MJFCIFSS!NJOJOH!FRVJQNFOU!

DP/
Model: T282B T282B TRUCK TEST PROCEDURE
S/N:
TI-2198-A
Date: SECTION A: PURPOSE AND INSTRUCTIONS PAGE 1 OF 5

TABLE OF CONTENTS

SECTION DESCRIPTION TOC

A PURPOSE AND INSTRUCTIONS

B WORKMANSHIP (INSPECTION)

C CAB COMPONENT CHECK

E SOFTWARE VERIFICATION

F CAB PRE-TEST

G POWER CIRCUIT

H FINAL TRUCK TEST - CONTROL CIRCUIT

J SERVICE SHEET

K ENGINE START UP

L HYDRAULIC SYSTEMS TEST

M LOAD BOX TEST AND FINAL CHECKS

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION A: PURPOSE AND INSTRUCTIONS
TI-2198-A
Date: PAGE 2 OF 5

FINISHED PRODUCT TEST PROCEDURE

DRIVE SYSTEM SUPPLIER ENGINE SUPPLIER

DRIVE SYSTEM TYPE: AC ENGINE MODEL:

FACTORY ACCEPTANCE TEST

I. Purpose: 1. To check all components for proper operation.
2. To adjust electrical components and sensing devices to required values.
3. To set and test hydraulic pressures.
4. To check engine/drive system for proper horsepower output.
5. To record component model and serial numbers.
6. To insure quality workmanship.
7. To acquire vehicle data documentation for warranty and service use.

II. Instructions:
A. In the blocks to the left or right of each test step, the person conducting the test shall enter a their initials
(of full name) inside the block upon completion and verification of the test process.
B. DO NOT connect batteries, pressurize the system or activate/rotate equipment until instructed to do so by
this test procedure, the Test Engineer, or by the Engineering Department.
C. Any deviation from this test procedure must be approved by the Manufacturing Test Engineer or the
Engineering Department**.
D
D. S i
Steps written iin iitalics
li iindicate
di i l steps. U
optional Use "N/A" iin iinitial
i i l bl k if d
blocks i iis not used
device d or d
does not
exist.
E. Any deviation from this test procedure must be reported to, in writing , to the Engineering Department**.
**In the cases that pertain to software updates or changes, Engineering approval is mandatory!!

F. Throughout this test procedure the instructions say to check for 24 VDC. With fully charged batteries a range
of 20 - 28 VDC is acceptable when testing for 24 VDC. Use a battery charger while testing to maintain fully
charged batties.

G. Resistance is measured in Ohms symbolized as Ω. Any reading less than 0.5 Ω can be considered equivalent
to zero but this will be affected by wire length or coil windings, etc. that are part of the circuit.

H. If a test pressure, voltage, resistance, etc. fails or is incorrect, enter a bold X in the signature box and make an
entry in the variance / incident table on the last page including logging whatever corrective action was taken to
correct the problem.

I. In each section where a test gauge or meter is used, blank lines in this test procedure call for the name of that
gauge or meter. Most meters have a name similar to LME123, list this name in each section. In the table on the
last page provide all meter details as requested by the table. Note that metal boxes containing several
pressure gauges are calibrated and named as one single unit. If you use one or more gauges in that box, list
the name of the box; each individual gauge kept in that box is not identified or calibrated by itself.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION A: PURPOSE AND INSTRUCTIONS
TI-2198-A
Date: PAGE 3 OF 5

ABBREVIATION LEGEND
3GB = 3-GANG BLOCK PROX = PROXIMITY
4-GB = 4-GANG BLOCK PSW = PRESSURE SWITCH
6GB = 6-GANG BLOCK R = RESISTOR
A = AMPERES RB = RESISTOR BLOCK
BAT = BATTERY REC = RECEPTACLE
CAN = CONTROLLER AREA NETWORK RLY = RELAY
CB = CIRCUIT BREAKER SDR = SENDER
CKT = CIRCUIT SOL = SOLENOID
CON = CONNECTOR SW = SWITCH
DB = DIODE BLOCK TB = TERMINALL BOARD
GB = GROUND BLOCK TCU = TRACTION CONTROL UNIT
GND = GROUND TSW = TEMPERATURE SWITCH
GP = GROUND POINT VAC = VOLTS ALTERNATING CURRENT
IND = INDICATOR VDC = VOLTS DIRECT CURRENT
LT = LIGHT VLV = VALVE
LVL = LEVEL YCON = Y-CONNECTOR
Ω = OHMS

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION A: PURPOSE AND INSTRUCTIONS
TI-2198-A
Date: PAGE 4 OF 5

EQUIPMENT LIST

QUANTITY DESCRIPTION

1 Simpson 260 Volt-Ohm Milliammeter Analog Meter

OR
1 Fluke Digital Multi-meter (DMM)

1 Portable 24 VDC Power Supply (> 15A)

1 Megger (500 Volt Minimum)

1 Notebook Computer (w/ necessary software loaded)

Must have Serial Port or USB-Serial Port Adapter and Parallel Port

1 Set of 18-14 AWG Jumpers (6 ft)

1 AMP Terminal Crimpers

1 Deutsch Crimpers

1 Packard Weather Pack Crimpers

1 Packard MetriPack Crimpers

1 AMP Socket & Pin (Weigh System) Crimpers

1 AMP Comm Port Crimpers

1 Harting (TCU) Crimpers

1 AMP Pin Extractors (Weigh System)

1 AMP Pin Extractors (Comm Port)

1 Deutsch Pin Extractors

1 Harting Pin Extractors

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION A: PURPOSE AND INSTRUCTIONS
TI-2198-A
Date: PAGE 5 OF 5

INCIDENTS
Section# Page# Line# Incident Cause Resolution

TOOLS USED
LME tool # Description Date Calibrated Calibration Due

SIGNATURES / INITIALS
Print Names Department Title Initials

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/ TOC
Model: T282B
S/N: SECTION B: WORKMANSHIP
TI-2198-A
Date: PAGE 1 OF 2

CAB SUB-ASSEMBLY PRE-TEST CHECK

ASSY
INITIALS
1 Verify that all ground block backing nuts are tight before installing the terminals.
2 Verify that all empty holes in the Cab are plugged.
3 Verify that all gauges have 24 Volt bulbs installed instead of 12 Volt bulbs.
4 Verify that the proper Indicator Panel is installed.
5 Verify that the proper types of switches are in place.
6 Verify that the components are clearly labeled.
7 Verify that the wires are routed correctly for length and to prevent rubbing.
8 Verify that the Driver seat is properly installed.
9 Verify the Passenger seat is properly installed.
10 Verify that the Steering Wheel functions properly.
11 Verify that all terminal lugs are crimped correctly.
12 Verify that the door seals have no splices between the corners.
13 Verify that the doors close properly and the door handles latch correctly.
14 Verify that the Steering Column U-joint cap screw and locknut are in place and
have at least 2 threads showing.
15 Vacuum the Cab before setting on the Superstructure.
16 Place the weighing system offload cable in the passenger side door pocket.
17 Place one copy of the Drive System Schematic, Controls Schematic, and
Hydraulic Schematic in the passenger side door pocket.
18 Record the Serial Numbers for the cab seats and the cab assembly.
Driver seat:
Passenger seat:
Cab assembly:

CONTROL BOX (SUPERSTRUCTURE MOUNTED) PRE-TEST CHECK

ASSY
INITIALS
1 Power cables and wiring crimped correctly.
2 All power cables connecting to bus bars have correct hardware.
3 All cap screws and/or nuts are tight.
4 All cables and wiring are routed to prevent chaffing.
5 Cables and wiring are clearly labeled.
6 Wire and cable tensions are correct. (Visible slack in cable to allow for flex.)
7 Verify the control box has no visible damage on the interior or exterior.
8 All loose nuts, washers, cap screws or misc. hardware removed from control box.
9 Cable clamps supporting power cables are secure but not over-torqued to the
point to cause insulation damage.
10 Cable grips are the correct size and have been tightened.
11 Control box ground strap installed.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION B: WORKMANSHIP
TI-2198-A
Date: PAGE 2 OF 2

GRID BOX PRE-TEST CHECK

ASSY
INITIALS
1 Verify that cables clearly labeled.
2 Verify that cables routed to prevent chafing.
3 Verify that cables crimped correctly.
4 Bus bars and cable lugs are secure and are not less than 1/2" from grid box frame
or lid.
5 Verify Grid Blower Cowling is securely mounted.
6 Verify that the Grid Box ground strap is installed.
7 Verify that all terminal ends have correct cap screws and are tight.
8 Verify that the Grid Box is clean and free of debris especially in blower intake area.
9 Verify all grids are correct type as per assembly.
10 Verify all grids in Grid Box have passed quality inspection (see vendor QA, serialized stickers).

FINAL ASSEMBLY TRUCK PRE-TEST CHECK

1 Verify that all loose cap screws, nuts, washers, and foreign material are removed ASSY
from: INITIALS
the Grid Box.
the Control Box.
the Cab.
the Deck.
the Axle Box.
the Frame.
the Battery Control Box.
2 Verify that all Cables and Wires are clearly labeled.
3 Verify that the Cables are routed correctly for length and to prevent rubbing.
4 Verify that all Cables are clamped securely.
5 Verify that the hoses are routed correctly for length and to prevent rubbing.
6 Verify that all hoses, tubing, and ducts are clamped securely.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/ TOC
Model: T282B
S/N: SECTION C: CAB COMPONENT CHECK
TI-2198-A
Date: PAGE 1 OF 1
Verify that the following components are installed and in good working condition:
ASSY ASSY
Left Dash Panel Standard INITIALS Left Dash Panel Options INITIALS
Park Brake Switch Engine Heater
Head Light Switch Fog Lights
Ladder/Eng Svc Light Switch Engine Shut Down Switch
Back Up Light Switch
Manual Lube Switch
Data Store Switch
Fault Reset Switch
Wiper Motor Switch
Washer Motor Switch
Hand Brake Switch

Center Dash Panel Standard Center Dash Panel Options

Truck Display Monitor None

Right Dash Panel Standard Right Dash Panel Options

Indicator Panel including: Indicator Panel including:
Engine Stop Indicator Gear Oil Cooling
Engine Warning Ind.
Engine Maintenance Ind.
Service Brake Ind.
Retard Ind.
Drive System Fault Ind.
Lube Fault
Park Brake Indicator
Keypad
Master Switch
Cruise Enable Switch
Cruise Up/down Switch

Accessory Panel Standard Accessory Panel Options

ATC Control Panel (HVAC)
Drive Sys. Comm. Port
Engine Communication Port
Weigh System Display
Weigh Sys. Comm. Port
Hourmeter
AM/FM Radio
Radio ships loose (not in cab) Yes / No (circle one)

Center Console Standard Center Console Options

Dump Body Joystick
Shift Selector Switch
Circuit Breaker Box
Cigarette Lighter
Storage Bin

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/ TOC
Model: T282B
S/N: SECTION E: SOFTWARE VERIFICATION
TI-2198-A
Date: PAGE 1 OF 1

ECOMAT CR0020

SOFTWARE ID

TEST TEAM
SOFTWARE TESTED AND VERIFIED BY:

SBS COMPUTER GHOST IMAGE

SOFTWARE ID

ENGINEERING TEST TEAM

RELEASED BY: J. KING SOFTWARE TESTED AND VERIFIED BY:

SIBAS SYSTEM
DSP SOFTWARE ID
ZR SOFTWARE ID

SOFTWARE VARIABLES
PROPULSION SPEED LIMIT
Siemens /LBC Gear Ratio

SIEMENS COMMISSIONING TEST TEAM

SOFTWARE TESTED AND VERIFIED BY:

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/ TOC
Model: T282B
S/N: SECTION F: CAB PRE-TEST - STANDARD EQUIPMENT
TI-2198-A
Date: PAGE 1 OF 19

ACCELERATOR PEDAL
Tool Record: LME#:____________________ Cal. Date:____________________
1 Connect the pos. (+) lead to S2-P and the neg. (-) lead to S2-Q. (TCU OUT: 15V & GND)
2 Measure 2.0kΩ. [NOTE: ALL PEDAL VALUES TO BE WITHIN 15% OR SUGGESTED VALUE]
3 Record the reading. Ω
4 Connect the pos. (+) lead to S2-P and the neg. (-) lead to S1-E.
5 Measure 3.0 kΩ.
6 Record the reading. Ω
7 Depress the Accelerator Pedal.
8 Measure 2.2 kΩ.
9 Record the reading. Ω
10 Connect the pos. (+) lead to S1-E and the neg. (-) lead to S2-Q.
11 Measure 1.4 kΩ.
12 Record the reading. Ω
13 Depress the Accelerator Pedal.
14 Measure 2.3 kΩ.
15 Record the reading. Ω

RETARD PEDAL
Tool Record: LME#:____________________ Cal. Date:____________________
1 Connect the pos. (+) lead to S2-P and the neg. (-) lead to S2-Q.
2 Measure 2.0kΩ. [NOTE: ALL PEDAL VALUES TO BE WITHIN 15% OF SUGGESTED VALUE]
3 R d the
Record th reading.
di Ω
4 Connect the pos. (+) lead to S2-P and the neg. (-) lead to S1-F.
5 Measure 2.9 kΩ.
6 Record the reading. Ω
7 Depress the Retard Pedal.
8 Measure 2.2 kΩ.
9 Record the reading. Ω
10 Connect the pos. (+) lead to S1-F and the neg. (-) lead to S2-Q.
11 Measure 1.2 kΩ.
12 Record the reading. Ω
13 Depress the Retard Pedal.
14 Measure 2.2 kΩ.
15 Record the reading. Ω

SET SPEED CHECKS

1 Measure 0 Ω between Con A-32 and S2-H (TCU OUT: DIESEL SET SPEED)
2 Measure 1 kΩ between Con A-11 and S2-H (TCU OUT: DIESEL SET SPEED)
3 Measure 0 Ω between Con A-39 and S2-J (TCU OUT: DIESEL SET SPEED GND)
4 Measure 0 Ω between Con A-9 and S2-K. (TCU IN: OPTIMUM SPEED SIGNAL)

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION F: CAB PRE-TEST - STANDARD EQUIPMENT
TI-2198-A
Date: PAGE 2 OF 19
DASH COMMUNICATION PORT
Tool Record: LME#:____________________ Cal. Date:____________________
1 Measure 0 Ω between S2-L and Serial Con, Pin 2. (TCU OUT: DIAG. RS232 TXD)
2 Measure 0 Ω between S2-M and Serial Con, Pin 3. (TCU OUT: DIAG. RS232 RXD)
3 Measure 0 Ω between S2-N and Serial Con, Pin 5. (TCU OUT: DIAG. RS232 GND)
SBS COMPUTER COM 1
Tool Record: LME#:____________________ Cal. Date:____________________
1 Measure 0.7 Ω between S2-F(+) and Serial Con, Pin 3(-). (TCU OUT: RS232 TX)
2 Measure OPEN CKT between S2-E(-) and Serial Con, Pin 3(+). (TCU OUT: RS232 TX)
3 Measure 0 Ω between S2-E and Serial Con, Pin 2. (TCU OUT: RS232 RX)
4 Measure 0 Ω between S2-G and Serial Con, Pin 5. (TCU OUT: RS232 GND)

VOLTAGE CHECK
Tool Record: LME#:____________________ Cal. Date:____________________
1 Pull all breakers OUT
2 Turn all panel switches OFF.
3 Connect B-48 wire (RED) and B-19 wire (RED) to (+) positive terminal of the Power Supply.
4 C t B-54
Connect B 54 wire
i (BLK) to
t (-)
( ) negative
ti terminal
t i l off the
th Power
P S l
Supply.
5 Jumper Con B-30 to GB7. (LEAVE THIS JUMPER IN UNTIL SECTION F IS COMPLETE)
6 Jumper Con B-31 to GB7. (LEAVE THIS JUMPER IN UNTIL SECTION F IS COMPLETE)
7 Jumper D-6 to S2-A. (LEAVE THIS JUMPER CONNECTED UNTIL TEST IS COMPLETE)
8 Turn the Power Supply ON.
9 Push in all Circuit Breakers one at a time.
(NOTE: If any of the CB's fail to remain in, check for a short in the circuit. DO NOT proceed until the problem has been corrected.)

