MAX SPARE RETURN
MANIFOLD
BODY LIMIT LUBE
HOIST PUMPS
CASE VALVE HOIST PILOT RETURN
HIGH PRESSURE FILTER (HOIST) DRAIN
HPPD QD RETURN
HYD PORT FOR OPTIONAL
HPPU
TANK QUICK DISCONNECT
FOR DISABLED TRUCK
STEERING RETURN
ATMOSPHERIC BREATHERS
E E
TREADLE VALVE AND BRAKE MANIFOLD RETURN FROM BRAKE CABINET
RELAY VALVE PORT T RETURN FROM AXLE BOX
TEMPERATURE DIFFUSERS
SENSOR
BAFFLE
BRAKE/HOIST RETURN MANIFOLD

FRONT BRAKES
LOW
LEVEL
SENSOR
INLET STRAINERS
REAR BRAKES
ORIFICE BLOW-OFF VALVE
35 PSI CRACKING
.45 IN DIA (TYP) RETURN FROM ACC TAP LINCOLN LUBE RETURN
MANIFOLD
F F
58B-60-21400-00 AUG 15
HYD OIL COOLER
STEERING, HOIST & BRAKE COOLING
HYDRAULICS SCHEMATIC
WET BRAKE COOLING
OIL RETURN TEMPERATURE 980E-4
SENSORS
A40003 & UP
58B-33-00030-1 AUG 15
BRAKE HYDRAULICS SCHEMATIC
960E-1 / -2: A30001 & UP
960E-1K / -2K: A50003 & UP
980E-4: A40003 & UP
90 Diagrams and drawings CEN90014-00
NOTES
3
980E Dump truck

© 2016 KOMATSU
All Rights Reserved
4
CEN90015-00
980E

980E-4 A40003 and up

Electrical circuit diagrams
Electrical circuit diagram ...................................................................................................................58B-06-02261
Electrical sub-system circuit diagram................................................................................................58B-06-02230
1
NOTES
2
HARNESS REFERENCE
AUXILIARY CABINET CONNECTIONS FOR FRAME HARNESSES CIRCUIT
CIRCUIT INDEX
SHT
HARNESS REF. KEY
REFERENCE TRUCK LOCATION
HARNESS DESIGNATION TABLE
ATTRIBUTE PART NUMBER DESCRIPTION
SEE SHEET 2 12VDC SUPPLY

AHT CONNECTION OPTION
6
16
A
B
AUXILIARY CABINET
BRAKE CABINET
AA1
AA2
58F-06-41550
58E-06-00513
WIRING HARNESS, AUXB INTERN
WIRING HARNESS, AUXB INTERN PWR
CN11 CN13 CN14 AUTOLUBE SYSTEM 14 C OPERATOR CAB AA3 58E-06-00524 WIRING HARNESS, GE INTERF
CN12 CN46 CN16 CN15
AUXILIARY CABINET HARNESS LAYOUT 2 D REAR CASE AA4 58E-06-08031 WIRING HARNESS, PLM4
BATTERY BOX 4 E ENGINE AA5 58E-06-00541 WIRING HARNESS, CAN RPC
AH1
RIGHT FRONT FRAME RAIL
AR1 AJ1 AJ4 AH2 AJ2 AD1 BODY/HOIST LIMIT 11 F RIGHT DECK AA7 XC2803 WIRING HARNESS, AHT PLUG1
FRONT PAYLOAD / WHL SPEED HARNESS FRONT LEFT FRAME RAIL LADDER OPTION HARNESS RIGHT REAR FRAME RAIL LEFT REAR FRAME RAIL CAB ENTERTAINMENT RADIO 6 G LEFT DECK AA8 58B-06-30090 WIRING HARNESS, AHT PLUG2
REAR AXLE WHEEL MOTOR SPEED CAB SPARE WIRES 9 H RIGHT FRAME AA9 58E-06-10821 WIRING HARNESS, CAN RPC
CN505 CN18 CAMERA SYSTEM CAN NETWORKS 19 J LEFT FRAME AA10 58E-06-10831 WIRING HARNESS, CAN J1939
ENGINE OIL RESERVE
CONTROL MODULE
ENGINE OIL RESERVE
CONTROL MODULE HOIST PUMP
CN565
JT1 CENTER DECK
CAMERA SYSTEM OPTION
CAMERA SYSTEM SWITCH PANEL
18
19
K
L
BATTERY BOX
RADIATOR GRILL
AA11
AA12
58E-06-10730
58E-06-10720
WIRING HARNESS, CAN RPC
WIRING HARNESS, CAN J1939
CN151 PRESSURE SW 1 LIGHT 1
LEFT FRONT CAN 3RD PARTY 16 M BODY AA13 58E-06-08070 WIRING HARNESS, 3RD PARTY
CN507 CN19 CN721
ENGINE OIL RESERVE PAYLOAD SENSOR HOIST PUMP CENTER DECK LEFT WHEEL MOTOR CAN J1939 N ISOLATION STATION AA14
ENGINE OIL 16 58E-06-08060 WIRING HARNESS, 3RD PARTY
TANK LEVEL RESERVE PUMP PRESSURE SW 2 AMBIENT AIR LIGHT 2 SPEED SENSOR CAN RPC 16 P PANTOGRAPH AA15 58E-06-07561 CABLE, CAT5E PLM4
CN150 TEMP SENSOR CN720
JJ2
RIGHT FRONT CUSTOMER ACCESSORY POWER 6 R FRONT FRAME AA16 58E-06-07572 WIRING HARNESS, ENET SW PWR
CN511
HH3 AUTOLUBE PUMP
PAYLOAD SENSOR
CN20
ENGINE OIL RESERVE
TANK LEVEL
CN534 LADDER LIGHT SW
OPTION LOCATION
FUEL TANK MARKER
LIGHT (OPT) STEERING PRESSURE
SENSOR
RIGHT WHEEL MOTOR
SPEED SENSOR DIRECTIONAL SHIFTER 8 S PROPULSION ALTERNATOR AA23 58E-06-07532 WIRING HARNESS, KWB AUX
SOLENOID ELECTRONIC GAUGE DISPLAY 9 T CONTROL CABINET AA24 58E-06-06981 CABLE, MMS AUX
AHT LEFT REAR BRAKE
JJ5 BODY UP SW LOW STEERING ENGINE INTERFACE 7 U AHT ODS BOX AA25 58E-06-06981 CABLE, MMS AUX
LEFT FRONT WHEEL CN830 CN536 GROUND LEVEL PRESSURE SENSOR (OPT)
SPEED SENSOR HYDRAULIC ACCESS LADDER PRESURE SW ENGINE OIL RESERVE SYSTEM OPTION 7 AA26 58E-06-06981 CABLE, MMS AUX
AUTOLUBE TANK SHUTDOWN SW
LEVEL SW UP SWITCH 0PTION FUEL TANK HARNESS AHT RIGHT REAR BRAKE ENGINE SHUTDOWN 5 AA27 58E-06-06900 CABLE, CAT5E GE
OPTION LOCATION STEERING ACCUMULATOR
HH4
CN730 PRESSURE SENSOR (OPT)
BLEEDDOWN SOLENOID ENGINE SHUTTER OPTION 7 AB1 58B-06-02540 WIRING HARNESS, AUXB HYD
CN501 RIGHT FRONT WHEEL HOIST FILTER
SPEED SENSOR ENGINE START PRE-LUBE 4 AC1 58B-06-02500 WIRING HARNESS, AUXB CAB-GE
PRESSURE SW 1
SUCTION HEATED LINES
JJ1
STEERING ACCUMULATOR ENGINE STARTERS 4 AC2 58B-06-02511 WIRING HARNESS, AUXB CAB-DIAG
CN511
CN502 HOIST FILTER BLEEDDOWN PRESS SW
AUTOLUBE SOL ENGINE TIER 2 7 AC3 58B-06-02521 WIRING HARNESS, AUXB CAB-DASH
ACCUMULATOR HYDRAULIC ACCESSORY PRESSURE SW 2 CN732
RETURN HEATED LINES HYDRAULIC TANK ETHER START OPTION 7 AC4 58B-06-02530 WIRING HARNESS, AUX CAB OH
PRE-CHARGE PRESS SW #1 FILTER SWITCH
CN503 STEERING FILTER MARKER LIGHT (OPT) ETHERNET WIRING 6 AC51 58E-06-08040 WIRING HARNESS, ENET AUX/CAB
AUTOLUBE LEVEL SW (OPT) PRESSURE SW FRAME HARNESS GROUND RETURNS 6 AD1 58B-06-20140 WIRING HARNESS, REAR WHEEL SPD
TEMP SWITCH ACCUMULATOR HYDRAULIC TANK
GE ALTERNATOR 16 AE1 58E-06-00492 WIRING HARNESS, QSK60/78
CN506 PRE-CHARGE PRESS SW #2 FUEL LEVEL LEVEL SENDER
SENDER GE INTERFACE 11 AE2 58E-06-00582 WIRING HARNESS, ENG AUX BOX
PUMP HOIST LIMIT GE INTERFACE 13 AF1 58B-06-20051 WIRING HARNESS, PLM AUXB LH
CN180 SOLENOID GE WHEEL MOTOR POWER CABLES 16 AG1 58F-06-02331 WIRING HARNESS, KWB
OIL RESERVE SYSTEM
ATFS GE WHEEL MOTOR SPEED SENSORS 11 AH1 58B-06-20061 WIRING HARNESS, RIGHT FRONT
CONTROL BOX HYDRAULIC STEERING
FILTER SW (AHT OPT) HEATED MIRRORS 15 AH2 58B-06-20080 WIRING HARNESS, RIGHT REAR
CN170
OIL RESERVE SYSTEM HORN FRONT VEHICLE 12 AJ1 58B-06-20071 WIRING HARNESS, LEFT FRONT
LEVEL SW (OPT) CN710 HOT START OPTION 16 AJ2 58B-06-20091 WIRING HARNESS, LEFT REAR
RIGHT REAR COMPONENT RH REAR BRAKE TEMP
JUNCTION BOX HYDRAULIC BRAKE CABINET 14 AR1 58B-06-20171 WIRING HARNESS, FRONT WHEEL SPD
SENSOR
TB60, TB61 HYDRAULIC CABINET 5 AR2 58B-06-20190 WIRING HARNESS, RH LADDER
CN709 HYDRAULIC LADDER OPTION 17 BB1 58F-06-10120 WIRING HARNESS, IND BRAKE HYD CAB
LH REAR BRAKE TEMP
CN505 INTERFACE MODULE 5 CC1 58E-06-00592 WIRING HARNESS, CAB GE
DD4
SENSOR
OIL RESERVE SYSTEM
CONTROL BOX DD2 CN703
BLOWER
PRESSURE SW
CN708
RH FRONT BRAKE TEMP
INTERFACE MODULE
ISOLATION STATION
14
4
CC2
CC3
58E-06-00605
58E-06-00611
WIRING HARNESS, CAB DIAG
WIRING HARNESS, CAB DASH
CN541 RIGHT UPRIGHT FRAME RAIL SENSOR KEY SWITCH 5 CC4 58E-06-00622 WIRING HARNESS, CAB OH
FH1 UPPER ENG

STARTER # 1 RELAY
CN540 LEFT UPRIGHT FRAME RAIL GND
CN707
LH FRONT BRAKE TEMP
KOMTRAX PLUS 13 CC5 EJ1556 HRN STR RADIO JUMPER
GJ1
SERVICE LIGHT LAMP ROTATING BEACON OPTION 15 CC7 EJ6371 VHMS JUMPER PLUG (CN2B)
CN704 SENSOR
UPPER ENG LAMPS AUX BOX DOME 6 CC8 EJ6372 VHMS HARNESS CODE JUMPER (CN1-6)
LOWER ENG STARTER #2 RELAY SERVICE LIGHT LAMPS BACKUP 12 CC11 58E-06-80040 CABLE, CAT5E MMS CAB
SERVICE LIGHT
LAMPS CLEARANCE 10 CC12 58E-06-02932 WIRING HARNESS, ARCS CAB
LOWER ENG CN563
RH ENGINE
SERVICE LIGHT SW BATTERY BOX SERVICE LIGHT
DD1
LAMPS DECK AND LADDER
LAMPS ENGINE SERVICE
10
11
CC13
CC21
58E-06-02941
58E-06-80050
WIRING HARNESS, CAB CAM
CABLE, CAT5E PC CAB
LH ENGINE LAMPS FOG 10 CC22 58E-06-80060 CABLE, CAT5E KPLUS CAB
SERVICE LIGHT SW REAR AXLE EXTERNAL HARNESS
RIGHT DECK HARNESS LAMPS FRONT TURN 10 CD2 58B-06-02480 WIRING HARNESS, RADAR 5-8
FF1
CN502 AHT MODE LIGHT
LAMPS HAZARD 10 CG1 58B-06-02460 WIRING HARNESS, CAMERA 2-6
CONNECTION
RIGHT PLM CN503 LEFT DECK HARNESS RBML LAMPS HEADLIGHT 9 CL1 58B-06-02450 WIRING HARNESS, CAMERA 1
RED LIGHT
GG1 LEFT PLM
AHT MODE
LIGHTS (OPT) LAMPS HYDRAULIC CABINET 12 CR1 58B-06-02490 WIRING HARNESS, RADAR 1-4
RIGHT PLM RED LIGHT LAMPS PUMP MODULE SERVICE OPTION 11 DD1 58B-06-20240 WIRING HARNESS, REAR AXLE
RIGHT RADIATOR GRILL HARNESS YELLOW LIGHT RIGHT REAR LAMPS REAR TURN AND TAIL 12 DD4 EL9925 HRN STR BLWR PRESS SW
CN543 LEFT REAR
HL1 CN520
SHUTTER CONTROL RIGHT PLM
LEFT PLM
YELLOW LIGHT
BACKUP HORN BACKUP HORN LAMPS STOP
OP-CAB WINDOW MOTORS
12
11
DD6
EE2
58F-06-03670
58B-06-21050
WIRING HARNESS, RADAR 5-6
WIRING HARNESS, PRE LUBE
SOLENOID GREEN LIGHT
LEFT PLM OPERATOR CAB HVAC 7 EE3 58B-06-21040 WIRING HARNESS, EXTERNAL QSK78
LOW MOUNT RIGHT HEATED GREEN LIGHT OPERATOR CAB SEAT 8 EK1 58B-06-21061 WIRING HARNESS, START RELAY
RIGHT LOW BEAM MIRROR LEFT RADIATOR GRILLE HARNESS LEFT REAR RIGHT REAR ORBCOMM MODULE 13 FF1 58B-06-21001 WIRING HARNESS, DECK RH
CN542 LEFT HEATED STOP/TAIL LIGHT
JL1
STOP/TAIL LIGHT WIRING HARNESS, SCOREBOARD LH/RH
RIGHT BACKUP CN520 MIRROR PARK BRAKE/BRAKE LOCK 8 FG1 58B-06-21140
LOW MOUNT RIGHT
HIGH BEAM LIGHT ETHER START LEFT REAR RIGHT REAR PAYLOAD METER IV 15 FG2 58B-06-21150 WIRING HARNESS, TANK LTS
SOLENOID LEFT TURN/CLEARANCE RETARD LIGHT RETARD LIGHT POWER DISTRIBUTION 6 FH1 58B-06-21011 WIRING HARNESS, UPRIGHT RH
RIGHT FOG RIGHT TURN/CLEARANCE LIGHT 1 REFERENCE AUX BOX HARNESS LAYOUT 2 GG1 58B-06-21021 WIRING HARNESS, DECK LH
LIGHT LIGHT 1 LOW MOUNT LEFT LEFT REAR RIGHT REAR
LOW BEAM LEFT TURN/CLEARANCE BACKUP LIGHT REFERENCE CAMERA HARNESS LAYOUT 3 GG4 58F-06-01280 CABLE, KWB
BACKUP LIGHT
HIGH MOUNT RIGHT RIGHT TURN/CLEARANCE LIGHT 2 REFERENCE CONNECTOR TABLE 23 GJ1 58B-06-21031 WIRING HARNESS, UPRIGHT LH
LOW BEAM LIGHT 2 LOW MOUNT LEFT HOIST HID BACKUP REFERENCE ENGINE & HYD CABINET HARNESS LAYOUT 2 HH3 EM5759 HRN STR AUTOLUBE
HIGH BEAM LEFT ROTATING LIMIT SW LIGHT
HIGH MOUNT RIGHT BEACON REFERENCE FRAME AND OP-CAB HARNESS LAYOUT 1 HH4 58E-06-00030 WIRING HARNESS, FUEL TANK
RIGHT ROTATING
HIGH BEAM BEACON LEFT FOG AUTO LUBE REFERENCE HARNESS INDEX TABLE 1 HL1 58B-06-20230 WIRING HARNESS, RH HEADLIGHT
LIGHT GRND-1 PRESSURE SW
LEFT BACKUP REFERENCE ISOLATION STATION HARNESS LAYOUT 1 HL2 EM3430 HRN STR SHUTTER CONTROL
RIGHT DECK RIGHT DECK AHT
BODY
LIGHT REFERENCE TERMINAL BOARD TABLE 23 JJ1 EM5759 HRN STR AUTOLUBE
BODY
LIGHT #1 MODE LIGHTS (OPT) HIGH MOUNT LEFT LOW LEFT REAR RIGHT REAR
BEAM PAYLOAD SENSOR REFERENCE WIRE TABLE 20 JJ2 EM7830 HRN STR LADDER SWITCH JUMPER LH
HORN PAYLOAD SENSOR
RIGHT DECK REFERENCE WIRE TABLE 21 JJ5 58F-06-02770 WIRING HARNESS, ESDS JUMPER
MM2 MM1
LIGHT #2 HIGH MOUNT LEFT CN54 CN55 RIGHT STOP/TURN/CLEARANCE REFERENCE WIRE TABLE 22 JJ10 58D-06-01091 JUMPER, RLS
HIGH BEAM LEFT DECK AHT LEFT STOP/TURN/CLEARANCE
MODE LIGHTS (OPT) LIGHT 1 VEC BLOCK POWER AND GROUND 6 JL1 58B-06-20220 WIRING HARNESS, LH HEADLIGHT
LIGHT 1
CN537 LEFT DECK LIGHT WINDSHIELD WIPER AND WASHER 12 JR1 58B-06-02410 WIRING HARNESS, RLS
MASTER GROUND
NN1 AJ1 (OPTIONAL) LEFT STOP/TURN/CLEARANCE
LIGHT 2
RIGHT STOP/TURN/CLEARANCE
LIGHT 2
JR2
JT1
58F-06-03200
58F-06-03020
WIRING HARNESS, LADDER
WIRING HARNESS, CONT CAB LIGHTS
DISCONNECT SW LEFT DIAGONAL
KK1 XB3625 HRN STR BATTERY BOX
LADDER LIGHT
MASTER LOCKOUT MM1 58B-06-03011 WIRING HARNESS, RIGHT BODY LIGHTS
SW CLOSED LIGHT MM2 58B-06-03001 WIRING HARNESS, LEFT BODY LIGHTS
NN1 58E-06-01310 WIRING HARNESS, ISO STATION IND
STARTER LOCKOUT OP-CAB DIAGNOSTIC RR1 58B-06-10291 WIRING HARNESS, ORS JUMPER
GE CONTROL / ELECTRONIC DASH CAB LOWER DASH OVERHEAD DASH
DISCONNECT SW CN03
CN01 CN02 CN04
STARTER LOCKOUT SW
RELAY
CC1 CN235 CC2 DID
CC3 KEY SW
CC4 CABLE DESIGNATION TABLE
GE DID PANEL
RETARD PEDAL
CN32 ATTRIBUTE PART NO. DESCRIPTION
STARTER LOCKOUT DIAG1
ROTATING BEACON AJ3 58B-06-20160 CABLE STR 2/0 BLK
SW OPEN LIGHT GE TCI DIAGNOSTIC
SW (OPT) AK1 58B-06-20151 CABLE STR 2/0 RED
STARTER LOCKOUT CN236 DIAG2 CN33
ACCELERATOR HEATED MIRROR DT1 CH2236 CABLE STR 7M1A1
SW CLOSED LIGHT GB12 ENGINE CENSE TIER I GB12
PEDAL SW (OPT) DT2 CH2237 CABLE STR 7M1A2
CN237 LEFT FRONT SPEAKER
PROPEL CN34 DT3 CH2238 CABLE STR 7M1B1
LOCKOUT SW RETARD LEVER
GB10 TB10 GRID DRY SW DT4 CH2239 CABLE STR 7M1B2
(930 OPT)
CN35 LEFT REAR SPEAKER DT5 CH2240 CABLE STR 7M1C1
PROPEL LOCKOUT DIAG4
DRIVE SYSTEM DT6 CH2241 CABLE STR 7M1C2
SW RELAY TB10 ENGINE DIAGNOSTIC TB10 REST SW ROTATING BEACON DT7 CH2242 CABLE STR 7M2A1
(OPT) RIGHT FRONT SPEAKER
PROPEL LOCKOUT CN903 DIAG5 CN37 DT8 CH2243 CABLE STR 7M2A2
SW OPEN LIGHT ACTIA DASH PRE-SHIFT
INTERFACE MODULE SERVICE BRAKE DT9 CH2244 CABLE STR 7M2B1
PANEL 1 BRAKE TEST SW
LIGHT RIGHT REAR SPEAKER
PROPEL LOCKOUT SW CN902 CN38 CN120 DT10 CH2245 CABLE STR 7M2B2
CLOSED LIGHT ACTIA DASH LADDER HORN CN210 DT11 CH2246
DYNAMIC CABLE STR 7M2C1
PANEL 2 CONTROL SW BUTTON
RETARD LIGHT DT12 CH2247 CABLE STR 7M2C2
GROUND CN21
DISPLAY MODE
WIPER MOTOR
CN07 CN121
STEERING COLUMN
COMBO CNTL LEVER
CAB DOME CN211 CC5 RADIO
EE4 58B-06-20250 CABLE, PRELUBE
CONTROL SW 1 LIGHT EE5 CH4327 PRELUBE GND CABLE 1/0 BLK
MASTER DISCONNECT CN18 CN20 WADT CN39 EE6
DASH LIGHT CH4303 CABLE STR 1/0 BLK
SW RELAY DISPLAY MODE WASHER DELAY BRAKE LOCK SW CNA
RHEOSTAT ORBCOMM MODULE EE9 CH4605 CABLE STR 2/0 BLK
CONTROL SW 2 TIMER SONALERT
MASTER DISCONNECT CN228 PTX-C CN08 CN36 (OPT) EE10 CH4503 CABLE STR 2/0 BLK
SW OPEN LIGHT MODULAR MINING WIPER RELAY CN1
AIR SEAT HAZARD LIGHT SW EJ1 58B-06-21130 CABLE STR 2/0 BLK
PTX-C DISPLAY HIGH
EK2 58B-06-21110 CABLE STR 2/0 RED
ISOLATION
CN229 CN09 CN140
RETARD SPEED WIPER RELAY CAB HVAC CN2A KOMTRAX EN1 58B-06-21070 CABLE STR 4/0 RED
AIR SEAT CONTROL SW CONNECTOR PLUS EN2 58B-06-21080 CABLE STR 4/0 RED
LOW
ESSW CN10 CN59 MODULE EN3 58B-06-21090 CABLE STR 4/0 BLK
SECONDARY ENGINE WIPER DELAY LEFT WINDOW CN3A
STATION
DATA STORE SW SHUTDOWN SW MOTOR EN4 58B-06-21100 CABLE STR 4/0 BLK
TIMER
CN212 CN22 CN58 EN5 58E-06-01830 CABLE ASSY PRELUBE FUSE LINK
RESET / BODY RIGHT WINDOW CN3B EN6 58B-06-21120
FOG LIGHT CABLE ASSY PRELUBE FUSE LINK
DRIVER SEAT BELT SW OVERRIDE CONTROL MOTOR
SW JN1 58F-06-00820 CABLE STR 2/0 BLK
RSP SW CN23 CN071
CN108
RETARD SPEED RIGHT WINDOW CN4A KK2 CH5827 CABLE STR 4/0 RED
MANUAL BACKUP
DIRECTIONAL SHIFTER POT MOTOR SW KK3 CH5828 CABLE STR 4/0 RED
LIGHT SW
CN24 CN072 KK4 CH5755 CABLE STR 4/0 BLK
LADDER LIGHT LEFT WINDOW CN4B KK5 CH5756 CABLE STR 4/0 BLK
SW MOTOR SW
P322B CN25 CN601 KK6 CH5829 CABLE STR 4/0 BLK
KOMVISION COMM RADIO KK7 CH5829 CABLE STR 4/0 BLK
J1939 TEE HEADLIGHT SW CONNECTOR (OPT) CN6 CN6A
KOMTRAX PLUS KK9 58F-06-02900 CABLE STR, 2/0 RED
CN263 CN602
P323B RETRACTIBLE LADDER FIRE SUPPRESSION HARNESS CODE KN1 58F-06-00640 CABLE STR 4/0 RED
KOMVISION RELAY (OPT) CONNECTOR (OPT) KN2 58F-06-00650 CABLE STR 4/0 RED
CN2B JUMPER PLUG
J1939 TEE CN262 KN3 58F-06-00830 CABLE STR 4/0 BATT BLK
RETRACTIBLE 12V POWER KOMTRAX PLUS
LADDER (OPT) PLUG 1 (CC7) KN4 58F-06-00840 CABLE STR 4/0 BATT BLK
ACTIA P207B P321B
MMS PTX
P308B
MMS PTX ST1 CH3687 CABLE STR 71J
RPC TEE J1939 TEE 12V POWER J1939 TEE ST2 CH3688 CABLE STR 74D
PLUG 2 P304R
CAN_TP P220B
KOMVISION TERMINATING
THIRD PARTY RPC TEE RESISTOR
DIAG
P211B
P407B P221B
ACTIA RPC
MMS PTX THIRD KOMVISION
TEE
PARTY TEE RPC TEE
P201R
OPERATOR CAB
TERMINATING
RESISTOR
CNX07 TO KOMVISION
MAIN CAB HARNESS,
SEE SHEET 2 SHEET 3 58B-06-02261-00 SEP 15

ELECTRICAL SCHEMATIC
980E-4
A40003 & UP
Sheet 1 of 24
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 R57
ENGINE SERVICE VEHICLE ELECT CENTER 91 VEC-91
AHT WHEEL SPD
INTERFACE
LIGHT TIMER (VEC-91) CONNECTORS POWER &
RESISTOR R57
P1,P2,P3,P4,P9,P10,P11,P12 GROUND R58
HYD PUMP SERVICE
LIGHT TIMER AA2 AA2 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
WINDSHIELD
WASHER MOTOR 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
QSK72 ECM T2
CN802
SERVICE BRAKE
DEGRADE PRESSURE SW
CN804
CN803
COOLANT LEVEL SW
FG1
A/C COMPRESSOR
CN805 CLUTCH
LOW BRAKE
PRESSURE SW
A/C RECEIVER DRIER
PARK BRAKE RELEASE CN806 PRESSURE SW
PRESSURE SW LP
CN820 FUEL FILTER

SERVICE LIGHT 1
WIF
WATER IN FUEL
SERVICE LIGHT 2 CN826 SEPERATOR
FUEL FILTER CONN
CNRIN
SERVICE LIGHT SWITCH CN815
EE2 GB3
RIGHT PLM
GB8 PRELUBE SCOREBOARD
PRESSURE SW OPTION
HYD CABINET
PRELUBE
MAG SW
PRELUBE
RELAY
ENGINE RUN OIL

PRESSURE SW
TIER II ENGINE HARN
58B-06-02261-00 SEP 15
980E-4
A40003 & UP
Sheet 2 of 24
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
TERMX1
TX0
P21TX0B2 CC13
KOMVISION CAMERA CAB HARNESS
CNX10 CF1 CAM1
KOMVISION CAMERA 1 HARNESS
CAMERA 1
P21TX0D
KOMVISION CONTROLLER CNX11 CF2
CAM2
AUTOLIV TEE CAMERA 2
KVIS-A CNX12
CF3
KOMVISION CAMERA 3 HARNESS CAM3
CAMERA 3
KOMVISION
KVIS-B
CONTROLLER
NTSC1 CNX13
CD1
KOMVISION CAMERA 4 HARNESS CAM4
CAMERA 4
P0028X CC6 CN0178X CC12 CNX14 CG1 CAM5

KOMVISION DIM KOMVISION SWITCH PANEL KOMVISION MAIN CAB KOMVISION CAMERA 5 HARNESS
SWITCH CAMERA 5
RGB
P0128X
KOMVISION
CANCEL SWITCH
P0038X
CNX15 CG2
CAM6
CAMERA 6
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
KOMVISION RH
FRONT SWITCH
P0168X
KOMVISION LH
REAR SWITCH
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-06-02261-00 SEP 15
980E-4
A40003 & UP
Sheet 3 of 24
74SB1-003-AJ1 (DBL 14ga ) 21 21 74SB1-002-AA1 (DBL 14ga ) SH18:J-18
4 4
BATTERY ISOLATION STATION P12 J12
71GG-000-NN1 (YEL 16ga ) 3 3 71GG-001-AJ1 (YEL 16ga ) SH5:A-2
BATTERY BOX / ISOLATION STATION SWITCH PROPEL LOCKOUT (PLOS)
1 F1 F2 1 71GH-000-NN1 (ORG 16ga ) 2 2 71GH-001-AJ1 (ORG 16ga ) SH5:B-2

BAT(+)-009-NN1 (RED 16ga ) 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 ) SH13:M-5
PC2528
PC2834 J537 P537
P12 J12
71PS-001-NN1 (LBL 16ga )
RELAY PROPEL LOCKOUT LAMP LED PROPEL

(+) (-) 72RRQ-001-NN1 (DBL 16ga ) LOCKOUT ON
71PS-001-NN1 (LBL 16ga ) 86 85
71PS-000-NN1 (LBL 16ga ) 1 RED
(NO) 87
CH5509 CH5510 30 (C) 0-032-NN1 (BLK 16ga ) 2 BLACK
BAT(+)-013-NN1 (RED 16ga )
(NC)
1
2
1
2
87A
PLON
PLREL_K 58E-06-01990
BATTERY BOX 58E-06-10020
PLREL_K
LAMP LED PROPEL
BATT1 BATT2 LOCKOUT LOCKED OUT
- + - + RELAY STARTER LOCKOUT
1 1 0-516-KK6 (BLK 4/0 ) 1 1 BAT(+)-000-KK2 (RED 4/0 ) (+) (-)
86 85 72RRQ-000-NN1 (DBL 16ga ) 1 RED
VZ0639 VZ0639 BAT(+)-002-KK1 (RED 6ga )

0-033-NN1 (BLK 16ga ) 2 BLACK
1
BUSS BAR (NO) 87
24VDC JB1 PLLO
BAT(+)-009-NN1 (RED 16ga ) 30 (C) 58E-06-01990
BATT BOX (NC)
1 BAT(+)-010-NN1 (RED 16ga ) 87A 0-448-NN1 (BLK 16ga ) 8
XB3583
1
SLREL_K 0-033-NN1 (BLK 16ga ) 7
BATT3 BATT4 1
58E-06-10020
BAT(+)-007-KN1 (RED 4/0 ) 1 BAT(+)-011-NN1 (RED 16ga ) SLREL_K 0-032-NN1 (BLK 16ga ) 6
1 - + 1 1 - + 1
0-517-KK7 (BLK 4/0 ) BAT(+)-001-KK3 (RED 4/0 ) 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
VZ0639 VZ0639 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 ALTERNATOR
58E-06-01990
1 2
300A LAMP LED MASTER
58E-06-07090 DISCONNECT OPEN
1M-000-NN1 (LTG 16ga ) 1 RED
BAT(-)-004-NN1 (BLK 16ga ) 2 BLACK
MLLO
25A-000-EK1 (DGR 6ga ) 58E-06-01990
SH6:G-18 0-050-AA1 (BLK 14ga ) 54 54 0-049-AJ1 (BLK 14ga )
53 53
GB70 FRAME GND
SH6:G-3 21PT-001-AA1 (DBL 14ga ) 21PT-000-AJ1 (DBL 14ga )
1 A1 A2 1
GB31-B
B2 E1
1 0-002-AJ3 (BLK 2/0 )
J12 P12
25B-000-EK1 (LTG 6ga )
MOTOR STARTER 1 MOTOR STARTER 2

(STRT1) (STRT2)
11-013-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
11-027-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
0-028-EE10 (BLK 2/0 )
ENGINE STARTERS 11ST-003-EE9 (RED 2/0 )
11ST-000-EN5 (RED 1/0 )
11SM2-003-EE3 (DGR 14ga ) R R 11SM2-001-AE2 (DGR 14ga ) SH5:K-11

11SM1-003-EE3 (GRY 14ga ) S S 11SM1-001-AE2 (GRY 14ga ) SH5:K-11
B B GB31-B
36-001-AE2 (YEL 14ga ) SH7:K-8 A1
36-005-EE2 (YEL 14ga ) 3 3 36-003-EE3 (YEL 14ga ) C C 0-215-AE2 (BLK 14ga )
F F 21PS-001-AE2 (BRN 14ga ) SH5:K-11
SWITCH ENGINE RUN OIL
ENGINE START PRE-LUBE PRESSURE (EOPSW)
G G 21PT-007-AE2 (DBL 14ga ) SH6:G-3
1 1 2 2 4 4
0-717-EE2 (BLK 14ga ) 0-359-EE3 (BLK 14ga ) J801 P801
8 PSI
EOPS PC2979 EOPS
SWITCH ENGINE PRELUBE OIL PRESS (PLPSW)
SP108
2 C NO 1 1 1
21PS-004-EE2 (BRN 14ga ) 21PS-003-EE2 (BRN 14ga ) 21PS-006-EE3 (BRN 14ga )
21PT-006-EE2 (DBL 14ga ) 2 2 21PT-011-EE3 (DBL 14ga )
4psi
P815 J815
PLPSW PLPSW
D87
21PT-003-EE2 (DBL 14ga ) 21PT-012-EE2 (DBL 14ga ) 2 1

SP107 NOTE:
PC2834 DIODE D87 PROVIDES CONTINUOUS
21PT-004-EE2 (DBL 14ga )
PRE-LUBE DURING CRANKING
RELAY ENGINE PRELUBE 21PL-001-EE2 (DBL 14ga )
85 85 86 86
21PT-005-EE2 (DBL 14ga )
87 87
30 30
87A
21PS-005-EE2 (BRN 14ga )
87A
GB5 FRAME GB4 ENG SUBFRAME
P800 GND BLOCK GND BLOCK
PC1146
P800 1 1
0-042-EE2 (BLK 14ga ) 1 0-025-EE6 (BLK 1/0 ) 1
58B-06-02261-00 SEP 15
RELAY ENGINE PRELUBE GB3 ENG
MAG SWITCH (PLMS) GND BLOCK
0-041-EE2 (BLK 14ga ) 1 B1
980E-4
1 + - 1
21PL-000-EE2 (DBL 14ga )
FUSE LINK1 ENGINE PRELUBE HIGH VOLUME PUMP 1 B3
(300A)
PUMP
1 1 2 1
11ST-000-EN5 (RED 1/0 )
FUS-1
1 1
FUS-2
11PL-000-EN6 (RED 1/0 )
PLMS-1 VL6217 PLMS-2
11PF-000-EE4 (RED 1/0 )
PLPM-(+)
1 + - 1 0-040-EE5 (BLK 1/0 )
PLPM-(-)
A40003 & UP
XA4488
Sheet 4 of 24
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
TB34 F17
2E 2F GE CONTROL INTERFACE
SH15: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
(ESDS) 3C VEC-90
11S-000-AA1 (RED 16ga ) C 71GH-002-AA1 (ORG 16ga ) 1 L1 L2 1 71GH-003-AA3 (ORG 18ga ) M PROPEL LOCKOUT INTERRUPT1
(OPTIONAL LEFT AND VEC-90 15 F15
71CK BUSS 86 85 3G
RIGHT LOCATIONS) VEC90-P3 G 73S1-000-AA1 (DBL 18ga ) SH5:H-16 P303
5 TB25
87 R PARK BRAKE RELEASED
A B 3H 510E-000-AA1 (DGR 18ga ) 1 N1 N2 1 510E-001-AA3 (DGR 18ga )
30 H SWITCH CAB SECONDARY
87a 510E-000-AA1 (DGR 18ga )
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 SH8:F-19 49-006-CC2 (TAN 16ga ) 1 1 0-310-CC2 (BLK 18ga ) SH8:D-14
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
439-000-CC2 (YEL 16ga ) 17 17 439-001-AC2 (YEL 16ga ) R1 R2 439-002-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
11KS-003-AA1 (BRN 16ga ) D
PC1375 30 4G J02 P02
G 23FA-000-AA1 (YEL 16ga ) 23F-000-AA1 (TAN 16ga ) 1 L1 L2 1 23F-001-AC2 (TAN 16ga ) 5 5 23F-002-CC2 (TAN 16ga )
2-1 2-2
87a
J702
11KS-005-JJ5 (BRN 16ga )
2-3 2-4
VEC90-P4 SH7:A-8 439-003-AE1 (YEL 16ga )
19 19
20 20
ENGINE AHT
P02 J02 PC1375 SH5:H-9 439-005-AA1 (YEL 20ga )
D1 INTERLOCK RELAY 19 AUXBOX CONNECTOR
P702
1H AHT
H (OPT)
AUXBOX CONNECTOR SH6:F-12 712-001-AA3 (ORG 18ga ) r KEY SW +24V TO CNTRL PWR SW
TB24 86 85 1C
C 712M-000-AA1 (PNK 20ga ) (OPT)
VEC90-P1
11KS-002-AA1 (BRN 16ga ) 1 H1 H2 1 1A P305
87 A 712IM-000-AA1 (ORG 16ga )
30
87a
TO VEC-90
ENGINE RUN VEC90-P1
TIMED ENGINE RELAY 21 (30)
11KS-004-AC3 (BRN 16ga ) SHUTDOWN RELAY 20
712K-002-AA1 (LBL 16ga )

SWITCH KEY (KEYSW)
712K-004-CC3 (LBL 16ga ) SH12:B-8
OFF
TB23
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
21S-000-CC3 (YEL 16ga ) N4 712K-003-AA1 (LBL 20ga )
P03 J03 0808610000
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 )
SH9:K-9 0-014-AA2 (BLK 16ga )
KEY SWITCH / ENGINE SHUTDOWN SH6:F-10 712-000-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 439-005-AA1 (YEL 20ga ) SH5:D-18 SH17: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 ) SWITCH PARK BRAKE RELEASE PRESSURE
SH5:C-13 73S1-000-AA1 (DBL 18ga ) M1 M2 73S1-002-AB1 (DBL 14ga ) 2 1
E E C NO
IM2 73S-003-BB1 (LBL 14ga )
N2 PC2834 C B 0-051-BB1 (BLK 16ga )
F F A NC
52A-001-AB1 (DBL 14ga ) 52A-000-BB1 (DBL 14ga ) GB8
1400A/1250R
PC1557 PBRPS
ENGINE SHUTDOWN DELAY F BRAKE
21NSL-003-AA1 (LTG 20ga ) SH7:C-9 PBRPS
GB31-B CABINET
D4 1
IM3 0-225-AB1 (BLK 14ga ) H H 0-227-BB1 (BLK 14ga ) 1
0-226-AB1 (BLK 14ga ) P P 0-228-BB1 (BLK 14ga )
P240 J240
ENGINE SHUTDOWN DELAY RELAY H 712M-000-AA1 (PNK 20ga )
IM1
KEY SW DIRECT P 712K-003-AA1 (LBL 20ga )
CRANK REQUEST j 21S-003-AA1 (YEL 20ga )
IM2
SH14:I-15 24VIM-008-AA1 (LBL 16ga ) TB32 24VIM-002-AA1 (LBL 18ga ) SH14: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 ) SH9:F-12
SH9:D-16 24VIM-006-AC4 (LBL 16ga ) G4
VEC-91
4F 85 86 2D
START ENABLE B 21SL-000-AA1 (TAN 20ga ) 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 VEC-91 F27

11SM2-002-AA1 (DGR 20ga ) G2 G1 11SM2-001-AE2 (DGR 14ga ) SH4:M-17 11 BUSS
G 3G
11INT-000-AA1 (PNK 20ga )
10
IM3 VEC91-P3
VEC-91 F28
4E 11 BUSS
11IM2-000-AA1 (WHT 20ga ) E
VBATT A 10
11INT-000-AA1 (PNK 20ga )
VEC91-P4
VBATT2 F 11IM2-000-AA1 (WHT 20ga )
IM1 INTERFACE MODULE
58B-06-02261-00 SEP 15
980E-4
A40003 & UP
Sheet 5 of 24
11B1-002-AA1 (LBL 10ga ) SH6:I-9
VEC-91
712 BUSS SH15:E-8 0-091-AC4 (BLK 16ga )
0 BUSS 85 86 10 10 0-202-CC4 (BLK 18ga )

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 1 1
65-000-AA1 (TAN 16ga ) 1 D1 D2 1 65-002-AC4 (TAN 16ga ) 65-003-CC4 (TAN 18ga )
VEC91-P10
ENTERTAINMENT
RADIO RELAY 37 SH10:N-1 65-005-AC4 (TAN 16ga ) 1 D3 D4 1 65-004-AA23 (TAN 20ga ) SH6:N-8 P04 J04
12E E
DL1 PC3010
VEC91-P12
F22 TB21
0-018-AA2 (BLK 16ga ) B
11G G 12 12 3 3 VEC-91 F55
12VREG-000-AA1 (LBL 12ga ) B1 B2 12VREG-001-AC3 (LBL 14ga ) 12VREG-003-CC3 (LBL 14ga ) 12VREG-005-CC3 (LBL 12ga )
20 9F 712 BUSS
SP156 F
CUSTOMER OP-CAB 5
712L-001-AA2 (DBL 16ga ) A
VEC91-P11 B3 12VREG-002-AC3 (LBL 14ga ) 13 13 12VREG-004-CC3 (LBL 14ga )
F40 VEC-91 TB22 COMMUNICATION DL1
VEC91-P9
11 BUSS 11C
C 21 21 1 1 RADIO CONNECTION
11ER-000-AA1 (RED 12ga ) 1 D1 D2 1 11ER-001-AC3 (RED 14ga ) 11ER-003-CC3 (RED 14ga ) 11ER-005-CC3 (RED 12ga )
20
F41 VEC-91
VEC91-P11
TB22 GB31-A
D3 1 11ER-002-AC3 (RED 14ga ) 22 22 11ER-004-CC3 (RED 14ga )
SP155
GB12
CAB ENTERTAINMENT RADIO SWITCH AUX BOX DOME LIGHT (DLS)
0-019-AA2 (BLK 16ga )
DL2
B
PC3010
SP104
11 BUSS 11B
B C1
67 67 1 A1 A2 1 2 2 1 2 3 1
SP100
11FS-000-AA1 (RED 16ga ) 1 F1 F2 1 0-203-AC3 (BLK 14ga ) 0-207-CC3 (BLK 14ga ) 0-211-CC3 (BLK 12ga ) 712A-000-AA1 (WHT 16ga ) 712L-000-AA2 (DBL 16ga ) 712L-002-AA2 (DBL 16ga ) A
5 ENTERTAINMENT RADIO
SR8325 DL2
VEC91-P11 0-204-AC3 (BLK 14ga ) 68 68 0-208-CC3 (BLK 14ga ) 0-212-CC3 (BLK 12ga ) 4 4
GB31-A GB12
C4 J601_CP
0-205-AC3 (BLK 14ga ) 69 69 0-209-CC3 (BLK 14ga ) 1 B1 A A 65-001-CC5 (ORG 18ga ) 7 (+) 12V SUPPLY
B B 13 SPEAKER LEFT FRONT (+) DL3 PC3010
LF(+)-000-CC5 (WHT 18ga )
0-206-AC3 (BLK 14ga ) 70 70 0-210-CC3 (BLK 14ga ) 0-213-CC3 (BLK 16ga ) B B + B RF(+)-001-CC4 (WHT 18ga ) C C RF(+)-000-CC5 (WHT 18ga ) 11 SPEAKER RIGHT FRONT (+) 0-024-AA2 (BLK 16ga ) 0-020-AA2 (BLK 16ga ) B
CUSTOMER ENTERTAINMENT RIGHT D D 4 IGNITION
65A-001-CC5 (TAN 18ga )
11FS-001-AC3 (RED 16ga ) 26 26 A A OP-CAB FIRE FRT SPEAKER - A
11FS-002-CC3 (RED 16ga ) RF(-)-001-CC4 (BLK 18ga ) 712L-007-AA2 (DBL 16ga ) 712L-003-AA2 (DBL 16ga ) A
SUPPRESSION E E 6 DIMMER
RFSPK 65A-002-CC5 (TAN 18ga ) DL3
C C CONNECTION F F
P03 J03 PC0724 12 SPEAKER RIGHT FRONT (-)
J602_CP P211 J211
RF(-)-000-CC5 (BLK 18ga ) PC3010
LF(-)-000-CC5 (BLK 18ga ) 14 SPEAKER LEFT FRONT (-) DL4
+ B LF(+)-001-CC4 (WHT 18ga ) 0-021-AA2 (BLK 16ga ) B
ENTERTAINMENT LEFT A A 8 GROUND
0-099-CC5 (BLK 18ga )
FRT SPEAKER - A B B 15 SPEAKER LEFT REAR (+)
LF(-)-001-CC4 (BLK 18ga ) LR(+)-000-CC5 (WHT 18ga ) 712L-004-AA2 (DBL 16ga ) A
12VDC POWER PORT #1 LFSPK C C RR(+)-000-CC5 (WHT 18ga ) 9 SPEAKER RIGHT REAR (+)
F63 VEC-91 TB24 D D 10 SPEAKER RIGHT REAR (-)
DL4
12V BUSS 9H PC0724 RR(-)-000-CC5 (BLK 18ga )
H 29 29 1 1 2 1 E E 16 SPEAKER LEFT REAR (-)
67C-000-AA1 (BRN 12ga ) 1 V1 V2 1 67C-001-AC3 (BRN 14ga ) 67C-003-CC3 (BRN 14ga ) LR(-)-000-CC5 (BLK 18ga )
20 F F GB31-A DL5 PC3010
B3
VEC91-P9 V4 1 PC1374 + B LR(+)-001-CC4 (WHT 18ga ) P737 0-017-AA2 (BLK 16ga ) 0-022-AA2 (BLK 16ga ) B
40 40 ENTERTAINMENT LEFT J210 P210 SP257
0-385-AC3 (BLK 14ga ) 0-383-CC3 (BLK 14ga ) PC2172
12VDC POWER PORT #2 REAR SPEAKER - A LR(-)-001-CC4 (BLK 18ga ) 712L-005-AA2 (DBL 16ga ) A
LRSPK SP256
30 30 1 1 2 1 DL5
67C-002-AC3 (BRN 14ga ) 67C-004-CC3 (BRN 14ga ) PC0724 0-010-AA2 (BLK 16ga ) SH8:M-15
DL6 PC3010
PC1374
0-386-AC3 (BLK 14ga ) 41 41 0-384-CC3 (BLK 14ga ) 0-023-AA2 (BLK 16ga ) B
AUX BOX DOME LIGHTS

+ B RR(+)-001-CC4 (WHT 18ga )
ENTERTAINMENT RIGHT 712L-006-AA2 (DBL 16ga ) A
REAR SPEAKER -
12VDC SUPPLY & CUSTOMER OPTIONAL ACCESSORY POWER
A RR(-)-001-CC4 (BLK 18ga )
P03 J03 DL6
RRSPK
PC0724
24VDC BUS
SH4:G-9 11-007-AK1 (RED 2/0 ) A1 C2 11-004-AA2 (RED 8ga ) SH5:F-10 TB24 AUXBOX FRAME GROUND CONNECTIONS GB31-B
SP08
0-401-AA1 (BLK 14ga )
0-421-AA1 (BLK 14ga )
SH15:D-7
SH11:F-17
C2
SH18:K-22 11-014-AA2 (RED 14ga ) C1 C4 11-005-AA2 (RED 8ga ) SH5:F-6 712-000-AA2 (ORG 8ga ) 1 J1 J2 1 712-001-AA3 (ORG 18ga ) SH5:D-19 0-416-AA1 (BLK 6ga ) 0-135-AA1 (BLK 16ga ) SH10:M-15
0-129-AA1 (BLK 14ga ) SH9:L-11 0-255-AA1 (BLK 14ga ) SH12:E-7
1 GB31-A
SH5:B-9 11-010-AA1 (RED 16ga ) B1 B2 11-012-AA2 (RED 8ga ) EB7418 J3
C2
SP12 0-128-AA1 (BLK 14ga ) SH9:L-11 0-403-AA1 (BLK 14ga ) SH15:B-8
VEC-89
0-413-AA1 (BLK 6ga ) 0-055-AA1 (BLK 14ga ) SH9:N-10
SH17:B-21 11-017-AA1 (RED 18ga ) B3 B4 11-011-AA2 (RED 8ga ) 11-012-AA2 (RED 8ga ) 1 K1 K2 1 712-003-AA2 (ORG 10ga ) 0-094-AA1 (BLK 14ga ) SH9:P-10
INTERFACE MODULE 712 BUSS
1 S5A 0-425-AA1 (BLK 14ga ) SH10:C-16
SH13:F-5 11-015-AA3 (RED 18ga ) D1 C3 11-006-AA2 (RED 8ga ) 712-005-AA1 (ORG 16ga ) 1 K3 K4 1 712-004-AA2 (ORG 10ga ) VEC89-S5A 0-424-AA1 (BLK 14ga ) SH11:G-16 0-222-AA1 (BLK 14ga ) SH7:P-8
GB31-B
1
S5B D2
SP09 0-104-AA1 (BLK 14ga ) SH10:B-16
0 BUSS 0-417-AA1 (BLK 6ga ) 0-127-AA1 (BLK 14ga ) SH9:M-11
+12V LOADS h 11B1-003-AA1 (LBL 20ga ) 0-005-AA2 (BLK 10ga ) 1 0-219-AA1 (BLK 14ga ) SH7:M-8 0-008-AA1 (BLK 14ga ) SH9:O-10
S7A GB31-A
VEC89-S7A D2
SP13 0-162-AA1 (BLK 14ga ) SH10:G-13 0-223-AA1 (BLK 14ga ) SH7:P-8
1
S7B 0-414-AA1 (BLK 6ga ) 0-163-AA1 (BLK 14ga ) SH10:G-13 0-420-AA1 (BLK 14ga ) SH11:G-17
GE CNTRL PWR ON SIG M 71GE-002-AA1 (BRN 20ga ) 0-216-AA1 (BLK 14ga ) SH7:M-8
71CK BUSS
71CK-001-AA2 (PNK 8ga ) 1 S6A 0-080-AA1 (BLK 16ga ) SH7:D-14
VEC89-S6A 0-050-AA1 (BLK 14ga ) SH4:I-3
CRANK SENSE U 21PT-010-AA1 (DBL 20ga ) 1
TB28 S6B
RELAY KEY/GE CNTRL 11 BUSS 0-084-AA1 (BLK 14ga ) SH9:P-10
SH4:I-3 21PT-001-AA1 (DBL 14ga ) 1 J1
VEC-91 PWR (KCNPR) 11-012-AA2 (RED 8ga ) 1
S8A 0-423-AA1 (BLK 18ga ) SH14:I-15 0-165-AA1 (BLK 14ga ) SH10:D-13
D14 GB31-A
IM3 0-006-AA2 (BLK 16ga ) SH5:F-6 VEC89-S8A 0-270-AA1 (BLK 14ga ) SH11:C-16 SP10 0-164-AA1 (BLK 14ga ) SH10:E-13
712 BUSS 10H H 86 85 GB31-B A2
SH4:M-17 1 71C-000-AA1 (ORG 16ga ) 1 1 1 SH10:L-15 SH9:N-11
21PT-007-AE2 (DBL 14ga ) J3
S8B A2
SP14 0-147-AA1 (BLK 16ga ) 0-130-AA1 (BLK 6ga ) 0-126-AA1 (BLK 14ga )
TB24 0-160-AA1 (BLK 6ga ) 0-161-AA1 (BLK 14ga ) SH10:H-13 0-344-AA1 (BLK 16ga ) SH14:O-15
D15
VEC91-P10 TB24 0-334-AA1 (BLK 16ga ) SH14:O-6 0-075-AA1 (BLK 16ga ) SH7:C-17
GE CONTROL INTERFACE G 10G
1 G1 G2 1 71GE-001-AA1 (BRN 16ga ) 0-333-AA1 (BLK 16ga ) SH14: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 ) SH14:I-15
CNTRL PWR ON SIG N 71GE-000-AA3 (BRN 16ga ) 1 G3 VEC91-P10
SH18:K-22 71CK-004-AA2 (PNK 14ga ) 1 N4 N3 1 71CK-003-AA1 (PNK 12ga ) SH7:O-1
58E-06-04150
P305 0-422-AA1 (BLK 14ga ) SH12:M-11
VEC-90 GB31-A
71CK BUSS 0-242-AA1 (BLK 14ga ) SH12:C-10 SP11 0-263-AA1 (BLK 14ga ) SH12:F-7
1 GB31-B B2
71CK-001-AA2 (PNK 8ga ) S8A B2
SP15 0-240-AA1 (BLK 14ga ) SH12:B-10 0-131-AA1 (BLK 6ga ) 0-134-AA1 (BLK 16ga ) SH10:J-15
0-007-AA2 (BLK 16ga ) VEC90-S8A 0-415-AA1 (BLK 6ga ) 0-146-AA1 (BLK 16ga ) SH10:M-15 0-426-AA1 (BLK 14ga ) SH11:F-16
1 0-241-AA1 (BLK 14ga ) SH12:B-10 0-402-AA1 (BLK 14ga ) SH15:D-7
12VDC S8B
CONVERTER VEC90-S8B 0 BUSS 0-521-AA1 (BLK 14ga ) SH7:O-8 0-407-AA1 (BLK 14ga ) SH15:C-8
(12VCN) 0-005-AA2 (BLK 10ga ) 1 0-523-AA1 (BLK 18ga ) SH7:O-7 0-522-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 ) 0-012-AA2 (BLK 10ga ) 1
S7B
24Vb VEC90-S7B
PB8460
12Va 1 1 88 88A 1
11B1-001-AA2 (LTG 8ga ) 11B1-001-AA2 (LTG 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 ) SH18:J-22
58E-06-04150
GNDa 1
0-009-AA2 (BLK 8ga ) 1 L3 L4 1 11B1-002-AA1 (LBL 10ga ) SH6:A-3 VEC-91
GNDb 12V BUSS 0-233-AA2 (BLK 16ga ) SH13:C-6
1 GB31-A
12V-000-AA2 (ORG 8ga ) S7A
TB35 C3
MC1192 VEC91-S7A 0-234-AA2 (BLK 16ga ) SH15:M-15
PC1110 1
SH6:M-13 12V-003-AA16 (ORG 18ga ) X3 X1 12V-001-AA2 (ORG 16ga ) S7B
GB31-A
A3 VEC91-S7B 0 BUSS
0-012-AA2 (BLK 10ga ) 1
S6A
B1 VEC91-S6A
0-011-AA2 (BLK 10ga ) 0-011-AA2 (BLK 10ga ) 1
S6B
VEC91-S6B 712 BUSS
1
S8A
VEC91-S8A
S8B
11 BUSS
11-011-AA2 (RED 8ga ) 11-011-AA2 (RED 8ga ) 1
S5A
VEC91-S5A
S5B
VEC BLOCK / GROUND / POWER DISTRIBUTION
ETHERNET WIRING ETHERNET SWITCH

MODULAR MINING DISPLAY
(PTX-C)
SHIELD-178
SHIELD-172 SHIELD-180 SHIELD-180 SHIELD-175 SHIELD-175
TX(+) 6 91ET1-000-CC11 (W-OR 24ga ) 1 1 91ET1-002-AC51 (W-OR 24ga ) 1 1 91ET1-001-AA24 (W-OR 24ga ) 1 MMS TX(+) GE TX(+) 1 94ET1-000-AA27 (W-OR 24ga ) SH13:B-4
TX(-) 4 91ET2-000-CC11 (ORG 24ga ) 3 3 91ET2-002-AC51 (ORG 24ga ) 3 3 91ET2-001-AA24 (ORG 24ga ) 3 MMS TX(-) GE TX(-) 3 94ET2-000-AA27 (ORG 24ga ) SH13:B-4
RX(+) 5 91ER1-000-CC11 (W-GR 24ga ) 2 2 91ER1-002-AC51 (W-GR 24ga ) 2 2 91ER1-001-AA24 (W-GR 24ga ) 2 MMS RX(+) GE RX(+) 2 94ER1-000-AA27 (W-GR 24ga ) SH13:B-4
RX(-) 8 91ER2-000-CC11 (GRN 24ga ) 4 4 91ER2-002-AC51 (GRN 24ga ) 4 4 91ER2-001-AA24 (GRN 24ga ) 4 MMS RX(-) GE RX(-) 4 94ER2-000-AA27 (GRN 24ga ) SH13:B-4
MC772 MC786 MC773
MMS_ENET JENET4 PENET4 PENET1 JENET1 PORT1 PORT4 MC768
USER PC
SHIELD-173 SHIELD-181 SHIELD-181 SHIELD-176 SHIELD-176 SHIELD-179

TX(+) 1 92ET1-000-CC21 (W-OR 24ga ) 1 1 92ET1-002-AC51 (W-OR 24ga ) 1 1 92ET1-001-AA25 (W-OR 24ga ) 1 PC TX(+)
RX(+) 2 92ET2-000-CC21 (ORG 24ga ) 3 3 92ET2-002-AC51 (ORG 24ga ) 3 3 92ET2-001-AA25 (ORG 24ga ) 3 PC TX(-) PAYLOAD TX(+) 1 95ET1-000-AA15 (W-OR 24ga ) SH15:N-17
TX(-) 3 92ER1-000-CC21 (W-GR 24ga ) 2 2 92ER1-002-AC51 (W-GR 24ga ) 2 2 92ER1-001-AA25 (W-GR 24ga ) 2 PC RX(+) PAYLOAD TX(-) 3 95ET2-000-AA15 (ORG 24ga ) SH15:N-17
RX(-) 6 92ER2-000-CC21 (GRN 24ga ) 4 4 92ER2-002-AC51 (GRN 24ga ) 4 4 92ER2-001-AA25 (GRN 24ga ) 4 PC RX(-) PAYLOAD RX(+) 2 95ER1-000-AA15 (W-GR 24ga ) SH15:N-17
MC771 MC787 MC774 PAYLOAD RX(-) 4 SH15:O-17
PC-ENET JENET5 PENET5 PENET2 JENET2 PORT2 95ER2-000-AA15 (GRN 24ga )
PORT6 MC767
SHIELD-174 SHIELD-182 SHIELD-182 SHIELD-177 SHIELD-177

SH13:K-16 93ET1-000-CC22 (W-OR 24ga ) 1 1 93ET1-002-AC51 (W-OR 24ga ) 1 1 93ET1-001-AA26 (W-OR 24ga ) 1 KOMTRAX TX(+) MC1192
SH13:K-16 93ET2-000-CC22 (ORG 24ga ) 3 3 93ET2-002-AC51 (ORG 24ga ) 3 3 93ET2-001-AA26 (ORG 24ga ) 3 KOMTRAX TX(-) V(+) 4 12V-003-AA16 (ORG 18ga ) SH6:I-10
2 2 2 2 2 KOMTRAX RX(+) GB31-A
SH13:K-16 93ER1-000-CC22 (W-GR 24ga ) 93ER1-002-AC51 (W-GR 24ga ) 93ER1-001-AA26 (W-GR 24ga ) E1
SH13:K-16 93ER2-000-CC22 (GRN 24ga ) 4 4 93ER2-002-AC51 (GRN 24ga ) 4 4 93ER2-001-AA26 (GRN 24ga ) 4 KOMTRAX RX(-) V(-) 2 0-543-AA16 (BLK 18ga )
MC769 MC788 MC775
JENET6 PENET6 PENET3 JENET3 PORT3
ENET_PWR
OPERATOR CAB 1 BULLET TX(+) GND SCREW 1 0-550-AA1 (BLK 16ga )

GB31-B
C4
3 BULLET TX(-) SH14:H-13

SW_GND 0-361-AA1 (BLK 18ga )
2 BULLET RX(+)
GB31-B 4 BULLET RX(-)
SP500
C3
0-214-AA23 (BLK 20ga ) SHIELDS ARE
PORT5 58E-06-04160 GROUNDED TO THE
SHIELD-129
ANTENNA KWB
SH6:B-9 65-004-AA23 (TAN 20ga )
SP510
SHELL OF THE M12
AUX BOX
MODULE
PLUGS AT THE
ETHERNET SWITCH
T3
WIRELESS BRIDGE
SHIELD-132 SHIELD-131 SHIELD-131 SHIELD-129
+12VDC2 5 65-008-GG4 (W-BL 24ga ) 1 1 65-010-AG1 (W-BL 24ga ) 1 1 65-012-AA23 (W-BL 24ga )
+12VDC 4 65-059-GG4 (BLU 24ga ) 7 7 65-011-AG1 (BLU 24ga ) 7 7 65-013-AA23 (BLU 24ga )
GND2 7 0-193-GG4 (BRN 24ga ) 3 3 0-754-AG1 (BRN 24ga ) 3 3 0-756-AA23 (BRN 24ga )
GND 8 0-236-GG4 (W-BR 24ga ) 2 2 0-753-AG1 (W-BR 24ga ) 2 2 0-755-AA23 (W-BR 24ga )
58B-06-02261-00 SEP 15
TX(+)
TX(-)
6
3
90ET1-001-GG4 (W-OR 24ga )
90ET2-001-GG4 (ORG 24ga )

6
4
6
4
90ET1-000-AG1 (W-OR 24ga )
90ET2-000-AG1 (ORG 24ga )

6
4
6
4
90ET1-002-AA23 (W-OR 24ga )
90ET2-002-AA23 (ORG 24ga )

RX(+) 2 90ER1-001-GG4 (W-GR 24ga ) 5 5 90ER1-000-AG1 (W-GR 24ga ) 5 5 90ER1-002-AA23 (W-GR 24ga ) 980E-4
RX(-) 1
KWB
90ER2-001-GG4 (GRN 24ga )
MC1191
J607
8 8
P607
MC1090
90ER2-000-AG1 (GRN 24ga )
P606
8 8
J606
MC1091
90ER2-002-AA23 (GRN 24ga )
A40003 & UP
Sheet 6 of 24
ENGINE QSK78 INTERFACE
FUEL IGNITION SIGNAL 1
ENGINE INTERFACE CIRCUITS
SH5:D-18 VEC-91
5 5 TB27 F36
P806 439-006-EE3 (YEL 16ga ) 439-003-AE1 (YEL 16ga )
2A 11 BUSS
UNSWITCHED BATTERY POWER 1 D 11E1-006-EE3 (YEL 14ga ) 1 1 11E1-001-AE1 (YEL 14ga ) A1 A2 11E1-000-AA1 (YEL 12ga ) A
7 7 20
11E1-002-AE1 (YEL 14ga )
UNSWITCHED BATTERY POWER 2 G 11E2-006-EE3 (LBL 14ga ) 2 2 11E2-001-AE1 (LBL 14ga ) A3 VEC91-P2
8 8 VEC-91 F37
11E2-002-AE1 (LBL 14ga ) 2B 11 BUSS
P805 3 3 11E3-001-AE1 (DBL 14ga ) B1 B2 11E2-000-AA1 (LBL 12ga ) B
9 9 20
11E3-002-AE1 (DBL 14ga )
B3 VEC91-P2
4 4 VEC-91 F38
11E4-001-AE1 (BRN 14ga ) 11 BUSS
64 64 GB31-B H
2H
0-069-AE1 (BLK 14ga ) C1 C2 11E3-000-AA1 (DBL 12ga )
65 65 C1 20
0-070-AE1 (BLK 14ga )
66 66 0-071-AE1 (BLK 14ga ) C3 VEC91-P2
67 67 B4 VEC-91 F39
0-072-AE1 (BLK 14ga ) 2G 11 BUSS
BATTERY GROUND 2 23 68 68 0-073-AE1 (BLK 14ga ) D1 D2 11E4-000-AA1 (BRN 14ga ) G
A/C SHUTTER CONTROL
ENGINE SHUTTERS / ETHER START OPTIONS
69 69 D1 20
0-355-EE3 (BLK 14ga ) 0-074-AE1 (BLK 14ga ) VEC91-P2 RELAY - R1
M1 M2
G
12G VEC-91 GB31-A
P806 65S-000-AA1 (BRN 16ga )
A1 86(+) 85(-) C2 D1
0 BUSS SH7:K-11 65T-000-AA1 (DBL 16ga ) 1 1 0-079-AA1 (BLK 18ga )
SHUTTER CONTROL A 85 86 SOLENOID ENGINE
65S-003-EE3 (BRN 16ga ) VEC91-P12 RTMR1-A1 RTMR1-C2
87 A2 SHUTTER (OPT)
12H H
SH17:D-18 0-690-AA1 (BLK 16ga )
ENGINE DELAY SHUTDOWN (3 MIN) C F25 87 C1 30
21NSL-002-EE3 (LTG 16ga ) 712 BUSS
65SR-000-AA1 (ORG 16ga ) 1
30 87a B2 58 58 15 15 1 1
RTMR1-C1 1 65SS-000-AA1 (LBL 16ga ) 65SS-001-AH1 (LBL 16ga ) 65SS-002-HL1 (LBL 16ga ) 65SS-003-HL2 (LBL 16ga ) 2 1
25 25 10 87a 59 59 16 16 2 2
P805 65S-001-AE1 (BRN 16ga ) RTMR1-B2 SH6:G-21 0-075-AA1 (BLK 16ga ) 0-076-AH1 (BLK 14ga ) 0-077-HL1 (BLK 14ga ) 0-078-HL2 (BLK 16ga )
VEC91-P12 VEC RTMR1
ESSOL ESSOL
TB27 SHUTTER CONTROL 58E-06-01940 P520_CP J520
COOLANT LVL SWITCH +V SUPPLY 4 924-001-EE3 (PNK 16ga ) 12 12 21NSL-001-AE1 (LTG 16ga )
VEC91-P12 (OPT) RELAY 39 J11 P11 J543 P543
SWITCH COOLANT LEVEL E1 E2 21NSL-003-AA1 (LTG 20ga ) SH5:H-9
COOLANT LVL SWITCH V RETURN 6 D 12D VEC-91
925-001-EE3 (TAN 16ga )
C +5V E4
SOLENOID ETHER
B GND
58B-06-00130 0 BUSS 85 86 START (OPT)
P806
COOLANT LEVEL SWITCH HIGH S 930-001-EE3 (LTG 16ga ) D HIGH 21NSL-004-AA2 (LTG 18ga ) 2 1 0-388-AA2 (BLK 18ga )
A LOW 1KΩ 2W F21 87 12C C 51 51 15 15 1 1
28E-000-AA1 (DBL 16ga ) 28E-001-AJ1 (DBL 16ga ) 28E-002-JL1 (DBL 16ga ) 28E-003-JL2 (DBL 16ga ) 2 1
TB27 R51 11 BUSS 30
COOLANT LEVEL SWITCH LOW T 52 52 16 16 2 2
926-001-EE3 (WHT 16ga ) P802 XA3603 10 87a
0-081-AJ1 (BLK 16ga ) 0-450-AJ1 (BLK 14ga ) 0-082-JL1 (BLK 14ga ) 0-429-JL2 (BLK 16ga )
18 18 28EC-002-AE1 (DBL 16ga ) H1 H2 28EC-000-AA1 (DBL 18ga ) VEC91-P12 SP796 ESOL ESOL
ETHER1_CP ETHER2
P805 J542 P542
16 16 ETHER START
21OR-001-AE1 (YEL 16ga ) K1 K3 21OR-005-AA1 (LBL 16ga ) SH7:N-8 (OPT) RELAY 36 J12 P12
ENGINE ETHER START OUTPUT 26 28EC-003-EE3 (DBL 16ga ) 21OR-002-AA1 (LBL 16ga ) SH7:P-8 11A
11 11 21ORR-001-AE1 (WHT 16ga ) K2 SH6:G-18 0-080-AA1 (BLK 16ga ) 0-342-AJ1 (BLK 16ga ) SH14:N-16
P806 EB7418 CONNECTION FOR LOW LEVEL SENSOR
+5V REFERENCE M L1 L2
5EFQ-000-EE3 (BLK 16ga ) FOR RESERVE OIL TANK OPTION
ENGINE RPM COMMAND SIGNAL REFERENCE P L3 21ORR-005-AA1 (DGR 16ga ) SH7:N-8
MC680 MC203 21ORR-003-AA1 (DGR 16ga ) SH7:P-8 TB27
ENGINE RPM COMMAND SIGNAL (PWM) L 556-003-EE3 (WHT 18ga ) 60 60 556-002-AE1 (WHT 16ga ) MC203 GE CONTROL INTERFACE
556-002-AE1 (WHT 16ga ) T1 T2 556-000-AA3 (WHT 18ga )
58B-06-00130
MC202 MC202
P805 47 47 556A-001-AE1 (GRN 16ga ) 2 1 556-001-AE1 (WHT 16ga ) T3 556-000-AA3 (WHT 18ga ) q ANALOG ENG RPM COMMAND SUPP
1KΩ 2W
61 61
R50 r ANALOG ENG RPM COMMAND COMM
952M/0-002-AE1 (BLK 16ga ) 952M/0-002-AE1 (BLK 16ga ) W1 W2 952M/0-001-AA3 (BLK 18ga ) 952M/0-001-AA3 (BLK 18ga )
ENGINE RPM COMMAND 10 916M-000-EE3 (BLK 18ga ) 62 62 916M-002-AE1 (RED 16ga ) W4 W3 0-235-AA2 (BLK 16ga ) SH15:M-15 916M-001-AA3 (RED 18ga ) s ANALOG ENG RPM COMMAND SIG
0-267-AA2 (BLK 16ga ) SH14:D-3
63 63 916M-002-AE1 (RED 16ga ) V1 V2 916M-001-AA3 (RED 18ga ) x ANALOG ENG RPM COMMAND SHIELD
SHIELD-771 SHIELD-205 SHIELD-202
ENGINE BLUE LIGHT FAULT 17 528A-000-EE3 (LBL 16ga ) 22 22 X1 X2
SHIELD-205 SHIELD-202
ENGINE YELLOW LIGHT FAULT 16 419I-004-EE3 (DBL 16ga ) 20 20 419I-003-AE1 (DBL 16ga ) F1
509-007-EE3 (GRY 16ga ) 21 21 509-002-AE1 (GRY 16ga ) S1
ENGINE RED LIGHT FAULT 18 509-005-EE3 (GRY 16ga ) 6 6 509-003-AE1 (GRY 16ga ) S3
ENGINE TEST MODE FAN CLUTCH (LOW) 27 TB31

22FO-002-EE3 (TAN 16ga ) FAN ON FULL
17 17 22FO-001-AE1 (TAN 16ga ) X1
ENGINE TEST
P806
ENGINE RED LIGHT INPUT K GB31-B
D3
70 70 0-086-AE1 (BLK 14ga ) e SYS RUN TO ENG ECU
72CPU-001-AA3 (BLK 18ga )
BATTERY GROUND 1 X TB29
0-356-EE3 (BLK 14ga )
SH8:M-9 79RD-000-AA1 (BRN 18ga ) S1 S2 79RD-001-AA3 (BRN 18ga ) b REVERSE OUT
ROCKFORD FAN CLUTCH CONTROL H
TB24 a FORWARD OUT
JB41
SH8:M-9 72FD-000-AA1 (WHT 18ga ) R1 R2 72FD-001-AA3 (WHT 18ga )
ENGINE FAN CLUTCH CONTROL (LOW) F 26 26 72CPU-000-AE1 (BLK 16ga ) 1 W1 W2 1 72CPU-001-AA3 (BLK 18ga )
22C-009-EE3 (GRY 16ga ) 1 P302
P805 22C-008-EE3 (GRY 16ga )
22C-007-EE3 (GRY 16ga )
2
3
W3 1
HYD BRAKE CABINET SWITCH SERVICE BRAKE PSI
NO
TB35
4 C 44R-004-BB1 (GRY 14ga ) K K 44R-005-AB1 (GRY 14ga ) F1
ENGINE FAN CLUTCH CONTROL 11 TB27 n GE CPU RUNNING B C
PC1150 FAN ON FULL 72CPU-003-AA1 (BLK 20ga ) 71BC-006-BB1 (DGR 14ga )
31 31 NC A
22C-006-EE3 (GRY 16ga ) 22C-005-AE1 (GRY 16ga ) G1 SH12:G-2 44R-003-AA1 (GRY 18ga ) F3 F4 44R-001-AA1 (GRY 20ga ) SH8:H-19
TEST POINT 15R/75A
IM2
GE CPU RUNNING SIGNAL 8 PC1677
72CPU-002-EE3 (BLK 16ga ) JB4A
SBPS
71BC-007-BB1 (DGR 14ga ) J J 71BC-003-AB1 (DGR 14ga ) SH8:F-10
P806 1
MC258 2
MC683 MC258
CAN J1939 HIGH A 939YE-002-EE3 (YEL 18ga ) 57 57 939YE-001-AE1 (YEL 18ga ) SH16:B-2 3 SOLENOID PARK BRAKE
4
CAN J1939 LOW B 939GE-002-EE3 (GRN 18ga ) 58 58 939GE-001-AE1 (GRN 18ga ) SH16:B-2 71BC-005-BB1 (DGR 14ga ) 2 1 52CS-004-BB1 (GRY 14ga ) 52CS-006-BB1 (GRY 14ga ) G G 52CS-003-AB1 (GRY 14ga ) SH8:I-11
PC1150
SP161
CAN J1939 SHLD C 59 59 PBS XA3347 PBS
P820 D2 J240 P240
71BC-004-BB1 (DGR 14ga ) 1 2 52CS-005-BB1 (GRY 14ga )
TB31
PC2834
ENGINE INTERFACE CIRCUITS
MC682 MC685 MC686 MC688 MC688
CENSE COMM RS232 TRANSMIT L 39 39 66 66 C
927-000-EE3 (RED 18ga ) 927-001-AE1 (RED 18ga ) A1 A2 927-002-AC2 (RED 18ga ) 927-003-CC2 (RED 18ga ) ENGINE CENSE
CENSE COMM RS232 RECIEVE M 40 40 67 67 B
RS232
928-000-EE3 (BLK 18ga ) 928-001-AE1 (BLK 18ga ) B1 B2 928-002-AC2 (BLK 18ga ) 928-003-CC2 (BLK 18ga ) CAB DIAGNOSTIC
CENCE COMM RS232 GROUND N 41 41 C1 C2 68 68 A DIAG2 CONNECTOR
929-000-EE3 (WHT 18ga ) 929-001-AE1 (WHT 18ga ) 929-002-AC2 (WHT 18ga ) 929-003-CC2 (WHT 18ga )
(OPT)
CENSE COMM RS232 SHLD P 42 42 D1 D2 69 69 DIAG2
SHIELD-774 SHIELD-774 SHIELD-782 SHIELD-782 SHIELD-787 SHIELD-787 SHIELD-793
P804
TB28
MC681 MC684 MC687 MC689 ENGINE CENSE
ENGINE QUANTUM J1587 DIAGNOSTIC SUPPLY 2 32 32 49 49
900-000-EE3 (WHT 18ga ) 900-001-AE1 (WHT 18ga ) T1 T2 900-002-AC2 (WHT 18ga ) 900-003-CC2 (WHT 18ga ) SH16:C-11 J1587
CAB DIAGNOSTIC
ENGINE QUANTUM J1587 DIAGNOSTIC RETURN 3 901-000-EE3 (BLK 18ga ) 33 33 901-001-AE1 (BLK 18ga ) V1 V2 901-002-AC2 (BLK 18ga ) 50 50 901-003-CC2 (BLK 18ga ) SH16:D-11
ENGINE 1400 RPM COMMAND 21
DIAG2 CONNECTOR
ENGINE 1000 RPM COMMAND 9 34 34 S1 S2 51 51 (OPT)
SHIELD-773 SHIELD-781 SHIELD-781 SHIELD-788 SHIELD-788 SHIELD-794
J808 P808
P806
P02 J02
GB3 ENG
SWITCH A/C RECIEVER DRYER GND BLOCK
NO2 F49 VEC-91 TB22
3 4 0-358-EE3 (BLK 16ga ) 1 A1 SOLENOID A/C
C2 712 BUSS 9A
COMPRESSOR CLUTCH A 12H-000-AA1 (LBL 16ga ) 1 G1 G2 1 12H-001-AC3 (LBL 16ga )
15
1 2 65C-003-EE3 (DBL 14ga ) 1 2 VEC91-P9 SH8:K-16 0-090-CC3 (BLK 16ga ) B
C1 NC1
SH11:J-20 41TS-011-CC3 (DGR 16ga ) C OP-CAB HVAC MODULE
TB30
RECDR PC1804 RECDR P803 XB7317 P803 2 2 12H-002-CC3 (LBL 16ga ) A PC2600
65T-002-AE2 (DBL 14ga ) X1 X4 65T-003-AC3 (DBL 16ga ) 1 1 65T-004-CC3 (DBL 16ga ) D
0-357-EE3 (BLK 14ga ) P140
X2 65T-000-AA1 (DBL 16ga ) SH7:B-14 P03 J03
N N TB28
65T-005-EE3 (DBL 14ga )
SH4:M-17 36-001-AE2 (YEL 14ga ) A1 A2 36-002-AA1 (YEL 18ga ) SH8:G-9
OPERATOR CAB HVAC
A3
J801 P801
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 )
58 58 2 NEG (BLK) COM (WHT) SP001
VEC-91
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 11RCNT-000-AA1 (TAN 14ga )
15 CM1_LSW_CP
SH7:D-9 21OR-005-AA1 (LBL 16ga ) 59 59
60 60 NEG2 (BLK) SP003
VEC91-P4 SH7:D-9 21ORR-005-AA1 (DGR 16ga ) 1 FVAL-000-RR1 (WHT 14ga )
F31 VEC-91 VAL (WHT) SP004
2 0-524-RR1 (BLK 14ga )
11 BUSS 4C C 11ORS-002-AA1 (LBL 14ga )
15 CM1_FVAL_CP
VEC91-P4 65TS-006-AA1 (DBL 16ga ) 65TS-009-AA1 (DBL 16ga ) 69 69

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 )
66 66 11POR-007-AH1 (GRY 16ga ) 1 TEMP SW COM (BLK)
11PHH-000-AA1 (RED 14ga ) 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
1 88 88A 1
11PHH-001-AA1 (RED 14ga ) CONTROL BOX (RH OPTION)
F58 VEC-91 OIL RESERVE SYS
SP780
SH6:H-12 71CK-003-AA1 (PNK 12ga ) D 1D
20
1C C
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-06-02261-00 SEP 15
VEC91-P1 VEC91-P1 HI (GRN) C
P180_CP LSW-L-001-RR1 (LTG 14ga )
SH6:F-21 28 28 0-518-AH1 (BLK 14ga )
0-222-AA1 (BLK 14ga ) CM2_LSW_CP
11POR-002-AA1 (GRY 14ga ) 27 27 11POR-005-AH1 (GRY 14ga )
69 69 SP776 NEG2 (BLK)
980E-4
65TS-008-AA1 (DBL 16ga ) 65TS-007-AH1 (DBL 16ga ) 1 FVAL-001-RR1 (WHT 14ga )
SH6:H-21 0-522-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:D-9 21OR-002-AA1 (LBL 16ga ) 21OR-004-AH1 (LBL 16ga )
SH7:D-9 21ORR-003-AA1 (DGR 16ga ) 26 26 21ORR-004-AH1 (DGR 16ga )
P170_CP
2 LEVEL SW
(OPT) A40003 & UP
J11 P11
Sheet 7 of 24
F56 VEC-89 TB24 JB4E
712 BUSS 4B
B 712DS-000-AA1 (ORG 14ga ) 1 C1 C2 1 712DS-001-AC2 (ORG 14ga ) 2 2 712DS-002-CC2 (ORG 14ga ) 1
10 2
712DS-003-CC2 (ORG 14ga )
VEC89-P4 712DS-004-CC2 (ORG 14ga ) 3
4
P02 J02
PC1150
MOTOR, DRIVERS SEAT
SUPPLY 1 712DS-003-CC2 (ORG 14ga )
RETURN 2 0-309-CC2 (BLK 14ga )
J228
MOTOR, PASSENGER SEAT

SUPPLY 1 712DS-004-CC2 (ORG 14ga )
RETURN 2 0-308-CC2 (BLK 14ga )
J229
JB6C
OPERATOR CAB SEATS
GB12 REAR CAB
1 0-266-CC2 (BLK 14ga ) 1 D3
2 0-308-CC2 (BLK 14ga )
3 0-309-CC2 (BLK 14ga )
4 0-260-CC2 (BLK 18ga ) SH8:F-20
5 0-310-CC2 (BLK 18ga ) SH5:C-18
6 0-311-CC2 (BLK 18ga ) SH11:I-9
56B-06-11510
F43 TB23
71CK BUSS 4A
3 3
DIRECTIONAL SHIFTER / PARK BRAKE

A 71SS-000-AA1 (LBL 18ga ) T2 T1 71SS-001-AC2 (LBL 18ga ) 71SS-002-CC2 (LBL 18ga )
P701
1
10
11
12
1
2
3
VEC-89
VEC89-P4
AHT
P02 J02
AUXBOX CONNECTOR
10
11
12
J701
1
2
3
(OPT) GE CONTROL INTERFACE
72AF-000-AA3 (GRY 18ga ) p FWD DIR REQ
TB23
79BA-001-AA3 (YEL 18ga ) X1 X2 79BA-002-AA1 (YEL 18ga ) SH12:C-2
H SEL SW IN REVERSE JB6B

79BA-000-AA3 (YEL 18ga )
4
TB24
1 49-003-CC2 (TAN 16ga ) SH9:J-7
52CA-001-AA3 (BRN 18ga ) 1 E1 E2 1 52CA-000-AA3 (BRN 18ga ) K PARK BRAKE SW CLOSED 3 49-006-CC2 (TAN 16ga ) SH5:C-16
5 49-007-CC2 (TAN 16ga ) SH11:I-6
E4 1 52CA-003-AA1 (BRN 20ga ) SH8:H-19 P304 6 49-008-CC2 (TAN 16ga ) SH11:J-9
2
TB25
56B-06-11510
V2 1 71BC-003-AB1 (DGR 14ga ) SH7:G-18
SHIFTER DIRECTION SELECTOR
V4 1 71BC-000-AA1 (DGR 16ga )
TB21 49-004-CC2 (TAN 16ga ) 1 A B 2 0-260-CC2 (BLK 18ga ) SH8:D-14
SHIFTER CURRENT LIMIT RESISTOR
13 13 P C 1 2
36-002-AA1 (YEL 18ga ) SH7:K-11 52C-002-AA3 (BRN 18ga ) K1 K2 52C-001-AC2 (BRN 18ga ) 52C-000-CC2 (BRN 18ga ) 4 3 71SR-000-CC2 (LTG 18ga ) 71SS-002-CC2 (LBL 18ga )
50.0
14 14 R EM5648
79B-003-AA3 (YEL 18ga ) L1 L2 79B-001-AC2 (YEL 18ga ) 79B-000-CC2 (YEL 18ga ) 5 P108 P250 P250
15 15 N
79B-002-AA1 (YEL 18ga ) L3 72N-000-CC2 (PNK 18ga ) 6
F19 VEC-90
71CK BUSS 9B F
B 72N-002-AA1 (PNK 18ga ) M1 M2 72N-001-AC2 (PNK 18ga ) 16 16 72-000-CC2 (GRY 18ga ) 7
10
D14 9 9 T
72-003-AA3 (GRY 18ga ) N1 72T-000-CC2 (YEL 18ga ) 8
H 9H 85 86
VEC90-P9
72-002-AA1 (GRY 18ga ) N3 N2 72-001-AC2 (GRY 18ga ) P108
87 D2
30 TO 1G
G
P02 J02
72-002-AA1 (GRY 18ga ) P2 72T-001-AC2 (YEL 18ga )
87a VEC-90
RELAY 20 D3
(87a) 1F INTERFACE MODULE
ENGINE RUNNING F 72N-002-AA1 (PNK 18ga )
RELAY 21
D4 C SERVICE BRAKE PRESS SW
1E SH7:G-20 44R-001-AA1 (GRY 20ga )
E 79B-002-AA1 (YEL 18ga )
D13
85 86 T SELECTOR SWITCH PARK
SH8:F-14 52CA-003-AA1 (BRN 20ga )
TB24
VEC90-P1
87 11B
B 52PB-000-AA1 (PUR 16ga ) 1 B1 B2 1 52PB-003-AA1 (PUR 20ga ) V PARK BRAKE RELEASE REQUEST
30 D5
87a B4 1 52PB-001-AC3 (PUR 16ga ) SH17:L-13 TO HYD ACCESS SH17:C-19 510E2-001-AA1 (DGR 20ga ) 1 2 510E2D-000-AA1 (DGR 20ga ) P HYD LADDER NOT UP
LADDER RELAY
PARK BRAKE PC2834 IM3
REQUEST RELAY 22 TB21
SH14: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
SH7:H-18 52CS-003-AB1 (GRY 14ga ) K1 K2 52CS-002-AA2 (GRY 18ga ) 1 2 0-231-AA2 (BLK 18ga ) X3
11A R18 SH14:M-15 0-345-AA2 (BLK 18ga )

87 A
0 BUSS 52CS-000-AA1 (GRY 16ga ) K3 SH14: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 72FNR-000-AA1 (DBL 16ga )
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 712BL-002-AC3 (DGR 16ga ) IM3
PARK BRAKE TB32

SWITCH RELAY 24 S1 52ABA-000-AA1 (TAN 20ga ) R PARK BRAKE PROTECTION (OPT)
52ABA-000-AA1 (TAN 20ga )
0 BUSS GB10 FRT CAB GND IM1
A4
52B1-003-CC3 (PUR 16ga )
1 0-095-CC3 (BLK 16ga ) i BRAKE LOCK
86 85 SWITCH BRAKE LOCK
0-090-CC3 (BLK 16ga ) SH7:J-12 IM2
D6
87 B B A A
30
87a
52B1-001-AC3 (PUR 16ga ) 25 25 52B1-002-CC3 (PUR 16ga ) 3 3
9D 2
D 52B-000-AA1 (PUR 16ga ) 2 712BL-003-CC3 (DGR 16ga ) 24 24
TRUCK MOVING 1 1
RELAY 25 D7 31 31 6
39HA-001-AC3 (YEL 16ga ) 39HA-000-CC3 (YEL 16ga ) 6 5 5
0-320-CC3 (BLK 16ga ) SH13:P-7 J03 P03
39H-001-AC3 (YEL 16ga ) 28 28 39H-000-CC3 (YEL 16ga ) 4
D8 TB23 4
0 BUSS 9C 0-096-CC3 (BLK 16ga )
85 86 C B1 B2
52B1-000-AA1 (PUR 16ga ) 52B1-001-AC3 (PUR 16ga )
D D C C
87
VEC90-P9 P03 J03
30
P39 P39
87a PC1766
J12-CC3 (WHT 16ga )

PARK BRAKE
D9 LATCH RELAY 26
RELAY PARK BRAKE PROTECTION
(930 OPTION ONLY) 0-097-CC3 (BLK 16ga )
E 9E
RELAY - R2
D10 86 85
52B-001-AA1 (PUR 20ga )
86(+) 85(-) TB32
SOLENOID BRAKE LOCK GB8
F 9F D1 F2
71ABA-001-AA1 (YEL 16ga ) 1 1 52ABA-001-AA1 (TAN 20ga )
87 3
J4 L L 2 1 1
30 VEC90-P11 RTMR1-D1 D2 RTMR1-F2 J1 52B-003-AB1 (PUR 14ga ) 52B-004-BB1 (PUR 14ga ) 52B-005-BB1 (PUR 14ga ) 0-098-BB1 (BLK 14ga )
VEC90-P9 87 SP160
1 52B-002-AA1 (PUR 16ga )
87a 11D F1 30 XA3347
D 1 BLS BLS
71ABA-000-AA1 (YEL 16ga ) E2 RTMR1-D2
87a
RTMR1-F1 1 P240 J240
GE INTERFACE D3
RELAY 27 TB32 VEC RTMR1 P3003 1 2
52B-006-BB1 (PUR 16ga ) 0-239-BB1 (BLK 16ga )
58E-06-01940
71ABA-002-AA1 (YEL 16ga ) T1
58B-06-02020
PC2834
71ABA-001-AA1 (YEL 16ga ) T3 T2 71ABA-003-AA2 (YEL 16ga ) 1 2 0-010-AA2 (BLK 16ga ) SH6:D-20
6800.0
R1
79RD-000-AA1 (BRN 18ga ) SH7:F-16

AHT
P702
AUXBOX CONNECTOR
72FD-000-AA1 (WHT 18ga ) SH7:G-16 (OPT)
1
TB23
1
J702
V2 39HA-001-AC3 (YEL 16ga )

TB22
SH15: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-AC3 (YEL 16ga )
58B-06-02261-00 SEP 15
980E-4
A40003 & UP
Sheet 8 of 24
ELECTRONIC GAUGE DISPLAY
0-180-CC1 (BLK 16ga )
SWITCH DISPLAY MODE #2
A
A B B
SH10:C-5 71LS-005-CC1 (DGR 16ga ) 0-181-CC1 (BLK 16ga ) TB26 INTERFACE MODULE
GB10 1
1 55A-000-CC1 (LBL 16ga ) 24 24 55A-001-AC1 (LBL 16ga ) N1 N2 55A-002-AA1 (LBL 20ga ) H MODE SW 1
B4 2
1 0-179-CC1 (BLK 16ga ) 2
3 3 25 25 J MODE SW 2
55B-000-CC1 (DBL 16ga ) 55B-001-AC1 (DBL 16ga ) P1 P2 55B-002-AA1 (DBL 20ga )
4 4
5 5
6 6
71LS-006-CC1 (DGR 16ga )

71LS-007-CC1 (DGR 16ga ) C C D D
P20 P20
PC1945
0-182-CC1 (BLK 16ga )

0-183-CC1 (BLK 16ga ) K MODE SW 3
ACTIA DASH DISPLAY
+7.5V +7.5V IM3
1 1 SWITCH DISPLAY MODE #1
ACTIA STATUS PANEL GND PC1942 GND
PC3588 2 2
LIN LIN PC3385
3 3
A
A B B
4 4
TB26
1
1
2
3
4
5
6
7
8
1 55C-000-CC1 (YEL 16ga ) 26 26 55C-001-AC1 (YEL 16ga ) R1 R2 55C-002-AA1 (YEL 20ga )

2
2
1 2 3 4 1 2 3 4 1 2 3 4 +7.5V +7.5V 3 3
1 1 55D-000-CC1 (PUR 16ga ) 27 27 55D-001-AC1 (PUR 16ga ) S1 S2 55D-002-AA1 (PUR 20ga ) q MODE SW 4
NOT USED
HIGH BEAM
RIGHT TURN
GND GND 4 4
LEFT TURN
HIGH BEAM
POWER 7.5V
2 2
POWER
LIN 3 3 LIN 5 5 IM2
PC1942
4 4 6 6
PC1942
J01 P01
GND
LIN

0-184-CC1 (BLK 16ga )
COOLANT TEMP GAUGE
FUEL GAUGE D9
P21 PC1944 P21
+7.5V +7.5V 1 2 712G-005-CC4 (LTG 16ga ) 22 22 712G-001-AC4 (LTG 16ga ) SH9:F-13
1 1
2 GND SPEEDOMETER & DISPLAY GND 2 JB4D
LIN (MASTER GAUGE) LIN 3 PC2834
3 D10
4 4 1 24SON-002-CC4 (LBL 16ga )
2 24SON-003-CC4 (LBL 16ga ) 1 2 24VIM-007-CC4 (LBL 16ga ) 3 3 24VIM-006-AC4 (LBL 16ga ) SH5:J-10
3 24SON-000-CC4 (LBL 16ga )
+7.5V +7.5V 4 PC2834
1 1 24SON-001-CC4 (LBL 16ga ) SONALERT
GND PC1942 GND
+7.5V 1 2 2 (SONA)
PC1943 LIN LIN PC1150
GND 2 3 3
LIN 58B-06-00190 1
3 4 4 +
2 1 TB34
PC1943 4
470Ω 2W
COMMUNICATION - 1 31IML-002-CC4 (BRN 16ga ) 31IML-004-CC4 (BRN 16ga ) 23 23 31IML-001-AC4 (BRN 16ga ) N1 N2 31ILM-000-AA1 (BRN 20ga ) M SONALERT
TO SLAVE DEVICES
R16
SP723
OIL TEMP GAUGE CNP2
DRIVE SYSTEM TEMP GAUGE (BLACK) PB1951
LEFT TURN 1 31 31
1 45LL-005-CC1 (BRN 16ga ) 45LL-006-AC1 (BRN 16ga ) SH10:L-13 31IML-003-CC4 (BRN 16ga ) J04 P04
RIGHT TURN 2 30 30
2 45RL-005-CC1 (DBL 16ga ) 45RL-006-AC1 (DBL 16ga ) SH10:L-13
HIGH BEAM HIGH BEAM 3
3 41H-006-CC1 (TAN 16ga ) SH9:J-15
KEY SWITCH 4 TB10
LEFT
TURN
RIGHT
4 TB23
5 5 712G-004-CC1 (LTG 16ga ) F1 F2 712G-003-CC1 (LTG 16ga )
6 6 6 6 712G-002-AC1 (LTG 16ga ) H1 H2 712G-000-AA1 (LTG 16ga )
WARNING LAMP 1 2 WARNING LAMP RETURN 7 3 3
1 2 7 11RWL-CC1 (PUR 16ga )
3 4 WARNING LAMP +24V 8 4 4
8 24VIM-004-CC1 (LBL 16ga ) H4 712G-001-AC4 (LTG 16ga ) SH9:D-16
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 PC1939
6 24VIM-005-AC1 (LBL 16ga ) SH5:J-13
7
8
9
10
11 KEY SWITCH
12 LEFT TURN
RIGHT TURN VEC-91 F54
13
14 GB10 FRT CAB GND 9C 712 BUSS
C
15 1 D3 5
IM ON SIGNAL 0-185-CC1 (BLK 16ga )
16
TB23 VEC91-P9
PC1938 VEC-91 F26
CNP1 2E 11 BUSS
11DISP-003-CC1 (YEL 16ga ) 1 1 G1 G2 E
24V BATT+ (GRAY) 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
CAN/RPC-L 2 2 49-002-CC1 (TAN 16ga ) SH9:J-7
4
IM ON SIGNAL 3 2 2 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
CAN/RPC-H MC254 MC254
7 5 5 939YP-001-CC1 (YEL 18ga ) SH16:E-18 IM1
CAN TERMINATOR CAN/RPC-L
8 6 6 939GP-001-CC1 (GRN 18ga ) SH16:E-18 J01 P01
7 7
CAN TERMINATOR SHIELD-263
8 8
PC1339 PC1938 P903
41TS-001-CC3 (LBL 16ga )

HEADLIGHT LAMP SWITCH
SWITCH HEADLIGHTS SPARE WIRES - AUX BOX TO CAB
0-186-CC3 (BLK 16ga ) SH10:G-5
A A B B
F64 TB22 1
1
SPR_5 1 SPR1-000-AC3 (DGR 14ga ) 59 59 SPR1-001-CC3 (DGR 14ga ) 1
SPR_13
OP-CAB
712 BUSS 2D 2
D 11D-000-AA1 (PNK 16ga ) 1 A1 A2 1 11D-001-AC3 (PNK 16ga ) 5 5 11D-002-CC3 (PNK 16ga ) 2 SH9:K-2 41H-004-CC3 (TAN 16ga ) CENTER CONSL
5 3 3
SPR_14 SPARE WIRES
VEC-89 4 4
VEC89-P2 TB10 SWITCH COMBO
11D-003-CC3 (PNK 16ga ) 5 5 TB10
P03 J03 6 6
41L-000-CC3 (LBL 16ga ) L1 41L-001-CC3 (LBL 16ga ) 4 3 41H-000-CC3 (TAN 16ga ) K1
5 1 61 61 1 OP-CAB
D D SPR_7 SPR3-000-AC3 (DGR 14ga ) SPR3-001-CC3 (DGR 14ga ) SPR_15
SH10:M-4 11L-010-CC3 (YEL 16ga ) C C 0-100-CC3 (BLK 16ga ) P121
DIMMER SW
K3 LOWER DASH
PC1709 1 62 62 1 SPARE WIRES
P121 SPR_8 SPR4-000-AC3 (DGR 14ga ) SPR4-001-CC3 (DGR 14ga ) SPR_16
P25 P25 AUX BOX
41L-002-CC3 (LBL 16ga ) SH9:L-2 SH9:E-9 41H-006-CC1 (TAN 16ga ) SPARE
WIRES 1 63 63 1 OP-CAB
TB34 TB10 41TS-000-CC3 (DGR 16ga ) SPR_9 SPR5-000-AC3 (DGR 14ga ) SPR5-001-CC3 (DGR 14ga ) SPR_17
LOWER FRT
SH10:I-8 41TS-005-AA1 (DGR 18ga ) A1 A2 41TS-003-AC2 (DGR 16ga ) 18 18 41TS-002-CC2 (DGR 16ga ) A3 A1 41TS-010-CC3 (DGR 16ga ) SH11:J-20 SPR_10 1 SPR6-000-AC3 (DGR 14ga ) 64 64 SPR6-001-CC3 (DGR 14ga ) 1
SPR_18 SPARE WIRES
ACTIA DISPLAY PANEL DIMMER
SH8:F-19 49-003-CC2 (TAN 16ga ) D4 A4 41TS-006-CC1 (DGR 16ga ) 1

50.0
P02 J02 P03 J03
SH9:G-9 49-002-CC1 (TAN 16ga ) D3 D2 49-001-CC1 (TAN 16ga ) 2
49-005-CC1 (TAN 16ga ) 58B-06-00290

3
SPR_19
OP-CAB
1 2
P18 569-06-61711 OVERHEAD
GB10 FRT CAB GND
SPR_20 SPARE WIRES
R27 1 B2
0-178-CC1 (BLK 16ga )
0-187-CC1 (BLK 16ga )
P04 J04
RELAY HI-BEAM 0-014-AA2 (BLK 16ga ) SH5:F-6

HEADLIGHT
TB34 (HBHR) GB31-B
18 18
86 85 B1
SH9: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
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
VEC-89 42 42 6 6 2
VEC89-P12 F4 SH6:F-18 0-129-AA1 (BLK 14ga ) 0-110-AJ1 (BLK 14ga ) 0-111-JL1 (BLK 14ga )
58E-06-04150
TB34 HMLHB
SH9:J-13 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 ) SH10: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
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
VEC-89 40 40 4 4 2
VEC89-P9 SH6:F-18 0-055-AA1 (BLK 14ga ) 0-114-AJ1 (BLK 14ga ) 0-113-JL1 (BLK 14ga )
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 ) SH12:D-8
LAMP HIGH MOUNT LEFT LOW-BEAM
J11 P11 J543 P543 58D-06-10080
F5
11 BUSS 9G
1 88
15
VEC-89
G
VEC89-P9
11LR-000-AA1 (PNK 10ga )
88A 1
41HM-000-AA1 (PNK 14ga ) 45 45
46 46
41HM-002-AJ1 (PNK 14ga ) 9
10 10
9 41HM-003-JL1 (PNK 14ga ) 1
2
58B-06-02261-00 SEP 15
SH6:F-18 0-094-AA1 (BLK 14ga ) 0-118-AJ1 (BLK 14ga ) 0-117-JL1 (BLK 14ga )
58E-06-04150
HMLLB
LAMP HIGH MOUNT RIGHT LOW-BEAM
J12 P12 J542 P542
980E-4
58D-06-10080
41HM-001-AA1 (PNK 14ga ) 45 45 41HM-004-AH1 (PNK 14ga ) 9 9 41HM-005-HL1 (PNK 14ga ) 1
HEADLIGHT LAMPS SH6:G-21 0-084-AA1 (BLK 14ga ) 46 46 0-119-AH1 (BLK 14ga ) 10 10 0-120-HL1 (BLK 14ga ) 2 A40003 & UP
HMRLB
J11 P11 J543 P543 Sheet 9 of 24
J11-CC3 (WHT 18ga )
SWITCH FOG LAMP (OPT)

0-268-CC3 (BLK 16ga ) SH12:C-5
A A B B
0-150-CC3 (BLK 16ga ) FOG LAMPS LAMP RIGHT FOG
3 3 58D-06-10060
2
71LS-003-CC3 (DGR 16ga ) 2
1 1 TB34 37 37 1 1 1
48LF-001-AA1 (GRY 14ga ) 48LF-003-AH1 (GRY 14ga ) 48LF-005-HL1 (GRY 14ga )
6 55 55 1B
48F-000-CC3 (GRY 16ga ) 48F-001-AC3 (GRY 16ga ) E1 E2 48F-002-AA1 (GRY 18ga ) B
6
71LS-004-CC3 (DGR 16ga ) 5 5 SH6:F-21 0-104-AA1 (BLK 14ga ) 38 38 0-103-AH1 (BLK 14ga ) 2 2 0-102-HL1 (BLK 14ga ) 2
0 BUSS 85 86 VEC-89
4 VEC89-P1
4 F62 RFLT
GB10 J03 P03 11 BUSS 87 TB34 J11 P11 J543 P543 LAMP LEFT FOG
C C D D 1 A3 15 30 1D 58D-06-10060
0-151-CC3 (BLK 16ga ) D 48LF-000-AA1 (GRY 12ga ) D1 D2
87a
P22 P22 VEC89-P1 48LF-002-AA1 (GRY 14ga ) 37 37 48LF-004-AJ1 (GRY 14ga ) 1 1 48LF-006-JL1 (GRY 14ga ) 1
PC1496 FOG LAMP (OPT)
RELAY 40
J10-CC3 (WHT 18ga ) SH6:F-18 0-425-AA1 (BLK 14ga ) 38 38 0-106-AJ1 (BLK 14ga ) 2 2 0-105-JL1 (BLK 14ga ) 2
LFLT
71LS-003-CC3 (DGR 16ga ) TB10 TB23 J12 P12 J542 P542
F44
4D 71CK BUSS
SH15:D-1 71LS-011-CC3 (DGR 16ga ) C2 C1 71LS-002-CC1 (DGR 16ga ) 5 5 71LS-001-AC1 (DGR 16ga ) M2 M1 71LS-000-AA1 (DGR 16ga ) D
5
VEC-89
C3 71LS-005-CC1 (DGR 16ga ) SH9:B-8 VEC89-P4
J01 P01
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)
48B-006-CC3 (PUR 16ga ) 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
0-101-CC3 (BLK 16ga ) SH12:B-5 0-494-AH1 (BLK 14ga ) 13 13 0-495-FH1 (BLK 14ga ) N N 0-496-FF1 (BLK 14ga ) 2
13 13
TB34
48C-001-AA1 (ORG 18ga ) RELAY ACCESS LADDER LIGHT (ALLR) DLT_CP
A A B B
0-188-CC3 (BLK 16ga ) L1 XA5780
TB34 J541 P541 P502 J502
3 3 P46 J46
48B-000-CC3 (PUR 16ga ) 53 53 48B-001-AC3 (PUR 16ga ) K1 K2 48B-002-AA1 (PUR 18ga ) 11 11 48B-003-AR2 (PUR 16ga )
2 86 85
SH10:M-3 11L-008-CC3 (YEL 16ga ) 2 48C-000-AA1 (ORG 18ga ) 1 1 0-016-AA2 (BLK 16ga ) SH9:N-9
1 1 54 54 12 12
48A-000-CC3 (YEL 16ga ) 48A-001-AC3 (YEL 16ga ) J1 J2 48A-002-AA1 (YEL 18ga ) 48A-003-AR2 (YEL 16ga )
6
6 TB26
5 5
J46 P46 LEFT DECK LAMPS
4 11DSL-000-AA1 (RED 12ga ) 1 88 88A 1
48-000-AA1 (DBL 8ga ) T1 T2
4 J03 P03
F10 LAMP LH DIAGONAL LADDER
V2
11 BUSS 12G 58E-06-04150
C C D D
0-186-CC3 (BLK 16ga ) SH9:I-11 G
20 47 47 11 11 1
VEC-89
48-003-AA1 (DBL 14ga ) 48-011-AJ1 (DBL 14ga ) 48-012-JL1 (DBL 14ga )
P24 P24 VEC89-P12
PC1502 48 48 12 12 2
SH6:G-18 0-163-AA1 (BLK 14ga ) 0-170-AJ1 (BLK 14ga ) 0-171-JL1 (BLK 14ga )
48A-006-CC3 (YEL 16ga ) 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 ) 0-176-JT1 (BLK 14ga ) 2
P565 J565 CDL1

XA5780
J14 P14 LAMP CONTROL CABINET WORK LIGHT #2
48-018-JT1 (DBL 14ga ) 1
0-177-JT1 (BLK 14ga ) 2
CDL2
XA5780
11F
SH9:J-4 41TS-005-AA1 (DGR 18ga ) F
VEC-89
0 BUSS 85 86
VEC89-P11
FRONT TURN / CLEARANCE LAMPS / HAZARD SWITCH 11 BUSS
F8
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
45L-000-CC3 (DGR 16ga ) 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
TB10 VEC-89
AMB
F11 3 3 3 3 C C
J1 45L-001-CC3 (DGR 16ga ) PWR SH6:H-21 0-134-AA1 (BLK 16ga ) 0-136-AJ1 (BLK 16ga ) 0-137-GJ1 (BLK 16ga ) 0-138-GG1 (BLK 16ga ) LCL1 58D-06-00830
11 BUSS
TB22 15 GND SP142
LOAD 0-139-GG1 (BLK 16ga )
SWITCH COMBO 17 17 45L-003-AC3 (DGR 16ga ) 1 P1 P2 1 J12 P12 J540 P540 P503 J503 LAMP MARKER/TURN LEFT FRT DECK
TURN SW
9 45R-000-CC3 (LBL 16ga ) 45R-003-AC3 (LBL 16ga ) 1 R1 R2 1
FLASHER
SH15:H-21 0-363-GG1 (BLK 16ga )
56 56 10 TB10 A C
712T-002-CC3 (BRN 16ga ) RELAY 13 45LL-010-GG1 (BRN 16ga )
11 M1 45R-001-CC3 (LBL 16ga ) 19 19 AMB
12D
P121 45L-004-AA1 (DGR 16ga ) D LCL2
PC1709 B
P03 J03 P121 J03 P03 41T-007-GG1 (TAN 16ga )
0 BUSS 85 86
AMB
LCL2 58D-06-00830
87 TB35 12 12 B
TB23 D13 F52 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 )
R1 R2 H 11H
712 BUSS 87a
24 24 A
LEFT SIDE
712T-001-AC3 (BRN 16ga ) 712T-000-AA1 (BRN 16ga ) 45LL-007-AA1 (BRN 16ga ) 45LL-011-AJ2 (BRN 16ga )
5 MARKER/
VEC-91 LEFT TURN SH9:E-12 45LL-006-AC1 (BRN 16ga ) J3 J4
VEC91-P11 SH6:G-18 0-147-AA1 (BLK 16ga ) 1 1 0-149-AJ2 (BLK 16ga ) C TURN

VEC-91 F35 RELAY 11
3A 11 BUSS 12B P732_CP
11L-000-AA1 (YEL 14ga ) A 45R-004-AA1 (LBL 16ga ) B
15
45R-002-CC3 (LBL 16ga ) 0 BUSS J14 P14 LAMP MARKER/TURN RIGHT FRT DECK
85 86
VEC91-P3 D4 VEC89-P12
87 TB35 SP145
45L-002-CC3 (DGR 16ga ) 1 2 45LR-002-CC3 (LTG 16ga ) 45RL-004-FF1 (DBL 16ga ) 45RL-007-FF1 (DBL 16ga ) A C
30 12A
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
87a
PC2834 45LR-007-CC3 (DGR 16ga ) SP146 RCL1
SH9: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
RIGHT TURN VEC89-P12
SWITCH HAZARD LIGHTS AMB
RELAY 12
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
SH9:I-8 11L-010-CC3 (YEL 16ga ) SP147
A A B B
0-133-CC3 (BLK 16ga ) 0-144-FF1 (BLK 16ga )
3 3 J11 P11 J541 P541 P502 J502 LAMP MARKER/TURN RIGHT SIDE DECK
2
11L-004-CC3 (YEL 16ga ) 11L-009-CC3 (YEL 16ga ) 2
1 1 A C
SP732 SH15:F-21 0-364-FF1 (BLK 16ga ) 45RL-009-FF1 (DBL 16ga )
TB22 TB10 6 AMB
1 C1 C2 1 11L-001-AC3 (YEL 14ga ) 9 9 11L-002-CC3 (YEL 14ga ) G1 G3 11L-006-CC3 (YEL 16ga ) 5 5 6
RCL2
4 41T-012-FF1 (TAN 16ga ) B
4
SH10:F-2 11L-008-CC3 (YEL 16ga ) H2 H1 SH6:H-18 0-146-AA1 (BLK 16ga ) 14 14 0-156-AH2 (BLK 16ga ) C AMB
EB7418 OPTIONAL RCL2 58D-06-00830
P03 J03
SH15:D-1 11L-003-CC3 (YEL 14ga ) C C D D
41T-015-AA1 (TAN 16ga ) 15 15 41T-016-AH2 (TAN 16ga ) 41T-017-AH2 (TAN 16ga ) B RIGHT SIDE
0-132-CC3 (BLK 16ga ) SH13:O-10 SP149 MARKER/ 0-145-FF1 (BLK 16ga )
P36 P36 45RL-008-AA1 (DBL 16ga ) 19 19 45RL-010-AH2 (DBL 16ga ) 45RL-011-AH2 (DBL 16ga ) A TURN
PC0493
SP148 P731_CP
J21-CC3 (BLK 18ga ) 45LL-008-AA1 (BRN 16ga ) 18 18
LAMP CAB DOME 41T-018-AH2 (TAN 16ga ) SH12:F-10 TO REAR AXLE

TURN /
J16 P16
SH6:B-6 65-005-AC4 (TAN 16ga ) 2 2 65-006-CC4 (TAN 16ga ) 45RL-012-AH2 (DBL 16ga ) SH12:G-10 CLEARANCE
LIGHTING
CDL -
58F-54-08100 45LL-012-AH2 (BRN 16ga ) SH12:G-10
P04 J04
58B-06-02261-00 SEP 15
980E-4
A40003 & UP
Sheet 10 of 24
GE CONTROL INTERFACE
TB21
GE INTERFACE AND WHEEL MOTOR SPEED SENSORS
REVERSE MODE RELAY DRIVER S 72A-000-AA3 (PNK 18ga ) E1
TB33
P304 AHT RH WHEEL
M1 M2 15SRW-001-AA1 (RED 18ga ) 15SRW-003-AA1 (RED 18ga ) 1
SPD RESISTOR
SP728 2
(OPT) R56
P56_CP
MC242 MC242
RH FT WHEEL SP +15V Q 15SRW-002-AA3 (RED 18ga ) L4 33RF-003-AA1 (WHT 18ga ) MC239 MC232 MC232 P501
15SRW-004-AA1 (RED 18ga ) 1 1 15SRW-005-AR1 (RED 16ga ) A +V SUPPLY
RH FT WHEEL SP SIGNAL X 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
RH FT WHEEL SP COMM 2
P
S
0RF-002-AA3 (BLK 18ga ) K1 K2
MC239
0RF-001-AA1 (BLK 18ga )
0RF-001-AA1 (BLK 18ga ) 3 3 0RF-000-AR1 (BLK 16ga ) C GROUND ENGINE AND PUMP MODULE SERVICE LAMPS
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
SPD RESISTOR TIMER (1HR) HYDRAULIC PUMP MOD (HPLT) LAMP HYD TANK SERVICE
TB33 (OPT) R57
T 1 42PMS-000-AA1 (DBL 16ga ) 35 35 42PMS-001-AJ2 (DBL 16ga ) A A
S1 S2 15SLW-001-AA1 (RED 18ga ) 15SLW-003-AA1 (RED 18ga ) 1 42PML-003-FG2 (ORG 14ga ) 1
SP729 2
MC244 MC244
LH FT WHEEL SP +15V J R4 1 33 33 B B B 2
15SLW-002-AA3 (RED 18ga ) P57_CP 42PML-000-AA1 (ORG 14ga ) 42PML-001-AJ2 (ORG 14ga ) 42PML-002-FG2 (ORG 14ga ) 0-632-FG2 (BLK 14ga )
1 SP712
MC238 33LF-003-AA1 (WHT 18ga ) 11SL-002-AA1 (DBL 14ga )
HSL
LH FT WHEEL SP SIGNAL W 33LF-002-AA3 (WHT 18ga ) R1 R2 33LF-001-AA1 (WHT 18ga )
MC238 MC234 MC234 P507 LAMP FUEL TANK SERVICE
LH FT WHEEL SP COMM H P1 P2 5 5 PC2644
0LF-002-AA3 (BLK 18ga ) 0LF-001-AA1 (BLK 18ga ) 15SLW-005-AA1 (RED 18ga ) 15SLW-006-AR1 (RED 16ga ) A +V SUPPLY
42PML-004-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
SH6:G-18 0-270-AA1 (BLK 14ga ) 25 25 0-271-AJ2 (BLK 14ga ) C C C 0-631-FG2 (BLK 14ga ) 0-633-FG2 (BLK 14ga ) 2
LH FT WHEEL SP SHIELD O 7 7 F34 VEC-91 TB24
N1 N2
SHIELD-239 0LF-001-AA1 (BLK 18ga ) 0LF-000-AR1 (BLK 16ga ) C GROUND SP713
11 BUSS 4D D P563_CP J563_CP J563 FSL
11SL-000-AA1 (DBL 14ga ) 1 A1
8 8 15
SHIELD-239 SHIELD-233 SHIELD-233 D SHIELD J14 P14
SENSOR LEFT FRONT WHEEL SPEED VEC91-P4
J13 P13
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
SENSOR LEFT REAR WHEEL SPEED 19 19 19 19
TB29 42A-001-AJ1 (LTG 16ga ) 42A-002-AA1 (LTG 16ga ) 42A-003-AH1 (LTG 16ga )
MC217 3 22 22 1 1
MC228 MC228 MC217 MC205 MC205 T 1 42SL-000-AA1 (ORG 16ga ) 42SL-001-AJ1 (ORG 16ga ) 3 3
LH RR WHEEL SP +15V B A1 A2 77P-002-AA1 (RED 18ga ) TW1 1 1 77P-004-AD1 (RED 18ga ) TW1 A A 42B-001-AJ1 (BRN 16ga ) 20 20 42B-002-AA1 (BRN 16ga ) 20 20 42B-003-AH1 (BRN 16ga )
77P-003-AA3 (RED 18ga ) TW1
NO 1 VA2828 VA2828
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
J12 P12
1 C
NC P12 J12 J11 P11
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 4 4 F F PC2644

77DP-003-AA3 (BLK 18ga ) TW2 D1 D2 77DP-001-AA1 (BLK 18ga ) TW2 77DP-000-AD1 (BLK 18ga ) TW2
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
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
SP742
TB35
P301 CONTINUITY CHECK2 y 71CNCK-000-AA3 (PNK 18ga ) 42-000-AA2 (BRN 12ga ) M1 M2 42-001-AA1 (BRN 14ga ) 0-288-AH1 (BLK 16ga )
42-002-AA1 (BRN 14ga )
42-008-AA1 (BRN 14ga ) M3
P301 CONTINUITY CHECK1 z 42-007-AA1 (BRN 14ga )
SENSOR RIGHT REAR WHEEL SPEED
MC221 MC221 TB29 LAMP LEFT UPPER LAMP RIGHT UPPER
MC213 MC209 MC209 ENGINE SERVICE ENGINE SERVICE
RH RR WHEEL SP +15V k 714P-003-AA3 (RED 18ga ) TW1 H1 H2 714P-001-AA1 (RED 18ga ) TW1 13 13 714P-002-AD1 (RED 18ga ) TW1 A A
RH RR WHEEL SP COMM j 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
714G-003-AA3 (BLK 18ga ) TW1
RH RR WHEEL SP SIGNAL +V2 m 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
714A-003-AA3 (WHT 18ga ) TW2
LUESL RUESL
RH RR WHEEL SP -V2 n
714DP-003-AA3 (BLK 18ga ) TW2 L1 L2 714DP-001-AA1 (BLK 18ga ) TW2 16 16 714DP-000-AD1 (BLK 18ga ) TW2 F F XA5780 XA5780
RH RR WHEEL SP +V1 p 17 17 G G LAMP LEFT LOWER LAMP RIGHT LOWER

714B-003-AA3 (GRN 18ga ) TW3 M1 M2 714B-001-AA1 (GRN 18ga ) TW3 714B-000-AD1 (GRN 18ga ) TW3
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
SHIELD-213 SHIELD-214 SHIELD-214 1 17 17 17 17 17 17 42-004-AH1 (BRN 14ga ) 17 17 1
SP765 SP769 SP770 42-011-GJ1 (BRN 14ga ) 42-010-AJ1 (BRN 14ga ) 42-005-FH1 (BRN 14ga )
SHIELD-223 P1 P2 19 19 E E
SHIELD-213
RH RR WHEEL SP SHIELD r 2 18 18 18 18 SH6:F-18 SH6:G-21 18 18 18 18 2
SHIELD-007-AA3 (BLK 18ga ) SHIELD-005-AA1 (BLK 18ga ) SHIELD-012-AD1 (BLK 18ga ) SHIELD-004-AD1 (BLK 18ga ) P720 0-280-GJ1 (BLK 14ga ) 0-279-AJ1 (BLK 14ga ) 0-424-AA1 (BLK 14ga ) 0-420-AA1 (BLK 14ga ) 0-285-AH1 (BLK 14ga ) 0-286-AH1 (BLK 14ga ) 0-287-FH1 (BLK 14ga )
SP741 LLESL SP165 RLESL
P301 XA5780 XA5780
J15 P15 P540 J540 P12 J12 J11 P11 J541 P541
DIG OUT (EXT RETARD LIGHT) t 74ZA-000-AA3 (DGR 18ga ) SH12:H-2

SENSOR GE ALTERNATOR SPEED
MC250 MC250 TB33 MC252 MC252
ENG SP REF PASS MAG PICK-UP s 74X-002-AA3 (WHT 18ga ) T1 T2 74X-001-SS1 (WHT 16ga ) B REF
ENG SP COMM x 74Z-002-AA3 (BLK 18ga ) W1 W2 74Z-001-SS1 (BLK 16ga ) A COM

71P-007-AC3 (DGR 16ga ) SH13:M-4
ENG SP SHIELD w V1 V2 G SHIELD 71P-005-AA1 (BRN 16ga ) SH13:D-5
VEC-91 F56
ALTSP TB23 9E 11 BUSS
67P-000-AA1 (YEL 12ga ) E
P301 J1 J2 20
TB33 F45
SHIELD-251 2E 71CK BUSS VEC91-P9
BUFFERED RH RR SP SIG SHIELD P G1 10 10 71P-001-AC2 (BRN 14ga ) J3 J4 71P-000-AA1 (BRN 14ga ) E
SHIELD-251 15
BUFFERED RH RR SP SIG POS VEC-89
Q 714Z-000-AA3 (WHT 18ga ) C1 VEC89-P2 GB12 REAR CAB
J02 P02 SWITCH LEFT WINDOW
D1
1
BUFFERED RH RR SP SIG RET R 714Y-000-AA3 (BLK 18ga ) D1 71P-006-CC2 (BRN 14ga ) GB12 REAR CAB
MC246 MC246 A A
SWITCH BODYUP OVERRIDE / RESET
D2
1 0-192-CC3 (BLK 18ga ) B B
TB33
MC248 MC248 (ORS) 3
BUFFERED LH RR SP SIG RET X 77Y-000-AA3 (BLK 18ga ) E1
3 MOTOR LEFT WINDOW
TB24 0-191-CC3 (BLK 14ga ) 2
2 67M-001-CC3 (GRY 14ga ) 67M-000-CC3 (GRY 16ga ) B
BUFFERED LH RR SP SIG POS W 77Z-000-AA3 (WHT 18ga ) F1 SH8:F-19 49-007-CC2 (TAN 16ga ) 1 1 0-311-CC2 (BLK 18ga ) SH8:D-14 32 32 1
1
A B JB4B 1 T2 T1 1 67P-001-AC3 (YEL 14ga ) 67P-004-CC3 (YEL 14ga ) 67P-005-CC3 (YEL 14ga ) SP778 A MOTOR
SP135 6 6
BUFFERED LH RR SP SIG SHIELD Y 1
67P-006-CC3 (YEL 14ga ) 5 5 P059 SM2740
H1 33 33
SHIELD-252 SHIELD-252 67P-002-AC3 (YEL 14ga ) 67P-003-CC3 (YEL 14ga ) 67L-001-CC3 (PNK 14ga ) 67L-000-CC3 (PNK 16ga )
1-1 1-2 2 4 4
0-195-CC3 (BLK 14ga ) SP779
P305 CONN INSTALL CHECK z 3
71H-002-CC2 (LBL 16ga ) 1 1-3 1-4 1 71P-003-CC2 (BRN 16ga ) 4 D D C C
0-194-CC3 (BLK 18ga ) 41TS-009-CC3 (DGR 16ga )
P305 SWITCH 41TS-004-CC3 (DGR 16ga )
2-1 2-2
DATA STORE PC1150
P072 P072
(DSSW) PC0490 JB4F
P304 CONN INSTALL CHECK z 71CN1-000-AA3 (PNK 18ga )
2-3 2-4
71P-004-CC2 (BRN 16ga ) 1
TB21 41TS-010-CC3 (DGR 16ga ) SH9:J-10
NC 2
RESET/BODY UP OVERRIDE h 11 11 PC1377 C 1 SWITCH RETARD 41TS-004-CC3 (DGR 16ga )
71H-000-AA3 (LBL 18ga ) R1 R2 71H-001-AC2 (LBL 16ga ) 71P-002-CC2 (BRN 16ga ) 3
SPEED CONTROL 41TS-007-CC3 (DGR 16ga )
4 SH7:K-12
STORE DATA J S1 S2 12 12 1
NO (RSCS) SWITCH RIGHT WINDOW 41TS-011-CC3 (DGR 16ga )
73DS-000-AA3 (TAN 18ga ) 73DS-001-AC2 (TAN 16ga ) 73DS-002-CC2 (TAN 16ga )
GB12 REAR CAB PC1150
PB8624 A A
S4 73DS-003-AC4 (TAN 16ga ) SH13:L-17 SH8:F-19 49-008-CC2 (TAN 16ga ) 1
A B
1 C2
1 0-197-CC3 (BLK 18ga ) B B 41TS-008-CC3 (DGR 16ga )
3 MOTOR RIGHT WINDOW
0-198-CC3 (BLK 14ga ) 3
1 1 TB24 2
33RR-001-CC2 (WHT 16ga ) 2 67S-001-CC3 (DBL 14ga ) 67S-000-CC3 (DBL 16ga ) B
TB31 GB12 REAR CAB 1
1 S2 S1 1 67R-001-AC3 (PUR 14ga ) 34 34 67R-004-CC3 (PUR 14ga ) 67R-005-CC3 (PUR 14ga ) 1 SP782 A MOTOR
D4
RETARD SP CONT P 31RR-002-AA3 (LTG 18ga ) E1 E2 31RR-001-AC2 (LTG 16ga ) 1 0-312-CC2 (BLK 18ga ) 1 1 SP138 6 6
67R-006-CC3 (PUR 14ga ) 5 5 SM2740
35 35 P058
65 65 1 1
67R-002-AC3 (PUR 14ga ) 67R-003-CC3 (PUR 14ga ) 67T-001-CC3 (LBL 14ga ) 67T-000-CC3 (LBL 16ga )
P304 31RR-000-CC2 (LTG 16ga ) 71P-004-CC2 (BRN 16ga ) 0-200-CC3 (BLK 14ga ) 4 4 SP783
AUTONOMOUS MODE REQUEST P D D C C
P03 J03 0-201-CC3 (BLK 18ga ) 41TS-007-CC3 (DGR 16ga )
PC1376
TB31 P071 P071
0-314-CC2 (BLK 18ga ) PC0490
RETARD SP CONT POT SHIELD J
SHIELD-277 SHIELD-277 64 64
H1 H2 33RS-000-CC2 (LBL 16ga )
RETARD SP CONT POT WIPER A 33RR-003-AA3 (WHT 18ga ) F1 F2 33RR-002-AC2 (WHT 18ga ) 63 63 33RR-000-CC2 (WHT 18ga ) VEC-91 F62
RETARD SPEED CONTROL
RETARD SP CONT POT GND K 0-316-AA3 (BLK 18ga ) G1 G2 0-315-AC2 (BLK 18ga ) 62 62 0-313-CC2 (BLK 18ga ) C C
67R-000-AA1 (PUR 12ga ) G 9G
20
11 BUSS
OP-CAB WINDOW MOTOR
MC262 MC262
VEC91-P9
SH13:F-20 0-446-AA1 (BLK 18ga ) G3 B B
ACCEL, RSC, RET PEDAL/LEVER POT HI REF t 10V-000-AA3 (LBL 18ga ) M1 M2 10V-001-AC2 (RED 18ga ) 61 61 10V-006-CC2 (RED 18ga ) A A
MC261 MC261 MC260 MC260 RSP
M3 M4 10V-008-AC1 (RED 18ga ) XC2455
EB7418 P02 J02
N1 N3 10V-007-AC2 (LBL 18ga ) SH13:G-9
ACCEL PEDAL POT LOW REF m 0ACL-002-AA3 (BLK 18ga ) TB23
F51 VEC-91
712 BUSS 10F F 712H-003-AA1 (LBL 16ga ) W1
10V-008-AC1 (RED 18ga ) 10
TB31
P303 VEC91-P10
0ACL-002-AA3 (BLK 18ga ) W3 N2 10V-009-AC1 (RED 18ga )
MC269 MC269 712H-004-AA1 (LBL 16ga )
ACCEL PEDAL POT WIPER - y 0ACL-003-AA3 (BLK 18ga ) 0ACL-003-AA3 (BLK 18ga ) W1 N4 10V-010-AC1 (RED 18ga )
SWITCH HOIST LIMIT
ACCEL PEDAL POW WIPER + t 525A-000-AA3 (WHT 18ga ) W4 W2 0ACL-001-AC1 (BLK 18ga ) 3 1
30 30 712H-001-AH2 (LBL 16ga ) 3 1
EB7418 4 2
ACCEL SHIELD u 4 2
V3 V2 0RET-001-AC1 (BLK 18ga )
SHIELD-295 22 22
53H-001-AA1 (PNK 16ga ) 53H-002-AH2 (PNK 16ga ) PC2818
0RET-002-AA3 (BLK 18ga ) V1 V4 0-546-AA2 (BLK 18ga ) SH11:P-8 10 10 HLS HLS
SHIELD-286 SHIELD-282 ACCELERATOR PEDAL
P304 MC266
10V-008-AC1 (RED 18ga ) 7 7 10V-003-CC1 (RED 18ga ) C +VDC SUPPLY J16 P16
0ACL-001-AC1 (BLK 18ga ) 9 9 0ACL-000-CC1 (BLK 18ga ) A GROUND

SHIELD-295 TB31
TB35
525-002-AA3 (WHT 18ga ) T1 T2 525-001-AC1 (WHT 18ga ) 8 8 525-000-CC1 (WHT 18ga ) B PEDAL SIGNAL
N1 N2 53H-003-AB1 (PNK 14ga ) R R 830E HOIST LIMIT
MC265 MC265
J701
525A-001-AA3 (WHT 18ga ) MC266 P236

SP738 S1 S2 SOLENOID POWER
AHT SHIELD-286
4
AUXBOX CONNECTOR
4
RETARD PEDAL SHIELD W P240 J240

P701
SHIELD-296 (OPT)
MC270
RETARD PEDAL COMMON V 0RET-002-AA3 (BLK 18ga ) 14 14
SHIELD-287 SHIELD-281 RETARD CONTROL PEDAL
MC267
RETARD PEDAL SIG P 74NA-000-AA3 (WHT 18ga ) 10V-009-AC1 (RED 18ga ) 11 11 10V-004-CC1 (RED 18ga ) C +VDC SUPPLY
MC270 SOLENOID HOIST LIMIT
P302 0RET-001-AC1 (BLK 18ga ) 13 13 0RET-000-CC1 (BLK 18ga ) A GROUND
SHIELD-296 TB31 3 3 1 2
53H-005-AA1 (PNK 16ga ) 53H-009-AJ2 (PNK 16ga ) 53H-010-AJ2 (PNK 16ga ) 0-430-AJ2 (BLK 16ga ) SH14:O-2
R1 R2 12 12 B PEDAL SIGNAL SP794
74NA-001-AA3 (WHT 18ga ) 74N-002-AA3 (WHT 16ga ) 74N-001-AC1 (WHT 18ga ) 74N-000-CC1 (WHT 18ga ) HS HS
SP739 MC264
J701
MC267 MC264 P235

AHT P1 P2
SHIELD-287 J14 P14
6
RETARD LEVER SHIELD U AUXBOX CONNECTOR D88

SHIELD-297
(OPT)
6
P701
MC271 1 2
BODY HOIST LIMIT

RETARD LEVER COMMON T 0LEV-002-AA3 (BLK 18ga ) 53H-008-AJ2 (PNK 16ga ) 0-419-AJ2 (BLK 16ga ) SH14:O-2
SHIELD-280 RETARD LEVER PC2834

RETARD LEVER SIG S 18 18
52RA-000-AA3 (WHT 18ga )
TB31 SHIELD-288 MC100 MC100 SENSOR (OPT)
MC271 MC263
P302 CONN INSTALL CHECK Z
SHIELD-288 15 15 C C +VDC SUPPLY
SHIELD-297
J1 J2 10V-010-AC1 (RED 18ga ) 10V-005-CC1 (RED 18ga ) 10V-011-CC9 (RED 18ga ) C
P302
0LEV-002-AA3 (BLK 18ga ) L1 L2 0LEV-001-AC1 (BLK 18ga ) 17 17
16 16
0LEV-000-CC1 (BLK 18ga ) A
B
A
B
0LEV-003-CC9 (WHT 18ga ) B GROUND
LEVER SIGNAL
58B-06-02261-00 SEP 15
L3 52R-001-AC1 (WHT 18ga ) 52R-000-CC1 (WHT 18ga ) 52R-003-CC9 (BLK 18ga ) A
MC268 MC268 MC263 P237 J237 P814
52RA-001-AA3 (WHT 18ga ) 52R-002-AA3 (WHT 18ga ) K1 K2
P303 CONN INSTALL CHECK Z SP740
J701
71CN2-000-AA3 (PNK 18ga )
980E-4
5
P303 P01 J01

5
P701
0-546-AA2 (BLK 18ga ) SH11:M-7

AHT GB31-A
AUXBOX CONNECTOR 0-601-AA2 (BLK 18ga )
D4 A40003 & UP
(OPT)
Sheet 11 of 24
SP901 0-251-AH2 (BLK 16ga ) SH12:D-13
SH6:H-18 0-240-AA1 (BLK 14ga ) 1 1 0-243-AH2 (BLK 14ga ) 0-252-AH2 (BLK 16ga ) SH12:E-13
BACKUP LAMPS SWITCH MANUAL BACKUP LIGHT

0-301-AH2 (BLK 16ga ) SH12:J-12
SH10:F-5 0-101-CC3 (BLK 16ga ) SP902 0-264-AH2 (BLK 16ga ) SH12:E-16

SH6:H-18 0-241-AA1 (BLK 14ga ) 2 2 0-244-AH2 (BLK 14ga ) 0-265-AH2 (BLK 16ga ) SH12:F-16
B B A A
TB22 0-269-CC3 (BLK 16ga ) 0-254-AH2 (BLK 16ga ) SH12:I-13
0-253-AH2 (BLK 16ga ) SH12:I-13
47S-002-AA1 (LBL 16ga ) 1 T2 T1 1 47S-001-AC3 (LBL 16ga ) 51 51 47S-000-CC3 (LBL 16ga ) 3 3
2
2 712K-004-CC3 (LBL 16ga ) SH5:E-11 SP903 0-289-AH2 (BLK 14ga ) SH14:L-21
1 1 SH6:H-18 0-242-AA1 (BLK 14ga ) 3 3 0-245-AH2 (BLK 14ga ) 0-249-AH2 (BLK 16ga ) SH12:D-16
6 0-248-AH2 (BLK 16ga ) SH12:C-16
P03 J03 6 5 5
0-300-AH2 (BLK 16ga ) SH12:H-12
4
4
HORN BACKUP LEFT
D D C C
SH10:A-5 0-268-CC3 (BLK 16ga )
79A-002-AH2 (DBL 16ga ) 1 - 1 0-248-AH2 (BLK 16ga ) SH12:C-14
+
P23 P23 SP231 LRBH-(+) LRBH-(-)
PC1500 29 29
11B 79A-000-AA1 (DBL 14ga ) 79A-001-AH2 (DBL 14ga ) 79A-003-AH2 (DBL 16ga )
SH8:E-15 79BA-002-AA1 (YEL 18ga ) B
VEC-89
J22-CC3 (WHT 16ga ) HORN BACKUP RIGHT
0 BUSS 85 86 TB35
47S-003-CC3 (LBL 16ga )
F3 10 10 1 1
47-000-AA2 (GRY 10ga ) L1 L2 47-001-AA1 (GRY 14ga ) 47-003-AH2 (GRY 14ga ) - 0-249-AH2 (BLK 16ga ) SH12:C-14
+
11 BUSS 87
15 30 11C RRBH-(+) RRBH-(-)
C 79A-000-AA1 (DBL 14ga ) 47-008-AA1 (GRY 14ga ) L3 47-002-AA1 (GRY 14ga ) 13 13 47-004-AH2 (GRY 14ga )
87a
D14
11D RELAY BACKUP LIGHT 47-012-AA1 (GRY 14ga ) J16 P16 LAMP BACKUP RIGHT REAR
BACKUP HORN D 47A-000-AA1 (PNK 16ga ) (BULR)
RELAY 3
D15 1
86 85 1 1
11E
VEC89-P11 0-157-AA2 (BLK 16ga ) SH9:O-9 47-003-AH2 (GRY 14ga )
47S-002-AA1 (LBL 16ga ) E
SH12:B-14 0-251-AH2 (BLK 16ga ) 2
F2
VEC89-P11 9C RRBL
11 BUSS
C 47B-000-AA1 (TAN 10ga ) 1 88 88A 1
47-000-AA2 (GRY 10ga ) 58D-06-10350
25
VEC-89 LAMP BACKUP LEFT REAR
VEC89-P9
LAMP BACKUP RIGHT 58E-06-04150
DECK (OPT) 1
47-004-AH2 (GRY 14ga )
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 ) SH12:B-14 0-252-AH2 (BLK 16ga ) 2
LRBL
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
XA6208
LAMP STOP/TAIL LEFT
J502 P502 P541 J541 P11 J11
A C
44-004-AH2 (GRY 16ga ) A C 0-264-AH2 (BLK 16ga ) SH12:B-14
RED
LAMP BACKUP LEFT DECK
LRSTL
(OPT) B
B
41T-019-AH2 (TAN 16ga )
RED
1 47-015-GG1 (GRY 14ga ) H H 47-014-GJ1 (GRY 14ga ) 8 8 47-013-AJ1 (GRY 14ga ) 8 8 47-012-AA1 (GRY 14ga ) SP220 41T-019-AH2 (TAN 16ga ) LRSTL 58D-06-00820
SH10:N-19 41T-018-AH2 (TAN 16ga ) 41T-020-AH2 (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 41T-022-AH2 (TAN 16ga ) LAMP STOP/TAIL RIGHT
LBUL 41T-021-AH2 (TAN 16ga )
XA6208
A C
44-005-AH2 (GRY 16ga ) A C 0-265-AH2 (BLK 16ga ) SH12:B-14
J503 P503 P540 J540 P12 J12
RED
B
RRSTL
41T-020-AH2 (TAN 16ga ) B
RED
RRSTL 58D-06-00820
LAMP BODY RIGHT SIDE TURN
A C
45RL-017-MM1 (DBL 16ga ) A C
AMB
B
RSTL
B
AMB
11H RSTL
SH7:G-17 44R-003-AA1 (GRY 18ga ) H
VEC-89
SH10:N-19 45LL-012-AH2 (BRN 16ga ) 58D-06-00830
0 BUSS 85 86
VEC89-P11 SH10:N-19 45RL-012-AH2 (DBL 16ga ) A A 45RL-017-MM1 (DBL 16ga ) 0-463-MM1 (BLK 16ga )
TB35
F9 87 12E 16 16 B B LAMP BODY RIGHT SIDE MARKER
E 44-000-AA1 (GRY 14ga ) G1 G2 44-001-AA1 (GRY 14ga ) 44-003-AH2 (GRY 14ga ) 44-004-AH2 (GRY 16ga ) 41T-022-AH2 (TAN 16ga ) 41T-029-MM1 (TAN 16ga )
11 BUSS 30
SP229 44-005-AH2 (GRY 16ga )
10 87a C C A C
74ZA-000-AA3 (DGR 18ga ) SH11:G-4 VEC89-P12 G4 SH12:C-14 0-300-AH2 (BLK 16ga ) 0-460-MM1 (BLK 16ga )
J16 P16 RED
SERVICE BRAKE P55 J55
SP716 RSCL1
LAMP RELAY 9 B
LAMP RETARD LEFT REAR 41T-030-MM1 (TAN 16ga )
TB21
RED
1C
D1 D2 74ZA-001-AA1 (DGR 18ga ) C RSCL1 58D-06-00820
VEC-89 A C
44D-005-AH2 (LBL 16ga ) 44D-005-AH2 (LBL 16ga ) A C SP717
71CK BUSS 86 85
D4 VEC89-P1 AMB 0-461-MM1 (BLK 16ga )
TB35
LRL
F13 87 1F
17 17 B
B LAMP BODY RIGHT REAR MARKER
F 44D-000-AA1 (LBL 16ga ) H1 H2 44D-001-AA1 (LBL 16ga ) 44D-003-AH2 (LBL 14ga ) 44D-006-AH2 (LBL 16ga )
11 BUSS 30
SP230 AMB
10 87a A C
VEC89-P1 H4 LRL 58D-06-00830
J16 P16 RED
RETARD LAMPS
RSCL2
RELAY 15 LAMP RETARD RIGHT REAR B
41T-031-MM1 (TAN 16ga )
RED
A C
44D-006-AH2 (LBL 16ga ) A C RSCL2 58D-06-00820
AMB 0-462-MM1 (BLK 16ga )
INTERFACE MODULE RRL
B
B
LAMP SERVICE BRAKE OP-CAB LAMP BODY LEFT SIDE TURN
74ZA-002-AA1 (DGR 20ga ) Z RETARD SWITCH INPUT AMB
RRL 58D-06-00830
A C
IM3 44-002-AC4 (GRY 16ga ) 7 7 44-006-CC4 (GRY 16ga ) 1 A C
SBL SH12:B-14 0-254-AH2 (BLK 16ga ) AMB
SH12:B-14 0-253-AH2 (BLK 16ga ) LSTL
EM8073 B
B
AMB
LSTL
LAMP RETARD OP-CAP 58D-06-00830
0-465-MM2 (BLK 16ga )

44D-002-AC4 (LBL 16ga ) 5 5 44D-004-CC4 (LBL 16ga ) 1
LAMP BODY LEFT SIDE MARKER
DRL
45LL-012-AH2 (BRN 16ga ) A A 45LL-017-MM2 (BRN 16ga )
EM8074 A C
SP719
REAR TURN / TAIL / STOP LAMPS P04 J04
41T-021-AH2 (TAN 16ga ) B B 41T-032-MM2 (TAN 16ga ) RED
LSCL1
SH12:B-14 0-301-AH2 (BLK 16ga ) C C 0-464-MM2 (BLK 16ga ) 41T-033-MM2 (TAN 16ga ) B
SP720 RED
J54 P54 58D-06-00820
LSCL1
0-466-MM2 (BLK 16ga )

LAMP BODY LEFT REAR MARKER
A C
F50 VEC-91 TB24
RED
712 BUSS 10C C
63-009-AA1 (PNK 14ga ) 1 R1 R2 1 63-000-AC3 (PNK 14ga ) LSCL2
10 B
41T-034-MM2 (TAN 16ga )
VEC91-P10 RED
LSCL2 58D-06-00820
TB10
0-467-MM2 (BLK 16ga )
63-002-CC3 (PNK 16ga ) E1 E2 63-001-CC3 (PNK 14ga ) 58 58
JB6G
1 63-003-CC3 (PNK 14ga ) J03 P03 SWITCH HORN BUTTON
2 63-004-CC3 (PNK 16ga ) RELAY VEHICLE TB22
3 63-005-CC3 (PNK 16ga ) HORN POWER
4 63-006-CC3 (PNK 16ga ) 63-006-CC3 (PNK 16ga ) 1 B1 B2 1 57 57 1 A B
(HPR) 11H-000-AA1 (DGR 16ga ) 11H-001-AC3 (DGR 16ga ) 11H-002-CC3 (DGR 16ga )
5 63-007-CC3 (PNK 16ga ) 2
6 1
86 85 1
63-008-CC3 (PNK 16ga ) 11A-011-AA1 (TAN 16ga ) P120
PC1621
56B-06-11510 P03 J03 HORN FRONT VEHICLE
11A-001-AA1 (TAN 12ga ) 1 88 88A 1

11HS-000-AA1 (DBL 14ga ) 13 13 11HS-001-AJ1 (DBL 14ga ) 13 13 11HS-002-GJ1 (DBL 14ga ) N N 11HS-003-GG1 (DBL 14ga ) 11HS-004-GG1 (DBL 14ga ) A A
JB4C TIMER WASHER DELAY (WADT) SP167
1 PC0566 63L1-002-CC3 (BRN 16ga ) 1 1 14 14 14 14 O O B B
63W-000-CC3 (GRY 16ga ) TIMER WIPER DELAY 0-422-AA1 (BLK 14ga ) 0-290-AJ1 (BLK 14ga ) 0-291-GJ1 (BLK 14ga ) 0-292-GG1 (BLK 14ga ) 0-293-GG1 (BLK 14ga )
2 58E-06-04150 SP168
63W-001-CC3 (GRY 16ga ) AHS
3 63W-002-CC3 (GRY 16ga ) 63-008-CC3 (PNK 16ga ) 86 63-007-CC3 (PNK 16ga ) 1 2 SH6:H-21 PC0244
X
4
J12 P12 J540 P540 P503 J503
1 3
T
63T1-000-CC3 (PUR 16ga ) 87 0-380-CC3 (BLK 16ga ) 0-294-GG1 (BLK 16ga )

P
PC1150
4 FRONT VEHICLE HORN D1
L
63L1-003-CC3 (BRN 16ga ) 85

P10 11HS-005-GG1 (DBL 16ga ) 1 2
5 TB35
REAR AXLE
11A-001-AA1 (TAN 12ga ) A1 A2 11A-002-AA1 (TAN 16ga ) 4 4 PC2834
SWITCH COMBO SERVICE LAMP
63W-002-CC3 (GRY 16ga ) 1 6
WASHER SW 1
POWER
A3
8 7 63W-001-CC3 (GRY 16ga ) 63W-000-CC3 (GRY 16ga ) EB7418 J16 P16
WIPER CONT
SW
MOTOR WINDSHIELD WASHER 1 B1 B2
12 F33 VEC-91
P121 INT 63T1-000-CC3 (PUR 16ga ) PUMP
11 BUSS 4B
LO 2 65 65 63W-003-AC3 (GRY 16ga ) 1 + - 1 B 11A-000-AA1 (TAN 12ga ) B3 B4
PARK
HI 1 15
63H1-000-CC3 (LTG 16ga ) GB12
6 VEC91-P4
C3 VE5339
1 0-379-CC3 (BLK 16ga ) 66 66 0-377-AC3 (BLK 16ga ) SH16:D-9 11A-004-AC2 (TAN 18ga )
PC1709
P121 D15
11A-003-AB1 (TAN 14ga )
63L2-000-CC3 (LBL 16ga ) 2 1
J03 P03
PC2834
SWITCH HYDRAULIC LAMP
C C 11A-008-BB1 (TAN 14ga ) 1 2 1 1
RELAY WIPER MOTOR LOW
JB4H (+) (-) MOTOR WINDSHIELD WIPER HLSW-2 SR8325 HLSW-1
86 85
1 5
5 4 4
63L1-000-CC3 (BRN 16ga ) 63L-000-CC3 (DGR 16ga ) P240 J240
2 63L1-001-CC3 (BRN 16ga ) 11A1-000-BB1 (LBL 16ga )
(NO) 6 1 1
3 63L1-002-CC3 (BRN 16ga ) 87 6 MOTOR
4 30 (C) LAMP HYDRAULIC CABINET #1
63L1-003-CC3 (BRN 16ga )
(NC) 87A A
PC1150
11A1-001-BB1 (LBL 16ga )
2 2 GB8 BRAKE CABINET
P09_K SP171
PC1730 3 3 4
1 B
P09_K 0-445-BB1 (BLK 16ga )
63P-000-CC3 (DBL 16ga ) P07
PB9923 P07
HL1 PC3010 58B-06-02261-00 SEP 15
RELAY WIPER MOTOR HIGH
(+) (-) SH17:L-9 0-382-CC3 (BLK 16ga )
86 85 0-378-CC3 (BLK 16ga )
0-376-CC3 (BLK 16ga ) SH17:L-9
30 (C)
(NO) 87 63H-000-CC3 (TAN 16ga )
LAMP HYDRAULIC CABINET #2
A
980E-4
11A1-002-BB1 (LBL 16ga )
(NC)
WINDSHIELD WIPER / WASHER A40003 & UP
87A
HYD CABINET LAMP

P08_K 0-444-BB1 (BLK 16ga ) B
PC1730
P08_K HL2 PC3010
Sheet 12 of 24
GE INTERFACE
GE CONTROL INTERFACE
MC768
TX DATA+ F 94ET1-000-AA27 (W-OR 24ga ) SH6:L-13
TX DATA - E SH6:L-13
94ET2-000-AA27 (ORG 24ga ) MC275 MC275
RX DATA+ C 94ER1-000-AA27 (W-GR 24ga ) SH6:L-13 77-003-AA4 (WHT 18ga ) SH15:K-8
RX DATA- B 94ER2-000-AA27 (GRN 24ga ) SH6:L-13 77A-003-AA4 (BLK 18ga ) SH15:K-8
ETC2
MC274 TB26
KOMTRAX PLUS MODULE / ORBCOMM MODULE
MC274 MC272
TRUCK SPEED FM SIGNAL R 77-000-AA3 (WHT 18ga ) K2 K1 77-001-AA1 (WHT 20ga ) SH14:C-4
K3
TRUCK SP FM SIG f 77A-000-AA3 (BLK 18ga ) L2 L1 77A-001-AA1 (BLK 20ga ) SH14:C-4
DIFF TRUCK SPEED SIG SHIELD Y L3

SHIELD-613
M4 M1
P303 SHIELD-613 SHIELD-616
SH13:F-18 0-232-AA2 (BLK 16ga ) M5 M3
SHIELD-610 KOMTRAX PLUS MODULE MC695 MC695
SH6:I-16 0-233-AA2 (BLK 16ga )
SWITCH TRACTION MOTOR PRESSURE COMM_CAN_H_0 (RPC) 6 939YP-010-CC4 (YEL 20ga ) SH16:E-21
(BPSW)
COMM_CAN_L_0 (RPC) 14 939GP-010-CC4 (GRN 20ga ) SH16:F-21
NO C C
1 75A2-002-DD4 (WHT 18ga )
C COMM_CAN_SH_0 (RPC) 5
1 SHIELD-816
NC A A
1 75A1-000-DD4 (RED 18ga )
MC696 MC696
PB4673 COMM_CAN_H_1 (J1939) 4
71P-014-DD4 (BLK 18ga ) B B 939YE-010-CC4 (YEL 20ga ) SH16:C-19
TB35 J703 P703 COMM_CAN_L_1 (J1939) 12 939GE-010-CC4 (GRN 20ga ) SH16:C-19
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 )
COMM_CAN_SH_1 (J1939) 13
SHIELD-817
SH11:H-12 71P-005-AA1 (BRN 16ga ) 26 26 71P-010-AH2 (BRN 14ga ) 71P-011-AH2 (BRN 16ga ) 2 2 71P-013-DD1 (WHT 14ga )
SP180
MC699 MC698 OP-CAB
P72 J72 SP191 MC698
COMM_232C_TXD_0 (PC TOOL) 11 90VHT-000-CC4 (WHT 18ga ) 90VHT-001-CC4 (WHT 20ga ) 2 KOMTRAX
71P-012-AH2 (BRN 16ga ) SP192 DIAGNOSTIC
COMM_232C_RXD_0 (PC TOOL) 10 90VHR-000-CC4 (RED 18ga ) 90VHR-001-CC4 (RED 20ga ) 3 DIAG-6
SWITCH BODY-UP PROXIMITY SP193 CONNECTOR
TB35 GND_COMM (PC TOOL) 9 5
90VHG-000-CC4 (BLK 18ga ) 90VHG-001-CC4 (BLK 20ga )
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 P4A SP194
4 4 2
2
DIAG6
SH15:J-8 71F-002-AA4 (LTG 20ga ) S3 S4 71F-003-AA1 (LTG 20ga ) PC2818
P301 J16 P16 BUSW BUSW
MC701 MC701 TB29 MC702 MC702
71F-003-AA1 (LTG 20ga ) SH14:G-5 MC700
90VHT-002-CC4 (WHT 18ga ) 16 16 90VHT-003-AC4 (WHT 18ga ) W1 W2 90VHT-004-AA1 (WHT 20ga ) 2 AUXBOX
KOMTRAX
90VHR-002-CC4 (RED 18ga ) 17 17 3
VEC RTMR1
90VHR-003-AC4 (RED 18ga ) V1 V2 90VHR-004-AA1 (RED 20ga ) DIAGNOSTIC
DID POWER SUPPLY
FUSE - F4 18 18 5
CONNECTOR
90VHG-002-CC4 (BLK 18ga ) 90VHG-003-AC4 (BLK 18ga ) T1 T2 90VHG-004-AA1 (BLK 20ga )
A10 B10 +24VDC SUPPLY POWER
SH6:F-3 11-015-AA3 (RED 18ga ) 1 1 11DID-000-AA3 (PNK 18ga ) 7
VHMS
10A 19 19 X1 X2
58E-06-20110 SHIELD-823 SHIELD-824 SHIELD-824 SHIELD-825
SH13:N-3 0-614-AA3 (BLK 18ga ) 6 +24VDC SUPPLY GROUND
JUMPER7 16 SE1-000-CC4 (BLK 20ga ) 1 1 SH13:C-6 0-232-AA2 (BLK 16ga ) X5 X4 0-446-AA1 (BLK 18ga ) SH11:L-3
OUTPUT ENABLE SIGNAL (INPUT) JUMPER2 5 SE2-000-CC4 (BLK 20ga ) 2 2
15VDI-000-AA3 (WHT 18ga ) 8 J04 P04
JUMPER6 15 SE3-000-CC4 (BLK 20ga ) 3 3
+15VDC GROUND RETURN JUMPER5 14 SE4-000-CC4 (BLK 20ga ) 4 4
0COM-010-AA3 (BLK 18ga ) 1
JUMPER1 3 SE5-000-CC4 (BLK 20ga ) 5 5
CONNECTOR_SEL2_(GND) 6 6
5VDI-005-AA3 (YEL 18ga ) 10 +5VDC OUTPUT (2) 9 SE6-000-CC4 (BLK 20ga ) SE9-000-CC4 (BLK 20ga )
GND_SIG4 13 SE7-000-CC4 (BLK 20ga ) SP730
JUMPER8 P6A J6
-15VDI-003-AA3 (LTG 18ga ) 11 -15VDC OUTPUT 4 SE8-000-CC4 (BLK 20ga )
TB22
P3A F47
VEC-90
1 K1 K2 1 15DID-002-AA3 (BRN 18ga ) 12 +15VDC OUTPUT 1B 71CK BUSS
TB28 B
71VHM-000-AA1 (DGR 16ga )
P500 8 8 B1 B2
5
71VHM-002-CC4 (DGR 16ga ) 71VHM-001-AC4 (DGR 16ga )
58B-06-00970 58B-06-08000
VEC90-P1
13 13 VEC-91 F29
15VDI-004-AC2 (WHT 18ga ) 1 2 10V-007-AC2 (LBL 18ga ) SH11:L-5 85-001-AC4 (GRY 14ga ) C1 C2
TB21 4H 11 BUSS
270Ω 2W
85-000-AA1 (GRY 14ga ) H
SNSR & CNTRL +15V SUPP1 G
R17 9 9 10
15VDI-002-AA3 (WHT 18ga ) T1 T2
GE DID PANEL VEC91-P4
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 0-346-AC4 (BLK 14ga ) SH15:E-8
TB21 J04 P04
SNSR & CNTRL -15V SUPP1 L 23 23 9 9 JB6E
1 V1 V2 -15VDI-001-AC2 (LTG 14ga ) -15VDI-000-CC2 (LTG 14ga )
85-002-CC4 (GRY 14ga ) 1
SNSR & CNTRL +5V SUPP2 C TB21 PWR_IN_BATT1 6 2
85-003-CC4 (GRY 16ga ) 85-003-CC4 (GRY 16ga )
SNSR & CNTRL +5V SUPP1 A 25 25 5 5 85-004-CC4 (GRY 16ga ) 3
1 W1 W2 5VDI-001-AC2 (YEL 14ga ) 5VDI-000-CC2 (YEL 14ga )
PWR_IN_BATT2 7 85-004-CC4 (GRY 16ga ) 85-005-CC4 (GRY 20ga ) 4
SNSR & CNTRL +5V SUPP3 E 85-006-CC4 (GRY 20ga ) 5 ANTENNA
PWR_IN_BRY_1 8 6 ORBCOMM
71VHM-003-CC4 (DGR 16ga ) 85-007-CC4 (GRY 20ga ) SATELLITE / GPS
SP187
56B-06-11510 (OPT)
PWR_IN_BRY_2 9 71VHM-004-CC4 (DGR 16ga )
JB8A
0-347-CC4 (BLK 14ga ) 1
T1
GND_PWR1 11 0-348-CC4 (BLK 18ga ) 2
SNSR & CNTRL +5V COMM1 B
TB22 3 ORBCOMM MODULE (OPT)
0-349-CC4 (BLK 18ga )
SNSR & CNTRL +5V COMM2 D 24 24 GND_PWR2 12 4
1 S1 S2 1 0COM-001-AC2 (BLK 14ga ) 0COM-000-CC2 (BLK 14ga ) 10 10 0-349-CC4 (BLK 18ga ) 0-350-CC4 (BLK 18ga )
SNSR & CNTRL +5V COMM3 F 0-351-CC4 (BLK 18ga ) 5 85-007-CC4 (GRY 20ga ) 39 PWR_IN_BATT1
SNSR & CNTRL -15V COMM1 M GND_PWR3 19 0-350-CC4 (BLK 18ga ) 6
SNSR & CNTRL +15V COMM1 H 7 85-006-CC4 (GRY 20ga ) 40 PWR_IN_BATT2
SNSR & CNTRL +15V COMM2 K GND_PWR4 20 0-351-CC4 (BLK 18ga ) 8
85-005-CC4 (GRY 20ga ) 36 POWER_CTR_KEY
DOS_L_LAMP 16 56B-06-11530
74DS-000-CC4 (GRY 18ga ) SH14:F-2
P302 P1
0-353-CC4 (BLK 20ga ) 38 GROUND2
MC279 MC279 TB25 MC277 37 GROUND1

MC277 MC278 MC278 0-352-CC4 (BLK 20ga )
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
29 DOUT (GND)
DID PANEL RS232 RECEIVE D 31 31 2 2 PWR_CTR_EXT 17 7HMWU-000-CC4 (YEL 20ga )
90DIR-000-AA3 (WHT 18ga ) 1 B1 B2 1 90DIR-001-AC2 (WHT 18ga ) 90DIR-002-CC2 (WHT 18ga )
19 WAKE UP
P2A
DID PANEL RS232 TRANSMIT C 1 1 30 30 1 1
90DIT-000-AA3 (RED 18ga ) C1 C2 90DIT-001-AC2 (RED 18ga ) 90DIT-002-CC2 (RED 18ga ) MC724 MC724
GND_COMM (ORBCOMM) 1 3 900CG-000-CC4 (BLK 20ga ) 11 RS232 GND
DID PANEL COMM RS232 SHIELD O 33 33
SHIELD-625 1 1 SHIELD-620
D1 D2
SHIELD-625 SHIELD-620 SHIELD-621 COMM_232C_RXD_1 (ORBCOMM) 10 5 RS232 VHMS-R/ORB-T
DID
900CT-000-CC4 (WHT 20ga )
P02 J02 58B-06-00110 COMM_232C_TXD_1 (ORBCOMM) 4 4 RS232 VHMS-T/ORB-R
900CR-000-CC4 (RED 20ga )
MC280 MC280 TB25 MC286 MC286 MC283 MC283 CNA
DSC RS232 RECEIVE V 42 42 3 GND_COMM (ORBCOMM) 2 9
90CAR-000-AA3 (WHT 18ga ) 1 E1 E2 1 90CAR-001-AC2 (WHT 18ga ) 90CAR-002-CC2 (WHT 20ga ) GE - DSC SHIELD-911
P4B
7826122502
DIAGNOSTIC
DSC RS232 TRANSMIT W 90CAT-000-AA3 (RED 18ga ) 1 F1 F2 1 90CAT-001-AC2 (RED 18ga ) 41 41 90CAT-002-CC2 (RED 20ga ) 2
DIAG 1
DSC RS232 GND d 43 43 5 CONNECTOR
90CAG-000-AA3 (BLK 18ga ) 1 G1 G2 1 90CAG-001-AC2 (BLK 18ga ) 90CAG-002-CC2 (BLK 20ga )
GND_SIG3 9 J14-CC7 (BLK 18ga )
DSC RS232 SHIELD X 44 44 DIAG1
SHIELD-628 SHIELD-628 1 H1 H2 1 SHIELD-634 SHIELD-634 SHIELD-631 CONNECTOR_SEL1(GND) 12
P02 J02 P2B

TB36
MC282 MC282
MMS RS232 RECEIVE y 90MMR-000-AA3 (WHT 18ga ) G1 G4
COMM_LAN_TX_+ 1 93ET1-000-CC22 (W-OR 24ga ) SH6:M-3

TB36
MC289
MMS RS232 TRANSMIT w COMM_LAN_TX_- 2 SH6:M-3
90MMT-000-AA3 (RED 18ga ) F1 F4 90MMR-003-AA1 (WHT 20ga ) SH14:L-2 93ET2-000-CC22 (ORG 24ga )
COMM_LAN_RX_+ 3 SH6:M-3
90MMT-003-AA1 (RED 20ga ) SH14:L-2 93ER1-000-CC22 (W-GR 24ga )
TB36
MMS RS232 GND z COMM_LAN_RX_- 6 SH6:M-3
90MMG-000-AA3 (BLK 18ga ) H1 H4 90MMG-003-AA1 (BLK 20ga ) SH14:L-2 93ER2-000-CC22 (GRN 24ga )
P5
TB36
MMS RS232 SHIELD x J1 J5
DIS_L_SNAPSHOT.SW1 2 73DS-005-CC4 (TAN 18ga ) 12 12 73DS-003-AC4 (TAN 16ga ) SH11:J-5
TERMINAL BLOCK
P303 SPLIT UP. SEE SWITCH DC POWER P3B
CONNECTOR CHART OFF - REST SWITCH J04 P04
FOR LOCATIONS GB10 FRT CAB GND 7826148502
C1
0-052-CC3 (BLK 18ga ) SH17:B-22
1 0-317-CC3 (BLK 16ga ) B A 72RR-001-CC3 (ORG 16ga )
1
2
TB23 D71 3
REST REQUEST O 72RQ-003-AA3 (GRY 18ga ) K1 K2 72RQ-004-AC3 (GRY 16ga ) 46 46 72RQ-005-CC3 (GRY 16ga ) 1 2 72RR-000-CC3 (ORG 16ga ) 4
5
K4 72RQ-002-AA1 (GRY 14ga ) SH4:C-22 PC2834 6
P304 P35
PC2146
P35
72RR-001-CC3 (ORG 16ga )
SH11:H-12 71P-007-AC3 (DGR 16ga ) 27 27 71P-008-CC3 (DGR 16ga )
72GD-003-CC3 (TAN 16ga )
SWITCH GRID DRY
0-318-CC3 (BLK 16ga )
B B A A
TB23
ENG WARMUP REQ b 72GD-000-AA3 (DBL 18ga ) S1 S2 72GD-001-AC3 (TAN 16ga ) 8 8 72GD-002-CC3 (TAN 16ga ) 3 3
2
2 71P-009-CC3 (DGR 16ga )
1 1
6
6 5 5
4
4
GB31-B
SH13:F-8 0-614-AA3 (BLK 18ga )
BATT CHG SYS FAIL IND RTN h B3
D D C C
0-322-AA3 (BLK 18ga ) 1 0-319-CC3 (BLK 16ga )
DIG OUT RET-CONN TO GND k 0-323-AA3 (BLK 18ga )
P34 P34
PC2317
J20-CC3 (WHT 16ga )
SWITCH BRAKE TEST
TB25
PRESHIFT BK TEST LIGHT DRIVER j 37 37 B B A A
33SBA-000-AA3 (YEL 18ga ) 1 W1 W2 1 33SBA-001-AC3 (YEL 16ga ) 33SBA-002-CC3 (YEL 16ga ) 712P-003-CC3 (YEL 16ga )
PRESHIFT BRAKE TEST a 72SBT-000-AA3 (WHT 18ga ) 1 X1 X2 1 72SBT-001-AC3 (DBL 16ga ) 43 43 72SBT-002-CC3 (DBL 16ga ) 3 3
2
2
P305 1 1
33SBA-003-CC3 (YEL 16ga ) 6
6 5 5
0-132-CC3 (BLK 16ga ) SH10:N-9
4
SH8:K-19 0-320-CC3 (BLK 16ga )

