Usage:
Introduction
This Special Instruction provides the necessary information to install the cab and chassis portion of the Electronic Unit Injection (EUI) Conversion Package on Mechanical Unit Injection (MUI) 789 Trucks. THIS INSTRUCTION MUST BE KEPT WITH THE TRUCK. The parts and assembly procedure will not be available in any other publication.
The major areas of change are the engine shutdown, ether system, throttle control, cab harness changes and chassis harness changes.
Reference: SEBP1645 789 Truck Parts Manual; SEHS9485 Converting ICM Transmission And Torque Converter Lock-up Controls To Spool-Type Solenoid Valve Group; SMHS8617 Installation Procedure For Transmission Speed Sensor; SEHS9065 Use of CE Connector Tools; SEHS8038 Use of 6V4810 VE Connector Tool Group; SEHS8863 Installation of 8W7507 Off-Highway Truck Engine Overspeed Warning Indicator Group.
NOTE: There are two basic styles of large connectors which may have been used on this truck. These are the CE and VE connectors. The CE connector is the latest connector manufactured by Deutsch®. The VE connector (no longer used) was manufactured by Cannon®. Some trucks may have both style connectors. The tooling used for removing and installing pins and sockets must be designed for that particular connector.
Necessary Parts
Removals
The existing system for ground level shutdown control is mechanically activated through a pull cable located near the front bumper. This governor related system will be replaced by an electronic activated system.
1. Remove the mechanical shut-off group which consists of the following items:
5T4482 Shut-Off Group (Mechanical) Remove All Parts
2. Connected to this group is the Governor Control Group (Chassis) which must be removed.
Remove the following items:
5T1028 Governor Control Group (Chassis) Remove All Parts
3. Some air lines and connections must be removed from the cab.
Remove the following items from the 5T0861 Air Tank Group (Cab) in order to remove the mechanical governor's air tank system:
5T0861 Air Tank Group (Reference Only)
Remove only the items listed in the top chart above labeled "Removal From 5T0861 Air Tank Group (Cab)".
2A6504 Air Tank Group
The group should now resemble 2A6504 Air Tank Group.
4. The Governor Control Group (Cab) group was supplied in two major version.
- * Without elevated low idle.
- * With elevated low idle.
NOTE: Remove the low idle from your truck.
5. WITHOUT elevated low idle - remove all the following items.
5T0853 Governor Control Group Without Elevated Low Idle
6. WITH elevated low idle - Remove the following items.
5T0853 Governor Control Group With Elevated Low Idle
NOTE: The elimination of the small air tank also dictates that changes be made to the control group-brake (service) (cab).
7. Remove the following items.
5T0851 Control Group - Service Brake
8. Install the following items, using the 2A6499 Service Brake Control Group as an installation guide.
- * 1-4S7572 Hose Assembly
- * 1-8X8579 Plate Assembly (Resembles 5T3031 Plate Assembly)
- * 1-8X7797 Gasket
- * 4-5M3062 Bolt
- * 4-8T4896 Washer
- * 1-8X8579 Plate Assembly (Resembles 5T3031 Plate Assembly)
2A6499 Page 1 of 2 (Reference Only)
2A6499 Page 2 of 2 (Reference Only)
9. With the removals and additions, the control group (brake) should resemble the 2A6499 Service Brake Control Group shown above.
5T6544 Brake Control Group
10. Connect 4S7527 Hose Assembly (1) of the (5T6544 Brake Control Group) to 4K2986 Anchor Tee (5T0851 Brake Control Group) after removing 2D7325 Tee and 3D6388 Hose Assembly from 5T0853 Governor Control Group (Cab).
11. Trucks with elevated low idle only: Connect 4S7528 Hose Assembly of the (5T0851 Brake Control Group) to 2G8815 Pressure Protection Valve, after removing 2D7325 Tee and 4D6243 Hose Assembly from 5T0853 Governor Control Group (Cab).
Typical Example
Typical Example
12. The pressure protection valve should look like one of the above photographs, depending upon the attachments on the truck and the date of manufacture.
NOTE: Connect all hoses.
Installation of Ground Level Shutdown
NOTE: The EUI ground level shutdown control will be electrical.