10 With all Circuit Breakers IN, proceed with the test.

IGNITION SWITCH
Tool Record: LME#:____________________ Cal. Date:____________________
1 Turn the Ignition Switch OFF.
2 Measure 24VDC at B-22 and B-49. (B+ inputs tied to B-19 and B-48, respectively)
3 Measure 0VDC at S2-A. (TCU OUT: POWER TO ACC RELAYS)
4 Move the Ignition Switch to the IGNITION position.
5 Measure 24VDC at B-22 and B-49. (B+ inputs tied to B-19 and B-48, respectively)
6 Measure 24VDC at S2-A.

CHECK FOR 24 VDC AT THE FOLLOWING LOCATIONS

A-74 B-1 B-77 C-9

A-84 B-2 B-87 C-15
A-85 B-10 B-91 C-20
A-98 B-29 B-98 C-21
A-99 B-74

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION F: CAB PRE-TEST - STANDARD EQUIPMENT
TI-2198-A
Date: PAGE 3 OF 19
ECOMAT SUPPLY/ INPUT AND OUTPUT CHECK (CR0020)
(Tech #1) Tool Record: LME#:____________________ Cal. Date:____________________
(Tech #2) Tool Record: LME#:____________________ Cal. Date:____________________
1 Observe all the Ecomat Connectors are disconnected.
2 Move the Master Switch to the IGNITION position.
3 Measure 24VDC between ECO-55 and ECO-01. (KEY ON SIEMENS)
4 Measure 24VDC between ECO-23 and ECO-01. (OUTPUT 24VDC)
5 Measure 24VDC between ECO-34 and ECO-15. (OUTPUT 24VDC-RLY)
6 Measure 24VDC between ECO-05 and ECO-15. (SUPPLY 24VDC)
7 Jumper ECO-23 to ECO-42. (LEAVE JUMPER IN ECO-23 & MOVE OTHER END AS INSTRUCTED)
8 Observe Drive System Fault indicator is ON. (ECO-42)
9 Move one end of the jumper from ECO-42 to ECO-48.
10 Observe Drive System Fault indicator is OFF
11 Observe Lube Fault Indicator is ON. (ECO-48)
12 Move one end of the jumper from ECO-48 to ECO-43.
13 Observe Lube Fault Indicator is OFF.
14 Observe Park Brake Indicator is ON. (ECO-43)
15 Move one end of the jumper from ECO-43 to ECO-39.
16 Observe Park Brake Indicator is OFF.
17 Observe the Engine Hourmeter is ON. (ECO-39)
18 Move one end of the jumper from ECO-39 to ECO-41.
19 Observe the Engine Hourmeter is OFF.
20 Observe the Ecomat Buzzer is ON. (ECO-41)
21 M
Move d off the
one end th jumper
j f
from ECO 41 to
ECO-41 t ECO-52.
ECO 52 (ECO-52:
(ECO 52 STEERING BLEEDOWN OUTPUT)
22 Observe the Ecomat Buzzer is OFF.
23 Measure 24VDC between B-81 and B-82. (ECO-81: STEERING BLEEDOWN)
24 Remove the jumper from ECO-23 to ECO-52. (COMPLETELY REMOVE THE JUMPER)
25 Measure 0VDC between B-81 and B-82.
26 Pull CB5 OUT.
27 Jumper ECO-51 to B-2. (ECO-51: LATCH POWER)
28 Measure 24VDC between ECO-23 and ECO-01.
29 Remove the jumper from ECO-51 to B-2.
30 Push CB5 IN.
31 Jumper ECO-45 to ECO-23. (START INHIBIT)
32 Verify the Park Brake Switch is pushed IN. (PARK BRAKE SET POSITION)
33 Verify the Engine Shutdown Switch is pulled OUT.
34 Move the Master Switch to the START position and HOLD.
35 Measure 24VDC at B-20. (START STRING)
36 Release the Master Switch and verify Master Switch returns to the IGNITION position.
37 Remove the jumper from ECO-45 to ECO-23.
38 Verify the Shift Selector Switch is in the NEUTRAL position.
39 Measure 24VDC at ECO-30. (NEUTRAL INPUT)
40 Move the Selector Switch to the FORWARD position.
41 Measure 0VDC at ECO-30.
42 Move the Selector Switch to the REVERSE position.
43 Measure 0VDC at ECO-30.
44 Move the Shift Selector Switch to the NEUTRAL position.
45 Jumper ECO-8 to ECO-50. (BRAKE ON INPUT to BRAKE ACTIVE IND.)

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION F: CAB PRE-TEST - STANDARD EQUIPMENT
TI-2198-A
Date: PAGE 4 OF 19

ECOMAT SUPPLY/ INPUT AND OUTPUT CHECK (CR0020)

46 Jumper C-21 to C-19. (BRAKE PEDAL PROXIMITY SWITCH).

47 Observe the Brake Active Indicator is ON.
48 Remove the jumper from C-21 to C-19.
49 Observe the Brake Active Indicator is OFF.
50 Remove the jumper from ECO-8 to ECO-50.
51 Jumper ECO-27 to ECO-22. (RETARD INPUT to RETARD ACTIVE IND.)
52 Jumper ECO-23 to S2-B. (LEAVE JUMPER IN ECO-23 & MOVE OTHER END AS INSTRUCTED)
53 Observe the Retard Active Indicator is ON.
54 Remove the jumper from S2-B.
55 Observe the Retard Active Indicator is OFF.
56 Remove the jumper from ECO-27 and ECO-22.
57 Measure 0VDC between ECO-09 and ECO-01. (INTERMITTENT WIPER INPUT)
58 Press the Intermittent Wiper setting on the Washer Switch ON.
59 Measure 24VDC between ECO-09 and ECO-01.
60 Release the Intermittent Wiper setting on the Washer Switch.
61 Press and HOLD the Washer setting on the Washer Switch IN.
62 Measure 24VDC between ECO-38 and ECO-01. (WASHER INPUT)
63 Release the Washer setting on the Washer Switch.
64 Measure 0VDC between ECO-38 and ECO-01.
65 Jumper ECO-23 to ECO-16. (WIPER OUTPUT)
66 Ob
Observe th Windshield
the Wi d hi ld Wiper
Wi i ON.
is ON
67 Remove the jumper from ECO-23 to ECO-16. (COMPLETELY REMOVE THE JUMPER)
68 Obeserve the Winshield Wiper is OFF.
69 Measure 0Ω between ECO-11 and TB4-J. (HAND BRAKE INPUT)
70 Jumper B-92 to B-93. (LUBE 1)
71 Measure 0Ω between ECO-54 and ECO-01. (LUBE 1 OUT)
72 Remove the jumper from B-92 to B-93.
73 Measure OPEN CIRCUIT (∞) between ECO-54 and ECO-01.
74 Jumper B-94 to B-93. (LUBE 2)
75 Measure 0Ω between ECO-17 and ECO-01. (LUBE 2 OUT)
76 Remove the jumper from B-94 to B-93.
77 Measure OPEN CIRCUIT (∞) between ECO-17 and ECO-01.
78 Move the Manual Lube Switch to the ON position.
79 Measure 24VDC at ECO-29. (MANUAL LUBE INPUT)
80 Move the Manual Lube Switch to the OFF position.
81 Measure 0VDC at ECO-29.
82 * Move the Park Brake Switch to the SET (PARKED) position.
83 * Jumper ECO-2 to ECO-35. (PARK BRAKE REQUEST to PARK BRAKE APPLY)
84 * Jumper pin 30 to pin 86 of the Propel Lockout Relay.
85 * Measure 24VDC between B-75 (+) and B-76 (-). (PARK BRAKE SOLENOID)
86 * Pull the Park Brake Switch OUT.
87 * Measure 0VDC between B-75 (+) and B-76 (-).
88 * Remove the jumpers between ECO-2 and ECO-35 and pins 30 and 86 of the Propel Lockout Relay.
89 * Jumper B-91 to B-86. (PARK BRAKE PRESSURE SWITCH)
90 Measure 24VDC between ECO-18 (+) and ECO-01 (-). (ECO-18: PARK BRAKE OFF INPUT)
* SKIP steps 82 through 89 for Hedweld ladder option; use Hedweld ladder option test.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION F: CAB PRE-TEST - STANDARD EQUIPMENT
TI-2198-A
Date: PAGE 5 OF 19

ECOMAT SUPPLY/ INPUT AND OUTPUT CHECK (CR0020)

91 Remove the jumper between B-91 and B-86.

92 Measure 0VDC between ECO-18 (+) and ECO-01 (-).
93 Jumper ECO-23 to ECO-53. (ECO-53: SBS PWR)
94 Measure 24VDC between Vin (+) and Vin (-) of the SBS Power Supply.
95 Remove the jumper from ECO-53 and jumper ECO-23 to ECO-46. (ECO-46: WDG TIMER)
96 Measure 0VDC between Vin (+) and Vin (-) of the SBS Power Supply.
97 Measure 24VDC between WDG-4(+) and WDG-3(-).
98 Remove the jumper from ECO-23 and ECO-46.
99 Measure 0Ω between A-12 and ECO-10. (ECO-10: ENGINE ON INPUT)
100 Jumper B-29 to B-28. (PROPEL INHIBIT SWITCH)
101 Measure 24VDC between ECO-20 and ECO-01. (ECO-20: PROPEL INHIBIT REQUEST)
102 Remove the jumper from B-29 and B-28.
103 Measure 0VDC between ECO-20 and ECO-01.
104 Measure 0Ω between S1-C and ECO-36. (ECO-36: PROPEL INHIBIT INPUT)
105 Measure 0Ω between S2-Oand ECO-37. (ECO-37: DRIVE SYSTEM FAULT INPUT)
106 Move the Ignition Switch to the OFF position.
107 Connect Con ECO to the Ecomat CR0020.
108 Move the Ignition Switch to the IGNITION position.
109 Observe the Ecomat CR0020 is running and the GREEN LED is flashing once per second.

TRUCK COMPUTER

1 Observe the truck computer is ON and the correct display configuration is running.
(Refer to Section E for SBS Ghost Image selection.)
2 Move the Ignition Switch to the OFF position.
3 Observe the truck display enters shutdown mode and powers OFF.
4 Move the Ignition Switch to the IGNITION position.
5 Observe the truck computer boots up without error and the correct display configuration is running.

POWER PORT
Tool Record: LME#:____________________ Cal. Date:____________________
1 Measure 11 to 14 VDC at the Power Port in the dash.

HORN
Tool Record: LME#:____________________ Cal. Date:____________________
1 Press the Horn Switch IN.
2 Measure 24 VDC, between C-3 and C-1.
3 Release the Horn Switch.
4 Measure 0VDC between C-3 and C-1.

AM/FM RADIO
Tool Record: LME#:____________________ Cal. Date:____________________
1 Measure 11 to 14 VDC between Con Rad-A and Con Rad-C.
2 Measure 11 to 14 VDC between Con Rad-B and Con Rad-C.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION F: CAB PRE-TEST - STANDARD EQUIPMENT
TI-2198-A
Date: PAGE 6 OF 19

TRUCK WINDOWS

DRIVER SIDE SWITCHES

1 Test that the drivers window goes up and down.
2 Test that the passengers window goes up and down.

PASSENGER SIDE SWITCH

1 Test that the passengers window goes up and down.

WINDSHIELD WIPER

1 Turn the Windshield Wiper Switch to the ON position.

2 Observe the Windshield Wiper Motor operates properly at BOTH LOW and HIGH speeds.
3 Turn the Windshield Wiper Switch to the OFF position.
4 V if that
Verify th t the
th Windshield
Wi d hi ld Wiper
Wi PARKS
PARKS.
5 Fill the Washer Bottle with water up to 1/4 full.
6 Temporarily connect DSCWB (Con B) to DSCWB (Washer Pump). [Con B-5-WHT(1), Con B-6-BLK(2)]
7 Push and Hold the Windshield Washer Switch IN.
8 Verify that the Windshield Washer Pump operates.
9 Release the Windshield Washer Switch.
10 Observe the Windshield Washer stops.
11 Disconnect connector DSCWB. [Con B-5-WHT(DSCWB-1), Con B-6-BLK(DSCWB-2)]

HVAC CONTROLS

1 Press the ON key to power the system.

2 Press and HOLD the Fan Speed UP key and verify the fan speed increases in 10% increments.
3 Press and HOLD the Fan Speed DOWN key and verify fan speed decreases in 10% increments.
4 Press and HOLD the Temperature UP key and verify the temp. increases up to max 95 ºF (35ºC).
5 Press and HOLD the Temperature DOWN key and verify the temp. decreases to max 55 ºF (13ºC).
6 Press the EXT key and verify the display switches to external temperature.
7 Verify the display returns to ambient temperature display after 5 seconds.
8 Press the DEF key and verify the mode door actuator OPENS the fresh air door in the blower unit.
9 Press the DEF key and verify the mode door actuator CLOSES the fresh air door in blower unit.
10 Verify the display shows temp. in ºF/ºC by pressing the EXT key then either Temp UP/DOWN key.
11 Verify system has no active faults by pressing EXT key 3 times and reading E00 on the display.
12 If any other codes are displayed, consult Figure 2 at the end of Section F.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION F: CAB PRE-TEST - STANDARD EQUIPMENT
TI-2198-A
Date: PAGE 7 OF 19

DOME LIGHT
Tool Record: LME#:____________________ Cal. Date:____________________
1 Move the Dome Light Switches at the light fixture to the ON position.
2 Observe the Dome Lights are ON.
3 Move the Dome Light Switches to the OFF position.
4 Observe the Dome Lights are OFF.

AIR SEAT
Tool Record: LME#:____________________ Cal. Date:____________________
1 Measure 24VDC between Con DAS-A and Con DAS-B.

SHIFT SELECTOR SWITCH

Tool Record: LME#:____________________ Cal. Date:____________________
1 Verify the Shift Selector Switch is in the NEUTRAL position.
2 Measure 0VDC at D-5. (TCU IN: FORWARD)
3 Measure 24VDC at D-3. (TCU IN: NEUTRAL)
4 Measure 0VDC at D-4. (TCU IN: REVERSE)
5 Move the Shift Selector Switch to the FORWARD position.
6 Measure 24VDC at D-5. (TCU IN: FORWARD)
7 Measure 0VDC at D-3. (TCU IN: NEUTRAL)
8 Measure 0VDC at D-4. (TCU IN: REVERSE)
9 Move the Shift Selector Switch to the REVERSE position.
10 M
Measure 0VDC att D-5.
D 5 (TCU IN
IN: FORWARD)
11 Measure 0VDC at D-3. (TCU IN: NEUTRAL)
12 Measure 24VDC at D-4. (TCU IN: REVERSE)
13 Move the Shift Selector Switch to the NEUTRAL position.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION F: CAB PRE-TEST - STANDARD EQUIPMENT
TI-2198-A
Date: PAGE 8 OF 19

HEADLIGHT
Tool Record: LME#:____________________ Cal. Date:____________________
Note: For pins C-5 & C-2 use C-1 as GND. For pins B-58 & B-61 use B-67 as GND. For pins B-57 & B-59 use B-66 as GND.
Note: All Switch LEDs share common input power and, thus, are all ON or OFF simultaneously.

1 Move the Headlight Switch to the OFF position.

A Measure 0VDC at A-78. (24VDC: AB & DB LTS) E Measure 0VDC at B-59. (24VDC: HI BM RT)
B Measure 0VDC at B-58. (24VDC: LO BM LT 1&2) F Measure 0VDC at C-5. (24VDC: CLLT LT)
C Measure 0VDC at B-61. (24VDC:LO BM RT1&2) G Measure 0VDC at C-2. (24VDC: CLLT RT)
D Measure 0VDC at B-57. (24VDC:HI BM LT) H Observe Switch LEDs & SS Sw OFF.
2 Turn the Headlight switch to the PARK position.
A Measure 24VDC at A-78. (24VDC: AB & DB LTS) E Measure 0VDC at B-59. (24VDC: HI BM RT)
B Measure 0VDC at B-58. (24VDC: LO BM LT 1&2) F Measure 24VDC at C-5. (24VDC: CLLT LT)
C Measure 0VDC at B-61. (24VDC: LO BM RT1&2) G Measure 24VDC at C-2. (24VDC: CLLT RT)
D Measure 0VDC at B-57. (24VDC: HI BM LT) H Observe Switch LEDs & SS Sw ON.
3 Move the Headlight Switch to the HEADLIGHT position.
A Measure 24VDC at A-78. (24VDC: AB & DB LTS) E Measure 0VDC at B-59. (24VDC: HI BM RT)
B Measure 24VDC at B-58. (24VDC: LO BM LT 1&2) F Measure 24VDC at C-5. (24VDC: CLLT LT)
C Measure 24VDC at B-61. (24VDC: LO BM RT1&2) G Measure 24VDC at C-2. (24VDC: CLLT RT)
D Measure 0VDC at B-57. (24VDC: HI BM LT) H Observe Switch LEDs & SS Sw ON.
4 Move the Dimmer Switch to the High Beam position.
A Measure 24VDC at B-58. (24VDC: LO BM LT 1&2) C Measure 24VDC at B-57. (24VDC: HI BM LT)
B Measure 24VDC at B-61. (24VDC: LO BM RT1&2) D Measure 24VDC at B-59. (24VDC: HI BM RT)
5 P ll CB20 OUT
Pull OUT.
A Measure 0VDC at B-58. (24VDC: LO BM LT 1&2) C Measure 24VDC at B-57. (24VDC: HI BM LT)
B Measure 24VDC at B-61. (24VDC: LO BM RT1&2) D Measure 24VDC at B-59. (24VDC: HI BM RT)
6 Push CB20 IN and Pull CB21 OUT.
A Measure 24VDC at B-58. (24VDC: LO BM LT 1&2) C Measure 24VDC at B-57. (24VDC: HI BM LT)
B Measure 0VDC at B-61. (24VDC: LO BM RT1&2) D Measure 24VDC at B-59. (24VDC: HI BM RT)
7 Push CB21 IN and Pull CB22 OUT.
A Measure 24VDC at B-58. (24VDC: LO BM LT 1&2) C Measure 0VDC at B-57. (24VDC: HI BM LT)
B Measure 24VDC at B-61. (24VDC: LO BM RT1&2) D Measure 24VDC at B-59. (24VDC: HI BM RT)
8 Push CB22 IN and Pull CB23 OUT.
A Measure 24VDC at B-58. (24VDC: LO BM LT 1&2) C Measure 24VDC at B-57. (24VDC: HI BM LT)
B Measure 24VDC at B-61. (24VDC: LO BM RT1&2) D Measure 0VDC at B-59. (24VDC: HI BM RT)
9 Push CB23 IN.

HIGH BEAM INPUT

Tool Record: LME#:____________________ Cal. Date:____________________
1 Move the Headlight Switch to the HEADLIGHT position.
2 Measure 0 Volts at Con D-7. (TCU IN: HI BEAM)
3 Move the Dimmer Switch to the High Beam position.
4 Measure 24 Volts at Con D-7.
5 Move the Dimmer Switch to the Low Beam position.
6 Turn the Headlight Switch to the OFF position.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION F: CAB PRE-TEST - STANDARD EQUIPMENT
TI-2198-A
Date: PAGE 9 OF 19

LEFT TURN INPUT

Tool Record: LME#:____________________ Cal. Date:____________________
1 Move the Turn Signal Switch to the LEFT TURN position.
2 Measure intermittent 24VDC at Con D-8. (TCU IN: LEFT TURN)
3 Measure intermittent 24VDC at Con A-80 (24VDC: STOP/TURN DB & AB LR)
4 Measure intermittent 24VDC at Con C-6. (24VDC: TURN FRONT LT)
5 Move the Turn Signal Switch to the NEUTRAL position.
6 Measure 0VDC at Con D-8.
7 Measure 0VDC at Con A-80
8 Measure 0VDC at Con C-6

RIGHT TURN INPUT

Tool Record: LME#:____________________ Cal. Date:____________________
1 Move the Turn Signal Switch to the RIGHT TURN position.
2 Measure intermittent 24VDC at Con D-9. (TCU IN: RIGHT TURN)
3 Measure intermittent 24VDC at Con A-79. (24VDC: STOP/TURN DB & AB RR)
4 Measure intermittent 24VDC at Con C-4. (24VDC: TURN FRONT RT)
5 Move the Turn Signal Switch to the NEUTRAL position.
6 Measure 0VDC at D-9
7 Measure 0VDC at Con A-79
8 Measure 0VDC at Con C-4

LADDER LIGHTS / ENGINE SERVICE LIGHTS (W/O TDR)

Tool Record: LME#:____________________ Cal. Date:____________________
1 Connect the wire from DSCDL-1 WHT to B-101. (24VDC: TO DECK (CAB) LT)
2 Connect the wire from DSCDL-2 BLK to B-102. (GND: TO DECK (CAB) LT)
3 Jumper B-14 to B-15. (24VDC: SIGNAL FROM GROUND LVL LADDER LT SW)
4 Toggle the Ladder Light Switch.
5 Measure 24VDC between B-62 and B-63. (24VDC: TO ENG SVC LTS)
6 Measure 24VDC between B-64 and B-65. (24VDC: TO LADDER LTS)
7 Observe the Deck (CAB) Light is ON.
8 Move the jumper to B-14 and B-13. (24VDC: SIGNAL FROM GROUND LVL LADDER LT SW)
9 Measure 0VDC between B-62 and B-63.
10 Measure 0VDC between B-64 and B-65.
11 Observe the Deck (CAB) Light is OFF.
12 Toggle the Ladder Light Switch.
13 Measure 24VDC between B-62 and B-63. (24VDC: TO ENG SVC LTS)
14 Measure 24VDC between B-64 and B-65. (24VDC: TO LADDER LTS)
15 Observe the Deck (CAB) Light is ON.
16 Remove the jumper between B-14 and B-13.
17 Remove the DSCDL (WHT & BLK) wires from B-101 and B-102.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION F: CAB PRE-TEST - STANDARD EQUIPMENT
TI-2198-A
Date: PAGE 10 OF 19
BACK UP LIGHTS / ALARM
Tool Record: LME#:____________________ Cal. Date:____________________
1 Verify the Back-Up Light Switch is OFF.
2 Move the Shift Selector Switch to the REVERSE position.
3 Measure 24VDC between C-7 (+) and C-8 (-). (24 V: BACK-UP LIGHT - DECK)
4 Measure 24VDC between A-86 and cab ground. (24VDC: BACK-UP LIGHTS - AXLE BOX)
5 Measure 24VDC between A-87 and cab ground. (24VDC: BACK-UP ALARM)
6 Move the Shift Selector Switch to the NEUTRAL position.
7 Measure 0VDC between C-7 (+) and C-8 (-). (24 V: BACK-UP LIGHT - DECK)
8 Measure 0VDC between A-86 and cab ground. (24VDC: BACK-UP LIGHTS - AXLE BOX)
9 Measure 0VDC between A-87 and cab ground. (24VDC: BACK-UP ALARM)
10 Move the Back-Up Light Switch to the ON position.
11 Measure 24VDC between C-7 (+) and C-8 (-). (24 V: BACK-UP LIGHT - DECK)
12 Measure 24VDC between A-86 and cab ground. (24VDC: BACK-UP LIGHTS - AXLE BOX)
13 Measure 0VDC between A-87 and cab ground. (24VDC: BACK-UP ALARM)
14 Move the Back-Up Light Switch to the OFF position.
15 Measure 0VDC between C-7 (+) and C-8 (-). (24 V: BACK-UP LIGHT - DECK)
16 Measure 0VDC between A-86 and cab ground. (24VDC: BACK-UP LIGHTS - AXLE BOX)
17 Measure 0VDC between A-87 and cab ground. (24VDC: BACK-UP ALARM)

RETARD LIGHTS
Tool Record: LME#:____________________ Cal. Date:____________________
1 Connect GRN wire from DC1-3 to B-32. (24VDC: RETARD LIGHT-TOP OF CAB)
2 C t BLK wire
Connect i from
f DC1 4 to
DC1-4 t B-9.
B 9 (GND
(GND: RETARD LIGHT TOP OF CAB)
LIGHT-TOP
3 Jumper 24VDC to S2-B. (TCU OUT: RETARD ACTIVE)
4 Observe the Retard Light on the Top of the Cab is ON.
5 Observe the Retard Light Indicator is ON.
6 Measure 24VDC between A-81 and cab ground.
7 Remove the jumper from S2-B.
8 Observe the Retard Light on the Top of the Cab is OFF.
9 Observe the Retard Light Indicator is OFF.
10 Measure 0VDC between A-81 and cab ground.
11 Remove the GRN wire from B-32, the BLK wire from B-9.

STOP/TURN AXLE BOX & DUMP BODY LIGHTS

Tool Record: LME#:____________________ Cal. Date:____________________
1 Connect Brake Pedal Test Harness: (BLK to C-21, BLU to C-19 and BRN to C-20).
2 Measure 0VDC at D-10. (TCU IN: BRAKE ON)
3 Measure 0VDC at A-79. (STOP/TURN AXLE BOX & DUMP BODY RIGHT)
4 Measure 0VDC at A-80. (STOP/TURN AXLE BOX & DUMP BODY LEFT)
5 Push Service Brake Pedal IN and HOLD.
6 Measure 24VDC at D-10. (TCU IN: BRAKE ON)
7 Measure 24VDC at A-79. (STOP/TURN AXLE BOX & DUMP BODY RIGHT)
8 Measure 24VDC at A-80. (STOP/TURN AXLE BOX & DUMP BODY LEFT)
9 Release Service Brake Pedal and remove Brake Pedal Test Harness.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION F: CAB PRE-TEST - STANDARD EQUIPMENT
TI-2198-A
Date: PAGE 11 OF 19

PARK BRAKE INDICATOR

Tool Record: LME#:____________________ Cal. Date:____________________
1 Move the Park Brake Switch to the ON position. (Ecomat CR0020 must be connected & operational)
2 Observe the Park Brake Indicator is ON.
3 Move theLadder Up/Down Switch to the DOWN position.
4 Move the Park Brake Switch to the OFF position.
5 Verify Service Brake is NOT APPLIED.
6 Observe the Park Brake Indicator is FLASHING.
7 Jumper B-28 to B-29. (SIMULATE PROPEL INHIBIT SWITCH)
8 Observe the Park Brake Indicator is FLASHING.
9 Depress Service Brake.
10 Observe the Park Brake Indicator is FLASHING.
11 Move theLadder Up/Down Switch to the UP position.
12 Jumper B-75 to B-86. (PARK BRAKE SOL to PRESSURE SWITCH)
13 Measure 24VDC at D-30. (TCU IN: PARK BRAKE OFF)
14 Observe the Park Brake Indicator is OFF.
15 Release Service Brake Pedal and remove jumpers from step 12. Jumper from step 7 used in next test.

PARK BRAKE SOLENOID

Tool Record: LME#:____________________ Cal. Date:____________________
1 Jumper B-28 to B-29. (SIMULATE PROPEL INHIBIT SWITCH)
2 Move the Park Brake Switch to the ON position. (Ecomat CR0020 must be connected & operational)
3 M th L dd Up/Down
Move theLadder U /D S it h to
Switch t the
th UP position.
iti
4 Measure 24VDC between B-75 (+) and B-76 (-). (PARK BRAKE SOLENOID)
5 Move theLadder Up/Down Switch to the DOWN position.
6 Measure 0VDC between B-75 (+) and B-76 (-). (PARK BRAKE SOLENOID)
7 Remove the jumper from step 1.
8 Jumper B-91 to B-86. (PARK BRAKE PRESSURE SWITCH)
9 Jumper D-30 to S2-C. (TCU OUT: PARK BRAKE)
10 Measure 0VDC between B-75 (+) and B-76 (-).
11 Remove the jumper from B-28 to B-29 and from steps 8 & 9.

HAND BRAKE PRESSURE SWITCH

Tool Record: LME#:____________________ Cal. Date:____________________
1 Jumper C-15 to C-16. (HAND BRAKE PRESSURE SWITCH)
2 Measure 24VDC at D-28. (TCU IN: HAND BRAKE ON)
3 Measure 24VDC at TB4-J. (HAND BRAKE ON TO WEIGH SYSTEM BOX)
4 Remove the jumper from C-15 and C-16.
5 Measure 0VDC at D-28.
6 Measure 0VDC at TB4-J.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION F: CAB PRE-TEST - STANDARD EQUIPMENT
TI-2198-A
Date: PAGE 12 OF 19

HAND BRAKE SOLENOID

Tool Record: LME#:____________________ Cal. Date:____________________
1 Verify the Shift Selector Switch is in the NEUTRAL position & Hand Brake Switch is OFF.
2 Jumper S2-D to D-3. (TCU OUT: HAND BRAKE ON)
3 Measure 24VDC between C-17 (+) and C-18 (-). (HAND BRAKE SOLENOID)
4 Remove the jumper from D-3 and S2-D.
5 Measure 0VDC between C-17 (+) and C-18 (-).
6 Move the Hand Brake Switch to the ON position.
7 Measure 24VDC between C-17 (+) and C-18 (-). (HAND BRAKE SOLENOID)
8 Measure 0VDC at S2-D.
9 Move the Hand Brake Switch to the OFF position.
10 Measure 0VDC between C-17 (+) and C-18 (-).

BRAKE PRESSURE SWITCH

Tool Record: LME#:____________________ Cal. Date:____________________
1 Jumper B-77 to B-79. (FRONT & REAR BRAKE PRESSURE SWITCHES)
2 Measure 24VDC at D-16. (TCU IN: BRAKE PRESSURE)
3 Remove the jumper from Con B-77 and B-79.
4 Measure 0VDC at D-16.

DUMP BODY PROXIMITY SWITCH

Tool Record: LME#:____________________ Cal. Date:____________________
1 C t connector
Connect t DSCDB (Con
(C B) to
t DSCDB (DB Prox.)
P ) [GRN->B-1,
[GRN B 1 WHT B 2 BLK
WHT->B-2, B 3]
BLK->B-3]
2 Place a metal washer on the face of the Dump Body Prox. Switch and HOLD.
3 Measure 24VDC at D-12. (TCU IN: DUMP BODY UP INPUT)
4 Measure 0VDC at TB4-H on the Weigh System Box. (DUMP BODY UP INPUT)
5 Measure 24VDC between B-34 and B-37. (FLOAT SOLENOID)
6 Remove the metal washer from the Dump Body Prox. Switch.
7 Measure 0VDC at D-12.
8 Measure 24VDC at TB4-H on the Weigh System Box.
9 Measure 0VDC between B-34 and B-37.
10 Disconnect connector DSCDB (Con B) from DSCDB (Dump Body Prox.)

DATA STORE SWITCH

Tool Record: LME#:____________________ Cal. Date:____________________
1 Press the Data Store Switch.
2 Measure 24VDC at D-22. (TCU IN: DATA STORE INPUT)
3 Release the Data Store Switch.
4 Measure 0VDC at D-22.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION F: CAB PRE-TEST - STANDARD EQUIPMENT
TI-2198-A
Date: PAGE 13 OF 19

CRUISE ENABLE/UP/DOWN
Tool Record: LME#:____________________ Cal. Date:____________________
1 Press the Cruise Control Enable Switch .
2 Measure 24VDC at D-23. (TCU IN: CRUISE ON/OFF)
3 Release the Cruise Control Enable Switch.
4 Measure 0VDC at D-23.
5 Move the Cruise Control Adjust (Up/Down) Switch to the UP position and HOLD.
6 Measure 24VDC at D-24. (TCU IN: CRUISE UP)
7 Measure 0VDC at D-25. (TCU IN: CRUISE DOWN)
8 Move the Cruise Control Adjust (Up/Down) Switch to the DOWN position and HOLD.
9 Measure 0VDC at D-24.
10 Measure 24VDC at D-25.
11 Release the Cruise Control Adjust Switch.

AXLE BOX TEMPERATURE

Tool Record: LME#:____________________ Cal. Date:____________________
1 Jumper A-83 to A-84. (AXLE BOX TEMPERATURE SWITCH)
2 Measure 24VDC at D-29. (TCU IN: AXLE BOX TEMP)
3 Remove the jumper From Con A-83 and A-84.
4 Measure 0VDC at D-29.

DUMP TEMPERATURE INPUT

T l Record:
Tool R d LME#:____________________
LME# C l Date:____________________
Cal. D t
1 Jumper B-74 to B-70. (DUMP TEMPERATURE SWITCH)
2 Measure 24VDC at D-18. (TCU IN: DUMP TEMPERATURE)
3 Remove the jumper from B-74 and B-70.
4 Measure 0VDC at D-18.

STEERING AND BRAKE TEMPERATURE INPUT

Tool Record: LME#:____________________ Cal. Date:____________________
1 Jumper B-74 to B-71. (STEERING/BRAKE TEMPERATURE SWITCH)
2 Measure 24VDC at D-19. (TCU IN: STEER/BRAKE TEMP.)
3 Remove the jumper from B-74 and B-71.
4 Measure 0VDC at D-19.

STEERING PRESSURE INPUT

Tool Record: LME#:____________________ Cal. Date:____________________
1 Jumper B-77 to B-80. (STEERING PRESSURE SWITCH)
2 Measure 24VDC at D-15. (TCU IN: STEERING PRESSURE)
3 Remove the jumper from B-77 and B-80.
4 Measure 0VDC at D-15.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION F: CAB PRE-TEST - STANDARD EQUIPMENT
TI-2198-A
Date: PAGE 14 OF 19

LUBE FAULT
Tool Record: LME#:____________________ Cal. Date:____________________
1 Jumper A-84 to A-82. (AUTO LUBE PRESSURE SWITCH)
2 Measure 24VDC at D-27. (TCU IN: AUTO LUBE)
3 Remove the jumper.
4 Measure 0VDC at D-27.

MAIN BLOWER STATUS INPUT

Tool Record: LME#:____________________ Cal. Date:____________________
1 Jumper A-74 to A-75. (BLOWER PRESSURE SWITCHES)
2 Measure 24VDC at Con D-14. (TCU IN: MAIN BLOWER)
3 Remove the jumper from A-74 and A-75.
4 Measure 0VDC at D-14.

JOYSTICK DUMP BODY OVERIDE SWITCH

Tool Record: LME#:____________________ Cal. Date:____________________
1 Depress the Joystick Dump Body Override Switch.
2 Measure 24VDC at D-21. (TCU IN: DUMP BODY OVERRIDE)
3 Release the Joystick Dump Body Override Switch.
4 Measure 0VDC at D-21.

STEERING ANGLE TRANSDUCER

T l Record:
Tool R d LME#:____________________
LME# C l Date:____________________
Cal. D t
1 Measure 24VDC between B-87 and B-88. (STEERING TRANSDUCER)
2 Jumper B-87 to B-89. (STEERING TRANSDUCER INPUT POWER TO OUTPUT SIGNAL)
3 Measure 24VDC at S1-D. (TCU IN: STEERING ANGLE)
4 Remove the jumper from B-87 and B-89.
5 Measure 0VDC at S1-D.

FAULT RESET SWITCH

Tool Record: LME#:____________________ Cal. Date:____________________
1 Press the Fault Reset Switch and HOLD.
2 Measure 24VDC on D-26. (TCU IN: FAULT RESET)
3 Release the Fault Reset Switch.
4 Measure 0VDC at D-26.

FUEL LEVEL INPUT

Tool Record: LME#:____________________ Cal. Date:____________________
1 Jumper B-74 to B-73. (FUEL LEVEL SENDER)
2 Measure 24VDC between Con D-17 and B-72. (TCU IN: FUEL LEVEL)
3 Remove the jumper from B-74 and B-73.
4 Measure 0VDC between D-17 and B-72.

BATTERY VOLTAGE INPUT

Tool Record: LME#:____________________ Cal. Date:____________________
1 Measure 8-10VDC at D-20. (TCU IN: BATTERY VOLTAGE)

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION F: CAB PRE-TEST - STANDARD EQUIPMENT
TI-2198-A
Date: PAGE 15 OF 19

DRIVE SYSTEM FAULT INDICATOR

Tool Record: LME#:____________________ Cal. Date:____________________
1 Jumper 24VDC to S2-O (TCU OUT: DRIVE SYSTEM FAULT INDICATOR)
2 Observe the Ecomat Buzzer is ON.
3 Observe the Drive System Fault Ind is ON.
4 Remove the jumper from step 1.
5 Observe both the Ecomat Buzzer and Drive System Fault Ind are OFF.

SIEMENS BUZZER
Tool Record: LME#:____________________ Cal. Date:____________________
1 Jumper 24VDC to S2-R (TCU OUT: FAULT BUZZER)
2 Observe the Siemens Buzzer is ON.
3 Remove the jumper to S2-R
4 Observe the SIEMENS buzzer is OFF.

ENGINE OIL PRESSURE

Tool Record: LME#:____________________ Cal. Date:____________________
1 Jumper A-74 to A-16. (JUMPERS 24VDC TO TCU: ENGINE OIL SENSOR INPUT)
2 Measure 24VDC at S1-A. (TCU IN: ENGINE OIL PRESSURE)
3 Remove the jumper from A-74 and A-16.
4 Measure 0 VDC at S1-A

ENGINE COOLANT TEMPERATURE

Tool Record: LME#:____________________ Cal. Date:____________________
1 Jumper A-74 to A-26. (TCU IN: ENGINE COOLANT TEMP)
2 Measure 24VDC at S1-B. (COOLANT SENSOR)
3 Remove the jumper from A-74 and A-26.
4 Measure 0VDC at S1-B. (COOLANT SENSOR)

STEERING BLEEDOWN SOLENOID

Tool Record: LME#:____________________ Cal. Date:____________________
1 Measure 0VDC between B-81(+) and B-82(-).
2 Move the Ignition Switch to the OFF position.
3 Measure 24VDC between B-81(+) and B-82(-).
4 Move the Ignition Switch to the IGNITION position.

AXLE BOX WORK LIGHTS

Tool Record: LME#:____________________ Cal. Date:____________________
1 Measure 24VDC at A-85. (POWER TO AXLE BOX WORK LIGHTS)
2 Pull CB16 OUT.
3 Measure 0VDC at A-85.
4 Push CB16 IN.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION F: CAB PRE-TEST - STANDARD EQUIPMENT
TI-2198-A
Date: PAGE 16 OF 19

MANUAL LUBE TEST

Tool Record: LME#:____________________ Cal. Date:____________________
1 Move the Ignition Switch to the OFF position, and then back to the ON postion.
2 Jumper A-74 to A-12.
3 Depress the Manual Lube Switch 5 times within 2 seconds.
After 30 seconds has elapsed,
4 Measure constant 24VDC between B-92(+) and B-93(-).
5 Measure intermittent 24VDC between B-94(+) and B-93(-).
After an additional 30 seconds has elapsed,
6 Measure 0VDC between B-92(+) and B-93(-).
7 Measure 0VDC between B-94(+) and B-93(-).
8 Remove the jumper from step 2.

GEAR OIL COOLING

1 Jumper Con B-2 to Con B-23 and jumper Con ECO-14 and Con ECO-31. (ECO-14: CAN H)
2 Observe the Gear Oil Cooling Ind is ON.
3 Remove the jumpers from step 1 (indicator should be OFF now).
4 Jumper Con B-2 to Con B-16 and jumper Con ECO-32 and Con ECO-31. (ECO-32: CAN L)
5 Observe the Gear Oil Cooling Ind is ON.
6 Remove the jumpers from step 4 (indicator should be OFF now).

DUMP ACTUATOR
Tool Record: LME#:____________________ Cal. Date:____________________
1 Connect the Dump Body Proximity Switch to B-1(GRN), B-2(WHT), & B-3(BLK).
2 Place a piece of magnetic steel (not stainless steel) in front of the Dump Body Proximity Switch.
3 Move the Dump Body Joystick to the UP position and HOLD.
4 Remove the piece of metal in front of the Dump Body Proximity Switch.
5 Using a multimeter, observe a PWM signal between B-35 and B-38. (HOIST UP SOLENOID)
6 Measure 0VDC between B-34 and B-37. (HOIST FLOAT SOLENOID)
7 Measure 0VDC between B-36 and B-39. (HOIST DOWN SOLENOID)
8 Measure 24VDC between B-78 and B-72. (HOIST PUMP CLUTCH - Optional: Use "NA" if does not exist. )
9 Release the Dump Body Joystick.
10 Measure 0VDC between B-35 and B-38.
11 Move the Dump Body Joystick to the DOWN position and HOLD.
12 Measure 0 VDC between B-35 and B-38.
13 Measure 0 VDC between B-34 and B-37.
14 Using a multimeter, observe a PWM signal between B-36 and B-39. (HOIST DOWN SOLENOID)
15 Release the Dump Body Joystick.
16 Place a piece of metal in front of the Dump Body Proximity Switch.
17 Measure 24VDC between B-34 and B-37.
18 Move the Dump Body Joystick to the UP position and HOLD.
19 Measure 0 Volts between B-34 and B-37.
20 Release the Dump Body Joystick.
21 Remove the piece of metal in front of the Dump Body Proximity Switch.
22 Measure 0 Volts between B-34 and B-37.
23 Disconnect the Dumpbody Prox Switch wires from B-1, B-2, & B-3.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION F: CAB PRE-TEST - STANDARD EQUIPMENT
TI-2198-A
Date: PAGE 17 OF 19

If the Joystick does not operate correctly use the following to adjust the Joystick until it is operating correctly.

ADJUSTMENT OF JOYSTICK AND CAMS

Clockwise (CW) adjustment of the trimpot increases the output.

Counterclockwise (CCW) adjustment of the trimpot decreases the output.
Adjustments affect output current, voltage or percentage of duty cycle to the coil.
The minimun and maximum output is preset at the factory.
”Maxout”Adjustment:
Adjusts the initial current flow or duty cycle, affecting the function response, or speed, when
the handle is first moved from the off position. Deflect the handle slowly to the position where
the controller first turns on. Adjust the threshold trimpot screw to the point where the
controlled function just starts to move, then turn the trimpot screw one full turn in the
counterclockwise direction. .
IntegratedRampSystem (IRS):
Provides smooth function response when reacting to an abrupt change in handle deflection.
Clockwise (CW) rotation of the trimpot increases ramp time and slows the response time.
Counterclockwise (CCW) decreases ramp time and increases the response time.
Hi RangeAdjustment:
With supply voltage applied to the “R” terminal, fully deflect the handle. Adjust the trimpot for
desired “ response or speed. Refer to adjustment procedures. Whenever the dual
range switch or contact is closed, the output should be adjusted for the maximum function
response or speed.
Lo RangeAdjustment:
With no voltage on the “R” terminal, fully deflect the handle. Adjust the trimpot for the
desired response or speed. Again refer to adjustment procedures. Whenever
the dual range switch or contact is open, you are in “Lo Range”.

TOP CAM: A/516

MIDDLE CAM: A517

BOTTOM CAM: A514

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION F: CAB PRE-TEST - STANDARD EQUIPMENT
TI-2198-A
Date: PAGE 18 OF 19

ENGINE STOP
Tool Record: LME#:____________________ Cal. Date:____________________
1 Jumper Con B-11 to Con B-12.
2 Pull the Engine Shutdown Switch OUT.
3 Observe the Engine Shutdown Ind is OFF.
4 Measure 24VDC between A-22(+) and A-23(-).
5 Push the Engine Shutdown Switch IN.
6 Observe the Engine Shutdown Ind is ON.
7 Measure 0VDC between A-22(+) and A-23(-).
8 Remove the jumper from step 1.

START STRING

1 Move the Selector Switch to the NEUTRAL Position

2 Turn the Park Brake Switch to the PARK position.
3 Pull the Engine Shutdown Switch OUT.
4 Jumper Con B-20 Con B-21.
5 Move the Master Switch to the START position and HOLD.
6 Measure 24 VDC between Con A-30(+) and Con A-31(-).
7 Measure 24VDC at D-3.
8 Measure 0 VDC on D-6
9 Turn the Park Brake Switch to the RELEASE position.
10 M
Measure b t
0VDC between C A-30(+)
Con A 30( ) and
d Con
C A-31(-).
A 31( )
11 Measure 24VDC at D-3.
12 Measure 0 VDC on D-6
13 Turn the Park Brake Switch to the ON position.
14 Push the Engine Shutdown Switch IN.
15 Measure 0 VDC between Con A-30(+) and Con A-31(-).
16 Measure 24VDC at D-3.
17 Measure 0 VDC on D-6
18 Pull the Engine Shutdown Switch OUT.
19 Move the Selector Switch to the FORWARD Position
20 Measure 0VDC between Con A-30(+) and Con A-31(-).
21 Measure 0 VDC at D-3.
22 Measure 0 VDC on D-6
23 Move the Selector Switch to the REVERSE Position
24 Measure 0VDC between Con A-30(+) and Con A-31(-).
25 Measure 0 VDC at D-3.
26 Measure 0 VDC on D-6
27 Move the Selector Switch to the NEUTRAL Position
28 Release the Ignition Switch to the IGNITION position
29 Remove all jumpers.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION F: CAB PRE-TEST - STANDARD EQUIPMENT
TI-2198-A
Date: PAGE 19 OF 19

WEIGH SYSTEM DISPLAY PROGRAMMING

SOFTWARE VERSION: 282_627u.tfb

1 Remove the front cover from the cab display unit.
2 Press S1 and S2 together to enter the display into the setup mode.
Use S2 or S3 to toggle the functions up or down to the following settings. S1 moves to the next function.
3 dc = OFF
4 ADD = 1
5 br = 1920
6 EH = ON
7 Just = r
8 Term = 1
9 Press S1 to return to the READY mode.
10 Replace the Display front cover.

TF TOOLS PROGRAM CHECK

Tool Record: LME#:____________________ Cal. Date:____________________
1 Open the lid of the weigh system box.
2 Turn ON notebook computer and connect one end of parallel cable into parallel port.
3 Connect other end of parallel cable into input on weigh system circuit board port.
4 Connect weigh system offload harness to serial port of notebook computer.
(Offload harness is located in passenger side pocket.)
5 C t other
Connect th end
d off offload
ffl d harness
h t offload
to ffl d connector
t ini cab
b dash
d h panel.l
6 Open TFTools program and open the program to be loaded into the weigh system.
7 Press buttons "CNTRL" + "C" to stop any active program.
8 Open the "Tattletale" menu and choose "Load OS Only".
9 A process indicator will appear and disappear when completed.
10 Ensure window displaying proper program is active.
11 Choose the "Launch" command under the "Tattletale" menu.
12 Verify program is running. ***If program is not running, repeat steps 1-11.***
13 Disconnect the offload harness and ensure the PDM is functioning correctly.
PDM should display "00 - 00"
14 Disconnect offload and parallel cables and close cover of weigh system box.
15 Measure 24VDC between TB4-K (+ lead) and TB4-B (-lead)
16 Measure 24VDC between TB4-A (+ lead) and TB4-B (-lead)
17 Pull CB19 OUT.
18 Measure 0VDC Between TB4-A (+ lead) and TB4-B (-lead)
19 Pull CB6 OUT. Push CB19 IN.
20 Measure 24VDC between TB4-A (+ lead) and TB4-B (-lead)
21 Measure 0 VDC between TB4-K (+ lead) and TB4-B (-lead)
22 Push CB6 IN.
23 Measure 24VDC between TB4-K (+ lead) and TB4-B (-lead)
24 Measure 24VDC between TB4-A (+ lead) and TB4-B (-lead)

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/ TOC
Model: T282B
S/N: SECTION G: POWER CIRCUIT
TI-2198-A
Date: PAGE 1 OF 4

GRID BOX

Trucks equipped with Siemens constant speed Grid Box, see figures 1 or 2; note capacitor in figure 1.
Trucks equipped with Mosebach Grid Box, see figure 3.
Trucks equipped with Siemens variable speed grid box, see figure 4 (next sheet).

FIGURE 1 FIGURE 2

FIGURE 3

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION G: POWER CIRCUIT
TI-2198-A
Date: PAGE 2 OF 4

FIGURE 4
COVERS REMOVED FOR CLARITY

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION G: POWER CIRCUIT
TI-2198-A
Date: PAGE 3 OF 4

GRID BOX CONNECTION CHECKS

Tool Record: LME#:____________________ Cal. Date:____________________

INITIAL
1 Verify that all grids are correct and not damaged prior to installation.
2 Verify the cables have the correct terminal ends as per drawing.
3 Verify the terminal ends of all cables are tight and insulated.
4 Verify that all bus bars are tight and secure.
5 Verify that 2 - 2.5 Ohms for Siemens, OR 1.5 - 2 Ohms for Mosebach, is measured
across bank A from PIG1p to PIG1n.
OHMS

6 Verify that 2 - 2.5 Ohms for Siemens, OR 1.5 - 2 Ohms for Mosebach, is measured
across bank B from PIG2p to PIG2n.
OHMS

7 Verify that the connections comply with figure 1, 2, 3 or 4.

FIELD EXCITER

1 Measure 7 to 7.9 Ohms between Pin 1 and 2, on cable 2CSO1.

( Plug located on the side of the control box) Ω

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION G: POWER CIRCUIT
TI-2198-A
Date: PAGE 4 OF 4

WHEEL MOTORS
(SKIP THIS STEP IF YOU ARE NOT MOUNTING THE WHEEL MOTORS)

MOTOR A (RIGHT SIDE) MOTOR B (LEFT SIDE)

1 M1-u/PIM1u 1 M2-u/PIM2u
2 M1-v/PIM1v 2 M2-v/PIM2v
3 M1-w/PIM1w 3 M2-w/PIM2w

WHEEL MOTOR A SPEED SENSOR WHEEL MOTOR B SPEED SENSOR

1 TB 30-R/M1A [WHT] 1 TB 30-W, M10A [WHT]

2 TB 30-S/M2A [YEL] 2 TB 30-X, M9A [YEL]
3 TB 30-T/M3A [RED] 3 TB 30-M/M3B [RED]
4 TB 30-V/M4A [BLU] 4 TB 30-V/M4B [BLU]
5 TB 30-P/SHIELD 5 TB 30-P/SHIELD
6 Verify the Speed Sensor cable 6 Verify the Speed Sensor cable
is routed to Wheel Motor A. is routed to Wheel Motor B.

TRANSFORMER

0906 0907

1 BLK-X1 1 BLK-X4
2 RED X2
RED-X2 2 RED X5
RED-X5
3 WHT-X3 3 WHT-X6

ALTERNATOR

ALTERNATOR ARMATURE LINES RECTIFIER LINES

1 T1 / PAT1 1 + / PAIDp
2 T2 / PAT2 2 - / PAIDn
3 T3 / PAT3

ALTERNATOR (ENGINE) SPEED SENSOR

1 ALT TB-1 / H1B [ORG]

2 ALT TB-2 / H2B [BLU]
3 ALT TB-3 / H3B [GRN]
4 [SHLD] / [SHLD]

BLOWER MOTOR

1 Observe the blower motor wiring is correct as per Figure 1 or 2 or 4.

(Blower motor for Mosebach (FIGURE 3) is prewired by Mosebach)

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/ TOC
Model: T282B
S/N: SECTION H: FINAL TRUCK TEST - CONTROL CIRCUIT
TI-2198-A
Date: PAGE 1 OF 11

VISUAL CHECK
Tool Record: LME#:____________________ Cal. Date:____________________
1 Verify the Battery Charger is installed correctly on engine.
2 Verify the Voltmeters are fully functional are have been calibrated.
3 Observe communications radios are fully operational.
4 Measure 0 Ω across each test jumper.
5 Ensure the top of the engine is clear of combustible material.
6 Verify the connectors 1XA through 1XM are not connected to the Control Box.

BATTERY CONNECTION
Tool Record: LME#:____________________ Cal. Date:____________________
1 Unplug 12C1 Cable from the Control Box
2 Unplug all engine cables.
3 Turn the Lucas Switch or Battery Disconnect Switch to the OFF position.
4 Turn the Axle Box Work Lights OFF.
5 Pull both Cab and Bumper Engine Shutdown Switches OUT.
6 Pull all Circuit Breakers in the Battery Control Box and the Cab OUT.
7 Move the Ignition Switch to the OFF position.
8 Turn all dash panel switches OFF.
9 Turn the Starter Isolation Switch ON.
10 Connect the Voltmeter pos. (+) lead to BC1 and the neg. (-) lead to XB1 of the Battery Box.
11 Record the resistance value: Ω
NOTE: If the reading is less than 150 Ω, check for a short circuit.
12 Measure approximately 0Ω between XB1 and frame ground. Ω
13 Measure greater than 150Ω between BC1 and frame ground. Ω
14 Jumper 1XD-14 to 1XA-1 (DO NOT REMOVE JUMPER UNLESS DIRECTED OTHERWISE)
15 Connect the battery cables, BC1 to pos. (+), XB1 to neg. (-) and all the Jumpers
16 Measure 24V between the positive and the negative bus bar
17 Connect the Battery Charger (+) to BC1 and (-) to XB1.
18 Turn the Lucas Switch or Battery Disconnect Switch ON.
19 Turn the Master Switch ON.
20 Push in all Circuit Breakers one at a time in the Cab.
21 Push in all Circuit Breakers one at a time inside the Battery Control Box.
(NOTE: If the CB's fail to remain in, check for a short in the circuit. DO NOT proceed
until the problem has been corrected.)
22 With all Circuit Breakers IN, proceed with the test.

HORN

1 Verify horn operation with horn button.

DOME LIGHT

1 Verify dome light operation using dome light switch.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION H: FINAL TRUCK TEST - CONTROL CIRCUIT
TI-2198-A
Date: PAGE 2 OF 11

HEADLIGHTS
Tool Record: LME#:____________________ Cal. Date:____________________
1 Move the Headlight Switch to the HEAD position
2 Observe the Headlights are ON.
3 Observe the Clearance Lights are ON.
4 Pull CB20 OUT.
5 Observe the Left Headlight is OFF.
6 Push CB20 IN and pull CB21 OUT.
7 Observe the Left Headlight is ON.
8 Observe the Right Headlight is OFF.
9 Push CB21 IN.
10 Observe the Right Headlight is ON.
11 Move the Dimmer Switch in the steering column to the HI BEAM position.
12 Observe the Hi Beam Headlights are ON.
13 Measure 24VDC at 1XC-5.
14 Pull CB22 OUT.
15 Observe the Left Hi Beam Headlight is OFF.
16 Measure 24VDC at 1XC-5.
17 Push CB22 IN and pull CB23 OUT.
18 Observe the Left Hi Beam Headlight is ON.
19 Observe the Right High Beam Headlight is OFF.
20 Measure 24VDC at 1XC-5.
21 Push CB23 IN.
22 Observe the Right Hi Beam Headlight is ON.
23 Move the Dimmer Switch in the steering column to the LOW BEAM position.
24 Measure 0VDC at 1XC-5.
25 Observe the Hi Beam Headlights are OFF.
26 Move the Headlight Switch to the OFF position
27 Observe the Headlights and Clearance Lights are OFF.

CLEARANCE LIGHTS
Tool Record: LME#:____________________ Cal. Date:____________________
1 Move the Headlight Switch to the CLEARANCE position
2 Observe the Clearance Lights on the Superstructure and Axle Box are ON.
3 Observe the Switch LEDs and Shift Selector Lamp are ON.
4 Move the Turn Signal Switch to the LEFT TURN position.
5 Observe the Left Clearance Lights on the Superstructure and Axle Box are FLASHING.
6 Measure intermittent 24 VDC at TB 30-H.
7 Measure intermittent 24 VDC at 1XC-6.
8 Move the Turn Signal Switch to the RIGHT TURN position.
9 Observe the Right Clearance Lights on the Superstructure and Axle Box are FLASHING.
10 Measure intermittent 24 V at TB 30-G
11 Measure intermittent 24 VDC at 1XC-7.
12 Move the Turn Signal Switch back to the NEUTRAL position.
13 Move the Headlight Switch to the PARK position.
14 Observe the Clearance Lights are OFF.
15 Observe the Switch LEDs and Shift Selector Lamp are OFF.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION H: FINAL TRUCK TEST - CONTROL CIRCUIT
TI-2198-A
Date: PAGE 3 OF 11

DUMP BODY LIGHTS

Tool Record: LME#:____________________ Cal. Date:____________________
1 Measure 0 VDC between 6C09-RED and 6C09-BLK.
2 Measure 0 VDC between 6C09-ORG and 6C09-BLK.
3 Measure 0 VDC between 6C09-BLU and 6C09-BLK.
4 Move the Headlight Switch to the CLEARANCE position
5 Measure 24 VDC between 6C09-RED and 6C09-BLK.
6 Press the Headlight switch to OFF position
7 Move the Turn Signal Switch to the RIGHT position
8 Measure intermittent 24 VDC between 6C09-BLU and 6C09-BLK.
9 Move the Turn Signal Switch to the LEFT position
10 Measure intermittent 24 VDC between 6C09-ORG and 6C09-BLK.
11 Turn the Signal light Switch to the NEUTRAL Position
12 Measure 0 VDC between 6C09-RED and 6C09-BLK.
13 Measure 0 VDC between 6C09-ORG and 6C09-BLK.
14 Measure 0 VDC between 6C09-BLU and 6C09-BLK.
15 Move the Headlight Switch to the OFF position

BACK UP LIGHTS

1 Move the Shift Selector Switch to the REVERSE position.

2 Observe the Back Up Lights on the Axle Box are ON.
3 Observe the Back Up Light(s) on the Superstructure is ON.
4 Observe the Back Up Horn is ON.
5 Move the Shift Selector Switch to the NEUTRAL position.
6 Verify that the Back Up Lights and Back Up Horn are OFF.
7 Turn the Back Up Light Switch ON.
8 Verify the Back Up Lights are ON.
9 Verify the Back Up Horn is OFF.
10 Turn the Back Up Light Switch OFF.
11 Verify the Back Up Lights are OFF.

LADDER LIGHTS / ENGINE SERVICE LIGHTS

1 Toggle the Ladder Light Switch in the Cab.

2 Observe that all the six Ladder/Enginer Service Lights are ON.
Two Engine Service Lights, Ladder Light (left), Ladder Light (right front), Ladder Light (right) and Deck Light (cab)
3 Toggle the Ladder Light Switch in the Cab.
4 Observe the Ladder Lights and Engine Service Lights are OFF.
5 Toggle the Ladder Light Switch in the Bumper.
6 Observe the Ladder Lights and Engine Service Lights are ON.
7 Toggle the Ladder Light Switch in the Bumper.
8 Observe the Ladder Lights and Engine Service Lights are OFF.

TECO STROBE LIGHT RELAY (OPTION)

Tool Record: LME#:____________________ Cal. Date:____________________
Monitor Teco strobe light relay outputs Q1-2, Q2-2, using a DC volt meter (24V DC is active).
(Note: verify on Teco strobe relay using ESC key that menu is set to "run", headlights must also be on.
1 Teco strobe relay outputs are not activated by left turn signal (0 VDC).
2 Teco strobe relay outputs are not activated by right turn signal (0 VDC).
3 Teco strobe relay outputs are activated by the flashers (continuous 24 VDC).
4 Teco strobe relay outputs go inactive without the flashers and/or without the headlights (0 VDC).

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION H: FINAL TRUCK TEST - CONTROL CIRCUIT
TI-2198-A
Date: PAGE 4 OF 11

BRAKE LIGHTS
Tool Record: LME#:____________________ Cal. Date:____________________
1 Depress the Service Brake Pedal.
2 Observe the two Stop Lights in the Axle Box are ON.
3 Observe the Brake Active Indicator is ON.
4 Observe the Stop Light atop of the cab is ON.
5 Measure 24VDC at 1XA-4.
6 Release the Service Brake Pedal.
7 Observe the two Stop Lights in the Axle Box are OFF.
8 Observe the Brake Active Indicator is OFF.
9 Observe the Stop Light atop of the cab is OFF.
10 Measure 0VDC at 1XA-4.

HAND BRAKE PRESSURE SWITCH

Tool Record: LME#:____________________ Cal. Date:____________________
1 Jumper 60A10[12C09-RED] to 69A1[12C09-BLU] at the Hand Brake Pressure Switch.
2 Measure 24 VDC at TB4-J (Weigh System Box)
3 Measure 24 VDC at 1XA-5.
4 Remove the jumper from 60A10 to 69A1 and reconnect the Hand Brake Pressure Switch.
5 Measure 0 VDC at TB4-J (Weigh System Box)
6 Measure 0 VDC at 1XA-5.

HAND BRAKE SOLENOID

1 Move the Hand Brake Switch to the ON position.

2 Observe the Hand Brake Solenoid is ENERGIZED (audible solenoid click).
3 Move the Hand Brake Switch to the OFF position.
4 Observe the Hand Brake Solenoid is OFF.

BRAKE PRESSURE INPUT

Tool Record: LME#:____________________ Cal. Date:____________________
1 Measure 0 VDC at 1XC-3.
2 Jumper 130A33[16C07-YEL] to C3E[16C07-YEL/BLK] at SW1(FBK PSW).
3 Jumper C3D[16C07-YEL/RED] to C3C[16C07-ORG/BLK] at SW2(RBK PSW).
4 Measure 24 VDC at 1XC-3.
5 Remove the jumpers from steps 2 and 3.
6 Replace the connectors to SW1 and SW2.

STEERING PRESSURE INPUT

Tool Record: LME#:____________________ Cal. Date:____________________
1 Measure 0 VDC at 1XC-4.
2 Jumper 130A34[16C07-ORG] to C4C[16C07-BRN/BLK] at SW3(STRG PSW).
3 Measure 24 VDC at 1XC-4.
4 Replace the connector to SW3.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION H: FINAL TRUCK TEST - CONTROL CIRCUIT
TI-2198-A
Date: PAGE 5 OF 11

PARK BRAKE PRESSURE SWITCH / INDICATOR

Tool Record: LME#:____________________ Cal. Date:____________________
1 Observe the Park Brake Indicator is ON.
2 Jumper 64A3[16C07-RED/BLK] to X64A4[16C07-BRN] at Park Brake Pressure Switch.
3 Measure 24VDC at 1XB-13.
4 Observe the Park Brake Indicator is OFF.
5 Remove the jumper from the Park Brake Pressure Switch and reconnect the connector.
6 Observe the Park Brake Indicator is ON
7 Measure 0VDC at 1XB-13.

PARK BRAKE SOLENOIDS

1 Move the Park Brake Switch to the OFF position (PARK BRAKE RELEASE).
2 Move the Propel Inhibit Switch to the ON position. (ALLOW PROPULSION)
3 Move the Ladder Up Switch to the UP position.
4 Observe the Park Brake Solenoid is ENERGIZED (audible solenoid click).
5 Move the Park Brake Switch to the ON position (PARK BRAKE APPLIED).
6 Observe the Park Brake Solenoid is OFF.
7 Move the Park Brake Switch to the OFF position (PARK BRAKE RELEASE).
8 Observe the Park Brake Solenoid is ENERGIZED (audible solenoid click).
9 Move the Propel Inhibit Switch to the OFF position. (PROPULSION INHIBITED)
10 Observe the Park Brake Solenoid is OFF.
11 Move the Propel Inhibit Switch to the ON position. (ALLOW PROPULSION)
12 Move the Ladder Down Switch to the DOWN position.
13 Observe the Park Brake Solenoid is OFF.

OUTBOARD WEIGH SYSTEM DISPLAY

1 Connect the notebook computer to the Offload connector in the cab via the Offload Harness.
2 Open the Payload program by clicking on the Payload icon on the computer desktop.
3 Under the Controls folder, choose the 30 Second Light Test.
4 Observe Payload Display Meter in the dash begins cyclings numbers 0-9 for 30 seconds.
5 Observe Out Board Display on the susperstructure begins cyclings numbers 0-9 for 30 seconds.

RETARD ACTIVE INDICATOR

1 Verify the Shift Selector Switch is in the NEUTRAL position. (For 24VDC to 1XA-12)
2 Jumper 1XD-10 to 1XA-12.
3 Observe the Retard Lights on the Axle Box are ON.
4 Observe the Retard Light on the top of the Cab is ON.
5 Observe the Retard Active Indicator is ON.
6 Remove the jumper from step 2.
7 Observe the Retard Lights on the Axle Box are OFF.
8 Observe the Retard Light on the top of the Cab is OFF.
9 Observe the Retard Active Indicator is OFF.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION H: FINAL TRUCK TEST - CONTROL CIRCUIT
TI-2198-A
Date: PAGE 6 OF 11

DUMP TEMPERATURE INPUT

Tool Record: LME#:____________________ Cal. Date:____________________
1 Measure 24 VDC at 1XC-1.
2 Remove the connector (4C57-RED and BLK) from the Dump Temperature Sensor.
3 Measure 0 VDC at 1XC-1.
4 Replace the connector (4C57-RED and BLK) to the Dump Temperature Sensor.

STEERING AND BRAKE TEMPERATURE INPUT

Tool Record: LME#:____________________ Cal. Date:____________________
1 Measure 24 VDC at 1XC-2.
2 Remove the connector (4C57-BLU and ORG) from the Steering and Brake Temperature Sensor.
3 Measure 0 VDC at 1XC-2.
4 Replace the connector (4C57-BLU and ORG) to the Steering and Brake Temperature Sensor.

MAIN BLOWER STATUS INPUT (INSIDE AXLE BOX)

Tool Record: LME#:____________________ Cal. Date:____________________
1 Jumper TB 31-S to TB 30-N.
2 Measure 24 VDC at 1XD-13
3 Remove the jumper from TB 31-S to TB 30-N.
4 Measure 0 VDC at 1XD-13.

AUTO LUBE PRESSURE INPUT (INSIDE THE AXLE BOX)

5 Remove connector at Autolube Pressure Switch and place a jumper between pin 1 and pin 2 of cable side.
6 Measure 24 VDC at 1XC-14.
7 Remove the jumper from step 1 and reinstall the connector.
8 Measure 0 VDC at 1XC-14.

AXLE BOX TEMPERATURE INPUT (INSIDE AXLE BOX)

9 Jumper TB 30-C to TB 30-A.

10 Measure 24 VDC at 1XB-14.
11 Remove the jumper from TB 30-C to TB 30-A.
12 Measure 0 VDC at 1XB-14.

AXLE BOX WORK LIGHTS (INSIDE AXLE BOX)

13 Verify axle box work light operation with the light switch in the axle box.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION H: FINAL TRUCK TEST - CONTROL CIRCUIT
TI-2198-A
Date: PAGE 7 OF 11

SIEMENS TCU POWER INPUT

Tool Record: LME#:____________________ Cal. Date:____________________
1 Measure 24VDC between 1XF-1 and 1XF-2.
2 Measure 24VDC between 1XF-3 and 1XF-4.
3 Measure 24VDC between 1XF-5 and 1XF-9.
4 Measure 24VDC between 1XF-6 and 1XF-10.
5 Measure 0VDC between 1XF-1 and 1XF-3.
6 Measure 0VDC between 1XF-2 and 1XF-4.
7 Measure 0VDC between 1XF-5 and 1XF-6.
8 Measure 0VDC between 1XF-9 and 1XF-10.

PT 100 RESISTANCE CHECK

Tool Record: LME#:____________________ Cal. Date:____________________
1 Measure approximately 100 Ω between 1XH-4 and 1XH-5 (ALT - RTD).
2 Measure approximately 100 Ω between 1XH-5 and 1XH-6 (ALT - RTD).
3 Measure approximately 100 Ω between 1XH-6 and 1XH-7 (ALT - RTD).
4 Measure approximately 100 Ω between 1XM-6 and 1XM-7 (WM B).

SHIFT SELECTOR - FORWARD INPUT

Tool Record: LME#:____________________ Cal. Date:____________________
1 Move the Shift Selector to the FORWARD position.
2 Measure 24VDC at 1XA-11.
3 Measure 0VDC at 1XA-12.
4 Measure 0VDC at 1XA-13.

SHIFT SELECTOR - NEUTRAL INPUT

Tool Record: LME#:____________________ Cal. Date:____________________
1 Move the Shift Selector to the NEUTRAL position.
2 Measure 0 VDC at 1XA-11
3 Measure 24VDC at 1XA-12.
4 Measure 0VDC at 1XA-13.

SHIFT SELECTOR - REVERSE INPUT

Tool Record: LME#:____________________ Cal. Date:____________________
1 Move the Shift Selector to the REVERSE position.
2 Measure 0VDC at 1XA-11.
3 Measure 0VDC at 1XA-12
4 Measure 24VDC at 1XA-13

DRIVE SYSTEM FAULT

1 Jumper 1XF-3 to 1XE-2.

2 Observe Drive System Fault Indicator is ON
3 Remove the jumper.
4 Observe Drive System Fault Indicator is OFF.

EMERGENCY STOP JUMPER

Tool Record: LME#:____________________ Cal. Date:____________________
1 Measure 0 Ω between 1XD-11 and 1XD-12.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION H: FINAL TRUCK TEST - CONTROL CIRCUIT
TI-2198-A
Date: PAGE 8 OF 11

SIEMENS BUZZER

1 Jumper 1XA-8 to 1XE-1.

2 Observe the Siemens Buzzer is ON.
3 Remove the jumper from 1XA-8 and 1XE-1.
4 Observe the Siemens Buzzer is OFF.

FAULT RESET
Tool Record: LME#:____________________ Cal. Date:____________________
1 Measure 0VDC at 1XA-2.
2 Move the Fault Reset Switch to the ON position and HOLD.
3 Measure 24VDC at 1XA-2.
4 Release the Fault Reset Switch.
5 Measure 0VDC at 1XA-2.

DATA STORE INPUT

Tool Record: LME#:____________________ Cal. Date:____________________
1 Move the Data Store Switch to the ON position and HOLD.
2 Measure 24 VDC at 1XA-10.
3 Release the Data Store Switch.
4 Measure 0 VDC at 1XA-10.

CRUISE ENABLE/UP/DOWN
Tool Record: LME#:____________________ Cal. Date:____________________
1 Press the Cruise Enable Switch .
2 Measure 24VDC at 1XA-14.
3 Release the Cruise Enable Switch.
4 Measure 0VDC at 1XA-14.
5 Move the Cruise Adjust Switch to the INCREASE position (UP) and HOLD.
6 Measure 24VDC at 1XA-15.
7 Measure 0VDC at 1XA-16.
8 Move the Cruise Adjust Switch to the DECREASE position (DOWN) and HOLD.
9 Measure 0VDC at 1XA-15.
10 Measure 24VDC at 1XA-16.
11 Release the Cruise Adjust Switch.

STEERING ANGLE
Tool Record: LME#:____________________ Cal. Date:____________________
1 Verify the front wheels are straight.
2 Measure approximately 5VDC at 1XB-5. Steering Test to be completed in Section N.

JOYSTICK DUMP BODY OVERRIDE SWITCH INPUT

Tool Record: LME#:____________________ Cal. Date:____________________
1 Depress the Joystick Dump Body Override Switch.
2 Measure 24 VDC at 1XA-6.
3 Release the Joystick Dump Body Override Switch.
4 Measure 0 VDC at 1XA-6.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION H: FINAL TRUCK TEST - CONTROL CIRCUIT
TI-2198-A
Date: PAGE 9 OF 11

DUMPBODY UP INPUT
Tool Record: LME#:____________________ Cal. Date:____________________
1 Place a piece of metal in front of the Dump Body Proximity Switch.
2 Measure 24 VDC at 1XA-3.
3 Remove the piece of metal in front of the Dump Body Proximity Switch.
4 Measure 0 VDC at 1XA-3.

LOAD STATUS INPUT

Tool Record: LME#:____________________ Cal. Date:____________________
1 Measure 24 VDC at 1XA-7.
2 Remove the TAN wire from TB4-L.
3 Measure 0 VDC at 1XA-7.
4 Reconnect the TAN wire to TB4-L.

FUEL LEVEL
Tool Record: LME#:____________________ Cal. Date:____________________
1 Measure 3 to 10 VDC at 1XC-8. REFERENCE: (Empty = 0VDC, Full = 10VDC, Half = 5VDC)
2 Verify the Fuel Gauge in the Central Service Box corresponds to the reading found in step 1.
3 Verify the voltage corresponds to the actual amount of fuel in the tank.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION H: FINAL TRUCK TEST - CONTROL CIRCUIT
TI-2198-A
Date: PAGE 10 OF 11

GEAR OIL COOLING

(SKIP THIS, IF REAR WHEEL MOTORS ARE NOT MOUNTED)

1 Using the Laptop Computer, start the Ecolites Program.

2 Under File select Open and select the Unified Version CR0020 under Projects folder.
3 Go to ONLINE and select LOGIN.
4 If it does not login check the Communications selection under ONLINE, should be 9600 baud.
5 Go to ONLINE and select LOGIN again it should compile and start to RUN.
6 Go to the Visualizations tab at the bottom of the left hand screen.
7 Select the Module Configuration tab.
8 Using the mouse select the following tabs on the right hand side of the screen:
9 AUTOLUBE DISABLED IN NEUTRAL
10 BATTERY MAINTENANCE INDICATOR LOGIC ENABLED
11 PROPULSION LOCKOUT ENABLED
12 SAFETY SELECT FOR PARK BRAKE RELEASE
13 PARK BRAKE CAB LIGHT
14 GEAR OIL TEMPERATURE MONITORING ENABLED
15 Select the u Control Thermo Couple Module tab.
16 A yellow bordered screen should appear to the left labeled uControled Thermocouple Module Node 8.
17 Turn all four Channels ON using the mouse and clinking on the the four bottom channel selections.
18 All four channels at the bottom of this screen should show a temperature reading, if not troubleshoot
the system until you get a reading for all four, (the light in the Can Bus in the Axle Box should have a
GREEN light. If the light is not GREEN check all wiring to make sure the Can Bus is wired
according to the schematic.
19 When the Can Bus is working record the reading for each channel.
20 CHANNEL 1 reading:____________________
21 CHANNEL 2 reading:____________________
22 CHANNEL 3 reading:____________________
23 CHANNEL 4 reading:____________________

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION H: FINAL TRUCK TEST - CONTROL CIRCUIT
TI-2198-A
Date: PAGE 11 OF 11

START STRING
Tool Record: LME#:____________________ Cal. Date:____________________
Optional steps are in italic font. Enter "NA" for all optional steps that do not apply to test.

1 Disconnect 2C60-BLK and 2C60 WHT inside the Power Distribution box.
2 Connect X1(MDEC) to the ECU.
3 Turn the Park Brake Switch to the ON position.
4 Verify that the Shift Selector is in the NEUTRAL position.
5 Pull both the Cab and Bumper Engine Shutdown Switches OUT
6 Turn the Master Switch to the ON position.
7 Measure 0 VDC between 2C60-BLK and 2C60-WHT inside the Power Distribution box
8 Open the two Hydraulic Valves.
9 Observe the Hydraulic Valve Proximity Switch Indicators are ON.
10 Observe the Hydraulic Valve Indicator on the dash is OFF.
11 Turn the Master Switch to the START position and HOLD.
12 Measure 24 VDC between 2C60-BLK and 2C60-WHT inside the Power Distribution box.
13 Turn the Park Brake Switch to the OFF position.
14 Measure 0 VDC between 2C60-BLK and 2C60 WHT inside the Power Distribution box.
15 Turn the Park Brake Switch to the ON position.
16 Push the Engine Shutdown Switch in the cab IN.
17 Measure 0 VDC between 2C60-BLK and 2C60 WHT inside the Power Distribution box.
18 Pull the Engine Shutdown Switch in the cab OUT.
19 Push the Engine Shutdown Switch in the bumper IN.
20 Observe the light on the Bumper Engine shutdown switch is ON.
21 Measure 0 VDC between 2C60-BLK and 2C60 WHT inside the Power Distribution box
22 Pull the Engine Shutdown Switch in the bumper OUT.
23 Observe the light on the Engine Shutdown Switch in the bumper is OFF.
24 Measure 24 VDC between 2C60-BLK and 2C60-WHT inside the Power Distribution box.
25 Release the Master Switch.
26 Reconnect 2C60-BLK and 2C60-WHT.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/ TOC
Model: T 282B
S/N: SECTION J: SERVICE SHEET
TI-2198-A
Date: PAGE 1 OF 1

POWER MODULE

1 Fill the engine crankcase. Filled by:

2 Fill the radiator. Filled by:
Verify that the following belts are tight:
3 Radiator fan Checked by:
4 Air conditioner Checked by:
Check the following air intakes (left and right ) for debris:
5 Turbo Chargers Checked by:
6 Air Cleaners Checked by:
7 Air Cleaner Pipes Checked by:
Check the following for tight elbow clamps and proper support ( left and right ) for debris:
8 Air Cleaners Checked by:
9 Pipes Checked by:
10 Verify the T-Bolt clamps & plugs on the radiator Checked by:
pipes are tight.

FRAME COMPONENTS
Tool Record: LME#:____________________ Cal. Date:____________________
1 Fill the Hydraulic tank. Filled by:
2 Fill the Steering reservoir. Filled by:
3 * Fill the Front Suspension Oil per Liebherr spec. Filled by:
Nitrogen PSI
4 * Fill the Rear Suspension Oil per Liebherr spec. Filled by:
Nitrogen PSI
Charge the following accumulators:
5 Front Brakes (1800 PSI) Nitrogen PSI
6 Rear Brakes (1800 PSI) Nitrogen PSI
7 Brake and Steering Pump Unloader (1800 PSI) Nitrogen PSI
8 Steering (1700 PSI) Nitrogen PSI
Charged by:
9 Fill the Lube system. Filled by:
10 Prime the Lube System. Completed By:
11 Verify the Lube Injectors are preset. Completed By:
12 Verify that grease is reaching all lube points; Checked by:
steering tie rod ends, idler arm bearings, front
control arms, kingpins, rear control arm, drag
links, suspensions, dump cylinders, etc.
13 * Fill both Wheel Motor Gear Sets with the Filled by:
specified oil (two places each).
14 Fill the Fuel Tanks. Filled by:
15 Prime the Fuel Lines and Filters. By:
Check the Front Wheels Oil level:
16 * Left Filled by:
17 * Right Filled by:

* These items are done at the mine site, not production line.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/ TOC
Model: T282B
S/N: SECTION K: ENGINE START UP
TI-2198-A
Date: PAGE 1 OF 2

PRE-START CHECK

ASSY SPVSR
MECHANICAL PRE-START CHECKS
INITIALS INITIALS
1 Verify the Service Sheet is complete. Verify the fluid levels are acceptable.
a. Engine oil
b. Radiator water level
c. Brake and Steering System Tank
d. Dump System tank
e. Fuel tank.
2 Verify all of the following valves are OPEN.
a. Brake and Steering Shut-off Valve.
b. Fuel Shut-off Valve.
c. Dump System Suction Valve.
3 Check for leaks.
4 Turn the Relief Valve screw adjuster of the Brake and Steering Manifold OUTWARD CCW completely..

HYDRAULIC PRESSURE CHECKS

ASSY
Install a 5000 PSI gauge (unless otherwise noted) at each test point listed below: INITIALS
1 "P" port of Flow Amplifier
2 G-4 (Brake and Steering System)
3 G-5 (Park Brake)
4 GPA (Valve Plate of Oilgear Brake and Steering Pump)
5 GB1 (Front Brake on the Cross Member)
6 SVB (Rear Brake on the outside of the Axle Box.)
7 Left Inlet Test Port Dump Valve
8 Right Inlet Test Port Dump Valve
9 PG (Brake and Steering System Pressure)
10 PG1 (Dump System Raise Pilot Pressure)(Gauge should be 1000 psi)
11 PG2 (Dump System Lower Pilot Pressure)(Gauge should be 1000 psi)
12 Open the pressure filter bleed plug on top of the Steering and Brake Filter
until oil flows out and tighten.
13 Crank the Engine over 3 times without starting to circulate the oil.

Tool Records:
LME #
Calibration Date

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION K: ENGINE START UP
TI-2198-A
Date: PAGE 2 OF 2
ASSY
ELECTRICAL PRE-START CHECKS
INITIALS
1 Observe all the Engine Cables are Connected.
2 Observe all the Junction Boxes are Covered.
3 Observe all Power cables going to the Control box are disconnected.
4 Observe A & B Connectors at the back of the Cab is covered.
5 Observe inside the Cab and the Superstructure are Clean.
6 Observe the Axle Box is clean and free of debris.
7 Observe the Alternator is clean and free of debris.
8 Observe the Superstructure is clean and free of debris.
9 Observe all junction boxes are clean and free of debris.
10 Observe there are no ladders underneath the truck.

ENGINE START

ASSY
INITIALS
1 Honk the Horn once.
2 Clear all personnel from underneath the Truck.
3 Turn key to the start position and hold.
The Prelube pump will run to build engine oil pressure, and stop.
Next the Prelube pump will activate the engine starter solenoids to crank the engine.
The engine will start.
Release key when engine runs smooth.
4 Check the pressure at G-4 on the Hydraulic Manifold and the Dump Valve.
Pressure should not meet or exceed 500 PSI.
5 Check for noise, leaks and excessive heat at the Hydraulic Tank, Lines and Valves.
6 Allow engine to idle for 15 minutes.
NOTE: AFTER 10 MINUTES OPEN THE FUEL CROSSOVER VALVE.

Rev. 8 CRC 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/ TOC
Model: T282B
S/N: SECTION L: HYDRAULIC SYSTEMS TEST
TI-2198-A
Date: PAGE 1 OF 5

Notes:

1 All pressures should be set to an accuracy of ± 50 psi (3.4 bar), unless otherwise noted.
2 See document TI-2249BC (T282B Hydraulic Test Procedure Locations) for locations of test ports, and components,
which are mentioned in this procedure.
3 See TI-2249BC to determine if truck is equipped with new Hand Brake Manifold Assembly.
4 For trucks equipped with the older Hand Brake Valve, GB1 should be 2880 - 3000 psi (198.6 - 206.8 bar) and SVB
should be 2000 psi (137.9 bar).
5 Note that if the truck is equipped with the new Hand Brake Manifold Assembly, and the correct pressures are not seen
at GB1, and SVB, it will be nessecary to adjust the Pressure Reducing Valve of the Hand Brake Manifold Assembly.
6 For optimum performance, ensure that the main relief valve of the brake and steering manifold is set no less than
300 psi (20.7 bar) higher than the unloader valve of either brake and steering pump.

VERIFICATION OF GEAR OIL COOLING LINES ROUTING (REFER TO GEAR OIL COOLING FRAME ASSY)

ASSY
INITIALS
1 Verify that the suction line for the Left Final Drive Pump is connected to the Right side of the axle box as shown on
the drawing listed above.
2 Verify that this suction line crosses over to the Left Final Drive Assemby inside the axle box.
3 Disconnect the discharge line of the Left Final Drive Pump. Install a plug, which had been drilled, and tapped for
NPTF threads. Install an air quick disconnect coupling in the NPTF port of the hose plug.
4 Disconnect the return line, which connects to the Left Final Drive Assembly inside the axle box.
5 Connect the air quick disconnect coupling to a compressed air source.
6 Verify that air comes out the disconnected return line for the Left Final Drive Assembly.
7 Return both lines to their previous state as listed in the drawing above.
8 Repeat steps 1 through 7 changing all occurances of "Left" to "Right", and vice versa.
9 Mark any lines, which will be disconnected for shipment of the truck. This will ensure they are re-connected
correctly when the truck is erected in the field.

Note: This section can be ommited by Newport News Manufacturing only for the instance where the
power module is shipped separate from the chassis.

CENTERING TIRES FOR STEERING ENCODER TEST

Verify the front truck tires are facing straight forward and centered.
STEERING ENCODER TEST

SIEMENS STEERING VOLTAGE MEASURED AT

STEERING WHEEL ROTATION
PERCENTAGE (%) STEERING ENCODER (VDC)

FULL LEFT
CENTER
FULL RIGHT

Connect the computer to the Siemens communication port on the dash. After opening the Monitor program
version 2.40 and making sure you have communication, select from the pull down menu APPLICATION-
OBSERVER and press ENTER. It will prompt you to enter CON

Rev. 8 MKY 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION L: HYDRAULIC SYSTEMS TEST
TI-2198-A
Date: PAGE 2 OF 5

BRAKE & STEERING PUMP PRESSURE SETTING PROCEDURE, SINGLE OILGEAR PVG 130 PUMP

ASSY
INITIALS
1 Verify that the 15 minute warm up of the truck is complete.
2 Verify the Relief Valve Screw Adjuster is turned OUTWARD CCW completely.
3 Turn in the unloader and pressure compensator adjusters of the Oilgear pump all the way in CW.
4 Turn the Relief Valve Screw Adjuster INWARD CW until the pressure at G-4 reads 4000 psi (276 bar).
5 Turn the unloader adjuster of the Oilgear pump all the way out CCW.
6 Relieve pressure at G-4 by engaging the manual override button of the steering accumulator valve (SV1).
7 Turn the unloader adjuster of the Oilgear pump in CW until you hear the pump come on stroke.
The gauge at GPA will stop at the current setting of the unloader valve. Approx. 1/4 turn = 200 psi (13.8 bar)
8 Repeat step 6 until 3200 psi (220.6 bar) is seen at GPA when pump comes back off stroke. Compare pressure seen
at GPA with pressure at G4. In most cases gauges should show the same value for the instant of time when the
pump comes OFF stroke. If this is not the case, set pump to come off stroke when G4 is at 3200 psi (220.6 bar).
9 If the unloader adjuster is turned in too far, it may be necessary to have the operator steer a little after turning
the unloader adjuster back CCW. This will make the pump come back on stroke thereby allowing one to
see the current setting of the unloader valve.
10 Read and Record outlet pressures at GPA port of pump at high and low end of cycle.
GPA, Pump psi Acceptable range is 3200 +/- 50 psi
(instant of time before pump comes off stroke)
GPA, Pump OFF stroke psi Acceptable range is 0 to 200 psi
11 Although cycle time from "pump on stroke" to "pump off stroke" will vary from truck to truck and also from one
cycle to the next, all pumps should remain "off stroke" a significant amount of time, while truck is at idle. This
time period should be greater than or equal to 20 seconds.
Actual Cycle Time Seconds

Tool Records:
LME #
Calibration Date

BRAKE & STEERING PUMP PRESSURE SETTING PROCEDURE, DUAL OILGEAR PVG 65 PUMPS

ASSY
INITIALS
1 Turn in both pressure compensator adjusters of the Oilgear pumps all the way in CW, and lock down.
2 Turn in both unloader adjusters of the external unloader valves all the way in CW.
3 Turn the Relief Valve Screw Adjuster OUTWARD CCW completely.
4 Start the truck up, and complete the 15 minute warm up, as listed in Section K.
5 Turn the Relief Valve Screw Adjuster INWARD CW until the pressure at G-4 reads 3500 psi (241 bar).
6 Tighten the lock nut of the Relief Valve Screw Adjuster.
7 Turn the unloader adjusters of the external unloader valves all the way out CCW.
8 Relieve pressure at G-4 by engaging the manual override button of the steering accumulator valve (SV1).
Allow prressure to drop to 2800 psi (193.1 bar), and close valve.
9 Turn the unloader adjuster of the drivers side external unloader valve in CW, until 3000 psi (206.8 bar) is seen at Gpa1.
10 Turn the unloader adjuster of the off drivers side external unloader valve in CW, until 3200 psi (220.6 bar) is seen at Gpa2.
11 Gpa1, and Gpa2 should not be less than 200 psi (13.8 bar) apart, once pressures have been set.
12 Read and record outlet pressures at Gpa2 port of pump at high and low end of the cycle
Gpa2, Pump ON stroke PSI Acceptable range is 3200 +/- 50 psi
(instant of time before pump comes off stroke)
Gpa2, Pump OFF stroke PSI Acceptable range is 0 to 200 psi
13 Although cycle time from "pump on stroke" to "pump off stroke" will vary from truck to truck and also from one
cycle to the next, all pumps should remain "off stroke" a significant amount of time, while truck is at idle. This
time period should be greater than or equal to 20 seconds.
Actual Cycle Time Seconds

Tool Records:
LME #
Calibration Date

Rev. 8 MKY 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION L: HYDRAULIC SYSTEMS TEST
TI-2198-A
Date: PAGE 3 OF 5

DUMP SYSTEM PRESSURE CHECK

ASSY
INITIALS
1 Verify the Shift Lever in the Neutral position.
2 Verify the Park Brake is ON.
3 Verify the Hand Brake is ON.
4 Move the Dump System Joystick backwards to the power up position and HOLD. ‫٭‬
The gauge at PG1 of the dump system actuator should read 400 - 450psi (27.6 - 31.0 bar).
Record the actual reading: psi
5 Move the Dump System Joystick forward to the power down position and HOLD.
Both inlet gauges should read 3000 psi (206.8 bar).
Left Inlet Pressure: psi
Right Inlet Pressure: psi
6 Move the Dump System Joystick to the power down position and HOLD. ‫٭‬
The gauge at PG2 of the dump system actuator should read 400 - 450psi (27.6 - 31.0 bar).
Record the actual reading: psi
7 With the engine at idle the pressure at PG should be 2880 - 3200 psi (198.6 - 220.6 bar).
Record the actual reading: psi
8 With the engine at idle move joystick to the raise position and record Extend & Retract pressures while extending both
stages of the dump cylinder. Note that stage 1 is defined as the large stage and stage 2 is defined as the small stage.
Extend pressure, stage 1 : psi Acceptable range is 200 to 700 psi
Retract pressure, stage 1 : psi See note below
Note: Measurement must be taken @ same time as extend pressure and value must be less than extend pressure.
Extend pressure, stage 2 : psi Acceptable range is 400 to 1100 psi
Retract pressure, stage 2 : psi See note below
Note: Measurement must be taken @ same time as extend pressure and value must be less than extend pressure.
9 With the engine at idle, move joystick to the lower position and record Retract and Extend pressures while retracting
both stages of the dump cylinder.
Retract pressure, stage 1 : psi Acceptable range is 650 to 1400 psi
Extend pressure, stage 1 : psi See note below
Note: Measurement must be taken @ same time as retract pressure and value must be less than retract pressure.
Retract pressure, stage 2 : psi Acceptable range is 3100 to 2800 psi
Extend pressure, stage 2 : psi See note below
Note: Measurement must be taken @ same time as retract pressure and value must be less than retract pressure.

* If the pressure indications at PG1 and PG2 are not 27 to 31 bar (390 to 450 psi), it is necessary to adjust the high range potentiometer of the
dump control lever.

Tool Records:
LME #
Calibration Date

SYSTEM BLEED CHECKS (this section to be completed at the mine site by Liebherr Service)

ASSY
INITIALS Bleed the following systems:
1 Pump the hydraulic brake pedal vigerously for 5 minutes to purge air from the front and rear brake circuit.
2 * Rear Left Park Brake
3 * Rear Right Park Brake
4 Turn the Steering Wheel lock to lock several times until smooth operation is obtained.
* Apply, and release Park Brake 4 times, and visually check to see that discs engage,
and disengage rotor. Bleed Park Brake when truck is erected in the field.

Rev. 8 MKY 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION L: HYDRAULIC SYSTEMS TEST
TI-2198-A
Date: PAGE 4 OF 5

BRAKE AND STEERING PRESSURE TEST

ASSY
INITIALS
1 Confirm system pressure by reading 2880 - 3200 psi (198.6 - 220.6 bar)at G-4 when pump has come off stroke.
2 With gauges at GB1 and SVB, manually apply the service brakes and record pressures. GB1 should measure
2880 - 3000 psi (198.6 - 206.8 bar) and SVB pressure should be 2000 psi (137.9 bar).
3 Record the actual reading at GB1: psi
4 Record the actual reading at SVB: psi
5 With gauges at GB1 and SVB, set the Hand Brake and record the pressures. For trucks equipped with the Hand
Brake Manifold Assembly, GB1 should be 1500 - 2200 psi (103.4 - 151.7 bar)and SVB pressure should be
1000 - 1200 psi (68.9 - 82.7 bar).
See Notes 3, 4, and 5.
6 Record the actual reading at GB1: psi
7 Record the actual reading at SVB: psi
8 With a gauge at PB, move the Park Brake switch to the RELEASE position and record the pressure.
The pressure should be 2880 - 3200 psi (198.6 - 220.6 bar).
Record the actual reading at PB: psi
9 With gauge installed at "P" port of Flow Amplifier and truck at idle, read and record the following pressures:
Wheels forward at idle, Pressure should be less than 1000 psi (69 bar): psi

Steering LEFT with Steering Cylinders BOTTOMED OUT: psi

Pressure should be 3000 psi (207 bar)
Steering RIGHT with Steering Cylinders BOTTOMED OUT: psi
Pressure should be 3000 psi (207 bar)
10 Observe and record time period elapsed from the time at which the steering accumulator starts to bleed off
(after the truck has been shut down) to the time at which Seconds
all pressure is relieved from the circuit. (Max. = 60 s)

Tool Records:
LME #
Calibration Date

AUTOLUBE SYSTEM

1 The SL-V injector’s pins are up at rest and move down under pressure. When they vent, the indicator pin will
move back up. Set all injectors for maximum output, per procedure listed below.
2a Remove plastic cap on bottom of injector.
2b Loosen stop nut and unscrew adjustment screw from body of injector.
2c Screw stop nut to bottom of adjustment screw.
2d Push indicator pin up to make sure that piston is at bottom of stoke.
2e Screw adjustment back into body of injector 5 turns - This will be full output. - (.075 cubic inches)
The indicator pin should be approximately level with the top opening of the adjustment.
2f Each additional turn in would equate to approximately .015 cubic inch decrease in output.
2g Once the adjustment is made. - tighten the stop nut and replace plastic cap.
2 Startup the truck and ensure that the lube pump comes on 5 minutes after startup, and then automatically shuts off.
3 After initial 5 minute cycle (step 2 above), lube pump should come on 20 minutes later.
4 Ensure that once lube pump comes on, all visual indicators of all injectors (except lines which are plugged OFF)
move up inside injectors, and then re-set after pump kicks off.
5 Ensure that the AUTOLUBE alarm in the cab does not come on at any time, and 2500-3000 psi is seen at the
test port on the outside of the Axle Box. This pressure should be checked with the end of line pressure switch connected.
6 Unplug the end of the line pressure switch and verify that 2500-3500 psi is seen at the test port on the outside of the Axle Box.

If the pressure is too high, turn the pressure reducing valve (beside pressure port, and stamped "PR10-32…") of the lube pu

Tool Records:
LME #
Calibration Date

Rev. 8 MKY 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/
Model: T282B
S/N: SECTION L: HYDRAULIC SYSTEMS TEST
TI-2198-A
Date: PAGE 5 OF 5

Brake Drag Notification Feature Test

Brake Drag Fault

Brake Drag Pressure Switches Brake Drag Indicator Output Service Brake Lamp
Pressure at Font Only Flashes Intermittently 1 Flash Intermittently
Pressure at Rear Only Flashes Intermittently 2 Flashes Intermittently
Pressure at Font, and Rear Flashes Intermittently 1 Then 2 Flashes Intermittently

TEST
INITIALS
1 Connect a laptop computer to the truck, which has the latest ECOMAT Program installed.
2 Start the truck with the Park Brake Applied, and the Hand Brake Released.
3 Go to "Module Configuration" within the Ecomat Program, and ensure the correct value is present for
Brake Drag Time Delay. Record this value. seconds Acceptable range is 10 to 15 seconds
4 Go to the "Visualization" application within the ECOMAT Program.
5 Manually apply the Service Brake Pedal, and ensure that the input for "Brake Pedal Prox. Switch" comes on.
6 Release the Service Brake Pedal. A Brake Drag Fault should not be present after the Brake Drag Time Delay has expired.
7 Apply the Hand Brake, and ensure that the input for "Hand Brake Press. Switch" comes on.
8 Release the Hand Brake. A Brake Drag Fault should not be present after the Brake Drag Time Delay has expired.
9 Apply the Retard Pedal, and ensure that the input for "Retard" comes on.
10 Release the Retard Pedal. A Brake Drag Fault should not be present after the Brake Drag Time Delay has expired.
11 Shut the truck down, disconnect the Brake Drag Lines from the Brake Pedal, and connect them to an external pressure
source. Establish, and maintain 25 to 30 psi at both Brake Drag Switches.
12 Repeat steps 2, and 4.
13 Upon successful boot up of the truck computer a Brake Drag Fault should be present.
14 Remove all pressure from both Brake Drag Switches, and ensure that the Brake Drag Fault goes away.
15 Manually apply, and hold down the Service Brake Pedal. While holding down the pedal re-establish, and maintain
25 to 30 psi at both Brake Drag Switches.
16 Release the Service Brake Pedal. A Brake Drag Fault should be present after the Brake Drag Time Delay has expired.
17 Remove all pressure from both Brake Drag Switches, and ensure that the Brake Drag Fault goes away.
18 Apply the Hand Brake. Re-establish, and maintain 25 to 30 psi at both Brake Drag Switches.
19 Release the Hand Brake. A Brake Drag Fault should be present after the Brake Drag Time Delay has expired.
20 Remove all pressure from both Brake Drag Switches, and ensure that the Brake Drag Fault goes away.
21 Manually apply, and hold down the Retard Pedal. While holding down the pedal re-establish, and maintain
25 to 30 psi at both Brake Drag Switches.
22 Release the Retard Pedal. A Brake Drag Fault should be present after the Brake Drag Time Delay has expired.
23 Remove all pressure from both Brake Drag Switches, and ensure that the Brake Drag Fault goes away.
24 Shut the truck down, and re-connect the Brake Drag Lines per the Deck Brake and Steering Assembly Drawing.

GEAR OIL COOLING PRESSURE SETTING PROCEDURE (REFER TO GEAR OIL COOLING FRAME ASSY)
(this section to be completed at the mine site by Liebherr Service)
ASSY
INITIALS
1 Turn the relief valve screw adjusters of both the right, and left gear oil cooling circuits all the way out (CCW).
2 Install pressure gauge (1000 psi / 69.0 bar recommended) in "TP1" test port of left lube oil filter manifold.
3 Start truck up and take engine to full throttle. Turn relief valve screw adjuster in (CW) until 300 psi (20.7 bar)
is seen at "TP1". If 300 psi (20.7 bar) can not be seen at "TP1," it will be nessecary to shut down the truck, and
then cap and plug outlet lines of lube oil filter manifold. It should be noted that the spring range for the relief valve is
150 to 600 psi (10.3 to 41.4 bar).
4 Tighten down jam nut while preventing relief valve screw adjuster from turning. Repeat steps 2 through 4 for right
final drive gear oil circuit.

Rev. 8 MKY 3 Feb 2010

 MJFCIFSS!NJOJOH!FRVJQNFOU!DP/ TOC
Model: T282B
S/N: SECTION M: LOAD BOX TEST AND FINAL CHECKS
TI-2198-A
Date: PAGE 1 OF 1

LOAD BOX PRE-CHECKS

TEST
INITIALS
1 Verify that the hydraulic pressures are set and correct.
2 Verify that deck is free of loose hardware, tools, trash, etc.
3 Verify that Cab panels are all present and secure.
4 Verify that all j-boxes have lids installed.
5 Verify the Main Blower is operational and the direction of airflow is correct.
6 Verify Engine Shutdown Switches are fully functional.
7 Verify the engine is fully functional and does not display any faults.
8 Verify a Fire Extinguisher is present, functional, and fully accessible.
9 Verify all non-essential personnel are clear of the truck.

LOAD BOX TEST NOTES:

COM ENGR TEST

INITIALS INITIALS
The Load Box Test has been completed and verified by:

FINAL CHECKS

TEST
INITIALS
1 Service Brake fully functional and does not generate faults.
2 Hand Brake fully functional and does not generate faults.
3 Park Brake fully functional and does not generate faults.
4 Steering System fully functional and does not generate faults.
5 Dump System fully functional and does not generate faults.
6 Retard System fully functional and does not generate faults.
7 Propulsion System fully functional and does not generate faults.
8 Drive System fully functional and does not generate faults.

ASSY TEST
INITIALS INITIALS
ALL SECTIONS OF THE TI-2198-A TEST PROCEDURE HAVE BEEN COMPLETED AND VERIFIED BY :

Rev. 8 CRC 3 Feb 2010