4
C C
58B-06-02261-00 SEP 15
D D
P37 P37
PC2648
712 BUSS
F57 VEC-89
4G
TB35 0-321-CC3 (BLK 16ga )
J13-CC3 (WHT 16ga )
980E-4
G 712P-000-AA1 (YEL 16ga ) D1 D2 712P-001-AC3 (YEL 16ga ) 15 15 712P-002-CC3 (YEL 16ga )
10
VEC89-P4
A40003 & UP
P03 J03
Sheet 13 of 24
INTERFACE MODULE
TB28 SWITCH DRIVERS SEAT BELT
OPERATOR SEAT BELT SWITCH g X1 X2 4 4 2 2 1 1

62SB-000-AA1 (ORG 20ga ) 62SB-001-AC2 (ORG 18ga ) 62SB-002-CC2 (ORG 18ga )
XK1267
IM2 P212 P212
GB31-B
A4
0-330-AC2 (BLK 18ga ) 1 1 0-329-CC2 (BLK 18ga )
P02 J02
SEAT BELT ALARM OPTION J 2A 85 86 2G

62A-000-AA1 (YEL 20ga ) 62A-000-AA1 (YEL 20ga ) A G 24VIM-002-AA1 (LBL 18ga ) SH5:J-13
TB30 58B-06-00290 2H 87 F63
62SBA-000-AA1 (ORG 14ga ) H 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 ) SH8:I-16 VEC89-P2 87a 15
R19 58B-06-02020 GB31-B
IM1 D4
1 2
E3 VEC-89 SEAT BELT ALARM
0-547-AA1 (BLK 16ga )
6800.0 (OPT) RELAY 41
TB32 R2
SEAT BELT ALARM
71CK BUSS
CUSTOMER ATTACHMENT L2
(OPT) VEC-89
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
MC272 PWR RELAY 14
J14 P14 D26 P14 J14
SH13:B-9 77-001-AA1 (WHT 20ga ) g TRUCK SPEED IN +
h TRUCK SPEED IN - 2 1 F42
SH13:C-9 77A-001-AA1 (BLK 20ga ) 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 VEC-89
87-001-AA1 (TAN 20ga ) J1 J2 VEC89-P4
SENSOR FUEL LEVEL
87-002-AA2 (TAN 18ga ) J3 38G-004-HH4 (GRY 16ga ) 1 + VDC SIGNAL
TB35 58B-06-00160
FUEL LEVEL SENSOR g 38G-000-AA1 (GRY 20ga ) C1 C2 38G-002-AA2 (GRY 18ga ) 1 2
MC703 MC703 560Ω 3W
0-324-HH4 (BLK 16ga ) 2 GROUND
j CAN-RPC-HI
R15
SH16:E-6 939YP-008-AA1 (YEL 20ga ) IM3 AHT C4
FLS PC2810
AUXBOX CONNECTOR
SH16:E-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 )
(OPT)
SP198 SWITCH STEERING FILTER #1
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 SWITCH HYDRAULIC FILTER #2
SH7:E-12 HYDRAULIC PUMP FILTERS PRESSURE Y 15 15 SH16:O-2 C NO
0-267-AA2 (BLK 16ga ) 39-000-AA1 (TAN 20ga ) J9-AA8 (BLK 18ga ) J16 P16 J730 P730 SWITCH HYDRAULIC FILTER #1 C
SP185
SH8:I-16 0-238-AA2 (BLK 16ga ) 1 X1 X3 1 0-387-AA1 (BLK 20ga ) 16 16 J27-AA8 (BLK 18ga ) SH16:O-2 C NO B 0-328-HH4 (BLK 16ga )
C NO C B A NC
IM2 C
39SP-000-HH4 (BRN 16ga )
SH15:M-13 0-701-AA4 (BLK 20ga ) 1 X2 B 39HP-000-HH4 (LBL 16ga ) A NC SFSW
J702 P702 XA5166
39AP-001-AH2 (YEL 16ga ) 39AP-001-AH2 (YEL 16ga ) 1 1 39AP-002-HH4 (YEL 16ga ) A NC HFSW2 SFSW
HFSW1 HFSW2 XA5166
SWITCH HYDRAULIC ACC FILTER XA5166
HFSW1
C NO
12 12 C B 2 2
39AP-000-AA1 (YEL 16ga ) 0-718-HH1 (BLK 16ga ) 0-698-AH2 (BLK 16ga )
MC705 ACCESSORY DRIVE PUMP FILTER PRESSURE X 39HP1-001-AA1 (TAN 20ga ) 8 8 39HP1-000-AH2 (TAN 16ga ) 1 1 39HP1-002-HH1 (TAN 16ga ) A NC
MC705
SH16:C-5 939YE-008-AA1 (YEL 20ga ) r CAN/J1939-HI HAFSW
IM3 GB31-B HAFSW XA5166 J58 P58_JP
E2
P58_JP J58
SH16:C-5 939GE-008-AA1 (GRN 20ga ) s CAN/J1939-LO 0-325-AA1 (BLK 16ga ) 21 21 0-326-AH2 (BLK 16ga ) 0-699-AH2 (BLK 16ga ) 4 4 0-327-HH4 (BLK 16ga )
SP006
q CAN/J1939-SHLD J730 P730
J16 P16
SWITCH PARK BRAKE SET
IM1 C NO
HYD BRAKE CABINET

TB32 C B 0-337-BB1 (BLK 16ga )
PARK BRAKE APPLY PSW f 33-002-AA1 (BRN 20ga ) D1 D2 33-001-AB1 (BRN 14ga ) D D 33-000-BB1 (BRN 14ga ) A NC
15R/75A
PC1677 PBPSW
PBPSW
TB32 SWITCH LOW BRAKE ACCUM PRESSURE
GB8 BRAKE CABINET
TB25 BRAKE ACCUMULATOR PRESSURE U S S C NO
33BP-002-AA1 (WHT 20ga ) E1 E2 33BP-001-AB1 (WHT 14ga ) 33BP-000-BB1 (WHT 14ga ) C 2
SH13:I-16 74DS-000-CC4 (GRY 18ga ) 11 11 74DS-001-AC4 (GRY 18ga ) 1 M2 M1 1 74DS-002-AA1 (GRY 20ga ) L SNAPSHOT IN PROGRESS B 0-338-BB1 (BLK 16ga ) 1
A NC
LBPS
LBPS PC1558
J04 P04
TB32 SWITCH SERVICE BRAKE DEGRADE PRESSURE
SH13:E-9 71F-003-AA1 (LTG 20ga ) R BODY DOWN SWITCH
BRAKE PRESSURE DEGRADATION V 33T-002-AA1 (DBL 20ga ) F1 F2 33T-001-AB1 (DBL 14ga ) N N 33T-000-BB1 (DBL 14ga ) C NO
C B
IM2 0-339-BB1 (BLK 16ga )
A NC
1175A/1000R
P240 J240 BDS
BDS PC1678
SENSOR STEERING PRESSURE 33SP-000-AA1 (WHT 20ga ) d STEERING PRESSURE TB28 MC718
MC653 MC653 MC654 MC720 MC720 MC718 MC717 MC717
DIAGNOSTIC RS232/TRANSM A 90IMT-000-AA1 (RED 20ga ) M1 M4 90IMT-002-AC2 (RED 18ga ) 52 52 90IMT-003-CC2 (RED 20ga ) 2
1 1 18VIM-002-AJ2 (BLK 18ga ) 27 27 18VIM-001-AA1 (BLK 18ga ) OP-CAB IM
TB30 DIAGNOSTIC
DIAGNOSTIC RS232/RECIEV B 90IMR-000-AA1 (WHT 20ga ) N1 N4 90IMR-002-AC2 (WHT 18ga ) 53 53 90IMR-003-CC2 (WHT 20ga ) 3
2
2 33SP-002-AJ2 (WHT 18ga ) 26 26 33SP-001-AA1 (WHT 18ga ) T1 DIAG-5
SPS DIAGNOSTIC RS232/GND C 90IMG-000-AA1 (BLK 20ga ) P1 P4 90IMG-002-AC2 (BLK 18ga ) 54 54 90IMG-003-CC2 (BLK 20ga ) 5 CONNECTOR
PC1538 28 28
SHIELD-001-AA1 (BLK 16ga ) SH14:K-10 55 55 DIAG5
SHIELD-733 IM2 R1 R4
SP737 SHIELD-896
18VIM-000-AA1 (WHT 20ga ) b +18V SENSOR
P14 J14 R2 0-361-AA1 (BLK 18ga ) SH6:N-12
SHIELD-130
TB30 P02 J02
SENSOR HOIST PRESSURE #1 MC651 MC651 MC652 0-447-AA1 (BLK 18ga ) SH14:J-12
W1
1 31 31
MC719
1 18VIM-004-AH2 (BLK 18ga ) 18VIM-003-AA1 (BLK 18ga ) 90IMT-001-AA1 (RED 20ga ) 2
W2
2
AUXBOX IM
2 33HP1-002-AH2 (WHT 18ga ) 32 32 33HP1-001-AA1 (WHT 18ga ) 3
90IMR-001-AA1 (WHT 20ga ) DIAGNOSTIC
W4
PC1537 HPS1 CONNECTOR
33 33 5
SHIELD-732 SHIELD-733 90IMG-001-AA1 (BLK 20ga )
N1
J372
SENSOR HYDRAULIC TANK LEVEL
33HP1-000-AA1 (WHT 20ga ) s HOIST PRESSURE 1 MC635
SH5:J-10 24VIM-008-AA1 (LBL 16ga ) 29 29 24VIM-009-AJ2 (RED 16ga ) A +VDC SUPPLY
SHIELD-013-AA1 (BLK 18ga ) SH14:K-10 SH6:H-18 0-341-AA1 (BLK 16ga ) 31 31 0-340-AJ2 (BLK 16ga ) B GROUND
SHIELD-731 LOW HYD TANK LEVEL k 30 30 C SIGNAL
SP773 34LL-001-AA1 (BRN 20ga ) 34LL-001-AA1 (BRN 20ga ) 34LL-002-AJ2 (WHT 16ga )
SH6:G-18 32 32
SENSOR HOIST PRESSURE #2 0-423-AA1 (BLK 18ga ) SHIELD-701 P712 EK8243
MC649 MC649 q HOIST PRESSURE 2 IM2
MC650 33HP2-000-AA1 (WHT 20ga ) TB30
1 1 18VIM-006-AH2 (BLK 18ga ) 5 5 18VIM-005-AA1 (BLK 18ga ) MC634
TB28 RIGHT REAR BRAKE TEMP SENSOR m 18 18
IM3 34BT4-002-AA1 (WHT 20ga ) A1 A2 34BT4-001-AA1 (WHT 18ga ) 34BT4-000-AJ2 (WHT 16ga ) 1 1
SENSOR BRAKE TEMP RH REAR
2
2 33HP2-002-AH2 (WHT 18ga ) 6 6 33HP2-001-AA1 (WHT 18ga ) K1 MC639 MC639 7861923320
2
L1 L2 20 20 2
PC1537 HPS2 5VIM-006-AA1 (BLK 18ga ) 5VIM-005-AJ2 (BLK 16ga )
7 7 EB7418
SHIELD-730 SHIELD-731 SHIELD-709 SHIELD-700 P710
+5V SENSOR MONITOR j K1
5VIM-001-AA1 (ORG 20ga ) SP790 SHIELD-999-AA1 (BLK 16ga ) 19 19 SHIELD-998-AJ2 (BLK 16ga ) SP791
P16 J16 SHIELD-709 MC755
+5V SENSOR c 5VIM-000-AA1 (ORG 20ga ) B2 0-447-AA1 (BLK 18ga ) SH14:H-14 1 1
SHIELD-710 SHIELD-974 SENSOR BRAKE TEMP LH REAR
SHIELD-710 2
7861923320
LEFT REAR BRAKE TEMP SENSOR i 34BT3-001-AA1 (WHT 20ga ) C1 C2 34BT3-000-AA1 (WHT 18ga ) 15 15 34BT3-002-AJ2 (WHT 16ga ) 2
MC640 MC640 P709
HYD BRAKE CABINET

K2 5VIM-002-AA1 (BLK 18ga ) 14 14 5VIM-009-AJ2 (BLK 16ga )
MC757
RIGHT FRONT BRAKE TEMPERATURE r H1 H2 40 40 34BT2-002-AJ2 (WHT 16ga ) 1
34BT2-001-AA1 (WHT 20ga ) 34BT2-000-AA1 (WHT 18ga ) 1
SENSOR BRAKE TEMP RH FRONT
MC641 MC641 7861923320
2
K3 5VIM-004-AA1 (BLK 18ga ) 39 39 5VIM-010-AJ2 (BLK 16ga ) 2
SHIELD-977
SH14:H-6 SHIELD-001-AA1 (BLK 16ga ) SHIELD-711 SHIELD-711 P708
SH14:I-6 B4 B3 SP792 38 38 SP789
SENSOR BRAKE PRESSURE SHIELD-013-AA1 (BLK 18ga ) SHIELD-725 SHIELD-997-AA1 (BLK 16ga ) SHIELD-996-AJ2 (BLK 16ga )
MC647 MC647 MC648
SHIELD-712 SHIELD-712 SHIELD-976 MC756
1 1 18VIM-008-BB1 (BLK 14ga ) A A 18VIM-007-AB1 (BLK 14ga ) 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
7861923320
2 2
2 33BPS-002-BB1 (WHT 14ga ) B B 33BPS-001-AB1 (WHT 14ga ) SH14:K-12 K4 36 36 5VIM-011-AJ2 (BLK 16ga ) 2
5VIM-003-AA1 (BLK 18ga )
MC642 MC642
PC1537 BPS SP774 SHIELD-728 SHIELD-729 SP775 MC648 P707
M M BRAKE PRESSURE p 33BPS-000-AA1 (WHT 20ga ) M2 M1 33BPS-001-AB1 (WHT 14ga ) SH14:K-5
SHIELD-009-BB1 (BLK 14ga ) SHIELD-010-AB1 (BLK 14ga )
B1
23 23 SENSOR DUCT AIR TEMPERATURE
J240 P240 SHIELD-725 SHIELD-723 MC645
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
2
L4 5VIM-008-AA1 (BLK 18ga ) 22 22 5VIM-007-AJ2 (BLK 16ga ) B
MC646 MC646
ATS AK7339
MC289
SH13:K-10 90MMR-003-AA1 (WHT 20ga ) D MMS RS232/RECIEV
J14 P14
SH13:K-10 E MMS RS232/TRANSM

90MMT-003-AA1 (RED 20ga ) SWITCH AUTOLUBE PRESSURE
F MMS RS232/GND NO C
SH13:L-10 90MMG-003-AA1 (BLK 20ga ) 0-289-AH2 (BLK 14ga ) SH12:B-14
AUTOLUBE PRESSURE SWITCH Y 68P-003-AA1 (PUR 20ga ) 23 23 68P-001-AH2 (PUR 14ga ) B C
NC A
SWITCH ACCUMULATOR 2000 PSIG RISING
IM3 J16 P16 LLPS
PRECHARGE PRESS #1 PC1654 LLPS
TB35 58B-06-00290
1 NO C 1 19 19 W LOW STEERING PRE-CHARGE AUTOLUBE SOLENOID T 1 2
51A2-000-AR1 (BRN 16ga ) 51A1-001-AR1 (LBL 16ga ) 51A1-000-AA1 (LBL 20ga ) 68-001-AA1 (TAN 20ga ) R1 R4 68-000-AA2 (TAN 18ga ) 0-345-AA2 (BLK 18ga ) SH8:I-16
ACCP1-NO 1202A/1100R
ACCP1-C R30
R3 R2
PC0909
IM1
AUTOLUBE SYSTEM
SWITCH ACCUMULATOR SOLENOID AUTO LUBE
PRECHARGE PRESS #2 2B
B 68ES-003-AA1 (DBL 16ga ) 68ES-004-AA1 (DBL 16ga ) 32 32 68ES-001-AJ1 (DBL 14ga ) E E 68ES-002-JJ1 (DBL 14ga ) 2 1
GB31-B VEC-89 F20
SP785
C E4 4C 85 86 71CK BUSS
1 NO 1 0-335-AR1 (BLK 16ga ) 20 20 0-336-AA1 (BLK 16ga ) C VEC89-P2 ALSOL PC2436 ALSOL
10 33 33 B B
ACCP2-NO 1202A/1100R
ACCP2-C 87
68-005-AA1 (TAN 16ga ) 68-003-AJ1 (TAN 14ga ) 68-004-JJ1 (TAN 14ga )
PC0909 30 4F SWITCH AUTOLUBE LEVEL (OPT)
F
P13 J13 4E 87a
E 68LS-003-AA1 (DGR 20ga ) 34 34 68LS-001-AJ1 (DGR 16ga ) C C 68LS-000-JJ1 (DGR 16ga ) C NO
C B
VEC89-P4
AUTO LUBE A NC
SWITCH LOW STEERING PRESSURE VEC89-P4 RELAY 29 J12 P12
P512
C NO P512 XA3247
C B 6 6 S LOW STEERING PRESSURE A A
33F-000-AJ2 (DBL 16ga ) 33F-001-AA1 (DBL 20ga ) SH7:D-18 0-342-AJ1 (BLK 16ga ) 0-343-JJ1 (BLK 16ga )
A NC
2600A/2300R J511 P511
ACPSW
ACPSW 58E-06-20280
57 57
68ES-000-AA1 (DBL 16ga )
0-331-AJ2 (BLK 16ga ) 2 2 0-333-AA1 (BLK 16ga ) SH6:H-18
SWITCH STEERING BLEED PRESSURE 54 54
68-002-AA1 (TAN 16ga )
NO C 9 9 Z STEERING BLEED PRESSURE SW
33JA-001-AA1 (YEL 20ga )
B C AUTOLUBE GREASE LEVEL W 68LS-002-AA1 (DGR 20ga ) 68LS-004-AA1 (DGR 20ga ) 56 56
NC A 33JA-000-AJ2 (YEL 16ga ) SP786
300A/255R
SABS IM3
58E-06-20290 SABS 55 55
SH6:G-21 0-344-AA1 (BLK 16ga )
0-418-AJ2 (BLK 16ga ) 0-332-AJ2 (BLK 16ga ) 34 34 0-334-AA1 (BLK 16ga ) SH6:G-18
SP799 J11 P11
SH11:O-20 0-430-AJ2 (BLK 16ga ) P14 J14

SH11:O-20 0-419-AJ2 (BLK 16ga )
58B-06-02261-00 SEP 15
TB33
A2 72AT-000-AA1 (PNK 20ga ) e AUTO MODE OPERATION REQUEST
B2 72MAN-000-AA1 (LTG 20ga )
IM2
s MANUAL MODE OPERATOR REQUEST
980E-4
A40003 & UP
INTERFACE MODULE
Sheet 14 of 24
SWITCH HEATED MIRROR
71LS-015-CC3 (DGR 16ga ) A A B B

J19-CC3 (BLK 18ga ) TB28
HEATED MIRROR
3 3 39 39
69MA-000-CC3 (YEL 16ga ) 69MA-001-AC3 (YEL 16ga ) W1 W2
2
71LS-014-CC3 (DGR 16ga ) 2
1 1
6
6 J03 P03
0-412-CC3 (BLK 18ga ) 5 5
4
4

J18-CC3 (BLK 18ga ) MIRROR HEATED RIGHT DECK
P33 P33 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
PC2238 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 )
2 2
69MA-002-AA1 (YEL 18ga ) MIRROR1
PC2930
1G J11 P11 J541 P541 P502 J502
G
0 BUSS 85 86
VEC89-P1 TB23
F53 87 1H
H 69M-000-AA1 (YEL 12ga ) F1 F2
MIRROR HEATED LEFT DECK
11 BUSS 30
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 VEC-89 2 2
(OPT) RELAY 39
MIRROR2
PC2930
J12 P12 J540 P540 P503 J503
4 4 4 4 D D 1 1
RIGHT DECK
11RB-002-AA1 (DGR 14ga ) 11RB-005-AH1 (DGR 14ga ) 11RB-007-FH1 (DGR 14ga ) 11RB-009-FF1 (DGR 14ga )
5 5 5 5 E E 2 2 ROTATING BEACON
SWITCH ROTATING BEACON (OPT) SH6:F-21 0-401-AA1 (BLK 14ga ) 0-395-AH1 (BLK 14ga ) 0-396-FH1 (BLK 14ga ) 0-397-FF1 (BLK 14ga )
OPTION
P548_CP J5207
SH10:C-1 71LS-011-CC3 (DGR 16ga ) A A B B
J17-CC3 (BLK 18ga ) TB22 J11 P11 J541 P541 P502 J502
3 3 38 38
2 11RB-000-CC3 (DGR 14ga ) 11RB-001-AC3 (DGR 14ga ) 1 E1 E2 1
SH10:M-3 11L-003-CC3 (YEL 14ga ) 2
1 1 4 4 4 4 D D 1 1
LEFT DECK
E4 1 11RB-003-AA1 (DGR 14ga ) 11RB-006-AJ1 (DGR 14ga ) 11RB-008-GJ1 (DGR 14ga ) 11RB-010-GG1 (DGR 14ga )
GB10 FRT CAB GND 6 5 5 5 5 E E 2 2 ROTATING BEACON
6 J03 P03 SH6:H-21 0-402-AA1 (BLK 14ga ) 0-398-AJ1 (BLK 14ga ) 0-399-GJ1 (BLK 14ga ) 0-400-GG1 (BLK 14ga )
D2
1 0-411-CC3 (BLK 18ga ) 5 5 E3 1 OPTION
4 P549_CP J5208
4
J12 P12 J540 P540 P503 J503

J16-CC3 (BLK 18ga )
P32 P32 11RB-004-AC4 (DGR 14ga ) 14 14 11RB-011-CC4 (DGR 14ga ) 1

PC2272 CAB MOUNT
RRBB1
GB31-A ROTATING BEACON
ROTATING BEACON OPTION B4

0-427-AC4 (BLK 14ga )
0-346-AC4 (BLK 14ga ) SH13:G-18
15 15 0-428-CC4 (BLK 14ga )
RRBB2
1 OPTION
0-091-AC4 (BLK 16ga ) SH6:A-8

P04 J04
LAMP RED PAYLOAD RIGHT
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 )
PAYLOAD METER IV
2G VEC-90
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 ) SH10:M-18
5 87a
SP195
TB34 RPLA_CP EK9381 RPLA_CP
PAYLOAD RED
LAMP RELAY 16
39A-000-AA4 (LTG 20ga ) S1 S2
3B LAMP GREEN PAYLOAD RIGHT
B
2D
39B-000-AA4 (BRN 20ga ) R1 R2 39B-001-AA1 (BRN 18ga ) D
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
2C RPLG_CP EK9382 RPLG_CP
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 ) SH10:K-18
SP196
PAYLOAD GREEN
LPLA_CP EK9381 LPLA_CP
LAMP RELAY 18
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 )
PAY LOAD METER 4
LPLG_CP EK9382 LPLG_CP
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 ) MC606
PWR & COMM GND 1 A 0-370-FG1 (BLK 16ga ) A PWR & COMM GND 2
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 VEC-90 SIGN RX D D SIGN TX2 REBROADCAST
35L10-000-FG1 (WHT 16ga )
VEC90-P4 24 VDC PWR IN E 712SL-002-FG1 (RED 16ga ) E 24 VDC PWR OUT
GB31-B MC606
A3 PC1137 CNRIN CNLO
0-365-AA4 (BLK 20ga ) 37 PLM4 GROUND
0-375-AA4 (BLK 18ga ) SH15: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
SH8:N-8 39H1-001-AA4 (YEL 20ga ) 49 BRAKE LOCK
MC605
RS232 T2 25 35L8-000-AA4 (WHT 18ga ) S1 S2 35L8-001-AF1 (WHT 16ga ) D SIGN RX
RS232 R2 24 35L9-000-AA4 (RED 18ga ) T1 T2 35L9-001-AF1 (BRN 16ga ) C SIGN TX

SH13:E-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
MC605 CNLIN
R4 0-375-AA4 (BLK 18ga ) SH15:J-9
MC275 MC275 PC1137
SHIELD-671
SH13:B-9 77-003-AA4 (WHT 18ga ) 16 SPEED INPUT - LO PASSIVE
6 SPEED INPUT - HI PASSIVE SHIELD-673
SH13:B-9 77A-003-AA4 (BLK 18ga )
MC601 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 MC711

CAN HI1 5 TO RPC
SENSOR PAYLOAD PRESSURE LEFT FRONT
C3 939YP-007-AA4 (YEL 20ga ) SH16:E-9
MC294 CAN LO1 11 939GP-007-AA4 (GRN 20ga ) SH16:E-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 MC785
CAN HI 2 12 SH16: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 ) SH16:H-6 NETWORK 0-235-AA2 (BLK 16ga ) SH7:E-12
SHIELD-878 SHIELD-660 CONNECTOR CHART CAN GND 2 22
FOR LOCATIONS SHIELD-858 CONNECTOR
P13 J13 0-700-AA4 (BLK 20ga ) 0-701-AA4 (BLK 20ga ) SH14:E-3

SHIELD-883
SP199
PLM4 COMMUNICATION BOX
MC777 MC777
SENSOR PAYLOAD PRESSURE LEFT REAR USB_PS_2 26 5VUSB-000-AA4 (BLU 24ga ) 1 USB_PS_2
USB_PS_1 36 2 USB_PS_1
MC743 MC743 USBV-000-AA4 (BRN 24ga )
1 1 39F-003-AH2 (BLK 16ga ) USB_PORT2--DM 29 USBDMH-000-AA4 (GRN 24ga ) 3 USB_PORT2--DM
USB_PORT2--DP 39 USBDPH-000-AA4 (W-GR 24ga ) 4 USB_PORT2--DP
2
2 39FB-003-AH2 (WHT 16ga ) USB_PORT1--DM 27 USBDPD-000-AA4 (ORG 24ga ) 5 USB_PORT1--DM
USB_PORT1--DP 28 6 USB_PORT1--DP
P152 SHIELD-950 SHIELD-884 SHIELD-884 40 40 SHIELD-883
USBDMD-000-AA4 (W-OR 24ga )
58E-06-10051
TB36 COMMA
SP233
SHIELD-951 37 37 3 SUSPENSION PRESSURE - LR
SENSOR PAYLOAD PRESSURE RIGHT REAR 39FB-002-AH2 (BLK 16ga ) 39FB-001-AA1 (BLK 18ga ) D1 D2 39FB-000-AA4 (BLK 18ga )
SP234 HEARTBEAT 8 72HC-000-AA4 (ORG 20ga ) 1 HEARTBEAT
MC744
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-002-AH2 (WHT 16ga ) 39 39 39FA-000-AA4 (WHT 18ga ) 4 SUSPENSION PRESSURE - RR MC778
39FA-004-AH2 (WHT 16ga ) 39FA-001-AA1 (WHT 18ga ) E1 E2
MC767
P153 MC744 SP236 MC715 ETHERNET TX1 20 ENTX1-000-AA4 (W-OR 24ga ) 4 ETHERNET TX1 TX(+) 1 95ET1-000-AA15 (W-OR 24ga ) SH6:M-13
58E-06-10051 MC714
P264 ETHERNET TX2 19 ENTX2-000-AA4 (ORG 24ga ) 5 ETHERNET TX2 TX(-) 2 95ET2-000-AA15 (ORG 24ga ) SH6:M-13
ETHERNET RX2 17 ENRX2-000-AA4 (GRN 24ga ) 8 ETHERNET RX2 RX(+) 3 95ER1-000-AA15 (W-GR 24ga ) SH6:M-13
P16 J16
ETHERNET RX1 18 ENRX1-000-AA4 (W-GR 24ga ) 9 ETHERNET RX1 RX(-) 6 95ER2-000-AA15 (GRN 24ga ) SH6:M-13
PLM4_ENET
5V 7 5VPL-000-AA4 (RED 20ga ) 6 5V
GND 30 0-520-AA4 (BLK 20ga ) 7 GND
COMMB
P264
58B-06-02261-00 SEP 15
980E-4
A40003 & UP
Sheet 15 of 24
IM CAN TEE GE CAN TEE KOMVISION CAN TEE MMS PTX CAN TEE
CAN TEE J1939 # 1 CAN TEE J1939 # 2 MC691 CAN TEE J1939 #4 CAN TEE J1939 #5 P304R TERM1
MC258 MC749 MC691 MC692 MC692 MC1176 MC693 MC693 MC716 SP812 MC1302 MC1302
FROM A1 A2 A1 A2 46 46
SP809 A1 A2 A1 A2 A A
SH7:H-9 939YE-001-AE1 (YEL 18ga ) A A 939YE-011-AA10 (YEL 18ga ) A A 939YE-004-AC2 (YEL 18ga ) 939YE-005-CC2 (YEL 18ga ) SP810
939YE-003-CC2 (YEL 18ga ) A A 939YE-006-CC2 (YEL 18ga ) A A 939YE-013-CC4 (YEL 18ga ) SP813
939YE-015-CC4 (YEL 18ga )
ENGINE SH7:H-9 939GE-001-AE1 (GRN 18ga ) B
B1 B2
B 939GE-011-AA10 (GRN 18ga ) B
B1 B2
B 939GE-004-AC2 (GRN 18ga ) 45 45 939GE-005-CC2 (GRN 18ga ) 939GE-003-CC2 (GRN 18ga ) B
B1 B2
B 939GE-006-CC2 (GRN 18ga ) B
B1 B2
B 939GE-013-CC4 (GRN 18ga ) 939GE-015-CC4 (GRN 18ga ) B B
CAN J1939 C1 C2 C1 C2 47 47
SP811 C1 C2 C1 C2 SP814 C C
SHIELD-270 C C SHIELD-962 SHIELD-962 C C SHIELD-802 SHIELD-802 SHIELD-805 SHIELD-813 SHIELD-813 C C SHIELD-808 SHIELD-808 C C SHIELD-818 SHIELD-826 SHIELD-826
P301B P315B MC705 P316B P305B MC751 MC694 P322B P323B MC752 P321B P308B MC696
A3 A3 A A3 A3 A 939YE-010-CC4 (YEL 20ga ) 58E-06-11500
A 939YE-008-AA1 (YEL 20ga ) SH14:E-4 A 939YE-012-AA12 (YEL 18ga ) A SH13:D-16
B3 B3 B GE CAN J1939 B3 B3 B
B 939GE-008-AA1 (GRN 20ga ) SH14:E-4 B 939GE-012-AA12 (GRN 18ga ) P02 J02 B 939GE-010-CC4 (GRN 20ga ) SH13:D-16
C3 C3 C CONNECTION C3 C3 C
C SHIELD-836 C SHIELD-966 SHIELD-966 SHIELD-811 C SHIELD-819 SHIELD-817
P306D P317D P318D P324D P311D
PC0616 PC0616 PC0616 PC0616
MC694
OPERATOR CAB CAN J1939 939YE-007-CC2 (YEL 20ga ) C
D
939GE-007-CC2 (GRN 20ga )
E
SHIELD-811
OP-CAB 939YE-014-CC12 (YEL 18ga ) SH18:G-5
MC689 MC689 CONNECTOR 939GE-014-CC12 (GRN 18ga ) SH18:G-5
SH7:I-13 F
900-003-CC2 (WHT 18ga ) ENGINE DATALINK
SH7:I-13 901-003-CC2 (BLK 18ga ) G
TIER 1 OR TIER 2
DIAGNOSTIC
CAN J1939 NETWORK SH12:N-11 11A-004-AC2 (TAN 18ga ) 48 48 11A-012-CC2 (TAN 18ga ) B
A DIAG4
CAN J1939 NETWORK
(RED) P02 J02
GB12 REAR CAB
C4
1 0-362-CC2 (BLK 18ga )
H
J (RED)
DIAG4
GE CAN TEE IM CAN TEE PLM4 CAN TEE KOMVISION CAN TEE ACTIA CAN TEE
TERM#2 CAN TEE RPC # 1 CAN TEE RPC # 2 CAN TEE RPC # 3 CAN TEE RPC # 4 CAN TEE RPC #5 P201R TERM3
MC704 MC704 MC748 MC748 MC706 MC706 MC707 MC707 P221B MC1175 MC1175 MC709 MC709 SP815 MC1303 MC1303
A A1 A2 A1 A2 A1 A2 57 57 A1 A2 A1 A2 939YP-013-CC4 (YEL 18ga ) A A
A 939YP-000-AA5 (YEL 18ga ) A A 939YP-012-AA9 (YEL 18ga ) A A 939YP-002-AC2 (YEL 18ga ) 939YP-003-CC2 (YEL 18ga ) A A 939YP-004-CC2 (YEL 18ga ) A A 939YP-005-CC4 (YEL 18ga )
PC0618 B B1 B2 B1 B2 B1 B2 B1 B2 B1 B2 SP816 B B
B 939GP-000-AA5 (GRN 18ga ) B B 939GP-012-AA9 (GRN 18ga ) B B 939GP-002-AC2 (GRN 18ga ) 58 58 939GP-003-CC2 (GRN 18ga ) B B 939GP-004-CC2 (GRN 18ga ) B B 939GP-005-CC4 (GRN 18ga ) 939GP-013-CC4 (GRN 18ga ) 58E-06-11500
C C1 C2 C1 C2 C1 C2 59 59 C1 C2 C1 C2 SP817 C C
C SHIELD-835 SHIELD-835 C C SHIELD-959 SHIELD-959 C C SHIELD-842 SHIELD-842 SHIELD-843 SHIELD-843 C C SHIELD-812 SHIELD-812 C C SHIELD-845 SHIELD-827 SHIELD-827
SHIELD-845
P205B MC750 P204B P215B MC703 MC703 P216B P203B MC711 MC711 MC753 MC753 P207B P211B MC254
SEE NOTE #1 A3 A A3 A3 P220B A3 A3
A 939YP-009-AA11 (YEL 18ga ) A 939YP-008-AA1 (YEL 20ga ) SH14:D-5 A 939YP-007-AA4 (YEL 20ga ) SH15:L-13 P02 J02 A 939YP-011-CC12 (YEL 18ga ) SH18:G-5 A 939YP-001-CC1 (YEL 18ga ) SH9:H-9 MC695 MC695
FOR AHT OPT B3 B GE CAN RPC B3 B3 B3 B3
B 939GP-009-AA11 (GRN 18ga ) B 939GP-008-AA1 (GRN 20ga ) SH14:D-5 B 939GP-007-AA4 (GRN 20ga ) SH15:L-13 B 939GP-011-CC12 (GRN 18ga ) SH18:G-5 B 939GP-001-CC1 (GRN 18ga ) SH9:H-9 939YP-010-CC4 (YEL 20ga ) SH13:C-16
C3 C CONNECTION C3 C3 C3 C3
C SHIELD-965 SHIELD-965 C SHIELD-834 C SHIELD-860 C SHIELD-820 C SHIELD-263 939GP-010-CC4 (GRN 20ga ) SH13:C-16
P218D P219D P206D P202D P222D P212D SHIELD-816
PC0616 PC0616 PC0616 PC0616 PC0616
NOTE:
1) OPTIONAL AHT CONNECTION TO CAN RPC REMOVES
TERM#2 RESISTOR FROM RPC CAN TEE #1 AND AHT
CONNECTOR P216B CONNECTS TO RPC CAN TEE #1
OPERATOR CAB CAN RPC CAN RPC NETWORK
(YELLOW)
CAN RPC NETWORK
(YELLOW)
OPERATOR CAB CAN THIRD

GE CAN TEE
PARTY
PLM4 CAN TEE
MMS PTX CAN TEE
CAN TEE 3RD PARTY #1 CAN TEE 3RD PARTY #2
CAN TEE 3RD PARTY #4
MC782 MC784 MC783 MC708 MC708
A A1 A2 A1 A2 19 19
SP806 A1 A2 A TERM#5
A 939YK-000-AA14 (YEL 18ga ) A A 939YK-002-AC2 (YEL 18ga ) 939YK-004-CC2 (YEL 18ga ) 939YK-005-CC2 (YEL 18ga ) A
PC0618 B B1 B2 B1 B2 20 20
SP807 B1 B2 B PC0618
B 939GK-000-AA14 (GRN 18ga ) B B 939GK-002-AC2 (GRN 18ga ) 939GK-004-CC2 (GRN 18ga ) 939GK-005-CC2 (GRN 18ga ) B
TERM#4 C C1 C2 C1 C2 21 21
SP808 C1 C2 C
C SHIELD-859 SHIELD-859 C C SHIELD-862 SHIELD-862 SHIELD-863 SHIELD-844 SHIELD-844 C
SHIELD-863
P402B MC781 P401B P400B MC785 MC255 P407B
A3 A A3 A3 A
A 939YK-003-AA13 (YEL 18ga ) A 939YK-001-AA4 (YEL 20ga ) SH15:M-13
B3 B GE CAN THIRD B3 B3 B
B 939GK-003-AA13 (GRN 18ga ) B 939GK-001-AA4 (GRN 20ga ) SH15:M-13
C3 C PARTY C3 C3 C
C SHIELD-861 SHIELD-861 C SHIELD-858 SHIELD-265
CONNECTION
P403D P404D P402D P409D
PC0616 PC0616 PC0616
MC255
939YK-006-CC2 (YEL 18ga ) 3
939GK-006-CC2 (GRN 18ga ) 10

F30 VEC-91 VEC91-P4
11 BUSS SH16:I-19 11M-003-CC2 (LTG 16ga )
4G G 11 OP-CAB
MMS PTX DISPLAY

20 TB32 SHIELD-265
THIRD PARTY
11M-000-AA1 (LTG 12ga ) P1 P2 11M-001-AC2 (LTG 14ga ) 39 39 11M-002-CC2 (LTG 14ga ) 11M-004-CC2 (LTG 14ga ) 1 DIAG
F48
71CK BUSS
SP710 CONNECTION
4E
E 712MM-000-AA1 (DBL 16ga ) R1 R2 712MM-001-AC2 (DBL 16ga ) 40 40 712MM-002-CC2 (DBL 16ga ) 712MM-003-CC2 (DBL 16ga ) 2
5 VEC-90
SP157
VEC90-P4 SH16:I-19 712MM-005-CC2 (DBL 16ga ) 712MM-004-CC2 (DBL 16ga ) 6
P02 J02 GB12 REAR CAB
B2
1 0-528-CC2 (BLK 14ga )
0-719-CC2 (BLK 14ga )
12
9
CAN THIRD PARTY NETWORK B3
1
SH16:H-9
SH16:I-9
11M-003-CC2 (LTG 16ga )
0-083-CC2 (BLK 16ga )
712MM-005-CC2 (DBL 16ga )
A
B
C
(GRAY)
GB12 REAR CAB
CAN THIRD PARTY NETWORK CAN_TP PTX_CP
(GRAY)
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 36 36 6 6 3 3 (OPT) JUNCTION
46YA-000-AA1 (TAN 14ga ) 46YA-002-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
P72 J72 MC723 1 F4 71J-000-ST1 (ORG 4/0-MCM )
4 4 0 G3 86-503-EJ3 (BLK 14ga ) SP703 A A ALT1
SHIELD-918 J16 P16 0-500-JJ6 (GRN 8ga ) 86-505-EJ3 (BLK 14ga ) T19
AHT 2 86-500-JJ6 (BLK 8ga ) 90-500-EJ3 (BLK 14ga ) SP704
90-502-EJ3 (BLK 14ga ) B B PC0292 AFSE 1 74D-000-ST2 (ORG 4/0-MCM ) 1 A2
MC728 MC726
5 5 8 8 1 1 RIGHT REAR 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 BRAKE PRESSURE 1 87-500-JJ6 (WHT 8ga ) EOH2
7 7 33PRR-000-AA1 (WHT 18ga ) 10 10 33PRR-001-AD1 (WHT 18ga ) 2 2 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
SH14: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- (BLK 18ga )
SH14: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-06-02261-00 SEP 15
39AP-004-AJ2 (YEL 16ga ) A
BFSW
980E-4
A40003 & UP
Sheet 16 of 24
OPTIONAL HYD ACCESS LADDER
KOMATSU HYDRAULIC LADDER OPTION F59 VEC-91
JUMPER PLUG NEEDED WHEN NO 1B 1A A
11LAD-008-AA1 (BRN 18ga ) B 11-017-AA1 (RED 18ga ) SH6:F-3
LADDER IS PRESENT 5
73S-006-JR1 (LBL 16ga ) 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 12LD-006-CC3 (LBL 18ga )
56B-06-11530
PARKING BRAKE SWITCH 10 SWITCH LADDER CONTROL
73S-006-JR1 (LBL 16ga )
8
7
6
5
4
3
2
1
A B 0-052-CC3 (BLK 18ga ) SH13:L-8
11LAD-009-JR1 (BRN 16ga ) 2 2 2 11LAD-004-AR2 (BRN 16ga ) 2 2
VBAT 7 TB21 1
11LAD-000-JR1 (BRN 20ga )
11LAD-001-JR1 (BRN 16ga ) 11LAD-007-AA1 (BRN 16ga ) F1 F2 11LAD-010-AC3 (BRN 16ga ) 3 3 11LAD-011-CC3 (BRN 16ga ) 2
11LAD-002-JR1 (BRN 16ga ) 11LAD-012-CC3 (BRN 16ga ) 3
4 12LD-005-CC3 (LBL 16ga )
P03 J03
11LAD-005-JR1 (BRN 16ga ) 11LAD-012-CC3 (BRN 16ga ) 5
11LAD-006-JR1 (BRN 16ga ) 6 12LU-005-CC3 (DBL 16ga )
C D 0-451-CC3 (BLK 18ga )

TB21
UP POSITION SENSOR 4 510E2-005-JR1 (DGR 20ga ) 510E2-006-JR1 (DGR 16ga ) 510E2-006-JR1 (DGR 16ga ) 1 J9-000-JJ10 (BLK 18ga ) 1 1 510E2-002-AR2 (DGR 16ga ) 3 3 510E2-003-AA1 (DGR 18ga ) A4 A2 510E2-001-AA1 (DGR 20ga ) SH8:H-17 P38 PC3590 P38
SP308
AHT 12LU-006-CC3 (DBL 18ga )

12DP-001-JR1 (BRN 16ga ) 12DP-001-JR1 (BRN 16ga ) 9 9 9 12DP-002-AR2 (ORG 16ga ) 4 4 12DP-003-AA1 (ORG 18ga ) 3 3 AUXBOX CONNECTOR
(OPT)
SENSOR POWER LADDER UP J702 P702
A A
510E2-007-JR1 (DGR 16ga ) B B C C 0-053-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
JB12D
58E-06-02630
DOWN POSITION SENSOR 5 12DP-000-JR1 (BRN 20ga ) 12DP-005-JR1 (BRN 16ga ) B B C C 0-108-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 )
0-089-JR1 (BLK 20ga )

0-054-JR1 (BLK 16ga )
0-058-JR1 (BLK 16ga )
0-093-JR1 (BLK 16ga )
0-107-JR1 (BLK 16ga )
0-057-JR1 (BLK 16ga )

RELAY CAB LADDER ALARM
(+) (-) TB21
CAB ALARM 1 12CA-000-JR1 (YEL 20ga ) 86 85 0-054-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 SWITCH GROUND LEVEL
58E-06-10020
CAR_K LADDER OVERRIDE
RELAY LADDER UP (SWITCH SHOWN PULLED OUT)
(+) (-)
SOLENOID 11 12HS-000-JR1 (LBL 20ga ) 86 85 0-058-JR1 (BLK 16ga )
4 3 SOLENOID HYDRAULIC LADDER
(NO) 87 1 2
13HS-000-JR1 (BRN 16ga ) 1 2 13LS-000-JR1 (LBL 16ga ) 13LS-002-JR1 (LBL 16ga ) 0-676-JR1 (BLK 16ga ) 0-107-JR1 (BLK 16ga )
30 (C) SP399
(NC) GLORS GLORS SP400
87A LSOL LSOL
58E-06-13190
LUR_K
58E-06-10020
LUR_K
ALARM GROUND
RELAY GROUND LEVEL ALARM LEVEL LADDER D7
(+) (-)
GROUND ALARM 2 12GLA-000-JR1 (PNK 20ga ) 86 85 0-093-JR1 (BLK 16ga ) 13LS-001-JR1 (LBL 16ga ) 1 2 0-677-JR1 (BLK 16ga )
1 +
PC2834
(NO) 87 -
13GLA-000-JR1 (LTG 16ga ) 2
30 (C)
(NC) GLA
87A
58E-06-08400
GLAR_K
58E-06-10020 TB21
GLAR_K 0-056-JR1 (BLK 16ga )
UP SWITCH 8 12LU-000-JR1 (DBL 20ga ) 12LU-000-JR1 (DBL 20ga ) 5 5 5 12LU-001-AR2 (DBL 16ga ) 7 7 12LU-002-AA1 (DBL 16ga ) H1 H2 12LU-004-AC3 (DBL 16ga ) 11 11 12LU-005-CC3 (DBL 16ga )
DN SWITCH 9 12LD-000-JR1 (LBL 20ga ) 12LD-000-JR1 (LBL 20ga ) 4 4 4 12LD-001-AR2 (LBL 16ga ) 6 6 12LD-002-AA1 (LBL 16ga ) G1 G2 12LD-004-AC3 (LBL 16ga ) 10 10 12LD-005-CC3 (LBL 16ga )
P7 J538 P538_JP P03 J03

P46 J46
HEDWELD HYDRAULIC LADDER OPTION

OP CAB HEDWELD
CONTROL MODULE
24Va 3
24Vb 4
1 1 SWITCH
2 2 HEDWELD LIMIT
LIMIT
8
2
A A A A 510E2-004-JR2 (DGR 16ga ) 1
C C C C 12DP-004-JR2 (ORG 16ga ) 9
B B B B 0-689-JR2 (BLK 16ga ) 3
6
J830 P830 7
5
(SWITCH SHOWN WITH
4
LADDER IN DOWN POSITION)
J538B
0-382-CC3 (BLK 16ga ) SH12:P-8

GB10 FRT CAB GND
RELAY HYDRAULIC LADDER
C3
1 0-381-CC3 (BLK 16ga ) PK STATUS (OPT)
(-) (+)
SH12:P-8 0-376-CC3 (BLK 16ga ) 85 86 52PB-004-CC3 (PUR 16ga ) 7 7 52PB-001-AC3 (PUR 16ga ) SH8:H-15
87 (NO)
(C) 30 J03 P03
87A (NC)
P263
PC1730 1 1
P263 52RS1-000-CC3 (YEL 16ga )
52RS2-000-CC3 (DGR 16ga ) 2 2
3 3
HEDWELD DISPLAY/CONTROLLER
4 4
P262_CP
58B-06-02261-00 SEP 15
980E-4
A40003 & UP
Sheet 17 of 24
OPERATOR CAB RADAR 1 KOMVISION
MC817
SH19:H-12 939YX1-005-CR1 (YEL 18ga ) 2 2
3 3 SHORT RANGE RADAR
SH18:G-10 8X013-028-CC12 (RED 20ga ) SH19:H-12 939GX1-005-CR1 (GRN 18ga )
4 4 LOCATED ON BUMPER
SH18:I-10 8X013-029-CC12 (RED 20ga ) 12VR-003-CR1 (RED 16ga )
1 1 FRONT FORWARD LH
SH18:K-11 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 ) 0-035-CR1 (BLK 16ga ) 0-567-CR1 (BLK 20ga )
SH18:I-14 0-716-CC2 (BLK 14ga ) 7 7 0-534-CC12 (BLK 14ga ) 1 12VR-020-CC12 (RED 16ga ) 1 1 12VR-003-CR1 (RED 16ga ) SP3806 J119
8
7
6
5
4
3
2
1
2 12VR-000-CC12 (RED 16ga ) 2 2 12VR-021-CR1 (RED 16ga )
8X013-020-CC12 (RED 18ga ) 2 12VR-001-CC12 (RED 16ga ) 3 3 12VR-022-CR1 (RED 16ga ) RADAR 2 KOMVISION
3 MC814
SH18:K-7 11CAM-007-CC12 (YEL 18ga ) 1 4 12VR-002-CC12 (RED 16ga ) 4 4 12VR-019-CR1 (RED 16ga ) SH19:I-12 939YX1-006-CR1 (YEL 18ga ) 2 2
PX07_CP JX07 56B-06-11530 JB10X
SH18:J-4 8X001-000-CC12 (ORG 18ga ) 6 5 12VR-004-CC12 (RED 16ga ) SH19:I-12 939GX1-006-CR1 (GRN 18ga ) 3 3
JB8C SHORT RANGE RADAR
6 1 5 5 0-035-CR1 (BLK 16ga ) 4 4
KOMVISION 12VR-005-CC12 (RED 16ga ) 0-637-CC12 (BLK 16ga ) 12VR-021-CR1 (RED 16ga ) LOCATED ON BUMPER
SH18:J-6 74SB1-007-CC12 (DBL 14ga ) 4 7 12VR-006-CC12 (RED 16ga ) 2 0-036-CC12 (BLK 16ga ) 6 6 0-589-CR1 (BLK 16ga ) 0-568-CR1 (BLK 16ga ) 1 1
DIAGNOSTIC FRONT FORWARD RH
8 12VR-009-CC12 (RED 16ga ) 3 0-037-CC12 (BLK 16ga ) 7 7 0-616-CR1 (BLK 16ga ) SP3807 0-569-CR1 (BLK 16ga ) 5 5
KOMVISION CONTROLLER CONNECTOR 8 8 6 6
(AIMING FRONT LH)
9 12VR-017-CC12 (RED 14ga ) SH18:J-10 4 0-038-CC12 (BLK 16ga ) 0-636-CR1 (BLK 16ga )
SH18:I-4 9 10 5
0-536-CC12 (BLK 20ga ) 0-539-CC12 (BLK 18ga ) 0-039-CC12 (BLK 16ga )
P01X_CP J01X J122
KEY SLG-1 4 SH18:I-4 0-537-CC12 (BLK 20ga ) 0-540-CC12 (BLK 18ga ) 12 11 6 0-548-CC12 (BLK 16ga )
KEY SLG-2 5 RADAR 3 KOMVISION
SH18:I-10 0-538-CC12 (BLK 20ga ) 12 7 0-044-CC12 (BLK 16ga ) MC816
GND PWR-1 6 J251X_CP 2 2
0-529-CC12 (BLK 20ga ) 8 0-045-CC12 (BLK 16ga ) SH19:I-9 939YX1-007-CR1 (YEL 18ga )
GND PWR-2 7 58E-06-02630 3 3 LONG RANGE RADAR
0-530-CC12 (BLK 20ga ) 9 0-714-CC12 (BLK 14ga ) SH19:I-9 939GX1-007-CR1 (GRN 18ga )
GND PWR-3 16 0-531-CC12 (BLK 20ga ) 10 12VR-022-CR1 (RED 16ga ) 4 4 LOCATED ON BUMPER
GND PWR-4 17 0-532-CC12 (BLK 20ga ) 0-533-CC12 (BLK 20ga ) 11 0-616-CR1 (BLK 16ga ) 0-571-CR1 (BLK 16ga ) 1 1 FRONT RIGHT CORNER
12 SP3808 5 5
P0178X J0178X
12
11
10
9
8
7
6
5
4
3
2
1
KVIS-B 6 6
JB12A 0-573-CR1 (BLK 16ga )
58E-06-02630 58E-06-02640
13 13 8X013-000-CC6 (RED 20ga ) SH19:E-5 J123
1 1 0-590-CC6 (BLK 20ga ) SH19:D-5
SWITCH CANCEL 36 RADAR 4 KOMVISION
8X011-001-CC12 (ORG 20ga ) 11 11 8X011-000-CC6 (ORG 20ga ) SH19:D-5 MC818
SWITCH BODY 37 8X010-001-CC12 (DBL 20ga ) 10 10 8X010-000-CC6 (DBL 20ga ) SH19:D-7 SH19:I-7 939YX1-008-CR1 (YEL 18ga ) 2 2
SWITCH LINE 38 8X009-001-CC12 (WHT 20ga ) 9 9 8X009-000-CC6 (WHT 20ga ) SH19:D-10 SH19:I-7 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 ) SH19:D-12 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 ) SH19:D-15 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 ) SH19:D-18 5 5
SWITCH RH FRONT 49 8X003-001-CC12 (PUR 20ga ) 3 3 8X003-000-CC6 (PUR 20ga ) SH19:D-21 6 6
J124
KVIS-A 18 18 8X045-002-CC6 (PUR 20ga ) SH19:G-21
12 12 8X012-000-CC6 (BRN 20ga ) SH19:G-17
INDICATOR POWER 48 8X045-003-CC12 (PUR 20ga ) 2 2 8X002-000-CC6 (LTG 20ga ) SH19:G-14
7 7 8X007-000-CC6 (GRY 20ga ) SH19:G-12
KVIS-B 6 6 8X006-000-CC6 (LBL 20ga ) SH19:G-9
17 17 8X017-000-CC6 (DBL 20ga ) SH19: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 ) SH19: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 ) 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 )
KVIS-A 6 6 0-047-CD2 (BLK 16ga ) 4 4 0-542-DD6 (BLK 16ga )
7 7 0-544-CD2 (BLK 16ga )
8 8 P16X J16X
MC753 MC753 0-545-CD2 (BLK 16ga )
VEHICLE CAN H 42 RADAR 5 KOMVISION
939YP-011-CC12 (YEL 18ga ) SH16:E-14 MC809
VEHICLE CAN L 41 P09X_CP J09X 2 2
939GP-011-CC12 (GRN 18ga ) SH16:E-14 SH19:J-13 939YX2-005-DD6 (YEL 18ga )
KOMVISION DISPLAY MONITOR 3 3
MC752 MC752 SH19:J-13 939GX2-005-DD6 (GRN 18ga ) SHORT RANGE RADAR
J1939 CAN H 32 939YE-014-CC12 (YEL 18ga ) SH16:C-16 8X016-001-CC12 (YEL 20ga ) 3 BRIGHTNESS + 4 4
LOCATED ON REAR AXLE
J1939 CAN L 31 939GE-014-CC12 (GRN 18ga ) SH16:C-16 8X017-001-CC12 (DBL 20ga ) 4 BRIGHTNESS - 0-577-DD6 (BLK 20ga ) 1 1
RH (AIMING REAR LH)
SP3809 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
SH18:C-4 6 LIGHT
8X013-028-CC12 (RED 20ga ) 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 SH19:K-13 939YX2-006-DD6 (YEL 18ga ) 2 2
SH19:K-13 3 3
P44 939GX2-006-DD6 (GRN 18ga )
KVIS-A 12VR-008-DD6 (RED 16ga ) 4 4 LONG RANGE RADAR
0-580-DD6 (BLK 16ga ) 1 1 LOCATED ON REAR AXLE
MC838 MC838 SP3810 0-581-DD6 (BLK 16ga ) 5 5 LH (AIMING REAR RH)
HSYNC A SP164 SP213 4 HSYNC 6 6
910-001-CC12 (WHT 20ga ) 910-000-CC12 (WHT 26ga ) MC838A 910-002-CC12 (WHT 20ga )
SP205
SHIELD-100-CC12 (BARE SHLD_16ga ) MC838A
SP214 J126
GND SIG SYNC J 0GSS-000-CC12 (BLK 20ga ) SHIELD-101-CC12 (BARE SHLD_16ga ) MC838B 0GSS-001-CC12 (BLK 20ga ) 11 GND SIG SYNC
VSYNC B SP206 SP215 5 VSYNC RADAR 7 KOMVISION
911-001-CC12 (YEL 20ga ) 911-000-CC12 (YEL 26ga ) MC838B 911-002-CC12 (YEL 20ga ) MC811
RGB R C SP207 SP216 9 RGB R 2 2
912-001-CC12 (RED 20ga ) 912-000-CC12 (RED 26ga ) MC838C 912-002-CC12 (RED 20ga ) SH19:K-9 939YX2-007-CD2 (YEL 18ga )
GND R D SP208 SP217 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 ) SH19:K-9 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 913-002-CC12 (DGR 20ga ) 12VR-014-CD2 (RED 16ga )
GND G F SP210 SP179 3 GND G 1 1 REAR
SHIELD-990-CC12 (BLK 20ga ) SHIELD-103-CC12 (BARE SHLD_16ga ) MC838D SHIELD-989-CC12 (BLK 20ga ) 0-544-CD2 (BLK 16ga ) 0-583-CD2 (BLK 16ga )
RGB B G SP211 SP218 6 RGB B SP3811 5 5
914-001-CC12 (DBL 20ga ) 914-000-CC12 (BLU 26ga ) MC838E 914-002-CC12 (DBL 20ga )
GND B H SP212 SP219 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 )
1 PWR IN BATT
RGB 11CAM-001-CC12 (YEL 20ga ) J127
SH18:C-4 8X013-029-CC12 (RED 20ga ) 12 PWR CTR KEY GB12 REAR CAB
ALARM 2 GND PWR RADAR 8 KOMVISION
SH18:D-5 0-538-CC12 (BLK 20ga ) MC812
INDICATOR ERROR 46 1 + KOMVISION 1 A4 SH19:K-6 2 2
8X048-000-CC12 (LBL 20ga ) P45 0-714-CC12 (BLK 14ga ) 939YX2-008-CD2 (YEL 18ga )
ERROR (ESON) SH19:K-6 939GX2-008-CD2 (GRN 18ga ) 3 3
SH18:D-5 0-536-CC12 (BLK 20ga ) 1 - SH18:D-2 0-716-CC2 (BLK 14ga ) 1 A3 12VR-015-CD2 (RED 16ga ) 4 4 LONG RANGE RADAR
PC0251 1 LOCATED ON FRONT
0-545-CD2 (BLK 16ga ) 1
5 5 BUMPER LEFT CORNER
ALARM 8X050-002-CC12 (DBL 14ga ) 2 2 8X050-001-CC2 (DBL 14ga ) 6 6
INDICATOR RADAR 47 1 + KOMVISION
8X047-000-CC12 (DBL 20ga ) J128
RADAR (RSON)
SH18:D-5 0-537-CC12 (BLK 20ga ) 1 -
PB1951 JX07 PX07_CP
RELAY RADAR POWER (RPR)

(+) (-)
RADAR POWER CTRL 39 8X049-002-CC12 (PNK 18ga ) 86 85 0-713-CC12 (BLK 18ga )
(NO) VEC RTMR1

AUX BOX
87 12VR-017-CC12 (RED 14ga ) SH18:D-11 FUSE - F2
PWR CTR EXT 3 30 (C) TB25
8X001-000-CC12 (ORG 18ga ) SH18:D-7
(NC) 87A 6 6 C9 D9
SP005 8X050-001-CC2 (DBL 14ga ) 8X050-000-AC2 (DBL 14ga ) 1 P1 P2 1 8X050-003-AA2 (DBL 14ga ) 1 1 11B1-004-AA2 (LBL 14ga ) SH6:I-9
SYSTEM BUSY 10 20A
74SB1-006-CC12 (DBL 18ga ) 74SB1-005-CC12 (DBL 14ga ) SH18:J-11 RPR_K RTMR1-C9 58E-06-02610 RTMR1-D9
PC1730 SWITCH KOMVISION ON/OFF
74SB1-007-CC12 (DBL 14ga ) SH18:D-7 RPR_K SH18:J-6 74SB1-005-CC12 (DBL 14ga ) 5 5 74SB1-000-CC2 (DBL 14ga ) 38 38 74SB1-001-AC2 (DBL 14ga ) 1 T1 T2 1 74SB1-002-AA1 (DBL 14ga ) SH4:B-22
4 4 1 VEC RTMR1
0-713-CC12 (BLK 18ga ) 0-535-CC2 (BLK 18ga ) FUSE - F1
PWR IN BATT-1 8 11CAM-001-CC12 (YEL 20ga ) TB25 2 1
11CAM-002-CC12 (YEL 18ga ) 71CKM-000-AA2 (BRN 14ga )
PWR IN BATT-2 9 1 1 8 8 1 3 A9 B9
11CAM-003-CC12 (YEL 18ga ) SH18: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 1 1 71CK-004-AA2 (PNK 14ga ) SH6:H-9
PWR IN BATT-3 18 15A
11CAM-004-CC12 (YEL 18ga ) KOMV-3 RTMR1-A9 58E-06-02390 RTMR1-B9
PWR IN BATT-4 19 4
11CAM-005-CC12 (YEL 18ga ) 11CAM-000-CC12 (YEL 18ga )
TB25 5 1 VEC RTMR1
11CAM-007-CC12 (YEL 18ga ) SH18:D-7 11CMX-000-AA2 (TAN 14ga ) FUSE - F3
3 3 7 7 1 R1 R2 1 1 6
11CAM-000-CC12 (YEL 18ga ) 11CAM-006-CC2 (YEL 18ga ) 11CAM-008-AC2 (YEL 14ga ) 11CAM-009-AA2 (YEL 14ga ) KOMV-5
8
7
6
5
4
3
2
1
E9 F9
KOMV-6 1258403H1 1 1 11-014-AA2 (RED 14ga ) SH6:F-3
15A
J02 P02 RTMR1-E9 58E-06-02390 RTMR1-F9
JB12B JB12C
56B-06-11530 58E-06-02630 58E-06-02640
JB8B JX07 PX07_CP
12
11
10
12
11
10
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
MC803
RADAR CAN1 L 11 939GX1-000-CC12 (GRN 18ga ) SH19:I-4
RADAR CAN1 H 12 939YX1-000-CC12 (YEL 18ga ) SH19:I-4
CAMERA 1
MC804
RADAR CAN2 H 2 939YX2-000-CC12 (YEL 18ga ) SH19:K-4 24CAM-009-CC13 (PNK 16ga ) 1 1 24CAM-001-CL1 (PNK 16ga ) 1 1
RADAR CAN2 L 1 939GX2-000-CC12 (GRN 18ga ) SH19: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-006-CC13 (WHT 25ga ) 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 )
PX10_CP JX10 CAM1
KVIS-B CAMERA 2
24CAM-008-CC13 (PNK 16ga ) 1 1 24CAM-002-CG1 (PNK 16ga ) 1 1
0DOS-008-CC13 (BLK 16ga ) 3 3 0DOS-002-CG1 (BLK 16ga ) 3 3
SP120 SP101 SP089 LOCATED ON RIGHT DECK
26AV1-006-CC13 (WHT 25ga ) 26AV1-005-CC13 (DGR 18ga ) 2 2 26AV1-001-CG1 (DGR 18ga ) 26AV1-003-CG1 (WHT 25ga ) 26AV1-002-CG1 (DGR 18ga ) 2 2
MC830 SP240 SP099 SP088 FACING FORWARD
8X074-003-CC13 (BLK 16ga ) 4 4 8X074-001-CG1 (BLK 16ga ) MC845 8X074-002-CG1 (BLK 16ga ) 4 4
PX11_CP JX11 CAM2
CAMERA 3
24CAM-007-CC13 (PNK 16ga ) 1 1 24CAM-003-CG1 (PNK 16ga ) 1 1
0DOS-007-CC13 (BLK 16ga ) 3 3 0DOS-003-CG1 (BLK 16ga ) 3 3 LOCATED ON RIGHT DECK
SP238 2 2 SP098 SP086 2 2
26AV2-006-CC13 (WHT 25ga ) 26AV2-003-CC13 (DGR 18ga ) 26AV2-001-CG1 (DGR 18ga ) 26AV2-004-CG1 (WHT 25ga ) SP085 26AV2-002-CG1 (DGR 18ga ) FACING RIGHT OF TRUCK
MC833 SP232 4 4 SP097 MC846 4 4
SHIELD-018 8X075-002-CC13 (BLK 16ga ) 8X075-001-CG1 (BLK 16ga ) SHIELD-004 SHIELD-004 8X075-003-CG1 (BLK 16ga )
PX12_CP JX12 CAM3
CAMERA 4
POWER OUT CAMERA A 24CAM-000-CC13 (PNK 20ga ) 24CAM-006-CC13 (PNK 16ga ) 1 1 24CAM-010-CG1 (PNK 16ga ) 1 1
0DOS-006-CC13 (BLK 16ga ) 3 3 0DOS-010-CG1 (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 ) 2 2 26AV3-001-CG1 (DGR 18ga ) 26AV3-004-CG1 (WHT 25ga ) 26AV3-002-CG1 (DGR 18ga ) 2 2
MC834 SP103 4 4 SP258 MC847 SP128 4 4
26AV3-006-CC13 (WHT 25ga ) SHIELD-017 8X076-002-CC13 (BLK 16ga ) 8X076-001-CG1 (BLK 16ga ) SHIELD-003 SHIELD-003 8X076-003-CG1 (BLK 16ga )
AV NTSC 0 C SP221
26AV-000-CC13 (DGR 20ga ) 26AV-006-CC13 (WHT 25ga ) CAM4
GND NTSC 0 D SP222 MC835 PX13_CP JX13 CAMERA 5
8X073-000-CC13 (BLK 20ga ) SHIELD-016
AV NTSC 1 E SP186 24CAM-005-CC13 (PNK 16ga ) 1 1 1 1
26AV1-000-CC13 (DGR 20ga ) 26AV1-006-CC13 (WHT 25ga ) 24CAM-011-CG1 (PNK 16ga )
GND NTSC 1 F SP223 MC830 3 3 3 3 LOCATED ON LEFT DECK
8X074-000-CC13 (BLK 20ga ) SHIELD-021 0DOS-005-CC13 (BLK 16ga ) 0DOS-011-CG1 (BLK 16ga )
AV NTSC 2 G SP188 SP255 2 2 SP159 SP079 2 2 FACING LEFT OF TRUCK
26AV2-000-CC13 (DGR 20ga ) 26AV2-006-CC13 (WHT 25ga ) 26AV4-006-CC13 (WHT 25ga ) 26AV4-003-CC13 (DGR 18ga ) 26AV4-001-CG1 (DGR 18ga ) 26AV4-004-CG1 (WHT 25ga ) 26AV4-002-CG1 (DGR 18ga )
GND NTSC 2 H SP189 MC833 MC831 SP197 4 4 SP096 MC848 SP127 4 4
8X075-000-CC13 (BLK 20ga ) SHIELD-018 SHIELD-020 8X077-002-CC13 (BLK 16ga ) 8X077-001-CG1 (BLK 16ga ) SHIELD-002 SHIELD-002 8X077-003-CG1 (BLK 16ga )
AV NTSC 3 J SP190
26AV3-000-CC13 (DGR 20ga ) 26AV3-006-CC13 (WHT 25ga ) CAM5
GND NTSC 3 K SP224 MC834 PX14_CP JX14 CAMERA 6
8X076-000-CC13 (BLK 20ga ) SHIELD-017
AV NTSC 4 L SP225 24CAM-004-CC13 (PNK 16ga ) 1 1 1 1
26AV4-000-CC13 (DGR 20ga ) 26AV4-006-CC13 (WHT 25ga ) 24CAM-012-CG1 (PNK 16ga )
GND NTSC 4 M SP226 MC831 3 3 3 3
8X077-000-CC13 (BLK 20ga ) SHIELD-020 0DOS-004-CC13 (BLK 16ga ) 0DOS-012-CG1 (BLK 16ga ) LOCATED ON LEFT DECK
AV NTSC 5 N SP227 SP102 2 2 SP095 SP126 2 2
26AV5-000-CC13 (DGR 20ga ) 26AV5-006-CC13 (WHT 25ga ) 26AV5-006-CC13 (WHT 25ga ) 26AV5-003-CC13 (DGR 18ga ) 26AV5-001-CG1 (DGR 18ga ) 26AV5-004-CG1 (WHT 25ga ) 26AV5-002-CG1 (DGR 18ga ) FACING FORWARD
GND NTSC 5 P SP228 MC832 MC832 SP118 4 4 SP094 MC849 SP125 4 4
8X078-000-CC13 (BLK 20ga ) SHIELD-019 SHIELD-019 8X078-002-CC13 (BLK 16ga ) 8X078-001-CG1 (BLK 16ga ) SHIELD-001 SHIELD-001 8X078-003-CG1 (BLK 16ga )
PX15_CP JX15 CAM6
NTSC1
KOMVISION OPTION
58B-06-02261-00 SEP 15
980E-4
A40003 & UP
Sheet 18 of 24
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 12 SP122 12 SP032 12 SP042 12 SP052 12 SP062 12 SP072 12 SP082 12
8X022-001-CC6 (PNK 20ga ) 12 8X036-001-CC6 (PNK 20ga ) 12 8X024-001-CC6 (PNK 20ga ) 12 8X026-001-CC6 (PNK 20ga ) 12 8X028-001-CC6 (PNK 20ga ) 12 8X030-001-CC6 (PNK 20ga ) 12 8X032-001-CC6 (PNK 20ga ) 12 8X034-001-CC6 (PNK 20ga ) 12
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
8 8X011-000-CC6 (ORG 20ga ) 8 8X010-000-CC6 (DBL 20ga ) 8 8X009-000-CC6 (WHT 20ga ) 8 8X008-000-CC6 (TAN 20ga ) 8 8X005-000-CC6 (BLK 20ga ) 8 8X004-000-CC6 (YEL 20ga ) 8 8X003-000-CC6 (PUR 20ga ) 8
8 8X018-000-CC6 (LTG 20ga ) 8 0-593-CC6 (BLK 20ga ) 8 0-597-CC6 (BLK 20ga ) 8 0-600-CC6 (BLK 20ga ) 8 0-602-CC6 (BLK 20ga ) 8 0-606-CC6 (BLK 20ga ) 8 0-608-CC6 (BLK 20ga ) 8 0-612-CC6 (BLK 20ga )
1
1 1
1 1
1 1
1 1
1 1
1 1
1 1
1
8X017-000-CC6 (DBL 20ga )
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
P0028X PC3712 P0028X P0128X PC3706 P0128X P0038X PC3705 P0038X P0048X PC3704 P0048X P0058X PC3703 P0058X P0068X PC3701 P0068X P0078X PC3702 P0078X P0088X PC3702 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 )
SP023 SP123 SP033 SP043 SP053 SP063 SP073 SP083
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 )
SP024
SH18:F-11 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 )
SP124 SP034 SP044 SP054 SP064 SP074 SP084
8X004-000-CC6 (YEL 20ga ) SH18:E-11 8X003-000-CC6 (PUR 20ga ) SH18:F-11

8X011-000-CC6 (ORG 20ga ) SH18:E-11 8X010-000-CC6 (DBL 20ga ) SH18:E-11 8X009-000-CC6 (WHT 20ga ) SH18:E-11 8X008-000-CC6 (TAN 20ga ) SH18:E-11 8X005-000-CC6 (BLK 20ga ) SH18:E-11
0-590-CC6 (BLK 20ga ) SH18:E-11
8X013-000-CC6 (RED 20ga ) SH18:E-11 SWITCH KOMVISION LH FRONT SWITCH KOMVISION FRONT SWITCH KOMVISION LOCK
SWITCH KOMVISION LH REAR
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
12 12 SP012
RED 8X020-001-CC6 (PNK 20ga )
P0098X
11 11 11 11 11 11 11 11 11
8X043-001-CC6 (YEL 20ga ) 8X041-001-CC6 (YEL 20ga ) 8X039-001-CC6 (YEL 20ga ) 8X037-001-CC6 (YEL 20ga )
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 )
1010 1010 1010 1010
7 7
8X013-033-CC6 (RED 20ga ) 4 4 8X013-032-CC6 (RED 20ga ) 4 4 8X013-024-CC6 (RED 20ga ) 4 4 8X013-022-CC6 (RED 20ga ) 4 4 8X020-002-CC6 (PNK 20ga )
9 9 8X043-002-CC6 (YEL 20ga ) 9 9 8X041-002-CC6 (YEL 20ga ) 9 9 8X039-002-CC6 (YEL 20ga ) 9 9 8X037-002-CC6 (YEL 20ga ) 8X013-019-CC6 (RED 20ga ) 1010
9 9
4 4
8X019-002-CC6 (YEL 20ga )
P0168X PC3702 P0168X P0158X PC3702 P0158X P0148X PC3701 P0148X P0138X PC3707 P0138X
P0018X PC3711 P0018X
SP093
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 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
SH18:F-11
SH18:F-11 SH18:F-11 SH18:F-11 SH18:F-11
8X045-000-CC6 (PUR 20ga )
8X045-001-CC6 (PUR 20ga ) 8X045-002-CC6 (PUR 20ga ) SH18:F-11
SP091
KOMVISION SWITCH PANEL
TERMX1 TX0
MC821 SP046 MC813 MC815 MC817
A A1 A2 SP049 SP056
A 939YX1-009-CR1 (YEL 18ga ) SP047 939YX1-002-CR1 (YEL 18ga ) 939YX1-003-CR1 (YEL 18ga ) 939YX1-005-CR1 (YEL 18ga ) SH18:C-19
PC0618 B B1 B2 SP050 SP057
B 939GX1-009-CR1 (GRN 18ga ) 939GX1-002-CR1 (GRN 18ga ) 939GX1-003-CR1 (GRN 18ga ) 939GX1-005-CR1 (GRN 18ga ) SH18:C-19
C C1 C2
C SHIELD-023 SP048 SP055 SP058
A3
P21TX0B2 MC803 SHIELD-023 SHIELD-030 SHIELD-030 SHIELD-028 SHIELD-028 SHIELD-026
A
B3
B
C3
C SHIELD-039
P21TX0D
PC0616
MC803 SHIELD-025 SHIELD-027 SHIELD-029

939YX1-000-CC12 (YEL 18ga ) SH18:L-5 939GX1-008-CR1 (GRN 18ga ) SH18:E-19 939GX1-007-CR1 (GRN 18ga ) SH18:E-19 939GX1-006-CR1 (GRN 18ga ) SH18:D-19
939GX1-000-CC12 (GRN 18ga ) SH18:K-5 939YX1-008-CR1 (YEL 18ga ) SH18:E-19 939YX1-007-CR1 (YEL 18ga ) SH18:D-19 939YX1-006-CR1 (YEL 18ga ) SH18:D-19
OPERATOR CAB MC818 MC816 MC814
AUTOLIV NETWORK (BLUE)
TERMX3 TX9
MC822 SP059 MC806 SP066 MC807 MC852 SP069 MC809
A A1 A2 5 5
A 939YX2-009-CD2 (YEL 18ga ) SP060 939YX2-002-CD2 (YEL 18ga ) SP067 939YX2-003-CD2 (YEL 18ga ) 939YX2-001-DD6 (YEL 18ga ) SP070
939YX2-005-DD6 (YEL 18ga ) SH18:G-19
PC0618 B B1 B2 6 6
B 939GX2-009-CD2 (GRN 18ga ) 939GX2-002-CD2 (GRN 18ga ) 939GX2-003-CD2 (GRN 18ga ) 939GX2-001-DD6 (GRN 18ga ) 939GX2-005-DD6 (GRN 18ga ) SH18:G-19
C C1 C2 7 7
C SHIELD-022 SP065 SP068 SHIELD-036 SHIELD-000 SP075
A3
P22TX9B2 MC804 SHIELD-022 SHIELD-037 SHIELD-037 SHIELD-036 SHIELD-000 SHIELD-034
A P16X J16X
B3
B
C3
C SHIELD-038
P22TX9D
PC0616

939YX2-000-CC12 (YEL 18ga ) SH18:L-5 939GX2-008-CD2 (GRN 18ga ) SH18:I-19 939GX2-007-CD2 (GRN 18ga ) SH18:H-19 939GX2-006-DD6 (GRN 18ga ) SH18:H-19
939GX2-000-CC12 (GRN 18ga ) SH18:L-5 939YX2-008-CD2 (YEL 18ga ) SH18:I-19 939YX2-007-CD2 (YEL 18ga ) SH18:H-19 939YX2-006-DD6 (YEL 18ga ) SH18:H-19
MC812 MC811 MC810
OPERATOR CAB
AUTOLIV NETWORK (GREEN)
58B-06-02261-00 SEP 15
980E-4
A40003 & UP
Sheet 18 of 24
WIRE TABLE CONTINUED ON DIAGRAM 21, 22 & 23
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
+24V-000 SWITCH HEDWELD LIMIT - - LIMIT 0-147 - J14 SP14 - 0-314 SWITCH RETARD SPEED CONTROL (R... RSCS-B SWITCH RETARD SPEED CONTROL (R... RSCS_1-3 0-494 SP246 - - J541 0ACL-001 TB31 TB31-W2 - P01 8X016-001 KOMVISION DISPLAY MONITOR P44 - P0178X
+24V-001 SWITCH HEDWELD LIMIT - - LIMIT 0-149 - P14 - P732_CP 0-315 - P02 TB31 TB31-G2 0-495 - P541 - P502 0ACL-002 GE CONTROL INTERFACE P303 TB31 TB31-W3 8X017-000 - J0178X SWITCH KOMVISION DIM P0028X
-15VDI-000 - J02 GE DID PANEL DID 0-150 SWITCH FOG LAMP (OPT) P22 SWITCH FOG LAMP (OPT) P22 0-316 GE CONTROL INTERFACE P303 TB31 TB31-G1 0-496 - J502 LAMP RH DECK (OPT) DLT_CP 0ACL-003 GE CONTROL INTERFACE P304 TB31 TB31-W1 8X017-001 KOMVISION DISPLAY MONITOR P44 - P0178X
-15VDI-001 TB21 TB21-V2 - P02 0-151 SWITCH FOG LAMP (OPT) P22 GB10 FRT CAB GND GB10-A3 0-317 SWITCH DC POWER OFF - REST SWI... P35 GB10 FRT CAB GND GB10-C1 0-500 - J712 TB-HTST TB-HTST-D4 0CAM-000 KOMVISION CONTROLLER KVIS-A KOMVISION DISPLAY MONITOR P44 8X018-000 SWITCH KOMVISION BRIGHT P0018X SWITCH KOMVISION DIM P0028X
-15VDI-003 TB21 TB21-V1 DID POWER SUPPLY P500 0-156 - P16 - P731_CP 0-318 SWITCH GRID DRY P34 GB10 FRT CAB GND GB10-C1 0-501 HEATER COOLANT LH - TB-HTST TB-HTST-C1 0COM-000 - J02 GE DID PANEL DID 8X019-000 SP011 - SWITCH KOMVISION BRIGHT P0018X
0-000 GB70 FRAME GND GB70-A2 BUSS_BAR_0 DISC(-)-5 0-157 RELAY HEADLIGHT HIGH MOUNT (HH... HHMR-85 RELAY BACKUP LIGHT (BULR) BULR-85 0-319 SWITCH GRID DRY P34 SWITCH GRID DRY P34 0-502 HEATER COOLANT RH - TB-HTST TB-HTST-C2 0COM-001 - P02 TB22 TB22-S2 8X019-001 SP011 - SWITCH KOMVISION BRIGHT P0018X
0-001 24VDC ALTERNATOR ALT(-) GB70 FRAME GND GB70-A1 0-158 SP195 - LAMP GREEN PAYLOAD RIGHT RPLG_CP 0-320 SWITCH BRAKE TEST P37 SWITCH BRAKE LOCK P39 0-503 SP801 - OIL RESERVE SYS P502_CP 0COM-010 TB22 TB22-S1 DID POWER SUPPLY P500 8X019-002 SWITCH KOMVISION BRIGHT P0018X SP011 -
0-002 GB70 FRAME GND GB70-B2 GB31-B GB31B-E1 0-160 GB31-B GB31B-A2 SP14 - 0-321 SWITCH BRAKE TEST P37 SWITCH BRAKE TEST P37 0-504 SP706 - THERMOSTAT ENGINE OIL EOTS 0COMX-000 KOMVISION CONTROLLER KVIS-B SP254 - 8X020-000 SP012 - SWITCH KOMVISION BRIGHT P0018X
0-003 BUSS_BAR_0 DISC(-)-4 MOTOR STARTER 1 (STRT1) STRT1-2A 0-161 - J14 SP14 - 0-322 GE CONTROL INTERFACE P305 GB31-B GB31B-B3 0-505 SP706 - TB-HTST TB-HTST-E1 0DOS-000 KOMVISION CONTROLLER NTSC1 JB12C JB12C 8X020-001 SP012 - SWITCH KOMVISION BRIGHT P0018X
0-004 BUSS_BAR_0 DISC(-)-3 MOTOR STARTER 2 (STRT2) STRT2-2A 0-162 - J12 SP13 - 0-323 GE CONTROL INTERFACE P305 GB31-B GB31B-B3 0-506 SP706 - SP705 - 0DOS-001 - JX10 CAMERA 1 CAM1 8X020-002 SWITCH KOMVISION BRIGHT P0018X SP012 -
0-005 VEC-90 VEC90-S7A VEC-89 VEC89-S7A 0-163 - J12 SP13 - 0-324 SENSOR FUEL LEVEL FLS SP185 - 0-507 HEATER ENGINE OIL LH EOH1 SP705 - 0DOS-002 - JX11 CAMERA 2 CAM2 8X021-000 SP021 - SWITCH KOMVISION DIM P0028X
0-006 RELAY KEY/GE CNTRL PWR (KCNPR) KCNPR-85 RELAY KEY SWITCH (KSWPR) KSWPR-85 0-164 - J11 SP10 - 0-325 - J16 GB31-B GB31B-E2 0-508 SP705 - HEATER ENGINE OIL RH EOH2 0DOS-003 - JX12 CAMERA 3 CAM3 8X021-001 SP021 - SWITCH KOMVISION DIM P0028X
0-007 RELAY KEY/GE CNTRL PWR (KCNPR) KCNPR-85 12V POWER RELAY (12VPR) 12VPR-85 0-165 - J11 SP10 - 0-326 SP006 - - P16 0-509 TB-HTST TB-HTST-D2 - CON1 0DOS-004 JB12C JB12C - PX15_CP 8X021-002 SWITCH KOMVISION DIM P0028X SP021 -
0-008 - J11 SP09 - 0-166 - P11 - J543 0-327 SP185 - - P730 0-510 SP709 - - CON2 0DOS-005 JB12C JB12C - PX14_CP 8X022-000 SP022 - SWITCH KOMVISION DIM P0028X
0-009 12VDC CONVERTER (12VCN) 12VCN-GND GB31-A GB31A-A3 0-167 - P543 LAMP RH DIAGONAL LADDER RDLLT_CP 0-328 SP185 - SWITCH STEERING FILTER #1 SFSW 0-511 HEATER HYDRAULIC OIL #1 HOHTR1 SP709 - 0DOS-006 JB12C JB12C - PX13_CP 8X022-001 SP022 - SWITCH KOMVISION DIM P0028X
0-010 R1 R1 GB31-A GB31A-B3 0-168 SP246 - - P11 0-329 - J02 SWITCH DRIVERS SEAT BELT P212 0-512 SP709 - HEATER HYDRAULIC OIL #2 HOHTR2 0DOS-007 - PX12_CP JB12C JB12C 8X022-002 SWITCH KOMVISION DIM P0028X SP022 -
0-011 VEC-91 VEC91-S6B GB31-A GB31A-B1 0-169 LAMP RH DECK RDLT_CP - P543 0-330 - P02 GB31-B GB31B-A4 0-513 SP801 - - P11 0DOS-008 - PX11_CP JB12C JB12C 8X023-000 SP031 - SWITCH KOMVISION BODY P0038X
0-012 VEC-91 VEC91-S6A VEC-90 VEC90-S7B 0-170 - J542 - P12 0-331 - P14 SWITCH LOW STEERING PRESSURE ACPSW 0-514 - CON3 TB-HTST TB-HTST-E2 0DOS-009 JB12C JB12C - PX10_CP 8X023-001 SP031 - SWITCH KOMVISION BODY P0038X
0-013 RELAY HEADLIGHT LOW MOUNT (HLM... HLMR-85 RELAY HEADLIGHT HIGH MOUNT (HH... HHMR-85 0-171 LAMP LH DIAGONAL LADDER LDLLT_CP - P542 0-332 - P14 SP799 - 0-515 HEATER OIL RESERVE TANK ECHTR2 - CON4 0DOS-010 - JX13 CAMERA 4 CAM4 8X023-002 SWITCH KOMVISION BODY P0038X SP031 -
0-014 RELAY HI-BEAM HEADLIGHT (HBHR) HBHR-85 RELAY KEY SWITCH (KSWPR) KSWPR-85 0-172 - J542 - P12 0-333 - J14 SP14 - 0-516 BATT1 BAT1(+) BATT2 BAT2(-) 0DOS-011 - JX14 CAMERA 5 CAM5 8X024-000 SP032 - SWITCH KOMVISION BODY P0038X
0-015 RELAY HI-BEAM HEADLIGHT (HBHR) HBHR-85 GB31-B GB31B-B1 0-173 - P542 LAMP LH DECK (OPT) LDLT_CP 0-334 - J14 SP14 - 0-517 BATT3 BAT3(+) BATT4 BAT4(-) 0DOS-012 - JX15 CAMERA 6 CAM6 8X024-001 SP032 - SWITCH KOMVISION BODY P0038X
0-016 RELAY HEADLIGHT LOW MOUNT (HLM... HLMR-85 RELAY ACCESS LADDER LIGHT (ALL... ALLR-85 0-174 - P565 - P14 0-335 SWITCH ACCUMULATOR PRECHARGE P... ACCP2-C - P13 0-518 OIL RESERVE SYS P506_CP - P11 0GSS-000 SP205 - KOMVISION CONTROLLER RGB 8X024-002 SWITCH KOMVISION BODY P0038X SP032 -
0-017 SP257 - GB31-A GB31A-B3 0-175 - J565 SP151 - 0-336 - J13 GB31-B GB31B-E4 0-519 - P46 - P538_JP 0GSS-001 SP214 - KOMVISION DISPLAY MONITOR P45 8X025-000 SP041 - SWITCH KOMVISION GRIDLINE P0048X
0-018 DL1 DL1 SP104 - 0-176 LAMP CONTROL CABINET WORK LIGH... CDL1 SP151 - 0-337 SWITCH PARK BRAKE SET PBPSW GB8 BRAKE CABINET GB8-2 0-520 PAY LOAD METER 4 P264 PLM4 COMMUNICATION BOX COMMB 0LEV-000 - J01 - P237 8X025-001 SP041 - SWITCH KOMVISION GRIDLINE P0048X
0-019 SP104 - DL2 DL2 0-177 LAMP CONTROL CABINET WORK LIGH... CDL2 SP151 - 0-338 GB8 BRAKE CABINET GB8-2 SWITCH LOW BRAKE ACCUM PRESSUR... LBPS 0-521 - J12 SP15 - 0LEV-001 TB31 TB31-L2 - P01 8X025-002 SWITCH KOMVISION GRIDLINE P0048X SP041 -
0-020 DL3 DL3 SP104 - 0-178 GB10 FRT CAB GND GB10-B2 ACTIA DISPLAY PANEL DIMMER P18 0-339 GB8 BRAKE CABINET GB8-2 SWITCH SERVICE BRAKE DEGRADE P... BDS 0-522 - J11 SP11 - 0LEV-002 GE CONTROL INTERFACE P302 TB31 TB31-L1 8X026-000 SP042 - SWITCH KOMVISION GRIDLINE P0048X
0-021 DL4 DL4 SP257 - 0-179 SWITCH DISPLAY MODE #2 P20 GB10 FRT CAB GND GB10-B4 0-340 - P14 SENSOR HYDRAULIC TANK LEVEL P712 0-523 HEATED HOSE RELAY TSW-85 SP15 - 0LEV-003 - J237 RETARD LEVER SENSOR (OPT) P814 8X026-001 SP042 - SWITCH KOMVISION GRIDLINE P0048X
0-022 DL5 DL5 SP257 - 0-180 SWITCH DISPLAY MODE #2 P20 SWITCH DISPLAY MODE #2 P20 0-341 - J14 SP14 - 0-524 SP004 - OIL RESERVE SYS CM1_FVAL_CP 0LF-000 - P13 SENSOR LEFT FRONT WHEEL SPEED P507 8X026-002 SWITCH KOMVISION GRIDLINE P0048X SP042 -
0-023 DL6 DL6 SP257 - 0-181 SWITCH DISPLAY MODE #2 P20 SWITCH DISPLAY MODE #2 P20 0-342 - J511 SP796 - 0-525 SP004 - OIL RESERVE SYS CM2_FVAL_CP 0LF-001 TB33 TB33-P2 - J13 8X027-000 SP051 - SWITCH KOMVISION MODE P0058X
0-024 SP104 - SP257 - 0-182 SWITCH DISPLAY MODE #2 P20 SWITCH DISPLAY MODE #1 P21 0-343 - P511 SWITCH AUTOLUBE LEVEL (OPT) P512 0-526 SP004 - OIL RESERVE SYS ORS_FVAL_CP 0LF-002 GE CONTROL INTERFACE P301 TB33 TB33-P1 8X027-001 SP051 - SWITCH KOMVISION MODE P0058X
0-025 GB5 FRAME GND BLOCK GB5-1 GB4 ENG SUBFRAME GND BLOCK GB4-1 0-183 SWITCH DISPLAY MODE #1 P21 SWITCH DISPLAY MODE #1 P21 0-344 - J11 SP10 - 0-527 SP801 - OIL RESERVE SYS P501_CP 0LF-003 GE CONTROL INTERFACE P301 TB33 TB33-P3 8X027-002 SWITCH KOMVISION MODE P0058X SP051 -
0-026 BUSS_BAR_0 DISC(-)-7 LAMP LED MASTER DISCONNECT CL... MLLON 0-184 SWITCH DISPLAY MODE #1 P21 SWITCH DISPLAY MODE #1 P21 0-345 R30 R30 TB21 TB21-X3 0-528 - CAN_TP GB12 REAR CAB GB12-B2 0RET-000 - J01 RETARD CONTROL PEDAL P235 8X028-000 SP052 - SWITCH KOMVISION MODE P0058X
0-027 BUSS_BAR_0 DISC(-)-7 JB1 JB1 0-185 ACTIA DASH DISPLAY P903 GB10 FRT CAB GND GB10-D3 0-346 - P04 GB31-A GB31A-B4 0-529 KOMVISION CONTROLLER KVIS-B JB12A JB12A 0RET-001 TB31 TB31-V2 - P01 8X028-001 SP052 - SWITCH KOMVISION MODE P0058X
0-028 MOTOR STARTER 1 (STRT1) STRT1-2B MOTOR STARTER 2 (STRT2) STRT2-2B 0-186 SWITCH CAB LADDER LIGHT P24 SWITCH HEADLIGHTS P25 0-347 - J04 JB8A JB8A 0-530 KOMVISION CONTROLLER KVIS-B JB12A JB12A 0RET-002 GE CONTROL INTERFACE P302 TB31 TB31-V1 8X028-002 SP052 - SWITCH KOMVISION MODE P0058X
0-030 JB1 JB1 RELAY PROPEL LOCKOUT PLREL_K 0-187 R27 R27 GB10 FRT CAB GND GB10-B2 0-348 KOMTRAX PLUS MODULE P1 JB8A JB8A 0-531 KOMVISION CONTROLLER KVIS-B JB12A JB12A 0RF-000 - P13 SENSOR RIGHT FRONT WHEEL SPEED P501 8X029-000 SP061 - SWITCH KOMVISION REAR P0068X
0-031 JB1 JB1 RELAY STARTER LOCKOUT SLREL_K 0-188 SWITCH CAB LADDER LIGHT P24 SWITCH CAB LADDER LIGHT P24 0-349 KOMTRAX PLUS MODULE P1 JB8A JB8A 0-532 KOMVISION CONTROLLER KVIS-B JB12A JB12A 0RF-001 - J13 TB33 TB33-K2 8X029-001 SP061 - SWITCH KOMVISION REAR P0068X
0-032 JB1 JB1 LAMP LED PROPEL LOCKOUT ON PLON 0-189 LAMP RED PAYLOAD RIGHT RPLR_CP SP195 - 0-350 KOMTRAX PLUS MODULE P1 JB8A JB8A 0-533 - P0178X JB12A JB12A 0RF-002 GE CONTROL INTERFACE P301 TB33 TB33-K1 8X029-002 SWITCH KOMVISION REAR P0068X SP061 -
0-033 JB1 JB1 LAMP LED PROPEL LOCKOUT LOCKED... PLLO 0-191 SWITCH LEFT WINDOW P072 GB12 REAR CAB GB12-D2 0-351 KOMTRAX PLUS MODULE P1 JB8A JB8A 0-534 JB12A JB12A - JX07 0RF-003 GE CONTROL INTERFACE P301 TB33 TB33-K3 8X030-000 SP062 - SWITCH KOMVISION REAR P0068X
0-034 LAMP LED STARTER LOCKOUT OPEN SLLO JB1 JB1 0-192 GB12 REAR CAB GB12-D1 SWITCH LEFT WINDOW P072 0-352 ORBCOMM MODULE (OPT) CNA JB8A JB8A 0-535 - PX07_CP GB12 REAR CAB GB12-A3 1M-000 LAMP LED MASTER DISCONNECT OPE... MLLO RELAY MASTER DISCONNECT MLREL_K 8X030-001 SP062 - SWITCH KOMVISION REAR P0068X
0-035 - J01X SP3806 - 0-193 - J607 WIRELESS BRIDGE KWB 0-353 ORBCOMM MODULE (OPT) CNA JB8A JB8A 0-536 ALARM KOMVISION ERROR (ESON) ESON(-) JB12A JB12A 1S-000 LAMP LED STARTER LOCKOUT OPEN SLLO RELAY STARTER LOCKOUT SLREL_K 8X030-002 SWITCH KOMVISION REAR P0068X SP062 -
0-036 - P01X_CP JB10X JB10X 0-194 SWITCH LEFT WINDOW P072 SWITCH LEFT WINDOW P072 0-355 - J808 ENGINE QSK78 INTERFACE P806 0-537 ALARM KOMVISION RADAR (RSON) RSON(-) JB12A JB12A 5EFQ-000 ENGINE QSK78 INTERFACE P805 ENGINE QSK78 INTERFACE P805 8X031-000 SP071 - SWITCH KOMVISION RH REAR P0078X
0-037 - P01X_CP JB10X JB10X 0-195 SWITCH LEFT WINDOW P072 GB12 REAR CAB GB12-D2 0-356 - J808 ENGINE QSK78 INTERFACE P805 0-538 KOMVISION DISPLAY MONITOR P45 JB12A JB12A 5VDI-000 - J02 GE DID PANEL DID 8X031-001 SP071 - SWITCH KOMVISION RH REAR P0078X
0-038 - P01X_CP JB10X JB10X 0-197 SWITCH RIGHT WINDOW P071 GB12 REAR CAB GB12-D1 0-357 GB3 ENG GND BLOCK GB3-A1 SOLENOID A/C COMPRESSOR CLUTCH P803 0-539 JB12A JB12A - J251X_CP 5VDI-001 TB21 TB21-W2 - P02 8X031-002 SP071 - SWITCH KOMVISION RH REAR P0078X
0-039 JB10X JB10X - P09X_CP 0-198 SWITCH RIGHT WINDOW P071 GB12 REAR CAB GB12-C2 0-358 GB3 ENG GND BLOCK GB3-A1 SWITCH A/C RECIEVER DRYER RECDR 0-540 JB12A JB12A - J251X_CP 5VDI-005 DID POWER SUPPLY P500 TB21 TB21-W1 8X032-000 SP072 - SWITCH KOMVISION RH REAR P0078X
0-040 ENGINE PRELUBE HIGH VOLUME PUM... PLPM-(-) GB3 ENG GND BLOCK GB3-B3 0-199 SP195 - LAMP AMBER PAYLOAD RIGHT RPLA_CP 0-359 - J801 - J815 0-541 - J16X SP3809 - 5VDI-009 - J15 - J702 8X032-001 SP072 - SWITCH KOMVISION RH REAR P0078X
0-041 RELAY ENGINE PRELUBE MAG SWITC... PLMS-(-) GB3 ENG GND BLOCK GB3-B1 0-200 GB12 REAR CAB GB12-C2 SWITCH RIGHT WINDOW P071 0-361 TB28 TB28-R2 GB31-B GB31B-C4 0-542 SP3810 - - J16X 5VDI-010 - P15 - RRBPS_CP 8X032-002 SP072 - SWITCH KOMVISION RH REAR P0078X
0-042 RELAY ENGINE PRELUBE P800 RELAY ENGINE PRELUBE MAG SWITC... PLMS-(-) 0-201 SWITCH RIGHT WINDOW P071 SWITCH RIGHT WINDOW P071 0-362 - DIAG4 GB12 REAR CAB GB12-C4 0-543 ETHERNET SWITCH ENET_PWR GB31-A GB31A-E1 5VDI-011 - J15 - J702 8X033-000 SP081 - SWITCH KOMVISION RH FRONT P0088X
0-044 - P09X_CP JB10X JB10X 0-202 - J210 - J04 0-363 SP142 - SP196 - 0-544 SP3811 - - J09X 5VDI-012 - P15 - LRBPS_CP 8X033-001 SP081 - SWITCH KOMVISION RH FRONT P0088X
0-045 JB10X JB10X - P09X_CP 0-203 - P03 GB31-A GB31A-C1 0-364 SP147 - SP195 - 0-545 RADAR 8 KOMVISION J128 - J09X 5VIM-000 TB30 TB30-K1 INTERFACE MODULE IM3 8X033-002 SWITCH KOMVISION RH FRONT P0088X SP081 -
0-046 - J09X - P16X 0-204 - P03 GB31-A GB31A-C1 0-365 PAY LOAD METER 4 P264 GB31-B GB31B-A3 0-546 TB31 TB31-V4 TB31 TB31-L3 5VIM-001 TB30 TB30-K1 INTERFACE MODULE IM3 8X034-000 SP082 - SWITCH KOMVISION RH FRONT P0088X
0-047 - J09X - P16X 0-205 - P03 GB31-A GB31A-C4 0-366 LAMP LED STARTER LOCKOUT CLOSE... SLON JB1 JB1 0-547 R2 R2 GB31-B GB31B-E3 5VIM-002 - J14 TB30 TB30-K2 8X034-001 SP082 - SWITCH KOMVISION RH FRONT P0088X
0-048 RELAY ENG STARTER 1 (ESREL1) ESREL1-85 RELAY ENG STARTER 2 (ESREL2) ESREL2-85 0-206 - P03 GB31-A GB31A-C4 0-367 SP196 - LAMP RED PAYLOAD LEFT LPLR_CP 0-548 JB10X JB10X - P09X_CP 5VIM-003 TB30 TB30-K4 - J14 8X034-002 SWITCH KOMVISION RH FRONT P0088X SP082 -
0-049 - P12 RELAY ENG STARTER 1 (ESREL1) ESREL1-85 0-207 - J03 GB12 REAR CAB GB12-A1 0-368 SP196 - LAMP AMBER PAYLOAD LEFT LPLA_CP 0-550 ETHERNET SWITCH SW_GND GB31-B GB31B-C4 5VIM-004 TB30 TB30-K3 - J14 8X035-000 SP121 - SWITCH KOMVISION CANCEL P0128X
0-050 - J12 SP13 - 0-208 - J03 GB12 REAR CAB GB12-A1 0-369 LAMP GREEN PAYLOAD LEFT LPLG_CP SP196 - 0-565 SP3806 - RADAR 1 KOMVISION J119 5VIM-005 - P14 SENSOR BRAKE TEMP RH REAR P710 8X035-001 SP121 - SWITCH KOMVISION CANCEL P0128X
0-051 GB8 BRAKE CABINET GB8-1 SWITCH PARK BRAKE RELEASE PRES... PBRPS 0-209 - J03 GB12 REAR CAB GB12-B1 0-370 SCORE BOARD RIGHT (OPT) CNRIN SCORE BOARD LEFT (OPT) CNLO 0-566 SP3806 - RADAR 1 KOMVISION J119 5VIM-006 - J14 TB30 TB30-L2 8X035-002 SP121 - SWITCH KOMVISION CANCEL P0128X
0-052 SWITCH LADDER CONTROL P38 GB10 FRT CAB GND GB10-C1 0-210 - J03 GB12 REAR CAB GB12-B1 0-375 TB36 TB36-R4 GB31-B GB31B-A3 0-567 SP3806 - RADAR 1 KOMVISION J119 5VIM-007 - P14 SENSOR DUCT AIR TEMPERATURE ATS 8X036-000 SP122 - SWITCH KOMVISION CANCEL P0128X
0-053 JB12D JB12D SENSOR POWER LADDER UP UPS 0-211 GB12 REAR CAB GB12-A2 - J601_CP 0-376 RELAY WIPER MOTOR HIGH P08_K RELAY HYDRAULIC LADDER PK STAT... P263 0-568 SP3807 - RADAR 2 KOMVISION J122 5VIM-008 - J14 TB30 TB30-L4 8X036-001 SP122 - SWITCH KOMVISION CANCEL P0128X
0-054 RELAY CAB LADDER ALARM CAR_K JB12D JB12D 0-212 GB12 REAR CAB GB12-A2 - J601_CP 0-377 MOTOR WINDSHIELD WASHER WW- - P03 0-569 SP3807 - RADAR 2 KOMVISION J122 5VIM-009 - P14 SENSOR BRAKE TEMP LH REAR P709 8X036-002 SWITCH KOMVISION CANCEL P0128X SP122 -
0-055 - J12 SP12 - 0-213 GB12 REAR CAB GB12-B1 - J602_CP 0-378 RELAY WIPER MOTOR LOW P09_K RELAY WIPER MOTOR HIGH P08_K 0-571 SP3808 - RADAR 3 KOMVISION J123 5VIM-010 - P14 SENSOR BRAKE TEMP RH FRONT P708 8X037-000 SP131 - SWITCH KOMVISION LOCK P0138X
0-056 JB12D JB12D ALARM GROUND LEVEL LADDER GLA 0-214 SP500 - GB31-B GB31B-C3 0-379 - J03 GB12 REAR CAB GB12-C3 0-573 SP3808 - RADAR 3 KOMVISION J123 5VIM-011 - P14 SENSOR BRAKE TEMP LH FRONT P707 8X037-001 SWITCH KOMVISION LOCK P0138X SP131 -
0-057 RELAY CAB LADDER ALARM CAR_K RELAY CAB LADDER ALARM CAR_K 0-215 - P801 GB31-B GB31B-A1 0-380 TIMER WASHER DELAY (WADT) WADT-3 RELAY WIPER MOTOR LOW P09_K 0-577 SP3809 - RADAR 5 KOMVISION J125 5VPL-000 PAY LOAD METER 4 P264 PLM4 COMMUNICATION BOX COMMB 8X037-002 SWITCH KOMVISION LOCK P0138X SP131 -
0-058 RELAY LADDER UP LUR_K JB12D JB12D 0-216 - J12 SP13 - 0-381 RELAY HYDRAULIC LADDER PK STAT... P263 GB10 FRT CAB GND GB10-C3 0-578 SP3809 - RADAR 5 KOMVISION J125 5VUSB-000 PLM4 COMMUNICATION BOX COMMA PAY LOAD METER 4 P264 8X038-000 SP132 - SWITCH KOMVISION LOCK P0138X
0-069 - P808 GB31-B GB31B-C1 0-218 - P12 OIL RESERVE SYS P505_CP 0-382 MOTOR WINDSHIELD WIPER P07 GB10 FRT CAB GND GB10-C3 0-579 SP3809 - RADAR 5 KOMVISION J125 7HMWU-000 ORBCOMM MODULE (OPT) CNA KOMTRAX PLUS MODULE P2A 8X038-001 SP132 - SWITCH KOMVISION LOCK P0138X
0-070 - P808 GB31-B GB31B-C1 0-219 - J12 SP13 - 0-383 12VDC POWER PORT #1 PWR1-2 - J03 0-580 SP3810 - RADAR 6 KOMVISION J126 7M1A1 GE CONTROL CABINET IPT1AX2 MOTOR WHEEL DRIVE # 1 MTR1-TA1 8X038-002 SWITCH KOMVISION LOCK P0138X SP132 -
0-071 - P808 GB31-B GB31B-B4 0-220 - P11 OIL RESERVE SYS P180_CP 0-384 12VDC POWER PORT #2 PWR2-2 - J03 0-581 SP3810 - RADAR 6 KOMVISION J126 7M1A2 GE CONTROL CABINET IPT1AX3 MOTOR WHEEL DRIVE # 1 MTR1-TA2 8X039-000 SP141 - SWITCH KOMVISION FRONT P0148X
0-072 - P808 GB31-B GB31B-B4 0-222 SP09 - - J11 0-385 - P03 GB31-A GB31A-C1 0-583 SP3811 - RADAR 7 KOMVISION J127 7M1B1 GE CONTROL CABINET IPT1BX2 MOTOR WHEEL DRIVE # 1 MTR1-TB1 8X039-001 SP141 - SWITCH KOMVISION FRONT P0148X
0-073 - P808 GB31-B GB31B-D1 0-223 - J11 SP09 - 0-386 - P03 GB31-A GB31A-C4 0-585 SP3811 - RADAR 7 KOMVISION J127 7M1B2 GE CONTROL CABINET IPT1BX3 MOTOR WHEEL DRIVE # 1 MTR1-TB2 8X039-002 SWITCH KOMVISION FRONT P0148X SP141 -
0-074 - P808 GB31-B GB31B-D1 0-225 GB31-B GB31B-D4 - P240 0-387 SP198 - TB24 TB24-X3 0-589 SP3807 - - J01X 7M1C1 GE CONTROL CABINET IPT1CX2 MOTOR WHEEL DRIVE # 1 MTR1-TC1 8X040-000 SP200 - SWITCH KOMVISION FRONT P0148X
0-075 - J11 SP10 - 0-226 - P240 GB31-B GB31B-D4 0-388 R51 R51 TB27 TB27-W4 0-590 - J0178X SP023 - 7M1C2 GE CONTROL CABINET IPT1CX3 MOTOR WHEEL DRIVE # 1 MTR1-TC2 8X040-001 SP200 - SWITCH KOMVISION FRONT P0148X
0-076 - J543 - P11 0-227 - J240 GB8 BRAKE CABINET GB8-1 0-395 - J541 - P11 0-591 SP023 - SWITCH KOMVISION DIM P0028X 7M2A1 GE CONTROL CABINET IPT2AX2 MOTOR WHEEL DRIVE # 2 MTR2-TA1 8X040-002 SWITCH KOMVISION FRONT P0148X SP200 -
0-077 - P520_CP - P543 0-228 - J240 GB8 BRAKE CABINET GB8-1 0-396 - P502 - P541 0-592 SP023 - SP123 - 7M2A2 GE CONTROL CABINET IPT2AX3 MOTOR WHEEL DRIVE # 2 MTR2-TA2 8X041-000 SP203 - SWITCH KOMVISION LH FRONT P0158X
0-078 - J520 SOLENOID ENGINE SHUTTER (OPT) ESSOL 0-229 TB21 TB21-X1 R19 R19 0-397 - P548_CP - J502 0-593 SP123 - SWITCH KOMVISION CANCEL P0128X 7M2B1 GE CONTROL CABINET IPT2BX2 MOTOR WHEEL DRIVE # 2 MTR2-TB1 8X041-001 SP203 - SWITCH KOMVISION LH FRONT P0158X
0-079 VEC RTMR1 RTMR1-C2 GB31-A GB31A-D1 0-230 INTERFACE MODULE IM1 TB21 TB21-X2 0-398 - J540 - P12 0-594 SP123 - SWITCH KOMVISION CANCEL P0128X 7M2B2 GE CONTROL CABINET IPT2BX3 MOTOR WHEEL DRIVE # 2 MTR2-TB2 8X041-002 SWITCH KOMVISION LH FRONT P0158X SP203 -
0-080 - J12 SP13 - 0-231 R18 R18 TB21 TB21-X3 0-399 - P503 - P540 0-595 SP123 - SP033 - 7M2C1 GE CONTROL CABINET IPT2CX2 MOTOR WHEEL DRIVE # 2 MTR2-TC1 8X042-000 SP152 - SWITCH KOMVISION LH FRONT P0158X
0-081 - P12 SP796 - 0-232 TB29 X5 TB29-X5 TB26 M5 TB26-M5 0-400 - P549_CP - J503 0-596 SP033 - SWITCH KOMVISION BODY P0038X 7M2C2 GE CONTROL CABINET IPT2CX3 MOTOR WHEEL DRIVE # 2 MTR2-TC2 8X042-001 SP152 - SWITCH KOMVISION LH FRONT P0158X
0-082 - P542 - ETHER1_CP 0-233 TB26 M5 TB26-M5 GB31-A GB31A-C3 0-401 - J11 SP08 - 0-597 SP033 - SWITCH KOMVISION BODY P0038X 8X001-000 KOMVISION CONTROLLER KVIS-B - J251X_CP 8X042-002 SWITCH KOMVISION LH FRONT P0158X SP152 -
0-083 GB12 REAR CAB GB12-B3 - PTX_CP 0-234 GB31-A GB31A-C3 TB36 TB36-K1 0-402 - J12 SP11 - 0-598 SP033 - SP043 - 8X002-000 - J0178X SWITCH KOMVISION FRONT P0148X 8X043-000 SP204 - SWITCH KOMVISION LH REAR P0168X
0-084 - J11 SP10 - 0-235 TB36 TB36-K1 TB27 TB27-W3 0-403 - J11 SP08 - 0-599 SP043 - SWITCH KOMVISION GRIDLINE P0048X 8X002-001 KOMVISION CONTROLLER KVIS-A - P0178X 8X043-001 SP204 - SWITCH KOMVISION LH REAR P0168X
0-086 - P808 GB31-B GB31B-D3 0-236 - J607 WIRELESS BRIDGE KWB 0-404 - J541 - P11 0-600 SP043 - SWITCH KOMVISION GRIDLINE P0048X 8X003-000 - J0178X SWITCH KOMVISION RH FRONT P0088X 8X043-002 SWITCH KOMVISION LH REAR P0168X SP204 -
0-089 JB12D JB12D POWER LADDER CONTROLLER P7 0-237 RELAY ACCESS LADDER LIGHT (ALL... ALLR-85 GB31-A GB31A-A4 0-405 - P502 - P541 0-601 GB31-A GB31A-D4 TB31 TB31-L3 8X003-001 KOMVISION CONTROLLER KVIS-A - P0178X 8X044-000 SP162 - SWITCH KOMVISION LH REAR P0168X
0-090 - P140 GB10 FRT CAB GND GB10-A4 0-238 TB24 TB24-X1 TB21 TB21-X4 0-406 MIRROR HEATED RIGHT DECK MIRROR1 - J502 0-602 SP053 - SWITCH KOMVISION MODE P0058X 8X004-000 - J0178X SWITCH KOMVISION RH REAR P0078X 8X044-001 SP162 - SWITCH KOMVISION LH REAR P0168X
0-091 GB31-A GB31A-B4 - P04 0-239 GB8 BRAKE CABINET GB8-3 D3 D3 0-407 - J12 SP11 - 0-603 SP053 - SWITCH KOMVISION MODE P0058X 8X004-001 KOMVISION CONTROLLER KVIS-A - P0178X 8X044-002 SWITCH KOMVISION LH REAR P0168X SP162 -
0-093 RELAY GROUND LEVEL ALARM GLAR_K JB12D JB12D 0-240 - J16 SP15 - 0-408 - J540 - P12 0-604 SP053 - SP063 - 8X005-000 - J0178X SWITCH KOMVISION REAR P0068X 8X045-000 SP091 - INDICATOR KOMVISION POWER P0098X
0-094 - J12 SP12 - 0-241 - J16 SP15 - 0-409 - P503 - P540 0-605 SP063 - SWITCH KOMVISION REAR P0068X 8X005-001 KOMVISION CONTROLLER KVIS-A - P0178X 8X045-001 SP091 - INDICATOR KOMVISION POWER P0098X
0-095 GB10 FRT CAB GND GB10-A4 SWITCH BRAKE LOCK P39 0-242 SP15 - - J16 0-410 MIRROR HEATED LEFT DECK MIRROR2 - J503 0-606 SP063 - SWITCH KOMVISION REAR P0068X 8X006-000 - J0178X SWITCH KOMVISION LH REAR P0168X 8X045-002 - J0178X SP091 -
0-096 SWITCH BRAKE LOCK P39 SWITCH BRAKE LOCK P39 0-243 - P16 SP901 - 0-411 SWITCH ROTATING BEACON (OPT) P32 GB10 FRT CAB GND GB10-D2 0-607 SP063 - SP073 - 8X006-001 KOMVISION CONTROLLER KVIS-A - P0178X 8X045-003 KOMVISION CONTROLLER KVIS-B - P0178X
0-097 SWITCH BRAKE LOCK P39 SWITCH BRAKE LOCK P39 0-244 - P16 SP902 - 0-412 GB10 FRT CAB GND GB10-D2 SWITCH HEATED MIRROR P33 0-608 SP073 - SWITCH KOMVISION RH REAR P0078X 8X007-000 - J0178X SWITCH KOMVISION LH FRONT P0158X 8X046-000 KOMVISION CONTROLLER KVIS-B KOMVISION DISPLAY MONITOR P44
0-098 SOLENOID BRAKE LOCK BLS GB8 BRAKE CABINET GB8-3 0-245 - P16 SP903 - 0-413 GB31-A GB31A-C2 SP12 - 0-609 SP073 - SWITCH KOMVISION RH REAR P0078X 8X007-001 KOMVISION CONTROLLER KVIS-A - P0178X 8X047-000 KOMVISION CONTROLLER KVIS-B ALARM KOMVISION RADAR (RSON) RSON(+)
0-099 - P210 ENTERTAINMENT RADIO P737 0-248 HORN BACKUP LEFT LRBH-(-) SP903 - 0-414 GB31-A GB31A-D2 SP13 - 0-610 SP083 - SP073 - 8X008-000 - J0178X SWITCH KOMVISION MODE P0058X 8X048-000 KOMVISION CONTROLLER KVIS-B ALARM KOMVISION ERROR (ESON) ESON(+)
0-100 SWITCH HEADLIGHTS P25 SWITCH HEADLIGHTS P25 0-249 HORN BACKUP RIGHT RRBH-(-) SP903 - 0-415 GB31-B GB31B-B2 SP15 - 0-611 SP083 - SWITCH KOMVISION RH FRONT P0088X 8X008-001 KOMVISION CONTROLLER KVIS-A - P0178X 8X049-002 KOMVISION CONTROLLER KVIS-B RELAY RADAR POWER (RPR) RPR_K
0-101 SWITCH CAB LADDER LIGHT P24 SWITCH MANUAL BACKUP LIGHT P23 0-251 LAMP BACKUP RIGHT REAR RRBL SP901 - 0-416 GB31-B GB31B-C2 SP08 - 0-612 SP083 - SWITCH KOMVISION RH FRONT P0088X 8X009-000 - J0178X SWITCH KOMVISION GRIDLINE P0048X 8X050-000 - P02 TB25 TB25-P1
0-102 LAMP RIGHT FOG RFLT - P543 0-252 LAMP BACKUP LEFT REAR LRBL SP901 - 0-417 GB31-B GB31B-D2 SP09 - 0-613 SP013 - SP083 - 8X009-001 KOMVISION CONTROLLER KVIS-A - P0178X 8X050-001 - J02 - PX07_CP
0-103 - J543 - P11 0-253 LAMP RETARD LEFT REAR LRL SP902 - 0-418 SP799 - SWITCH STEERING BLEED PRESSURE SABS 0-614 DID POWER SUPPLY P500 GB31-B GB31B-B3 8X010-000 - J0178X SWITCH KOMVISION BODY P0038X 8X050-002 RELAY RADAR POWER (RPR) RPR_K - JX07
0-104 - J11 SP09 - 0-254 SP902 - LAMP RETARD RIGHT REAR RRL 0-419 SP799 - D88 D88 0-615 SP013 - SWITCH KOMVISION BRIGHT P0018X 8X010-001 KOMVISION CONTROLLER KVIS-A - P0178X 8X050-003 TB25 TB25-P2 VEC RTMR1 RTMR1-C9
0-105 LAMP LEFT FOG LFLT - P542 0-255 - J11 SP08 - 0-420 SP09 - - J11 0-616 SP3808 - - J01X 8X011-000 - J0178X SWITCH KOMVISION CANCEL P0128X 8X073-000 SP222 - KOMVISION CONTROLLER NTSC1
0-106 - J542 - P12 0-256 - J541 - P11 0-421 SP08 - - J11 0-617 SP093 - SP013 - 8X011-001 KOMVISION CONTROLLER KVIS-A - P0178X 8X073-001 SP105 - - JX10
0-107 SP400 - JB12D JB12D 0-257 - P502 - P541 0-422 SP11 - - J12 0-618 SP093 - INDICATOR KOMVISION POWER P0098X 8X012-000 - J0178X SWITCH KOMVISION LOCK P0138X 8X073-002 SP090 - CAMERA 1 CAM1
0-108 JB12D JB12D SENSOR POWER LADDER DOWN DPS 0-258 LAMP BACKUP RIGHT DECK (OPT) RBUL - J502 0-423 - J14 SP14 - 0-619 SP133 - SP093 - 8X012-001 KOMVISION CONTROLLER KVIS-A - P0178X 8X073-003 SP243 - - PX10_CP
0-110 - J542 - P12 0-259 LAMP BACKUP LEFT DECK (OPT) LBUL - J503 0-424 - J12 SP12 - 0-620 SP133 - SWITCH KOMVISION LOCK P0138X 8X013-000 - J0178X SP024 - 8X074-000 KOMVISION CONTROLLER NTSC1 SP223 -
0-111 LAMP HIGH MOUNT LEFT HI-BEAM HMLHB - P542 0-260 JB6C JB6C SHIFTER DIRECTION SELECTOR P108 0-425 - J12 SP12 - 0-621 SP133 - SWITCH KOMVISION LOCK P0138X 8X013-001 SP024 - SWITCH KOMVISION DIM P0028X 8X074-001 - JX11 SP099 -
0-112 - J542 - P12 0-261 - P503 - P540 0-426 - J12 SP11 - 0-622 SP201 - SP133 - 8X013-002 SP024 - SP124 - 8X074-002 SP088 - CAMERA 2 CAM2
0-113 LAMP LOW MOUNT LEFT LOW-BEAM LMLLB - P542 0-262 - J540 - P12 0-427 - P04 GB31-A GB31A-B4 0-623 SP201 - SWITCH KOMVISION FRONT P0148X 8X013-003 SP124 - SWITCH KOMVISION CANCEL P0128X 8X074-003 SP240 - - PX11_CP
0-114 - J542 - P12 0-263 - J12 SP11 - 0-428 - J04 - RRBB2 0-624 SP201 - SWITCH KOMVISION FRONT P0148X 8X013-004 SP124 - SP034 - 8X075-000 KOMVISION CONTROLLER NTSC1 SP189 -
0-115 - P543 LAMP LOW MOUNT RIGHT LOW-BEAM LMRLB 0-264 SP902 - LAMP STOP/TAIL LEFT LRSTL 0-429 - ETHER2 SOLENOID ETHER START (OPT) ESOL 0-625 SP153 - SP201 - 8X013-005 SP034 - SWITCH KOMVISION BODY P0038X 8X075-001 SP097 - - JX12
0-116 - J543 - P11 0-265 LAMP STOP/TAIL RIGHT RRSTL SP902 - 0-430 SP799 - SOLENOID HOIST LIMIT HS 0-626 SP153 - SWITCH KOMVISION LH FRONT P0158X 8X013-006 SP034 - SP044 - 8X075-002 SP232 - - PX12_CP
0-117 - P542 LAMP HIGH MOUNT LEFT LOW-BEAM HMLLB 0-266 JB6C JB6C GB12 REAR CAB GB12-D3 0-432 - J16 GB31-A GB31A-D3 0-627 SP153 - SWITCH KOMVISION LH FRONT P0158X 8X013-007 SP044 - SWITCH KOMVISION GRIDLINE P0048X 8X075-003 SP085 - CAMERA 3 CAM3
0-118 - J542 - P12 0-267 TB24 TB24-X1 TB27 TB27-W3 0-433 - P16 - P72 0-628 SP163 - SP153 - 8X013-008 SP044 - SP054 - 8X076-000 KOMVISION CONTROLLER NTSC1 SP224 -
0-119 - J543 - P11 0-268 SWITCH FOG LAMP (OPT) P22 SWITCH MANUAL BACKUP LIGHT P23 0-434 - J12 GB31-A GB31A-D3 0-629 SP163 - SWITCH KOMVISION LH REAR P0168X 8X013-009 SP054 - SWITCH KOMVISION MODE P0058X 8X076-001 SP258 - - JX13
0-120 - P543 LAMP HIGH MOUNT RIGHT LOW-BEAM HMRLB 0-269 SWITCH MANUAL BACKUP LIGHT P23 SWITCH MANUAL BACKUP LIGHT P23 0-435 - P12 - J540 0-630 SP163 - SWITCH KOMVISION LH REAR P0168X 8X013-010 - P0178X JB8C JB8C 8X076-002 SP103 - - PX13_CP
0-121 LAMP LOW MOUNT LEFT HI-BEAM LMLHB - P542 0-270 - J14 SP14 - 0-436 - P540 - P503 0-631 - J563 SP713 - 8X013-011 KOMVISION CONTROLLER KVIS-B JB8C JB8C 8X076-003 SP128 - CAMERA 4 CAM4
0-122 - P11 - J543 0-271 - P563_CP - P14 0-437 - J503 - LDML_CP 0-632 SP713 - LAMP HYD TANK SERVICE HSL 8X013-012 SP054 - SP064 - 8X077-000 KOMVISION CONTROLLER NTSC1 SP226 -
0-123 - P543 LAMP HIGH MOUNT RIGHT HI-BEAM HMRHB 0-276 - J540 - P12 0-438 - J11 GB31-A GB31A-D3 0-633 SP713 - LAMP FUEL TANK SERVICE FSL 8X013-013 SP064 - SWITCH KOMVISION REAR P0068X 8X077-001 SP096 - - JX14
0-124 - P11 - J543 0-277 LAMP LEFT UPPER ENGINE SERVICE LUESL - P540 0-439 - J541 - P11 0-636 RADAR 4 KOMVISION J124 - J01X 8X013-014 SP064 - SP074 - 8X077-002 SP197 - - PX14_CP
0-125 - P543 LAMP LOW MOUNT RIGHT HI-BEAM LMRHB 0-279 - J540 - P12 0-440 - P541 - P502 0-637 - P01X_CP JB10X JB10X 8X013-015 SP074 - SWITCH KOMVISION RH REAR P0078X 8X077-003 SP127 - CAMERA 5 CAM5
0-126 - J11 SP10 - 0-280 LAMP LEFT LOWER ENGINE SERVICE LLESL - P540 0-441 - RDML_CP - J502 0-674 SP043 - SP053 - 8X013-016 SP074 - SP084 - 8X078-000 KOMVISION CONTROLLER NTSC1 SP228 -
0-127 - J11 SP09 - 0-282 - J541 - P11 0-442 - J72 - RBML2_CP 0-676 SOLENOID HYDRAULIC LADDER LSOL SP400 - 8X013-017 SP084 - SWITCH KOMVISION RH FRONT P0088X 8X078-001 SP094 - - JX15
0-128 - J12 SP12 - 0-283 LAMP RIGHT UPPER ENGINE SERVIC... RUESL - P541 0-444 LAMP HYDRAULIC CABINET #2 HL2 GB8 BRAKE CABINET GB8-4 0-677 D7 D7 SP400 - 8X013-018 SP014 - SP084 - 8X078-002 SP118 - - PX15_CP
0-129 - J12 SP12 - 0-285 SP165 - - P11 0-445 GB8 BRAKE CABINET GB8-4 LAMP HYDRAULIC CABINET #1 HL1 0-688 JB12D JB12D - J538 8X013-019 SP014 - SWITCH KOMVISION BRIGHT P0018X 8X078-003 SP125 - CAMERA 6 CAM6
0-130 SP10 - GB31-A GB31A-A2 0-286 - J541 SP165 - 0-446 TB31 TB31-G3 TB29 TB29-X4 0-689 - P830 - J538B 8X013-020 - J251X_CP JB8C JB8C 10V-000 GE CONTROL INTERFACE P303 TB31 TB31-M1
0-131 SP11 - GB31-A GB31A-B2 0-287 - P541 LAMP RIGHT LOWER ENGINE SERVIC... RLESL 0-447 TB30 TB30-B2 TB28 TB28-R2 0-690 - J46 GB31-A GB31A-D1 8X013-021 SP134 - SP014 - 10V-001 - P02 TB31 TB31-M2
0-132 SWITCH HAZARD LIGHTS P36 SWITCH BRAKE TEST P37 0-288 SWITCH RIGHT ENGINE SERVICE LA... RESLS-1 SP165 - 0-448 RELAY MASTER DISCONNECT MLREL_K JB1 JB1 0-698 SP006 - - P58_JP 8X013-022 SP134 - SWITCH KOMVISION LOCK P0138X 10V-003 - J01 ACCELERATOR PEDAL P236
0-133 SWITCH HAZARD LIGHTS P36 SWITCH HAZARD LIGHTS P36 0-289 SWITCH AUTOLUBE PRESSURE LLPS SP903 - 0-450 SP796 - - J542 0-699 SP006 - - J730 8X013-023 SP202 - SP134 - 10V-004 - J01 RETARD CONTROL PEDAL P235
0-134 - J12 SP11 - 0-290 - J540 - P12 0-451 SWITCH LADDER CONTROL P38 SWITCH LADDER CONTROL P38 0-700 SP199 - PAY LOAD METER 4 P264 8X013-024 SP202 - SWITCH KOMVISION FRONT P0148X 10V-005 - J01 - P237
0-135 - J11 SP08 - 0-291 - P503 - P540 0-460 SP717 - - J55 0-701 SP199 - TB24 TB24-X2 8X013-025 SP154 - SP202 - 10V-006 - J02 RETARD SPEED CONTROL RSP
0-136 - P12 - J540 0-292 - J503 SP168 - 0-461 SP717 - LAMP BODY RIGHT SIDE MARKER RSCL1 0-713 - JX07 RELAY RADAR POWER (RPR) RPR_K 8X013-026 KOMVISION CONTROLLER KVIS-B JB8C JB8C 10V-007 TB31 TB31-N3 R17 R17
0-137 - P540 - P503 0-293 HORN FRONT VEHICLE AHS SP168 - 0-462 LAMP BODY RIGHT REAR MARKER RSCL2 SP717 - 0-714 GB12 REAR CAB GB12-A4 JB10X JB10X 8X013-027 SP014 - SWITCH KOMVISION BRIGHT P0018X 10V-008 TB31 TB31-M4 - P01
0-138 - J503 SP142 - 0-294 D1 D1 SP168 - 0-463 SP717 - LAMP BODY RIGHT SIDE TURN RSTL 0-716 GB12 REAR CAB GB12-A3 - PX07_CP 8X013-028 KOMVISION DISPLAY MONITOR P44 JB8C JB8C 10V-009 TB31 TB31-N2 - P01
0-139 SP142 - LAMP MARKER/TURN LEFT SIDE DEC... LCL1 0-300 SP903 - - P55 0-464 SP720 - - P54 0-717 - P815 SWITCH ENGINE RUN OIL PRESSURE... EOPS 8X013-029 KOMVISION DISPLAY MONITOR P45 JB8C JB8C 10V-010 TB31 TB31-N4 - P01
0-140 SP142 - LAMP MARKER/TURN LEFT FRT DECK LCL2 0-301 SP901 - - J54 0-465 SP720 - LAMP BODY LEFT SIDE TURN LSTL 0-718 - J58 SWITCH HYDRAULIC ACC FILTER HAFSW 8X013-030 - JX07 JB8C JB8C 10V-011 - J237 RETARD LEVER SENSOR (OPT) P814
0-141 - P11 - J541 0-308 JB6C JB6C MOTOR, PASSENGER SEAT J229 0-466 SP720 - LAMP BODY LEFT SIDE MARKER LSCL1 0-719 GB12 REAR CAB GB12-B2 - CAN_TP 8X013-031 - J02 - PX07_CP 11-004 24VDC BUS 24VDC-C2 RELAY KEY SWITCH (KSWPR) KSWPR-88
0-142 - P541 - P502 0-309 JB6C JB6C MOTOR, DRIVERS SEAT J228 0-467 LAMP BODY LEFT REAR MARKER LSCL2 SP720 - 0-753 - P607 - P606 8X013-032 SP154 - SWITCH KOMVISION LH FRONT P0158X 11-005 24VDC BUS 24VDC-C4 RELAY KEY/GE CNTRL PWR (KCNPR) KCNPR-88
0-143 - J502 SP147 - 0-310 JB6C JB6C SWITCH CAB SECONDARY ENGINE SH... ESS-B 0-490 SP797 - - J1206 0-754 - P607 - P606 8X013-033 SP154 - SWITCH KOMVISION LH REAR P0168X 11-006 CB60 CB60-1 24VDC BUS 24VDC-C3
0-144 SP147 - LAMP MARKER/TURN RIGHT FRT DEC... RCL1 0-311 JB6C JB6C SWITCH BODYUP OVERRIDE / RESET... ORS-B 0-491 SP797 - SWITCH HEDWELD LIMIT - 0-755 - J606 SP500 - 8X013-034 - P02 TB25 TB25-S1 11-007 FUSE HOLDER AUX (FH2) FH2-2 24VDC BUS 24VDC-A1
0-145 SP147 - LAMP MARKER/TURN RIGHT SIDE DE... RCL2 0-312 SWITCH RETARD SPEED CONTROL (R... RSCS_1-3 GB12 REAR CAB GB12-D4 0-492 SP797 - SWITCH HEDWELD LIMIT - 0-756 - J606 SP500 - 8X013-035 TB25 TB25-S2 SWITCH KOMVISION ON/OFF KOMV-3 11-008 ENGINE JUMP START1 - BUSS BAR 24VDC BATT BOX BUS24V-2
0-146 - J16 SP15 - 0-313 - J02 RETARD SPEED CONTROL RSP 0-493 SP246 - - J543 0ACL-000 - J01 ACCELERATOR PEDAL P236 8X016-000 - J0178X SWITCH KOMVISION BRIGHT P0018X 11-009 ENGINE JUMP START2 - BUSS BAR 24VDC BATT BOX BUS24V-3
58B-06-02261-00 SEP 15
980E-4
A40003 & UP
Sheet 20 of 24
WIRE TABLE CONTINUED FROM DIAGRAM 20, 22 & 23
11-010 24VDC BUS 24VDC-B1 VEC-90 VEC90-P2 11RB-001 - P03 TB22 TB22-E1 21ORR-004 - P11 - P170_CP 33J-002 SOLENOID STEERING BLEED DOWN ACCBD SP184 - 39FA-002 - P16 SP236 - 44-003 - P16 SP229 -
11-011 24VDC BUS 24VDC-B4 VEC-91 VEC91-S5A 11RB-002 TB22 TB22-E2 - J11 21ORR-005 - J12 TB27 TB27-L3 33J-003 D26 D26 SP184 - 39FA-004 SENSOR PAYLOAD PRESSURE RIGHT ... P153 SP236 - 44-004 SP229 - LAMP STOP/TAIL LEFT LRSTL
11-012 24VDC BUS 24VDC-B2 VEC-89 VEC89-S8A 11RB-003 - J12 TB22 TB22-E4 21PL-000 RELAY ENGINE PRELUBE P800 RELAY ENGINE PRELUBE MAG SWITC... PLMS-(+) 33J-004 SP800 - VEC-89 VEC89-P1 39FB-000 TB36 TB36-D2 PAY LOAD METER 4 P264 44-005 SP229 - LAMP STOP/TAIL RIGHT RRSTL
11-013 24VDC ALTERNATOR ALT_SEN BUSS BAR 24VDC BATT BOX BUS24V-9 11RB-004 TB22 TB22-E3 - P04 21PL-001 D87 D87 RELAY ENGINE PRELUBE MAG SWITC... PLMS-(+) 33J-005 R2 R2 SP800 - 39FB-001 TB36 TB36-D1 - J16 44-006 - J04 LAMP SERVICE BRAKE OP-CAB SBL
11-014 VEC RTMR1 RTMR1-F9 24VDC BUS 24VDC-C1 11RB-005 - P11 - J541 21PS-000 VEC-91 VEC91-P3 TB28 TB28-H1 33JA-000 - P14 SWITCH STEERING BLEED PRESSURE SABS 39FB-002 - P16 SP234 - 44D-000 TB35 TB35-H1 VEC-89 VEC89-P1
11-015 VEC RTMR1 RTMR1-A10 24VDC BUS 24VDC-D1 11RB-006 - J540 - P12 21PS-001 TB28 TB28-H2 - P801 33JA-001 - J14 INTERFACE MODULE IM2 39FB-003 SENSOR PAYLOAD PRESSURE LEFT R... P152 SP234 - 44D-001 TB35 TB35-H2 - J16
11-017 24VDC BUS 24VDC-B3 VEC-91 VEC91-P1 11RB-007 - P541 - P502 21PS-003 SP108 - - P815 33JB-000 INTERFACE MODULE IM1 TB30 TB30-D1 39FC-000 PAY LOAD METER 4 P264 TB36 TB36-A2 44D-002 TB35 TB35-H4 - P04
11-027 FUSE HOLDER ALT (FH1) FH1-1 24VDC ALTERNATOR ALT(+) 11RB-008 - P503 - P540 21PS-004 SWITCH ENGINE PRELUBE OIL PRES... PLPSW SP108 - 33JB-001 TB30 TB30-D4 - J14 39FC-001 TB36 TB36-A1 - J13 44D-003 - P16 SP230 -
11A-000 VEC-91 VEC91-P4 TB35 TB35-B3 11RB-009 - J502 - P548_CP 21PS-005 SP108 - RELAY ENGINE PRELUBE P800 33JB-002 - P14 SP183 - 39FC-003 - P13 SENSOR PAYLOAD PRESSURE RIGHT ... P150 44D-004 - J04 LAMP RETARD OP-CAP DRL
11A-001 TB35 TB35-A1 RELAY VEHICLE HORN POWER (HPR) HPR-88 11RB-010 - P549_CP - J503 21PS-006 - J801 - J815 33JB-003 SOLENOID STEERING BLEED DOWN ACCBD SP183 - 39FD-000 PAY LOAD METER 4 P264 TB36 TB36-B2 44D-005 SP230 - LAMP RETARD LEFT REAR LRL
11A-002 TB35 TB35-A2 - J16 11RB-011 - J04 - RRBB1 21PT-000 - P12 RELAY ENG STARTER 1 (ESREL1) ESREL1-86 33JB-004 D26 D26 SP183 - 39FD-001 TB36 TB36-B1 - J13 44D-006 SP230 - LAMP RETARD RIGHT REAR RRL
11A-003 TB35 TB35-B2 - P240 11RCNT-000 VEC-91 VEC91-P4 TB28 TB28-L1 21PT-001 - J12 TB28 TB28-J1 33JB-005 R19 R19 TB30 TB30-D2 39FD-003 - P13 SENSOR PAYLOAD PRESSURE LEFT F... P151 44R-001 TB35 TB35-F4 INTERFACE MODULE IM3
11A-004 TB35 TB35-B4 - P02 11RCNT-001 TB28 TB28-L1 - J12 21PT-003 SWITCH ENGINE PRELUBE OIL PRES... PLPSW SP107 - 33LF-000 - P13 SENSOR LEFT FRONT WHEEL SPEED P507 39G-000 VEC-90 VEC90-P2 TB34 TB34-T1 44R-003 TB35 TB35-F3 VEC-89 VEC89-P11
11A-008 - J240 SWITCH HYDRAULIC LAMP HLSW-2 11RCNT-002 - P12 OIL RESERVE SYS P505_CP 21PT-004 SP107 - RELAY ENGINE PRELUBE P800 33LF-001 TB33 TB33-R2 - J13 39G-001 TB34 TB34-T2 PAY LOAD METER 4 P264 44R-004 - J240 SWITCH SERVICE BRAKE PSI SBPS
11A-011 RELAY VEHICLE HORN POWER (HPR) HPR-88 RELAY VEHICLE HORN POWER (HPR) HPR-86 11RCNT-003 - J11 TB28 TB28-L1 21PT-005 SP107 - RELAY ENGINE PRELUBE P800 33LF-002 TB33 TB33-R1 GE CONTROL INTERFACE P301 39H-000 SWITCH BRAKE LOCK P39 - J03 44R-005 - P240 TB35 TB35-F1
11A-012 - DIAG4 - J02 11RCNT-004 - P11 OIL RESERVE SYS P180_CP 21PT-006 - P815 SP107 - 33LF-003 TB33 TB33-R4 - P57_CP 39H-001 - P03 TB23 TB23-A2 45L-000 SWITCH COMBO P121 TB10 TB10-J1
11A1-000 SWITCH HYDRAULIC LAMP HLSW-1 SP171 - 11RWL ACTIA DASH DISPLAY P902 - J01 21PT-007 - P801 TB28 TB28-J3 33PG-000 - J15 - J702 39H-002 - J702 TB23 TB23-A1 45L-001 TB10 TB10-J1 - J03
11A1-001 LAMP HYDRAULIC CABINET #1 HL1 SP171 - 11RWL-001 - P01 TB35 TB35-P1 21PT-009 RELAY ENG STARTER 1 (ESREL1) ESREL1-86 RELAY ENG STARTER 2 (ESREL2) ESREL2-86 33PG-001 - P15 - RRBPS_CP 39H1-000 - J702 TB22 TB22-X2 45L-002 D4 D4 TB10 TB10-J1
11A1-002 SP171 - LAMP HYDRAULIC CABINET #2 HL2 11RWL-002 TB35 TB35-P2 INTERFACE MODULE IM1 21PT-010 INTERFACE MODULE IM3 TB28 TB28-J1 33PG-002 - J15 - J702 39H1-001 TB22 TB22-X1 PAY LOAD METER 4 P264 45L-003 - P03 TB22 TB22-P1
11B1-000 12VDC CONVERTER (12VCN) 12VCN-12VB TB24 TB24-L1 11S-000 VEC-90 VEC90-P3 - J46 21PT-011 - J801 - J815 33PG-003 - P15 - LRBPS_CP 39HA-000 SWITCH BRAKE LOCK P39 - J03 45L-004 TB22 TB22-P2 VEC-89 VEC89-P12
11B1-001 12VDC CONVERTER (12VCN) 12VCN-12VA 12V POWER RELAY (12VPR) 12VPR-88 11S-003 - P46 - P536 21PT-012 D87 D87 SP107 - 33PLR-000 - J15 - J702 39HA-001 - P03 TB23 TB23-V2 45LL-000 TB35 TB35-J1 VEC-89 VEC89-P12
11B1-002 TB24 TB24-L4 VEC-91 VEC91-P10 11S-004 - J536 SWITCH GROUND LEVEL SHUTDOWN (... ESDS-2 21S-000 SWITCH KEY (KEYSW) KEYSW-C - J03 33PLR-001 - P15 - LRBPS_CP 39HP-000 SWITCH HYDRAULIC FILTER #2 HFSW2 SWITCH HYDRAULIC FILTER #1 HFSW1 45LL-001 TB35 TB35-J2 - J12
11B1-003 TB24 TB24-L3 INTERFACE MODULE IM3 11SL-000 VEC-91 VEC91-P4 TB24 TB24-A1 21S-001 - P03 TB22 TB22-H1 33PRR-000 - J15 - J702 39HP1-000 - P58_JP - P16 45LL-002 - P12 - J540
11B1-004 VEC RTMR1 RTMR1-D9 TB24 TB24-L2 11SL-001 TB24 TB24-A1 TIMER (1HR) ENGINE SERVICE LAM... ESLT-C 21S-002 TB22 TB22-H4 VEC-91 VEC91-P2 33PRR-001 - P15 - RRBPS_CP 39HP1-001 - J16 INTERFACE MODULE IM3 45LL-003 - P540 - P503
11B5-000 CB60 CB60-2 12VDC CONVERTER (12VCN) 12VCN-24VA 11SL-002 TB24 TB24-A1 TIMER (1HR) HYDRAULIC PUMP MOD... HPLT-C 21S-003 TB22 TB22-H2 INTERFACE MODULE IM2 33RF-000 - P13 SENSOR RIGHT FRONT WHEEL SPEED P501 39HP1-002 - J58 SWITCH HYDRAULIC ACC FILTER HAFSW 45LL-004 - J503 SP144 -
11CAM-000 JB8B JB8B - JX07 11SM1-001 - P801 TB28 TB28-F1 21SL-000 VEC-91 VEC91-P4 INTERFACE MODULE IM1 33RF-001 - J13 TB33 TB33-L2 39L-000 BRAKE FILTER PRESS SW BFSW - SFSW_JP 45LL-005 ACTIA DASH DISPLAY P902 - J01
11CAM-001 JB8B JB8B KOMVISION DISPLAY MONITOR P45 11SM1-002 TB28 TB28-F2 INTERFACE MODULE IM3 22C-005 - P808 TB27 TB27-G1 33RF-002 GE CONTROL INTERFACE P301 TB33 TB33-L1 39SP-000 SWITCH STEERING FILTER #1 SFSW SWITCH HYDRAULIC FILTER #2 HFSW2 45LL-006 - P01 TB35 TB35-J3
11CAM-002 KOMVISION CONTROLLER KVIS-B JB8B JB8B 11SM1-003 - J801 MOTOR STARTER 1 (STRT1) STRT1-4B- 22C-006 - J808 JB41 JB41 33RF-003 TB33 TB33-L4 - P56_CP 41H-000 SWITCH COMBO P121 TB10 TB10-K1 45LL-007 TB35 TB35-J2 - J14
11CAM-003 KOMVISION CONTROLLER KVIS-B JB8B JB8B 11SM2-001 - P801 TB28 TB28-G1 22C-007 SWITCH A/C RECIEVER DRYER RECDR JB41 JB41 33RR-000 - J02 SWITCH RETARD SPEED CONTROL (R... RSCS_1-2 41H-001 - P03 TB34 TB34-B1 45LL-008 TB35 TB35-J4 - J16
11CAM-004 KOMVISION CONTROLLER KVIS-B JB8B JB8B 11SM2-002 TB28 TB28-G2 INTERFACE MODULE IM3 22C-008 ENGINE QSK78 INTERFACE P806 JB41 JB41 33RR-001 SWITCH RETARD SPEED CONTROL (R... RSCS_1-2 SWITCH RETARD SPEED CONTROL (R... RSCS_1-4 41H-002 TB34 TB34-B2 RELAY HI-BEAM HEADLIGHT (HBHR) HBHR-86 45LL-009 SP144 - LAMP MARKER/TURN LEFT SIDE DEC... LCL1
11CAM-005 KOMVISION CONTROLLER KVIS-B JB8B JB8B 11SM2-003 - J801 MOTOR STARTER 2 (STRT2) STRT2-4A- 22C-009 ENGINE QSK78 INTERFACE P805 JB41 JB41 33RR-002 - P02 TB31 TB31-F2 41H-004 TB10 TB10-K1 - J03 45LL-010 SP144 - LAMP MARKER/TURN LEFT FRT DECK LCL2
11CAM-006 - PX07_CP - J02 11ST-000 BUSS_BAR_11ST SDISC-4 FUSE LINK1 (300A) FUS-1 22FO-001 - P808 TB31 TB31-X1 33RR-003 GE CONTROL INTERFACE P303 TB31 TB31-F1 41H-006 TB10 TB10-K3 ACTIA DASH DISPLAY P902 45LL-011 - P14 - P732_CP
11CAM-007 JB8B JB8B - J251X_CP 11ST-001 BUSS_BAR_11ST SDISC-3 MOTOR STARTER 1 (STRT1) STRT1-1A 22FO-002 - J808 ENGINE QSK78 INTERFACE P806 33RS-000 RETARD SPEED CONTROL RSP SWITCH RETARD SPEED CONTROL (R... RSCS_1-1 41HB-000 RELAY HI-BEAM HEADLIGHT (HBHR) HBHR-88A TB34 TB34-F1 45LL-012 - P16 - J54
11CAM-008 - P02 TB25 TB25-R1 11ST-002 BUSS_BAR_11ST SDISC-5 MOTOR STARTER 2 (STRT2) STRT2-1A 23F-000 - J702 TB22 TB22-L1 33SBA-000 TB25 TB25-W1 GE CONTROL INTERFACE P305 41HB-001 - J12 TB34 TB34-F2 45LL-017 LAMP BODY LEFT SIDE TURN LSTL - P54
11CAM-009 TB25 TB25-R2 SWITCH KOMVISION ON/OFF KOMV-6 11ST-003 MOTOR STARTER 1 (STRT1) STRT1-1C MOTOR STARTER 2 (STRT2) STRT2-1B 23F-001 TB22 TB22-L2 - P02 33SBA-001 TB25 TB25-W2 - P03 41HB-002 - J12 TB34 TB34-F2 45LR-002 D4 D4 SWITCH HAZARD LIGHTS P36
11CMX-000 VEC RTMR1 RTMR1-E9 SWITCH KOMVISION ON/OFF KOMV-5 11ST-005 BUSS_BAR_11ST SDISC-8 RELAY STARTER LOCKOUT SLREL_K 23F-002 - J02 SWITCH CAB SECONDARY ENGINE SH... ESS_1-3 33SBA-002 - J03 SWITCH BRAKE TEST P37 41HB-003 - J11 TB34 TB34-F4 45LR-007 SWITCH HAZARD LIGHTS P36 SWITCH HAZARD LIGHTS P36
11D-000 TB22 TB22-A1 VEC-89 VEC89-P2 11ST-006 LAMP LED STARTER LOCKOUT CLOSE... SLON BUSS_BAR_11ST SDISC-8 23FA-000 VEC-90 VEC90-P4 - J702 33SBA-003 SWITCH BRAKE TEST P37 SWITCH BRAKE TEST P37 41HB-004 - J11 TB34 TB34-F4 45R-000 SWITCH COMBO P121 TB10 TB10-M1
11D-001 TB22 TB22-A2 - P03 12CA-000 POWER LADDER CONTROLLER P7 RELAY CAB LADDER ALARM CAR_K 24CAM-000 JB12B JB12B KOMVISION CONTROLLER NTSC1 33SP-000 INTERFACE MODULE IM3 TB30 TB30-T1 41HB-005 - J542 - P12 45R-001 TB10 TB10-M1 - J03
11D-002 - J03 SWITCH HEADLIGHTS P25 12DP-000 SP454 - POWER LADDER CONTROLLER P7 24CAM-001 - JX10 CAMERA 1 CAM1 33SP-001 TB30 TB30-T1 - J14 41HB-006 LAMP HIGH MOUNT LEFT HI-BEAM HMLHB - P542 45R-002 SWITCH HAZARD LIGHTS P36 TB10 TB10-M1
11D-003 SWITCH HEADLIGHTS P25 SWITCH HEADLIGHTS P25 12DP-001 SP454 - - J538 24CAM-002 - JX11 CAMERA 2 CAM2 33SP-002 - P14 SENSOR STEERING PRESSURE SPS 41HB-007 - J542 - P12 45R-003 - P03 TB22 TB22-R1
11DID-000 VEC RTMR1 RTMR1-B10 DID POWER SUPPLY P500 12DP-002 - P46 - P538_JP 24CAM-003 - JX12 CAMERA 3 CAM3 33T-000 - J240 SWITCH SERVICE BRAKE DEGRADE P... BDS 41HB-008 LAMP LOW MOUNT LEFT HI-BEAM LMLHB - P542 45R-004 TB22 TB22-R2 VEC-89 VEC89-P12
11DISP-000 VEC-91 VEC91-P2 TB23 TB23-G2 12DP-003 - J702 - J46 24CAM-004 JB12B JB12B - PX15_CP 33T-001 TB32 TB32-F2 - P240 41HB-009 - J543 - P11 45RL-000 TB35 TB35-K1 VEC-89 VEC89-P12
11DISP-001 TB23 TB23-G1 - P01 12DP-004 - P830 - J538B 24CAM-005 JB12B JB12B - PX14_CP 33T-002 TB32 TB32-F1 INTERFACE MODULE IM2 41HB-010 LAMP HIGH MOUNT RIGHT HI-BEAM HMRHB - P543 45RL-001 TB35 TB35-K2 - J11
11DISP-003 - J01 ACTIA DASH DISPLAY P903 12DP-005 SP454 - SENSOR POWER LADDER DOWN DPS 24CAM-006 JB12B JB12B - PX13_CP 34AT-000 - P14 SENSOR DUCT AIR TEMPERATURE ATS 41HB-011 - J543 - P11 45RL-002 - P11 - J541
11DSL-000 RELAY ACCESS LADDER LIGHT (ALL... ALLR-88 VEC-89 VEC89-P12 12DP-006 SWITCH HEDWELD LIMIT - - J1206 24CAM-007 JB12B JB12B - PX12_CP 34AT-001 - J14 TB30 TB30-J2 41HB-012 LAMP LOW MOUNT RIGHT HI-BEAM LMRHB - P543 45RL-003 - P541 - P502
11E1-000 TB27 TB27-A2 VEC-91 VEC91-P2 12GLA-000 RELAY GROUND LEVEL ALARM GLAR_K POWER LADDER CONTROLLER P7 24CAM-008 JB12B JB12B - PX11_CP 34AT-002 TB30 TB30-J1 INTERFACE MODULE IM3 41HM-000 RELAY HEADLIGHT HIGH MOUNT (HH... HHMR-88A - J12 45RL-004 - J502 SP145 -
11E1-001 TB27 TB27-A1 - P808 12H-000 VEC-91 VEC91-P9 TB22 TB22-G1 24CAM-009 JB12B JB12B - PX10_CP 34BT1-000 TB30 TB30-G2 - J14 41HM-001 - J11 RELAY HEADLIGHT HIGH MOUNT (HH... HHMR-88A 45RL-005 ACTIA DASH DISPLAY P902 - J01
11E1-002 TB27 TB27-A3 - P808 12H-001 TB22 TB22-G2 - P03 24CAM-010 - JX13 CAMERA 4 CAM4 34BT1-001 TB30 TB30-G1 INTERFACE MODULE IM3 41HM-002 - P12 - J542 45RL-006 - P01 TB35 TB35-K3
11E1-006 - J808 ENGINE QSK78 INTERFACE P805 12H-002 - J03 - P140 24CAM-011 - JX14 CAMERA 5 CAM5 34BT1-002 - P14 SENSOR BRAKE TEMP LH FRONT P707 41HM-003 LAMP HIGH MOUNT LEFT LOW-BEAM HMLLB - P542 45RL-007 SP145 - LAMP MARKER/TURN RIGHT FRT DEC... RCL1
11E2-000 TB27 TB27-B2 VEC-91 VEC91-P2 12HS-000 RELAY LADDER UP LUR_K POWER LADDER CONTROLLER P7 24CAM-012 - JX15 CAMERA 6 CAM6 34BT2-000 TB30 TB30-H2 - J14 41HM-004 - J543 - P11 45RL-008 TB35 TB35-K4 - J16
11E2-001 - P808 TB27 TB27-B1 12LD-000 POWER LADDER CONTROLLER P7 - J538 24SON-000 SONALERT (SONA) SONA(+) JB4D JB4D 34BT2-001 TB30 TB30-H1 INTERFACE MODULE IM3 41HM-005 LAMP HIGH MOUNT RIGHT LOW-BEAM HMRLB - P543 45RL-009 SP145 - LAMP MARKER/TURN RIGHT SIDE DE... RCL2
11E2-002 - P808 TB27 TB27-B3 12LD-001 - P538_JP - P46 24SON-001 R16 R16 JB4D JB4D 34BT2-002 - P14 SENSOR BRAKE TEMP RH FRONT P708 41L-000 SWITCH HEADLIGHTS P25 TB10 TB10-L1 45RL-010 - P16 SP148 -
11E2-006 - J808 ENGINE QSK78 INTERFACE P805 12LD-002 - J46 TB21 TB21-G1 24SON-002 D9 D9 JB4D JB4D 34BT3-000 - J14 TB30 TB30-C2 41L-001 TB10 TB10-L1 SWITCH COMBO P121 45RL-011 SP148 - - P731_CP
11E3-000 TB27 TB27-C2 VEC-91 VEC91-P2 12LD-004 TB21 TB21-G2 - P03 24SON-003 D10 D10 JB4D JB4D 34BT3-001 TB30 TB30-C1 INTERFACE MODULE IM3 41L-002 TB10 TB10-L1 - J03 45RL-012 SP148 - - P55
11E3-001 - P808 TB27 TB27-C1 12LD-005 SWITCH LADDER CONTROL P38 - J03 24VIM-000 INTERFACE MODULE IM1 TB32 TB32-H2 34BT3-002 - P14 SENSOR BRAKE TEMP LH REAR P709 41L-004 TB34 TB34-C1 - P03 45RL-017 LAMP BODY RIGHT SIDE TURN RSTL - J55
11E3-002 - P808 TB27 TB27-C3 12LD-006 SWITCH LADDER CONTROL P38 SWITCH LADDER CONTROL P38 24VIM-001 TB32 TB32-H1 VEC-91 VEC91-P2 34BT4-000 - P14 SENSOR BRAKE TEMP RH REAR P710 41L-005 TB34 TB34-C2 RELAY HEADLIGHT LOW MOUNT (HLM... HLMR-86 46GA-000 TB32 TB32-A1 - J702
11E4-000 TB27 TB27-D2 VEC-91 VEC91-P2 12LU-000 POWER LADDER CONTROLLER P7 - J538 24VIM-002 TB32 TB32-H1 VEC-89 VEC89-P2 34BT4-001 - J14 TB30 TB30-A2 41L-006 RELAY HEADLIGHT LOW MOUNT (HLM... HLMR-86 RELAY HEADLIGHT HIGH MOUNT (HH... HHMR-86 46GA-001 - P16 - P72
11E4-001 TB27 TB27-D1 - P808 12LU-001 - P538_JP - P46 24VIM-004 ACTIA DASH DISPLAY P902 - J01 34BT4-002 TB30 TB30-A1 INTERFACE MODULE IM3 41LM-000 RELAY HEADLIGHT LOW MOUNT (HLM... HLMR-88A - J12 46GA-002 - J16 TB32 TB32-A2
11ER-000 VEC-91 VEC91-P11 TB22 TB22-D1 12LU-002 - J46 TB21 TB21-H1 24VIM-005 TB32 TB32-G1 - P01 34LL-001 INTERFACE MODULE IM2 - J14 41LM-001 - J11 RELAY HEADLIGHT LOW MOUNT (HLM... HLMR-88A 46GA-003 - P12 - J540
11ER-001 TB22 TB22-D2 - P03 12LU-004 TB21 TB21-H2 - P03 24VIM-006 TB32 TB32-G4 - P04 34LL-002 - P14 SENSOR HYDRAULIC TANK LEVEL P712 41LM-002 - P12 - J542 46GA-004 - J12 TB32 TB32-A2
11ER-002 TB22 TB22-D3 - P03 12LU-005 SWITCH LADDER CONTROL P38 - J03 24VIM-007 D10 D10 - J04 35L2-000 PAY LOAD METER 4 P264 TB36 TB36-L1 41LM-003 LAMP LOW MOUNT LEFT LOW-BEAM LMLLB - P542 46GA-005 TB32 TB32-A1 - J11
11ER-003 - J03 SP155 - 12LU-006 SWITCH LADDER CONTROL P38 SWITCH LADDER CONTROL P38 24VIM-008 TB32 TB32-H2 - J14 35L2-001 - J362 TB36 TB36-L2 41LM-004 - P11 - J543 46GA-006 - J541 - P11
11ER-004 - J03 SP155 - 12V-000 12V POWER RELAY (12VPR) 12VPR-88A VEC-91 VEC91-S7A 24VIM-009 - P14 SENSOR HYDRAULIC TANK LEVEL P712 35L3-000 PAY LOAD METER 4 P264 TB36 TB36-M1 41LM-005 LAMP LOW MOUNT RIGHT LOW-BEAM LMRLB - P543 46GA-007 - P502 - P541
11ER-005 - J601_CP SP155 - 12V-001 VEC-91 VEC91-S7B TB35 TB35-X1 25A-000 RELAY ENG STARTER 1 (ESREL1) ESREL1-88a MOTOR STARTER 1 (STRT1) STRT1-3 35L3-001 - J362 TB36 TB36-M2 41T-000 TB35 TB35-E1 VEC-89 VEC89-P11 46GA-008 - RDML_CP - J502
11FS-000 VEC-91 VEC91-P11 TB22 TB22-F1 12V-003 ETHERNET SWITCH ENET_PWR TB35 TB35-X3 25B-000 RELAY ENG STARTER 2 (ESREL2) ESREL2-88a MOTOR STARTER 2 (STRT2) STRT2-3 35L4-000 PAY LOAD METER 4 P264 TB36 TB36-N1 41T-001 TB35 TB35-E2 - J12 46GA-009 - P503 - P540
11FS-001 TB22 TB22-F2 - P03 12VR-000 - P01X_CP JB9X JB9X 26AV-000 SP221 - KOMVISION CONTROLLER NTSC1 35L4-001 - J362 TB36 TB36-N2 41T-002 TB35 TB35-E4 - J11 46GA-010 - J503 - LDML_CP
11FS-002 - J602_CP - J03 12VR-001 - P01X_CP JB9X JB9X 26AV-001 SP110 - - JX10 35L7-000 PAY LOAD METER 4 P264 TB36 TB36-R1 41T-003 - P12 - J540 46GA-011 - J72 - RBML2_CP
11H-000 TB22 TB22-B1 RELAY VEHICLE HORN POWER (HPR) HPR-85 12VR-002 - P01X_CP JB9X JB9X 26AV-002 SP087 - CAMERA 1 CAM1 35L7-001 SCORE BOARD LEFT (OPT) CNLIN TB36 TB36-R2 41T-004 - P540 - P503 46RA-000 TB32 TB32-B1 - J702
11H-001 - P03 TB22 TB22-B2 12VR-003 - J01X RADAR 1 KOMVISION J119 26AV-003 SP110 - SP087 - 35L8-000 PAY LOAD METER 4 P264 TB36 TB36-S1 41T-005 - J503 SP143 - 46RA-001 - P16 - P72
11H-002 - J03 SWITCH HORN BUTTON P120 12VR-004 JB9X JB9X - P09X_CP 26AV-005 SP244 - - PX10_CP 35L8-001 SCORE BOARD LEFT (OPT) CNLIN TB36 TB36-S2 41T-006 SP143 - LAMP MARKER/TURN LEFT SIDE DEC... LCL1 46RA-002 - J16 TB32 TB32-B2
11HH-000 VEC-91 VEC91-P1 HEATED HOSE RELAY TSW-88 12VR-005 JB9X JB9X - P09X_CP 26AV-006 SP221 - SP244 - 35L9-000 PAY LOAD METER 4 P264 TB36 TB36-T1 41T-007 SP143 - LAMP MARKER/TURN LEFT FRT DECK LCL2 46RA-003 - P12 - J540
11HH-002 HEATED HOSE RELAY TSW-88 ORS RELAY ORS-86 12VR-006 - P09X_CP JB9X JB9X 26AV1-000 KOMVISION CONTROLLER NTSC1 SP186 - 35L9-001 SCORE BOARD LEFT (OPT) CNLIN TB36 TB36-T2 41T-008 - P11 - J541 46RA-004 - J12 TB32 TB32-B2
11HL-000 RELAY HI-BEAM HEADLIGHT (HBHR) HBHR-88 VEC-89 VEC89-P12 12VR-007 RADAR 5 KOMVISION J125 - J16X 26AV1-001 - JX11 SP101 - 35L10-000 SCORE BOARD RIGHT (OPT) CNRIN SCORE BOARD LEFT (OPT) CNLO 41T-009 - P541 - P502 46RA-005 - J11 TB32 TB32-B1
11HS-000 RELAY VEHICLE HORN POWER (HPR) HPR-88A - J12 12VR-008 RADAR 6 KOMVISION J126 - J16X 26AV1-002 SP089 - CAMERA 2 CAM2 36-001 - P801 TB28 TB28-A1 41T-010 - J502 SP146 - 46RA-006 - J541 - P11
11HS-001 - P12 - J540 12VR-009 JB9X JB9X - P09X_CP 26AV1-003 SP101 - SP089 - 36-002 TB28 TB28-A2 VEC-90 VEC90-P9 41T-011 SP146 - LAMP MARKER/TURN RIGHT FRT DEC... RCL1 46RA-007 - P541 - P502
11HS-002 - P540 - P503 12VR-010 - J09X - P16X 26AV1-005 SP120 - - PX11_CP 36-003 - J801 - J815 41T-012 SP146 - LAMP MARKER/TURN RIGHT SIDE DE... RCL2 46RA-008 - RDML_CP - J502
11HS-003 - J503 SP167 - 12VR-011 - J09X - P16X 26AV1-006 SP186 - SP120 - 36-004 ORS RELAY ORS-85 TB28 TB28-A3 41T-013 TB35 TB35-E4 - J14 46RA-009 - P540 - P503
11HS-004 SP167 - HORN FRONT VEHICLE AHS 12VR-014 RADAR 7 KOMVISION J127 - J09X 26AV2-000 KOMVISION CONTROLLER NTSC1 SP188 - 36-005 - P815 SWITCH ENGINE RUN OIL PRESSURE... EOPS 41T-014 - P14 - P732_CP 46RA-010 - J503 - LDML_CP
11HS-005 D1 D1 SP167 - 12VR-015 RADAR 8 KOMVISION J128 - J09X 26AV2-001 SP098 - - JX12 38G-000 TB35 TB35-C1 INTERFACE MODULE IM3 41T-015 TB35 TB35-E2 - J16 46RA-011 - J72 - RBML2_CP
11IM2-000 VEC-91 VEC91-P4 INTERFACE MODULE IM1 12VR-017 RELAY RADAR POWER (RPR) RPR_K JB9X JB9X 26AV2-002 SP086 - CAMERA 3 CAM3 38G-001 TB35 TB35-C4 - J16 41T-016 - P16 SP149 - 46YA-000 TB32 TB32-C1 - J702
11INT-000 VEC-91 VEC91-P3 INTERFACE MODULE IM1 12VR-019 RADAR 4 KOMVISION J124 - J01X 26AV2-003 SP238 - - PX12_CP 38G-002 R15 R15 TB35 TB35-C2 41T-017 SP149 - - P731_CP 46YA-001 - P16 - P72
11KS-001 - P46 - P536 12VR-020 - P01X_CP JB9X JB9X 26AV2-004 SP098 - SP086 - 38G-003 - P16 - J730 41T-018 SP149 - SP220 - 46YA-002 - J16 TB32 TB32-C2
11KS-002 - J46 TB24 TB24-H1 12VR-021 RADAR 2 KOMVISION J122 - J01X 26AV2-006 SP188 - SP238 - 38G-004 SENSOR FUEL LEVEL FLS - P730 41T-019 LAMP STOP/TAIL LEFT LRSTL SP220 - 46YA-003 - P12 - J540
11KS-003 TB24 TB24-H1 VEC-90 VEC90-P1 12VR-022 RADAR 3 KOMVISION J123 - J01X 26AV3-000 KOMVISION CONTROLLER NTSC1 SP190 - 39-000 - J702 INTERFACE MODULE IM2 41T-020 LAMP STOP/TAIL RIGHT RRSTL SP220 - 46YA-004 - J12 TB32 TB32-C2
11KS-004 - P03 TB24 TB24-H2 12VREG-000 VEC-91 VEC91-P11 TB21 TB21-B1 26AV3-001 SP170 - - JX13 39-001 - J702 - J14 41T-021 - J54 SP220 - 46YA-005 - J11 TB32 TB32-C1
11KS-005 - J536 SWITCH GROUND LEVEL SHUTDOWN (... ESDS-1 12VREG-001 TB21 TB21-B2 - P03 26AV3-002 SP080 - CAMERA 4 CAM4 39-002 - P14 - SFSW_JP 41T-022 - P55 SP220 - 46YA-006 - J541 - P11
11KS-006 - J03 SWITCH KEY (KEYSW) KEYSW-B 12VREG-002 TB21 TB21-B3 - P03 26AV3-003 SP119 - - PX13_CP 39A-000 PAY LOAD METER 4 P264 TB34 TB34-S1 41T-029 SP716 - - J55 46YA-007 - P541 - P502
11L-000 VEC-91 VEC91-P3 TB22 TB22-C1 12VREG-003 - J03 SP156 - 26AV3-004 SP170 - SP080 - 39A-001 VEC-90 VEC90-P2 TB34 TB34-S2 41T-030 SP716 - LAMP BODY RIGHT SIDE MARKER RSCL1 46YA-008 - RDML_CP - J502
11L-001 TB22 TB22-C2 - P03 12VREG-004 - J03 SP156 - 26AV3-006 SP190 - SP119 - 39AA-000 VEC-90 VEC90-P3 TB23 TB23-C1 41T-031 LAMP BODY RIGHT REAR MARKER RSCL2 SP716 - 46YA-009 - P503 - P540
11L-002 - J03 TB10 TB10-G1 12VREG-005 SP156 - - J601_CP 26AV4-000 KOMVISION CONTROLLER NTSC1 SP225 - 39AA-001 TB23 TB23-C1 - J11 41T-032 SP719 - - P54 46YA-010 - J503 - LDML_CP
11L-003 TB10 TB10-H2 SWITCH ROTATING BEACON (OPT) P32 13CA-001 - J538 RELAY CAB LADDER ALARM CAR_K 26AV4-001 SP159 - - JX14 39AA-002 - P11 - J541 41T-033 LAMP BODY LEFT SIDE MARKER LSCL1 SP719 - 46YA-011 - J72 - RBML2_CP
11L-004 TB10 TB10-G1 SP732 - 13CA-002 - P538_JP - P46 26AV4-002 SP079 - CAMERA 5 CAM5 39AA-004 - P541 - P502 41T-034 LAMP BODY LEFT REAR MARKER LSCL2 SP719 - 47-000 RELAY BACKUP LIGHT (BULR) BULR-88A TB35 TB35-L1
11L-006 SWITCH HAZARD LIGHTS P36 SWITCH HAZARD LIGHTS P36 13CA-003 TB21 TB21-C1 INTERFACE MODULE IM2 26AV4-003 SP255 - - PX14_CP 39AA-005 - J502 LAMP RED PAYLOAD RIGHT RPLR_CP 41TS-000 SWITCH HEADLIGHTS P25 TB10 TB10-A1 47-001 TB35 TB35-L2 - J16
11L-008 TB10 TB10-H2 SWITCH CAB LADDER LIGHT P24 13CA-005 - J46 TB21 TB21-C1 26AV4-004 SP159 - SP079 - 39AA-006 TB23 TB23-C1 - J12 41TS-001 SWITCH HEADLIGHTS P25 SWITCH HEADLIGHTS P25 47-002 TB35 TB35-L2 - J16
11L-009 SP732 - SWITCH HAZARD LIGHTS P36 13GLA-000 RELAY GROUND LEVEL ALARM GLAR_K ALARM GROUND LEVEL LADDER GLA 26AV4-006 SP225 - SP255 - 39AA-007 - P12 - J540 41TS-002 TB10 TB10-A3 - J02 47-003 - P16 LAMP BACKUP RIGHT REAR RRBL
11L-010 SP732 - SWITCH HEADLIGHTS P25 13HS-000 RELAY LADDER UP LUR_K SWITCH GROUND LEVEL LADDER OVE... GLORS 26AV5-000 KOMVISION CONTROLLER NTSC1 SP227 - 39AA-008 - P540 - P503 41TS-003 - P02 TB34 TB34-A2 47-004 - P16 LAMP BACKUP LEFT REAR LRBL
11LAD-000 POWER LADDER CONTROLLER P7 JB8E JB8E 13LS-000 SWITCH GROUND LEVEL LADDER OVE... GLORS SP399 - 26AV5-001 SP095 - - JX15 39AA-009 - J503 LAMP RED PAYLOAD LEFT LPLR_CP 41TS-004 SWITCH LEFT WINDOW P072 JB4F JB4F 47-008 TB35 TB35-L3 - J11
11LAD-001 JB8E JB8E SENSOR POWER LADDER UP UPS 13LS-001 D7 D7 SP399 - 26AV5-002 SP126 - CAMERA 6 CAM6 39AP-000 - J16 - J702 41TS-005 TB34 TB34-A1 VEC-89 VEC89-P11 47-009 - P11 - J541
11LAD-002 JB8E JB8E SENSOR POWER LADDER DOWN DPS 13LS-002 SP399 - SOLENOID HYDRAULIC LADDER LSOL 26AV5-003 SP102 - - PX15_CP 39AP-001 - P16 - J730 41TS-006 TB10 TB10-A4 ACTIA DISPLAY PANEL DIMMER P18 47-010 - P541 - P502
11LAD-004 - P538_JP - P46 15DID-000 - J02 GE DID PANEL DID 26AV5-004 SP095 - SP126 - 39AP-002 SWITCH HYDRAULIC FILTER #1 HFSW1 - P730 41TS-007 SWITCH RIGHT WINDOW P071 JB4F JB4F 47-011 - J502 LAMP BACKUP RIGHT DECK (OPT) RBUL
11LAD-005 RELAY LADDER UP LUR_K JB8E JB8E 15DID-001 - P02 TB22 TB22-K1 26AV5-006 SP227 - SP102 - 39AP-003 - J702 - J14 41TS-008 SWITCH RIGHT WINDOW P071 SWITCH RIGHT WINDOW P071 47-012 TB35 TB35-L3 - J12
11LAD-006 RELAY GROUND LEVEL ALARM GLAR_K JB8E JB8E 15DID-002 TB22 TB22-K2 DID POWER SUPPLY P500 28E-000 VEC-91 VEC91-P12 - J12 39AP-004 - P14 BRAKE FILTER PRESS SW BFSW 41TS-009 SWITCH LEFT WINDOW P072 SWITCH LEFT WINDOW P072 47-013 - P12 - J540
11LAD-007 - J46 TB21 TB21-F1 15SLW-001 TB33 TB33-S2 SP729 - 28E-001 - P12 - J542 39B-000 PAY LOAD METER 4 P264 TB34 TB34-R1 41TS-010 TB10 TB10-A1 JB4F JB4F 47-014 - P540 - P503
11LAD-008 TB21 TB21-F1 VEC-91 VEC91-P1 15SLW-002 GE CONTROL INTERFACE P301 TB33 TB33-S1 28E-002 - P542 - ETHER1_CP 39B-001 VEC-90 VEC90-P2 TB34 TB34-R2 41TS-011 - P140 JB4F JB4F 47-015 - J503 LAMP BACKUP LEFT DECK (OPT) LBUL
11LAD-009 - J538 JB8E JB8E 15SLW-003 SP729 - - P57_CP 28E-003 - ETHER2 SOLENOID ETHER START (OPT) ESOL 39BA-000 VEC-90 VEC90-P2 TB23 TB23-D1 42-000 TIMER (1HR) ENGINE SERVICE LAM... ESLT-NO TB35 TB35-M1 47A-000 RELAY BACKUP LIGHT (BULR) BULR-86 VEC-89 VEC89-P11
11LAD-010 TB21 TB21-F2 - P03 15SLW-005 SP729 - - J13 28EC-000 VEC-91 VEC91-P12 TB27 TB27-H2 39BA-001 TB23 TB23-D1 - J11 42-001 - J11 TB35 TB35-M2 47B-000 RELAY BACKUP LIGHT (BULR) BULR-88 VEC-89 VEC89-P9
11LAD-011 SWITCH LADDER CONTROL P38 - J03 15SLW-006 - P13 SENSOR LEFT FRONT WHEEL SPEED P507 28EC-002 - P808 TB27 TB27-H1 39BA-002 - P11 - J541 42-002 - J11 TB35 TB35-M2 47S-000 SWITCH MANUAL BACKUP LIGHT P23 - J03
11LAD-012 SWITCH LADDER CONTROL P38 SWITCH LADDER CONTROL P38 15SRW-001 TB33 TB33-M2 SP728 - 28EC-003 - J808 ENGINE QSK78 INTERFACE P806 39BA-004 - P541 - P502 42-003 - J541 - P11 47S-001 - P03 TB22 TB22-T1
11LL-000 RELAY HEADLIGHT LOW MOUNT (HLM... HLMR-88 VEC-89 VEC89-P9 15SRW-002 GE CONTROL INTERFACE P301 TB33 TB33-M1 31ILM-000 INTERFACE MODULE IM1 TB34 TB34-N2 39BA-005 - J502 LAMP AMBER PAYLOAD RIGHT RPLA_CP 42-004 - J541 - P11 47S-002 TB22 TB22-T2 VEC-89 VEC89-P11
11LR-000 RELAY HEADLIGHT HIGH MOUNT (HH... HHMR-88 VEC-89 VEC89-P9 15SRW-003 SP728 - - P56_CP 31IML-001 TB34 TB34-N1 - P04 39BA-006 TB23 TB23-D1 - J12 42-005 - P541 LAMP RIGHT LOWER ENGINE SERVIC... RLESL 47S-003 SWITCH MANUAL BACKUP LIGHT P23 SWITCH MANUAL BACKUP LIGHT P23
11M-000 VEC-91 VEC91-P4 TB32 TB32-P1 15SRW-004 - J13 SP728 - 31IML-002 SONALERT (SONA) SONA(-) SP723 - 39BA-007 - P12 - J540 42-006 - P541 LAMP RIGHT UPPER ENGINE SERVIC... RUESL 48-000 RELAY ACCESS LADDER LIGHT (ALL... ALLR-88A TB26 TB26-T1
11M-001 TB32 TB32-P2 - P02 15SRW-005 - P13 SENSOR RIGHT FRONT WHEEL SPEED P501 31IML-003 SP723 - R16 R16 39BA-008 - P540 - P503 42-007 - J12 TB35 TB35-M3 48-001 TB26 TB26-T2 - J11
11M-002 - J02 SP710 - 15VDI-000 TB21 TB21-T4 DID POWER SUPPLY P500 31IML-004 - J04 SP723 - 39BA-009 - J503 LAMP AMBER PAYLOAD LEFT LPLA_CP 42-008 - J12 TB35 TB35-M3 48-002 - J11 TB26 TB26-T2
11M-003 SP710 - - PTX_CP 15VDI-002 GE CONTROL INTERFACE P302 TB21 TB21-T1 31RR-000 - J02 SWITCH RETARD SPEED CONTROL (R... RSCS_2-1 39C-000 PAY LOAD METER 4 P264 TB34 TB34-P1 42-009 - J540 - P12 48-003 TB26 TB26-V2 - J12
11M-004 SP710 - - CAN_TP 15VDI-003 GE CONTROL INTERFACE P302 TB21 TB21-T3 31RR-001 - P02 TB31 TB31-E2 39C-001 VEC-90 VEC90-P2 TB34 TB34-P2 42-010 - J540 - P12 48-004 - J12 TB26 TB26-V2
11ONS-000 - J01 ACTIA DASH DISPLAY P903 15VDI-004 TB21 TB21-T2 R17 R17 31RR-002 GE CONTROL INTERFACE P304 TB31 TB31-E1 39CA-000 VEC-90 VEC90-P2 TB23 TB23-E1 42-011 LAMP LEFT LOWER ENGINE SERVICE LLESL - P540 48-005 - J14 TB26 TB26-V2
11ONS-001 - P01 TB35 TB35-T1 18VIM-000 INTERFACE MODULE IM3 TB30 TB30-W1 33-000 - J240 SWITCH PARK BRAKE SET PBPSW 39CA-001 TB23 TB23-E1 - J11 42-012 LAMP LEFT UPPER ENGINE SERVICE LUESL - P540 48-006 - J543 - P11
11ONS-002 TB35 TB35-T2 INTERFACE MODULE IM1 18VIM-001 TB30 TB30-W1 - J14 33-001 TB32 TB32-D2 - P240 39CA-002 - P11 - J541 42A-001 SWITCH LEFT ENGINE SERVICE LAM... LESLS-2 - P12 48-007 - P543 LAMP RH DIAGONAL LADDER RDLLT_CP
11ORS-001 TB28 TB28-D1 ORS RELAY ORS-88 18VIM-002 - P14 SENSOR STEERING PRESSURE SPS 33-002 TB32 TB32-D1 INTERFACE MODULE IM2 39CA-004 - P541 - P502 42A-002 - J12 - J11 48-009 - P11 SP245 -
11ORS-002 VEC-91 VEC91-P4 TB28 TB28-D2 18VIM-003 - J16 TB30 TB30-W2 33BP-000 - J240 SWITCH LOW BRAKE ACCUM PRESSUR... LBPS 39CA-005 - J502 LAMP GREEN PAYLOAD RIGHT RPLG_CP 42A-003 - P11 SWITCH RIGHT ENGINE SERVICE LA... RESLS-2 48-010 - P543 LAMP RH DECK RDLT_CP
11PF-000 RELAY ENGINE PRELUBE MAG SWITC... PLMS-2 ENGINE PRELUBE HIGH VOLUME PUM... PLPM-(+) 18VIM-004 - P16 SENSOR HOIST PRESSURE #1 HPS1 33BP-001 TB32 TB32-E2 - P240 39CA-006 TB23 TB23-E1 - J12 42B-001 - P12 SWITCH LEFT ENGINE SERVICE LAM... LESLS-3 48-011 - P12 - J542
11PHH-000 - J12 SP780 - 18VIM-005 - J16 TB30 TB30-W2 33BP-002 TB32 TB32-E1 INTERFACE MODULE IM2 39CA-007 - P12 - J540 42B-002 - J11 - J12 48-012 - P542 LAMP LH DIAGONAL LADDER LDLLT_CP
11PHH-001 HEATED HOSE RELAY TSW-88A SP780 - 18VIM-006 - P16 SENSOR HOIST PRESSURE #2 HPS2 33BPS-000 INTERFACE MODULE IM3 TB30 TB30-M2 39CA-008 - P540 - P503 42B-003 SWITCH RIGHT ENGINE SERVICE LA... RESLS-3 - P11 48-013 - P12 - J542
11PHH-002 SP805 - OIL RESERVE SYS P502_CP 18VIM-007 - P240 TB30 TB30-W4 33BPS-001 - P240 TB30 TB30-M1 39CA-009 - J503 LAMP GREEN PAYLOAD LEFT LPLG_CP 42PML-000 - J14 TIMER (1HR) HYDRAULIC PUMP MOD... HPLT-NO 48-014 - P542 LAMP LH DECK (OPT) LDLT_CP
11PHH-003 SP805 - - P11 18VIM-008 SENSOR BRAKE PRESSURE BPS - J240 33BPS-002 SENSOR BRAKE PRESSURE BPS - J240 39F-000 PAY LOAD METER 4 P264 TB36 TB36-C2 42PML-001 - P563_CP - P14 48-015 - P14 - P565
11PHH-004 - J11 SP780 - 21NSL-001 - P808 TB27 TB27-E1 33F-000 - P14 SWITCH LOW STEERING PRESSURE ACPSW 39F-001 TB36 TB36-C1 - J13 42PML-002 - J563 SP712 - 48-016 - J565 SP150 -
11PHH-005 SP805 - OIL RESERVE SYS P501_CP 21NSL-002 - J808 ENGINE QSK78 INTERFACE P805 33F-001 - J14 INTERFACE MODULE IM2 39F-002 TB36 TB36-C1 - J13 42PML-003 SP712 - LAMP HYD TANK SERVICE HSL 48-017 SP150 - LAMP CONTROL CABINET WORK LIGH... CDL1
11PL-000 FUSE LINK1 (300A) FUS-2 RELAY ENGINE PRELUBE MAG SWITC... PLMS-1 21NSL-003 TB27 TB27-E2 INTERFACE MODULE IM3 33HP1-000 INTERFACE MODULE IM3 TB30 TB30-N1 39F-003 SENSOR PAYLOAD PRESSURE LEFT R... P152 SP235 - 42PML-004 SP712 - LAMP FUEL TANK SERVICE FSL 48-018 LAMP CONTROL CABINET WORK LIGH... CDL2 SP150 -
11POR-001 ORS RELAY ORS-88A TB28 TB28-E1 21NSL-004 TB27 TB27-E4 R51 R51 33HP1-001 TB30 TB30-N1 - J16 39F-004 SENSOR PAYLOAD PRESSURE RIGHT ... P153 SP235 - 42PMS-000 - J14 TIMER (1HR) HYDRAULIC PUMP MOD... HPLT-3 48-019 SP245 - - J543
11POR-002 TB28 TB28-E2 - J11 21OR-001 - P808 TB27 TB27-K1 33HP1-002 SENSOR HOIST PRESSURE #1 HPS1 - P16 39F-007 - P13 SENSOR PAYLOAD PRESSURE RIGHT ... P150 42PMS-001 - P563_CP - P14 48-020 SP245 - - J541
11POR-003 TB28 TB28-E2 - J12 21OR-002 TB27 TB27-K3 - J11 33HP2-000 TB28 TB28-K1 INTERFACE MODULE IM3 39F-008 - P13 SENSOR PAYLOAD PRESSURE LEFT F... P151 42SL-000 TIMER (1HR) ENGINE SERVICE LAM... ESLT-3 - J12 48-021 - P541 - P502
11POR-005 SP776 - - P11 21OR-004 - P11 - P170_CP 33HP2-001 - J16 TB28 TB28-K1 39F-009 TB36 TB36-C3 - J16 42SL-001 - P12 SWITCH LEFT ENGINE SERVICE LAM... LESLS-1 48-022 - J502 LAMP RH DECK (OPT) DLT_CP
11POR-007 OIL RESERVE SYS P503_CP SP776 - 21OR-005 - J12 TB27 TB27-K3 33HP2-002 - P16 SENSOR HOIST PRESSURE #2 HPS2 39F-011 - P16 SP235 - 44-000 TB35 TB35-G1 VEC-89 VEC89-P12 48A-000 SWITCH CAB LADDER LIGHT P24 - J03
11POR-009 OIL RESERVE SYS P506_CP SP776 - 21ORR-001 - P808 TB27 TB27-L1 33J-000 - J14 SP800 - 39FA-000 TB36 TB36-E2 PAY LOAD METER 4 P264 44-001 TB35 TB35-G2 - J16 48A-001 - P03 TB34 TB34-J1
11RB-000 SWITCH ROTATING BEACON (OPT) P32 - J03 21ORR-003 TB27 TB27-L3 - J11 33J-001 SP184 - - P14 39FA-001 TB36 TB36-E1 - J16 44-002 TB35 TB35-G4 - P04 48A-002 TB34 TB34-J2 - J46
58B-06-02261-00 SEP 15
980E-4
A40003 & UP
Sheet 21 of 24
WIRE TABLE CONTINUED FROM DIAGRAM 20, 21 & 23
48A-003 - P46 - J535 65-059 - J607 WIRELESS BRIDGE KWB 71P-000 TB23 TB23-J4 VEC-89 VEC89-P2 77Z-000 GE CONTROL INTERFACE P305 TB33 TB33-F1 92ET1-002 - PENET5 - PENET2 900-000 - J808 ENGINE QSK78 INTERFACE P806
48A-006 SWITCH CAB LADDER LIGHT P24 SWITCH CAB LADDER LIGHT P24 65A-000 VEC-91 VEC91-P12 TB24 TB24-F1 71P-001 TB23 TB23-J3 - P02 79A-000 - J16 VEC-89 VEC89-P11 92ET2-000 USER PC PC-ENET - JENET5 900-001 - P808 TB28 TB28-T1
48A-007 SWITCH GROUND LEVEL LADDER LIG... LLSW-2 - P535 65A-001 ENTERTAINMENT RADIO P737 - J211 71P-002 SWITCH DATA STORE (DSSW) DSSW-C JB4B JB4B 79A-001 SP231 - - P16 92ET2-001 - JENET2 ETHERNET SWITCH PORT2 900-002 TB28 TB28-T2 - P02
48B-000 SWITCH CAB LADDER LIGHT P24 - J03 65A-002 - J211 ENTERTAINMENT RADIO P737 71P-003 SWITCH BODYUP OVERRIDE / RESET... ORS_1-4 JB4B JB4B 79A-002 SP231 - HORN BACKUP LEFT LRBH-(+) 92ET2-002 - PENET5 - PENET2 900-003 - J02 - DIAG4
48B-001 - P03 TB34 TB34-K1 65A-003 TB24 TB24-F2 - P04 71P-004 SWITCH RETARD SPEED CONTROL (R... RSCS_2-2 JB4B JB4B 79A-003 SP231 - HORN BACKUP RIGHT RRBH-(+) 93ER1-000 - JENET6 KOMTRAX PLUS MODULE P5 900CG-000 KOMTRAX PLUS MODULE P4B ORBCOMM MODULE (OPT) CNA
48B-002 TB34 TB34-K2 - J46 65A-004 - J04 - P211 71P-005 TB23 TB23-J2 - J16 79B-000 - J02 SHIFTER DIRECTION SELECTOR P108 93ER1-001 - JENET3 ETHERNET SWITCH PORT3 900CR-000 KOMTRAX PLUS MODULE P4B ORBCOMM MODULE (OPT) CNA
48B-003 - P46 - J535 65C-003 SWITCH A/C RECIEVER DRYER RECDR SOLENOID A/C COMPRESSOR CLUTCH P803 71P-006 - J02 JB4B JB4B 79B-001 - P02 TB21 TB21-L2 93ER1-002 - PENET6 - PENET3 900CT-000 KOMTRAX PLUS MODULE P4B ORBCOMM MODULE (OPT) CNA
48B-006 SWITCH CAB LADDER LIGHT P24 SWITCH CAB LADDER LIGHT P24 65S-000 VEC-91 VEC91-P12 TB27 TB27-M2 71P-007 TB23 TB23-J1 - P03 79B-002 VEC-90 VEC90-P1 TB21 TB21-L3 93ER2-000 - JENET6 KOMTRAX PLUS MODULE P5 901-000 - J808 ENGINE QSK78 INTERFACE P806
48B-007 SWITCH GROUND LEVEL LADDER LIG... LLSW-3 - P535 65S-001 TB27 TB27-M1 - P808 71P-008 - J03 SWITCH DC POWER OFF - REST SWI... P35 79B-003 TB21 TB21-L1 - J701 93ER2-001 - JENET3 ETHERNET SWITCH PORT3 901-001 - P808 TB28 TB28-V1
48C-000 TB34 TB34-L1 RELAY ACCESS LADDER LIGHT (ALL... ALLR-86 65S-003 - J808 ENGINE QSK78 INTERFACE P805 71P-009 SWITCH GRID DRY P34 SWITCH DC POWER OFF - REST SWI... P35 79BA-000 GE CONTROL INTERFACE P304 TB23 TB23-X1 93ER2-002 - PENET6 - PENET3 901-002 TB28 TB28-V2 - P02
48C-001 - J46 TB34 TB34-L1 65SR-000 VEC-91 VEC91-P12 VEC RTMR1 RTMR1-C1 71P-010 - P16 SP180 - 79BA-001 - J701 TB23 TB23-X1 93ET1-000 - JENET6 KOMTRAX PLUS MODULE P5 901-003 - J02 - DIAG4
48C-004 - J535 - P46 65SS-000 VEC RTMR1 RTMR1-B2 - J11 71P-011 SP180 - - P72 79BA-002 TB23 TB23-X2 VEC-89 VEC89-P11 93ET1-001 - JENET3 ETHERNET SWITCH PORT3 910-000 SP164 - SP213 -
48C-007 SWITCH GROUND LEVEL LADDER LIG... LLSW-1 - P535 65SS-001 - P11 - J543 71P-012 SP180 - SWITCH BODY-UP PROXIMITY BUSW 79RD-000 TB29 TB29-S1 VEC-90 VEC90-P9 93ET1-002 - PENET6 - PENET3 910-001 SP164 - KOMVISION CONTROLLER RGB
48F-000 SWITCH FOG LAMP (OPT) P22 - J03 65SS-002 - P543 - P520_CP 71P-013 - J72 - P703 79RD-001 GE CONTROL INTERFACE P302 TB29 TB29-S2 93ET2-000 - JENET6 KOMTRAX PLUS MODULE P5 910-002 SP213 - KOMVISION DISPLAY MONITOR P45
48F-001 - P03 TB34 TB34-E1 65SS-003 - J520 SOLENOID ENGINE SHUTTER (OPT) ESSOL 71P-014 - J703 SWITCH TRACTION MOTOR PRESSURE... BPSW-COM 85-000 TB28 TB28-C2 VEC-91 VEC91-P4 93ET2-001 - JENET3 ETHERNET SWITCH PORT3 911-000 SP215 - SP206 -
48F-002 TB34 TB34-E2 VEC-89 VEC89-P1 65T-000 VEC RTMR1 RTMR1-A1 TB30 TB30-X2 71PS-000 LAMP LED PROPEL LOCKOUT ON PLON SWITCH PROPEL LOCKOUT (PLOS) PLOS-B2 85-001 TB28 TB28-C1 - P04 93ET2-002 - PENET6 - PENET3 911-001 KOMVISION CONTROLLER RGB SP206 -
48LF-000 TB34 TB34-D1 VEC-89 VEC89-P1 65T-002 - P801 TB30 TB30-X1 71PS-001 RELAY PROPEL LOCKOUT PLREL_K SWITCH PROPEL LOCKOUT (PLOS) PLOS-B2 85-002 - J04 JB6E JB6E 94ER1-000 ETHERNET SWITCH PORT4 GE CONTROL INTERFACE ETC2 911-002 SP215 - KOMVISION DISPLAY MONITOR P45
48LF-001 TB34 TB34-D2 - J11 65T-003 TB30 TB30-X4 - P03 71SR-000 SHIFTER CURRENT LIMIT RESISTOR P250 SHIFTER DIRECTION SELECTOR P108 85-003 JB6E JB6E KOMTRAX PLUS MODULE P1 94ER2-000 ETHERNET SWITCH PORT4 GE CONTROL INTERFACE ETC2 912-000 SP216 - SP207 -
48LF-002 TB34 TB34-D2 - J12 65T-004 - J03 - P140 71SS-000 TB23 TB23-T2 VEC-89 VEC89-P4 85-004 JB6E JB6E KOMTRAX PLUS MODULE P1 94ET1-000 ETHERNET SWITCH PORT4 GE CONTROL INTERFACE ETC2 912-001 SP207 - KOMVISION CONTROLLER RGB
48LF-003 - P11 - J543 65T-005 - J801 SWITCH A/C RECIEVER DRYER RECDR 71SS-001 TB23 TB23-T1 - P02 85-005 JB6E JB6E ORBCOMM MODULE (OPT) CNA 94ET2-000 ETHERNET SWITCH PORT4 GE CONTROL INTERFACE ETC2 912-002 SP216 - KOMVISION DISPLAY MONITOR P45
48LF-004 - P12 - J542 65TS-006 HEATED HOSE RELAY TSW-86 SP781 - 71SS-002 - J02 SHIFTER CURRENT LIMIT RESISTOR P250 85-006 JB6E JB6E ORBCOMM MODULE (OPT) CNA 95ER1-000 ETHERNET SWITCH PORT6 PLM4 COMMUNICATION BOX PLM4_ENET 913-000 SP178 - SP209 -
48LF-005 - P543 LAMP RIGHT FOG RFLT 65TS-007 OIL RESERVE SYS P503_CP - P11 71VHM-000 TB28 TB28-B2 VEC-90 VEC90-P1 85-007 JB6E JB6E ORBCOMM MODULE (OPT) CNA 95ER2-000 ETHERNET SWITCH PORT6 PLM4 COMMUNICATION BOX PLM4_ENET 913-001 SP209 - KOMVISION CONTROLLER RGB
48LF-006 - P542 LAMP LEFT FOG LFLT 65TS-008 - J11 SP781 - 71VHM-001 TB28 TB28-B1 - P04 86-500 - J712 TB-HTST TB-HTST-F4 95ET1-000 ETHERNET SWITCH PORT6 PLM4 COMMUNICATION BOX PLM4_ENET 913-002 SP178 - KOMVISION DISPLAY MONITOR P45
49-001 TB10 TB10-D2 ACTIA DISPLAY PANEL DIMMER P18 65TS-009 - J12 SP781 - 71VHM-002 - J04 SP187 - 86-501 HEATER COOLANT LH - TB-HTST TB-HTST-G1 95ET2-000 ETHERNET SWITCH PORT6 PLM4 COMMUNICATION BOX PLM4_ENET 914-000 SP218 - SP211 -
49-002 ACTIA DASH DISPLAY P903 TB10 TB10-D3 67C-000 VEC-91 VEC91-P9 TB24 TB24-V1 71VHM-003 KOMTRAX PLUS MODULE P1 SP187 - 86-502 HEATER COOLANT RH - TB-HTST TB-HTST-G2 419I-003 - P808 TB27 TB27-F1 914-001 SP211 - KOMVISION CONTROLLER RGB
49-003 JB6B JB6B TB10 TB10-D4 67C-001 TB24 TB24-V2 - P03 71VHM-004 SP187 - KOMTRAX PLUS MODULE P1 86-503 TB-HTST TB-HTST-G3 SP703 - 419I-004 - J808 ENGINE QSK78 INTERFACE P806 914-002 SP218 - KOMVISION DISPLAY MONITOR P45
49-004 JB6B JB6B SHIFTER DIRECTION SELECTOR P108 67C-002 TB24 TB24-V4 - P03 72-000 - J02 SHIFTER DIRECTION SELECTOR P108 86-504 SP703 - HEATER ENGINE OIL LH EOH1 439-000 SWITCH CAB SECONDARY ENGINE SH... ESS_1-4 - J02 916M-000 - J808 ENGINE QSK78 INTERFACE P806
49-005 R27 R27 TB10 TB10-D2 67C-003 - J03 12VDC POWER PORT #1 PWR1-1 72-001 - P02 TB21 TB21-N2 86-505 SP703 - HEATER ENGINE OIL RH EOH2 439-001 - P02 TB27 TB27-R1 916M-001 TB27 TB27-V2 GE CONTROL INTERFACE P302
49-006 JB6B JB6B SWITCH CAB SECONDARY ENGINE SH... ESS-A 67C-004 - J03 12VDC POWER PORT #2 PWR2-1 72-002 VEC-90 VEC90-P1 TB21 TB21-N3 86-506 TB-HTST TB-HTST-H1 - CON1 439-002 TB27 TB27-R2 GE CONTROL INTERFACE P302 916M-002 - P808 TB27 TB27-V1
49-007 JB6B JB6B SWITCH BODYUP OVERRIDE / RESET... ORS-A 67L-000 MOTOR LEFT WINDOW P059 SP779 - 72-003 TB21 TB21-N1 - J701 86-507 SP707 - - CON2 439-003 TB27 TB27-R3 - P808 924-001 SWITCH COOLANT LEVEL P802 ENGINE QSK78 INTERFACE P806
49-008 JB6B JB6B SWITCH RETARD SPEED CONTROL (R... RSCS-A 67L-001 SWITCH LEFT WINDOW P072 SP779 - 72A-000 GE CONTROL INTERFACE P304 TB21 TB21-E1 86-508 SP707 - HEATER HYDRAULIC OIL #1 HOHTR1 439-005 TB27 TB27-R4 INTERFACE MODULE IM3 925-001 SWITCH COOLANT LEVEL P802 ENGINE QSK78 INTERFACE P806
51A1-000 - J13 INTERFACE MODULE IM2 67M-000 MOTOR LEFT WINDOW P059 SP778 - 72AF-000 - J701 GE CONTROL INTERFACE P304 86-509 SP707 - HEATER HYDRAULIC OIL #2 HOHTR2 439-006 - J808 ENGINE QSK78 INTERFACE P806 926-001 SWITCH COOLANT LEVEL P802 ENGINE QSK78 INTERFACE P805
51A1-001 - P13 SWITCH ACCUMULATOR PRECHARGE P... ACCP1-C 67M-001 SWITCH LEFT WINDOW P072 SP778 - 72AT-000 INTERFACE MODULE IM2 TB33 TB33-A2 86-510 - CON3 TB-HTST TB-HTST-H2 509-002 - P808 TB27 TB27-S1 927-000 - J808 ENGINE QSK78 INTERFACE P804
51A2-000 SWITCH ACCUMULATOR PRECHARGE P... ACCP1-NO SWITCH ACCUMULATOR PRECHARGE P... ACCP2-NO 67P-000 TB24 TB24-T2 VEC-91 VEC91-P9 72CPU-000 TB24 TB24-W1 - P808 86-511 THERMOSTAT OIL RESERVE TANK ECHTR1 - CON4 509-003 - P808 TB27 TB27-S3 927-001 - P808 TB31 TB31-A1
52A-000 - J240 SWITCH PARK BRAKE RELEASE PRES... PBRPS 67P-001 TB24 TB24-T1 - P03 72CPU-001 TB24 TB24-W2 GE CONTROL INTERFACE P302 87-000 TB21 TB21-J2 VEC-89 VEC89-P4 509-005 - J808 ENGINE QSK78 INTERFACE P806 927-002 TB31 TB31-A2 - P02
52A-001 - P240 TB32 TB32-N2 67P-002 TB24 TB24-T1 - P03 72CPU-002 - J808 ENGINE QSK78 INTERFACE P806 87-001 TB21 TB21-J1 INTERFACE MODULE IM3 509-007 - J808 ENGINE QSK78 INTERFACE P805 927-003 - J02 - DIAG2
52AA2-000 INTERFACE MODULE IM2 - J702 67P-003 - J03 SP135 - 72CPU-003 TB24 TB24-W3 INTERFACE MODULE IM2 87-002 R15 R15 TB21 TB21-J3 510E-000 VEC-90 VEC90-P3 TB25 TB25-N1 928-000 - J808 ENGINE QSK78 INTERFACE P804
52ABA-000 INTERFACE MODULE IM1 TB32 TB32-S1 67P-004 - J03 SP135 - 72FD-000 TB29 TB29-R1 VEC-90 VEC90-P9 87-500 - J712 TB-HTST TB-HTST-K4 510E-001 TB25 TB25-N2 GE CONTROL INTERFACE P304 928-001 - P808 TB31 TB31-B1
52ABA-001 TB32 TB32-S1 VEC RTMR1 RTMR1-F2 67P-005 SP135 - SWITCH LEFT WINDOW P072 72FD-001 GE CONTROL INTERFACE P302 TB29 TB29-R2 87-501 HEATER COOLANT LH - TB-HTST TB-HTST-J1 510E2-000 - J1206 SWITCH HEDWELD LIMIT - 928-002 TB31 TB31-B2 - P02
52B-000 VEC-90 VEC90-P9 TB32 TB32-J1 67P-006 SWITCH LEFT WINDOW P072 SP135 - 72FNR-000 VEC-90 VEC90-P12 TB24 TB24-M1 87-502 HEATER COOLANT RH - TB-HTST TB-HTST-J2 510E2-001 D5 D5 TB21 TB21-A2 928-003 - J02 - DIAG2
52B-001 INTERFACE MODULE IM2 TB32 TB32-J1 67R-000 TB24 TB24-S2 VEC-91 VEC91-P9 72FNR-001 TB24 TB24-M2 INTERFACE MODULE IM2 87-503 THERMOSTAT ENGINE OIL EOTS TB-HTST TB-HTST-J3 510E2-002 - P538_JP - P46 929-000 - J808 ENGINE QSK78 INTERFACE P804
52B-002 VEC RTMR1 RTMR1-D2 TB32 TB32-J1 67R-001 TB24 TB24-S1 - P03 72GD-000 TB23 TB23-S1 GE CONTROL INTERFACE P305 87-506 - CON1 TB-HTST TB-HTST-K1 510E2-003 TB21 TB21-A4 - J46 929-001 - P808 TB31 TB31-C1
52B-003 TB32 TB32-J4 - P240 67R-002 TB24 TB24-S1 - P03 72GD-001 - P03 TB23 TB23-S2 87-507 THERMOSTAT HYDRAULIC OIL HOSTAT - CON2 510E2-004 - P830 - J538B 929-002 TB31 TB31-C2 - P02
52B-004 - J240 SP160 - 67R-003 - J03 SP138 - 72GD-002 - J03 SWITCH GRID DRY P34 87-510 - CON3 TB-HTST TB-HTST-K2 510E2-005 POWER LADDER CONTROLLER P7 SP308 - 929-003 - J02 - DIAG2
52B-005 SP160 - SOLENOID BRAKE LOCK BLS 67R-004 - J03 SP138 - 72GD-003 SWITCH GRID DRY P34 SWITCH GRID DRY P34 87-511 HEATER OIL RESERVE TANK ECHTR2 - CON4 510E2-006 SP308 - - J538 930-001 SWITCH COOLANT LEVEL P802 ENGINE QSK78 INTERFACE P805
52B-006 SP160 - D3 D3 67R-005 SP138 - SWITCH RIGHT WINDOW P071 72HC-000 PAY LOAD METER 4 P264 PLM4 COMMUNICATION BOX COMMB 90-500 SP704 - THERMOSTAT ENGINE OIL EOTS 510E2-007 SP308 - SENSOR POWER LADDER UP UPS 939GE-001 - P808 CAN TEE J1939 # 1 P301B
52B1-000 VEC-90 VEC90-P9 TB23 TB23-B1 67R-006 SWITCH RIGHT WINDOW P071 SP138 - 72MAN-000 INTERFACE MODULE IM2 TB33 TB33-B2 90-501 HEATER ENGINE OIL LH EOH1 SP704 - 510E2D-000 D5 D5 INTERFACE MODULE IM3 939GE-002 ENGINE QSK78 INTERFACE P820 - J808
52B1-001 - P03 TB23 TB23-B2 67S-000 MOTOR RIGHT WINDOW P058 SP782 - 72N-000 - J02 SHIFTER DIRECTION SELECTOR P108 90-502 SP704 - HEATER ENGINE OIL RH EOH2 525-000 - J01 ACCELERATOR PEDAL P236 939GE-003 SP810 - CAN TEE J1939 #4 P322B
52B1-002 - J03 SWITCH BRAKE LOCK P39 67S-001 SWITCH RIGHT WINDOW P071 SP782 - 72N-001 - P02 TB21 TB21-M2 90-503 SP708 - THERMOSTAT HYDRAULIC OIL HOSTAT 525-001 TB31 TB31-T2 - P01 939GE-004 - P02 CAN TEE J1939 # 2 P305B
52B1-003 SWITCH BRAKE LOCK P39 SWITCH BRAKE LOCK P39 67T-000 MOTOR RIGHT WINDOW P058 SP783 - 72N-002 VEC-90 VEC90-P1 TB21 TB21-M1 90-506 HEATER HYDRAULIC OIL #1 HOHTR1 SP708 - 525-002 - J701 TB31 TB31-T1 939GE-005 - J02 SP810 -
52C-000 - J02 SHIFTER DIRECTION SELECTOR P108 67T-001 SWITCH RIGHT WINDOW P071 SP783 - 72RQ-000 D70 D70 - J537 90-507 SP708 - HEATER HYDRAULIC OIL #2 HOHTR2 525A-000 GE CONTROL INTERFACE P304 SP738 - 939GE-006 CAN TEE J1939 #4 P323B CAN TEE J1939 #5 P321B
52C-001 - P02 TB21 TB21-K2 68-000 TB35 TB35-R4 R30 R30 72RQ-001 - P537 - P12 90-510 HEATER OIL RESERVE TANK ECHTR2 THERMOSTAT OIL RESERVE TANK ECHTR1 525A-001 SP738 - - J701 939GE-007 - DIAG4 SP810 -
52C-002 TB21 TB21-K1 - J701 68-001 TB35 TB35-R1 INTERFACE MODULE IM1 72RQ-002 - J12 TB23 TB23-K4 90CAG-000 GE CONTROL INTERFACE P303 TB25 TB25-G1 528A-000 - J808 ENGINE QSK78 INTERFACE P806 939GE-008 INTERFACE MODULE IM1 CAN TEE J1939 # 1 P306D
52CA-000 TB24 TB24-E2 GE CONTROL INTERFACE P304 68-002 TB35 TB35-R3 - J11 72RQ-003 TB23 TB23-K1 GE CONTROL INTERFACE P304 90CAG-001 - P02 TB25 TB25-G2 556-000 GE CONTROL INTERFACE P302 TB27 TB27-T2 939GE-010 KOMTRAX PLUS MODULE P4A SP813 -
52CA-001 - J701 TB24 TB24-E1 68-003 - J511 - P12 72RQ-004 TB23 TB23-K2 - P03 90CAG-002 - J02 - DIAG1 556-001 R50 R50 TB27 TB27-T3 939GE-011 CAN TEE J1939 # 1 P315B CAN TEE J1939 # 2 P316B
52CA-003 TB24 TB24-E4 INTERFACE MODULE IM3 68-004 SOLENOID AUTO LUBE ALSOL - P511 72RQ-005 - J03 D71 D71 90CAR-000 GE CONTROL INTERFACE P303 TB25 TB25-E1 556-002 - P808 TB27 TB27-T1 939GE-012 - P318D CAN TEE J1939 # 2 P317D
52CS-000 VEC-90 VEC90-P11 TB32 TB32-K3 68-005 - J12 TB35 TB35-R2 72RR-000 D71 D71 SWITCH DC POWER OFF - REST SWI... P35 90CAR-001 - P02 TB25 TB25-E2 556-003 - J808 ENGINE QSK78 INTERFACE P805 939GE-013 SP813 - CAN TEE J1939 #5 P308B
52CS-001 TB32 TB32-K3 INTERFACE MODULE IM1 68ES-000 - J11 SP785 - 72RR-001 SWITCH DC POWER OFF - REST SWI... P35 SWITCH DC POWER OFF - REST SWI... P35 90CAR-002 - J02 - DIAG1 556A-001 - P808 R50 R50 939GE-014 KOMVISION CONTROLLER KVIS-B CAN TEE J1939 #4 P324D
52CS-002 TB32 TB32-K2 R18 R18 68ES-001 - J511 - P12 72RRQ-000 LAMP LED PROPEL LOCKOUT LOCKED... PLLO RELAY PROPEL LOCKOUT PLREL_K 90CAT-000 GE CONTROL INTERFACE P303 TB25 TB25-F1 712-000 RELAY KEY SWITCH (KSWPR) KSWPR-88A TB24 TB24-J1 939GE-015 TERM1 P304R SP813 -
52CS-003 - P240 TB32 TB32-K1 68ES-002 SOLENOID AUTO LUBE ALSOL - P511 72RRQ-001 RELAY PROPEL LOCKOUT PLREL_K D70 D70 90CAT-001 - P02 TB25 TB25-F2 712-001 GE CONTROL INTERFACE P305 TB24 TB24-J2 939GK-000 CAN TEE 3RD PARTY #1 P402B CAN TEE 3RD PARTY #2 P401B
52CS-004 SOLENOID PARK BRAKE PBS SP161 - 68ES-003 SP785 - VEC-89 VEC89-P2 72SBT-000 TB25 TB25-X1 GE CONTROL INTERFACE P305 90CAT-002 - J02 - DIAG1 712-003 TB24 TB24-K2 VEC-89 VEC89-S5A 939GK-001 PAY LOAD METER 4 P264 CAN TEE 3RD PARTY #2 P402D
52CS-005 D2 D2 SP161 - 68ES-004 - J12 SP785 - 72SBT-001 TB25 TB25-X2 - P03 90DIG-000 TB25 TB25-A1 GE CONTROL INTERFACE P303 712-004 TB24 TB24-K4 VEC-91 VEC91-S8A 939GK-002 - P02 CAN TEE 3RD PARTY #2 P400B
52CS-006 SP161 - - J240 68LS-000 - P511 SWITCH AUTOLUBE LEVEL (OPT) P512 72SBT-002 SWITCH BRAKE TEST P37 - J03 90DIG-001 TB25 TB25-A2 - P02 712-005 TB24 TB24-K3 12V POWER RELAY (12VPR) 12VPR-86 939GK-003 - P404D CAN TEE 3RD PARTY #1 P403D
52PB-000 VEC-90 VEC90-P11 TB24 TB24-B1 68LS-001 - J511 - P12 72T-000 - J02 SHIFTER DIRECTION SELECTOR P108 90DIG-002 - J02 GE DID PANEL DID 712A-000 VEC-91 VEC91-P9 SWITCH AUX BOX DOME LIGHT (DLS... DLS-2 939GK-004 SP807 - - J02
52PB-001 TB24 TB24-B4 - P03 68LS-002 INTERFACE MODULE IM3 SP786 - 72T-001 TB21 TB21-P2 - P02 90DIR-000 GE CONTROL INTERFACE P303 TB25 TB25-B1 712BL-000 VEC-90 VEC90-P12 TB23 TB23-L1 939GK-005 SP807 - CAN TEE 3RD PARTY #4 P407B
52PB-003 TB24 TB24-B2 INTERFACE MODULE IM3 68LS-003 - J12 SP786 - 73DS-000 GE CONTROL INTERFACE P304 TB21 TB21-S1 90DIR-001 - P02 TB25 TB25-B2 712BL-001 TB23 TB23-L2 INTERFACE MODULE IM3 939GK-006 - CAN_TP SP807 -
52PB-004 - J03 RELAY HYDRAULIC LADDER PK STAT... P263 68LS-004 - J11 SP786 - 73DS-001 TB21 TB21-S2 - P02 90DIR-002 - J02 GE DID PANEL DID 712BL-002 TB23 TB23-L4 - P03 939GP-000 CAN TEE RPC # 1 P205B CAN TEE RPC # 2 P204B
52R-000 - J01 - P237 68P-001 SWITCH AUTOLUBE PRESSURE LLPS - P16 73DS-002 - J02 SWITCH DATA STORE (DSSW) DSSW-NO 90DIT-000 GE CONTROL INTERFACE P303 TB25 TB25-C1 712BL-003 SWITCH BRAKE LOCK P39 - J03 939GP-001 ACTIA DASH DISPLAY P903 CAN TEE RPC #5 P212D
52R-001 TB31 TB31-K2 - P01 68P-003 - J16 INTERFACE MODULE IM3 73DS-003 TB21 TB21-S4 - P04 90DIT-001 TB25 TB25-C2 - P02 712DS-000 TB24 TB24-C1 VEC-89 VEC89-P4 939GP-002 - P02 CAN TEE RPC # 3 P203B
52R-002 TB31 TB31-K1 - J701 69M-000 TB23 TB23-F1 VEC-89 VEC89-P1 73DS-005 KOMTRAX PLUS MODULE P3B - J04 90DIT-002 - J02 GE DID PANEL DID 712DS-001 TB24 TB24-C2 - P02 939GP-003 - J02 CAN TEE RPC # 4 P220B
52R-003 - J237 RETARD LEVER SENSOR (OPT) P814 69M-001 TB23 TB23-F2 - J11 73S-000 D72 D72 TB22 TB22-J2 90ER1-000 - P607 - P606 712DS-002 - J02 JB4E JB4E 939GP-004 CAN TEE RPC # 4 P221B CAN TEE RPC #5 P207B
52RA-000 GE CONTROL INTERFACE P302 SP740 - 69M-002 TB23 TB23-F2 - J12 73S-002 - P240 TB22 TB22-J2 90ER1-001 - J607 WIRELESS BRIDGE KWB 712DS-003 MOTOR, DRIVERS SEAT J228 JB4E JB4E 939GP-005 SP816 - CAN TEE RPC #5 P211B
52RA-001 SP740 - - J701 69M-003 - P11 - J541 73S-003 - J240 SWITCH PARK BRAKE RELEASE PRES... PBRPS 90ER1-002 - J606 ETHERNET SWITCH PORT5 712DS-004 MOTOR, PASSENGER SEAT J229 JB4E JB4E 939GP-007 PAY LOAD METER 4 P264 CAN TEE RPC # 3 P202D
52RS1-000 RELAY HYDRAULIC LADDER PK STAT... P263 - P262_CP 69M-004 - P12 - J540 73S-004 TB22 TB22-J1 - J46 90ER2-000 - P607 - P606 712G-000 VEC-91 VEC91-P9 TB23 TB23-H2 939GP-008 INTERFACE MODULE IM1 CAN TEE RPC # 2 P206D
52RS2-000 RELAY HYDRAULIC LADDER PK STAT... P263 - P262_CP 69M-005 - P541 - P502 73S-005 - P538_JP - P46 90ER2-001 - J607 WIRELESS BRIDGE KWB 712G-001 TB23 TB23-H4 - P04 939GP-009 - P219D CAN TEE RPC # 1 P218D
53H-001 - J16 TB35 TB35-N1 69M-006 - P540 - P503 73S-006 POWER LADDER CONTROLLER P7 - J538 90ER2-002 - J606 ETHERNET SWITCH PORT5 712G-002 - P01 TB23 TB23-H1 939GP-010 KOMTRAX PLUS MODULE P4A SP816 -
53H-002 SWITCH HOIST LIMIT HLS - P16 69M-007 - J502 MIRROR HEATED RIGHT DECK MIRROR1 73S1-000 VEC-90 VEC90-P3 TB32 TB32-M1 90ET1-000 - P607 - P606 712G-003 TB10 TB10-F2 - J01 939GP-011 KOMVISION CONTROLLER KVIS-B CAN TEE RPC # 4 P222D
53H-003 TB35 TB35-N2 - P240 69M-008 - J503 MIRROR HEATED LEFT DECK MIRROR2 73S1-001 TB32 TB32-M1 INTERFACE MODULE IM2 90ET1-001 - J607 WIRELESS BRIDGE KWB 712G-004 ACTIA DASH DISPLAY P902 TB10 TB10-F1 939GP-012 CAN TEE RPC # 2 P215B CAN TEE RPC # 3 P216B
53H-005 TB35 TB35-N1 - J14 69MA-000 SWITCH HEATED MIRROR P33 - J03 73S1-002 TB32 TB32-M2 D72 D72 90ET1-002 - J606 ETHERNET SWITCH PORT5 712G-005 D9 D9 - J04 939GP-013 SP816 - TERM3 P201R
53H-008 SP794 - D88 D88 69MA-001 - P03 TB28 TB28-W1 74D-000 GE CONTROL CABINET T20 ALTERNATOR PROPULSION DRIVE ALT2 90ET2-000 - P607 - P606 712H-001 - P16 SWITCH HOIST LIMIT HLS 939GX1-000 KOMVISION CONTROLLER KVIS-B TX0 P21TX0D
53H-009 - P14 SP794 - 69MA-002 TB28 TB28-W2 VEC-89 VEC89-P1 74DS-000 KOMTRAX PLUS MODULE P1 - J04 90ET2-001 - J607 WIRELESS BRIDGE KWB 712H-003 VEC-91 VEC91-P10 TB23 TB23-W1 939GX1-002 SP047 - SP050 -
53H-010 SP794 - SOLENOID HOIST LIMIT HS 71ABA-000 TB32 TB32-T1 VEC RTMR1 RTMR1-F1 74DS-001 - P04 TB25 TB25-M2 90ET2-002 - J606 ETHERNET SWITCH PORT5 712H-004 - J16 TB23 TB23-W1 939GX1-003 SP050 - SP057 -
55A-000 SWITCH DISPLAY MODE #2 P20 - J01 71ABA-001 VEC RTMR1 RTMR1-D1 TB32 TB32-T3 74DS-002 TB25 TB25-M1 INTERFACE MODULE IM2 90IMG-000 INTERFACE MODULE IM2 TB28 TB28-P1 712IM-000 VEC-90 VEC90-P1 RELAY KEY SWITCH (KSWPR) KSWPR-86 939GX1-005 RADAR 1 KOMVISION J119 SP057 -
55A-001 - P01 TB26 TB26-N1 71ABA-002 TB32 TB32-T1 VEC-90 VEC90-P11 74HB-000 PAY LOAD METER 4 P264 PLM4 COMMUNICATION BOX COMMB 90IMG-001 - J372 TB28 TB28-P1 712K-000 SWITCH KEY (KEYSW) KEYSW-BR - J03 939GX1-006 RADAR 2 KOMVISION J122 SP057 -
55A-002 TB26 TB26-N2 INTERFACE MODULE IM3 71ABA-003 TB32 TB32-T2 R1 R1 74LA-000 PAY LOAD METER 4 P264 PLM4 COMMUNICATION BOX COMMB 90IMG-002 TB28 TB28-P4 - P02 712K-001 - P03 TB23 TB23-N1 939GX1-007 RADAR 3 KOMVISION J123 SP050 -
55B-000 SWITCH DISPLAY MODE #2 P20 - J01 71BC-000 VEC-90 VEC90-P9 TB25 TB25-V4 74N-000 - J01 RETARD CONTROL PEDAL P235 90IMG-003 - J02 - DIAG5 712K-002 TB23 TB23-N2 VEC-90 VEC90-P1 939GX1-008 RADAR 4 KOMVISION J124 SP047 -
55B-001 - P01 TB26 TB26-P1 71BC-003 TB25 TB25-V2 - P240 74N-001 TB31 TB31-R2 - P01 90IMR-000 INTERFACE MODULE IM2 TB28 TB28-N1 712K-003 TB23 TB23-N4 INTERFACE MODULE IM2 939GX1-009 SP047 - TX0 P21TX0B2
55B-002 TB26 TB26-P2 INTERFACE MODULE IM3 71BC-004 D2 D2 JB4A JB4A 74N-002 - J701 TB31 TB31-R1 90IMR-001 - J372 TB28 TB28-N1 712K-004 SWITCH KEY (KEYSW) KEYSW-BR SWITCH MANUAL BACKUP LIGHT P23 939GX2-000 KOMVISION CONTROLLER KVIS-B TX9 P22TX9D
55C-000 SWITCH DISPLAY MODE #1 P21 - J01 71BC-005 SOLENOID PARK BRAKE PBS JB4A JB4A 74NA-000 GE CONTROL INTERFACE P302 SP739 - 90IMR-002 TB28 TB28-N4 - P02 712L-000 SWITCH AUX BOX DOME LIGHT (DLS... DLS-3 SP100 - 939GX2-001 - J16X SP070 -
55C-001 - P01 TB26 TB26-R1 71BC-006 JB4A JB4A SWITCH SERVICE BRAKE PSI SBPS 74NA-001 SP739 - - J701 90IMR-003 - J02 - DIAG5 712L-001 SP100 - DL1 DL1 939GX2-002 SP060 - SP067 -
55C-002 TB26 TB26-R2 INTERFACE MODULE IM3 71BC-007 - J240 JB4A JB4A 74SB1-000 - PX07_CP - J02 90IMT-000 INTERFACE MODULE IM2 TB28 TB28-M1 712L-002 SP100 - DL2 DL2 939GX2-003 SP067 - - P16X
55D-000 SWITCH DISPLAY MODE #1 P21 - J01 71C-000 VEC-91 VEC91-P10 RELAY KEY/GE CNTRL PWR (KCNPR) KCNPR-86 74SB1-001 - P02 TB25 TB25-T1 90IMT-001 - J372 TB28 TB28-M1 712L-003 SP100 - DL3 DL3 939GX2-005 RADAR 5 KOMVISION J125 SP070 -
55D-001 - P01 TB26 TB26-S1 71CK-000 RELAY KEY/GE CNTRL PWR (KCNPR) KCNPR-88A TB24 TB24-N1 74SB1-002 - J12 TB25 TB25-T2 90IMT-002 TB28 TB28-M4 - P02 712L-004 SP256 - DL4 DL4 939GX2-006 RADAR 6 KOMVISION J126 SP070 -
55D-002 TB26 TB26-S2 INTERFACE MODULE IM2 71CK-001 VEC-90 VEC90-S8A VEC-89 VEC89-S6A 74SB1-003 - P537 - P12 90IMT-003 - J02 - DIAG5 712L-005 SP256 - DL5 DL5 939GX2-007 RADAR 7 KOMVISION J127 SP067 -
62A-000 INTERFACE MODULE IM1 VEC-89 VEC89-P2 71CK-002 VEC-90 VEC90-S8B TB24 TB24-N2 74SB1-005 - JX07 SP005 - 90MMG-000 GE CONTROL INTERFACE P303 TB36 TB36-H1 712L-006 SP256 - DL6 DL6 939GX2-008 RADAR 8 KOMVISION J128 SP060 -
62SB-000 INTERFACE MODULE IM2 TB28 TB28-X1 71CK-003 VEC-91 VEC91-P1 TB24 TB24-N3 74SB1-006 KOMVISION CONTROLLER KVIS-B SP005 - 90MMG-003 TB36 TB36-H4 INTERFACE MODULE IM2 712L-007 SP100 - SP256 - 939GX2-009 SP060 - TX9 P22TX9B2
62SB-001 TB28 TB28-X2 - P02 71CK-004 VEC RTMR1 RTMR1-B9 TB24 TB24-N4 74SB1-007 SP005 - - J251X_CP 90MMR-000 GE CONTROL INTERFACE P303 TB36 TB36-G1 712M-000 VEC-90 VEC90-P1 INTERFACE MODULE IM1 939YE-001 - P808 CAN TEE J1939 # 1 P301B
62SB-002 - J02 SWITCH DRIVERS SEAT BELT P212 71CKM-000 VEC RTMR1 RTMR1-A9 SWITCH KOMVISION ON/OFF KOMV-2 74X-001 TB33 TB33-T2 SENSOR GE ALTERNATOR SPEED ALTSP 90MMR-003 TB36 TB36-G4 INTERFACE MODULE IM2 712MM-000 VEC-90 VEC90-P4 TB32 TB32-R1 939YE-002 ENGINE QSK78 INTERFACE P820 - J808
62SBA-000 TB32 TB32-L2 VEC-89 VEC89-P2 71CN1-000 GE CONTROL INTERFACE P305 GE CONTROL INTERFACE P304 74X-002 GE CONTROL INTERFACE P301 TB33 TB33-T1 90MMT-000 GE CONTROL INTERFACE P303 TB36 TB36-F1 712MM-001 - P02 TB32 TB32-R2 939YE-003 SP809 - CAN TEE J1939 #4 P322B
63-000 TB24 TB24-R2 - P03 71CN2-000 GE CONTROL INTERFACE P303 GE CONTROL INTERFACE P302 74Z-001 TB33 TB33-W2 SENSOR GE ALTERNATOR SPEED ALTSP 90MMT-003 TB36 TB36-F4 INTERFACE MODULE IM2 712MM-002 - J02 SP157 - 939YE-004 - P02 CAN TEE J1939 # 2 P305B
63-001 - J03 TB10 TB10-E2 71CNCK-000 GE CONTROL INTERFACE P301 GE CONTROL INTERFACE P301 74Z-002 GE CONTROL INTERFACE P301 TB33 TB33-W1 90VHG-000 KOMTRAX PLUS MODULE P4A SP193 - 712MM-003 SP157 - - CAN_TP 939YE-005 - J02 SP809 -
63-002 TB10 TB10-E1 SWITCH COMBO P121 71F-000 TB35 TB35-S1 GE CONTROL INTERFACE P301 74ZA-000 GE CONTROL INTERFACE P301 TB21 TB21-D1 90VHG-001 - DIAG6 SP193 - 712MM-004 - CAN_TP SP157 - 939YE-006 CAN TEE J1939 #4 P323B CAN TEE J1939 #5 P321B
63-003 TB10 TB10-E1 JB6G JB6G 71F-001 - J16 TB35 TB35-S2 74ZA-001 TB21 TB21-D2 VEC-89 VEC89-P1 90VHG-002 SP193 - - J04 712MM-005 SP157 - - PTX_CP 939YE-007 - DIAG4 SP809 -
63-004 JB6G JB6G RELAY WIPER MOTOR LOW P09_K 71F-002 TB35 TB35-S3 PAY LOAD METER 4 P264 74ZA-002 TB21 TB21-D4 INTERFACE MODULE IM3 90VHG-003 - P04 TB29 TB29-T1 712P-000 TB35 TB35-D1 VEC-89 VEC89-P4 939YE-008 INTERFACE MODULE IM1 CAN TEE J1939 # 1 P306D
63-005 JB6G JB6G RELAY WIPER MOTOR HIGH P08_K 71F-003 TB35 TB35-S4 INTERFACE MODULE IM2 75A1-000 - J703 SWITCH TRACTION MOTOR PRESSURE... BPSW-NC 90VHG-004 TB29 TB29-T2 - VHMS 712P-001 TB35 TB35-D2 - P03 939YE-010 KOMTRAX PLUS MODULE P4A SP812 -
63-006 JB6G JB6G MOTOR WINDSHIELD WIPER P07 71F-004 - P16 SWITCH BODY-UP PROXIMITY BUSW 75A2-000 TB35 TB35-V1 GE CONTROL INTERFACE P301 90VHR-000 KOMTRAX PLUS MODULE P4A SP192 - 712P-002 - J03 SWITCH BRAKE TEST P37 939YE-011 CAN TEE J1939 # 1 P315B CAN TEE J1939 # 2 P316B
63-007 JB6G JB6G TIMER WASHER DELAY (WADT) WADT-2 71GE-000 GE CONTROL INTERFACE P305 TB24 TB24-G3 75A2-001 TB35 TB35-V2 - J16 90VHR-001 - DIAG6 SP192 - 712P-003 SWITCH BRAKE TEST P37 SWITCH BRAKE TEST P37 939YE-012 - P318D CAN TEE J1939 # 2 P317D
63-008 JB6G JB6G TIMER WIPER DELAY P10 71GE-001 TB24 TB24-G2 VEC-91 VEC91-P10 75A2-002 - J703 SWITCH TRACTION MOTOR PRESSURE... BPSW-NO 90VHR-002 SP192 - - J04 712PL-000 VEC-90 VEC90-P4 TB34 TB34-V1 939YE-013 SP812 - CAN TEE J1939 #5 P308B
63-009 VEC-91 VEC91-P10 TB24 TB24-R1 71GE-002 INTERFACE MODULE IM3 TB24 TB24-G1 75A2-003 - P16 - P72 90VHR-003 - P04 TB29 TB29-V1 712PL-001 TB34 TB34-V2 PAY LOAD METER 4 P264 939YE-014 KOMVISION CONTROLLER KVIS-B CAN TEE J1939 #4 P324D
63H-000 MOTOR WINDSHIELD WIPER P07 RELAY WIPER MOTOR HIGH P08_K 71GG-000 SWITCH PROPEL LOCKOUT (PLOS) PLOS-F1 - J537 75A2-004 - J72 - P703 90VHR-004 TB29 TB29-V2 - VHMS 712SL-000 VEC-90 VEC90-P3 TB36 TB36-P1 939YE-015 TERM1 P304R SP812 -
63H1-000 SWITCH COMBO P121 RELAY WIPER MOTOR HIGH P08_K 71GG-001 - P537 - P12 77-000 TB26 TB26-K2 GE CONTROL INTERFACE P303 90VHT-000 KOMTRAX PLUS MODULE P4A SP191 - 712SL-001 SCORE BOARD LEFT (OPT) CNLIN TB36 TB36-P2 939YK-000 CAN TEE 3RD PARTY #1 P402B CAN TEE 3RD PARTY #2 P401B
63L-000 RELAY WIPER MOTOR LOW P09_K MOTOR WINDSHIELD WIPER P07 71GG-002 - J12 TB25 TB25-K1 77-001 TB26 TB26-K1 INTERFACE MODULE IM1 90VHT-001 - DIAG6 SP191 - 712SL-002 SCORE BOARD RIGHT (OPT) CNRIN SCORE BOARD LEFT (OPT) CNLO 939YK-001 PAY LOAD METER 4 P264 CAN TEE 3RD PARTY #2 P402D
63L1-000 D15 D15 JB4H JB4H 71GG-003 TB25 TB25-K2 GE CONTROL INTERFACE P303 77-003 PAY LOAD METER 4 P264 TB26 TB26-K3 90VHT-002 SP191 - - J04 712T-000 VEC-91 VEC91-P11 TB23 TB23-R2 939YK-002 - P02 CAN TEE 3RD PARTY #2 P400B
63L1-001 RELAY WIPER MOTOR LOW P09_K JB4H JB4H 71GH-000 SWITCH PROPEL LOCKOUT (PLOS) PLOS-F2 - J537 77A-000 TB26 TB26-L2 GE CONTROL INTERFACE P303 90VHT-003 - P04 TB29 TB29-W1 712T-001 TB23 TB23-R1 - P03 939YK-003 - P404D CAN TEE 3RD PARTY #1 P403D
63L1-002 TIMER WASHER DELAY (WADT) WADT-1 JB4H JB4H 71GH-001 - P537 - P12 77A-001 TB26 TB26-L1 INTERFACE MODULE IM1 90VHT-004 TB29 TB29-W2 - VHMS 712T-002 - J03 SWITCH COMBO P121 939YK-004 SP806 - - J02
63L1-003 TIMER WIPER DELAY P10 JB4H JB4H 71GH-002 - J12 TB25 TB25-L1 77A-003 PAY LOAD METER 4 P264 TB26 TB26-L3 91ER1-000 MODULAR MINING DISPLAY MMS_ENET - JENET4 714A-000 - P15 SENSOR RIGHT REAR WHEEL SPEED P720 939YK-005 SP806 - CAN TEE 3RD PARTY #4 P407B
63L2-000 SWITCH COMBO P121 D15 D15 71GH-003 TB25 TB25-L2 GE CONTROL INTERFACE P303 77B-000 - P15 SENSOR LEFT REAR WHEEL SPEED P721 91ER1-001 - JENET1 ETHERNET SWITCH PORT1 714A-001 TB29 TB29-K2 - J15 939YK-006 - CAN_TP SP806 -
63P-000 MOTOR WINDSHIELD WIPER P07 SWITCH COMBO P121 71H-000 GE CONTROL INTERFACE P304 TB21 TB21-R1 77B-001 TB29 TB29-E2 - J15 91ER1-002 - PENET4 - PENET1 714A-003 GE CONTROL INTERFACE P301 TB29 TB29-K1 939YP-000 CAN TEE RPC # 1 P205B CAN TEE RPC # 2 P204B
63T1-000 SWITCH COMBO P121 TIMER WIPER DELAY P10 71H-001 TB21 TB21-R2 - P02 77B-003 GE CONTROL INTERFACE P301 TB29 TB29-E1 91ER2-000 MODULAR MINING DISPLAY MMS_ENET - JENET4 714B-000 - P15 SENSOR RIGHT REAR WHEEL SPEED P720 939YP-001 ACTIA DASH DISPLAY P903 CAN TEE RPC #5 P212D
63W-000 - J03 JB4C JB4C 71H-002 SWITCH BODYUP OVERRIDE / RESET... ORS_1-3 - J02 77C-000 - P15 SENSOR LEFT REAR WHEEL SPEED P721 91ER2-001 - JENET1 ETHERNET SWITCH PORT1 714B-001 TB29 TB29-M2 - J15 939YP-002 - P02 CAN TEE RPC # 3 P203B
63W-001 SWITCH COMBO P121 JB4C JB4C 71J-000 GE CONTROL CABINET T19 ALTERNATOR PROPULSION DRIVE ALT1 77C-001 TB29 TB29-C2 - J15 91ER2-002 - PENET4 - PENET1 714B-003 GE CONTROL INTERFACE P301 TB29 TB29-M1 939YP-003 - J02 CAN TEE RPC # 4 P220B
63W-002 TIMER WASHER DELAY (WADT) WADT-6 JB4C JB4C 71LS-000 TB23 TB23-M1 VEC-89 VEC89-P4 77C-003 GE CONTROL INTERFACE P301 TB29 TB29-C1 91ET1-000 MODULAR MINING DISPLAY MMS_ENET - JENET4 714DN-000 - P15 SENSOR RIGHT REAR WHEEL SPEED P720 939YP-004 CAN TEE RPC # 4 P221B CAN TEE RPC #5 P207B
63W-003 - P03 MOTOR WINDSHIELD WASHER WW+ 71LS-001 TB23 TB23-M2 - P01 77DN-000 - P15 SENSOR LEFT REAR WHEEL SPEED P721 91ET1-001 - JENET1 ETHERNET SWITCH PORT1 714DN-001 TB29 TB29-N2 - J15 939YP-005 SP815 - CAN TEE RPC #5 P211B
65-000 VEC-91 VEC91-P12 TB24 TB24-D1 71LS-002 TB10 TB10-C1 - J01 77DN-001 TB29 TB29-F2 - J15 91ET1-002 - PENET4 - PENET1 714DN-003 GE CONTROL INTERFACE P301 TB29 TB29-N1 939YP-007 PAY LOAD METER 4 P264 CAN TEE RPC # 3 P202D
65-001 ENTERTAINMENT RADIO P737 - J211 71LS-003 TB10 TB10-C2 SWITCH FOG LAMP (OPT) P22 77DN-003 GE CONTROL INTERFACE P301 TB29 TB29-F1 91ET2-000 MODULAR MINING DISPLAY MMS_ENET - JENET4 714DP-000 - P15 SENSOR RIGHT REAR WHEEL SPEED P720 939YP-008 INTERFACE MODULE IM1 CAN TEE RPC # 2 P206D
65-002 - P04 TB24 TB24-D2 71LS-004 SWITCH FOG LAMP (OPT) P22 SWITCH FOG LAMP (OPT) P22 77DP-000 - P15 SENSOR LEFT REAR WHEEL SPEED P721 91ET2-001 - JENET1 ETHERNET SWITCH PORT1 714DP-001 TB29 TB29-L2 - J15 939YP-009 - P219D CAN TEE RPC # 1 P218D
65-003 - P211 - J04 71LS-005 TB10 TB10-C3 SWITCH DISPLAY MODE #2 P20 77DP-001 TB29 TB29-D2 - J15 91ET2-002 - PENET4 - PENET1 714DP-003 GE CONTROL INTERFACE P301 TB29 TB29-L1 939YP-010 KOMTRAX PLUS MODULE P4A SP815 -
65-004 SP510 - TB24 TB24-D4 71LS-006 SWITCH DISPLAY MODE #2 P20 SWITCH DISPLAY MODE #2 P20 77DP-003 GE CONTROL INTERFACE P301 TB29 TB29-D1 92ER1-000 USER PC PC-ENET - JENET5 714G-000 - P15 SENSOR RIGHT REAR WHEEL SPEED P720 939YP-011 KOMVISION CONTROLLER KVIS-B CAN TEE RPC # 4 P222D
65-005 TB24 TB24-D3 - P04 71LS-007 SWITCH DISPLAY MODE #2 P20 SWITCH DISPLAY MODE #1 P21 77G-000 - P15 SENSOR LEFT REAR WHEEL SPEED P721 92ER1-001 - JENET2 ETHERNET SWITCH PORT2 714G-001 TB29 TB29-J2 - J15 939YP-012 CAN TEE RPC # 2 P215B CAN TEE RPC # 3 P216B
65-006 - J04 LAMP CAB DOME CDL 71LS-008 SWITCH DISPLAY MODE #1 P21 SWITCH DISPLAY MODE #1 P21 77G-001 - J15 TB29 TB29-B2 92ER1-002 - PENET5 - PENET2 714G-003 GE CONTROL INTERFACE P301 TB29 TB29-J1 939YP-013 SP815 - TERM3 P201R
65-008 - J607 WIRELESS BRIDGE KWB 71LS-011 TB10 TB10-C2 SWITCH ROTATING BEACON (OPT) P32 77G-003 GE CONTROL INTERFACE P301 TB29 TB29-B1 92ER2-000 USER PC PC-ENET - JENET5 714P-001 - J15 TB29 TB29-H2 939YX1-000 KOMVISION CONTROLLER KVIS-B TX0 P21TX0D
65-010 - P607 - P606 71LS-012 SWITCH ROTATING BEACON (OPT) P32 SWITCH ROTATING BEACON (OPT) P32 77P-002 TB29 TB29-A2 - J15 92ER2-001 - JENET2 ETHERNET SWITCH PORT2 714P-002 - P15 SENSOR RIGHT REAR WHEEL SPEED P720 939YX1-002 SP046 - SP049 -
65-011 - P607 - P606 71LS-013 SWITCH HEATED MIRROR P33 SWITCH ROTATING BEACON (OPT) P32 77P-003 GE CONTROL INTERFACE P301 TB29 TB29-A1 92ER2-002 - PENET5 - PENET2 714P-003 GE CONTROL INTERFACE P301 TB29 TB29-H1 939YX1-003 SP049 - SP056 -
65-012 - J606 SP510 - 71LS-014 SWITCH HEATED MIRROR P33 SWITCH HEATED MIRROR P33 77P-004 - P15 SENSOR LEFT REAR WHEEL SPEED P721 92ET1-000 USER PC PC-ENET - JENET5 714Y-000 GE CONTROL INTERFACE P305 TB33 TB33-D1 939YX1-005 RADAR 1 KOMVISION J119 SP056 -
65-013 - J606 SP510 - 71LS-015 SWITCH HEATED MIRROR P33 SWITCH HEATED MIRROR P33 77Y-000 GE CONTROL INTERFACE P305 TB33 TB33-E1 92ET1-001 - JENET2 ETHERNET SWITCH PORT2 714Z-000 GE CONTROL INTERFACE P305 TB33 TB33-C1 939YX1-006 RADAR 2 KOMVISION J122 SP056 -
58B-06-02261-00 SEP 15
980E-4
A40003 & UP
Sheet 22 of 24
WIRE TABLE CONTINUED FROM DIAGRAM 20, 21 & 22 TERMINAL BOARD TABLE
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 CONN WIRE ID'S SHEET-ZONE CONN WIRE ID'S SHEET-ZONE CONN WIRE ID'S SHEET-ZONE CONN WIRE ID'S SHEET-ZONE CONN WIRE ID'S SHEET-ZONE CONN WIRE ID'S SHEET-ZONE
939YX1-007 RADAR 3 KOMVISION J123 SP049 - SHIELD-029 SP058 - - - SHIELD-860 PAY LOAD METER 4 P264 CAN TEE RPC # 3 P202D TB-HTST-C1 0 16-K12 TB22-X2 39H1 8-N10 TB25-T1 74SB1 18-J16 TB29-F1 77DN 11-E4 TB32-F1 33T 14-G10 TB35-M1 42 11-E17
939YX1-008 RADAR 4 KOMVISION J124 SP046 - SHIELD-030 SP048 - SP055 - SHIELD-861 - P404D CAN TEE 3RD PARTY #1 P403D TB-HTST-C2 0 16-L12 TB23-A1 39H 8-N12 TB25-T2 74SB1 18-J17 TB29-F2 77DN 11-E4 TB32-F2 33T 14-G11 TB35-M2 42 11-E17
939YX1-009 SP046 - TX0 P21TX0B2 SHIELD-031 SP065 - - - SHIELD-862 - P02 CAN TEE 3RD PARTY #2 P400B TB-HTST-D2 0 16-L12 TB23-A2 39H 8-N13 TB25-V2 71BC 8-F9 TB29-G1 SHIELD 11-E4 TB32-G1 24VIM 5-J12 TB35-M3 42 11-F17
939YX2-000 KOMVISION CONTROLLER KVIS-B TX9 P22TX9D SHIELD-032 SP068 - - - SHIELD-863 - J02 SP808 - TB-HTST-D4 0 16-L12 TB23-B1 52B1 8-K12 TB25-V4 71BC 8-F9 TB29-G2 SHIELD 11-E4 TB32-G4 24VIM 5-J12 TB35-N1 53H 11-N14
939YX2-001 - J16X SP069 - SHIELD-033 SP075 - - - SHIELD-877 - P13 - -
TB-HTST-E1 0 16-L12 TB23-B2 52B1 8-K12 TB25-W1 33SBA 13-O4 TB29-H1 714P 11-F4 TB32-H1 24VIM 5-J12 TB35-N2 53H 11-N14
939YX2-002 SP059 - SP066 - SHIELD-034 SP075 - - - SHIELD-878 - P13 - -
TB-HTST-E2 0 16-L12 TB23-C1 39AA 15-F13 TB25-W2 33SBA 13-O4 TB29-H2 714P 11-F4 TB32-H2 24VIM 5-J12 TB35-P1 11RWL 9-F16
939YX2-003 SP066 - - P16X SHIELD-036 SP068 - - P16X SHIELD-883 - J16 TB36 TB36-J3
TB-HTST-F4 86 16-M12 TB23-D1 39BA 15-G13 TB25-X1 72SBT 13-O4 TB29-J1 714G 11-F4 TB32-J1 52B 8-L15 TB35-P2 11RWL 9-F16
939YX2-005 RADAR 5 KOMVISION J125 SP069 - SHIELD-037 SP065 - SP068 - SHIELD-884 - P16 SP233 -
TB-HTST-G1 86 16-M12 TB23-E1 39CA 15-H13 TB25-X2 72SBT 13-O4 TB29-J2 714G 11-F4 TB32-J4 52B 8-L15 TB35-R1 68 14-M12
939YX2-006 RADAR 6 KOMVISION J126 SP069 - SHIELD-038 SP254 - TX9 P22TX9D SHIELD-893 - J02 - -
TB-HTST-G2 86 16-M12 TB23-F1 69M 15-C7 TB26-K1 77 13-B7 TB29-K1 714A 11-F4 TB32-K1 52CS 8-I13 TB35-R2 68 14-M13
939YX2-007 RADAR 7 KOMVISION J127 SP066 - SHIELD-039 SP254 - TX0 P21TX0D SHIELD-894 - P02 TB28 TB28-R4
TB-HTST-G3 86 16-M12 TB23-F2 69M 15-C7 TB26-K2 77 13-B7 TB29-K2 714A 11-F4 TB32-K2 52CS 8-I13 TB35-R3 68 14-M12
939YX2-008 RADAR 8 KOMVISION J128 SP059 - SHIELD-100 SP205 - SP214 - SHIELD-896 TB28 TB28-R1 - -
TB-HTST-H1 86 16-M12 TB23-G1 11DISP 9-G12 TB26-K3 77 13-C7 TB29-L1 714DP 11-F4 TB32-K3 52CS 8-I13 TB35-R4 68 14-M13
939YX2-009 SP059 - TX9 P22TX9B2 SHIELD-101 SP214 - SP205 - SHIELD-911 KOMTRAX PLUS MODULE P4B - -
TB-HTST-H2 86 16-N12 TB23-G2 11DISP 9-G12 TB26-L1 77A 13-C7 TB29-L2 714DP 11-F4 TB32-L2 62SBA 14-B13 TB35-S1 71F 13-E5
952M/0-001 TB27 TB27-W2 GE CONTROL INTERFACE P302 SHIELD-102 SP208 - SP217 - SHIELD-913 - P15 - -
952M/0-002 - P808 TB27 TB27-W1 SHIELD-103 SP210 - SP179 - SHIELD-914 - P15 - - TB-HTST-J1 87 16-N12 TB23-H1 712G 9-F12 TB26-L2 77A 13-C7 TB29-M1 714B 11-G4 TB32-M1 73S1 5-H17 TB35-S2 71F 13-E5
BAT(+)-000 BATT2 BAT2(+) BUSS BAR 24VDC BATT BOX BUS24V-1 SHIELD-104 SP212 - SP219 - SHIELD-917 - J15 - J702 TB-HTST-J2 87 16-N12 TB23-H2 712G 9-F12 TB26-L3 77A 13-C7 TB29-M2 714B 11-G4 TB32-M2 73S1 5-H18 TB35-S3 71F 13-E5
BAT(+)-001 BATT4 BAT4(+) BUSS BAR 24VDC BATT BOX BUS24V-6 SHIELD-129 - - - - SHIELD-918 - J15 - J702 TB-HTST-J3 87 16-N12 TB23-H4 712G 9-F12 TB26-M1 SHIELD 13-C7 TB29-N1 714DN 11-G4 TB32-N2 52A 5-H18 TB35-S4 71F 13-E5
BAT(+)-002 BUSS BAR 24VDC BATT BOX BUS24V-5 RELAY ENG STARTER 2 (ESREL2) ESREL2-88 SHIELD-130 TB28 TB28-R1 - - SHIELD-929 GB LEFT DECK GND - - TB-HTST-K1 87 16-N12 TB23-J1 71P 11-H9 TB26-M3 SHIELD 13-C7 TB29-N2 714DN 11-G4 TB32-P1 11M 16-I5 TB35-T1 11ONS 9-G12
BAT(+)-003 RELAY ENG STARTER 1 (ESREL1) ESREL1-88 BUSS BAR 24VDC BATT BOX BUS24V-4 SHIELD-131 - - - - SHIELD-950 SP233 - - - TB-HTST-K2 87 16-O12 TB23-J2 71P 11-H9 TB26-M4 SHIELD 13-C7 TB29-P1 SHIELD 11-G4 TB32-P2 11M 16-I6 TB35-T2 11ONS 9-G12
BAT(+)-004 BUSS BAR 24VDC BATT BOX BUS24V-7 - FH1-2 SHIELD-132 - - - - SHIELD-951 SP233 - - - TB-HTST-K4 87 16-N12 TB23-J3 71P 11-H9 TB26-M5 0 13-C7 TB29-P2 SHIELD 11-G4 TB32-R1 712MM 16-I5 TB35-V1 75A2 13-D4
BAT(+)-007 BUSS BAR 24VDC BATT BOX BUS24V-11 BUSS_BAR_11 SDISC-1 SHIELD-172 - - - - SHIELD-959 CAN TEE RPC # 2 P215B CAN TEE RPC # 3 P216B TB10-A1 41TS 9-J9 TB23-J4 71P 11-H9 TB26-N1 55A 9-B15 TB29-R1 72FD 7-G18 TB32-R2 712MM 16-I6 TB35-V2 75A2 13-D4
BAT(+)-008 BUSS BAR 24VDC BATT BOX BUS24V-10 BUSS_BAR_11 SDISC-2 SHIELD-173 - - - - SHIELD-962 CAN TEE J1939 # 1 P315B CAN TEE J1939 # 2 P316B TB10-A3 41TS 9-J9 TB23-K1 72RQ 13-M4 TB26-N2 55A 9-B15 TB29-R2 72FD 7-G18 TB32-S1 52ABA 8-J13 TB35-X1 12V 6-I11
BAT(+)-009 BUSS_BAR_11 SDISC-6 SWITCH PROPEL LOCKOUT (PLOS) PLOS-B1 SHIELD-174 - - - - SHIELD-965 - P219D CAN TEE RPC # 1 P218D TB10-A4 41TS 9-J9 TB23-K2 72RQ 13-M4 TB26-P1 55B 9-B15 TB29-S1 79RD 7-F18 TB32-T1 71ABA 8-M11 TB35-X3 12V 6-I11
BAT(+)-010 BUSS_BAR_11 SDISC-6 RELAY STARTER LOCKOUT SLREL_K SHIELD-175 - - - - SHIELD-966 - P318D CAN TEE J1939 # 2 P317D TB10-C1 71LS 10-C4 TB23-K4 72RQ 13-M4 TB26-P2 55B 9-B15 TB29-S2 79RD 7-F18 TB32-T2 71ABA 8-M12 TB36-A1 39FC 15-L7
BAT(+)-011 LAMP LED MASTER DISCONNECT CL... MLLON BUSS_BAR_11 SDISC-7 SHIELD-176 - - - - SHIELD-974 SP791 - - - TB10-C2 71LS 10-C4 TB23-L1 712BL 8-J13 TB26-R1 55C 9-C15 TB29-T1 90VHG 13-F19 TB32-T3 71ABA 8-M11 TB36-A2 39FC 15-L8
BAT(+)-012 RELAY MASTER DISCONNECT MLREL_K BUSS_BAR_11 SDISC-7 SHIELD-177 - - - - SHIELD-976 SP789 - - - TB10-C3 71LS 10-C4 TB23-L2 712BL 8-J13 TB26-R2 55C 9-C15 TB29-T2 90VHG 13-F19 TB33-A2 72AT 14-P5 TB36-B1 39FD 15-L7
BAT(+)-013 RELAY PROPEL LOCKOUT PLREL_K SWITCH PROPEL LOCKOUT (PLOS) PLOS-B1 SHIELD-178 - - - - SHIELD-977 SP789 - - - TB10-D2 49 9-J9 TB23-L4 712BL 8-J13 TB26-S1 55D 9-D15 TB29-V1 90VHR 13-E19 TB33-B2 72MAN 14-P5 TB36-B2 39FD 15-L8
BAT(+)-014 RELAY MASTER DISCONNECT MLREL_K RELAY MASTER DISCONNECT MLREL_K SHIELD-179 - - - - SHIELD-985 SP217 - KOMVISION DISPLAY MONITOR P45 TB10-D3 9-J9 TB23-M1 71LS 10-C9 TB26-S2 55D 9-D15 TB29-V2 90VHR 13-E19 TB33-C1 714Z 11-I4 TB36-C1 39F
49 15-L7
BAT(-)-000 BATT1 BAT1(-) BUSS BAR BAT(-) BAT(-)-4 SHIELD-180 - - - - SHIELD-986 SP208 - KOMVISION CONTROLLER RGB
TB10-D4 49 9-J9 TB23-M2 71LS 10-C8 TB26-T1 48 10-F12 TB29-W1 90VHT 13-E19 TB33-D1 714Y 11-I4 TB36-C2 39F 15-L8
BAT(-)-001 BATT3 BAT3(-) BUSS BAR BAT(-) BAT(-)-1 SHIELD-181 - - - - SHIELD-987 SP219 - KOMVISION DISPLAY MONITOR P45
TB10-E1 63 12-L5 TB23-N1 712K 5-E12 TB26-T2 48 10-F13 TB29-W2 90VHT 13-E19 TB33-E1 77Y 11-I4 TB36-C3 39F 15-L7
BAT(-)-002 BUSS_BAR_BAT- DISC(-)-1 BUSS BAR BAT(-) BAT(-)-6 SHIELD-182 - - - - SHIELD-988 SP212 - KOMVISION CONTROLLER RGB
TB10-E2 63 12-L5 TB23-N2 712K 5-E12 TB26-V2 48 10-F13 TB29-X1 SHIELD 13-F19 TB33-F1 77Z 11-I4 TB36-D1 39FB 15-N7
BAT(-)-003 BUSS_BAR_BAT- DISC(-)-2 BUSS BAR BAT(-) BAT(-)-5 SHIELD-202 TB27 TB27-X2 GE CONTROL INTERFACE P302 SHIELD-989 SP179 - KOMVISION DISPLAY MONITOR P45
TB10-F1 712G 9-F9 TB23-N4 712K 5-E12 TB27-A1 11E1 7-A9 TB29-X2 SHIELD 13-F19 TB33-G1 SHIELD 11-H4 TB36-D2 39FB 15-N8
BAT(-)-004 LAMP LED MASTER DISCONNECT OPE... MLLO BUSS_BAR_BAT- DISC(-)-6 SHIELD-205 - P808 TB27 TB27-X1 SHIELD-990 SP210 - KOMVISION CONTROLLER RGB
TB10-F2 712G 9-F9 TB23-R1 712T 10-L2 TB27-A2 11E1 7-A9 TB29-X4 0 13-F19 TB33-H1 SHIELD 11-I4 TB36-E1 39FA 15-N7
BAT(-)-010 ENGINE JUMP START1 - BUSS BAR BAT(-) BAT(-)-2 SHIELD-211 SP768 - SP767 - SHIELD-996 - P14 SP789 -
TB10-G1 11L 10-M4 TB23-R2 712T 10-L2 TB27-A3 11E1 7-A9 TB29-X5 0 13-F19 TB33-J1 SHIELD 11-B4 TB36-E2 39FA 15-N8
BAT(-)-020 ENGINE JUMP START2 - BUSS BAR BAT(-) BAT(-)-3 SHIELD-213 SP765 - TB29 TB29-P2 SHIELD-997 SP792 - - J14
TB10-H2 11L 10-M4 TB23-S1 72GD 13-N4 TB27-B1 11E2 7-B9 TB30-A1 34BT4 14-J11 TB33-J2 SHIELD 11-B4 TB36-F1 90MMT 13-K5
ENRX1-000 PAY LOAD METER 4 P264 PLM4 COMMUNICATION BOX COMMB SHIELD-214 SP769 - SP770 - SHIELD-998 - P14 SP791 -
TB10-J1 45L 10-J5 TB23-S2 72GD 13-N4 TB27-B2 11E2 7-B9 TB30-A2 34BT4 14-J11 TB33-K1 0RF 11-B4 TB36-F4 90MMT 13-K5
ENRX2-000 PAY LOAD METER 4 P264 PLM4 COMMUNICATION BOX COMMB SHIELD-217 SP766 - TB29 TB29-G2 SHIELD-999 SP790 - - J14
ENTX1-000 PAY LOAD METER 4 P264 PLM4 COMMUNICATION BOX COMMB SHIELD-223 SP741 - TB29 TB29-P1 SHIELD899 - - - - TB10-K1 41H 9-I16 TB23-T1 71SS 8-E20 TB27-B3 11E2 7-B9 TB30-B1 SHIELD 14-K11 TB33-K2 0RF 11-B4 TB36-G1 90MMR 13-K5
ENTX2-000 PAY LOAD METER 4 P264 PLM4 COMMUNICATION BOX COMMB SHIELD-227 SP742 - TB29 TB29-G1 SPR1-000 - P03 - SPR_5 TB10-K3 41H 9-I16 TB23-T2 71SS 8-E19 TB27-C1 11E3 7-B9 TB30-B2 0, SHIELD 14-J11 TB33-K3 0RF 11-B4 TB36-G4 90MMR 13-K5
FVAL-000 SP003 - OIL RESERVE SYS CM1_FVAL_CP SHIELD-230 - P13 SENSOR RIGHT FRONT WHEEL SPEED P501 SPR1-001 - J03 - SPR_13 TB10-L1 41L 9-I12 TB23-V2 39HA 8-N13 TB27-C2 11E3 7-B9 TB30-B3 SHIELD 14-K11 TB33-L1 33RF 11-B4 TB36-H1 90MMG 13-L5
FVAL-001 SP003 - OIL RESERVE SYS CM2_FVAL_CP SHIELD-233 - P13 SENSOR LEFT FRONT WHEEL SPEED P507 SPR2-000 - P03 - SPR_6 TB10-M1 45R 10-K5 TB23-W1 712H 11-M16 TB27-C3 11E3 7-B9 TB30-B4 SHIELD 14-K11 TB33-L2 33RF 11-B4 TB36-H4 90MMG 13-L5
FVAL-002 SP003 - OIL RESERVE SYS ORS_FVAL_CP SHIELD-239 TB33 TB33-N2 - J13 SPR2-001 - J03 - SPR_14 TB21-A2 510E2 17-C18 TB23-X1 79BA 8-E13 TB27-D1 11E4 7-B9 TB30-C1 34BT3 14-J11 TB33-L4 33RF 11-B4 TB36-J1 SHIELD 13-L5
J1 - P701 - P701 SHIELD-240 - J13 TB33 TB33-J2 SPR3-000 - P03 - SPR_7 TB21-A4 510E2 17-C18 TB23-X2 79BA 8-E13 TB27-D2 11E4 7-B9 TB30-C2 34BT3 14-J11 TB33-M1 15SRW 11-A4 TB36-J3 SHIELD 15-M7
J2 - P701 - P701 SHIELD-245 TB33 TB33-J1 GE CONTROL INTERFACE P301 SPR3-001 - J03 - SPR_15 TB21-B1 12VREG 6-B5 TB24-A1 11SL 11-D16 TB27-E1 21NSL 7-C8 TB30-D1 33JB 14-B10 TB33-M2 15SRW 11-A4 TB36-J4 SHIELD 15-M8
J3 - P701 - P701 SHIELD-246 TB33 TB33-N1 GE CONTROL INTERFACE P301 SPR4-000 - P03 - SPR_8 TB21-B2 12VREG 6-B6 TB24-B1 52PB 8-H13 TB27-E2 21NSL 7-C8 TB30-D2 33JB 14-B11 TB33-N1 SHIELD 11-C4 TB36-J5 SHIELD 13-L5
J4 - P701 - P701 SHIELD-251 TB33 TB33-G1 GE CONTROL INTERFACE P305 SPR4-001 - J03 - SPR_16 TB21-B3 12VREG 6-B6 TB24-B2 52PB 8-H13 TB27-E4 21NSL 7-C8 TB30-D4 33JB 14-B11 TB33-N2 SHIELD 11-C4 TB36-K1 0 15-L14
J5 - P701 - P701 SHIELD-252 TB33 TB33-H1 GE CONTROL INTERFACE P305 SPR5-000 - P03 - SPR_9 TB21-C1 13CA 17-F17 TB24-B4 52PB 8-H13 TB27-F1 419I 7-E10 TB30-G1 34BT1 14-K11 TB33-P1 0LF 11-C4 TB36-K2 SHIELD 15-L15
J6 - P701 - P701 SHIELD-257 TB33 TB33-V1 GE CONTROL INTERFACE P301 SPR5-001 - J03 - SPR_17 TB21-D1 74ZA 12-H2 TB24-C1 712DS 8-A12 TB27-G1 22C 7-G8 TB30-G2 34BT1 14-K11 TB33-P2 0LF 11-C4 TB36-K3 SHIELD 15-L14
J7 - P702 - P702 SHIELD-260 TB33 TB33-V2 SENSOR GE ALTERNATOR SPEED ALTSP SPR6-000 - P03 - SPR_10 TB21-D2 74ZA 12-H2 TB24-C2 712DS 8-A12 TB27-H1 28EC 7-D8 TB30-H1 34BT2 14-J11 TB33-P3 0LF 11-C4 TB36-K4 SHIELD 15-L14
J8 - P702 - P702 SHIELD-263 ACTIA DASH DISPLAY P903 CAN TEE RPC #5 P212D SPR6-001 - J03 - SPR_18 TB21-D4 74ZA 12-H2 TB24-D1 65 6-A7 TB27-H2 28EC 7-D8 TB30-H2 34BT2 14-J11 TB33-R1 33LF 11-C4 TB36-L1 35L2 15-K14
J9 - P702 - P702 SHIELD-265 - CAN_TP SP808 - SPR7-000 - P04 - SPR_11 TB21-E1 11-A4 TB24-D2 65 6-A8 TB27-K1 21OR 7-D8 TB30-J1 14-L11 TB33-R2 33LF 11-C4 TB36-L2 35L2
72A 34AT 15-K15
J9-000 - J538C - J538C SHIELD-270 - P808 CAN TEE J1939 # 1 P301B SPR7-001 - J04 - SPR_19
TB21-F1 11LAD 17-C18 TB24-D3 65 6-B7 TB27-K3 21OR 7-D8 TB30-J2 34AT 14-L11 TB33-R4 33LF 11-C4 TB36-M1 35L3 15-K14
J10 SWITCH FOG LAMP (OPT) P22 SWITCH FOG LAMP (OPT) P22 SHIELD-272 - J02 - - SPR8-000 - P04 - SPR_12
TB21-F2 11LAD 17-C18 TB24-D4 65 6-B8 TB27-L1 21ORR 7-D8 TB30-K1 5VIM 14-J11 TB33-S1 15SLW 11-C4 TB36-M2 35L3 15-K15
J11 SWITCH FOG LAMP (OPT) P22 SWITCH FOG LAMP (OPT) P22 SHIELD-274 TB31 TB31-H2 - P02 SPR8-001 - J04 - SPR_20
TB21-G1 12LD 17-I18 TB24-E1 52CA 8-F13 TB27-L3 21ORR 7-D8 TB30-K2 5VIM 14-J11 TB33-S2 15SLW 11-C4 TB36-N1 35L4 15-L14
J12 SWITCH BRAKE LOCK P39 SWITCH BRAKE LOCK P39 SHIELD-277 TB31 TB31-H1 GE CONTROL INTERFACE P303 USBDMD-000 PLM4 COMMUNICATION BOX COMMA PAY LOAD METER 4 P264
TB21-G2 12LD 17-I18 TB24-E2 52CA 8-F13 TB27-M1 65S 7-B9 TB30-K3 5VIM 14-K11 TB33-T1 74X 11-H4 TB36-N2 35L4 15-L15
J13 SWITCH BRAKE TEST P37 SWITCH BRAKE TEST P37 SHIELD-280 - J01 - - USBDMH-000 PLM4 COMMUNICATION BOX COMMA PAY LOAD METER 4 P264
TB21-H1 12LU 17-H18 TB24-E4 52CA 8-F13 TB27-M2 65S 7-B9 TB30-K4 5VIM 14-K11 TB33-T2 74X 11-H4 TB36-P1 712SL 15-J13
J14 KOMTRAX PLUS MODULE P2B KOMTRAX PLUS MODULE P2B SHIELD-281 - J01 - - USBDPD-000 PLM4 COMMUNICATION BOX COMMA PAY LOAD METER 4 P264
TB21-H2 12LU 17-H18 TB24-F1 65A 6-A7 TB27-R1 439 5-C20 TB30-L2 5VIM 14-J11 TB33-V1 SHIELD 11-H4 TB36-P2 712SL 15-J14
J16 SWITCH ROTATING BEACON (OPT) P32 SWITCH ROTATING BEACON (OPT) P32 SHIELD-282 - J01 - - USBDPH-000 PLM4 COMMUNICATION BOX COMMA PAY LOAD METER 4 P264
TB21-J1 87 14-D13 TB24-F2 65A 6-A8 TB27-R2 439 5-C20 TB30-L4 5VIM 14-L11 TB33-V2 SHIELD 11-H4 TB36-R1 35L7 15-J13
J17 SWITCH ROTATING BEACON (OPT) P32 SWITCH ROTATING BEACON (OPT) P32 SHIELD-286 - P01 TB31 TB31-S2 USBV-000 PLM4 COMMUNICATION BOX COMMA PAY LOAD METER 4 P264
TB21-J2 87 14-D13 TB24-G1 71GE 6-H4 TB27-R3 439 5-C20 TB30-M1 33BPS 14-K11 TB33-W1 74Z 11-H4 TB36-R2 35L7 15-J14
J18 SWITCH HEATED MIRROR P33 SWITCH HEATED MIRROR P33 SHIELD-287 - P01 TB31 TB31-P2 WIRE13697 - J830 - P42263
J19 SWITCH HEATED MIRROR P33 SWITCH HEATED MIRROR P33 SHIELD-288 TB31 TB31-J2 - P01 WIRE13698 - P42263 - J830 TB21-J3 87 14-D13 TB24-G2 71GE 6-H4 TB27-R4 439 5-C20 TB30-M2 33BPS 14-K11 TB33-W2 74Z 11-H4 TB36-R4 0 15-K14
J20 SWITCH GRID DRY P34 SWITCH GRID DRY P34 SHIELD-295 TB31 TB31-S1 GE CONTROL INTERFACE P304 WIRE13699 - J830 - P42263 TB21-K1 52C 8-G13 TB24-G3 71GE 6-H4 TB27-S1 509 7-F10 TB30-N1 33HP1 14-I5 TB34-A1 41TS 9-J5 TB36-S1 35L8 15-J13
J21 SWITCH HAZARD LIGHTS P36 SWITCH HAZARD LIGHTS P36 SHIELD-296 TB31 TB31-P1 GE CONTROL INTERFACE P302 TB21-K2 52C 8-G13 TB24-H1 11KS 5-D7 TB27-S3 509 7-F10 TB30-T1 33SP 14-H5 TB34-A2 41TS 9-J5 TB36-S2 35L8 15-J14
J22 SWITCH MANUAL BACKUP LIGHT P23 SWITCH MANUAL BACKUP LIGHT P23 SHIELD-297 TB31 TB31-J1 GE CONTROL INTERFACE P302 TB21-L1 79B 8-G13 TB24-H2 11KS 5-D7 TB27-T1 556 7-D10 TB30-W1 18VIM 14-H5 TB34-B1 41H 9-K5 TB36-T1 35L9 15-J13
J23 - J6 - J6 SHIELD-610 TB26 TB26-M3 - - TB21-L2 79B 8-G13 TB24-J1 712 6-F11 TB27-T2 556 7-D11 TB30-W2 18VIM 14-H5 TB34-B2 41H 9-K5 TB36-T2 35L9 15-J14
J24 - J6 - J6 SHIELD-613 TB26 TB26-M4 GE CONTROL INTERFACE P303 TB21-L3 79B 8-G13 TB24-J2 712 6-F11 TB27-T3 556 7-E10 TB30-W4 18VIM 14-H5 TB34-C1 41L 9-L5
J25 - J6 - J6 SHIELD-616 TB26 TB26-M1 - - TB21-M1 72N 8-G13 TB24-K2 712 6-F11 TB27-V1 916M 7-E10 TB30-X1 65T 7-K9 TB34-C2 41L 9-L5
J26 - J6 - J6 SHIELD-620 - P02 TB25 TB25-D2 TB21-M2 72N 8-G13 TB24-K3 712 6-F11 TB27-V2 916M 7-E11 TB30-X2 65T 7-K9 TB34-D1 48LF 10-B14
J27 - P702 - P702 SHIELD-621 - J02 - - TB21-N1 72 8-G13 TB24-K4 712 6-F11 TB27-W1 952M/0 7-E10 TB30-X4 65T 7-K9 TB34-D2 48LF 10-B14
J27-000 - JP20 - JP20 SHIELD-625 GE CONTROL INTERFACE P303 TB25 TB25-D1 TB21-N2 72 8-G13 TB24-L1 11B1 6-I7 TB27-W2 952M/0 7-E11 TB31-A1 927 7-H9 TB34-E1 48F 10-B8
LF(+)-000 ENTERTAINMENT RADIO P737 - J211 SHIELD-628 GE CONTROL INTERFACE P303 TB25 TB25-H1 TB21-N3 72 8-G13 TB24-L2 11B1 6-I8 TB27-W3 0 7-E11 TB31-A2 927 7-H9 TB34-E2 48F 10-B9
LF(+)-001 - P211 ENTERTAINMENT LEFT FRT SPEAKER LFSPK SHIELD-630 TB36 TB36-J1 GE CONTROL INTERFACE P303 TB21-P2 72T 8-H13 TB24-L3 11B1 6-I7 TB27-W4 0 7-E10 TB31-B1 928 7-I9 TB34-F1 41HB 9-L9
LF(-)-000 ENTERTAINMENT RADIO P737 - J211 SHIELD-631 - J02 - - TB21-R1 71H 11-J4 TB24-L4 11B1 6-I8 TB27-X1 SHIELD 7-E10 TB31-B2 928 7-I9 TB34-F2 41HB 9-L9
LF(-)-001 - P211 ENTERTAINMENT LEFT FRT SPEAKER LFSPK SHIELD-634 - P02 TB25 TB25-H2 TB21-R2 71H 11-J4 TB24-M1 72FNR 8-J16 TB27-X2 SHIELD 7-E11 TB31-C1 929 7-I9 TB34-F4 41HB 9-L9
LR(+)-000 ENTERTAINMENT RADIO P737 - P210 SHIELD-654 TB36-J5 TB36-J5 - -
TB21-S1 73DS 11-J4 TB24-M2 72FNR 8-J16 TB28-A1 36 7-K9 TB31-C2 929 7-I9 TB34-J1 48A 10-F5
LR(+)-001 - J210 ENTERTAINMENT LEFT REAR SPEAKE... LRSPK SHIELD-656 TB36 TB36-K2 - -
TB21-S2 73DS 11-J4 TB24-N1 71CK 6-H10 TB28-A2 36 7-K9 TB31-D1 SHIELD 7-I9 TB34-J2 48A 10-F6
LR(-)-000 - P210 ENTERTAINMENT RADIO P737 SHIELD-660 - J13 TB36 TB36-J3
TB21-S4 73DS 11-J4 TB24-N2 71CK 6-H11 TB28-A3 36 7-K9 TB31-D2 SHIELD 7-I9 TB34-K1 48B 10-F5
LR(-)-001 - J210 ENTERTAINMENT LEFT REAR SPEAKE... LRSPK SHIELD-661 - J13 TB36 TB36-J3
TB21-T1 15VDI 13-G5 TB24-N3 71CK 6-H11 TB28-B1 71VHM 13-G18 TB31-E1 31RR 11-K4 TB34-K2 48B 10-F6
LSW-C-000 SP001 - OIL RESERVE SYS CM1_LSW_CP SHIELD-663 TB36 TB36-J4 - -
TB21-T2 15VDI 13-G5 TB24-N4 71CK 6-H10 TB28-B2 71VHM 13-G18 TB31-E2 31RR 11-K4 TB34-L1 48C 10-F10
LSW-C-001 SP001 - OIL RESERVE SYS CM2_LSW_CP SHIELD-667 TB36 TB36-K3 - -
TB21-T3 15VDI 13-G5 TB24-R1 63 12-K4 TB28-C1 85 13-G18 TB31-F1 33RR 11-K4 TB34-N1 31IML 9-E16
LSW-C-002 SP001 - OIL RESERVE SYS ORS_LSW_CP SHIELD-669 TB36 TB36-J4 - -
TB21-T4 15VDI 13-G5 TB24-R2 63 12-K4 TB28-C2 85 13-G18 TB31-F2 33RR 11-K4 TB34-N2 31ILM 9-E16
LSW-H-000 SP000 - OIL RESERVE SYS CM1_LSW_CP SHIELD-671 TB36 TB36-K3 - -
TB21-V1 13-G5 TB24-S1 67R 11-K14 TB28-D1 11ORS 7-M7 TB31-G1 0 11-L4 TB34-P1 39C 15-G8
LSW-H-001 SP000 - OIL RESERVE SYS CM2_LSW_CP SHIELD-673 TB36 TB36-K4 - -
LSW-H-002 SP000 - OIL RESERVE SYS ORS_LSW_CP SHIELD-700 SP791 - - - TB21-V2 13-G5 TB24-S2 67R 11-K14 TB28-D2 11ORS 7-M7 TB31-G2 0 11-L4 TB34-P2 39C 15-G8
LSW-L-000 SP002 - OIL RESERVE SYS CM1_LSW_CP SHIELD-701 - P14 - - TB21-W1 5VDI 13-H5 TB24-T1 67P 11-I14 TB28-E1 11POR 7-M7 TB31-G3 0 11-L4 TB34-R1 39B 15-G8
LSW-L-001 SP002 - OIL RESERVE SYS CM2_LSW_CP SHIELD-709 TB30 TB30-B2 SP790 - TB21-W2 5VDI 13-H5 TB24-T2 67P 11-I14 TB28-E2 11POR 7-M7 TB31-H1 SHIELD 11-K4 TB34-R2 39B 15-G8
LSW-L-002 SP002 - OIL RESERVE SYS ORS_LSW_CP SHIELD-710 TB30 TB30-B2 SP790 - TB21-X1 0 8-I17 TB24-V1 67C 6-D4 TB28-F1 11SM1 5-K9 TB31-H2 SHIELD 11-K4 TB34-S1 39A 15-G8
RF(+)-000 - J211 ENTERTAINMENT RADIO P737 SHIELD-711 TB30 TB30-B3 SP792 - TB21-X2 0 8-I17 TB24-V2 67C 6-D4 TB28-F2 11SM1 5-K9 TB31-J1 SHIELD 11-O7 TB34-S2 39A 15-G8
RF(+)-001 - P211 ENTERTAINMENT RIGHT FRT SPEAKE... RFSPK SHIELD-712 TB30 TB30-B3 SP792 - TB21-X3 0 8-I17 TB24-V4 67C 6-D4 TB28-G1 11SM2 5-K9 TB31-J2 SHIELD 11-O7 TB34-T1 39G 5-B5
RF(-)-000 - J211 ENTERTAINMENT RADIO P737 SHIELD-723 - P14 - - TB21-X4 0 8-I17 TB24-W1 72CPU 7-G9 TB28-G2 11SM2 5-K9 TB31-K1 52R 11-P7 TB34-T2 39G 5-B5
RF(-)-001 - P211 ENTERTAINMENT RIGHT FRT SPEAKE... RFSPK SHIELD-725 TB30 TB30-B3 - J14 TB22-A1 11D 9-I6 TB24-W2 72CPU 7-G9 TB28-H1 21PS 5-K12 TB31-K2 52R 11-P7 TB34-V1 712PL 15-I7
RR(+)-000 ENTERTAINMENT RADIO P737 - P210 SHIELD-728 SP774 - - - TB22-A2 11D 9-I7 TB24-W3 72CPU 7-G9 TB28-H2 21PS 5-K12 TB31-L1 0LEV 11-O7 TB34-V2 712PL 15-I8
RR(+)-001 - J210 ENTERTAINMENT RIGHT REAR SPEAK... RRSPK SHIELD-729 SP775 - TB30 TB30-B1 TB22-B1 11H 12-L13 TB24-X1 0 14-D4 TB28-J1 21PT 6-G4 TB31-L2 0LEV 11-O7 TB35-A1 11A 12-M12
RR(-)-000 - P210 ENTERTAINMENT RADIO P737 SHIELD-730 - P16 - - TB22-B2 11H 12-L13 TB24-X2 0 14-E4 TB28-J3 21PT 6-G4 TB31-L3 0 11-P7 TB35-A2 11A 12-M12
RR(-)-001 - J210 ENTERTAINMENT RIGHT REAR SPEAK... RRSPK SHIELD-731 - J16 SP773 - TB22-C1 11L 10-M1 TB24-X3 0 14-D5 TB28-K1 33HP2 14-I5 TB31-M1 10V 11-L4 TB35-B2 11A 12-N12
SE1-000 - P6A KOMTRAX PLUS MODULE P3A SHIELD-732 - P16 - - TB22-C2 11L 10-M1 TB25-A1 90DIG 13-I5 TB28-L1 11RCNT 7-M7 TB31-M2 10V 11-L4 TB35-B3 11A 12-N12
SE2-000 - P6A KOMTRAX PLUS MODULE P3A SHIELD-733 - J16 SP737 - TB22-D1 11ER 6-B5 TB25-A2 90DIG 13-I5 TB28-M1 90IMT 14-G12 TB31-M4 10V 11-L4 TB35-B4 11A 12-N12
SE3-000 - P6A KOMTRAX PLUS MODULE P3A SHIELD-734 - P14 - -
TB22-D2 11ER 6-B5 TB25-B1 90DIR 13-I5 TB28-M4 90IMT 14-G13 TB31-N2 10V 11-M6 TB35-C1 38G 14-D10
SE4-000 - P6A KOMTRAX PLUS MODULE P3A SHIELD-735 - J14 SP737 -
TB22-D3 11ER 6-B5 TB25-B2 90DIR 13-I5 TB28-N1 90IMR 14-H12 TB31-N3 10V 11-L4 TB35-C2 38G 14-D11
SE5-000 - P6A KOMTRAX PLUS MODULE P3A SHIELD-771 - J808 - -
TB22-E1 11RB 15-D6 TB25-C1 90DIT 13-J5 TB28-N4 90IMR 14-H13 TB31-N4 10V 11-M6 TB35-C4 38G 14-D11
SE6-000 SP730 - KOMTRAX PLUS MODULE P3A SHIELD-773 - J808 - -
TB22-E2 11RB 15-D7 TB25-C2 90DIT 13-J5 TB28-P1 90IMG 14-H12 TB31-P1 SHIELD 11-O7 TB35-D1 712P 13-P4
SE7-000 SP730 - KOMTRAX PLUS MODULE P3A SHIELD-774 ENGINE QSK78 INTERFACE P804 - J808
TB22-E3 11RB 15-D7 TB25-D1 SHIELD 13-J5 TB28-P4 90IMG 14-H13 TB31-P2 SHIELD 11-O7 TB35-D2 712P 13-P4
SE8-000 SP730 - KOMTRAX PLUS MODULE P3A SHIELD-775 ENGINE QSK78 INTERFACE P820 - J808
TB22-E4 11RB 15-D7 TB25-D2 SHIELD 13-J5 TB28-R1 SHIELD 14-H12 TB31-R1 74N 11-O7 TB35-E1 41T 10-J14
SE9-000 SP730 - - P6A SHIELD-781 - P808 TB28 TB28-S1
TB22-F1 11FS 6-C4 TB25-E1 90CAR 13-J5 TB28-R2 0 14-H13 TB31-R2 74N 11-O7 TB35-E2 41T 10-J14
SHIELD-000 SP075 - - J16X SHIELD-782 - P808 TB31 TB31-D1
TB22-F2 11FS 6-C4 TB25-E2 90CAR 13-J5 TB28-R4 SHIELD 14-H13 TB31-S1 SHIELD 11-N7 TB35-E4 41T 10-J14
SHIELD-001 SP737 - TB30 TB30-B4 SHIELD-787 - P02 TB31 TB31-D2
SHIELD-001 SP094 - SP125 - SHIELD-788 - P02 TB28 TB28-S2 TB22-G1 12H 7-J10 TB25-F1 90CAT 13-J5 TB28-S1 SHIELD 7-I9 TB31-S2 SHIELD 11-N7 TB35-F1 44R 7-G18
SHIELD-002 SP767 - - P15 SHIELD-793 - J02 - - TB22-G2 12H 7-J11 TB25-F2 90CAT 13-J5 TB28-S2 SHIELD 7-I9 TB31-T1 525 11-N7 TB35-F3 44R 7-G18
SHIELD-002 SP096 - SP127 - SHIELD-794 - J02 - - TB22-H1 21S 5-F13 TB25-G1 90CAG 13-J5 TB28-T1 900 7-I9 TB31-T2 525 11-N7 TB35-F4 44R 7-G19
SHIELD-003 SP768 - SENSOR LEFT REAR WHEEL SPEED P721 SHIELD-802 - P02 CAN TEE J1939 # 2 P305B TB22-H2 21S 5-F13 TB25-G2 90CAG 13-J5 TB28-T2 900 7-I9 TB31-V1 0RET 11-M5 TB35-G1 44 12-H7
SHIELD-003 SP258 - SP128 - SHIELD-805 - J02 SP811 - TB22-H4 21S 5-F13 TB25-H1 SHIELD 13-K5 TB28-V1 901 7-I9 TB31-V2 0RET 11-M6 TB35-G2 44 12-H7
SHIELD-004 SP770 - SENSOR RIGHT REAR WHEEL SPEED P720 SHIELD-808 CAN TEE J1939 #4 P323B CAN TEE J1939 #5 P321B TB22-J1 73S 5-H17 TB25-H2 SHIELD 13-K5 TB28-V2 901 7-I9 TB31-V4 0 11-M6 TB35-G4 44 12-H7
SHIELD-004 SP097 - SP085 - SHIELD-811 - DIAG4 SP811 - TB22-J2 73S 5-H18 TB25-K1 71GG 5-B15 TB28-W1 69MA 15-A6 TB31-W1 0ACL 11-M5 TB35-H1 44D 12-H7
SHIELD-005 SP765 - - J15 SHIELD-812 CAN TEE RPC # 4 P221B CAN TEE RPC #5 P207B TB22-K1 15DID 13-G6 TB25-K2 71GG 5-B15 TB28-W2 69MA 15-A6 TB31-W2 0ACL 11-M6 TB35-H2 44D 12-H7
SHIELD-005 SP099 - SP088 - SHIELD-813 SP811 - CAN TEE J1939 #4 P322B TB22-K2 15DID 13-G6 TB25-L1 71GH 5-B15 TB28-X1 62SB 14-A10 TB31-W3 0ACL 11-M5 TB35-H4 44D 12-H7
SHIELD-006 SP766 - - J15 SHIELD-816 KOMTRAX PLUS MODULE P4A SP817 - TB22-L1 23F 5-D14 TB25-L2 71GH 5-B15 TB28-X2 62SB 14-A11 TB31-X1 22FO 7-F8 TB35-J1 45LL 10-K14
SHIELD-006 SP105 - SP090 - SHIELD-817 KOMTRAX PLUS MODULE P4A SP814 - TB22-L2 23F 5-D14 TB25-M1 74DS 14-F6 TB29-A1 77P 11-D4 TB32-A1 46GA 16-L4 TB35-J2 45LL 10-K14
SHIELD-007 SP741 - GE CONTROL INTERFACE P301 SHIELD-818 SP814 - CAN TEE J1939 #5 P308B TB22-P1 45L 10-K7 TB25-M2 74DS 14-F6 TB29-A2 77P 11-D4 TB32-A2 46GA 16-L5 TB35-J3 45LL 10-L14
SHIELD-008 GE CONTROL INTERFACE P301 SP742 - SHIELD-819 CAN TEE J1939 #4 P324D - - TB22-P2 45L 10-K8 TB25-N1 510E 5-C19 TB29-B1 77G 11-D4 TB32-B1 46RA 16-M4 TB35-J4 45LL 10-L14
SHIELD-009 SP774 - - J240 SHIELD-820 CAN TEE RPC # 4 P222D - - TB22-R1 45R 10-K7 TB25-N2 510E 5-C20 TB29-B2 77G 11-D4 TB32-B2 46RA 16-M5 TB35-K1 45RL 10-L14
SHIELD-010 - P240 SP775 - SHIELD-821 SP194 - - -
TB22-R2 45R 10-K8 TB25-P1 8X050 18-J16 TB29-C1 77C 11-E4 TB32-C1 46YA 16-M4 TB35-K2 45RL 10-L14
SHIELD-011 INTERFACE MODULE IM1 SP198 - SHIELD-822 SP194 - - -
TB22-S1 0COM 13-H5 TB25-P2 8X050 18-J17 TB29-C2 77C 11-E4 TB32-C2 46YA 16-M5 TB35-K3 45RL 10-L14
SHIELD-012 SP769 - - P15 SHIELD-823 - J04 SP194 -
TB22-S2 0COM 13-H5 TB25-R1 11CAM 18-K16 TB29-D1 77DP 11-E4 TB32-D1 33 14-F10 TB35-K4 45RL 10-L14
SHIELD-013 SP773 - TB30 TB30-B4 SHIELD-824 - P04 TB29 TB29-X1
TB22-T1 47S 12-B3 TB25-R2 11CAM 18-K17 TB29-D2 77DP 11-E4 TB32-D2 33 14-F11 TB35-L1 47 12-D10
SHIELD-016 SP222 - SP243 - SHIELD-825 TB29 TB29-X2 - -
TB22-T2 47S 12-B2 TB25-S1 8X013 18-K16 TB29-E1 77B 11-E4 TB32-E1 33BP 14-F10 TB35-L2 47 12-D10
SHIELD-017 SP224 - SP103 - SHIELD-826 TERM1 P304R SP814 -
TB22-X1 39H1 8-N10 TB25-S2 8X013 18-K17 TB29-E2 77B 11-E4 TB32-E2 33BP 14-F11 TB35-L3 47 12-D10
SHIELD-018 SP189 - SP232 - SHIELD-827 SP817 - TERM3 P201R
SHIELD-019 SP228 - SP118 - SHIELD-834 SP198 - CAN TEE RPC # 2 P206D
SHIELD-020 SP226 - SP197 - SHIELD-835 CAN TEE RPC # 1 P205B CAN TEE RPC # 2 P204B
SHIELD-021 SP223 - SP240 - SHIELD-836 INTERFACE MODULE IM1 CAN TEE J1939 # 1 P306D
SHIELD-022 SP065 - TX9 P22TX9B2 SHIELD-842 - P02 CAN TEE RPC # 3 P203B
SHIELD-023 SP048 - TX0 P21TX0B2 SHIELD-843 - J02 CAN TEE RPC # 4 P220B
SHIELD-025 SP048 - - - SHIELD-844 SP808 - CAN TEE 3RD PARTY #4 P407B
SHIELD-026 SP058 - - - SHIELD-845 SP817 - CAN TEE RPC #5 P211B
SHIELD-027 SP055 - - - SHIELD-858 SP199 - CAN TEE 3RD PARTY #2 P402D
SHIELD-028 SP058 - SP055 - SHIELD-859 CAN TEE 3RD PARTY #1 P402B CAN TEE 3RD PARTY #2 P401B
58B-06-02261-00 SEP 15
980E-4
A40003 & UP
Sheet 23 of 24
DEVICE TABLE CONNECTOR TABLE
DEVICE SHEET-ZONE DEVICE SHEET-ZONE DEVICE SHEET-ZONE DEVICE SHEET-ZONE DEVICE SHEET-ZONE DEVICE SHEET-ZONE CONN SHEET-ZONE CONN SHEET-ZONE CONN SHEET-ZONE CONN SHEET-ZONE CONN SHEET-ZONE CONN SHEET-ZONE CONN SHEET-ZONE CONN SHEET-ZONE CONN SHEET-ZONE CONN SHEET-ZONE CONN SHEET-ZONE CONN SHEET-ZONE CONN SHEET-ZONE
12V POWER RELAY (12VPR) 6-I9 GB10 FRT CAB GND 13-L6 L BAR-1 5-J12 RELAY ENG STARTER 2 (ESREL2) 4-F7 SWITCH KOMVISION MODE 19-C13 VEC-91 17-B19 12VCN-12VA 6-I5 D15 12-N4 GB31A-C4 6-C5 IPT2AX3 16-L18 J16 11-M16 J5200 16-L9 MTR1-TC1 16-L21 P12 11-D15 P0128X 19-C5 P538_JP 17-I15 PLOS-F1 4-C16 SONA(+) 9-E13 VEC91-P12 6-B4
12VDC CONVERTER (12VCN) 6-I5 GB10 FRT CAB GND 15-D1 L BAR-2 6-F11 RELAY ENGINE PRELUBE 4-O9 SWITCH KOMVISION ON/OFF 18-K18 WIRELESS BRIDGE 6-P2 12VCN-12VB 6-I5 D26 14-C11 GB31A-D1 7-B17 IPT2BX2 16-M18 J16 12-H8 J5202 16-N8 MTR1-TC2 16-L21 P12 11-D18 P0128X 19-C5 P540 10-J17 PLOS-F2 4-C16 SONA(-) 9-E13 VEC91-P12 7-C13
12VDC POWER PORT #1 6-D9 GB10 FRT CAB GND 17-L8 L BAR-3 12-N12 RELAY ENGINE PRELUBE MAG SWITCH (PLMS) 4-P12 SWITCH KOMVISION REAR 19-C15 12VCN-24VA 6-H5 D26 14-C12 GB31A-D2 6-G15 IPT2BX3 16-M18 J16 12-H8 J5203 17-M12 MTR2-TA1 16-L21 P12 11-G15 P0138X 19-F16 P540 11-G14 PLPM-(+) 4-P13 SPS 14-H1 VEC91-P12 7-C10
12VDC POWER PORT #2 6-D9 GB12 REAR CAB 6-C9 L BAR-4 7-D8 RELAY GROUND LEVEL ALARM 17-H5 SWITCH KOMVISION RH FRONT 19-C21 12VCN-GND 6-I5 D70 4-C18 GB31A-D3 16-L4 IPT2CX2 16-M18 J16 12-D11 J5207 15-D13 MTR2-TA2 16-L21 P12 12-M13 P0138X 19-F15 P540 12-M14 PLPM-(-) 4-P14 STRT1-1A 4-K10 VEC91-P12 7-C13
24VDC ALTERNATOR 4-K7 GB12 REAR CAB 6-C9 L BAR-5 11-L4 RELAY HEADLIGHT HIGH MOUNT (HHMR) 9-O7 SWITCH KOMVISION RH REAR 19-C18 12VPR-85 6-H10 D70 4-C18 GB31A-D4 11-P9 IPT2CX3 16-M18 J16 12-M14 J5208 15-D13 MTR2-TB1 16-M21 P12 12-F5 P140 7-K14 P540 12-F4 PLPSW 4-N10 STRT1-1C 4-K10 VEC91-P12 7-B10
24VDC BUS 6-F4 GB12 REAR CAB 6-C9 L BAR-6 11-M5 RELAY HEADLIGHT LOW MOUNT (HLMR) 9-N7 SWITCH LADDER CONTROL 17-C21 12VPR-86 6-H9 D71 13-M7 GB31A-E1 6-M13 J01 9-G10 J16 13-E6 JB1 4-E18 MTR2-TB2 16-M21 P12 14-N16 P0148X 19-F13 P540 15-C10 PLPSW 4-N9 STRT1-2A 4-K11 VEC91-S5A 6-J13
24VDC BUS 6-F5 GB12 REAR CAB 8-C14 L BAR-7 14-J11 RELAY HI-BEAM HEADLIGHT (HBHR) 9-L7 SWITCH LEFT ENGINE SERVICE LAMP (LESLS) 11-D16 12VPR-88 6-I9 D71 13-M7 GB31B-A1 4-M17 J01 9-D13 J16 14-E11 JB4A 7-H12 MTR2-TC1 16-M21 P12 15-C9 P0148X 19-F13 P540 15-I16 PLREL_K 4-D16 STRT1-2B 4-K11 VEC91-S6A 6-I13
24VDC BUS 6-F5 GB12 REAR CAB 11-I16 LAMP AMBER PAYLOAD LEFT 15-H19 RELAY HYDRAULIC LADDER PK STATUS (OPT) 17-M10 SWITCH LEFT WINDOW 11-J18 12VPR-88A 6-I10 D72 5-H18 GB31B-A2 6-G15 J01 10-C7 J16 14-D13 JB4B 11-I10 MTR2-TC2 16-M21 P12 15-D9 P150 15-L3 P540 15-D10 PLREL_K 4-D16 STRT1-3 4-K10 VEC91-S6B 6-J13
24VDC BUS 6-F5 GB12 REAR CAB 11-K7 LAMP AMBER PAYLOAD RIGHT 15-F19 RELAY KEY SWITCH (KSWPR) 5-F8 SWITCH LOW BRAKE ACCUM PRESSURE 14-F14 24VDC-A1 6-F4 D72 5-H19 GB31B-A3 15-J8 J01 11-P9 J16 14-L16 JB4C 12-M2 NTSC1 18-N3 P12 15-I15 P151 15-M3 P540 16-L7 PORT1 6-L10 STRT1-4B- 4-K10 VEC91-S7A 6-I13
24VDC BUS 6-F4 GB12 REAR CAB 11-K16 LAMP BACKUP LEFT DECK (OPT) 12-F2 RELAY KEY/GE CNTRL PWR (KCNPR) 6-H9 SWITCH LOW STEERING PRESSURE 14-N2 24VDC-B1 6-F4 D87 4-N13 GB31B-A4 14-A11 J01X 18-D14 J16 14-J3 JB4D 9-E10 ORS-85 7-M6 P12 16-L6 P152 15-N2 P541 10-M17 PORT2 6-M10 STRT2-1A 4-K12 VEC91-S7B 6-I13
24VDC BUS 6-F5 GB12 REAR CAB 11-I16 LAMP BACKUP LEFT REAR 12-E15 RELAY LADDER UP 17-G5 SWITCH MANUAL BACKUP LIGHT 12-C6 24VDC-B2 6-F5 D87 4-N13 GB31B-B1 9-K9 J02 5-C19 J16 15-N6 JB4E 8-A15 ORS-86 7-M5 P13 11-D10 P153 15-N2 P541 10-F17 PORT3 6-M10 STRT2-1B 4-K12 VEC91-S8A 6-J13
24VDC BUS 6-F4 GB12 REAR CAB 12-N6 LAMP BACKUP RIGHT DECK (OPT) 12-E2 RELAY MASTER DISCONNECT 4-G16 SWITCH MASTER GROUND DISCONNECT (DISC-) 4-G14 24VDC-B3 6-F4 D88 11-O19 GB31B-B2 6-H15 J02 5-D16 J16 16-M7 JB4F 11-J19 ORS-88 7-M5 P13 14-M4 P0158X 19-F10 P541 11-G21 PORT4 6-L11 STRT2-2A 4-K13 VHMS 13-F21
24VDC BUS 6-F4 GB12 REAR CAB 16-I11 LAMP BACKUP RIGHT REAR 12-D15 RELAY PROPEL LOCKOUT 4-D16 SWITCH PARK BRAKE RELEASE PRESSURE 5-H20 24VDC-B4 6-F5 D88 11-O18 GB31B-B3 13-N4 J02 7-I11 J16X 18-G17 JB4H 12-O3 ORS-88A 7-M6 P13 15-M5 P0158X 19-F11 P541 12-E4 PORT5 6-N10 STRT2-2B 4-K13 WADT-1 12-M8
24VDC BUS 6-F4 GB12 REAR CAB 16-D11 LAMP BODY LEFT REAR MARKER 12-K18 RELAY RADAR POWER (RPR) 18-J9 SWITCH PARK BRAKE SET 14-F14 24VDC-C1 6-F4 DIAG1 13-J9 GB31B-B4 7-B8 J02 8-G16 J16X 19-K9 JB6B 8-F17 ORS-A 11-I7 P14 10-H15 P0168X 19-F7 P541 15-B10 PORT6 6-M11 STRT2-3 4-K12 WADT-2 12-M8
24VDC BUS 6-F5 GB12 REAR CAB 16-I18 LAMP BODY LEFT SIDE MARKER 12-J18 RELAY STARTER LOCKOUT 4-E16 SWITCH PROPEL LOCKOUT (PLOS) 4-C16 24VDC-C2 6-F5 DIAG2 7-I13 GB31B-C1 7-B8 J02 8-A13 J46 5-C4 JB6C 8-D12 ORS-B 11-I8 P14 10-L17 P0168X 19-F8 P541 15-G16 PWR1-1 6-D9 STRT2-4A- 4-K12 WADT-3 12-M8
ACCELERATOR PEDAL 11-N11 GB12 REAR CAB 18-I15 LAMP BODY LEFT SIDE TURN 12-J18 RELAY VEHICLE HORN POWER (HPR) 12-L11 SWITCH RETARD SPEED CONTROL (RSCS) 11-K10 24VDC-C3 6-F5 DIAG4 16-D13 GB31B-C2 6-F19 J02 8-E21 J46 10-F8 JB6E 13-H20 ORS_1-3 11-I7 P14 11-C17 P0178X 18-F10 P541 15-D10 PWR1-2 6-D9 SW_GND 6-N11 WADT-6 12-M8
ACTIA DASH DISPLAY 9-H8 GB12 REAR CAB 18-I15 LAMP BODY RIGHT REAR MARKER 12-I18 RELAY WIPER MOTOR HIGH 12-P6 SWITCH RIGHT ENGINE SERVICE LAMP (RESLS) 11-D21 24VDC-C4 6-F5 DIAG5 14-H17 GB31B-C3 6-N9 J02 9-J7 J46 10-F7 JB6G 12-L2 ORS_1-4 11-I8 P14 11-O16 P201R 16-E21 P541 16-K7 PWR2-1 6-D9 T19 16-M18 WW+ 12-N8
ACTIA DISPLAY PANEL DIMMER 9-J12 GB31-A 6-J7 LAMP BODY RIGHT SIDE MARKER 12-H18 RELAY WIPER MOTOR LOW 12-O6 SWITCH RIGHT WINDOW 11-K18 24VDC-D1 6-F4 DIAG6 13-E18 GB31B-C4 6-N13 J02 11-H8 J46 17-I16 JB8A 13-I18 P01 9-D13 P14 14-C13 P202D 16-F7 P542 7-D18 PWR2-2 6-D9 T20 16-M18 WW- 12-N8
ACTIA STATUS PANEL 9-D1 GB31-A 6-I7 LAMP BODY RIGHT SIDE TURN 12-G18 RETARD CONTROL PEDAL 11-O11 SWITCH ROTATING BEACON (OPT) 15-E3 ACCBD 14-C12 DID 13-J9 GB31B-D1 7-B8 J02 11-L6 J54 12-J14 JB8B 18-K5 P01 9-G10 P14 14-H3 P203B 16-E7 P542 9-P13 R1 8-M13 TSW-85 7-O6
ALARM GROUND LEVEL LADDER 17-H8 GB31-A 6-G15 LAMP CAB DOME 10-N4 RETARD LEVER SENSOR (OPT) 11-P12 SWITCH SERVICE BRAKE DEGRADE PRESSURE 14-G14 ACCBD 14-C11 DISC(-)-1 4-F14 GB31B-D2 6-F19 J02 13-J7 J55 12-H14 JB8C 18-D6 P01 10-C7 P14 14-C9 P204B 16-E4 P542 9-N13 R1 8-M13 TSW-86 7-O5
ALARM KOMVISION ERROR (ESON) 18-I5 GB31-A 6-I15 LAMP CONTROL CABINET WORK LIGHT #1 10-H20 RETARD SPEED CONTROL 11-L11 SWITCH SERVICE BRAKE PSI 7-G14 ACCP1-C 14-L3 DISC(-)-2 4-G14 GB31B-D3 7-F8 J02 13-K7 J58 14-E12 JB8E 17-B3 P01 11-P9 P14 14-O4 P205B 16-E2 P542 9-L13 R2 14-B14 TSW-88 7-O5
ALARM KOMVISION RADAR (RSON) 18-I5 GB31-A 6-C5 LAMP CONTROL CABINET WORK LIGHT #2 10-I20 RTMR1-F1 18-K20 SWITCH STEERING BLEED PRESSURE 14-O2 ACCP1-NO 14-L3 DISC(-)-3 4-G14 GB31B-D4 5-H18 J02 14-H14 J58 14-E14 JB9X 18-D10 P1 13-I14 P14 14-L16 P206D 16-F5 P542 10-G16 R2 14-B14 TSW-88A 7-O6
ALTERNATOR PROPULSION DRIVE 16-M21 GB31-A 6-D18 LAMP FUEL TANK SERVICE 11-C22 RTMR1-F2 18-J20 SWITCH STEERING FILTER #1 14-E20 ACCP2-C 14-M3 DISC(-)-4 4-G14 GB31B-E1 4-I11 J02 14-A12 J72 13-D9 JB10X 18-E13 P02 5-C19 P14 16-O4 P207B 16-E16 P542 10-C19 R15 14-D12 UPS 17-D5
ANTENNA KWB MODULE 6-O1 GB31-A 6-G19 LAMP GREEN PAYLOAD LEFT 15-I19 RTMR1-F3 18-K20 SWITCH TRACTION MOTOR PRESSURE (BPSW) 13-D8 ACCP2-NO 14-M3 DISC(-)-5 4-G14 GB31B-E2 14-E10 J02 16-E10 J72 16-M8 JB12A 18-E5 P02 5-D16 P15 11-G9 P210 6-D14 P543 7-C19 R15 14-D12 UPS 17-D6
ANTENNA ORBCOMM SATELLITE / GPS (OPT) 13-H21 GB31-A 6-H19 LAMP GREEN PAYLOAD RIGHT 15-G19 RTMR1-F4 13-F7 TERM#2 16-E1 ACPSW 14-N2 DISC(-)-6 4-F14 GB31B-E3 14-B15 J02 16-B9 J119 18-C21 JB12B 18-K7 P02 7-I11 P15 16-N5 P211 6-C14 P543 9-O13 R16 9-E12 VEC89-P1 10-B10
BATT1 4-D2 GB31-A 6-C5 LAMP HIGH MOUNT LEFT HI-BEAM 9-L15 SCORE BOARD LEFT (OPT) 15-J17 TERM#4 16-H1 ACPSW 14-N2 DISC(-)-7 4-G14 GB31B-E4 14-M6 J02 16-D11 J122 18-D21 JB12C 18-K8 P02 8-E21 P16 10-N16 P211B 16-E16 P543 9-N13 R16 9-E12 VEC89-P1 10-B13
BATT2 4-D3 GB31-A 6-F15 LAMP HIGH MOUNT LEFT LOW-BEAM 9-P15 SCORE BOARD RIGHT (OPT) 15-J14 TERM#5 16-H13 AHS 12-M17 DL1 6-B22 GB70-A1 4-I9 J02 16-I8 J123 18-E21 JB12D 17-E8 P02 8-G16 P16 11-M16 P212 14-A14 P543 9-P13 R17 13-G7 VEC89-P1 12-H6
BATT3 4-E2 GB31-A 6-M13 LAMP HIGH MOUNT RIGHT HI-BEAM 9-M15 SENSOR BRAKE PRESSURE 14-K1 TERM1 16-B20 ALLR-85 10-F11 DL2 6-C22 GB70-A2 4-I10 J02 18-K15 J124 18-F21 JB41 7-G4 P02 8-A13 P16 12-H8 P212 14-A14 P543 10-E17 R17 13-G7 VEC89-P1 12-H3
BATT4 4-E3 GB31-A 7-B17 LAMP HIGH MOUNT RIGHT LOW-BEAM 9-P15 SENSOR BRAKE TEMP LH FRONT 14-K19 TERM3 16-E21 ALLR-86 10-F11 DL3 6-C22 GB70-B2 4-I10 J03 5-E11 J125 18-G21 JENET1 6-L8 P02 9-J7 P16 12-H8 P212D 16-F16 P543 10-B19 R18 8-I15 VEC89-P1 14-C16
BRAKE FILTER PRESS SW 16-P5 GB31-A 10-E11 LAMP HYD TANK SERVICE 11-C22 SENSOR BRAKE TEMP LH REAR 14-J19 TERMX1 19-H1 ALLR-88 10-F11 DL4 6-D22 GLA 17-H8 J03 5-E7 J126 18-H21 JENET2 6-M8 P02 11-L6 P16 12-D11 P215B 16-E5 P565 10-H16 R18 8-I15 VEC89-P1 15-C6
BUSS BAR 11L 10-M5 GB31-A 11-P9 LAMP HYDRAULIC CABINET #1 12-O12 SENSOR BRAKE TEMP RH FRONT 14-K19 TERMX3 19-K1 ALLR-88A 10-F11 DL5 6-D22 GLAR_K 17-H5 J03 6-C7 J127 18-I21 JENET3 6-M8 P02 11-H8 P16 12-M14 P216B 16-E7 P606 6-P8 R19 14-B12 VEC89-P1 15-B3
BUSS BAR 24VDC BATT BOX 4-E6 GB31-A 15-E7 LAMP HYDRAULIC CABINET #2 12-P12 SENSOR BRAKE TEMP RH REAR 14-J19 THERMOSTAT ENGINE OIL 16-M15 ALSOL 14-M19 DL6 6-E22 GLAR_K 17-H5 J03 6-E7 J128 18-I21 JENET4 6-L5 P02 13-J7 P16 13-E6 P218D 16-F2 P607 6-P6 R19 14-B12 VEC89-P2 9-I5
BUSS BAR BAT(-) 4-F4 GB31-A 16-L4 LAMP LED MASTER DISCONNECT CLOSED 4-G19 SENSOR DUCT AIR TEMPERATURE 14-L19 THERMOSTAT HYDRAULIC OIL 16-N16 ALSOL 14-M19 DLS-2 6-C19 GLORS 17-G8 J03 7-K12 J0178X 18-F10 JENET5 6-M5 P02 13-K7 P16 14-E11 P219D 16-F3 P701 8-E11 R27 9-J11 VEC89-P2 11-H10
BUSS_BAR_0 4-G14 GB31-B 4-I11 LAMP LED MASTER DISCONNECT OPEN 4-H19 SENSOR FUEL LEVEL 14-D16 THERMOSTAT OIL RESERVE TANK 16-K16 ALT(+) 4-K7 DLS-3 6-C19 GLORS 17-G8 J03 8-K16 J210 6-D14 JENET6 6-M5 P02 14-A12 P16 14-J3 P220B 16-E12 P701 11-N5 R27 9-J10 VEC89-P2 14-M12
BUSS_BAR_11 4-E14 GB31-B 4-M17 LAMP LED PROPEL LOCKOUT LOCKED OUT 4-E19 SENSOR GE ALTERNATOR SPEED 11-H6 TIMER (1HR) ENGINE SERVICE LAMP (ESLT) 11-D14 ALT(-) 4-K7 DPS 17-E5 GND 15-I17 J03 8-K19 J211 6-C14 JP20 16-O5 P02 14-H14 P16 14-D13 P221B 16-E13 P701 11-P5 R30 14-M14 VEC89-P2 14-B18
BUSS_BAR_11ST 4-F14 GB31-B 5-H17 LAMP LED PROPEL LOCKOUT ON 4-D19 SENSOR HOIST PRESSURE #1 14-H1 TIMER (1HR) HYDRAULIC PUMP MOD (HPLT) 11-C16 ALT1 16-M21 DPS 17-E6 HAFSW 14-E13 J03 9-J19 J228 8-B12 JX07 18-K12 P02 16-B9 P16 14-L16 P222D 16-F13 P701 11-O5 R30 14-M14 VEC89-P2 14-B16
BUSS_BAR_BAT- 4-G14 GB31-B 6-F19 LAMP LED STARTER LOCKOUT CLOSED 4-G19 SENSOR HOIST PRESSURE #2 14-I1 TIMER WASHER DELAY (WADT) 12-M8 ALT2 16-M21 DRL 12-J10 HAFSW 14-E13 J03 9-L3 J229 8-C12 JX07 18-D3 P02 16-D11 P16 15-N6 P235 11-O11 P702 5-D13 R50 7-E9 VEC89-P4 8-A10
CAMERA 1 18-L19 GB31-B 6-N13 LAMP LED STARTER LOCKOUT OPEN 4-F19 SENSOR HYDRAULIC TANK LEVEL 14-I19 TIMER WIPER DELAY 12-M5 ALTSP 11-H6 DSSW-C 11-J9 HBHR-85 9-K8 J03 9-I8 J237 11-P11 JX07 18-I12 P02 16-I8 P16 16-M7 P236 11-N11 P702 8-M11 R50 7-E8 VEC89-P4 8-E18
CAMERA 2 18-L19 GB31-B 6-N8 LAMP LEFT FOG 10-C20 SENSOR LEFT FRONT WHEEL SPEED 11-D12 TX0 19-H1 ALT_SEN 4-K7 DSSW-NO 11-J8 HBHR-86 9-K7 J03 10-K1 J240 5-I19 JX10 18-L12 P02 16-E10 P16X 18-G17 P237 11-P10 P702 14-D10 R51 7-C9 VEC89-P4 10-C10
CAMERA 3 18-M19 GB31-B 6-F19 LAMP LEFT LOWER ENGINE SERVICE 11-G13 SENSOR LEFT REAR WHEEL SPEED 11-E12 TX9 19-K1 ATS 14-L19 ECHTR1 16-K16 HBHR-88 9-L7 J03 10-F4 J240 7-H16 JX11 18-L12 P02 18-K15 P16X 19-K9 P240 5-I19 P702 16-O2 R51 7-C9 VEC89-P4 13-P2
CAMERA 4 18-M19 GB31-B 6-G15 LAMP LEFT UPPER ENGINE SERVICE 11-F13 SENSOR PAYLOAD PRESSURE LEFT FRONT 15-M3 USER PC 6-M2 BAT(-)-1 4-F4 ECHTR2 16-L16 HBHR-88A 9-L8 J03 10-B6 J240 8-L17 JX12 18-M12 P2A 13-I14 P18 9-J12 P240 7-H16 P702 17-C18 RBUL 12-E2 VEC89-P4 14-C17
CAMERA 5 18-N19 GB31-B 6-H15 LAMP LH DECK (OPT) 10-G20 SENSOR PAYLOAD PRESSURE LEFT REAR 15-N2 VEC RTMR1 7-C15 BAT(-)-2 4-F5 ENET_PWR 6-M11 HFSW1 14-E18 J03 10-K6 J240 11-N16 JX13 18-M12 P2B 13-K14 P0018X 19-F20 P240 8-L17 P703 13-D10 RCL1 10-L21 VEC89-P4 14-N12
CAMERA 6 18-N19 GB31-B 7-B8 LAMP LH DIAGONAL LADDER 10-G20 SENSOR PAYLOAD PRESSURE RIGHT FRONT 15-L3 VEC RTMR1 8-L12 BAT(-)-3 4-F5 EOH1 16-M16 HFSW1 14-E17 J03 10-M3 J240 12-O10 JX14 18-N12 P03 5-E11 P0018X 19-F20 P240 11-N16 P707 14-K19 RCL1 10-L21 VEC89-P4 14-N9
CAN TEE 3RD PARTY #1 16-H1 GB31-B 7-B8 LAMP LOW MOUNT LEFT HI-BEAM 9-L15 SENSOR PAYLOAD PRESSURE RIGHT REAR 15-N2 VEC RTMR1 13-F6 BAT(-)-4 4-F4 EOH2 16-M16 HFSW2 14-E18 J03 11-K15 J240 14-G12 JX15 18-N12 P03 5-E7 P20 9-B10 P240 12-O10 P708 14-K19 RCL2 10-M21 VEC89-P9 9-O5
CAN TEE 3RD PARTY #2 16-H4 GB31-B 7-F8 LAMP LOW MOUNT LEFT LOW-BEAM 9-N15 SENSOR POWER LADDER DOWN 17-E5 VEC RTMR1 18-J20 BAT(-)-5 4-F4 EOPS 4-M12 HFSW2 14-E19 J03 12-B5 J240 14-K3 KCNPR-85 6-G9 P03 6-E7 P20 9-B10 P240 14-G12 P709 14-J19 RCL2 10-M21 VEC89-P9 9-N5
CAN TEE 3RD PARTY #4 16-H12 GB31-B 7-B8 LAMP LOW MOUNT RIGHT HI-BEAM 9-N15 SENSOR POWER LADDER UP 17-D5 VEC RTMR1 18-K20 BAT(-)-6 4-F5 EOPS 4-M11 HHMR-85 9-O7 J03 12-N7 J362 15-L17 KCNPR-86 6-G8 P03 6-C7 P21 9-D10 P240 14-K3 P710 14-J19 RECDR 7-J3 VEC89-P9 12-D4
CAN TEE J1939 # 1 16-B3 GB31-B 9-K9 LAMP LOW MOUNT RIGHT LOW-BEAM 9-O15 SENSOR RIGHT FRONT WHEEL SPEED 11-B12 VEC RTMR1 18-K20 BAT1(+) 4-D2 EOTS 16-M15 HHMR-86 9-O7 J03 12-L15 J372 14-I15 KCNPR-88 6-H8 P03 7-K12 P21 9-D10 P250 8-G21 P712 14-I19 RECDR 7-J4 VEC89-P11 10-J12
CAN TEE J1939 # 2 16-B6 GB31-B 13-N4 LAMP MARKER/TURN LEFT FRT DECK 10-K21 SENSOR RIGHT REAR WHEEL SPEED 11-G12 VEC-89 6-G13 BAT1(-) 4-D2 ESDS-1 5-C1 HHMR-88 9-O7 J03 12-L6 J502 10-M18 KCNPR-88A 6-H9 P03 8-K19 P21TX0B2 19-H2 P250 8-G21 P720 11-G11 RESLS-1 11-D21 VEC89-P11 10-I9
CAN TEE J1939 #4 16-B13 GB31-B 14-M6 LAMP MARKER/TURN LEFT SIDE DECK 10-J21 SENSOR STEERING PRESSURE 14-H1 VEC-89 8-A10 BAT2(+) 4-D3 ESDS-2 5-C2 HHMR-88A 9-O7 J03 13-P6 J502 10-F18 KEYSW-B 5-E8 P03 8-K16 P21TX0D 19-I2 P263 17-M10 P721 11-E11 RESLS-2 11-D21 VEC89-P11 12-D6
CAN TEE J1939 #5 16-B16 GB31-B 14-A11 LAMP MARKER/TURN RIGHT FRT DECK 10-L21 SHIFTER CURRENT LIMIT RESISTOR 8-G21 VEC-89 8-E18 BAT2(-) 4-D3 ESLT-3 11-D14 HL1 12-O12 J03 15-A5 J502 12-E3 KEYSW-BR 5-E9 P03 9-J19 P22 10-B4 P263 17-M10 P730 14-D14 RESLS-3 11-D21 VEC89-P11 12-G3
CAN TEE RPC # 1 16-E1 GB31-B 14-E10 LAMP MARKER/TURN RIGHT SIDE DECK 10-M21 SHIFTER DIRECTION SELECTOR 8-G18 VEC-89 9-L6 BAT3(+) 4-E2 ESLT-C 11-D14 HL2 12-P12 J03 15-D5 J502 15-G18 KEYSW-C 5-E9 P03 9-I8 P22 10-B3 P264 15-N9 P730 14-E16 RFLT 10-B20 VEC89-P11 12-D3
CAN TEE RPC # 2 16-E4 GB31-B 14-B15 LAMP RED PAYLOAD LEFT 15-H19 SOLENOID A/C COMPRESSOR CLUTCH 7-J5 VEC-89 9-I5 BAT3(-) 4-E2 ESLT-NO 11-D14 HLMR-85 9-N7 J03 17-L11 J502 15-D11 KOMV-2 18-J18 P03 9-L3 P22TX9B2 19-K2 P264 15-O11 P737 6-D16 RFSPK 6-C12 VEC89-P12 9-L6
CAN TEE RPC # 3 16-E7 GB31-B 15-J7 LAMP RED PAYLOAD RIGHT 15-F19 SOLENOID AUTO LUBE 14-M19 VEC-89 9-O5 BAT4(+) 4-E3 ESOL 7-C22 HLMR-86 9-N7 J03 17-I20 J502 15-B11 KOMV-3 18-K18 P03 10-K6 P22TX9D 19-K2 P301 11-G2 P800 4-O9 RGB 18-I3 VEC89-P12 10-L12
CAN TEE RPC # 4 16-E12 GB70 FRAME GND 4-I10 LAMP RETARD LEFT REAR 12-H14 SOLENOID BRAKE LOCK 8-L20 VEC-89 9-N5 BAT4(-) 4-E3 ESOL 7-C21 HLMR-88 9-N7 J03 17-C19 J502 16-K8 KOMV-5 18-K18 P03 10-K1 P23 12-C6 P301 11-H2 P800 4-O10 RLESL 11-G22 VEC89-P12 10-G10
CAN TEE RPC #5 16-E16 GB70 FRAME GND 4-I10 LAMP RETARD OP-CAP 12-J10 SOLENOID ENGINE SHUTTER (OPT) 7-C22 VEC-89 10-C10 BDS 14-G14 ESON(+) 18-I5 HLMR-88A 9-N7 J04 6-A10 J503 10-J18 KOMV-6 18-K18 P03 10-M3 P23 12-C7 P301 13-E3 P801 4-M15 RPR_K 18-J9 VEC89-P12 10-L9
CB60 6-H6 GB70 FRAME GND 4-I10 LAMP RETARD RIGHT REAR 12-I14 SOLENOID ETHER START (OPT) 7-C22 VEC-89 10-G10 BDS 14-G14 ESON(-) 18-I5 HLS 11-M18 J04 9-E15 J503 12-M15 KSWPR-85 5-F8 P03 10-F5 P24 10-G3 P301B 16-B3 P801 7-K6 RPR_K 18-J9 VEC89-P12 12-H6
D1 12-M16 GE CONTROL CABINET 16-M18 LAMP RH DECK 10-E20 SOLENOID HOIST LIMIT 11-O18 VEC-89 10-L9 BFSW 16-P5 ESREL1-85 4-F7 HLS 11-M18 J04 9-K19 J503 12-F3 KSWPR-86 5-F8 P03 10-B6 P24 10-G3 P302 5-C21 P802 7-C5 RRBB1 15-E11 VEC89-S5A 6-F13
D2 7-H14 GE CONTROL INTERFACE 5-D21 LAMP RH DECK (OPT) 10-F20 SOLENOID HYDRAULIC LADDER 17-G10 VEC-89 10-I9 BLS 8-L20 ESREL1-86 4-F6 HLSW-1 12-O11 J04 10-N3 J503 15-I18 KSWPR-88 5-F8 P03 11-K15 P25 9-I9 P302 7-G20 P803 7-J6 RRBB2 15-E11 VEC89-S6A 6-G13
D3 8-M20 GE CONTROL INTERFACE 6-H3 LAMP RH DIAGONAL LADDER 10-D20 SOLENOID PARK BRAKE 7-H14 VEC-89 10-B10 BLS 8-L20 ESREL1-88 4-F6 HLSW-2 12-O11 J04 12-J8 J503 15-D11 KSWPR-88A 5-F8 P03 12-N7 P25 9-I10 P302 11-N2 P803 7-J5 RRBH-(+) 12-D15 VEC89-S7A 6-G13
D4 10-L6 GE CONTROL INTERFACE 7-G20 LAMP RIGHT FOG 10-B20 SOLENOID STEERING BLEED DOWN 14-C11 VEC-89 11-H10 BPS 14-K1 ESREL1-88a 4-F7 HMLHB 9-L15 J04 13-L15 J503 15-C11 KVIS-A 18-F3 P03 12-L14 P0028X 19-C2 P302 11-O2 P804 7-I2 RRBH-(-) 12-D15 VEC89-S8A 6-G13
D5 8-H19 GE CONTROL INTERFACE 8-F15 LAMP RIGHT LOWER ENGINE SERVICE 11-G22 SONALERT (SONA) 9-E13 VEC-89 12-D4 BPSW-COM 13-D8 ESREL2-85 4-F8 HMLLB 9-P15 J04 13-G17 J503 16-L8 KVIS-A 18-F3 P03 12-L6 P0028X 19-C2 P302 13-I3 P805 7-A2 RRBL 12-D15 VEC90-P1 5-D12
D7 17-H10 GE CONTROL INTERFACE 11-P2 LAMP RIGHT UPPER ENGINE SERVICE 11-F22 STARTER DISCONNECT (SDISC) 4-F14 VEC-89 12-G3 BPSW-NC 13-D9 ESREL2-86 4-F7 HMRHB 9-M15 J04 13-F17 J511 14-N17 KVIS-A 18-H3 P03 12-B5 P32 15-E3 P303 5-B21 P805 7-D2 RRL 12-I14 VEC90-P1 5-D9
D9 9-D12 GE CONTROL INTERFACE 13-O3 LAMP SERVICE BRAKE OP-CAB 12-I10 SWITCH A/C RECIEVER DRYER 7-J3 VEC-89 12-H3 BPSW-NO 13-D9 ESREL2-88 4-F7 HMRLB 9-P15 J04 14-F4 J520 7-C20 KVIS-B 18-F3 P03 13-P5 P32 15-E3 P303 11-L2 P805 7-C2 RRL 12-I14 VEC90-P1 8-H10
D10 9-D13 GE DID PANEL 13-J9 LAMP STOP/TAIL LEFT 12-F15 SWITCH ACCUMULATOR PRECHARGE PRESS #1 14-L3 VEC-89 12-D3 BULR-85 12-D7 ESREL2-88a 4-F8 HOHTR1 16-O16 J04 15-E9 J535 10-E7 KVIS-B 18-E3 P03 15-A5 P33 15-B3 P303 11-P2 P805 7-G2 RRSPK 6-E12 VEC90-P1 13-G20
D15 12-N3 HEATED HOSE RELAY 7-O5 LAMP STOP/TAIL RIGHT 12-F15 SWITCH ACCUMULATOR PRECHARGE PRESS #2 14-M3 VEC-89 13-P2 BULR-86 12-D7 ESS-A 5-C17 HOHTR2 16-O16 J6 13-F16 J536 5-C3 KVIS-B 18-G3 P03 15-D5 P33 15-B3 P303 13-C3 P805 7-D2 RRSTL 12-F15 VEC90-P2 5-B6
D26 14-C11 HEATER COOLANT LH 16-K14 MIRROR HEATED LEFT DECK 15-C12 SWITCH AUTOLUBE LEVEL (OPT) 14-N19 VEC-89 14-B16 BULR-88 12-D7 ESS-B 5-C17 HOSTAT 16-N16 J09X 18-G14 J537 4-C19 KVIS-B 18-L3 P03 17-L12 P34 13-N9 P303 13-L3 P806 7-G2 RRSTL 12-F15 VEC90-P2 5-B8
D70 4-C18 HEATER COOLANT RH 16-K14 MIRROR HEATED RIGHT DECK 15-B12 SWITCH AUTOLUBE PRESSURE 14-L19 VEC-89 14-C16 BULR-88A 12-D7 ESSOL 7-C21 HPLT-3 11-C16 J11 7-C18 J538 17-I13 KWB 6-P2 P03 17-I19 P34 13-N8 P304 5-C21 P806 7-A2 RSCL1 12-H18 VEC90-P2 15-H12
D71 13-M7 HEATER ENGINE OIL LH 16-M16 MODULAR MINING DISPLAY 6-L2 SWITCH AUX BOX DOME LIGHT (DLS) 6-C19 VEC-89 14-C17 BUS24V-1 4-E6 ESSOL 7-C22 HPLT-C 11-C16 J11 7-P9 J538B 17-K13 LBPS 14-F14 P03 17-C19 P35 13-M8 P304 8-F15 P806 7-D2 RSCL1 12-H18 VEC90-P2 15-H9
D72 5-H19 HEATER ENGINE OIL RH 16-M16 MOTOR LEFT WINDOW 11-I21 SWITCH BODY-UP PROXIMITY 13-E7 VEC-89 14-N9 BUS24V-2 4-E6 ESS_1-3 5-C17 HPLT-NO 11-C16 J11 9-O11 J538C 17-I15 LBPS 14-F14 P3A 13-F14 P35 13-M9 P304 11-A2 P806 7-I2 RSCL2 12-H18 VEC90-P3 5-B6
D87 4-N13 HEATER HYDRAULIC OIL #1 16-O16 MOTOR RIGHT WINDOW 11-K21 SWITCH BODYUP OVERRIDE / RESET (ORS) 11-J7 VEC-89 15-B3 BUS24V-3 4-E6 ESS_1-4 5-C17 HPR-85 12-L12 J11 9-N12 J540 10-J17 LBUL 12-F2 P3B 13-L14 P36 10-M8 P304 11-K2 P806 7-C2 RSCL2 12-I18 VEC90-P3 5-C12
D88 11-O18 HEATER HYDRAULIC OIL #2 16-O16 MOTOR STARTER 2 (STRT2) 4-K12 SWITCH BRAKE LOCK 8-K17 VEC-90 5-D9 BUS24V-4 4-E6 ETC2 13-B3 HPR-86 12-L11 J11 9-P11 J540 11-G14 LCL1 10-J21 P04 6-A10 P36 10-M7 P304 11-M2 P806 7-F2 RSCS-A 11-J10 VEC90-P3 15-G12
DEV2195 7-C15 HEATER OIL RESERVE TANK 16-L16 MOTOR STARTER 1 (STRT1) 4-K10 SWITCH BRAKE TEST 13-P9 VEC-90 5-B7 BUS24V-5 4-E6 ETHER2 7-D20 HPR-88 12-L11 J11 10-E15 J540 12-M14 LCL1 10-J21 P04 9-E15 P37 13-P9 P304 13-M3 P806 7-B2 RSCS-B 11-J10 VEC90-P4 5-D12
DEV2196 8-L12 HORN BACKUP LEFT 12-C15 MOTOR WHEEL DRIVE # 1 16-L21 SWITCH CAB LADDER LIGHT 10-G3 VEC-90 6-H13 BUS24V-6 4-E6 FH1-1 4-H5 HPR-88A 12-L12 J11 10-B17 J540 12-F5 LCL2 10-K21 P04 9-K19 P37 13-P8 P304R 16-B20 P808 7-I6 RSCS_1-1 11-J10 VEC90-P4 15-I6
DID POWER SUPPLY 13-G9 HORN BACKUP RIGHT 12-D15 MOTOR WHEEL DRIVE # 2 16-M21 SWITCH CAB SECONDARY ENGINE SHUTDOWN (ESS) 5-D17 VEC-90 8-L7 BUS24V-7 4-E6 FH1-2 4-G5 HPS1 14-H1 J11 10-M16 J540 15-I16 LCL2 10-K21 P04 10-N2 P38 17-C21 P305 5-D21 P814 11-P12 RSCS_1-2 11-J10 VEC90-P4 16-I4
DL1 6-B22 HORN FRONT VEHICLE 12-M17 MOTOR WINDSHIELD WASHER 12-N8 SWITCH COMBO 9-I14 VEC-90 13-G20 BUS24V-9 4-E6 FH2-2 4-G5 HPS2 14-I1 J11 11-D19 J540 15-D10 LESLS-1 11-D16 P04 12-J8 P38 17-C20 P305 6-H3 P815 4-N13 RSCS_1-3 11-K10 VEC90-P9 8-K10
DL2 6-C22 INDICATOR KOMVISION POWER 19-E18 MOTOR WINDSHIELD WIPER 12-O8 SWITCH COMBO 10-K2 VEC-90 15-H9 BUS24V-10 4-E6 FLS 14-D16 HS 11-O18 J11 11-G18 J540 15-C10 LESLS-2 11-D17 P04 13-L16 P0038X 19-C8 P305 11-I2 P820 7-H2 RSCS_1-4 11-K10 VEC90-P9 8-G10
DL3 6-C22 INTERFACE MODULE 5-L7 MOTOR, DRIVERS SEAT 8-B12 SWITCH COMBO 12-N2 VEC-90 15-I6 BUS24V-11 4-E6 FSL 11-C22 HS 11-O18 J11 12-E6 J540 16-L7 LESLS-3 11-D17 P04 13-G17 P0038X 19-C7 P305 13-O3 P830 17-K11 RSCS_2-1 11-K10 VEC90-P9 8-L7
DL4 6-D22 INTERFACE MODULE 6-G2 MOTOR, PASSENGER SEAT 8-C12 SWITCH COOLANT LEVEL 7-C5 VEC-90 16-I4 BUSW 13-E8 FUS-1 4-P10 HSL 11-C22 J11 14-O16 J541 10-M17 LFLT 10-C20 P04 13-F17 P39 8-K18 P305B 16-B6 P902 9-F8 RSCS_2-2 11-K10 VEC90-P11 8-I10
DL5 6-D22 INTERFACE MODULE 7-G11 OIL RESERVE SYS 7-O12 SWITCH DATA STORE (DSSW) 11-J8 VEC-91 5-L14 BUSW 13-E7 FUS-2 4-P10 IM1 5-L7 J11 15-D9 J541 10-F17 LFSPK 6-D12 P04 14-F4 P39 8-K17 P306D 16-C3 P903 9-H8 RSON(+) 18-I5 VEC90-P11 8-L10
DL6 6-E22 INTERFACE MODULE 8-J20 OIL RESERVE SYS 7-M12 SWITCH DC POWER OFF - REST SWITCH 13-M8 VEC-91 5-K14 CAM1 18-L19 GB3-A1 7-J5 IM1 5-K7 J11 15-G15 J541 11-G21 LIMIT 17-J9 P04 15-E9 P44 18-H11 P308B 16-B16 P3003 8-M13 RSON(-) 18-I5 VEC90-P12 8-J10
ENGINE JUMP START1 4-D6 INTERFACE MODULE 9-G17 OIL RESERVE SYS 7-P12 SWITCH DISPLAY MODE #1 9-D10 VEC-91 5-K14 CAM2 18-L19 GB3-B1 4-P15 IM1 5-I7 J11 15-B9 J541 12-E5 LLESL 11-G13 P4A 13-E14 P45 18-I11 P311D 16-C16 P3599 5-J12 RSP 11-L11 VEC90-S7A 6-H13
ENGINE JUMP START2 4-D7 INTERFACE MODULE 12-I3 OP CAB HEDWELD CONTROL MODULE 17-J9 SWITCH DISPLAY MODE #2 9-B10 VEC-91 6-C3 CAM3 18-M19 GB3-B3 4-P15 IM1 8-J20 J11 16-K6 J541 15-B10 LLPS 14-L19 P4B 13-J14 P46 5-C4 P315B 16-B3 P3600 5-J12 RSTL 12-G18 VEC90-S7B 6-H13
ENGINE PRELUBE HIGH VOLUME PUMP 4-P14 INTERFACE MODULE 14-P7 ORBCOMM MODULE (OPT) 13-J20 SWITCH DRIVERS SEAT BELT 14-A14 VEC-91 6-D3 CAM4 18-M19 GB4-1 4-O15 IM1 8-I20 J12 4-I4 J541 15-D10 LLPS 14-L20 P5 13-K14 P46 10-F7 P316B 16-B5 P3601 7-D8 RSTL 12-G18 VEC90-S8A 6-H13
ENGINE QSK78 INTERFACE 7-I2 INTERFACE MODULE 17-F18 ORS RELAY 7-M5 SWITCH ENGINE PRELUBE OIL PRESS (PLPSW) 4-N9 VEC-91 6-B3 CAM5 18-N19 GB5-1 4-O14 IM1 9-G17 J12 4-C21 J541 15-G16 LLSW-1 10-E5 P6A 13-F16 P46 10-F8 P317D 16-C6 P3602 7-D8 RTMR1-A1 7-B15 VEC90-S8B 6-H13
ENTERTAINMENT LEFT FRT SPEAKER 6-D12 JB1 4-E18 PAY LOAD METER 4 15-N9 SWITCH ENGINE RUN OIL PRESSURE (EOPSW) 4-M11 VEC-91 6-B18 CAM6 18-N19 GB8-1 5-H22 IM1 14-E7 J12 4-B21 J541 16-K7 LLSW-2 10-E6 P07 12-O8 P46 17-I16 P318D 16-C8 P3609 14-J11 RTMR1-A9 18-K20 VEC91-P1 7-O4
ENTERTAINMENT LEFT REAR SPEAKER 6-D12 JB4A 7-H12 PLM4 COMMUNICATION BOX 15-O14 SWITCH FOG LAMP (OPT) 10-B4 VEC-91 6-A1 CAN_TP 16-I13 GB8-2 14-F16 IM1 14-B9 J12 5-B3 J542 7-D18 LLSW-3 10-E6 P07 12-O8 P0048X 19-C10 P321B 16-B16 P3610 11-L4 RTMR1-A10 13-F6 VEC91-P1 7-O2
ENTERTAINMENT RADIO 6-D16 JB4B 11-I10 POWER LADDER CONTROLLER 17-I2 SWITCH GRID DRY 13-N8 VEC-91 6-H5 CAR_K 17-G5 GB8-3 8-L21 IM1 14-M9 J12 7-D15 J542 9-P13 LMLHB 9-L15 P7 17-I2 P0048X 19-C10 P322B 16-B13 P3611 11-L4 RTMR1-B2 7-C16 VEC91-P1 17-B19
ENTERTAINMENT RIGHT FRT SPEAKER 6-C12 JB4C 12-M2 R1 8-M13 SWITCH GROUND LEVEL LADDER LIGHT(LLSW) 10-E5 VEC-91 6-J13 CAR_K 17-G5 GB8-4 12-O11 IM2 5-J7 J12 7-O9 J542 9-L13 LMLLB 9-N15 P08_K 12-P6 P54 12-J14 P323B 16-B14 P3612 11-M5 RTMR1-B9 18-K21 VEC91-P1 17-B20
ENTERTAINMENT RIGHT REAR SPEAKER 6-E12 JB4D 9-E10 R2 14-B14 SWITCH GROUND LEVEL LADDER OVERRIDE 17-G8 VEC-91 7-B10 CB60-1 6-H6 GB10-A3 10-B5 IM2 5-H7 J12 9-N11 J542 9-N13 LMRHB 9-N15 P08_K 12-P6 P55 12-H14 P324D 16-C14 P3613 11-M5 RTMR1-B10 13-F7 VEC91-P2 5-K15
ETHERNET SWITCH 6-N10 JB4E 8-A15 R15 14-D12 SWITCH GROUND LEVEL SHUTDOWN (ESDS) 5-C1 VEC-91 7-O2 CB60-2 6-H6 GB10-A4 8-J15 IM2 7-G10 J12 9-L12 J542 10-G16 LMRLB 9-O15 P09_K 12-O6 P058 11-K21 P400B 16-H5 P4392 12-M12 RTMR1-C1 7-C15 VEC91-P2 7-B10
FUSE ALTERNATOR 4-H5 JB4F 11-J19 R16 9-E12 SWITCH HAZARD LIGHTS 10-M7 VEC-91 7-C11 CDL 10-N4 GB10-B2 9-K13 IM2 8-J20 J12 9-P11 J542 10-C19 LRBH-(+) 12-C15 P09_K 12-O6 P0058X 19-C13 P401B 16-H4 P4393 12-N12 RTMR1-C2 7-B16 VEC91-P2 7-A10
FUSE AUX BOX 4-G5 JB4H 12-O3 R17 13-G7 SWITCH HEADLIGHTS 9-I9 VEC-91 7-B11 CDL1 10-H19 GB10-B4 9-B8 IM2 8-J20 J12 10-C17 J543 7-C19 LRBH-(-) 12-C15 P10 12-M5 P0058X 19-C13 P402B 16-H2 P5200 6-C10 RTMR1-C9 18-J20 VEC91-P2 7-B10
FUSE HOLDER ALT (FH1) 4-H5 JB6B 8-F17 R18 8-I15 SWITCH HEATED MIRROR 15-B3 VEC-91 7-N3 CDL2 10-I19 GB10-C1 13-L6 IM2 9-D17 J12 10-G15 J543 9-P13 LRBL 12-E15 P11 7-C18 P58_JP 14-E12 P402D 16-H5 P5203 6-C10 RTMR1-D1 8-L12 VEC91-P2 7-B10
FUSE HOLDER AUX (FH2) 4-G5 JB6C 8-D12 R19 14-B12 SWITCH HEDWELD LIMIT 17-K10 VEC-91 7-B10 CNA 13-J20 GB10-C3 17-L8 IM2 14-I9 J12 10-J16 J543 9-N13 LRL 12-H14 P11 7-P9 P58_JP 14-E14 P403D 16-H2 P37616 6-F13 RTMR1-D2 8-L13 VEC91-P2 9-G15
FUSE LINK1 (300A) 4-P10 JB6E 13-H20 R27 9-J10 SWITCH HOIST LIMIT 11-M18 VEC-91 7-M3 CNLIN 15-J17 GB10-D2 15-D1 IM2 14-A9 J12 11-D18 J543 9-O13 LRL 12-H14 P11 9-N12 P059 11-I21 P404D 16-H3 P37617 6-G13 RTMR1-D9 18-J21 VEC91-P3 5-K13
GB LEFT DECK 15-I17 JB6G 12-L2 R30 14-M14 SWITCH HORN BUTTON 12-L16 VEC-91 7-A10 CNLO 15-J17 GB10-D3 9-G9 IM2 14-D9 J12 11-D15 J543 10-B19 LRSPK 6-D12 P11 9-P12 P62 6-F11 P407B 16-H12 P37618 6-G13 RTMR1-E9 18-K20 VEC91-P3 5-K13
GB3 ENG GND BLOCK 4-P15 JB8A 13-I18 R50 7-E9 SWITCH HYDRAULIC ACC FILTER 14-E13 VEC-91 7-J9 CNRIN 15-J14 GB12-A1 6-C8 IM2 14-P7 J12 11-G16 J543 10-E17 LRSTL 12-F15 P11 9-O12 P63 6-F11 P409D 16-H13 P37619 6-G13 RTMR1-F1 8-L12 VEC91-P3 10-L3
GB3 ENG GND BLOCK 4-P15 JB8B 18-K5 R51 7-C9 SWITCH HYDRAULIC FILTER #1 14-E17 VEC-91 7-B10 COMMA 15-N14 GB12-A2 6-C9 IM2 14-G7 J12 12-F6 J563 11-C19 LRSTL 12-E15 P11 10-E15 P0068X 19-C16 P500 13-G9 P42263 17-K11 RTMR1-F2 8-L13 VEC91-P4 5-L13
GB3 ENG GND BLOCK 7-J5 JB8C 18-D6 RADAR 1 KOMVISION 18-C21 SWITCH HYDRAULIC FILTER #2 14-E19 VEC-91 9-G15 COMMB 15-O14 GB12-A3 18-I15 IM2 14-H9 J12 12-M13 J565 10-H16 LSCL1 12-J18 P11 10-B17 P0068X 19-C15 P501 11-B11 PBPSW 14-F14 RTMR1-F9 18-K21 VEC91-P4 5-K13
GB4 ENG SUBFRAME GND BLOCK 4-O15 JB8E 17-B3 RADAR 2 KOMVISION 18-D21 SWITCH HYDRAULIC LAMP 12-O11 VEC-91 9-G15 CON1 16-O14 GB12-A4 18-I15 IM2 17-F18 J12 14-N16 J606 6-P8 LSCL1 12-J18 P11 10-M16 P071 11-K18 P502 10-M18 PBPSW 14-F14 RUESL 11-F22 VEC91-P4 7-M3
GB5 FRAME GND BLOCK 4-O14 JB9X 18-D10 RADAR 3 KOMVISION 18-E21 SWITCH KEY (KEYSW) 5-E9 VEC-91 10-L3 CON2 16-O14 GB12-B1 6-C8 IM3 5-H7 J12 15-D9 J607 6-P6 LSCL2 12-K18 P11 11-G18 P071 11-K18 P502 10-F18 PBRPS 5-H20 SABS 14-O2 VEC91-P4 7-N3
GB8 BRAKE CABINET 5-H22 JB10X 18-E13 RADAR 4 KOMVISION 18-F21 SWITCH KOMVISION BODY 19-C7 VEC-91 10-L3 CON3 16-L15 GB12-B2 16-I11 IM3 5-H7 J12 15-C9 J701 8-E11 LSCL2 12-K18 P11 11-D20 P072 11-J18 P502 12-E3 PBRPS 5-H21 SABS 14-O2 VEC91-P4 11-D14
GB8 BRAKE CABINET 8-L21 JB12A 18-E5 RADAR 5 KOMVISION 18-G21 SWITCH KOMVISION BRIGHT 19-F20 VEC-91 11-L15 CON4 16-L15 GB12-B3 16-I18 IM3 5-K7 J12 15-I15 J701 11-P5 LSOL 17-G11 P11 12-E5 P072 11-J18 P502 15-B11 PBS 7-H14 SBL 12-I10 VEC91-P4 12-N11
GB8 BRAKE CABINET 12-O11 JB12B 18-K7 RADAR 6 KOMVISION 18-H21 SWITCH KOMVISION CANCEL 19-C5 VEC-91 11-D14 D1 12-M16 GB12-C2 11-K16 IM3 6-G2 J12 16-L6 J701 11-N5 LSOL 17-G10 P11 14-O16 P72 13-D9 P502 15-G17 PBS 7-H14 SBPS 7-G14 VEC91-P4 13-G20
GB8 BRAKE CABINET 14-F16 JB12C 18-K8 RADAR 7 KOMVISION 18-I21 SWITCH KOMVISION DIM 19-C2 VEC-91 11-H15 D1 12-M16 GB12-C3 12-N6 IM3 8-J20 J13 11-D10 J701 11-O5 LSTL 12-J18 P11 15-G15 P72 16-M8 P502 15-D11 PC-ENET 6-M2 SBPS 7-G14 VEC91-P4 16-I4
GB10 FRT CAB GND 8-J15 JB12D 17-E8 RADAR 8 KOMVISION 18-I21 SWITCH KOMVISION FRONT 19-F13 VEC-91 11-M15 D2 7-H14 GB12-C4 16-D12 IM3 8-H20 J13 14-M5 J702 5-D13 LSTL 12-I18 P11 15-D9 P0078X 19-C18 P502 16-K8 PENET1 6-L8 SDISC-1 4-E14 VEC91-P9 6-B18
GB10 FRT CAB GND 9-G9 JB41 7-G4 RELAY ACCESS LADDER LIGHT (ALLR) 10-F11 SWITCH KOMVISION GRIDLINE 19-C10 VEC-91 12-K3 D2 7-H14 GB12-D1 11-I16 IM3 9-C17 J13 15-M5 J702 8-N11 LUESL 11-F13 P11 15-B9 P0078X 19-C18 P503 10-J18 PENET2 6-M8 SDISC-2 4-E14 VEC91-P9 6-D3
GB10 FRT CAB GND 9-K13 KOMTRAX PLUS MODULE 13-L14 RELAY BACKUP LIGHT (BULR) 12-D7 SWITCH KOMVISION LH FRONT 19-F10 VEC-91 12-N11 D3 8-M20 GB12-D2 11-I16 IM3 12-I3 J14 10-L17 J702 14-D10 LUR_K 17-G5 P11 16-K6 P0088X 19-C21 P503 12-M15 PENET3 6-M8 SDISC-3 4-F14 VEC91-P9 7-J9
GB10 FRT CAB GND 9-B8 KOMVISION CONTROLLER 18-N3 RELAY CAB LADDER ALARM 17-G5 SWITCH KOMVISION LH REAR 19-F7 VEC-91 13-G20 D3 8-M20 GB12-D3 8-C14 IM3 14-I7 J14 10-H15 J702 16-O3 LUR_K 17-G5 P12 4-C21 P0088X 19-C21 P503 12-F3 PENET4 6-L6 SDISC-4 4-F14 VEC91-P9 9-G15
GB10 FRT CAB GND 10-B5 KOMVISION DISPLAY MONITOR 18-I12 RELAY ENG STARTER 1 (ESREL1) 4-F6 SWITCH KOMVISION LOCK 19-F15 VEC-91 16-I4 D4 10-L6 GB12-D4 11-K7 IM3 14-O9 J14 11-O16 J702 17-C17 MIRROR1 15-B12 P12 4-I4 P0098X 19-E18 P503 15-D11 PENET5 6-M6 SDISC-5 4-F14 VEC91-P9 11-L15
D4 10-L6 GB31A-A2 6-G19 IM3 14-D9 J14 11-C17 J703 13-D10 MIRROR2 15-C12 P12 4-B21 P0098X 19-F18 P503 15-I17 PENET6 6-M6 SDISC-6 4-E14 VEC91-P9 11-H15
D5 8-H18 GB31A-A3 6-I7 IM3 14-L9 J14 14-O5 J712 16-N11 MLLO 4-H19 P12 5-B3 P108 8-G18 P503 15-C11 PLLO 4-E19 SDISC-7 4-E14 VEC91-P10 6-A1
D5 8-H19 GB31A-A4 10-E12 IM3 14-E9 J14 14-C13 J730 14-E16 MLLON 4-G19 P12 7-D16 P108 8-G19 P503 16-L8 PLM4_ENET 15-O15 SDISC-8 4-F14 VEC91-P10 6-G7
D7 17-H10 GB31A-B1 6-J7 IPT1AX2 16-K18 J14 14-L16 J730 14-D14 MLREL_K 4-G16 P12 7-O9 P120 12-L16 P507 11-D11 PLMS-(+) 4-P12 SFSW 14-D20 VEC91-P10 6-H5
D7 17-H11 GB31A-B2 6-H19 IPT1AX3 16-K18 J14 14-C9 J801 4-M15 MLREL_K 4-G16 P12 9-L12 P121 9-I14 P511 14-N17 PLMS-(-) 4-P12 SFSW 14-E20 VEC91-P10 11-M15
D9 9-D12 GB31A-B3 6-D18 IPT1BX2 16-L18 J14 14-H3 J801 7-K6 MMS_ENET 6-L2 P12 9-N12 P121 9-I14 P512 14-N19 PLMS-1 4-P12 SFSW_JP 16-O5 VEC91-P10 12-K3
D9 9-D13 GB31A-B4 15-E7 IPT1BX3 16-L18 J14 16-O4 J808 7-I6 MTR1-TA1 16-K21 P12 9-P12 P121 10-K3 P512 14-N19 PLMS-2 4-P12 SLLO 4-F19 VEC91-P11 6-B4
D10 9-D13 GB31A-C1 6-C5 IPT1CX2 16-L18 J15 11-G9 J815 4-N13 MTR1-TA2 16-K21 P12 10-G15 P121 10-K2 P535 10-E7 PLON 4-D19 SLON 4-G19 VEC91-P11 6-C3
D10 9-D13 GB31A-C2 6-F15 IPT1CX3 16-L18 J15 16-N5 J830 17-K11 MTR1-TB1 16-L21 P12 10-J16 P121 12-N2 P536 5-C3 PLOS-B1 4-C16 SLREL_K 4-E16 VEC91-P11 6-B3
D15 12-N3 GB31A-C3 6-I15 IPT2AX2 16-L18 J16 10-N16 J1206 17-K10 MTR1-TB2 16-L21 P12 10-C17 P121 12-N2 P537 4-C20 PLOS-B2 4-C16 SLREL_K 4-E16 VEC91-P11 10-L3
58B-06-02261-00 SEP 15
980E-4
A40003 & UP
Sheet 24 of 24
1 2 3 4 5 6 7 8 9 10
1 INDEX
2 AUTOLUBE
3 BATT POWER DISTRIBUTION

A A
4 BATTS, STARTERS, KEY
5 BRAKES
6 CAN BUSES
7 DISPLAY
8 DRIVE FEEDBACK CIRCUITS
9 DRIVE SYSTEM IO CHART

B B
10 ENGINE CONTROLS,
11 ENGINE IO CHART
12 ETHERNET, WIRELESS ACCESS
13 HVAC, RADIO, SEAT
14 HYD LADDER
15 IM IO CHARTS
C 16 IM IO CIRCUITS C
17 KOMTRAX +, MOD MINING

18 KOMVISION CHARTS
19 KOMVISION CONTROL
20 KOMVISION SWITCHES
21 LAMPS, FOG, EXT WARNING

D 22 LAMPS, HEAD, TAIL, CLR, STOP D
23 LAMPS, SERVICE, CONVENIENCE
24 OPERATOR DRIVE CONTROLS
25 PLM4 IO CHARTS & CIRCUITS
26 PLM4
27 RELAY & DIODE CHARTS
28 STEERING, HYDRUALIC, FUEL

E E
29 SWITCHES & RESISTORS
30 VEC IO CHART
31 WINDOW WIPE, WASH, PWR
F F
58B-06-02230-00 JUL 15
ELECTRICAL SUB-SYSTEM SCHEMATIC
980E-4
A40003 & UP
Sheet 1 of 31
1 2 3 4 5 6 7 8 9 10
BUSS VEC-89
VEC BUS
A 71CK A
10 A
F20
68ES 2B
AUTO
LUBE
VALVE
B B
IM
DI 3-Y (Auto Lube Pressure Sw) 68P
68LS DI 3-W (Auto Lube Grease Level) 68
DO 1-T (Auto Lube Solenoid)

LOW
GREASE
V36ZA80 AUTO LUBE
SW
PRESS SW
(2000 PSI)
C C
AUTO LUBE
D D
E E
F F
58B-06-02230-00 JUL 15
980E-4
A40003 & UP
Sheet 2 of 31
1 2 3 4 5 6 7 8 9 10
CIRCUIT 11 (BATTERY DIRECT) FUSES & BREAKERS
CHART OF OTHER FUSES & BREAKERS GROUPED BY POWER SOURCE
VEC DEVICE AMPS CIRCUIT # FUNCTION SHEET LOCATION
External Breaker 50 11B5 Supply to 24/12 Converter BATTS, STARTERS, KEY D-6 SUPPLY OUTPUT
VEC DEVICE AMPS FUNCTION SHEET LOCATION
RTMR1 F4 10 11DID Battery Power to DID Power Supply OPERATOR DRIVE CONTROLS D-1 CIRCUIT # CIRCUIT #
RTMR1 F3 15 11CMX Battery Power to Komvision Control KOMVISION CONTROL A-3 External 11ST 11PL Pre-Lube Pump Circuit BATTS, STARTERS, KEY A-10
Fuselink 300
F2 25 47B Back Up Lamps D-4
LAMPS, FOG, EXT WARNING
F3 15 79 Back Up Horns & Lamps D-5
A F4 15 11LL Left Low Beam Headlights A-4
RTMR1 F2 20 8X050 Power to Komvision Radar KOMVISION CONTROL A-1
A
F5 15 11LR Right Low Beam Headlights A-5 20 11B1 12VREG Communication Radio Connector BATTS, STARTERS, KEY D-9
F22
F6 25 11HL High Beam Headlights LAMPS, HEAD, TAIL, CLEAR, STOP A-7 10
F23 65 Entertainment Radio HVAC, RADIO, SEAT C-1
VEC-89 F8 15 11T Tail & Clearance Lamps D-3
F9 10 44A Stop Lights D-6
F10 20 11DSL Ladder Lights LAMPS, SERVICE, CONVENIENCE A-2 VEC-91
F63 20 12V 67C Auxiliary 12 Volt Plugs BATTS, STARTERS, KEY D-8
F11 15 11F Turn Signal Flasher LAMPS, HEAD, TAIL, CLR, STOP D-1
F12 10 11BD Hydraulic Bleed Down Power STEERING, HYDRAULIC, FUEL A-1
F13 10 44C Retard Lamps LAMPS, FOG, EXT WARNING D-7
F17 5 39G Payload Meter Battery Power PLM4 A-2
VEC-90
F18 15 11S Key Switch Supply & Timed Engine Shutdown BATTS, STARTERS, KEY D-2
F21 10 11ES Ether Start Circuit ENGINE CONTROLS A-7
F26 15 11DISP Display Power DISPLAY A-4
CIRCUIT 71CK (DIODE OR OF KEYSWITCH & GE CONTROL POWER) FUSES
F27 10 11INT Power to Interface Module
IM IO CHARTS A-6 VEC DEVICE AMPS CIRCUIT # FUNCTION SHEET LOCATION
F28 10 11IM2 Interface Module Power # 2
11 F29 10 85 Komtrax + & Orbcom Power KOMTRAX +, MOD MINING A-3 RTMR1 F1 15 71CKM Keyswitch Power to Komvision Control & Monitor KOMVISION CONTROL A-2
F14 5 712SL Keyswitch Power to PLM4 Lamps PLM4 A-1
B F30 20 11M Modular Mining Hub Power CAN BUSES B-7
F15 5 23D Engine Interlock Relay & Park Brake Status THIS SHEET E-8 B
F31 15 11ORS Reserve Oil Pump ENGINE CONTROLS C-7 VEC-90
F19 10 71BC Brake Controls BRAKES A-2
F32 15 11RCNT Reserve Oil Control ENGINE CONTROLS C-7 F20 10 68ES Auto Lube AUTOLUBE A-3
VEC-91 F33 15 11A Service Lights & Forward Horn THIS SHEET D-2 F42 5 87 Keyswitch OR to Interface Module & Fuel Sensor STEERING, HYDRAULIC, FUEL A-10
F34 15 11SL Service Lamps LAMPS, SERVICE, CONV D-1 VEC-89 F43 1 71SS Direction Selector Switch OPERATOR DRIVE CONTROLS A-1
F35 15 11L Hazard & Ladder Lts, Dome Lt, Beacon THIS SHEET C-3 F44 5 71LS Display Mode, Beacon, & Mirror Switch LEDs THIS SHEET D-8
F45 15 71P Drive Controls & Feedback THIS SHEET D-8
F36 20 11E1 Engine ECM Power #1 ENGINE CONTROLS A-4 F46 5 712PL Keyswitch Power to PLM4 PLM4 A-1
VEC-90 F47 5 71VHM Keyswitch OR to Komtrax + KOMTRAX +, MOD MINING A-2
F37 20 11E4 Engine ECM Power #4 ENGINE CONTROLS A-3 F48 5 712MM Keyswitch OR to Modular Mining Connector CAN BUSES B-6
F38 20 11E3 Engine ECM Power #3 F63 15 62SBC Seat Belt Alarm Output HVAC, RADIO, SEAT A-3
ENGINE CONTROLS A-3 VEC-89
F39 20 11E2 Engine ECM Power #2 ENGINE CONTROLS A-4 F64 5 11D Headlight Switch & Relay Coils LAMPS, HEAD, TAIL, CLR, STOP A-2
F40 20 11ER Communications Radio Connector D-9 VEC-91 F58 20 11HH Reserve Oil Line Heaters ENGINE CONTROLS C-6
BATTS, STARTER, KEY
F41 5 11FS Fire Suppression Connector D-10
TO KEYSWITCH OR CIRCUIT
VEC-89 F53 20 11HM Heated Mirror Fuse LAMPS, FOG, EXT WARNING D-2 SHT (BATTS, STARTERS, KEY) F-6
C VEC-91 F59 5 11LAD Hydraulic Ladder Control (Optional) HYD LADDER A-2 C
VEC-89 F62 15 11LF Fog Lights LAMPS, FOG, EXT WARNING A-3 TO F58 FOR RESERVE OIL SYSTEM
SHT (ENGINE CONTROLS) C-6
TO RTMR1-F1 FOR KOMVISION CONTROL
TO BATTERY DIRECT SUPPLY SHT (KOMVISION CONTROL) A-2
11
SHT (BATTS, STARTERS, KEY) F-6
71CK
TO OPTIONAL HYDRAULIC LADDER 71CK Internal Bus BUSS VEC-89
SHT (HYD LADDER) A-2 71CK
TO RTMR1-F3 FOR KOMVISION CONTROL 6S
SHT (KOMVISION CONTROL) A-3
11 Internal Bus
15 A 5A
11 8S 11 F45 F44
712 Internal Bus

11 Internal Bus BUSS VEC-91 5S 712
11 0 Internal Bus
D 11 5S D
7S 0
712 Internal Bus
15 A 15 A
8S 712 F33 F35
2E 4D
0 Internal Bus
6S 0 71P 71LS
TO DISPLAY MODE SWITCH LEDs
TO OPERATOR DRIVE SYSTEM CONTROLS SHT (DISPLAY) D-1
4B 3A SHT (OPERATOR DRIVE CONTROLS) A-4
TO BEACON AND MIRROR SWITCH LEDs
TO BODY UP SWITCH SHT (LAMPS, FOG, EXT WARNING) A-1
712 11A 11L SHT (STEERING, HYDRAULIC, FUEL) D-1
TO ROTATING BEACONS 11
TO HYD CAB & REAR AXLE SERVICE LTS SHT (LAMPS, FOG, EXT WARNING) A-6 TO BLOWER PRESSURE SWITCH
SHT (LAMPS, SERVICE, CONV) A-6 SHT (DRIVE FEEDBACK CIRCITS) A-7
TO HAZARD LIGHT SWITCH
TO FORWARD HORN & RELAY SHT (LAMPS, HEAD, TAIL, CLR, STOP) A-1
SHT (LAMPS, FOG, EXT WARNING) A-8
TO LADDER LIGHT SWITCH & CAB DOME LIGHT
TO ENGINE DIAGNOSTIC PORT SHT (LAMPS, SERVICE, CONV) A-4
E SHT (CAN BUSES) D-4
E
71CK Internal Bus
BUSS VEC-90
712 71CK
TO KEYSWITCH CIRCUIT 8S
SHT (BATTS, STARTERS, KEY) F-4 11 Internal Bus
712 5A
2F 11 F15
TO DRIVE CONTROL CIRCUITS
SHT (DRIVE FEEDBACK CIRCUITS) E-6 0 Internal Bus TO ENGINE INTERLOCK RELAY
SHT (ENGINE CONTROLS) A-1
23D
TO 12 VOLT POWER RELAY 7S 0
SHT (WINDOW WIPE, WASH, PWR) A-5 CIRCUIT 712 (KEYSWITCH) FUSES
TO PARK BRAKE STATUS CIRCUIT
VEC DEVICE AMPS CIRCUIT # FUNCTION SHEET LOCATION SHT (BRAKES) A-9
F25 10 712R Radiator Shutter Control ENGINE CONTROLS B-10
F49 15 12H Heater Blower Motor HVAC, RADIO, SEAT A-6
F50 10 63 Windshield Wiper & Washer WINDOW WIPE, WASH, PWR A-1
D-4
F F51
F52
10
5
712H
712T1
Hoist Limit Switch Circuit
Turn Signal Switch
STEERING, HYDRAULIC, FUEL
LAMPS, HEAD, TAIL, CLR, STOP B-1
F
VEC-91
58B-06-02230-00 JUL 15
F54 712G Switched Input to Display & Sonalert DISPLAY
5 A-3
F55 5 712A Aux Cabinet Service Lamps LAMPS, SERVICE, CONVENIENCE A-9
980E-4
F56 20 67P Left Window Motor B-5
WINDOW WIPE, WASH, PWR
F62 20 67R Right Window Motor B-7
F56 10 712DS Power to Operator’s Seat HVAC, RADIO, SEAT A-1 A40003 & UP
VEC-89 BRAKES
F57 10 712P Pre-Shift Brake Test Circuit A-8 Sheet 3 of 31
1 2 3 4 5 6 7 8 9 10
11ST
21S
2C
IM VEC-91
21S
VO 1-W (Isolated IM Power) 24VIM 2D 24VIM
DO 1-B (Start Enable) 21SL
C
DI 3U (Crank Sense) START
ENABLE
A 4F
R30
A
NO
NC
GE 21SL
24V STARTER DI CNX4-k (Start Request)
DISCONNECT
3H
11 11
GE 21PT
PRE
TRUCK 71GG VO CNX3-N (Interlock Volts) LUBE 300 AMP
BATTS VI CNX3-M (Interlock Volts) 11 PRESS
+ + PROPEL SW
71GH 21PS
LOCKOUT
SW 11ST
- - 11
71PS 11ST
11 21PT
+BATT
24VDC R ENGINE ENGINE
24V CHARGE
C
24VDC PRE 11PL
AUX ALT START START
24V 24V AUX LUBE
C
C
PROPEL RELAY RELAY
B B
C
CONN CONN MASTER - STARTER
LOCKOUT RELAY
#1 #2
NO
LOCKOUT
NC
LOCKOUT
RELAY RELAY RELAY
NO
NO
NC
NC
NO
NC
TRUCK 21PL
BATTS 72RRQ
+ + 25A PRE
MASTER 1S LUBE
11 LOCKED MAG
LED PROPEL
NOT SWITCH
- - 11ST 25B
LOCKED PROPEL STARTER
STARTER
LED LOCKED OUT NOT 11PF
LOCKED
LED OUT LED LOCKED
MASTER LED
MASTER NOT +
DISCONN LOCKED IM PRELUBE
LED STARTER STARTER HIGH
72RRQ 11SM1 DI 3-R (Start Motor #1) 11SM2 M
MOTOR MOTOR VOLUME
DI 3-S (Start Motor #2)
#1 MA MA #2 PUMP
C -
C
TO PROPEL REST CIRCUIT

21S SHT (OPERATOR DRIVE CONTROLS) B-6
11 11 BUSS VEC-91
11 Internal Bus
11 (Internal Bus) 11 TO KOMVISION RADAR

50 AMP SHT (KOMVISION CONTROL) A-1 5 AMP
GE F41
15 AMP 11
F18 VI BATFU-1 (24 Volt Input) BATP
BUSS VEC-90 VO CNX5-N (GE Control Power)
11FS
11S 24VDC / 12VDC 60 AMP
D VI RTN BUS (Battery Ground) CONVERTER 11B5 TO ENTERTAINMENT RADIO CIRCUIT 11B
D
3C 24V SHT (HVAC, RADIO, SEAT) C-1
71GE
12V 11B1 10E
11B1 20 A
GND 11FS
F40
GROUND IM
LEVEL 7S
FIRE
SHUTDOWN DI 3-M (GE Control Power)
A SUPPRESSION
SWITCH 20 A 20 A
12V POWER CONNECTOR
F63 F22 B
11KS RELAY
10G IM (75 AMPS) C
11KS AI 3-h (+12V Loads)
712 Internal Bus 12V 9H 11G 11C
1D D15
D14
TO ETHERNET SWITCH COMM RADIO
TO ENGINE INTERLOCK RELAY 712 CONNECTOR
71C SHT (ETHERNET, WIRELESS
KEY SW SHT (ENGINE CONTROLS) B-1
VEC-91 ACCESS) A-4 1
11ER
E BR RUN 11KS
10H 2 12VREG E
B 3
C
4
START 712K 67C
TIMED KEY /
C
ENGINE CONTROL POWER POWER

IM 21S SHUTDOWN POWER 12V PLUG 12V PLUG
R20 RELAY 11 #2
NO
#1
NC
DI 2-j (Crank Request)

(75 AMP)
DI 2-P (Keyswitch Direct) TO ENGINE RUN RELAY
75IOF
SHT(BRAKES) A-4
TO BATTERY DIRECT CIRCUIT BREAKERS
1H SHT (BATT POWER DISTRIBUTION) C-1
D1 1C
11 71CK TO ALL KEYSWITCH OR CIRCUITS
1A 712M IM SHT (BATT POWER DISTRIBUTION) C-6
DO 1-H (Shutdown Delay Relay)
712IM
TO MANUAL BACK UP LIGHT SW
F SHT (LAMPS, FOG, EXT WARNING) D-2 F
KEYSWITCH
POWER
712
58B-06-02230-00 JUL 15
RELAY
(75 AMP) ELECTRICAL SUB-SYSTEM SCHEMATIC
980E-4
712 TO ALL KEYSWITCH CIRCUITS
SHT (BATT POWER DISTRIBUTION) E-1 A40003 & UP
Sheet 4 of 31
1 2 3 4 5 6 7 8 9 10
71BC 71BC 712 (VEC BUS)
9B BUSS 10 AMP TO F15 (5 AMPS)
71CK (VEC BUS)

VEC-89 F57 23D
SHT (BATT POWER DISTRUBUTION) F-8
BUSS VEC-90 10 AMP TO SHUTDOWN DELAY RELAY SHT TO SELECTOR SWITCH FNR CIRCUIT 4G
F19 (BATTS, STARTERS, KEY) E-2 SHT (OPERATOR DRIVE CONTROLS) C-3
PARK
NC
NO
BRAKE
A 71BC 71BC
712P
STATUS A
R28
C
72FNR
A
C
2
75IOF D14 D13 PRESHIFT
BRAKE
510E
TEST SW
PARK 73S
C
PARK
C
BRAKE
B
4
3
1
6
ENG RUN BRAKE
R21 SOL
REQUEST 3H VEC-90
NO
NC
NO
NC
R22 33SBA
36
C
C
TRUCK 72SBT 3G
INTERFACE MOVING 71BL 71ABA
R27 72FNR GE
R25 510E
NO
NC
DI CMX5-a (Pre-Shift Brake Test Sw)
NO
NC
9H 11D 52PB DO CNX5-j (Pre-Shift Brake Test Light)
C
71BN PARK
SWITCH DI CNX4-R (Park Brake Status)
0BN 52CS
D9 R24 TO RESERVE OIL SYSTEM DO CNX5-k (Pre-Shift Brk Test Lt Return)
NO
NC
11B
B SHT (ENGINE) E-5 B
D10
72FD 71BM ENGINE
RUN OIL IM
D6 D5 11A DO 1E (Park Brake Solenoid)
PRESS AUTO
71BK HYD LADDER CONTROLLER
C
9E 9F SW BRAKE (OPTIONAL)
12A APPLY
RELAY PARK DI 2M (Park Brake Released) 73S DI 10 (Park Brake Release Press Sw)
NC
NO
79RD
NO
NC
RTMR1-R2 BRAKE V36ZA80 DI 2f (Park Brake Applied) 33 PARK BRAKE R
RELEASE
712BL 6.8 K RELEASE
R23
C
GE PRESS SW
0
>1250 PSI
C
A
B
2
5
PARK BRAKE W
DO CNX2-b (True Reverse Signal) YEL GRN BRAKE 52B APPLY
LOCK PRESS SW
DO CNX2-a(True Forward Signal) 52B1 SW <75 PSI B
0
D
B
4
1
6
712BL PLM4
52ABA 52RS1
39H AHT 39H1 DI 49 (Brake Lock On) HEDWELD CONTROL
C 52PB
HYD LADDER DI P4-1 (Park Brake Status)
C
C
9C PARK DI P4-2 (Park Brake Status)
71BN STATUS
(OPTIONAL)
NO
52B1
NC
71BM IM
D8 D7
DI 3L (Brake Lock Switch Power Supply) 52RS2 THERMISTOR FOR AMBIENT
9D DO 1R (Auto Brake Apply Relay) TEMPERATURE
DI 3V (Park Brake Request)
52B DI 2i (Brake Lock) TEMP RESISTANCE
(DEG C) (K OHM)
C
LATCH BRK -40 360

R26 LOCK 0 33.63
SOL
NO
NC
25 10
100 0.637
125 0.316
D 5VIM D
IM 34AT
SERVICE
BRAKE AI 3j (+5 Volt Sensor Supply Monitor)
PRESSURE
5VIM
SWITCH LEFT FRONT AMBIENT
(75 PSI) HYDRAULIC BRAKE 34BT1 AO 3c (+5 Volt Sensor Supply Output) TEMP
TEMP SENSOR SENSOR
44R 4 to 20 mA
AI 3t (Left Front Hydraulic Oil Temperature) 0 to 4000 psi
5VIM
34BT2 AI 3r (Right Front Hydraulic Oil Temperature) 18VIM 1
TO STOP LAMPS
SHT (LAMPS, HEAD, TAIL, CLR, STOP) D-8 RIGHT FRONT 33BPS SERVICE
HYDRAULIC BRAKE 5VIM BRAKE
TEMP SENSOR 34BT3 AI 3i (Left Rear Hydraulic Oil Temperature) PRESSURE
5VIM 2
IM 34BT4 AI 3m (Right Rear Hydraulic Oil Temperatue)
E DI 2U (Low Brake Pressure Switch)

DI 2V (Brake Lock Degrade Pressure Switch)
AI 3e (Ambient Temperature) E
LEFT REAR
AO 3b (+18 Volt Sensor Supply Output)
DI 3C (Service Brake Pressure Switch) HYDRAULIC BRAKE
TEMP SENSOR AI 3p (Service Brake Pressure)
33BP
33T NOTE: GROUND SHIELDS FOR ALL ANALOG
RIGHT REAR INPUT CABLES AT PRIMARY GROUND POINT
HYDRAULIC BRAKE FOR INTERFACE MODULE.
TEMP SENSOR
THERMISTOR FOR HYDRAULIC
OIL TEMPERATURE
TEMP RESISTANCE
(DEG C) (K OHM)
25 42.7
C BRAKE C LOW 30 35.13
LOCK BRAKE 6.556
F DEGRADE PRESS
80
85 6.572
F
B PRESS SW B SWITCH
90 4.925 58B-06-02230-00 JUL 15
95 4.290
100 3.750 ELECTRICAL SUB-SYSTEM SCHEMATIC
980E-4
105 3.288
110 2.892
115 2.551 A40003 & UP
120 2.257
130 1.781 Sheet 5 of 31
1 2 3 4 5 6 7 8 9 10
KOMTRAX PLUS
CAN P4A-5 (RPC Shield) GE
CUMMINS 120
CAN P4A-6 (RPC HI) OHM
CAN P4A-14 (RPC LO) CAN ECM/3PIN-C (J1939 Shield) CAN CAN3-C (3RD PARTY Shield)
CAN ECM/3PIN-A (J1939 HI) 939YE CAN CAN3-A (3RD PARTY HI) 939YK
120 CAN ECM/3PIN-B (J1939 LO) 939GE CAN CAN3-B (3RD PARTY LO) 939GK
OHM
A A
IM
CAN 1-q (J1939 Shield) PLM4
DISPLAY CAN 1-r (J1939 HI) 939YE CAN 22 (3RD PARTY Shield)
CAN 1-s (J1939 LO) 939GE CAN 12 (3RD PARTY HI) 939YK
CAN P1-7 (RPC Shield)
CAN P1-5 (RPC HI) 939YP CAN 13 (3RD PARTY LO) 939GK
CAN P1-6 (RPC LO) 939GP
CAN P1-8 (RPC TERMINATOR)
NOTE: DO NOT SHORT PINS P1-6 & P1-8 GE

WHEN TERMINATING OTHER THEN AT
DISPLAY. CAN CAN1-C (J1939 Shield) 11 Internal Bus
CAN CAN1-A (J1939 HI) 939YE 71CK Internal Bus
VEC-91
BUSS
CAN CAN1-B (J1939 LO) 939GE 11
71CK
B B
VEC-90
BUSS
20 A
KOMVISION CONTROL 5A F30
F48
DIAGNOSTIC PORT 4
CAN B-42 (RPC HI) 939YP
CAN B-41 (RPC LO) 939GP 4G 3RD PARTY
4E DIAG PORT
A
1
B 11M
TO F33 (15 AMPS) 11A 2
SHT (BATT POWER DISTRIBUTION) E-2 C 712MM
939YE 3
D 939YK
939GE 4
E 939GK
CUMMINS 5
F
DB ECM/31PIN-2 (J1587 Supply) 900 6
G TO MMS PTX DISPLAY
PLM4 DB ECM/31PIN-3 (J1587 Return) 901 7
H SHT (KOMTRAX+, MOD MINING) C-8
CAN 14 (RPC Shield)
8
CAN 5 (RPC HI) 939YP
C CAN 11 (RPC LO) 939GP
J
9 C
10
11
12
IM
KOMVISION CONTROL
CAN 1-i (RPC Shield)
CAN 1-j (RPC HI) 939YP CAN B-32 (J1939 HI) 939YE MODULAR
CAN 1-k (RPC LO) 939GP CAN B-31 (J1939 LO) 939GE MINING
A
939YK
B
939GK
C
120
OHM
D GE MMS PTX CAN TEE D
A
CAN CAN2-C (RPC Shield) 939YE
CAN CAN2-A (RPC HI) 939YP B
939GE
CAN CAN2-B (RPC LO) 939GP C
120
OHM
3RD PARTY BUS
NOTES FOR 3RD PARTY BUS:
1. SHIELD MUST BE GROUNDED AT ONE POINT
AND ONE POINT ONLY.
2. BUS MUST BE TERMINATED ON EACH END WITH
KOMTRAX PLUS RESISTORS BETWEEN END POINTS. ORDER OF
THE MODULES IS OF NO CONSEQUENCE.
CAN P4A-13 (J1939 Shield)
3. MAX STUB LENGTH IS 1 METER TO MINIMIZE
CAN P4A-4 (J1939 HI) 939YE
REFLECTIONS.
E CAN/RPC BUS CAN P4A-12 (J1939 LO) 939GE
E
120
OHM
NOTES FOR CAN/RPC BUS:
1. SHIELD MUST BE GROUNDED AT ONE POINT
AND ONE POINT ONLY.
2. BUS MUST BE TERMINATED ON EACH END. THE
DISPLAY HAS OPTIONAL INTERNAL CIRCUITRY TO
TERMINATE ONE END. THE OTHER END NEEDS A
RESISTOR BETWEEN THE END POINTS. ORDER
OF THE MODULES IS OF NO CONSEQUENCE.
3. MAX STUB LENGTH IS 1 METER TO MINIMIZE
REFLECTIONS.
J1939 BUS
NOTES FOR CAN/J1939 BUS:
F 1. CUMMINS PROVIDES THE SHIELD GROUND. NO OTHER F
GROUND IS NEEDED.
2. BUS MUST BE TERMINATED AT EACH END. CUMMINS 58B-06-02230-00 JUL 15
PROVIDES THE TERMINATION ON ONE END. THE OTHER
END NEEDS A RESISTOR. BETWEEN THE END POINTS,
ORDER OF THE MODULES IS OF NO CONSEQUENCE.
3. MAX STUB LENGTH IS 1 METER TO MINIMIZE 980E-4
REFLECTIONS.
A40003 & UP
Sheet 6 of 31
1 2 3 4 5 6 9 10 9 10
TO LEFT TURN LAMP CIRCUIT

SHT (LAMPS, HEAD, TAIL, CLR, STOP) F-1
MASTER GAUGE LIGHT MODULE
TO RIGHT TURN LAMP CIRCUIT
SHT (LAMPS, HEAD, TAIL, CLR, STOP) F-4
TO HIGH BEAM CIRCUIT
SHT (LAMPS, HEAD, TAIL, CLR, STOP) A-7
45LL
INSTRUMENT J3 P1
45RL
A 712 Internal Bus 11 Internal Bus PANEL Power 7.5 V
GND
1
2
3
Actia LIN connector, from
Master Gauge to all other
gauges and light panel by a
Power 7.5 V
GND
1
2
3
A
712 11 LIN daisy chain connection., LIN
VEC-91
4 4
5A 41H
15 A
F54 F26
TO SLAVE DEVICES TO SLAVE DEVICES
P2 (Deutsch DT06-08SB-EP06) (KOM 08192-18202) Mating Conn: Tyco 9-1419167-0 Mating Conn: Tyco 9-1419167-0
TO HEADLIGHT SWITCH TAIL/CLEAR CONNECTION 1
SHT (LAMPS, HEAD, TAIL, CLR, STOP) A-2 9C 2E Left Turn (45LL)
2
Right Turn (45RL)
3
D9 4
712G Keyswitch (712G) 1 5
41TS 5 Hi Beam (41H)
D10 J2 2 6
11DISP 6 1 1 9
+ 24SON 24VIM 3 7
SONALERT - 7 2 2 10
RED
B IM
8
11RWL WARNING 3 11
4 8 B
510 OHM LAMP
(Protected 24V Output) DO 1-W 24VIM
2 WATT 4 12
(Red Warning Light Driver) DO 1-G 11RWL POWER & COMMUNICATION
5 13
1
31IML DO 1-M (Sonalert Driver) WARNING LAMP 6 14
Mating Conn: Tyco 1411001-1
DASH LIGHT
RHEOSTAT DO 1-K (Display Hold On Signal) 7 15
2
3 8 16
P1 (Deutsch DT06-08SA-EP06) (KOM 08192-018201)
1 HIGH LEFT RIGHT
11DISP MASTER I/O
2 BEAM TURN TURN
49 Display Dimming (49) PILOT PILOT PILOT
3 LAMP LAMP LAMP
11ONS IM On Signal (11ONS)
4
TO LIGHT ON SECONDARY ENGINE SHUTDOWN SWITCH GND
SHT (ENGINE CONTROLS) C-1 5
RPC-H (939YP) J1
6
RPC-L (939GP)
C TO LIGHTS ON DIRECTION SELECTOR SW & BODY UP
OVERRIDE SW 7
1 5
Pin 4 to Pin 8 short C
2 6 creates CAN
SHT (OPERATOR DRIVE CONTROLS) A-6 8
V36ZA80 CAN Terminator 3 7 termination at display
module
4 8
0
POWER & COMMUNICATION

0
TO F44 (5 AMPS)
SHT (BATT POWER DISTRIBUTION) D-8
D D
IM
71LS 55B DI 3-J (Display Mode Control Switch (OK)

55A DI 3-H (Display Mode Control Switch LEFT)
55D DI 2-q (Display Mode Control Switch UP)
55C DI 3-K (Display Mode Control Switch DOWN)
D
D
B
B
6
6
1
1
3
DISPLAY DISPLAY
MODE MODE
CONTROL CONTROL
SWITCH SWITCH
C
C
A
A
2
71LS
E E
0
CHART OF CONNECTIONS FOR DISPLAY MODULE
CONN PIN WIRE # FUNCTION SHEET SHOWING DETAILS LOCATION

1 11DISP Battery Direct
2 49 Dimming
THIS SHEET C-5
3 11ONS IM On Signal
4 0 Ground
P1
5 939YP CAN RPC HI
6 939GP CAN RPC LO A-2
CAN BUSES
F 7 CAN RPC Shield F
8 939GP CAN Terminator NOT USED
1 45LL Left Turn Lamp 58B-06-02230-00 JUL 15
2
3
45RL Right Turn Lamp
41H High Beam Lamp ELECTRICAL SUB-SYSTEM SCHEMATIC
P2 THIS SHEET B-5
4 712G Keyswitch 980E-4
7 11RWL Red Warn Lamp
8 24VIM IM Power Out A40003 & UP
Sheet 7 of 31
1 2 3 4 5 6 7 8 9 10
GE TO F45 (15 AMPS)

SHT (BATT POWER DISTRIBUTION) E-7
71P
A PROPULSION A 74Z FI CNX1-x (ESSGND02) A
ALTERNATOR B 74X FI CNX1-s (ESS02)
SPEED
SENSOR C FI CNX1-w (ESSSHD02) BLOWER
PRESSURE
SW
0RF F1 CNX1-S (SS4GND)

D FI CNX1-V (SS4SHLD)
RT FRONT C 0RF FI CNX1-P (SS4GND)
WHEEL
SPEED B 33RF FI CNX1-X (RFSPDP)
SENSOR A 15SRW 15SRW PS CNX1-Q (SS4P15V)
DI CNX1-c (Traction Motor Pressure Switch) 75A2

0LF FI CNX1-L (SS3GND)
B B
D F1 CNX1-O (SS3SHLD)
LEFT
FRONT C 0LF FI CNX1-H (SS3GND)
WHEEL B 33LF FI CNX1-W (LFSPDP)
SPEED
SENSOR A 15SLW PS CNX1-J (SS3P15V)
+15V A 714P PS CNX1-k (SS2P15V)

COMMON B 714G FI CNX1-j (SS2GND)
C C
RT REAR V1 C 714A FI CNX1-m (SS2TAINP)
__
WHEEL F 714DP FI CNX1-n (SS2TAINN)
V1
SPEED __
SENSOR V2 G 714B FI CNX1-p (SS2TAIAP)
V2 D 714DN F1 CNX1-q (SS2TAIAN)
E FI CNX1-r (SS2SHLD)
+15V A 77P PS CNX1-B (SS1P15V)

D D
COMMON B 77G FI CNX1-A (SS1GND)
LEFT REAR V1 C 77C FI CNX1-C (SS1TAINP)
__
WHEEL V1 F 77DP F1 CNX1-D (SS1TAINN)
SPEED __
SENSOR V2 G 77B FI CNX1-E (SS1TAIAP)
V2 D 77DN F1 CNX1-F (SS1TAIAN)
E FI CNX1-G (SS1SHLD)
DI CNX5-r (Keyswitch Power) 712 TO KEYSWITCH CIRCUITS

E E
F
58B-06-02230-00 JUL 15
980E-4
A40003 & UP
Sheet 8 of 31
1 2 3 4 5 6 7 8 9 10
CONTROL CONNECTIONS CONTROL CONNECTIONS
DID PANEL CONNECTIONS
CONN PIN WIRE # FUNCTION SHEET SHOWING DETAILS LOCATION CONN PIN WIRE # FUNCTION SHEET SHOWING DETAILS LOCATION
A 77G SS1GND D-4 D
B 77P SS1P15V F
C 77C SS1TAINP H 79BA Selector Switch (Reverse) OPERATOR DRIVE CONTROLS B-2 DID 1 90DIT RS232 Transmit (to DID) OPERATOR DRIVE CONTROLS C-2
D 77DP SS1TAINN J 73DS Data Store Switch OPERATOR DRIVE CONTROLS B-4 DID 2 90DIR RS232 Receive (from DID) OPERATOR DRIVE CONTROLS D-2
D-4 DID 3 90DIG RS232 Ground (to DID) OPERATOR DRIVE CONTROLS D-2
E 77B SS1TAIAP K 52CA Selector Switch (Park) OPERATOR DRIVE CONTROLS B-2
F 77DN SS1TAIAN M DID 5 5VDI 5V for DID Panel OPERATOR DRIVE CONTROLS C-2
A G SS1SHLD N DID 6 15VDI 15V for DID Panel OPERATOR DRIVE CONTROLS C-2 A
H 0LF SS3GND O 72RQ Drive System Rest Switch OPERATOR DRIVE CONTROLS B-6 DID 9 -15VDI -15V for DID Panel OPERATOR DRIVE CONTROLS C-2
J 15SLW SS3P15V P 31RR Retard Speed Control Switch OPERATOR DRIVE CONTROLS B-9 DID 10 0COM Ground for DID Panel OPERATOR DRIVE CONTROLS C-2
L 0LF SS3GND
B-4 R 510E Park Brake Status BRAKES B-8
O SS3SHLD
P 0RF SS4GND W
CNX4
Q 15SRW SS4P15V Y
DRIVE FEEDBACK CIRCUITS
S 0RF SS4GND A-4 Z
CNX1
V SS4SHLD a
W 33LF LFSPDP B-4 d
X 33RF RFSPDP f
c 75A2 Traction Motor Pressure Switch B-6 g
j 714G SS2GND h 71H Body Up Override OPERATOR DRIVE CONTROLS B-3
k 714P SS2P15V k 21PT Engine Start Request BATTS, STARTERS, KEY A-8
m 714A SS2TAINP n
n 714DP SS2TAINN C-4 p 72AF Selector Switch (Forward) OPERATOR DRIVE CONTROLS B-1
B p 714B SS2TAIAP t 525A Accel Pedal Vout BUFFERED SPEED CONNECTIONS FOR AUTONOMOUS TRUCK B
q 714DN SS2TAIAN u Accel Pedal Shield OPERATOR DRIVE CONTROLS D-9
r SS2SHLD y Accel Pedal Ground GE
0
s 74X ESS02 A-4 z 71CN1 Conn Install Check THIS SHEET E-9
FO CNX5-W (Buffered Left Rear Speed) 77Z
t 74ZA Retard Lamp Drive LAMPS, FOG, EXT WARNING E-8 N 71GE GE Control Power out BATTS, STARTERS, KEY D-5
v 71F Body Up STEERING, HYDRAULIC, FUEL D-2 a 72SBT Pre-Shift Brake Test Sw BRAKES B-8 FO CNX5-X (Buffered Left Rear Speed) 77Y
w ESSSHD02 b 72GD Engine Warm / Grid Dry Sw OPERATOR DRIVE CONTROLS B-6
DRIVE FEEDBACK CIRCUITS, 960E A-4 CNX5
x 74Z ESSGND02 j 33SBA Pre-Shift Brake Test Light
BRAKES B-8 FO CNX5-Q (Buffered Right Rear Speed) 714Z
y 71CNCK Conn Install Check k 0 Pre-Shift Brake Test Light Ret
THIS SHEET D-9 FO CNX5-R (Buffered Right Rear speed) 714Y
z 71CNCK Conn Install Check
r 712 Key Switch On DRIVE FEEDBACK CIRCUITS D-6
A VO CNX5-Y (Ground for Rear Speed Signals)
B z 71CN1 Conn Install Check THIS SHEET E-9
C
D BATFU 1 11 Battery + Connection
BATTS, STARTERS, KEY D-5
E RTN BUS 0 Battery Ground Connection
F
G 15VDI 15V for DID Panel E-5
C H OPERATOR DRIVE CONTROLS C
J 15VDI 15V for DID Panel E-5
K
L
M
P 74NA Retard Pedal Vout CONN PIN WIRE # FUNCTION SHEET SHOWING DETAILS LOCATION
S 52RA Retard Lever Output X 77Y Buffered LR Speed
CNX2 T 0LEV Retard Lever Ground CAN CONNECTIONS W Buffered LR Speed
OPERATOR DRIVE CONTROLS D-9 77Z
U Retard Lever Shield THIS SHEET B-10
CNX5 R 714Y Buffered RR Speed
V 0RET Retard Pedal Ground CONN PIN WIRE # FUNCTION SHEET SHOWING DETAILS LOCATION Q 714Z Buffered RR Speed
W Retard Pedal Shield A 939YE CAN HI (J1939) Y SHLD Ground for Rear Shields THIS SHEET C-10
Z 71CN2 Conn Install Check THIS SHEET E-9 1 B 939GE CAN LO (J1939) B-5
a 72FD True Forward C Shield CAN Shield (J1939)
BRAKES C-1
b 79RD True Reverse A 939YP CAN HI (RPC)
c 2 B 939GP CAN LO (RPC) CAN BUSES D-2
e 72CPU GE Operating Signal ENGINE CONTROLS E-3 C CAN Shield (RPC)
Shield
g
D q 556 Frequency Command for RPM
A 939YK CAN HI (3RD PARTY) D
3 B 939GK CAN LO (3RD PARTY) A-8
r 925M/0 Frequency Command Ground ENGINE CONTROLS E-1 C Shield CAN Shield (3RD PARTY)
s 916M Frequency Pull-Up
u
v
w 72ES Fuel Ignition
ENGINE CONTROLS E-1 ETHERNET CONNECTIONS GE
x Frequency Command Shield
y CC X1-y (Conn Install Check)
z CONN PIN WIRE # FUNCTION SHEET SHOWING DETAILS LOCATION 71CNCK
CC X1-z (Conn Install Check)
A 33RR Retard Speed Control Pot OPERATOR DRIVE CONTROLS B-9 B 94ER2 Receive -
B C 94ER1 Receive + CC X2-Z (Conn Install Check)
E2 ETHERNET, WIRELESS ACCESS A-7 71CN2
C 90DIT RS232 Transmit (to DID) E 94ET2 Transmit - CC X3-Z (Conn Install Check)
OPERATOR DRIVE CONTROLS D-3
D 90DIR RS232 Receive (from DID) F 94ET1 Transmit +
CC X4-z (Conn Install Check)
G 71CN1
H 90DIG RS232 Ground (to DID) OPERATOR DRIVE CONTROLS D-3 CC X5-z (Conn Install Check)
J Retard Speed Shield
OPERATOR DRIVE CONTROLS B-9
K 0 Retard Speed Ground CONNECTION CHECK CIRCUIT
E M 71GH Propel Lockout Vin
E
BATTS, STARTERS, KEY A-5
N 71GG Propel Lockout Vout
O RS232 Shield (to DID) OPERATOR DRIVE CONTROLS D-3
R
V 90CAR RS232 Receive from PSC Conn
W 90CAT RS232 Transmit to PSC Conn OPERATOR DRIVE CONTROLS E-3
X RS232 Shield to PSC Conn
CNX3
Y
Z 71CN2 Conn Install Check THIS SHEET E-9
d 90CAG RS232 Ground with PSC Conn OPERATOR DRIVE CONTROLS E-3
f
k
m 0 Pot Reference -
OPERATOR DRIVE CONTROLS B-6
n Pot Reference Shield
q
r
s
F t 10V Pot Reference + OPERATOR DRIVE CONTROLS B-6
F
w 58B-06-02230-00 JUL 15
x
y ELECTRICAL SUB-SYSTEM SCHEMATIC
980E-4
z
A40003 & UP
Sheet 9 of 31
1 2 3 4 5 6 7 8 9 10
COOLANT LEVEL SWITCH
CUMMINS
D
HIGH 930 DI ECM/21PIN-S (Coolant Level High)
A
LOW 926 DI ECM/21PIN-T (Coolant Level Low)
BUSS VEC-91 +5V
C
924 VO ECM/31PIN-4 (Coolant Level +5V)
B
GROUND 925 VO ECM/31PIN-6 (Coolant Level Ground)
BUSS VEC-90 11 Internal Bus
A A
11
TO F15 (5 AMPS)
BUSS VEC-91
11 Internal Bus
712 Internal Bus
23D
BUSS VEC-91
11
712
20 A 20 A 10 A
4C F21 CUMMINS 10 A
F37 F36 12D DO ECM/31PIN-26 (Ether Start Control) F25
28EC DO ECM/21PIN-A (Shutter Control) 12G
TO GROUND LEVEL POWER 11ES 65S

SHT (BATTS, STARTERS, KEY) E-2 2B 2A 712R
VI ECM/31PIN-27 (Eng Test / Fan Clutch)
11KS 22FO
C
ETHER
START Test Point In Aux Box
C
SHUTTER
R36
NO
NC
CONTROL
NC
NO
B ENGINE R39 B
NO
NC
INTERLOCK 11E2
R19 11E1
C
CUMMINS 12C 65SR

23FA VI ECM/21PIN-D (Unswitched Battery Supply)
VI ECM/21PIN-G (Unswitched Battery Supply) 28E 12H
VI ECM/31PIN/1 (Switched Battery Supply)
4G ETHER
VI ECM/21PIN-X (Battery Ground) START
VALVE
(OPTIONAL) TO A/C COMPRESSOR CIRCUIT 65T
VI ECM/31PIN-23 (Battery Ground)
SHT (HVAC, RADIO, SEAT) A-9
439
A/C
C
AHT SHUTTER
CONTROL
BUSS VEC-91
NO
NC
RTMR1-R1
TO KEYSWITCH OR CIRCUIT 11 Internal Bus
C TO DASH LIGHT 23F
SHT(BATT POWER DIST) C-6
71CK 1D
65SS
C
RHEOSTAT
SHT(DISPLAY) C-2 49
A 1-1 1-3 2-1 2-3
20 A 15 A 15 A SHUTTER
SECONDARY ENGINE F58 F31 F32 CONTROL
R SHUTDOWN SWITCH SOLENOID
(SHOWN PULLED UP) (OPTIONAL)
B 1-2 1-4 2-2 2-4 1C 4C 4A
11ORS
11HH RESERVE
OIL PUMP
RELAY
439
(75 AMP)
D TO ENGINE OIL PRESSURE SWTICH 11RCNT D

SHT (BRAKES) B-5 36 RESERVE OIL LEVEL
IM SENSOR
DI 3-E (Secondary Engine Shutdown)
DI 3-F (Engine Shutdown Delay) RESERVE OIL AFC 500 AUTO REFILL
THERMOSTAT CONTROL BOX
DI 2-n GE Operating Signal GRN HI
+24V SENSOR HI
SENSOR COM WHT COM
65T
SENSOR LO BLK LO
72CPU 11POR FILL VALVE

RESERVE
OIL LINE VALVE FVAL
HEATER -24V
RELAY
GE
(75 AMPS)
DI CNX2-w (Fuel Ignition)
VI CNX2-s (Frequency Pull Up)
E FO CNX2-q (Frequency Command for RPM) E
FO CNX2-r (Frequency Command Ground) 21NSL CUMMINS ECM 11PHH
FO CNX2-x (Frequency Command Shield)
952M/0 21ISL = HIGH
916M IF ALL THE FOLLOWING ARE TRUE; RESERVE

DO CNX2-e (GE Operating Signal)
OIL LINE RESERVE
(1) ENG SPEED IS ABOVE 1650 RPM HEATERS M OIL PUMP
(2) ENG FUEL ABOVE 390 cu mm/sec
(3) COOLANT TEMP ABOVE 180 F
72CPU
21ISL REMAINS HIGH FOR 3 MINUTES
AFTER ANY OF THE FOLLOWING
CUMMINS OCCURENCES:
556
(1) ENG SPEED BELOW 900 RPM
DI ECM/31PIN-8 (GE Operating Signal) (2) ENG FUEL BELOW 290 cu mm/sec
(3) COOLANT TEMP BELOW 170 F
F DO ECM/31PIN-18 (Engine Red Light Fault)
DI ECM/21PIN-K (Red Light Input) 509
F
DO ECM/21PIN-C (Engine Shutdown Delay)
FI ECM/21PIN-L (Frequency Command for RPM)
58B-06-02230-00 JUL 15
CAB DIAGNOSTIC PORT #2
VO ECM/31PIN-10 (Frequency Pull Up) CUMMINS
1K C
VO ECM/21PIN-M (+5V Reference)
5EFQ AI ECM/21PIN-P (RPM Command Ref)
RS232 ECN/23PIN-L (Transmit)
RS232 ECM/23PIN-M (Receive)
927
B 980E-4
928
RS232 ECM/23PIN-N (Ground)
929
A A40003 & UP
RS232 ECM/23PIN-P (Shield)
Sheet 10 of 31
1 2 3 4 5 6 7 8 9 10
I/O CONNECTIONS FOR CUMMINS ENGINE

CONN PIN WIRE # FUNCTION INPUT TYPE SHEET SHOWING DETAILS LOCATION
A 939YE J1939 HI
3 PIN B 939GE J1939 LO CAN BUSES A-5
C Shield J1939 Shield
A A 65S Shutter Control ENGINE CONTROLS B-9 A
C 21NSL Shutdown Delay ENGINE CONTROLS F-3
D 11E1 Unswitched Batt ENGINE CONTROLS B-4
F 22C Fan On Full HVAC, RADIO, SEAT A-10
G 11E2 Unswitched Batt ENGINE CONTROLS B-4
21 K 31MTR Red Light Input ENGINE CONTROLS F-3
PIN L 556 Freq Cmd for rpm ENGINE CONTROLS F-1
M 5EFQ +5V Reference ENGINE CONTROLS F-1
P 5EFQ RPM Cmd Ref ENGINE CONTROLS F-1
S 930 Cool Level High ENGINE CONTROLS A-9
T 926 Cool Level Low ENGINE CONTROLS A-9
X 0 Ground ENGINE CONTROLS B-4
C
D
E
23 F
PIN L 927 RS232 Transmit
B M 928 RS232 Receive
ENGINE CONTROLS F-5
B
N 929 RS232 Ground
P SHLD RS232 Shield
1 439 Switched Batt ENGINE CONTROLS B-4
2 900 J1587 Supply
CAN BUSES C-4
3 901 J1587 Return
4 924 Cool Level +5V
ENGINE CONTROLS A-9
6 925 Cool Lev Ground
8 72CPU GE Operating ENGINE CONTROLS F-3
9
31
10 916M Freq Pull Up ENGINE CONTROLS F-1
PIN
11 22C Fan +5V Pull Up HVAC, RADIO, SEAT A-10
16 419I Eng Yellow Light NOT USED
18 31MTR Engine Red Light ENGINE CONTROLS F-3
21
23 0 Battery Ground ENGINE CONTROLS C-4
26 28EC Ether Start ENGINE CONTROLS A-8
C 27 22FO Eng Test Fan Cl ENGINE CONTROLS B-9 C
D D
E E
F F
58B-06-02230-00 JUL 15
980E-4
A40003 & UP
Sheet 11 of 31
1 2 3 4 5 6 7 8 9 10
ANTENNA
KWB MODULE TURCK ETHERNET SWITCH
(OPT) TO 12 VOLT POWER
12V VI PWR-4 (+12V Power)
SHT (BATTS, STARTERS, KEY) E-7
TO F23 IN BUSS VEC-91
65
SHT (HVAC, RADIO, SEAT) D-3
KOMATSU WIRELESS ACCESS

A ETH KWB-1 (Transmit +) 90ET1 ETH P5-1 (Wireless Access Transmit +) A
ETH KWB-2 (Transmit -) 90ET2 ETH P5-3 (Wireless Access Transmit -)
ETH KWB-3 (Receive +) 90ER1 ETH P5-2 (Wireless Access Receive +)
ETH KWB-6 (Receive -) 90ER2 ETH P5-4 (Wireless Access Receive -)
VI KWB-5 (+12V DC2) 65 GENERAL ELECTRIC
VI KWB-4 (+12V DC) 65
ETH P4-1 (GE Transmit +) 94ET1 ETH E2-F (GE Transmit +)
VI KWB-8 (Ground 2) 0
VI KWB-7 (Ground) ETH P4-3 (GE Transmit -) 94ET2 ETH E2-E (GE Transmit -)
0
ETH P4-2 (GE Receive +) 94ER1 ETH E2-C (GE Receive +)
ETH P4-4 (GE Receive -) 94ER2 ETH E2-B (GE Receive -)
MODULAR MINING DISPLAY

ETH MM-6 (Transmit +) 91ET1 ETH P1-1 (Modular Mining Transmit +)
ETH MM-4 (Transmit -) 91ET2 ETH P1-3 (Modular Mining Transmit -)
ETH MM-5 (Receive +) 91ER1 ETH P1-2 (Modular Mining Receive +)
B ETH MM-8 (Receive -) 91ER2 ETH P1-4 (Modular Mining Receive -)
PAYLOAD METER COMM BOX
B
ETH P6-1 (Payload Meter Transmit +) 95ET1 ETH E-1 (PLM Transmit +)
ETH P6-3 (Payload Meter Transmit -) 95ET2 ETH E-2 (PLM Transmit -)
ETH P6-2 (Payload Meter Receive +) 95ER1 ETH E-3 (PLM Receive +)
USER PC ETH P6-4 (Payload Meter Receive -) 95ER2 ETH E-6 (PLM Receive -)
ETH PC-1 (Transmit +) 92ET1 ETH P2-1 (PC Transmit +)
ETH PC-2 (Transmit -) 92ET2 ETH P2-3 (PC Transmit -)
ETH PC-3 (Receive +) 92ER1 ETH P2-2 (PC Receive +)
ETH PC-6 (Receive -) 92ER2 ETH P2-4 (PC Receive -)
KOMTRAX PLUS
ETH KTX-1 (Transmit +) 93ET1 ETH P3-1 (Komtrax Transmit +)
ETH KTX-2 (Transmit -) 93ET2 ETH P3-3 (Komtrax Transmit -)
C ETH KTX-3 (Receive +) 93ER1 ETH P3-2 (Komtrax Receive +)
C
ETH KTX-6 (Receive -) 93ER2 ETH P3-4 (Komtrax Receive -)
0 VI PWR-2 (Ground)
0 Ground Screw
D D
E E
F F
58B-06-02230-00 JUL 15
980E-4
A40003 & UP
Sheet 12 of 31
1 2 3 4 5 6 7 8 9 10
BUSS 71CK Internal Bus

BUSS TO TAIL LAMP CIRCUIT
VEC-89 VEC-91 SHT (LAMPS, HEAD, TAIL CLR, STOP) B-1
BUSS VEC-89
712 Internal Bus
712 Internal Bus 15 A 41TS
F63 TO RADIATOR SHUTTER CONTROLS
65T
SHT (ENGINE CONTROLS) C-9
10 A 62SBC 15 A
A F56 F49 CUMMINS A
SEAT DI ECM/21PIN-F (Fan On Full)
4B 9A
C
BELT 22C VO ECM/31PIN-11 (5 Volt Pull Up)
ALARM
OPTION 12H
NO
NC
712DS 22C
R41
A C D
1 1
2A 2H 2G HEATER / AC Test Point In Aux Box
1 3
AIR SEAT AIR SEAT CONTROL IN CAB A/C TRINARY
24VIM IM
SWITCH SWITCH PRESSURE SW BLK YEL
VO 1-W (Protected 24V Source)
62A DO 1-J (Optional Seat Belt Alarm Output)
WATER SHOWN: SHOWN:
+ +
VALVE POT 22.5 < PSI < 325 PSI < 200
DI 2-g (Seat Belt Switch)
DRIVERS PASSENGER
B M AIR SEAT M AIR SEAT 62SB BKW ORG B
MOTOR MOTOR B
- - 2 4
SEAT 0
BELT
2 2
SW YEL
65C
2 3 WATER
VALVE
RED 1 4 0
ACTUATOR
BLK
A/C
SOLENOID
TO 12 VOLT CONVERTER OUTPUT
SHT (BATTS, STARTERS, KEY) D-8
11B1
BUSS VEC-91
C C
712 Internal Bus
10 A
F23
65 712
C
RADIO
RELAY
R37
NO
NC
D D
12E 12F
TO KWB
65
SHT (ETHERNET, WIRELESS BRIDGE) A-4
ENTERTAINMENT
RADIO
65 7 BATTERY 12 VOLT +
65A 4 DIM
6 IGN
RIGHT FRONT SPEAKER (+) 11 RFPOS
RIGHT FRONT SPEAKER (-) 12 RFNEG
E E
LFNEG 14 LEFT FRONT SPEAKER (-)
LFPOS 13 LEFT FRONT SPEAKER (+)
RIGHT REAR SPEAKER (+) 9
+
+
-
LEFT FRONT RIGHT FRONT

RIGHT REAR SPEAKER (-) 10 SPEAKER
SPEAKER
16 LEFT REAR SPEAKER (-)
15 LEFT REAR SPEAKER (+)
8 GROUND
LRPOS
RRPOS
LRNEG
F F
LEFT REAR
SPEAKER
RRNEG
RIGHT REAR 58B-06-02230-00 JUL 15
0 SPEAKER
+
+
-
980E-4
A40003 & UP
Sheet 13 of 31
1 2 3 4 5 6 7 8 9 10
VEC-91
TO BATTERY CIRCUITS
11 1A
SHT (BATT POWER DISTRIBUTION) A-2
5A
F59
KOMATSU HYDRAULIC LADDER OPTION
1B
A A
11LAD 11LAD
A A
HYD LADDER HYD LADDER CONTROLLER
POSITION POSITION
CONTROLLER B B DO 12 (Cab Light) 12LL
A
C
SENSOR SENSOR
VI 7 (24 Volt Power) (UP) (DWN) DO 1 (Cab Alarm Buzzer)
LADDER
CONTROL DO 11 (Hydraulic Solenoid) 12HS
12CA DO 2 (Ground Level Alarm) 12GLA
SWITCH C C
D
B
4
3
1
6
DI 4 (Up Position Sensor) 510E2

DI 5 (Down Position Sensor) 12DP
12LU DI 8 (Ladder Up Positon) GROUND CAB
C
C
C
CAB LADDER
C
12LD DI 9 (Ladder Down Position) AHT LEVEL LADDER
510E2 LADDER UP
ALARM LIGHT
ALARM RELAY
NO
NO
NO
NC
NC
NC
VI 6 (Ground) RELAY RELAY
NO
NC
RELAY
B B
13HS
0
13CA
510E2D INTERFACE MODULE
INTERFACE MODULE B-3 B-1 A-3 A-1 GROUND
DI 2a (Hyd Ladder Alarm Input)
DI 3P (Hydraulic Ladder Not Up) LEVEL
13GLA LADDER
NOTE: REMOVE GROUND WIRE FROM B-4 B-2 A-4 A-2 OVERRIDE
INTERFACE MODULE CONNECTION 3-P TO
INSTALL OPTIONAL HYDRAULIC LADDER.
0 0 13LS
GROUND
LEVEL +
- LADDER
I/O CONNECTIONS FOR KOMATSU HYD LADDER CONTROLLER ALARM SOLENOID
PIN WIRE # FUNCTION
C SHEET SHOWING DETAILS LOCATION C
1 12CA Cab Alarm Buzzer A-6
2 12GLA Ground Level Alarm A-7
4 510E2 Up Position Sensor B-3
5 12DP Down Position Sensor B-3
THIS SHEET
6 0 Ground Connection B-2
7 11LAD B+ Connection A-2
8 12LU Ladder Up Position Sw B-2
9 12LD Ladder Down Position Sw B-2
10 73S Park Brk Release Pres Sw BRAKES B-10
11 12HS Hydraulic Solenoid
THIS SHEET A-7
12 12LL Cab Light
D D
HEDWELD HYDRAULIC LADDER OPTION
INTERFACE MODULE
510E2D DI 3P (Hydraulic Ladder Not Up)
NOTE: REMOVE GROUND WIRE FROM

E D5
INTERFACE MODULE CONNECTION 3-P TO E
INSTALL OPTIONAL HYDRAULIC LADDER.
HEDWELD CONTROL
VO 4P-3 (24V to Limit Switch) 510E2

DI 4P-4 (Up Position) 12DP AHT
24VB
3 2 7 6
HEDWELD
24VA
LIMIT
SWITCH I/O CONNECTIONS FOR HEDWELD HYD LADDER CONTROLLER
4 1 8 5
PIN WIRE # FUNCTION SHEET SHOWING DETAILS LOCATION
1 52RS1 Park Brake Status
BRAKES C-6
2 52RS2 Park Brake Status
F 3 24VA 24V to Limit Switch
THIS SHEET E-1
F
4 24VB Up Position
58B-06-02230-00 JUL 15
980E-4
A40003 & UP
Sheet 14 of 31
1 2 3 4 5 6 7 8 9 10
6
DIAGNOSTIC
9
7
8
11 Internal Bus
CONN IN AUX
BOX
5
1
BUSS VEC-91
10 AMP 10 AMP
DIAGNOSTIC F28 F27
CONN IN CAB
1
A 6
A
2
IM 7 11IM2 11INT
3
RS232 2-A (Transmit) 90IMT 8
RS232 2-B (Receive) 90IMR 4
9
RS232 2-C (Ground) 90IMG
5
4E 3G
DI 2-e (Autonomous Auto Mode) 72AT Not Used
DI 2-s (Autonomous Manual Mode) 72MAN Not Used IM
11INT VI 1-A (Battery + Input)

11IM2 VI 1-F (Interface Module Power #2)
B 0 VI 1-C (Ground)
B
CONN PIN WIRE # FUNCTION INPUT / OUTPUT TYPE SHEET SHOWING DETAILS LOCATION DI 3-P (Ground)
A 11INT Battery + Input (Unswitched) This Sheet B-9 IM CONNECTIONS 0
NOTE: The ground wire to
B 21SL Start Enable Output Digital Output #2 (Low Side Switch) BATTS, STARTERS, KEY A-8 3-P must be disconnected
C 0 Ground This Sheet B-9 if optional hydraulic ladder
is installed on the truck.
E 52CS Park Brake Solenoid Digital Output #3 (Low Side Switch) BRAKES B-7
F 11IM2 Interface Module Power #2 This Sheet B-9
G 11RWL Red Warn Light driver Digital Output #5 (Low Side Switch) DISPLAY B-4
H 712M Shutdown Delay Relay Digital Output #2 (Low Side Switch) BATTS, STARTERS, KEY F-2 CONN PIN WIRE # FUNCTION INPUT / OUTPUT TYPE SHEET SHOWING DETAILS LOCATION
J 62A Seat Belt Alarm Option Digital Output #2 (Low Side Switch) HVAC, RADIO, SEAT B-4 A
K 11ONS Display Hold On Signal Digital Output #1 (Low Side Switch) DISPLAY B-4 B
L C 44R Service Brake Press Switch Digital Input #2 (Switch to 24V) BRAKES E-1
M 31IML Sonalert driver Digital Output #1 (Low Side Switch) DISPLAY B-3
E 439 Secondary Engine Shutdown Digital Input #2 (Switch to 24V) ENGINE CONTROLS D-1
P 33JB Strg Bleed Solenoid driver Digital Output #4 (Low Side Switch) STEERING, HYDRAULIC, FUEL B-2
C R 52ABA Auto Brake Apply Relay Digital Output #4 (Low Side Switch) BRAKES B-5
F 21NSL Engine Shutdown Delay Digital Input #2 (Switch to 24V) ENGINE CONTROLS D-2 C
1 S
T 68 Auto Lube Solenoid driver Digital Output #4 (Low Side Switch) AUTOLUBE C3 G 87 Keyswitch OR Input to IM Digital Input #2 (Switch to 24V) STEERING, HYDRAULIC, FUEL B-9
HVAC, RADIO, SEAT B-4 H 55A Display Mode Switch “LEFT” Digital Input #1 (Switch to Ground)
BATTS, STARTERS, KEY A-8 J 55B Display Mode Switch “OK” Digital Input #1 (Switch to Ground) DISPLAY D-3
W 24VIM Isolated 24V Power Out
DISPLAY B-4 K 55C Display Mode Switch “DOWN” Digital Input #1 (Switch to Ground)
STEERING, HYDRAULIC, FUEL B-8
L 712BL Brake Lock Sw Power sense Digital Input #2 (Switch to 24V) BRAKES C-4
X
M 71GE G. E. Control Power Digital Input #2 (Switch to 24V) BATTS, STARTERS, KEY D-4
g
h 0 Optional Hyd Ladder Not Present THIS SHEET B-9
i CAN RPC Shield P 510E2D Hyd Ladder Not Up (Komatsu) Digital Input #1 (Switch to Ground) B-3
HYD LADDER
j 939YP CAN RPC HI CAN BUSES D-2 510E2D Hyd Ladder Not Up (Hedweld) E-3
k 939GP CAN RPC LO R 11SM1 Start Motor #1 Digital Input #2 (Switch to 24V) C-8
BATTS, STARTERS, KEY
q CAN J1939 Shield S 11SM2 Start Motor #2 Digital Input #2 (Switch to 24V) C-9
r 939YE CAN J1939 HI CAN BUSES A-5 T 52CA Selector Switch Park Digital Input #2 (Switch to 24V) OPERATOR DRIVE CONTROLS C-2
s 939GE CAN J1939 LO U 21PT Crank Sense Digital Input #2 (Switch to 24V) BATTS, STARTERS, KEY
D A 90IMT RS232 DIAG (IM Transmit)
A-8 D
V 52PB Park Brake Request Digital Input #2 (Switch to 24V) BRAKES C-6
B 90IMR RS232 DIAG (IM Receive) This Sheet A-2
C 90IMG RS232 DIAG (Ground) W 68LS Auto Lube Grease Level Low Digital Input #1 (Switch to Ground) C-2
D X AUTOLUBE
E Y 68P Auto Lube Pressure Switch Digital Input #1 (Switch to Ground) B-3
3
F Z 74ZA Retard Switch Input Digital Input #1 (Switch to Ground) LAMPS, FOG, EXT WARNING E-8
L 74DS Snapshot in Progress Digital Input #1 (Switch to Ground) KOMTRAX +, MOD MINING C-3 STEERING, HYDRAULIC, FUEL B-8
b 18VIM +18 Volt Sensor Supply
M 73S Park Brake Released Digital Input #1 (Switch to Ground) BRAKES B-8 BRAKES E-8
N 72FNR Selector Switch FNR Digital Input #2 (Switch to 24V) OPERATOR DRIVE CONTROLS C-2
P 712K Keyswitch Direct Digital Input #2 (Switch to 24V) BATTS, STARTERS, KEY E-1 c 5VIM +5 Volt Sensor Supply BRAKES D-7
R
S 33F Low Steering Pressure Digital Input #1 (Switch to Ground) STEERING, HYDRAULIC, FUEL B-3 d 33SP Steering Pressure Analog Input #4 (0 to 25 mA) STEERING, HYDRAULIC, FUEL B-8
U 33BP Low Brake Accum Pressure Digital Input #1 (Switch to Ground) BRAKES e 34AT Ambient Temperature Analog Input #1 (0 to 5.375 Volts) BRAKES E-8
E-2
g 38G Fuel Level Sensor Analog Input #5 (0 to 15 Volts) STEERING, HYDRAULIC, FUEL B-9
V 33T Brake Lock Degrade Digital Input #1 (Switch to Ground) BRAKES
h 11B1 +12 Volt Loads Analog Input #3 (0 to 20 Volts) BATTS, STARTERS, KEY E-6
E W 51A1 Low Steering Precharge Digital Input #1 (Switch to Ground) B-3 i 34BT3 Left Rear Hyd Oil Temp Analog Input #1 (0 to 5.375 Volts) BRAKES E-7
E
2 Y 39 Hydraulic Filter Pressure Digital Input #1 (Switch to Ground) STEERING, HYDRAULIC, FUEL B-8
Z 33JA Strg Accum Bled Press Sw Digital Input #1 (Switch to Ground) B-2 j 5VIM +5 Volt Supply feedback Analog Input #3 (0 to 30 Volts) BRAKES D-7
a 13CA Hyd Ladder Alarm Input Digital Input #1 (Switch to Ground) HYD LADDER B-6
b
m 34BT4 Right Rear Hyd Oil Temp Analog Input #1 (0 to 5.375 Volts) BRAKES E-7
c
e 72AT Autonomous Auto Mode Digital Input #1 (Switch to Ground) This Sheet B-2
f 33 Park Brake Set Digital Input #1 (Switch to Ground) BRAKES B-8 p 33BPS Brake Oil Pressure Analog Input #4 (0 to 25 mA) BRAKES E-8
g 62SB Seat Belt Switch Digital Input #1 (Switch to Ground) HVAC, RADIO, SEAT B-4 q 33HP2 Hoist Pump #2 Pressure Analog Input #4 (0 to 25 mA) STEERING, HYDRAULIC, FUEL B-8
i 52B Brake Lock Solenoid Sense Digital Input #2 (Switch to 24V) BRAKES C-4 r 34BT2 Right Front Hyd Oil Temp Analog Input #1 (0 to 5.375 Volts) BRAKES D-7
j 21S Crank Request Digital Input #2 (Switch to 24V) BATTS, STARTERS, KEY E-1 s 33HP1 Hoist Pump #1 Pressure Analog Input #4 (0 to 25 mA) STEERING, HYDRAULIC, FUEL B-8
k 34LL Low Hydraulic Oil Level Digital Input #1 (Switch to Ground) STEERING, HYDRAULIC, FUEL B-8
t 34BT1 Left Front Hyd Oil Temp Analog Input #1 (0 to 5.375 Volts) BRAKES D-7
n 72CPU GE Operating Signal Digital Input #1 (Switch to Ground) ENGINE CONTROLS D-2
p
Display Mode Switch “UP”
F q
r
55D Digital Input #1 (Switch to Ground) DISPLAY D-3 F
s 72MAN Autonomous Manual Mode Digital Input #1 (Switch to Ground) This Sheet B-2 58B-06-02230-00 JUL 15
t
980E-4
A40003 & UP
Sheet 15 of 31
1 2 3 4 5 6 7 8 9 10
2L
2M
2S DIGITAL OUTPUT #1
2T DIGITAL INPUT #1 (Switch to Ground) (38 available) DIGITAL OUTPUT #2
TLE6240 Low Side Switch
ANALOG INPUT #1 (0 TO 5.375 Volts) (5 available) 2U 1 Amp Max Short Circuit
TLE6240 Low Side Switch
2V 1 Amp Max Short Circuit
PWM Capability
2W (4 available)
(4 available) 1K
3e 2X 1B
3i 2Y +24V 1L Ext. 1H Ext.
A Ext.
3m
750
+ 2Z
3A 1M Conn. 1J Conn. A
Conn. 3B 1N 1U
3t 2a
3D
3r - 2b 10K
3H
0.1uF 1K 2c
100K 11V 3J
2d 47K
Ext. 3K
2e
Conn. 3N
2f
5.1V 3P
2g
3W
2h
3X 0.1uF 4.7V
2k
3Y
2m
3Z
2n
3r
2p
2q
2s
2t
ANALOG INPUT #2 (0 TO 30 Volts) (1 available)
B DIGITAL OUTPUT #3 DIGITAL OUTPUT #4 B
TLE6240 Low Side Switch TLE6220 Low Side Switch
3 Amp Max Short Circuit 3 Amp Max Short Circuit
PWM Capability PWM Capability
Ext. 10K (4 available) (4 available)
3j + 1E 1N
Conn. 1X Ext. 1P Ext.
- 1Y Conn. 1R Conn.
0.1uF 1K 1Z 1T
200K 5.1V DIGITAL INPUT #2 (Switch to 24V) (16 available)
3C
3E
3F
2N 3G
Ext. 2P 3L 47K
Conn. 2R 3M
2i 3R
C 2j 3S C
3T 0.1uF 4.7V
3U 10K
3V
ANALOG INPUT #3 (0 TO 20 Volts) (3 available)

DIGITAL OUTPUT #5
3h 10.5K BSP76 Low Side Switch
Ext. 3k
Conn. 5 Amp Max Short Circuit
3n PWM Capability
(1 available)
3.48K 5.1V Ext.
0.1uF 1G Conn.
D D
ANALOG INPUT #4 (0 TO 25 mA) (4 available)
5.6K
3d
Ext. 3q
Conn. 3p
3s
24
E 200 5.1V 0.1uF E
ANALOG INPUT #5 (0 to 15 Volt) (1 available)
10K
Ext. 3g
Conn.
4.99K uF 5.1V
F F
58B-06-02230-00 JUL 15
980E-4
A40003 & UP
Sheet 16 of 31
1 2 3 4 5 6 7 8 9 10
11 Internal Bus
BUSS VEC-91
BUSS VEC-90
MODULAR MINING PTX DISPLAY CONNECTION CHART
KOMTRAX 71CK Internal Bus
71CK
11
MODULAR CONN PIN WIRE #
A 11
FUNCTION
24V Batt Power
SHEET SHOWING DETAILS LOCATION
5A 10 A POWER B 0 Ground THIS SHEET C-9
A PLUS F47 F29
MINING CAN /
J1939
C
A
B
71CK
939YE
939GE
Keyswitch OR
J1939 HI
J1939 LO CAN BUSES D-5
A
1B 4H C J1939 Shield
CAN / A 939YK 3RD PARTY HI
3RD B 939GK 3RD PARTY LO CAN BUSES D-9
PARTY C 3RD PTY Shield
KOMTRAX PLUS 71VHM 85 ORBCOM (OPT)
4 91ET2 TX- Ethernet
VI 1-8 (Keyswitch OR Input) 5 91ER1 RX+ Ethernet
VI 1-9 (Keyswitch OR Input) ETHERNET ETHERNET, WIRELESS ACCESS B-2
VI A-36 (Unswitched Battery Input) 6 91ET1 TX+ Ethernet
VI 1-6 (Unswitched Battery Input) VI A-39 (Unswitched Battery Input) 8 91ER2 RX- Ethernet
VI 1-7 (Unswitched Battery Input) VI A-40 (Unswitched Battery Input)
DI 2A-17 (Wake Up) 7HMWU DO A-19 (Wake Up)
RS232 4B-4 (Transmit) 900CR RS232 A-4 (Receive)
RS232 4B-10 (Receive) 900CT RS232 A-5 (Transmit)
RS232 4B-3 (Ground) 900CG RS232 A-11 (Ground)
RS232 4B-9 (Shield)
B VI 1-11 (Ground)
B
VI 1-12 (Ground) VI A-37 (Ground)
VI 1-19 (Ground) VI A-38 (Ground)
VI 1-20 (Ground)
KOMTRAX PLUS IM
DO 1-16 (Snapshot In Progress) 74DS DI 2-L (Snapshot In Progress)
VO 2B-9 (Ground)
DI 2B-12 (Connector Select)
MMS PTX DISPLAY
A
C KOMTRAX DIAG CONN (AUX BOX)
TO F30 (20A)
11M C
SHT (CAN BUSES) C-8 B
MODEL SELECTION 5
CONNECTOR 9 TO F48 (5A) C
712MM
KOMTRAX PLUS 4 SHT (CAN BUSES) C-8
3A-16 1 8
2 3
3A-5 90VHG
7
3A-15 3 90VHR
2
4 90VHT
3A-14 6
3A-3 5 1
3A-9 6
3A-13 KOMTRAX DIAG CONN (CAB)

5
3A-4
9
4
D 8 D
KOMTRAX PLUS 3
RS232 4A-11 (Transmit) 90VHT 7
RS232 4A-10 (Receive) 90VHR 2
RS232 4A-9 (Ground) 90VHG 6
1
KOMTRAX+ CONNECTION CHART KOMTRAX+ CONNECTION CHART
6 85 Battery Direct 4 939YE J1939 - HI E-5
7 85 Battery Direct 5 RPC - SHLD CAN BUSES
A-2
8 71VHM Keyswitch OR 6 939YP RPC - HI
9 71VHM Keyswitch OR 9 90VHG RS232-Ground
1 11 0 Ground This Sheet B-2 4A 10 90VHR RS232-Receive This Sheet D-2
E 12 0 Ground 11 90VHT RS232-Transmit E
16 74DS Snapshot in Prog 12 939GE J1939 - LO
E-5
19 0 Ground 13 J1939 - SHLD CAN BUSES
20 0 Ground 14 939GP RPC - LO A-2
2A 17 7HMWU Wake Up This Sheet B-2 3 900CG RS232-Ground
9 Jumper 1 Ground 4 900CR RS232-Transmit
2B This Sheet C-2 4B This Sheet B-2
12 Jumper 1 Connector Select 9 RS232-Shield
3 SE1 Configuration 10 900CT RS232-Receive
4 SE6 Configuration C-1 1 93ET1 TX + Ethernet
5 SE2 Configuration 2 93ET2 TX - Ethernet
5 ETHERNET, WIRELESS ACCESS C-2
9 SE6 Configuration 3 93ER1 RX + Ethernet
3A This Sheet
13 SE6 Configuration 6 93ER2 RX - Ethernet
14 SE3 Configuration D-1
15 SE4 Configuration
16 SE5 Configuration ORBCOM CONNECTION CHART(OPTIONAL)
3B 2 73DS Data Store OPERATOR DRIVE CONTROLS B-4
F 4 900CR RS232-Receive F
5 900CT RS232-Transmit
11 900CG RS232-Ground 58B-06-02230-00 JUL 15
A
19
36
7HMWU
85
Wake Up
Battery Direct This Sheet B-3
37 0 Ground 980E-4
38 0 Ground
39 85 Battery Direct A40003 & UP
40 85 Battery Direct
Sheet 17 of 31
1 2 3 4 5 6 7 8 9 10
KOMVISION CONTROLLER CHART KOMVISION MONITOR CHART
8 0CAM GND_SLG_D2 KOMVISION CONTROL A-5
2 8X046 DISPLAY ON/OFF KOMVISION CONTROL A-5
30 8X012 SWITCH LOCK KOMVISION SWITCHES B-1 3 8X016 BRIGHTNESS+ D-2
KOMVISION SWITCHES
31 4 8X017 BRIGHTNESS- D-1
A 32 5 0CAM SIGNAL GROUND A-5 A
KOMVISION CONTROL
36 8X011 SWITCH CANCEL 6 8X013 LIGHT A-2
P44
37 8X010 SWITCH BODY 7
KOMVISION SWITCHES B-1
38 8X009 SWITCH LINE 8
39 8X008 SWITCH MODE 9
A
40 8X007 SWITCH LH FRONT C-1 10
41 11
42 12
46 8X006 SWITCH LH REAR C-1 1 11CAM PWR IN BAT A-5
KOMVISION CONTROL
47 8X005 SWITCH REAR 2 0 GROUND POWER A-4
48 8X004 SWITCH RH REAR KOMVISION SWITCHES 3 Shld GND-G A-9
B-1 KOMVISION CONTROL
49 8X003 SWITCH RH FRONT 4 910 HSYNC A-9
50 8X002 SWITCH FRONT P45 5 911 VSYNC
A-9
6 914 RGB-B
1 939GX2 Radar Autoliv Net L 7 Shld GND-B B-9
F-3
2 939YX2 Radar Autoliv Net H 8 913 RGB-G A-9
KOMVISION CONTROL
B 3 8X001 PWR CTR EXT
KEY SLG-1
A-5 9 912 RGB-R A-9 B
4 8X013 10 Shld GND-R A-9
B-2
5 8X013 KEY SLG-2 11 0GSS GND SIG SYNC B-9
6 0 GND PWR-1 12 8X013 PWR CTR KEY A-2
A-5
7 0 GND PWR-2
8 11CAM PWR IN BATT
KOMVISION CONTROL A-5
9 11CAM PWR IN BATT
10 29BUS System Busy B-2
11 939GX1 Radar Autoliv Net L
D-3
12 939YX1 Radar Autoliv Net H
B 16 0 GND PWR-3
A-5
17 0 GND PWR-4
18 11CAM PWR IN BATT
A-5
19 11CAM PWR IN BATT
31 939GE J1939 LO
CAN BUSES D-5
32 939YE J1939 HI
35 Shield GND COMM-3 E-3
C 38 8X046 DISPLAY ON/OFF KOMVISION CONTROL A-5 C
39 8X049 RADAR PWR CNTL A-1
41 939GP CAN RPC LO
CAN BUSES B-2
42 939YP CAN RPC HI
46 8X048 INDICATOR ERROR
KOMVISION CONTROL B-9
47 8X047 INDICATOR RADAR
48 8X045 INDICATOR PWR KOMVISION SWITCHES B-1
A 910 HSYNC
B 911 VSYNC
C 912 RGB-R
A-7
D Shld GND-R
RGB E 913 RGB-G KOMVISION CONTROL
F Shld GND-G
G 914 RGB-B
B-7
H Shld GND-B
J 0GSS GND SIG SYNC A-7
A PWR_OUT_CAMERA
D B
24CAM
0DOS DOS_L_MR
D
C 26AV AV_NTSC_0
D 8X073 GND_NTSC_0
E 26AV1 AV_NTSC_1 C-7
F 8X074 GND_NTSC_1
G 26AV2 AV_NTSC_2
KOMVISION CONTROL
H 8X075 GND_NTSC_2
J 26AV3 AV_NTSC_3
NTSC
K 8X076 GND_NTSC_3
L 26AV4 AV_NTSC_4
M 8X077 GND_NTSC_4 D-7
N 26AV5 AV_NTSC_5
P 8X078 GND_NTSC_5
E E
F F
58B-06-02230-00 JUL 15
980E-4
A40003 & UP
Sheet 18 of 31
1 2 3 4 5 6 7 8 9 10
TO KEYSWITCH OR TO BATTERY POWER
SHT (BATT POWER DIST) C-6 71CK 11 SHT (BATT POWER DIST) D-1 KOMVISION CONTROLLER
KOMVISION MONITOR KOMVISION MONITOR
RTMR1 RTMR1
P44-2 (DISPLAY ON/OFF) 8X046 B-38 (DISPLAY ON/OFF)
F1 F3
P44-5 (SIGNAL GND) OCAM A-8 (GND_SLG_D2) KOMVISION CONTROLLER
TO 12 VOLT SUPPLY 15 A 15 A P45-1 (PWR IN BATT) 11CAM B-8 (PWR IN BATT) RGB-A (HSYNC) 910 P45-4 (HSYNC)
SHT (BATTS, STARTERS, KEY) D-7
11B1 71CKM 11CMX P45-2 (Ground Power) B-9 (PWR IN BATT)
0GSS
B-18 (PWR IN BATT) RGB-J (GND SIG SYNC) P45-11 (GND SIG SYNC)
KOMVISION MONITOR KOMVISION B-19 (PWR IN BATT)
A RTMR1 ON/OFF SW B-3 (PWR CNT EXT)
B-6 (GND PWR-1)
RGB-B (VSYNC) 911 P45-5 (VSYNC)
A
F2 P44-6 (LIGHT) 8X013
20 A B-7 (GND PWR-2) RGB-C (RGB-R) 912 P45-9 (RGB R)
P45-12 (PWR CTR KEY)
11CAM B-16 (GND PWR-3)
B-17 (GND PWR-4) RGB-D (GND-R) SHIELD P45-10 (GND R)
TO SWITCH PANEL
SHT (KOMVISION 1 RGB-E (RGB-G) 913 P45-8 (RGB G)
SWITCHES) A-1 2
8X013 RGB-F (GND-G) SHIELD P45-3 (GND G)
3
KOMVISION CONTROLLER 8X013 RGB-G (RGB-B) 914 P45-6 (RGB B)
8X050 4
74SB1
B-4 (KEY SLG-1) 5 RGB-H (GND-B) SHIELD P45-7 (GND B)
B-5 (KEY SLG-2)
B-10 (System Busy) 6
8X001
8X049 B-39 (RADAR PWR CNTRL) 7
KOMVISION
8 SERVICE KOMVISION CONTROLLER
9 CONNECTOR
B B-46 (INDICATOR ERROR) 8X048
8X047
ALARM ERROR
B
10 B-47 (INDICATOR RADAR)
ALARM RADAR
C
RADAR
11
POWER 0
RELAY 12
NO
NC
RADAR 1 (SHORT RANGE)

939YX1 2
939GX1 3 KOMVISION CONTROLLER
ON BUMPER FRONT CAMERA 1
12VR 12VR 4 FORWARD LH NTSC-A (PWR_OUT_CAMERA) 24CAM 24CAM 1-POWER IN ON
0 1 (AIMING FRONT RH) 26AV 2-VIDEO OUT ACCESS
0 5 NTSC-B (DOS_L_MR) 0DOS 0DOS 3-MIR LADDER
0 6 SHLD 8X073 4-GND
NTSC-C (AV_NTSC_0) 26AV
RADAR 2 (SHORT RANGE) CAMERA 2
939YX1 2 NTSC-D (GND_NTSC_0) SHLD 8X073 ON RIGHT
24CAM 1-POWER IN
939GX1 3 DECK
C ON BUMPER FRONT NTSC-E (AV_NTSC_1) 26AV1
26AV1
0DOS
2-VIDEO OUT
3-MIR FACING C
12VR 4 FORWARD RH SHLD 8X074 4-GND FORWARD
0 1 (AIMING FRONT LH) NTSC-F (GND_NTSC_1) SHLD 8X074
0 5
6 NTSC-G (AV_NTSC_2) 26AV2 CAMERA 3 ON RIGHT
24CAM 1-POWER IN DECK
NTSC-H (GND_NTSC_2) SHLD 8X075 26AV2 2-VIDEO OUT
RADAR 3 (LONG RANGE) FACING
939YX1 0DOS 3-MIR RIGHT OF
2 NTSC-J (AV_NTSC_3) 26AV3
939GX1 SHLD 8X075 4-GND TRUCK
3
ON BUMPER FRONT NTSC-K (GND_NTSC_3) SHLD 8X076
12VR 4 CAMERA 4
RIGHT CORNER
0 1 NTSC-L (AV_NTSC_4) 26AV4 24CAM 1-POWER IN
5 ON REAR
26AV3 2-VIDEO OUT
0 6 NTSC-M (GND_NTSC_4) SHLD 8X077 AXLE
0DOS 3-MIR
SHLD 8X076 4-GND
NTSC-N (AV_NTSC_5) 26AV5
939YX1 2 SHLD 8X078 CAMERA 5 ON LEFT
NTSC-P (GND_NTSC_5)
D 939GX1 3 24CAM 1-POWER IN DECK D
RIGHT UPRIGHT 26AV4 2-VIDEO OUT FACING
KOMVISION CONTROLLER 12VR 4 0DOS 3-MIR LEFT OF
REAR
0 1 SHLD 8X077 4-GND TRUCK
B-12 RADAR Autoliv Net H) 5
B-11 (RADAR Autoliv Net L) 6
CAMERA 6 ON LEFT
24CAM 1-POWER IN DECK
RADAR 5 (SHORT RANGE) 26AV5 2-VIDEO OUT
939YX2 FACING
2 0DOS 3-MIR FORWARD
939GX2 3 SHLD 8X078 4-GND
12VR 4 ON REAR AXLE RH

0 1 (AIMING REAR LH)
0 5
0 6
RADAR 6 (LONG RANGE)

939YX2 2
E 939GX2 3 E
ON REAR AXLE LH
12VR 4
(AIMING REAR RH)
0 1
B-35 (GND COMM-3) 0 5
6

939YX2 2
939GX2 3
12VR 4 ON LH UPRIGHT
0 1 REAR
5
0 6
RADAR 8 (LONG RANGE)

939YX2 2
F 939GX2 3 F
12VR
0
4
1
ON FRONT BUMPER
LEFT CORNER 58B-06-02230-00 JUL 15
B-2 (RADAR Autoliv Net H)
5
6
B-1 (RADAR Autoliv Net L) 980E-4
A40003 & UP
Sheet 19 of 31
1 2 3 4 5 6 7 8 9 10
KOMVISION KOMVISION KOMVISION KOMVISION KOMVISION KOMVISION KOMVISION KOMVISION KOMVISION KOMVISION KOMVISION KOMVISION
KOMVISION RH FRONT BRIGHT FRONT
CANCEL BODY GRIDLINE MODE REAR RH REAR LOCK LH FRONT LH REAR
DIM SWITCH SWITCH SWITCH SWITCH
SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH
8X021 8X035 8X023 8X025 8X027 8X029 8X031 8X033 8X019 KOMVISION 8X037 8X039 8X041 8X043
8X022 8X036 8X024 8X028 8X030 8X032 8X034 8X020 INDICATOR 8X038 8X040 8X042 8X044
8X026
8X022 8X036 8X024 8X032 8X034 8X020 POWER 8X038 8X040 8X044
8X026 8X028 8X030 8X042
8X021 8X035 8X023 8X025 8X027 8X029 8X031 8X033 8X019 8X037 8X039 8X041 8X043
A 8X011 8X010 8X009 8X008 8X005 8X004 8X003 8X018 8X002 8X007 8X006 A
8X017 8X012
8X036 8X024 8X026 8X028 8X030 8X032 8X034 8X020 8X038 8X040 8X042 8X044
8X021 8X035 8X023 8X027 8X029 8X033 8X019 8X037 8X039 8X041 8X043
8X025 8X031
0 0 0 0 0 0 0 0 0 0 0 0 0
TO KOMVISION ON/ 8X018
OFF SWITCH 8X013 8X013 8X013 8X013 8X013 8X013 8X013 8X013 8X013 8X013 8X013 8X013
SHT (KOMVISION
CONTROL) A-2
8X011
KOMVISION CONTROLLER
8X016 8X045
B A-36 (SWITCH CANCEL) B
A-37 (SWITCH BODY) 8X010
A-38 (SWITCH LINE) 8X009
A-39 (SWITCH MODE) 8X008
A-47 (SWITCH REAR) 8X005
A-48 (SWITCH RH REAR) 8X004
A-49 (SWITCH RH FRONT) 8X003
B-48 (INDICATOR POWER) 8X045
A-30 (SWITCH LOCK) 8X012
A-50 (SWITCH FRONT) 8X002
A-40 (SWITCH LH FRONT) 8X007
A-46 (SWITCH LH REAR) 8X006
C
C
KOMVISION MONITOR
P44-3 (BRIGHTNESS +) 8X016
8X017 P44-4 (BRIGHTNESS -)

D D
E E
F F
58B-06-02230-00 JUL 15
980E-4
A40003 & UP
Sheet 20 of 31
1 2 3 4 5 6 7 8 9 10
TO F44 (5 AMPS)
SHT (BATT POWER DISTRIBUTION) E-8 TO F35 (15 AMPS)
71LS
TO F33 (15 AMPS)

11 Internal Bus 11L
A
C
2
A GRN YEL 11 71LS A
FOG
LIGHT
SWITCH 15 A
B
4
3
1
6
F62 11A
A
C
2
48F
ROTATING
71LS
BEACON
1B SWITCH
B
4
3
1
6
11LF
HORN
RELAY
NC
NO
FOG (75 AMP)
LAMPS
R40
C
B B
11RB
VEC-89
1D 11H
11HS
48LF
OPTION
OPTION
FORWARD
LEFT RIGHT HORN #1
CAB HORN
LEFT RIGHT DECK DECK
ROTATING BUTTON +
FOG FOG ROTATING ROTATING
BEACON
LAMP LAMP BEACON BEACON -
0 0
C C
TO SELECTOR SWITCH (REVERSE) 79BA

SHT (OPERATOR DRIVE CONTROLS C-2
11 Internal Bus
11B
11
11 Internal Bus 71CK Internal Bus
VEC-89
11
20 A TO KEYSWITCH CIRCUIT 11 71CK
F53 SHT (BATTS, STARTERS, KEY) F1
712K 25 A 15 A
F2 F3 10 A
79BA F13
D D
47B 79
A
C
A
C
HEATED J2 MANUAL
MIRROR BACK-UP
NC
NO
SWITCH LIGHT BACK UP
SWITCH HORN
D
B
4
3
1
6
B
4
3
1
6
R3
C
11HM 79A
1G IM
D15 D14
47S 11E
C
RETARD DI 3-Z (Retard Switch Input)
69MA
LAMPS
9C 11D 11C R15
NO
NC
GE
E E
C
HEATED
MIRROR 74ZA 1C DO CNX1-t (Retard Lamp Drive)
47A
R39
NO
NC
BUSS VEC-89 BACK UP

1F
LAMPS
1H (75 AMP)
44D
69M
47 47 79A
LEFT RIGHT
LEFT RIGHT REAR BACK-UP BACK-UP
LEFT RIGHT LEFT RIGHT
DECK DECK HORN HORN RIGHT CAB TOP
HEATED HEATED OPTION DECK
BACK-UP
DECK
BACK-UP
BERM
BACK-UP
REAR
BACK-UP
REAR
BACK-UP + +
LEFT
REAR REAR RETARD
MIRROR MIRROR LAMP RETARD RETARD LAMP
LAMP LAMP LAMP LAMP - -
LAMP LAMP
F F
0
58B-06-02230-00 JUL 15
980E-4
A40003 & UP
Sheet 21 of 31
1 2 3 4 5 6 7 8 9 10
BUSS VEC-89
71CK Internal Bus 11 Internal Bus
11
HEADLIGHT SWITCH CHART 71CK 11
POS CONTACT LEDS
5A
BOTTOM 1-2 & 4-5 GRN F64
MIDDLE 2-3 & 4-5 GRN & YEL 15 A 15 A 25 A
F4 F5 F6
A TOP 2-3 & 5-6 GRN & YEL
2D BUSS VEC-89 A
11L 11D
9A 9G 12F
TO F35 (15 AMPS)
A
C
2
GRN YEL HEADLIGHT 11HL
TO DISPLAY DIMMING CIRCUIT SWITCH 11LL 11LR
SHT (DISPLAY) A-1 TO DISPLAY HIGH BEAM PILOT LAMP CIRCUIT
41TS 41H
TO WINDOW SWITCH LEDS SHT (DISPLAY) A-4
B
4
3
1
6
SHT (WINDOW WIPE, WASH, PWR) C-5 41L
41TS
TO HEATER CONTROL
SHT (HVAC, RADIO, SEAT) A-7 BOTTOM HIGH MTG HIGH
MTG. LOW LOW BEAMS BEAMS
41L BEAMS (75 AMPS) (75 AMPS)
11L (75 AMPS)
712 Internal Bus
712
B 5A
B
F52 41LM
D13 41HM 41HB
712T1 11H 712T
BUSS VEC-91
41HL
HAZARD
11L LT SW 10 4 RIGHT LOW LEFT LOW LH HI-MTD RH HI-MTD LH HI-MTD LEFT HIGH RIGHT HIGH RH HI-MTD
BEAM BEAM LOW BEAM LOW BEAM HIGH BEAM BEAM BEAM HIGH BEAM
PNK
GRY
41TS HEADLAMP HEADLAMP HEADLAMP HEADLAMP HEADLAMP HEADLAMP HEADLAMP HEADLAMP

A
C
RIGHT
TURN
LEFT
DIM
SIG/DIM
SW
R/W
WHT
PUR
D
B
4
3
1
6
9 11 3
0 0
45LR
C C
45L
45R
12D 12B 11F
11 Internal Bus
41TS
11
11
15 A
F11 15 A 10 A
F8 F9
D 11F 11T
D
44A TO SERVICE BRAKE PRESSURE SWITCH
44R 11H
SHT(BRAKES) E-1
CLEAR
C
PWR
& TAIL BUSS VEC-89
FLASHER
C
GND LAMP BRAKE
R13
NO
LIGHT
NC
R8
LOAD R9
NO
NC
45F
45L
45R
45F
44
E 41T E
NC
NO
NC
NO
LEFT RIGHT
TURN TURN
R11 R12
C
C
45RL
12C 11G 12A 12E
45LL TO DISPLAY RIGHT TURN INPUT

TO DISPLAY LEFT TURN INPUT SHT (DISPLAY) A-4
SHT (DISPLAY) A-4
41T 41T
44
45LL 45RL
F 41T F
LEFT LEFT LEFT LEFT RIGHT RIGHT RIGHT RIGHT
C B A
DECK C B A
DECK
C B A
BODY
C B A
BODY
C B A
DECK C B A
DECK
C B A
BODY
C B A
BODY
C B A LEFT TAIL/ C B A RIGHT TAIL/
CAB TOP 58B-06-02230-00 JUL 15
SERVICE
SIDE FRONT SIDE REAR SIDE FRONT SIDE REAR
CLR/TRN CLR/TRN CLR/TRN CLR/TRN CLR/TRN CLR/TRN CLR/TRN CLR/TRN STOP LAMP STOP LAMP BRAKE
LAMP LAMP LAMP LAMP LAMP LAMP LAMP LAMP LAMP
980E-4
A40003 & UP
Sheet 22 of 31
1 2 3 4 5 6 7 8 9 10
TO F35 (15 AMPS)
11L
BUSS VEC-91
A
C
2
712 Internal Bus
GRN GRN LADDER
LIGHT
A SWITCH
11 Internal Bus
712 A
D
B
4
3
1
6
11
TO F33 (15 AMPS) 5A
11A
20 A SHT (BATT POWER DISTRIBUTION) E-2 F55
BUSS VEC-89
F10
48B
48A REAR 9F
AXLE
SERVICE 712A
GROUND 11DSL
LIGHT
LEVEL SW 11A DOME
11L
LADDER LIGHT
LIGHT SWITCH
SWITCH
11AL
48C 12G
B HYD CABINET 712L B

DOME LIGHT SW
REAR
LADDER
C
AXLE
LAMP SERVICE T
RELAY LIGHT
NO
NC
(75 AMPS) TIMER
11A1
48
11ALT
48 CAB DL1 DL2 DL3 DL4 DL5 DL6

DOME
CONT. CONT. LAMP HYD CAB HYD CAB
DIAGONAL DIAGONAL REAR
DECK DECK LADDER CAB & CAB & AXLE LEFT RIGHT
LADDER DECK DECK
LAMP 1 LAMP 2 LAMP 2 SERVICE
LAMP 1 LAMP 1 LAMP 2 LIGHT
C C
0
SERVICE LAMPS IN AUX BOX

11 Internal Bus
VEC-91
BUSS
15 A
F34
4D
11SL
D 11SL
D
ENGINE
C
HYDRAULIC
SERVICE
T T PUMP LIGHT
LAMP
TIMER
TIMER
NO
NO
NC
NC
42PMS
42
42SL
HYDRAULIC
PUMP LIGHT
SWITCH
LEFT
ENGINE
SERVICE
E LAMP
E
SWITCH
42A
42B
42PML
RIGHT
ENGINE OPTION
SERVICE
LAMP
SWITCH
HYD.
LEFT ENG LEFT ENG RIGHT ENG RIGHT ENG PUMP
SERVICE SERVICE SERVICE SERVICE MODULE
LAMP 1 LAMP 2 LAMP 2 LAMP 1 SERVICE
LAMP
F F
58B-06-02230-00 JUL 15
980E-4
A40003 & UP
Sheet 23 of 31
1 2 3 4 5 6 7 8 9 10
49 49
71CK Internal Bus TO F45 (15 AMPS) TO PANEL LAMP

71CK SHT (BATT POWER DISTRIBUTION) D-7 DIMMING CIRCUIT
SHT (DISPLAY) C-2
1 AMP
F43
71SS BUSS VEC-89 71P 71P 71P
A 4A 2-4 2-2 1-4 1-2 DATA

A
A BODY UP
A
5
2
RETARD
2-1
2-3
STORE
1-1
1-3
A
C
2
OVERRIDE A
50 OHMS
SW
DRIVE SYS GRN YEL ENGINE SPEED
B SW WARM / CONTROL
2-3 2-1 1-3 1-1 REST SW
50 WATT GRID DRY B SW
2-4
2-2
1-2
1-4
J1 SWITCH (SHOWN ON)
B
4
3
1
6
B
4
3
1
6
71SR
72RR 33RS 31RR
RETARD
73DS SPEED POT
71H TO PROPEL LOCKOUT CIRCUIT 33RR
DIRECTION 72RRQ
SHT (BATTS, STARTERS, KEY) C-5 1
SELECTOR
3 2 GE
P 4 72RQ DI CNX4-P (Retard Speed Control Sw)
2 52C AHT GE GE 3 AI CNX3-A (Retard Speed Control Pot)
R 5 D4 DI CNX4-J (Data Store Sw)
79B 1E DI CNX4-O (Drive System Rest Sw) 0 AI CNX3-K (Retard Speed Ground)
1 TF N DI CNX4-h (Body Up Override)
B AHT 72FNR DI CNX5-b (Engine Warm / Grid Dry Sw) 72GD AI CNX3-J (Retard Speed Shield) B
8 7 6 D3
72N 1F
KOMTRAX + AI CNX3-t (Pot Reference +)
D2 DI CN3B-2 (Data Store Sw) PS CNX3-m (Pot Reference -)
72T 72 1G PS CNX3-n (Pot Reference Shield) 0
Spare AHT 79BA
Connection for GE 72FNR
Trolley Use 72AF DI CNX4-p (Forward)
DI CNX4-H (Reverse)
DI CNX4-K (Park)
IM 52CA
DI 3T (Park) 270 OHM
TO BRAKE CIRCUITS 10V
DI 2N (Selector FNR) 12D SHT (BRAKES) A-5
79BA BUSS VEC-90

RETARD
C TO BACK UP HORN CIRCUIT THROTTLE RETARD LEVER
(OPTION ON
C
SHT (LAMPS, FOG, EXT PEDAL PEDAL
WARNING) C-5 960E MODEL
ONLY)
15VD1
10V 10V GE
74N 52R AHT 52RA AI CNX2-S (Retard Lever Vout)
10V
TO BATTERY DIRECT CIRCUITS OLEV AI CNX2-T (Retard Lever Ground)
11 AI CNX2-U (Retard Lever Shield)
SHT (BATT POWER DISTRIBUTION) A-1
AHT 74NA AI CNX2-P (Retard Pedal Vout)

RTMR1
0RET AI CNX2-V (Retard Pedal Ground)
D F4
AI CNX2-W (Retard Pedal Shield)
D
10A
525 AHT 525A AI CNX4-t (Accel Pedal Vout)

0 AI CNX4-y (Accel Pedal Ground)
AI CNX4-u (Accel Pedal Shield)
11DID DID POWER SUPPLY
VI DIDPS-7 (+24VDC Input)
DI DIDPS-8 (Enable Input)
DID
GE
E VO DIDPS-12 (+15 Volt Output) 15DID PS DID-6 (+15 Volt Supply) PS CNX2-G (+15 Volt Supply) E
PS CNX2-J (+15 Volt Supply)
VO DIDPS-10 (+5 Volt Output) 5VDI PS DID-5 (5 Volt Supply)
VO DIDPS-11 (-15 Volt Output) -15VDI PS DID-9 (-15 Volt Supply)

VO DIDPS-1 (Ground Return) 0COM PS DID-10 (Ground)
RS232 CNX3-O (Shield)

0 VI DIDPS-6 (Ground) RS232 DID-3 (Ground with DID) 90DIG RS232 CNX3-H (Ground with DID)
RS232 DID-2 (Receive from DID) 90DIR RS232 CNX3-D (Receive from DID)
RS232 DID-1 (Transmit to DID) 90DIT RS232 CNX3-C (Transmit to DID)
5
90CAG RS232 CNX3-d (Ground with Conn)
9
90CAR RS232 CNX3-V (Receive from Conn)
F DSC
4 90CAT RS232 CNX3-W (Transmit from PSC) F
8
RS232 CNX3-X (Shield for PSC)
3 58B-06-02230-00 JUL 15
7
2
6
1
980E-4
A40003 & UP
Sheet 24 of 31
1 2 3 4 5 6 7 8 9 10
PLM4
10 uH
CLAMP
CHART OF PLM4 CONNECTIONS CHART OF PLM4 COMM BOX CONNS
TO PRE AMP FOR
PIN CIRCUIT A/D CONVERSION CONN PIN WIRE # FUNCTION SHEET SHOWING DETAILS LOCATION I/O CIRCUIT TYPE CONN PIN WIRE # FUNCTION SHEET SHOWING DETAILS LOCATION
1 39FD LF Pressure 1 5VUSB USB PS2
2 39FC RF Pressure 2 USBV USB PS1 PLM4 C-7
PLM4 A-5 Analog Input Type #1
2200 174 3 39FB LR Pressure 3 USBDMH USB Port 2 DM
.1 uf 10 uF 4.3V A
pF OHM 4 39FA RR Pressure 4 USBDPH USB Port 2 DP
A 5 939YP CAN/RPC - HI CAN BUSES, C-2 5 USBDMD USB Port 1 DM PLM4 D-7 A
6 SPEED POS Not Used 6 USBDPD USB Port 1 DP
7 5VPL +5V PLM4 D-6
8 72HC HEARTBEAT PLM4 D-6 1 72HC Heartbeat
9 72LA ELINK ACK PLM4 D-6 2 74HB Haul Cycle
10 74HB HAUL CYCLE PLM4 D-6 3 72LA Enet Link
TYPE # 1 INPUT CIRCUIT (ANALOG 4 TO 20 MA INPUT) 11 939GP CAN/RPC - LO CAN BUSES C-2 4 ENTX1 Enet Transmit 1
12 939YK CAN/3P - HI CAN BUSES B 5 ENTX2 Enet Transmit 2 PLM4 D-7
A-8
13 939GK CAN/3P - LO CAN BUSES 6 5VPL + 5 Volt Input
14 CAN/RPC-SHLD CAN BUSES C-2 7 0 Ground
15 35L3 RS232-Receive 1 PLM4 E-3 8 ENRX2 Enet Receive 2
16 SPEED NEG Not Used 9 ENRX1 Enet Receive 1
17 ENRX2 ENET RX 2
18 ENRX1 ENET RX 1 1 VBUS 5V
PLM4 D-6
19 ENTX2 ENET TX 2 2 DN Data -
USB1 PLM4 E-8
20 ENTX1 ENET TX 1 3 DP Data +
B 21 35L4 RS232-Transmit 1 PLM4 E-3 4 GND Ground B
22 CAN/3P-SHLD CAN BUSES A-8
23 35L2 RS232-Ground 1 PLM4 E-3 1 95ET1 Enet Transmit +
24 35L9 RS232-Receive 2 PLM4 E-2 2 95ET2 Enet Transmit -
ENET ETHERNET, WIRELESS ACCESS B-8
25 35L8 RS232-Transmit 2 PLM4 E-2 3 95ER1 Enet Receive +
PLM4
26 5VUSB USB-PS2 PLM4 C-6 6 95ER2 Enet Receive -
27 USBDMD USB Port 1 DM PLM4 C-6
28 USBDPD USB Port 1 DP PLM4 D-6
29 USBDMH USB Port 2 DM PLM4 D-6
30 0 Ground PLM4 D-6
31 39G Battery Direct PLM4 B-4
32 Spare Not Used
+24V +5V 33 Spare Not Used
34 35L7 RS232-Ground 2 PLM4 E-2
35 TCI 110% Not Used
5.1K 36 USBV USB-PS1 PLM4 C-6
37 0 Ground PLM4 B-4
C PLM4
47K 38 0 Ground PLM4 B-4 C
TO DIGITAL INPUT 39 USBDPH USB Port 2 DP PLM4 D-6
PIN 40 39F +18V PLM4 A-5
41 TCI 100% Not Used
42 TCI 70% Not Used
43 39A Red Lamp
2200
.1 uF 15K 44 39C Green Lamp PLM4 B-4 Digital Output Type #1
pF
45 39B Amber Lamp
46 71F Body Up STEERING, HYDRAULIC, FUEL E-2 Digital Input Type #4
47 Select Switch Not Used
48 Clear Switch Not Used
49 39H1 Brake Lock On BRAKES C-4 Digital Input Type #3
50 712PL Keyswitch PLM4 B-4
TYPE # 3 INPUT CIRCUIT (DIGITAL INPUT SWITCHED EXTERNALLY TO GROUND)
+5V
D D
47K
PLM4
TO DIGITAL INPUT
PIN
2200 5.1K .1 uF 15K

pF
TYPE # 4 INPUT CIRCUIT (DIGITAL INPUT SWITCHED EXTERNALLY TO B+)

E E
+24V
1.5 MEG
BSP 752R
PLM4
3
PIN
2200
F pF F
58B-06-02230-00 JUL 15
980E-4
A40003 & UP
TYPE # 1 OUTPUT CIRCUIT (DIGITAL OUTPUT SWITCHED INTERNALLY TO B+)
Sheet 25 of 31
1 2 3 4 5 6 7 8 9 10
PLM4
VO 40 (+18VDC) 39F
71CK Internal Bus 11 Internal Bus AI 1 (Left Front Pressure) 39FD
AI 2 (Right Front Pressure) 39FC
AI 3 (Left Rear Pressure) 39FB
71CK AI 4 (Right Rear Pressure) 39FA
11 39F
A BUSS VEC-90 A
5 AMP 5 AMP 5 AMP

F14 F46 F17
39FC
BRN
BRN
39G 2E + 39FD +
LF SUSP PRESS RF SUSP PRESS

39G 4K psi 4K psi
4 to 20 ma 4 to 20 ma
PLM4
RED
RED
- -
VI 31 (Battery Power)
712PL 4D 712PL VI 50 (Keyswitch Power)

3B 712SL
B 39A 2G 39A DO 43 (Red Payload Lamp)
B
39B 2D 39B DO 45 (Amber Payload Lamp)
39F
39C 2B 39C DO 44 (Green Payload Lamp)
VI 37 (Ground)
RED AMBER GREEN VI 38 (Ground) 39FA
C
C
C
LAMP LAMP LAMP
BRN
BRN
RELAY + 39FB +
RELAY RELAY
R16 R17
NO
R18
NC
NO
NC
NO
NC
LR SUSP PRESS RR SUSP PRESS
4K psi 4K psi
39CA 4 to 20 ma 4 to 20 ma
RED
RED
39BA - -
39AA
C 3A 2C 2A C
39AA 39BA 39CA
LEFT RED RIGHT RED LEFT AMBER RIGHT AMBER LEFT GREEN RIGHT GREEN PLM4 PLM4 COMM BOX
PAYLOAD PAYLOAD PAYLOAD PAYLOAD PAYLOAD PAYLOAD USB 26 (PS 2) 5VUSB USB A1 (PS 2)
LAMP LAMP LAMP LAMP LAMP LAMP USB 36 (PS 1) USBV USB A2 (PS1)
USB 29 (Port 2 DM) USBDMH USB A3 (Port 2 DM)
USB 39 (Port 2 DP) USBDPH USB A4 (Port 2 DP)
USB 27 (Port 1 DM) USBDMD USB A5 (Port 1 DM)
PLM4 DIAG
USB 28 (Port 1 DP) USBDPD USB A6 (Port 1 DP)
CONN IN
AUX BOX
712SL DO 8 (Heartbeat) 72HC DI B1 (Heartbeat)
6
9
DO 10 (Haul Cycle) 74HB DI B2 (Haul Cycle)

DO 9 (Ethernet Link) 72LA DI B3 (Ethernet Link)
D D
5
ENET 20 (Ethernet Transmit 1) ENTX1 ENET B4 (Ethernet Transmit 1)

35L2
ENET 19 (Ethernet Transmit 2) ENTX2 ENET B5 (Ethernet Transmit 2)
35L3 ENRX2 ENET B8 (Ethernet Receive 2)
ENET 17 (Ethernet Receive 2)
35L4 ENET 18 (Ethernet Receive 1) ENRX1 ENET B9 (Ethernet Receive 1)
VO 7 (+5 Volt Output) 5VPL VI B6 (+5 Volt Input) CAB PLM

VO 30 (Ground) 0 VI B7 (Ground) USB PORT
1
PLM4 USB 1 (5V) VBUS
USB 2 (Data -) DN 2
35L8 RS232 25 (Transmit 2)
35L9 RS232 24 (Receive 2) USB 3 (Data +) DP 3
35L7 RS232 34 (Ground 2) USB 4 (Ground) GND 4
RS232 23 (Ground 1)
RS232 15 (Receive 1)
RS232 21 (Transmit 1)
E E
35L7
LEFT SCOREBOARD RIGHT SCOREBOARD

VI LINE IN-A (Ground) 0 VI LINE IN-A (Ground)
35L9 RS232 LINE IN-C (Transmit) 35L10 RS232 LINE IN-D (Receive)
35L8 RS232 LINE IN-D (Receive) 712S1 VI LINE IN-E (+24 Volt)
VI LINE IN-E (+24 Volt)
VI LINE OUT-A (Ground)
RS232 LINE OUT-D (Transmit)
VI LINE OUT-E (+24 Volt)
F F
58B-06-02230-00 JUL 15
980E-4
A40003 & UP
Sheet 26 of 31
1 2 3 4 5 6 7 8 9 10
DIODES EXTERNAL TO THE VEHICLE ELECTRICAL CENTERS

RELAYS EXTERNAL TO THE VEHICLE ELECTRICAL CENTERS
COIL + COIL – CATHODE ANODE
TYPE AMPS FUNCTION SHEET LOCATION FUNCTION SHEET LOCATION
WIRE # WIRE # WIRE # WIRE #
SPST 75 712 Ground 12 Volt Power Relay BATTS, STARTERS, KEY D-7 72RQ 72RR Propel Lockout / Rest Switch Circuit B-6
OPERATOR DRIVE CONTROL
SPDT 40 71PS Ground Propel Lockout Relay B-5 72RQ 72RRQ Propel Lockout / Rest Switch Circuit B-6
SPDT 40 11ST Ground Starter Lockout Relay B-6 21PL 21PT Pre-Lube while Cranking BATTS, STARTERS, KEY B-9
A SPDT 40 21PT Ground Engine Pre-Lube Relay B-9 510E2 510E2E Hyd Ladder Input Circuit to IM HYD LADDER B-3/E-2
A
SPST 21PT Ground Engine Starter Relay #1 B-8 24SON 712G Keyswitch Supply to Sonalert B-3
BATTS, STARTERS, KEY DISPLAY
SPST 21PT Ground Engine Starter Relay #2 B-9 24SON 24VIM IM Supply to Sonalert B-3
SPST 21PL Ground Pre-Lube Mag Switch B-10 63L1 63L2 Supply to Low Speed Windshield Wiper WINDOW WIPE, WASH, PWR B-2
SPST 75 712IM Ground Key Switch Power Relay F-2
SPST 75 71C Ground Key / Control Power Relay (Diode OR) E-5
SPST 40 11 Ground Master Lockout Relay BATTS, STARTERS, KEY B-3
SPST 40 71ABA 52ABA Auto Brake Apply Relay BRAKES DIODES INCLUDED IN THE BUSS VEC-89 (32258-0) ELECTRICAL CENTER
SPST 40 63H1 Ground Wiper Relay (High Speed) C-1
WINDOW WIPE, WASH, PWR CATHODE ANODE
SPST 40 63L1 Ground Wiper Relay (Low Speed) C-2 DIODE FUNCTION SHEET LOCATION
WIRE # WIRE #
SPST 75 65T Ground E-6 D14 47A 79A Back Up Horn to Back Up Lamp Relay E-5
Reserve Oil Line Heater Relay LAMPS, FOG, EXT WARNING
ENGINE CONTROLS D15 47A 47S Manual Switch to Back Up Lamp Relay E-4
SPST 75 11HH 36 Reserve Oil Pump Relay D-6
SPST 50 11A 11H Forward Horn Power Relay B-7

SPST 75 47A Ground Back Up Light Relay E-4
B SPST 75 41L Ground Bottom Mounted Low Beam Headlights B-4 B
SPST 75 41L Ground High Mounted Low Beam Headlights LAMPS, HEAD, TAIL, CLR, STOP B-5 DIODES INCLUDED IN THE BUSS VEC-90 (32259-0) ELECTRICAL CENTER
SPST 75 41H Ground High Beam Headlights B-7
SPST 75 48C Ground Ladder & Deck Light Relay LAMPS, SERVICE, CONVENIENCE B-1
SPDT 40 12CA Ground Cab Ladder Alarm Relay B-6 CATHODE ANODE
DIODE FUNCTION SHEET LOCATION
WIRE # WIRE #
SPDT 40 12GLA Ground Ground Level Alarm Relay HYD LADDER B-8
SPDT 40 12HS Ground Ladder Up Relay B-9 D1 712IM 712K Key Switch Sense Signal BATTS, STARTERS, KEY F-2
SPDT 40 8X049 Ground Radar Power Relay KOMVISION CONTROL B-1 D2 72FNR 72 Selector Switch Forward B-3
D3 72FNR 72N Selector Switch Neutral OPERATOR DRIVE CONTROLS B-3
D4 72FNR 79B Selector Switch Reverse B-3
D5 712BL 71BK Brake Lock Switch Power Supply B-3
RELAYS INCLUDED IN BUSS VEC-89 (32258-0) ELECTRICAL CENTER D6 712BL 71BM Brake Lock Switch Power Supply B-3
D7 52B 52B1 Brake Lock Solenoid C-3
BRAKES
D8 Coil + 52B1 Latch Relay C-3
COIL + COIL – D9 72FD 0BN True Forward Signal B-1
NUM TYPE AMPS FUNCTION SHEET LOCATION
WIRE # WIRE # D10 79RD 0BN True Reverse Signal B-1
R3 SPDT 20 79BA Ground Back Up Horn Relay LAMPS, FOG, EXT WARNING D-5 D11
C R8 SPDT 20 41TS Ground Clearance & Tail Light Relay D-3 D12 C
R9 SPDT 20 44R Ground Brake Light Relay D-7 D13 Coil + 72FNR Park Brake Request Relay A-6
BRAKES
R11 SPDT 20 45L Ground Left Turn Light Relay LAMPS, HEAD, TAIL, CLR, STOP E-1 D14 Coil + 71BC Engine Run Relay A-3
R12 SPDT 20 45R Ground Right Turn Light Relay E-4
R13 FLASHER 20 11F Ground Turn Signal Flasher D-1
R14 SPDT 20 71CK Ground Steering Bleed Power Relay STEERING, HYDRAULIC, FUEL B-1
R15 SPST 20 71CK 74ZA Retard Lamp Relay LAMPS, FOG, EXT WARNING E-7
R29
R39 SPDT 20 69MA Ground Heated Mirror Relay E-1
R40 SPDT 20 48F Ground Fog Lamp Relay B-2
R41 SPDT 20 24VIM 62SBA Seat Belt Alarm Option IM IO CHARTS A-3
DIODES INCLUDED IN THE BUSS VEC-91 (32266-0) ELECTRICAL CENTER
CATHODE ANODE
DIODE FUNCTION SHEET LOCATION
WIRE # WIRE #
D13 712T 712T1 Power to Turn Signal Switch LAMPS, HEAD, TAIL, CLR, STOP B-1
D14 71C 712 Key / Control Power Relay Coil + E-5
D RELAYS INCLUDED IN BUSS VEC-90 (32259-0) ELECTRICAL CENTER D15 71C 71GE Key / Control Power Relay Coil + E-5 D
COIL + COIL –
WIRE # WIRE #
R16 SPDT 20 39A Ground Red Payload Lamp Relay C-1
R17 SPDT 20 39B Ground Amber Payload Lamp Relay PLM4 C-2
R18 SPDT 20 39C Ground Green Payload Lamp Relay C-3
R19 SPDT 20 23D Ground Engine Interlock Relay ENGINE CONTROLS B-1
R20 SPDT 20 11KS 712M Timed Engine Shutdown Relay BATTS, STARTERS, KEY E-2
R21 SPDT 20 D14-C 36 Engine Run Relay A-3
R22 SPDT 20 D13-C 36 Park Brake Request Relay A-6
R23 SPDT 20 52PB Ground Park Brake Release Relay B-6
R24 SPDT 20 72FNR Ground Park Switch Relay B-4
BRAKES
R25 SPDT 20 71BN Ground Truck Moving Relay B-2
R26 SPDT 20 D8-C Ground Latch Relay D-3
R27 SPDT 20 71BC 0BN Interface Relay B-1
R28 SPDT 20 23D 73S Park Brake Status Relay A-9
E E
RELAYS INCLUDED IN BUSS VEC-91 (32266-0) ELECTRICAL CENTER

COIL + COIL –
WIRE # WIRE #
R30 SPDT 20 24VIM 21SL Start Enable Relay BATTS, STARTERS, KEY A-9
R34 SPDT 20 73MSL Ground Payload at 70% Relay
NOT USED
R35 SPDT 20 73LSL Ground Payload at 100% Relay
R36 SPDT 20 28EC Ground Ether Start Relay ENGINE CONTROLS B-8
R37 SPDT 20 712 Ground Radio Relay HVAC, RADIO, SEAT D-1
R38 SPDT 20 65T Ground A / C Compressor Fan Relay (NOT USED) Not Shown
R39 SPDT 20 65S Ground Radiator Shutter Control Relay ENGINE CONTROLS B-10
RELAYS INCLUDED IN RTMR1

F F
COIL + COIL –
WIRE # WIRE # 58B-06-02230-00 JUL 15
Ground
R1 SPDT 20 65T AC Shutter Control Relay ENGINE CONTROLS C-10
980E-4
A40003 & UP
Sheet 27 of 31
1 2 3 4 5 6 7 8 9 10
71CK Internal Bus

71CK Internal Bus
BUSS VEC-89
11 Internal bus
71CK
BUSS VEC-89
10 A 18VIM 1
A F12 33HP1 HOIST
5A
F42
A
71CK PUMP #1
PRESSURE
2 4 to 20 mA
0 to 4000 psi 4H
11BD 18VIM 1
33HP2 HOIST
87
PUMP #2
STEERING PRESSURE
C
BLEED 2 4 to 20 mA
POWER
0 to 4000 psi
NO
NC
R14 NOTE: GROUND SHIELDS FOR ALL ANALOG 560 OHM

INPUT CABLES AT PRIMARY GROUND POINT 3 WATT
FOR INTERFACE MODULE.
1E IM
AI 3q (Hoist Pump #2 Pressure)
B IM
AI 3s (Hoist Pump #1 Pressure) 87
B
33J LOW STRG AO 3b (+18 Volts Sensor Supply Output)
PRECHARGE #1
DI 2W (Low Accumulator Precharge) 51A1 < 1400 PSI 1 18VIM 38G
DI 2S (Low Steering Pressure) STEERING 33SP AI 3d (Steering Pressure)
STEERING
DO 1P (Steering Bleed Valve) PRESSURE 39 DI 2Y (Hydraulic Filter Pressure)
BLEED
VALVE DI 2Z (Steering Accum Bled Sw) 4 to 20 mA DI 3G (Keyswitch OR Input to IM)
0 to 4000 psi 2 AI 3g (Fuel Level) 38G
51A2 AHT
6.8K 33JA 33F 24VIM AO 1W (Protected +24V Output)
DI 2k (Low Hydraulic Oil Level)
33JB 39AP
FUEL LEVEL
34LL
STEERING HYD FILT #1 SENSOR
ACCUM BLED LOW
LOW STRG PRESS SW FUEL LEVEL SENSOR
V36ZA80 PRESS SW STEERING
PRECHARGE #2 < 35 PSI
< 75 PSI PRESS SW
< 1400 PSI A RESISTANCE FILL
< 2300 PSI 39HP
R (OHM) (FRACTION)
HYD FILT #2 C 250 Empty
C
C PRESS SW
LOW
155
105
1/4
1/2
C
<35 PSI
B HYDRAULIC 70 3/4
39SP OIL LEVEL 30 Full
B
STRG FILT #1
PRESS SW
< 35 PSI
TO F45 (15 AMPS)

SHT (BATT POWER DISTRIBUTION) E-7 BUSS VEC-91
71P
712 Internal Bus
BODY UP SW
(SHOWN 712
BODY UP)
D 10 A
F51
D
GE
DI CNX1-v (Dump Body Down)

10F
71F
712H
HOIST
LIMIT
PLM4 SWITCH
DI 46 (Body Up)
E E
53H
HOIST
LIMIT
VALVE
F F
58B-06-02230-00 JUL 15
980E-4
A40003 & UP
Sheet 28 of 31
1 2 3 4 5 6 7 8 9 10
CHART OF OPERATOR CONTROL SWITCHES
SUB SUPPLY OUTPUT LOCATION ON CHART OF SEPARATELY MOUNTED RESISTORS & VARISTORS
SWITCH FUNCTION SHEET LOCATION
FUNCTION CIRCUIT # CIRCUIT # TRUCK
Body Up Override 71P 71H Center Console OPERATOR DRIVE CONTROLS A-3 RESISTANCE SIZE SUPPLY OUTPUT
A Brake Test, Preshift 712P 72SBT Cab Overhead
BRAKES
A-8 RESISTOR FUNCTION
(OHMS) (WATTS) CIRCUIT # CIRCUIT #
SHEET LOCATION A
Brake Lock 712BL 52B1 Upper Right Dash C-3
CAN / RPC Termination 120 939YP 939GP CAN BUSES A-2
Data Store, Drive System 71P 73DS Center Console OPERATOR DRIVE CONTROLS A-5
CAN / RPC Termination 120 939YP 939GP CAN BUSES D-2
OK 0 55B
Display Mode Switch #1 Lower Left Dash DISPLAY E-1 J1939 Termination 120 939YE 939GE CAN BUSES E-5
LEFT 0 55A
CAN 3RD PARTY Termination 120 939YK 939GK CAN BUSES A-9
UP 0 55D
Display Mode Switch #2 Lower Left Dash DISPLAY E-2 CAN 3RD PARTY Termination 120 939YK 939GK CAN BUSES D-9
DOWN 0 55C
Lower Right Dash Alarm Low Noise Suppression 510 2W 24SON 31IML DISPLAY B-2
Drive System Rest 71P 72RR OPERATOR DRIVE CONTROLS A-6
ENGINE CONTROLS C-1
Engine Shutdown, Secondary 23F 439 Center Console
ENGINE CONTROLS C-1
Engine Warm / Grid Dry 71P 72GD Lower Right Dash OPERATOR DRIVE CONTROLS A-7
Engine Shutdown Delay Filter 1K 21NSL 0 ENGINE CONTROLS F-3
Heated Mirror 71LS 69MA Lower Right Dash LAMPS, FOG, EXT WARNING D-1
Load Protection for Shifter 50 50 W 71SS 71SR OPERATOR DRIVE CONTROLS A-1
Horn 0 11H Steering Column LAMPS, FOG, EXT WARNING C-8
Calibration for Fuel Level Sensor 560 3W 87 38G STRG, HYDRAULIC, FUEL B-10
Fan Speed
HVAC 12H HVAC Console HVAC, RADIO, SEAT A-6 Noise Suppression for Steering Bleed Valve 6.8 K 33J Ground STRG, HYDRAULIC, FUEL B-1
Mode
Noise Suppression for Auto Brake Apply Relay 6.8 K 71ABA Ground BRAKES
Up 12LU
Hydraulic Ladder Control 11HLD Cab A-1 Frequency Command for RPM (Filter) 1K 556 556A ENGINE CONTROLS E-1
Down 12LD HYD LADDER
B Hydraulic Ladder Override 13HS 13LS Front Bumper B-9
Dropping Resistor for 10 Volt Power Source from GE 270 15VD1 10VI OPERATOR DRIVE CONTROLS C-5 B
Protection for Panel Lamp Dimmer V36ZA80 49 0 DISPLAY C-1
Run 712K
Key 11KS Steering Column BATTS, STARTERS, KEY E-1 Steering Bleed Valve Circuit Protection for IM Driver V36ZA80 33JB Ground STRG, HYDRAULIC, FUEL C-1
Start 21S
Batt Power 11CMX 11CAM Park Brake Valve Circuit Protection for IM Driver V36ZA80 52CS Ground BRAKES B-7
Komvision On / Off KOMVISION CONTROL A-3
Keysw Pwr 71CKM 8X013
Autolube Valve Circuit Protection for IM Driver V36ZA80 68 Ground AUTOLUBE C-3
Left Side 45L
Lights, Hazard 11L Upper Right Dash LAMPS, HEAD, TAIL, CLR, STOP C-1
Right Side 45R
Lights, Back Up 712K 47S Lower Left Dash LAMPS, FOG, EXT WARNING D-3
Lights, Fog 71LS 48F Lower Left Dash LAMPS, FOG, EXT WARNING A-2
Head 41L
Lights, Head 11D Lower Left Dash LAMPS, HEAD, TAIL, CLR, STOP A-2
Tail, Clear 41TS
Lights, Headlight Dimmer 41L 41H Steering Column LAMPS, HEAD, TAIL, CLR, STOP C-3
Lights, Panel Dimmer 41TS 49 Lower Left Dash DISPLAY B-1
Lights, Rotating Beacon 11L 11RB Lower Right Dash LAMPS, FOG, EXT WARNING A-6
Left 45L
Lights, Turn Signals 712T Steering Column LAMPS, HEAD, TAIL, CLR, STOP C-2
Right 45R
Radio, Entertainment 65A Radio Console HVAC, RADIO, SEAT E-2
C Seat, Operator’s 712DS Operator’s Seat HVAC, RADIO, SEAT A-1
C
Seat, Passenger’s 712DS Passenger’s Seat HVAC, RADIO, SEAT A-2
Park 52C
Reverse 79B
Selector, Direction Neutral 71SR 72N Center Console OPERATOR DRIVE CONTROLS B-1
Forward 72
Trolley 72T
On/Off 71P 31RR
Speed Control, Retard Pot Sig 33RS 33RR Center Console OPERATOR DRIVE CONTROLS A-9
Sig Off 33RR 0
Up 67L
Window, Left 67P Center Console WINDOW WIPE, WASH, PWR B-5
Down 67M
Up 67T
Window, Right 67R Center Console WINDOW WIPE, WASH, PWR B-7
Down 67S
D Intermittent 1 63T1 D
Intermittent 2 63T1
Windshield Wiper Intermittent 3 63 63T1 Steering Column WINDOW WIPE, WASH, PWR B-2
Low 63L2
High 63HI
Windshield Wash 63 63W Steering Column WINDOW WIPE, WASH, PWR B-3
CHART OF SWITCHES FOR SERVICE & CONVENIENCE LAMPS
SUB SUPPLY OUTPUT LOCATION ON

E Aux Cabinet Service Lamps 712A 712L Aux Cabinet LAMPS, SERVICE, CONVENIENCE B-9 E
Cab Dome Lamp 11L Cab Roof LAMPS, SERVICE, CONVENIENCE C-4
Left Engine Service Lamp 42SL 42A/42B Left Eng Lamp LAMPS, SERVICE, CONVENIENCE E-1
Right Engine Service Lamp 42A/42B 0 Right Eng Lamp LAMPS, SERVICE, CONVENIENCE F-1
Hydraulic Cabinet Service Lamp 11A 11A1 Hydraulic Cabinet LAMPS, SERVICE, CONVENIENCE B-6
Hydraulic Pump Service Lamp 42PMS 0 Hydraulic Pump Light LAMPS, SERVICE, CONVENIENCE E-5
Ladder Light (Upper Switch) 11L 48A/48B Lower Left Dash LAMPS, SERVICE, CONVENIENCE A-1
Ladder Light (Lower Switch) 48A/48B 48C Front Bumper LAMPS, SERVICE, CONVENIENCE B-1
Rear Axle Service Lamps 11A 11AL Rear Axle LAMPS, SERVICE, CONVENIENCE A-5
CHART OF BATTERY DISCONNECTS & LOCKOUTS
SUB SUPPLY OUTPUT LOCATION ON

F F
Ground Level Shutdown 11S 11KS Front Bumper BATTS, STARTERS, KEY D-2
Master Battery Disconnect B- Gnd Battery Box BATTS, STARTERS, KEY C-3 58B-06-02230-00 JUL 15
Propel Lockout
Indicator
Lockout
11
71GG
71PS
71GH
Battery Box BATTS, STARTERS, KEY B-5 ELECTRICAL SUB-SYSTEM SCHEMATIC
Starter Disconnect 11 11ST Battery Box BATTS, STARTERS, KEY A-6 980E-4
A40003 & UP
Sheet 29 of 31
1 2 3 4 5 6 7 8 9 10
COOPER/BUSSMANN VEHICLE ELECTRICAL CENTER BUSS VEC-89 (32258-0) COOPER/BUSSMANN VEHICLE ELECTRICAL CENTER BUSS VEC-91 (32266-0)
CONN CIRCUIT # FUNCTION SHEET LOCATION CONN CIRCUIT # FUNCTION SHEET LOCATION
5S 712 Keyswitch Power 5S 11 Battery Positive (Not Switched)
BATT POWER DISTRIBUTION D-1
6S 71CK Keyswitch OR Power 6S 0 Ground
BATT POWER DISTRIBUTION D-6
7S 0 Ground 7S 12V Regulated 12 Volt Supply BATTS, STARTERS, KEY D-8
8S 11 Battery Positive (Not Switched) 8S 712 Keyswitch Power BATT POWER DISTRIBUTION D-1
1B 48F Fog Lamp Relay Control A-2 1A 11 Unswitched Battery Power A-2
HYD LADDER
1C 74ZA Retard Lamp Control LAMPS, FOG, EXT WARNING E-7 1B 11LAD Batt Power to Komatsu Ladder Control A-2
A 1D 48LF Fog Lamp Power B-2 1C 11HH Pwr to Reserve Oil Line Heaters D-6 A
ENGINE CONTROLS
1E 33J Steering Bleed Power STEERING, HYDRAULIC, FUEL B-1 1D 71CK Keyswitch OR Pwr to Reserve Oil Heaters C-5
1F 44D Retard Lamp Power E-7 1E
1G 69MA Heated Mirror Relay Control LAMPS, FOG, EXT WARNING E-1 1F
1H 69M Heated Mirror Power E-1 1G
2A 62A Seat Belt Relay Control HVAC, RADIO, SEAT B-3 1H
2B 68ES Auto Lube Power AUTOLUBE A-4 2A 11E1 Unswitched Battery Supply to Cummins ENGINE CONTROLS A-4
2B
2C
2C 21S Key Switch Start A-9
2D 11D Headlight Switch Power LAMPS, HEAD, TAIL, CLR, STOP A-2 2D 24VIM Protected 24V out of IM A-8
2E 71P Drive Control & Feedback Power BATT POWER DISTRIBUTION D-8 2E 11DISP Unswitched Power to Display DISPLAY A-4
2F 2F
2G 24VIM Seat Belt Alarm Control Power B-4 2G 11E2 Unswitched Battery Supply to Cummins T2 ENGINE CONTROLS A-4
HVAC, RADIO, SEAT
2H Open Seat Belt Alarm Output (Optional) B-3 2H
4A 41SS Power to Direction Selector Switch OPERATOR DRIVE CONTROLS A-1 3A 11L Hazard & Ladder Light Controls BATT POWER DISTRIBUTION D-3
B 4B 712DS Power to Operator’s Seat HVAC, RADIO, SEAT A-1 B
3F
4C
4D 71LS Power to Display Mode Sw & Sw LEDs BATT POWER DISTRIBUTION D-8 3G 11INT Unswitched Battery Supply to IM IM IO CHARTS B-6
4E 3H 21PS Start Enabled Circuit BATTS, STARTERS, KEY A-9
4F 4A 11RCNT Pwr to Reserve Oil Control ENGINE CONTROLS D-6
4B 11A Power to Service Lamps & Forward Horn BATT POWER DISTRIBUTION D-2
4G 712P Power to Pre-Shift Brake Test Circuit BRAKES A-8
4C 11ORS Power to Oil Auto Refill Pump ENGINE CONTROLS D-6
4H 87 Key OR Power to IM & Fuel Sensor STEERING, HYDRAULIC, FUEL A-10 4D 11SL Power to Service Lamps LAMPS, SERVICE, CONV D-1
9A 11LL Power to Left Low Beam Headlights LAMPS, HEAD, TAIL, CLR, STOP A-4 4E 11IM2 Unswitched Power Supply # 2 to IM IM IO CHARTS B-6
9C 47B Power to Back Up Lamps LAMPS, FOG, EXT WARNING E-4 4F 21SL Start Enable Relay Control BATTS, STARTERS, KEY A-8
4G 11M Unswitched Battery Power to 3RD Party Conn CAN BUSES B-7
9G 11LR Power to Right Low Beam Headlights LAMPS, HEAD, TAIL, CLR, STOP A-5 4H 85 Battery Power to KOMTRAX + & ORBCOMM KOMTRAX +, MOD MINING A-3
11B 79BA Back Up Horn Relay Control C-5 9A 12H Key Switch Power to Cab Heater HVAC, RADIO, SEAT A-6
11C 79A Back Up Horn Power
LAMPS, FOG, EXT WARNING E-5
11D 47A Back Up Lamp Relay Control 9C 712G Key Switch Power to Display DISPLAY A-3
11E 47S Manual Back Up Switch Input E-4
11F 41TS Clear & Tail Lamp Relay Control C-3 9E 67P Keyswitch Power to Left Window Switch WINDOW WIPE, WASH, PWR B-5
C 11G 41T Clear & Tail Lamp Power LAMPS, HEAD, TAIL, CLR, STOP F-3 9F 712A Power to Service Lamp Switch in Aux Box LAMPS, SERVICE, CONVENIENCE A-9 C
11H 44R Brake Light Relay Control D-7 9G 67R Keyswitch Power to Right Window Switch WINDOW WIPE, WASH, PWR B-7
12A 45RL Power to Right Turn Lights E-4 9H 67C 12V Power to Auxiliary Connectors BATTS, STARTERS, KEY D-8
12B 45R Right Turn Relay Control D-2
12C 45LL Power to Left Turn Lights F-1 10C 63 Key Switch Power to Windshield Wipers WINDOW WIPE, WASH, PWR A-1
LAMPS, HEAD, TAIL, CLEAR, STOP
12D 45L Left Turn Relay Control C-1
12E 44 Power to Brake Lights E-6 10E 11B1 12V Power for Entertainment & Comm Radios BATTS, STARTERS, KEY D-8
12F 11HL Power to Hight Beam Headlights A-7 10F 712H Key Switch Power to Hoist Limit Switch STEERING, HYDRAULIC, FUEL D-4
12G 11DSL Power to Ladder Lights LAMPS, SERVICE, CONVENIENCE B-2 10G 71GE GE Control Power
BATTS, STARTERS, KEY E-5
10H 71C Key / Control Power Relay Control
11A
COOPER/BUSSMANN VEHICLE ELECTRICAL CENTER BUSS VEC-90 (32259-0) 11B 11FS Battery Power to Fire Suppression Connector
D-10
11C 11ER Battery Power to Comm Radio Connector E-9
CONN CIRCUIT # FUNCTION SHEET LOCATION
7S 0 Ground F-6 11G 12VREG 12V Power to the Comm Radio Connector BATTS, STARTERS, KEY E-9
BATT POWER DISTRIBUTION
8S 71CK Keyswitch OR Power E-6 712T Key Switch Power to Turn Signal Switch LAMPS, HEAD, TAIL, CLR, STOP B-1
D 11H
12A 65F Power to A/C Compressor Fans
D
1A 712IM Keyswitch Power Relay Control BATTS, STARTERS, KEY F-2 NOT USED
12B 65T A/C Compressor Fan Relay Control
1B 71VHM Keyswitch OR to VHMS KOMTRAX +, MOD MINING A-2 12C 28E Ether Start Valve B-7
1C 712M Shutdown Delay Relay Control F-2 ENGINE CONTROLS
BATTS, STARTERS, KEY 12D 28EC Ether Start Relay Control A-8
1D 11KS Power to Engine Shut Down Circuits E-2 12E 65 12V Power Unswitched to Entertain Radio
1E 79B Selector Switch, Reverse HVAC, RADIO, SEAT D-1
12F 65A 12V Power Switched to Entertainment Radio
1F 72N Selector Switch, Neutral OPERATOR DRIVE CONTROLS B-2 12G 65S Shutter Relay Control B-10
1G 72 Selector Switch Forward ENGINE CONTROLS
12H 65SR Shutter Solenoid Valve C-10
1H 712K Key Switch Run BATTS, STARTERS, KEY F-2
2A 39CA Power to Green Payload Lamps C-3
2B 39C Green Payload Lamp Relay Control B-4
2C 39BA Power to Amber Payload Lamps PLM4 C-2
2D 39B Amber Payload Lamp Relay Control B-4
2E 39G Battery Power to Payload Meter A-4
2F 11 Battery Positive (Not Switched) BATT POWER DISTRIBUTION E-6
2G 39A Red Payload Lamp Relay Control PLM4 B-4
E 3A 39AA Power to Red Payload Lamps

PLM4
C-1 E
3B 712SL Power to Payload Lamps & Scoreboard B-1
3C 11S Power to Ground Level Shutdown Switch BATTS, STARTERS, KEY D-2
3G 73S Park Brake Status Relay Control B-9

BRAKES
3H 510E Park Brake Status Signal to GE A-9
4A
4B
4C 23D Keyswitch OR Power to Engine Shutdown ENGINE CONTROLS B-2
4D 712PL Keyswitch OR Power to PLM4 PLM4 B-4
4E 712MM Keyswitch OR Power to 3RD Party Conn CAN BUSES B-6
4G 23FA Power to Secondary Engine Shut Down Sw ENGINE CONTROLS B-1

4H
9B 71BC Power Supply for Brake Controls A-3
9C 52B1 Power Out of Brake Lock Switch
C-3
9D 52B Power to Brake Lock Solenoid
F 9E 72FD True Forward Signal F
BRAKES B-1
9F 72RD True Reverse Signal
9H 36 Eng Run & Park Brake Request Relay Control B-5
58B-06-02230-00 JUL 15
11A
11B
52CS
52PB
Park Brake Release Solenoid
Park Brake Release Relay Control
B-7
B-6
11D 71ABA PB Request for Auto Brake Apply BRAKES 980E-4
12A 712BL Power to Brake Lock Switch BRAKES B-3 A40003 & UP
12D 72FNR Forward, Neutral, Reverse Signal OPERATOR DRIVE CONTROLS C-2 Sheet 30 of 31
1 2 3 4 5 6 7 8 9 10
BUSS VEC-91
712 Internal Bus
A 712 A
10 A
F50
10C
712 Internal Bus BUSS VEC-91
63 712
20 A 20 A
6 8
+ F56 F62
WNDSHLD WIPER SW GRN
67R
BU 67P
OFF OFF
HI I1 HI I1 WASH
B LO
I3
I2 LO
I3
I2 SW 9E 9G B
BRN
OR BLK RD
63P
1 2 12 7 5 WASHER 0 0
63L2 4 DELAY
B
B
6
6
4
3
1
1
63W 6 TIMER LEFT RIGHT
63HI 1 2 3 MODULE WINDOW WINDOW
63T1 SWITCH
SWITCH
63 0
C
A
A
2
5
2
63L1
WIPER 41TS
X DELAY
P TIMER
L TO PANEL LAMP DIMMER
MODULE 41TS
SHT (LAMPS, HEAD, TAIL, CLR, STOP) A-2 67M 67S
67L 67T
C 63W
C
63
C
WIPER WIPER
C
RELAY RELAY
(HIGH) (LOW) LEFT RIGHT
NO
NC
NO
NC
M WINDOW M WINDOW
MOTOR MOTOR
63H
63L
+
2 5 WNDSHLD
6 M WASHER
PK HI LO MOTOR
-
C
D M D
WNDSHLD
NO
NC
WIPER
MOTOR 0
3 1
E E
F F
58B-06-02230-00 JUL 15
980E-4
A40003 & UP
Sheet 31 of 31
90 Diagrams and drawings CEN90015-00
NOTES
3
980E Dump truck

© 2016 KOMATSU
All Rights Reserved

SM 980E-4 A40003-UP CEBM031000 (Ingles)

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CEBM031000

SERIAL NUMBERS A40003 & UP

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 CEBM031000

00 Index and foreword

10 Structure, function and maintenance standard

20 Standard value table

30 Testing and adjusting

90 Diagrams and drawings

00 Index and foreword

10 Structure, function and maintenance standard

Cab air conditioning CEN10008-02

20 Standard value table

30 Testing and adjusting

Interface module (IM) CEN30068-00

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

Precautions while performing service Working under the truck

Adding fuel or oil

Radiator coolant level Handling high pressure hoses

Precautions when performing maintenance near

Tires Refer to the Society of Automotive Engineers (SAE),

Mounted tires stored as spares must be inflated to

Precautions for performing repairs Engine shutdown procedure after AC drive

Capacitor discharge system