The new system will replace the mechancial shutdown shown.
8W0646 Cover
1. Modify the existing 8W0646 Cover to accept the new switch as shown in the illustration above. The vacant hole from the removal of the pull cable may be plugged with a 7P3895 Button.
Typical Example
2. Push the switch lever up to activate the engine shutdown system. The switch is located at the lower left corner of the cowl area.
4D1836 Switch and 3E5169 Guard
7I4821 Harness Assembly
3. Power to the switch will be provided through a harness assembly which connects to a breakout of the EUI engine harness.
5. Connect the shutdown harness to the engine harness. The mating connection must match the wire codings.
6. Weld two 9D5659 Bosses (1) to the front inside LH frame at location (A) and one 9D6166 Boss (2) to the top of the LH frame with a 3 mm (.12 in) fillet weld, ALL AROUND, at location (B) as shown above.
Support Assembly
7. Weld a 4D6293 Boss (3) to the top of the support assembly with a 3 mm (.12 in) fillet weld, both sides, at location (C) to the dimensions shown.
8. Fasten the shutdown harness to the engine front housing and to the new bosses as shown above.
Ether Systems
A new manual ether system has been designed for the 789 EUI engine. Therefore, the old ether system must be removed and the new manual system installed. There may be some items which may be reused. These items will be noted in the parts list.
1051173 New Battery Cable Harness
All 789 with PIN 9ZC440 and up were shipped with the automatic ether system. Some earlier trucks were retrofitted with the auto ether system using Special Instruction SEHS9293. Follow the ether system instructions which correspond to the 9ZC440 and up PIN range.
Check the PIN of your truck and the ether system. If the ether system matches that of the original equipped system, follow the corresponding PIN range instructions.
9ZC1-129 and 133-136
5T0850 Starting Aid Group
Early trucks (9ZC1-129 and 133-136) had a single bottle mounted on the ROPS tube assembly. This single bottle system existed with a single injection port.
1. Remove all existing ether tubing and 5T9417 Battery Cable Harness Assembly.
2. A block must be added to the ROPS tube to support another bottle to update the truck to the EUI requirements.
3. Fasten a 8D8832 Plate at the 830 mm (32.7 in) dimension to the tube with a 3 mm (.12 in) fillet weld at location (B) as shown in the illustration above.
4. Fasten a 3V8988 Bar at the 500 mm (19.7 in) dimension to the tube with a 3 mm (.12 in) fillet weld at location (A) as shown in the illustration above.
5. Install the new 1051173 Battery Cable Harness, following the general path of the old harness. If the truck was equipped with a resistor in line with the disconnect switch, it is no longer needed. Connect the 203-BK wire directly to the battery side of the disconnect switch.
6. Install a 6G8167 Plate Assembly to the existing and newly welded 8D8832 Plates on the ROPS tube assembly. One of these may already be positioned on the original system. (Both need 6G8167 Plate Assemblies).
7. Install the following items.
Ether Aid Group
8. Install a 9X7137 Valve Assembly on the right 6G8167 Plate Assembly. This may be already on the truck.
9. Install the 8X1440 Plate Assembly and 9X7137 Valve Assembly on the left 6G8167 Plate Assembly. Install the resistors and control group as shown in the illustration.
10. Install the 3E5239 Relay on the 3V8988 Bar. Connect the valve assembly, control group, resistors and relay as shown in the illustration above.
11. The remaining tube assemblies and other items may be installed using the illustration shown above as a guide.
NOTE: Adapters on the turbo system may need to be modified or replaced in order to provide correct port locations for the ether tubes.
NOTE: Follow instructions for cab modifications necessary to complete the EUI ether system.
NOTE: If these earlier trucks were modified to use the automatic ether system, they will need to be modified similar to the later trucks where the auto ether system was standard equipment. (See PIN 9ZC440 and above or Special Instruction SEHS9293).
9ZC130-132 and 137-252
These trucks were equipped with two bottles in a manual ether system but major changes must be made in order to provide a compatible ether system with the EUI engine.
8W8157 Starting Aid Group (Original Ether System)
1. Remove all existing ether tubing, battery cable and relay found on the ROPS tube.
5T7718 Tube Assembly
2. Fasten a 3V8988 Bar at the 500 mm (19.5 in) to the tube with a 3 mm (.12 in) fillet weld at location (A) to the dimensions shown in the illustration above.
3. Install the new battery cable harness, following the general path of the old harness. If the truck was equipped with a resistor in line with the disconnect switch, it is no longer needed. Connect the 203-BK wire directly to the battery side of the disconnect switch.
4. Install a 6G8167 Plate Assembly to each of the existing 8D8832 Plates on the ROPS tube assembly. These may already be positioned on the original truck.
NOTE: Check illustrations used for earlier PIN for part locations.
5. Install a 9X7137 Valve Assembly on the right 6G8167 Plate Assembly. This may be already on the truck.
6. Install the 8X1440 Plate Assembly and 9X7137 Valve Assembly on the left 6G8167 Plate Assembly. Install the resistors and control group as shown in the illustration.
7. Install the relay on the 3V8988 Bar. Connect the valve assembly, control group, resistors and relay as shown in the illustration.
8. The remaining items may be installed as shown in the ether aid group earlier.
NOTE: Adapters on the turbo system may need to be modified or replaced in order to provide correct port locations for the ether tubes.
NOTE: Follow instructions for cab modifications necessary to complete the EUI ether system.
NOTE: If these early date trucks were modified to use the automatic ether system, they will need to be modified similar to the later trucks where the auto ether system was standard equipment. (See Serial Number 9ZC440 and above or Special Instruction SEHS9293).
9ZC253-439
These trucks were equipped with a more sophisticated manual ether system, with two bottles, two resisters, a control group and relay similar to that found in the EUI system.
It is to be noted that it would be possible to retain the battery harness, resistors, control group and relay as originally equipped and only replace the engine ether tubes, fittings and clips outlined below. However, the original relay is no longer serviced and the new battery harness provides a better insulated connection to the relay. It is recommended that the following steps be taken during the EUI conversion process.
1. Remove all existing ether tubing, battery cable and relay found on the ROPS tube. (8W8181 Harness Assembly and 8X1439 Harness Assembly).
To update the ether system to EUI requirements a bar must be installed on the ROPS tube to support a relay.
2. Fasten a 3V8988 Bar at the 500 mm (19.7 in) to the tube with a 3 mm (.12 in) fillet weld at location (A) to the dimensions shown in the illustration above.
3. Install the new battery cable harness, following the general path as the old harness. If the truck was equipped with a resistor in line with the disconnect switch, it is no longer needed. Connect the 203-BK wire directly to the battery side of the disconnect switch.
4. Install a 6G8167 Plate Assembly to each of the existing 8D8832 Plates on the ROPS tube assembly. These may already be positioned on the original truck.
NOTE: Check illustrations used for earlier PINs for part location.
5. Install a 9X7137 Valve Assembly on the right 6G8167 Plate Assembly. This may be already on the truck.
6. Install the 8X1440 Plate Assembly and 9X7137 Valve Assembly on the left 6G8167 Plate Assembly. Install the resistors and control group as shown in the illustration.
7. Install the relay on the 3V8988 Bar. Connect the valve assembly, control group, resistors and relay as shown in the illustration.
8. The remaining tube assemblies and other items may be installed as shown in the ether aid group illustration earlier.
NOTE: Adapters on the turbo system may need to be modified or replaced in order to provide correct port locations for the ether tubes.
NOTE: Follow instructions for cab modifications necessary to complete the EUI ether system.
NOTE: If these early date trucks were modified to use the automatic ether system, they will need to be modified similar to the later trucks where the auto ether system was standard equipment. (See PIN 9ZC440 and above or Special Instruction SEHS9293).
9ZC440-Up and Trucks Updated Per SEHS9293
These trucks all had automatic ether systems.
8X4574 Ether Starting Aid Group
1. Remove the four ether bottles, their bolted on mounting brackets, all ether tubing, battery cable harness and its connecting ether harness. (8W8181 Harness Assembly and 8X3704 Harness Assembly).
This leaves the ROPS tube assembly with four (two sets) 8D8832 Plates. Only one plate of these will be used. In the first set from the left, the plate with the dimension of 1060 mm (41.7 in) will be used.
2. Fasten a 8D8832 Plate at the 830 mm (32.7 in) dimension to the tube with a 3 mm (.12 in) fillet weld at location (A) to the dimensions shown in the illustration above.
3. Fasten a 3V8988 Bar at the 500 mm (19.7 in) to the tube with a 3 mm (.12 in) fillet weld at location (B) to the dimensions shown in the illustration above.
4. Install the new battery cable harness, following the general path as the old harness.
5. Install a 6G8167 Plate Assembly to the existing and new 8D8832 Plate on the ROPS tube assembly. These may already be positioned on the original truck.
NOTE: Check illustrations used for earlier PIN for part location.
6. Install a 9X7137 Valve Assembly on the right 6G8167 Plate Assembly. This may be already on the truck.
7. Install the 8X1440 Plate Assembly and 9X7137 Valve Assembly on the left 6G8167 Plate Assembly. Install the remaining items as shown in the illustration above.
8. Install the relay on the 3V8988 Bar. Connect the valve assembly, control group, resistors and relay as shown in the illustration.
9. The remaining tube assemblies and other items may be installed as shown in the ether aid group earlier.
NOTE: Adapters on the turbo system may need to be modified or replaced in order to provide correct port locations for the ether tubes.
NOTE: Follow instructions for the cab modifications necessary to complete the EUI ether system.
Engine Modification
The engine harness and the majority of the engine sensors were installed during the engine conversion. The ground strap and converter/retarder temperature switch assembly is covered under the engine modification section.
2A6529 Wiring Group (Chassis). 1. Two 3S2093 Strap. 2. Two 7N3718 Clip. 3. 5P8167 Bolt. 4. 5P1075 Washer. 5. 3K0360 Seal. 6. 7N7854 Switch Assembly. 7. 318761 Cable Assembly.
Air-Conditioner
The a/c compressor and refrigerant switch wiring is now a part of the EUI engine harness. The 789 Trucks have the switch on the receiver/dryer. (The 789B Trucks have the refrigerant switch mounted on the compressor.) The retrofit has been designed to continue the use of the receiver/dryer mounted switch. The receiver/dryer is located on the left frame support. Thus, the EUI harness breakout for the compressor mounted switch must be shorted. This is done by using the 1049533 Harness Assembly.
1. 1049533 Harness Assembly. 2. Three 3S2093 Strap. 3. 3T3048 Clip Assembly. 4. 5M3062 Bolt. 5. 6V3265 Clip. 6. 8C9677 Harness Assembly. 7. 8T4896 Washer. 8. 9G9150 Clip.
1049533 Harness Assembly
8C9677 Harness Assembly
The a/c compressor was originally powered through a breakout on the engine harness. Early production of this harness connected directly to the compressor. The EUI engine harness provides power to the a/c compressor through a sure seal connector, therefore; 8C9677 Harness is provided to run from the sure seal connector to the a/c compressor.
Existing a/c fittings may be reconnected to the compressor.
Cab Wall Modification
Existing wall plate. 1. Aeta. 2. Engine. 3. Battery Cable Harness. 4. Chassis. 5. Fire Suppression. 6. Transmission.
1. It is recommended that the new EUI battery cable and its mating cab battery harness connector be connected at the hole marked (2), the old engine harness location. This will leave the hole marked (3), the old battery cable harness location, for the new EUI engine harness.
Illustration A
2. The existing cab wall plate must be modified to accept the rectangular connector of the new EUI harness. 1057181 Plate will provide an accurate location for mounting the connector.
1057181 Plate (EUI Retrofit Cab Wall)
3. Place the plate over the hole, where the old battery cable harness was previously located.
4. Scribe a rectangular opening to the dimensions given in Illustration A, and cut out the rectangle.
5. Align 1057181 Plate with the opening and tack weld.
6. Install the plate to the harness plate with a 3 mm (.12 in) fillet weld all around.
7. Drill two 5.5 mm (.22 in) diameter holes in line with the top and bottom holes in 1057181 Plate.
8. This location for EUI engine harness is some what optional but the connector must clear the hood and leave adequate room for access to it from both sides of the wall.
9. A hole must be provided for the breakout of the EUI retro harness which will extend outside the cab wall to connect with other vehicle harnesses. This 28 mm (1.1 in) diameter hole must be lined with a 9P0719 Grommet.
10. If another location for EUI harness is desired, a 7M3248 Button may be used to plug the mounting hole of the now removed MUI engine harness.
The following data will provide the necessary information to install the main cab EUI Retrofit harness. This harness connects to the existing main cab harness (at its old engine harness connector) and to the new EUI Engine harness at its 40 pin connector.
It also has breakouts to power various new and revised functions in the cab such as a new throttle sender, an atmospheric pressure switch, connections to the new data-link, breakouts for the new control switches located on the console. A breakout also extends through the cab wall to connect with a new or existing battery harness, the existing chassis harness and a shutter attachment.
This new harness acts as a link between the existing cab harnesses, the chassis harness, the new or existing battery cable harness and the new engine harness.
Atmospheric Pressure
1. Two lugs must be welded on the left wall at the rear of the cab to support the mounting for the atmospheric pressure sensor.
Inside Wall of Cab Rear
2. Locate two 8F9836 Lugs from the existing payload lamp mounting holes as shown in the illustration above.
3. Fasten the lugs with 3 mm (.12 in) fillet weld, all around, at location (A).
1. Two 5M3062 Bolts. 2. Two 8T4896 Washers. 3. 6I1653 Bracket Assembly. 4. 6V1926 Sensor Assembly. 5. 9X0262 Adapter. 6. Two 6V5084 Seals. 7. 9G5127 Breather. 8. Two 3S2093 Straps. 9. 8M2770 Clip.
Circuit Breaker Panel
1. 105 Amp Main Breaker. 2. 20 Amp Ether Breaker. 3. 15 Amp Engine ECM Breaker.
Modifications to the circuit breaker panel:
- * Addition of a wire and circuit breaker (for manual ether system)
- * Increase main circuit breaker from 80 to 105 amps.
- * Add a breaker for the EUI electronic control module
- * Increase main circuit breaker from 80 to 105 amps.
1. Provide the cutout and fastening holes for the two breakers as shown in the illustration above or use an existing location.
2. Fasten the new 3T8728 Ether Breaker and 6N8589 Breaker to the panel. Connect 315-GN wire from EUI Retro Harness to the breaker.
3. Remove the existing main 80 amp circuit breaker and replace it with a 3E7294 105 amp breaker. Connect the wires that were removed (101-RD and 109-OR).
4. Connect 8W9561 Wire Assembly from the main circuit breaker to the ether breaker. Label the new breakers with usage and amperes.
5. Connect a breakout from the EUI retrofit harness to the main relay. (112-PU)
6. Two ring terminals connect to the ground boss in the rear of the cab. (200-BK)
7. One single socket breakout must be inserted into pin 10 of the existing diagnostic connector located on the dividing wall at the rear of the cab.
8. A breakout for connecting attachments to the data link is also located in the rear of the cab and plugged when not in use.
9. The 40 pin connector of the EUI Retro harness may be secured to the modified cab wall using four 5P8394 Screws, 4B8394 Nuts and 4B4863 Washers.
10. A 7T1099 Weld Link is provided to help secure the EUI Retro harness to the main cab harness. Use tie wraps where necessary.
Console Area
Another portion of the EUI Retro harness extends into the console area through a 3V4791 Grommet to make connections with:
- * Ether switch
- * Service meter
- * An extension for 1053652 Panel Group
- * Data-link extension for optional update of the transmission control group using the new EPTC II retrofit package.
- * Service meter
1. Disconnect the existing connections at the ether switch located on the console. Tape and secure these back to avoid shorting.
Seen From The Underside of Console
2. Connect EUI Retro harness console wires 308-YL, 310-PU and 307-OR to existing or replaced 8C9812 Switch Assembly as shown in the illustration.
NOTE: Install the switch using the keyway pilot hole and orient the wires as shown in the sketch.
3. If the truck was equipped with auto ether, remove the two 8X3708 Lamp Assemblies and tape the existing leads.
4. If the truck was equipped with auto ether, apply 1053217 Film over the holes and existing film.
5. Disconnect the existing connection to the service meter. