KOMATSU CHECKOUT PROCEDURE 58D-06-03400

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NAME: MACHINE & MODEL:

IM Checkout 730E 730E-8
WRITTEN BY: DATE:
Gregg Walraven 08/10/16

CHECKED BY: DATE:

Tim Imig 08/10/16

APPROVED BY: DATE: 0 NEW RELEASE

DASH DESCRIPTION OF CHANGE DATE ECN BY CK’D
G. Horst 08/10/16
A SIZE MICROFILM

Purpose:
This procedure is used to checkout the IM installation.

Necessary Equipment:
1. This checkout procedure and vehicle wiring schematic.
2. Laptop computer with GE’s wPTU software installed.
3. Laptop computer with IM Realtime Data Monitor Software installed. This software
can be found on the Komatsu America Extranet:
https://www.komatsuamerica.net/northamerica/.
4. RS232 serial cable with a male DB9 connector on one end and a female connector
on the other end.
5. 3/8 inch nut driver, voltmeter, 3 inch (or longer) jumper wire

INSTALL THE APPLICATION CODE

Before the Interface Module can be put to work, the application code must be installed.
Application code must be matched to the truck model that the Interface Module is installed
on.

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

the necessary files and instructions.

Validate the correct IM software is installed by using the IM Realtime Data Monitoring
software to locate the CRC number of installed IM software. Compare the CRC number on
the IM Realtime Data Monitoring software to the CRC number on the software drawing, and
confirm these numbers are the same.

How to use the IM Realtime Data Monitor software:

Connect a DB9 straight through cable from the serial port on the laptop to the IM Diagnostic
connector in the cab or auxiliary cabinet. The IM must be powered to communicate with the laptop.

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Double click the shortcut to IM Realtime Monitor on the Desktop screen. After the program runs, a
blank window shows up. On the menu select “Select Serial Port” to pick the serial port used and
then select “Start/Stop” to view the data.

CHECK FOR FAULT CODES ASSOCIATED WITH THE INTERFACE

MODULE

Key on then run the IM Realtime Data Monitor Software and confirm that there are no fault codes
associated with the Interface Module. If any are found, these circuits should be analyzed to
determine the cause of the fault and they should be repaired or if required the IM should be
replaced.

INTERFACE MODULE I/O

Use the IM Realtime Data Monitor software to confirm the functionality of all IM inputs and serial
connections. The key switch must be on for all tests below.

CHECK DIGITAL INPUTS TO THE INTERFACE MODULE

1. Hydraulic Tank Level (IM2-k) – Disconnect wire 34LL from connector CN14 at TB21-T.
Short TB21-T to ground momentarily and confirm state change (one to zero). Reconnect
disconnected wire.
2. Low Steering Precharge (IM2-W) – Disconnect wire 51A1 from precharge pressure
switch #1 at TB21-K. Short TB21-K to ground momentarily and confirm state change
(one to zero). Reconnect disconnected wire.
3. Pump Filter Switches (IM2-Y) – disconnect wire 39 from TB35-C momentarily and
confirm state change (zero to one).
4. Park Brake Released (IM2-M) – short wire 73S to ground at TB32-M momentarily and
confirm state change (one to zero).
5. Park Brake Request (IM3-V) – Short the engine oil pressure switch wire circuit 36 on
TB28-K to ground. Move shift lever from neutral to park position and confirm state
change (one to zero). Remove the ground from TB28-K.
6. GE Batt + (IM3-M) -- confirm this is a one.
7. Starter Motor 1 Energized (IM3-R) – Disconnect wire 11SM1 from cranking motor to
TB28-F at TB28-F. Momentarily short TB28-F to 24V and confirm state change (zero to
one). Reconnect disconnected wire.
8. Starter Motor 2 Energized (IM3-S) – Disconnect wire 11SM2 from cranking motor to
TB28-G at TB28-G. Momentarily short TB28-G to 24V and confirm state change (zero to
one). Reconnect disconnected wire.

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9. Crank Sense (IM3-U) – Open the Start Battery Disconnect switch so that there is no
battery voltage to the starters. Momentarily short TB28-J to 24V and confirm state
change (zero to one). After removing 24V short from TB28-J, close the Start Battery
Disconnect switch.
10. Selector Switch (Park) (IM3-T) – Place shifter into park position and confirm 1 state then
shift into neutral and confirm 0 state. Return shifter to park position.
11. Selector Switch (FNR) (IM2-N) – Place shifter into park position and confirm 0 state then
shift into neutral, forward, and reverse and confirm 1 state for each of these positions.
Return shifter to park position.
12. Strg Bleed Pressure Sw (IM2-Z) – Disconnect the steering bleed down pressure switch,
identified by circuit 33JA, and confirm state change (zero to one). Reconnect the switch.
13. Brake Lock Switch Power Supply (IM3-L) – Ensure that shifter is in park position. Use
GE’s wPTU software to turn on FWD True output signal. Confirm state change (zero to
one). Leave GE FWD True signal on until completion of step 14.
14. Brake Lock (IM2-i) –Actuate brake lock switch and confirm state change (zero to one).
Turn off GE FWD True signal. Confirm input state remains at one. Turn off brake lock
switch. Confirm input state returns to zero. (The Brake Lock Switch Power Supply test,
item 13, must be completed before this test can be successfully completed.) Turn off GE
FWD True signal.
15. Service Brake Set sw (IM3-C) – Short wire 44R at TB31-P to 24 volts momentarily and
confirm state change (zero to one).
16. Cummins Shutdown Delay (IM3-F) – Disconnect wire 21INS from the Cummins ECM at
TB27-E leaving wire 21INS to IM connected at TB27-E. Momentarily short TB27-E to
24V and confirm state change (zero to one). Remove short, and then reconnect 21INS
to TB27-E.
17. Secondary Engine Shutdown sw (IM3-E) – Actuate the Secondary Engine Shutdown
switch and confirm state change (one to zero).
18. Keyswitch (IM3-G) – confirm state is a one.
19. Mode sw1 (IM3-H) – Actuate the “left arrow” LCD screen navigation switch and confirm
state change (one to zero).
20. Mode sw2 (IM3-J) – Actuate the “OK” LCD screen navigation switch and confirm state
change (one to zero).
21. Mode sw3 (IM3-K) – Actuate the “down arrow” LCD screen navigation switch and
confirm state change (one to zero).
22. Mode sw4 (IM2-q) – Actuate the “up arrow” LCD screen navigation switch and confirm
state change (one to zero).
23. Crank Request (IM2-j) – Open the Starter Disconnect switch so that there is no battery
voltage to the starters. Momentarily turn keyswitch to the crank position and confirm
state change (zero to one).
24. Autonomous Mode Request (IM2-e) – Should read one.
25. Park Brake Set (IM2-f) – Momentarily disconnect Park Brake Pressure switch, identified
by circuit 33, and confirm state change (zero to one).
26. Engine warming/Grid dry (IM2-h) – Turn on grid dry (switch) and confirm state change
(one to zero). Turn off grid dry switch.
27. Manual Mode Request (IM2-s) – Should read one.

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28. Snapshot In-Progress (IM2-L) – Actuate the Data Store Switch. Confirm state change
(one to zero).
29. Low Steering Pressure sw1 (IM2-S) – Short wire 33F to ground at TB30-A momentarily
and confirm state change (one to zero).
30. Brake Accum Pressure sw (IM2-U) –Momentarily short wire 33BP to ground at TB32-E.
Confirm state change (one to zero).
31. Brake Lock Degrade sw (IM2-V) – Short wire 33T to ground at TB32-F momentarily and
confirm state change (one to zero).
32. Keyswitch Direct (IM2-P) – Confirm state is a one. Turn keyswitch off for 1 second and
then back on. Confirm state changes to zero and then back to one.
33. Auto Lube Level (IM3-W) – Disconnect wire 68LS coming from lube level switch to
TB34-R at TB34-R while leaving the IM connected. Short wire 68LS to ground at TB34-R
momentarily and confirm state change (one to zero). Reconnect disconnected wire.
34. Auto Lube Sol Sense (IM3-X) – Disconnect wire circuit 68 to IM from TB34-N. Short this
wire to ground momentarily and confirm state change (one to zero). Reconnect wire to
TB34-N.
35. Auto Lube Press Sw (IM3-Y) – Short wire 68P to ground at TB35-P momentarily and
confirm state change (one to zero).
36. Stop Engine Light (IM3-N) – Momentarily short circuit 509 at TB27-T to ground. Confirm
state change (one to zero). Remove short circuit from TB27-T.

CHECK ANALOG INPUTS TO THE INTERFACE MODULE

Verify that the used analog inputs are in the range of the values listed below.

1. Steering Pressure [kPa] (IM3-d): Disconnect steering pressure sensor, identified by

circuit 33SP, and confirm fault A204, Steering Pressure Sensor Low, is active.
Reconnect sensor.
2. Ambient Air Temp [C] (IM3-e): confirm reported temperature matches ambient
temperature within 3 C.
3. Fuel Level [%] (IM3-g): confirm reported % level matches actual fuel level in tank +/- 5%.
4. 12V Converter [V] (IM3-h): confirm reported voltage is 13.5V +/- 0.5V. (24V Battery
voltage must be greater than 18 volts.)
5. Brake Pressure [kPa] (IM3-p): Disconnect service brake pressure sensor located in
brake cabinet, identified by circuit 33BPS, and confirm fault A205, Brake Pressure
Sensor Low, is active. Reconnect sensor.
6. Hydraulic Tank Oil Temp [C] (IM3-m): Disconnect hydraulic tank oil temp sensor and
confirm fault A103, Hydraulic Oil Temp - Tank Sensor Low, is active. Reconnect sensor.
7. Hoist Pressure 1 [kPa] (IM3-s): Short wire 33HP1 to ground momentarily at TB36-C and
confirm fault A202, Hoist Pressure 1 Sensor Low, is active.
8. Battery Voltage 24V [V] (IMint): confirm reported voltage is +/- 1 volt of actual measured
battery voltage.

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CHECK SERIAL INTERFACES TO THE IM

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

CHECK OUTPUTS FROM THE INTERFACE MODULE

Note: Before performing these next steps, the key switch must be turned off for at
least 7 minutes to allow the IM to completely shutdown. Confirm that the IM has
shutdown by verifying that the green LED on the IM controller has stopped flashing.
While performing the following IM output checks, ensure that no output short circuit
fault codes are reported by the IM Realtime Data Monitor software.

1. Park Brake Solenoid output (IM1-E). Short the engine oil pressure switch wire circuit 36
to ground on TB28-K. Key on and shift into neutral. Confirm that the park brake solenoid
is energized by verifying that the coil is magnetized. Use the GE DID panel to set the
truck speed to a speed above 1 kph. Shift into park. Confirm that the park brake solenoid
remains energized. Reduce the truck speed to 0 kph. Confirm that after one second the
park brake solenoid de-energizes. Remove the ground from TB28-K.
2. Start Enable output (IM1-B). Disconnect circuit 21PL from pre-lube timer prior to
performing this step. Place shifter in park and confirm that circuit 21PS on TB28-H is 24
volts while cranking. Place shifter in neutral and confirm that circuit 21PS on TB28-H is 0
volts while cranking. Reconnect circuit 21PL to pre-lube timer.
3. IM On Signal (IM1-K). With keyswitch on, confirm voltage on circuit 110NS at TB41-B is
approximately 0 volts.
4. Red Warn output (IM1-G), Sonalert output (IM1-M). Disconnect the IM from the
CAN/RPC network by unplugging its T-connection to the network then confirm the
following on the dash panel:
a. all status panel indicators flash on/off
b. the red warning indicator flashes on/off
c. two separate audible alarms can be heard sounding on/off
d. a loss of communications message is displayed on the speedometer
e. the needles in all of the gauges are moving through their entire range of motion
Reconnect the IM to the CAN/RPC network.
5. Steering Bleed Down Solenoid output (IM1-P). Confirm steering bleed down solenoid is
de-energized. Turn key switch off and confirm that steering bleed down solenoid is
energized by verifying that coil is magnetized.

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S/N ___________________
IM Installation Checkout Checklist

Software Validation Check

IM Realtime Display CRC Number Software Drawing CRC Number Comments

Function Description Expected Result Result (OK/Fail) Comments

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

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

10 - Selector Switch 1 to 0
(Park)

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

(FNR) Neutral, and Reverse

12 - Steering Bleed 0 to 1
Pressure input

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Function Description Expected Result Result (OK/Fail) Comments

13 - Brake Lock Switch 0 to 1
Power Supply input

14 - Brake Lock input 0 to 1

15 - Service Brake Set 0 to 1

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

19 - Mode switch 1 input 1 to 0

20 - Mode switch 2 input 1 to 0

21 - Mode switch 3 input 1 to 0

22 - Mode switch 4 input 1 to 0

23 - Crank Request input 0 to 1

24- Autonomous Mode 1

Request input
25 - Park Brake Set input 0 to 1

26 – Engine Warming / 1 to 0
Grid Dry switch input
27 – Manual Mode 1
Request input
28 - Snapshot input 1 to 0

29 - Low Steering 1 to 0
Pressure switch input
30 - Brake Accumulator 1 to 0
Pressure switch input
31 - Brake Lock Degrade 1 to 0
switch input
32 - Keyswitch Direct 1 to 0 to 1
input
33 - Auto Lube Level 1 to 0
switch input

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Function Description Expected Result Result (OK/Fail) Comments

34 - Auto Lube Solenoid 1 to 0
sense input
35 - Auto Lube Pressure 1 to 0
switch input
36 – Stop Engine input 1 to 0

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Function Description Expected Result Result (OK/Fail) Comments

ANALOG INPUT CHECKS:
1 - Steering Pressure fault A204

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

3 - Fuel Level tank level +/- 5%

4 - Converter Voltage 13.5 +/- 0.5V

(12V)
5 - Brake Pressure fault A205

6 – Hydraulic Tank Oil fault A103

Temp
7 - Hoist Pressure 1 fault A202

8 - Battery Voltage 24V measured battery voltage

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

2 - Start Enable output 24 V, 0 V

3 - IM On Signal output 0V

4 - Electronic Dash Panel Items 4a-e function as

check and warning described
outputs
5 - Steering Bleed Solenoid de-energized
Solenoid output then energized

Completed By: _________________________________________ Date: _______________________

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