CEAW001400

REMOTE-MANAGEMENT SYSTEM

FIELD ASSEMBLY MANUAL

for

GD530 / GD650 / GD670 Motor Grader

March 2001 Copyright 2001 Komatsu

DataKom Publishing Corporation
INSTALLATION

12 TABLE OF APPLICABLE MACHINES

Model S/N and up

GD530A-2A/AW-2A 202002
GD530A-2B/AW-2B 202002
GD530A-2C/AW-2C 202727

GD650/670A-2A/AW-2A 202002
GD650/670A-2B/AW-2B 202002
GD650/670A-2C/AW-2C 202727

GD650A/AW-2B 202487
GD650A/AW-2C 202727

GD670A/AW-2B 202487
GD670A/AW-2C 202727

CEAW001400
INSTALLATION

CEAW001400
KOMTRAX Table of Contents

Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PRECAUTIONS PRIOR TO INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PRECAUTIONS FOR INACTIVE MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PROCEDURES FOR STARTING UP INACTIVE MACHINES . . . . . . . . . . . . . . 4
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PARTS EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLING THE CONTROLLER MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . 10
CONTROLLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CONTROLLER AND RELAY TO BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . 12
MODIFICATION AND PREPARATION TO R.H. SIDE CONSOLE . . . . . . . . . . . . . . . 14
REMOVE R.H. AIR DUCT AND COVER PLATE . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVE COVER FOR R.H. SIDE CONSOLE CONTROL PANEL . . . . . . . . . 14
ANTENNA INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DRILLING HOLES IN HOOD FOR INSTALLING ANTENNAS . . . . . . . . . . . . . 16
DRILLING HOLES IN GRILL FOR ANTENNA CABLE CLAMPS . . . . . . . . . . . 18
INSTALLING CLAMPS FOR ROUTING ANTENNA CABLES . . . . . . . . . . . . . . 18
INSTALLING GPS AND COMMUNICATION ANTENNAS . . . . . . . . . . . . . . . . 20
BATTERY DISCONNECT SWITCH CABLE CHANGES . . . . . . . . . . . . . . . . . . . . . . . 22
WIRE HARNESS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
WIRE HARNESS ROUTING AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . 24
at the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CONTROLLER CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
WIRE DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
FINAL ACTIONS BEFORE START UP PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . 32
START UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CONTINUITY TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
CONTROLLER WIRE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
KOMTRAX ACTIVATION FORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
USER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

ceaw001400-toc.fm
KOMTRAX Table of Contents

ceaw001400-toc.fm
INSTALLATION INTRODUCTION

12
INTRODUCTION
★ Be sure to read this manual prior to installation of system.
GENERAL INFORMATION
★ This manual describes the procedures required to install the Komtrax Remote-Management System on a machine. It
includes instructions to install the satellite communications controller, wiring harness, Global Positioning Satellite (GPS)
antenna, communication antenna and other components to operate the system.

1. The following six connections are required to connect the controller to the machine’s electrical system.

P1 Constant Power Source - supplies constant power to the controller even if the machine is shut down. Enables peri-
odic communication with the communication satellite and updating of machine’s location and status.
★ This circuit must be protected by a 10 amp fuse.

G Constant ground - Enables constant power source to function.

C Clock Signal - Enables controller to track machine’s engine hours. (only the hours of the engine running)

S1 Start Signal Interrupt - Used to interrupt the starter signal so that the machine cannot be restarted.

S2 Start Signal Interrupt - Used to interrupt the starter signal so that the machine cannot be restarted.

P2 Switchable Power Source - Supplies power to the start interrupt relay to interrupt starter function. Also used to
locally cancel remote interrupt command. (Goes ON and OFF with the ignition key switch.)
★ This circuit must be protected by a 10 amp fuse.

2. Prior to starting installation, review the parts list to ensure that all of the correct parts are in the installation kit.

3. Register your machine with your dealer.

• A Komtrax Activation form is located in the back of this manual. Please fill out this form and forward it to your
dealer. The information supplied on the application is required to register your machine and controller on the server.
Without the correct information the program will not work correctly.

4. Follow all the Komatsu shop manual procedures and safety precautions for any disassembly and assembly operations
being performed on your machine.

A. Refer to the Komatsu Shop Manual for any detail information of disassembly and assembly, removal and
installation of components that are not covered in this manual.

CEAW001400 1
INSTALLATION GENERAL INFORMATION

12
SAFETY PRECAUTIONS

WARNING! Observe all the safety precautions. Not following these safety precautions may
result in serious injury or equipment damage.

WARNING! Always observe all environmental safety and standards to which the equipment
and maintenance personal are subject to.

WARNING! Consult the appropriate "Shop Manual" and your Komatsu district service man-
ager with any and all questions regarding safety, removal, installation and repair
instructions that may not be contained in this publication.

WARNING! Whenever operating or working on these machines, always be familiar with and
follow the Komatsu safety precautions and procedures as given in the Komatsu
Operation and Maintenance Manual and Shop Manual.

WARNING! Install the controller securely. Poor installation may allow the controller to fall and
cause injury or damage.

WARNING! Do not damage antenna cables or electrical wires during installation. A pinched or
broken wire can cause a short circuit or controller failure or even a fire. A broken
cable can cause communication failure.

WARNING! Do not disassemble, repair or modify the controller. Repairs by unauthorized per-
sons may cause the controller to be inoperable or even start a fire.

WARNING! Only use the orbcomm antenna supplied with the installation kit. Failure to use the
correct antenna may cause the system not to work properly.

WARNING! When reconnecting the batteries be sure the proper connections for the positive
and negative terminals are made. Improper connection may damage the controller
and make it inoperable.

2 CEAW001400
INSTALLATION GENERAL INFORMATION

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PRECAUTIONS PRIOR TO INSTALLATION

WARNING! Do not remove a controller activated for one machine and place it on another
machine without notifying your Komatsu Distributor’s Komtrax Administrator. The
new machine has to be registered or the transmitted information will be logged to
the first machine the controller was on.

NOTE: Komtrax Administrator: A person at the dealership who controls everyday operation of the Komtrax System.

1. You must apply for activation before the installation of the controller or the controller will not be able to communi-
cate with the Komtrax system. The Komtrax Activation form is in the back of this manual. If you have any ques-
tions on the activation process, please contact your Komtrax Administrator.

2. A “Start Up Procedure” must be performed after the controller is installed. This will ensure proper operation. This inspec-
tion is performed outside to ensure unobstructed communication with the satellite. The “Start Up Inspection” starts com-
munication between the controller and the Komtrax system. If a controller is repaired and reinstalled this procedure will
have to be done again.
• The “Start Up Procedure” only needs to be performed once after installation. If the controller is transferred to another
machine, contact the Komtrax Administrator for assistance.

CEAW001400 3
INSTALLATION GENERAL INFORMATION

12
PRECAUTIONS FOR INACTIVE MACHINES

WARNING! Refer to the Komatsu Operation and Maintenance Manual for all other procedures
concerning inactive machine and placing machines in storage.

WARNING! Remove the fuse protecting the Komtrax system to avoid draining the battery
when a machine will be parked or not used for a long period of time or disconnect
the battery.

★ The Komtrax system will use power from the battery even while the machine is not in use. Machines that are going to be
in storage or inactive for a long period of time (two or more weeks) should have the fuse for the Komtrax system
removed, to avoid draining the battery or disconnect the battery.

1. Remove the fuse protecting the Komtrax system and place it in a safe place or disconnect the battery.

2. Place a "reminder tag" on the machine to remind the next start up operator to reinstall the fuse before starting the machine
or reconnect the battery, which ever applies.

PROCEDURES FOR STARTING UP INACTIVE MACHINES

WARNING! Refer to the Komatsu Operation and Maintenance Manual for all other procedures
concerning starting up inactive machines and machines that were in storage.

1. Re-install the komtrax fuse before starting the machine or reconnect the battery, which ever applies.

2. Remove the "reminder tag" and perhaps place it in a safe place to reuse for next time the machine will be inactive for a
long period of time (two weeks or more).

4 CEAW001400
INSTALLATION PARTS LIST

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PARTS LIST
Item Part Number Description Qty. Reference

1 7826-20-1060 Controller (12V) 1

2 7826-20-9100 GPS Antenna 1

3 7826-20-9200 Communication 1
Antenna

4 7826-20-9300 Antenna Cable 1 For communication antenna

5 01580-00806 Nut - M8 4 For mounting the controller

6 01643-30823 Washer - M8 4 For mounting the controller

7 08037-01008 Grommet 1 To protect the GPS antenna

cable

113-06-A0080 Controller Mount- To mount the controller to the

8 1
ing Bracket machine

9 113-06-A0090 Controller Cover 1 To protect the controller

10 01023-10308 Screw M3-8 4 To install the controller cover

11 7826-21-1970 Clip, adhesive 5 To secure antenna cables

CEAW001400 5
INSTALLATION PARTS LIST

Item Part Number Description Qty. Reference

12 08036-01014 Clamp 3 To secure antenna cables.

13 01010-80820 Bolt - M8-20 3 To fasten antenna cable clamp

14 01643-30823 Washer - M8 6 To fasten antenna cable clamp.
15 01580-00806 Nut - M8 3 To fasten antenna cable clamp.

16 569-06-61960 Relay - 24V 1 For start interrupt.

17 01010-80610 Bolt - M6-10 1 To fasten the relay to the controller mtg. bracket.
18 01643-30623 Washer - M6 1 To attach the relay to the controller mtg. bracket.

19 113-06-A170 Harness 1 To connect the controller to the

machine’s electrical system

20 08036-01814 Clamp 2 For wire harness and antenna

cables

21 01010-810201 Bolt M10-20 2 To fasten the wire harness clamps

22 01643-31032 Washer M10 2 To fasten the wire harness clamps
23 113-06-A0460 Boss 1 To fasten the wire harness clamps
24 08034-20519 Nylon tie 15 For wire harness and antenna cables
25 08036-01214 Clamp 1 For wire harness
26 08018-00115 Sleeve Connector 1 For S2 wire lead
27 08033-10440 Heatshrink tubing 1 To protect S2 wire lead connection

113-06-A0410 Cable, battery pos.

28 1 Replacement
to switch

113-06-A0420 Cable switch to

29 1 Replacement
starter pos.
Cable battery neg.
30 1252290H1 1 Replacement
to starer
31 08034-20834 Nylon tie 5 For positive battery cables
32 113-06-A0300 Decal 1 Change of function
33 08041-01000 Fuse, 10A 1 To protect the controller’s electrical circuit

6 CEAW001400
INSTALLATION PARTS EXPLODED VIEW

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PARTS EXPLODED VIEW
Refer to “PARTS LIST” on page 5 for item number call-outs.

CEAW001400 7
INSTALLATION PARTS EXPLODED VIEW

12

MEMORANDA

8 CEAW001400
INSTALLATION PREPARATION

12
PREPARATION
★ Prior to starting any work, get the most up to date information from your Komatsu distributor. He will provide
you with any additions, amendments or changes that have been made.

1. Park the machine on a flat level surface and articulate the machine by turning it to the left to open the area on the right
hand side between the cab and the engine compartment.

2. Lower all work equipment to the ground

3. Shut the engine off and cycle the hydraulic controls to remove any residual hydraulic pressure from the hydraulic circuits.

4. Apply the parking brake fully.

5. Place chocks at the front and rear of all wheels to prevent the machine from moving.

6. Remove the key from the key start switch and keep it in a safe place until the installation is complete. Place a tag on the
steering wheel advising: "Do Not Operate". (The machine should not be started or moved for any reason until this
tag is removed by the person doing the installation)

7. Disconnect the negative (-) cable of the battery.

8. Do not allow unauthorized persons near the machine.

CEAW001400 9
INSTALLATION OVERVIEW

12
OVERVIEW
• The controller will be mounted under the operator’s seat.
• The communication antenna will be mounted on top of the engine hood just behind the cab.
• The GPS antenna will be mounted on top of the engine hood just behind the cab.
• The wire harness will be routed from the controller to the ignition key switch, alternator, and battery disconnect switch.
• The new battery cables will revise the battery disconnect from a negative interrupt to a positive interrupt.

INSTALLING THE CONTROLLER MOUNTING BRACKET

The controller is to be mounted under the operator’s seat between the two seat rails by welding the controller mounting bracket
between the seat rails.

1. Remove the operator’s seat but leave the seat rails in place.

2. Layout and position the controller mounting bracket (item 8) as shown.

(See “Figure 11A Controller Mounting Bracket Location” on page 11)
• The positioning of the mounting bracket is critical in order to fit the controller with it’s cover, so that the diodes can
be seen through the window in the cover when looking behind the operator’s seat and also because the cover has a
groove in the top side of it, which allows it to clear the seat track trip bar, when it is in motion.
• Dimensions 45 mm and 50 mm are from the mounting hole that mounts the seat’s sliding track to the seat deck and
not from the holes on the track that are used for mounting the seat.
(See “Figure 11B Clear the Seat Track” on page 11)

3. The six holes in the controller mounting bracket are for welding it to the seat deck.
A. Clean and prepare the six areas on the platform for welding, by removing paint and debris.

4. Weld the controller mounting bracket to the platform along the perimeter of the six holes as shown.
(See “Figure 11A Controller Mounting Bracket Location” on page 11)

5. Weld (item 23) boss in the position shown (no dimensions are given), this is for mounting the clamp to support the wire
harness coming from the controller.

6. After all the welding has cooled, repaint with matching paint.

10 CEAW001400
INSTALLATION INSTALLING THE CONTROLLER MOUNT-

12

Figure 11A Controller Mounting Bracket Location

Figure 11B Clear the Seat Track

CEAW001400 11
INSTALLATION CONTROLLER INSTALLATION

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CONTROLLER INSTALLATION

CONTROLLER AND RELAY TO BRACKET ASSEMBLY

Refer to “PARTS LIST” on page 5 for item number call-outs.

★ Do not install controller until the controller mounting bracket has been welded in place.
(See “INSTALLING THE CONTROLLER MOUNTING BRACKET” on page 10)

1. Place controller (item 1) over the four studs on the mounting bracket (item 8) with the harness
connections on the controller facing towards the R.H. side of the cab.
(See “Figure 13A Controller and Relay to Bracket Assembly” on page 13)
(See “Figure 13B Controller and Relay to Bracket Assembly” on page 13)

A. Assemble clamp (item 20) to the right rear controller mounting stud on top of the control-
ler mounting foot and fasten loosely with nut (item 5) and washer (item 6). Do not tighten
until the wire harness and antenna cables are routed through the clamp.
B. Fasten securely the remaining three controller mounts with nuts (item 5) and washers
(item 6).

2. Assemble clamp (item 20) to the welded boss (item 23) loosely, with bolt (item 21) and washer
(item 22). Do not tighten until the wire harness and antenna cables are routed through the
clamp.
(See “Figure 13A Controller and Relay to Bracket Assembly” on page 13)

3. Fasten securely the relay (item 16) onto the mounting bracket (item 8) with bolt (item 17) and
washer (item 18).
(See “Figure 13A Controller and Relay to Bracket Assembly” on page 13)

12 CEAW001400
INSTALLATION CONTROLLER INSTALLATION

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Figure 13A Controller and Relay to Bracket Assembly

Figure 13B Controller and Relay to Bracket Assembly

CEAW001400 13
INSTALLATION MODIFICATION AND PREPARATION TO R.H.

12
MODIFICATION AND PREPARATION TO R.H. SIDE CONSOLE

REMOVE R.H. AIR DUCT AND COVER PLATE

• You will need to gain access under the floor behind the R.H. Side Console to route the wire harness leads C, G and P1 and
antenna cables out of the cab and to route wire leads S1, S2 and P2 to the R.H. Side Console Control Panel.

1. Remove the R.H. air duct and cover plate as shown.

(See “Figure 15A Air Duct and Cover Plate Removal” on page 15)

REMOVE COVER FOR R.H. SIDE CONSOLE CONTROL PANEL

• You will need to gain access to the inside of the R.H. side console to make wire connections to the back of the ignition key
switch and start button switch and for routing the wire harness.

1. Remove the cover on the R.H. side console.

(See “Figure 15B R.H. Side Console Cover Removal” on page 15)

2. Carefully lift out the control panel that has the ignition key switch and turn it over without pulling any wires loose and
place it in a position where it will be easiest for making the wire connections to the back of the ignition key switch.
(See “Figure 15C Back of Control Panel” on page 15)

14 CEAW001400
INSTALLATION MODIFICATION AND PREPARATION TO R.H.

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Figure 15A Air Duct and Cover Plate Removal

Figure 15B R.H. Side Console Cover Removal

Figure 15C Back of Control Panel

CEAW001400 15
INSTALLATION ANTENNA INSTALLATIONS

12
ANTENNA INSTALLATIONS
Refer to “PARTS LIST” on page 5 for item number call-outs.

DRILLING HOLES IN HOOD FOR INSTALLING ANTENNAS

WARNING! Do not install communication antenna closer than

500mm to a radio antenna or interference may occur.

WARNING! Do not drill through any studs or wires.

WARNING! There must not be any obstruction between the GPS satellite and the GPS antenna
in order for the controller to receive signals from the GPS satellite.

(See “Figure 17A Drill Hole Locations on Hood for GPS and Communication Antennas” on page 17)

• Two holes are required in the hood, one is for mounting the communication antenna and the
other is for routing the GPS antenna cable.

NOTE: A 15 mm hole is required for mounting the commutation antenna.

A 17 mm hole is required for the grommet to protect the GPS antenna cable.

1. Drill a 15 mm dia. hole through the hood using the 70 mm and 120 mm dimension as shown.

2. Drill a 17 mm dia. hole through the hood using the 100 mm and 120 mm dimensions as shown.

3. For general safety precautions de burr the holes of any sharp edges.

4. Install grommet (item 7) into the 17 mm hole.

16 CEAW001400
INSTALLATION ANTENNA INSTALLATIONS

Figure 17A Drill Hole Locations on Hood for GPS and Communication Antennas

CEAW001400 17
INSTALLATION ANTENNA INSTALLATIONS

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DRILLING HOLES IN GRILL FOR ANTENNA CABLE CLAMPS
(See “Figure 19A Antenna Cable Clamp Mounting Holes” on page 19)

• Three holes are required in the grill, for mounting clamps (item12). The three clamps will support the antenna cables, that
are being routed to the controller.

1. Remove the R.H. grill and drill a 25 mm dia. clearance hole for the center clamp mounting bolt as shown.

2. Drill three 10 mm dia. holes in the grill mounting U-post at locations as shown.
★ Be sure the location of the center hole is the same location as the 25 mm clearance hole.

INSTALLING CLAMPS FOR ROUTING ANTENNA CABLES

(See “Figure 19A Antenna Cable Clamp Mounting Holes” on page 19)
(See “Figure 19B Mounting Cable Clamps” on page 19)

1. Install the 3 clamps (item 12) inside the U-channel post to the three new drilled holes as
shown.

2. Position the clamps to allow the GPS and communication antenna cables to be routed through
them and fasten loosely using 3 bolts (item 13), 6 washers (item 14) and 3 nuts (item 15).

18 CEAW001400
INSTALLATION ANTENNA INSTALLATIONS

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Figure 19A Antenna Cable Clamp Mounting Holes

Figure 19B Mounting Cable Clamps

CEAW001400 19
INSTALLATION ANTENNA INSTALLATIONS

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INSTALLING GPS AND COMMUNICATION ANTENNAS
• The GPS antenna has a magnetic bottom and can be placed on the hood and the cable must be routed to the controller.
• The communication antenna will be mounted on the hood to the communication antenna cable and routed to the control-
ler.
(See “Figure 21A Routing Antenna Cables” on page 21)

1. Place the GPS antenna (item 2) on the hood, somewhere near the 17 mm hole and route the
cable down through the grommet (item 7) (leave the cable hanging until the communication
antenna is installed).

2. Insert the communication antenna cable (item 4) (the end that attaches to the antenna) from
underneath the hood up through the 15 mm hole in the hood and attach with bulkhead nut sup-
plied with the cable then assemble the communication antenna (item 3) to it.

3. Route both the GPS antenna cable (item 2) and the communication antenna cable (item 4)
together down through the three clamps (item 12) in the front center U-post of the grill and
secure clamps in place.

4. Route both cables under the grill and across the center hinge along side the throttle cable.

5. Then up through the bottom of the cab behind the R.H. console corner plate.

6. Then through clamp (item 20) on the welded boss and through clamp (item 20) on the control-
ler right rear mount. Do not fasten clamps securely until the wire harness has been routed along
with it.

7. Connect both antenna cables to the controller as shown.

20 CEAW001400
INSTALLATION ANTENNA INSTALLATIONS

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Figure 21A Routing Antenna Cables

CEAW001400 21
INSTALLATION BATTERY DISCONNECT SWITCH CABLE

12
BATTERY DISCONNECT SWITCH CABLE CHANGES
• This machines has a battery disconnect switch that interrupts the negative to ground cable, which leads from the battery to
the metal frame of the machine.
• If the disconnect switch interrupts the negative ground then the controller could get damaged from a high voltage surge.
The controller and the communication antenna are grounded to the frame. If someone tried to start the machine when the
disconnect switch was positioned to interrupt the negative ground, then too much current would pass through the control-
ler and the controller harness. Ether one or both could get damaged.

WARNING! To protect the controller from any high voltage damage, revise the cable leads from the battery
so the disconnect switch will interrupt the positive cable lead.

★ The following cable changes are required in order to make the disconnect switch interrupt the positive wire lead between
the battery and the starter instead of interrupting the negative to ground cable lead.
Refer to “PARTS LIST” on page 5 for item number call-outs.

(See “Figure 23A Battery Disconnect Switch Cable Changes” on page 23)

1. Remove existing battery cables

i. between the disconnect switch and the starter.
ii. between the disconnect switch and the battery.
iii. between the battery positive post and starter.

2. Install cable (item 28) to go from the battery positive post to the disconnect switch.
A. Secure cable routing with nylon ties (item 31).

3. Install cable (item 29) to go from the disconnect switch to the positive terminal on the starter.

4. Install cable (item 30) to go from the battery negative post to the ground terminal on the starter.

5. Install master electrical shut -off decal (item 32) on the inside panel of the access door to the battery disconnect switch.

22 CEAW001400
INSTALLATION BATTERY DISCONNECT SWITCH CABLE

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Figure 23A Battery Disconnect Switch Cable Changes

CEAW001400 23
INSTALLATION WIRE HARNESS INSTALLATION

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WIRE HARNESS INSTALLATION

WIRE HARNESS ROUTING AND CONNECTIONS

• The wire harness will be routed from the controller to the key switch and start button switch at the instrument control
panel, then to the alternator and battery disconnect switch.

WARNING! To avoid a possible short circuit or fire, DO NOT allow the wire harness to lay
across or contact anything that may get very hot.

Refer to “PARTS LIST” on page 5 for item number call-outs.

Note: See “GENERAL INFORMATION” on page 1 for the functional description of each wire
lead connection.

AT THE CONTROLLER

1. Route harness (item 19) wire leads P1, G, C, S1, S2 and P2 from the controller to the corner plate in the right rear corner
of the cab.
(See “Figure 25A Under the Corner Plate” on page 25)
★ (Do not connect wire harness to the controller until after the continuity test has been completed.)
A. Secure the wire harness with clamp (item 20) on the controller right rear mount and clamp (item 20) on the welded
boss, along with the GPS and communication antenna cables and 2 nylon ties (item 24) as shown.
(See “Figure 25B Antenna Cables and Wire Harness Routing at the Controller” on page 25)

2. Route wire leads S1, S2 and P2 under the rear wall of the R.H. console then inside the console to the back of the instru-
ment control panel.
(See “Figure 25C S1, S2 and P2 Connections” on page 25)

A. Remove the original start wire lead (start motor signal) from the back of the start button switch.
B. Remove the heat shrink that is covering the ring terminal for the S1 wire lead.
C. Connect S1 (ring terminal) to the post where you removed the original start wire.
D. Connect wire lead S2 and the original start wire together.
i. Cut off the ring terminal on the original start wire and strip the wire to fit sleeve connector (item 26).
ii. Cut off the spade terminal on the S2 wire lead and strip the wire to fit sleeve connector (item 26).
iii. Use sleeve connector (item 26) to connect wire lead S2 and the original start wire together and use heat shrink
tubing (item 27) to seal and protect the connection. (Place the heat shrink tubing over the wires before crimping
the sleeve connector.)
E. Fasten P2 ring terminal unto the ACC post on the back of the ignition key switch.

24 CEAW001400
INSTALLATION WIRE HARNESS INSTALLATION

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Figure 25A Under the Corner Plate

Figure 25B Antenna Cables and Wire Harness Routing at the Controller

Figure 25C S1, S2 and P2 Connections

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INSTALLATION WIRE HARNESS INSTALLATION

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3. Route wire leads P1, G and C through the bottom of the cab.

4. Follow the throttle and antenna cable across the center hinge.
(See “Figure 27A Center Hinge Crossing” on page 27)
A. Secure wire harness to cables with nylon ties (item 24) as shown.

5. Then route across the bottom of the radiator to the R.H. side of the machine.
(See “Figure 27B Route Across Bottom of Radiator” on page 27)
A. Secure wire harness to cables with nylon tie (item 24) as shown.
B. Secure wire harness with clamp (item 25), use existing hardware as shown.

6. Follow the heater hoses along the right side of he engine.

7. Route wire leads C and G to the alternator.

(See “Figure 27C Alternator Connections” on page 27)
A. Connect wire lead C (pin grip terminal) to the signal post.
B. Connect wire lead G (ring terminal) to the ground screw on the alternator.
C. Secure wire harness with nylon tie (item 24) as shown.

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INSTALLATION WIRE HARNESS INSTALLATION

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Figure 27A Center Hinge Crossing

Figure 27B Route Across Bottom of Radiator

Figure 27C Alternator Connections

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INSTALLATION WIRE HARNESS INSTALLATION

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8. Route wire lead P1 along the battery cables to the battery master disconnect switch (if equipped), otherwise to the starter
motor.
(See “Figure 29A Battery Disconnect Switch Connection” on page 29)
A. Secure wire harness to cables with nylon ties (item 24) as shown.
B. Connect the wire lead P1 for the constant power supply to the battery disconnect switch, on the battery side of the
switch (the terminal that has a wire lead going to the battery and not the one that goes to the starter) sharing the same
post and reusing the existing washer and nut.
i. If machine is not equipped with a battery disconnect switch then connect the wire lead P1 for the constant
power supply to the positive terminal on the starter motor.
C. Install fuse (item 33) into the fuse holder on the P1 wire lead.

CONTROLLER CONNECTIONS
Refer to “PARTS LIST” on page 5 for item number call-outs.

(See “Figure 29B Controller Connections A, B and R” on page 29)

1. BEFORE connecting the remaining harness connectors (A, B and R) to the controller, perform the continuity tests steps 1
through 4
See “CONTINUITY TESTS” on page 35.
A. Connect wire harness (item 19) connectors A and B to the controller as shown.
B. Connect wire harness (item 19) connector R to the start interrupt relay (item 16) as shown.

2. Now complete step 5 of the continuity tests.

28 CEAW001400
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Figure 29A Battery Disconnect Switch Connection

Figure 29B Controller Connections A, B and R

CEAW001400 29
INSTALLATION WIRE DIAGRAM

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WIRE DIAGRAM

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INSTALLATION WIRE DIAGRAM

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CIRCUIT DIAGRAM

CEAW001400 31
INSTALLATION FINAL ACTIONS BEFORE START UP PRO-

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FINAL ACTIONS BEFORE START UP PROCEDURES
1. Reinstall the R.H. console instrument control panel.

2. Reinstall operator’s seat

3. Reinstall anything that has been disassembled for this installation.

4. Restore the machine to it’s operational condition.

5. Reconnect the battery.

6. Remove chocks from wheels.

7. Close all compartments

8. Remove safety bar.

9. Remove do not operate tag.

10. Release the parking brake.

11. Drive the machine to an open area outdoors to have unobstructed communication with the satellite.

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START UP PROCEDURE
NOTE: The machine must be outdoors to have unobstructed communication with the satellite

• There are four diode lights that can be seen through the small window of the controller. With the controller installed under
the seat pedestal you may need a mirror placed in front of this window in-order to see these lights.

Light 1- Green Clock, constant ON when engine is running.

Light 2- Red Starter Lockout, ON when starter lockout is ON.

Light 3- Green Communication with satellite. Constant ON when engine is running.

Light 4- Green Holding messages to send at the next communication interval.

Constant ON, when engine is running.
Flashes, when it is holding messages to send.

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INSTALLATION START UP PROCEDURE

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1 Turn the key switch to the START position and hold it there for approximately 1 second
OK If the engine starts and the clock light (#1) is lit-up on the controller.
Go to step 4.
OK If the engine does not start and lockout light (#2) is lit-up on the controller. Go to step 2.
Fix If the engine starts and the clock light (#1) is not lit-up, check connections, then go to step 3.

2 Turn the key switch to the ACC position and hold it there for approximately 1 to 2 seconds (this actuates the controller
set up sequence). Go to step 3.

3 Turn the key switch to the START position and hold it there for approximately 1 second.
OK If the engine starts and the clock light (#1) is lit-up on the controller. Go to step 4.
Fix If the engine does NOT start, check that all connections are correct and retry starting.

4 Turn the engine OFF.

OK If the clock light goes out, inspection complete.
Fix If the clock light stays ON, the controller may be defective. Contact your Operation Administer.

NOTE: If all connections are correct and the problems persist, contact your Operation Administrator.

NOTE: Communication light (#3) should stay on and message light (#4) should flash until controller goes to sleep. Approxi-
mately 4-5 minutes.

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CONTINUITY TESTS
CONTROLLER WIRE HARNESS
NOTE: A test light is required for these tests

Harness CN-A
Perform each test at the wire harness pin location.

WARNING! When reconnecting the batteries be sure the proper connections for the positive
and negative terminals are made. Improper connection may damage the controller
and make it inoperable.

1. Before the wire harness is connected to the controller:

A. Reconnect the battery.
B. Perform the following continuity tests using a test light:

1a At pin 7, check for a constant power supply with the battery disconnect switch in the OFF position.
OK If the test light is ON then go to step 1b
Fix If the test light is OFF, then check for proper connections.
1b At pin 7, check for a constant power supply with the battery disconnect switch in the ON position.
OK If the test light is ON, then go to step 2a
Fix If the test light is OFF, then inspect the fuse in that line and retest.

2a At pin 10 Check for a constant ground with the battery disconnect switch in the OFF position.
OK If the test light is ON then go to step 2b
Fix If the test light is OFF, then inspect the ground connections and retest.
2b At pin 10 Check for a constant ground with the battery disconnect switch in the On position.
OK If the test light is ON then go to step 3
Fix If the test light is OFF, then inspect the ground connections and retest.

3a At pin 3 Check the clock signal wire with the engine OFF
OK If the test light is OFF, then go to step 3b
Fix If the test light is ON then check the connection at signal wire source and retest.
3b At pin 3 Check the clock signal wire with the engine ON
OK If the test light is ON then go to step 4
Fix If the test light is OFF, then inspect the connection at signal wire source and retest.

CEAW001400 35
INSTALLATION CONTINUITY TESTS

4a At pin 4 with the key switch in the OFF position

OK If the test light is OFF, then go to step 4b
Fix If the test light is ON, Check and ensure that the ACC wire is connected correctly.
4b At pin 4 with the key switch in the ACC position
OK If the test light is ON then go to step 4c
Fix If the test light is OFF, then inspect the fuse in that line and retest.
4c At pin 4 with the key switch in the RUN position
OK If the test light is ON then go to step 4d
Fix If the test light is OFF, Check and ensure that the ACC wire is connected correctly.
4d At pin 4 with the key switch in the START position
OK If the test light is ON then go to step 5
Fix If the test light is OFF, Check and ensure that the ACC wire is connected correctly.

2. After all of the above tests have been verified OK then proceed to the controller installation section.

3. After completing controller installation to machine.

• The controller must be mounted to the machine in-order to provide a proper ground.

NOTE: A mirror may be required in-order to see the four diode lights on the controller.
• There are four diode lights that can be seen through the small window on the controller. Now that the controller is
installed you may need a mirror placed in front of this window in-order to perform steps 5a and 5b

NOTE: If a controller has been transferred from another machine or has already been tested, the message light may come on
in step 5b. This is OK and is not a problem with the controller.

5a With the key switch in the OFF position

OK None of the diode lights in the small window on the controller are ON, then go to step 5b
Fix If any of the diode lights are ON, check and ensure that all connection are correct.
5b With the key switch in the RUN position
OK None of the diode lights in the small window on the controller are ON, the test is complete. Proceed to start up procedure
Fix If any of the diode lights are ON, check and ensure that all connection are correct.

4. If all connections are correct and problems persist, contact your Operation Administrator.

36 CEAW001400
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INSTALLATION NOTES

CEAW001400 37
INSTALLATION INSTALLATION NOTES

38 CEAW001400
INSTALLATION KOMTRAX ACTIVATION FORM

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KOMTRAX ACTIVATION FORM
NOTE: This is the form to activate your machine for the Komtrax Remote-Management System.

NOTE: Please ensure all of the information is correct. Wrong information will cause your machine records to be incorrect.

USER
• Fill out the information below.
• Then forward application to your Komtrax Administrator (Dealer).

User Information

Customer
Location
Phone Number
E-mail Address
Note: e-mail address is optional

Machine Information

Manufacturer
Serial Number
Model Number
Hour Meter
Reading

Controller (Terminal) Information

Model Number
Serial Number

Name
Date

CEAW001400 39
INSTALLATION KOMTRAX ACTIVATION FORM

40 CEAW001400
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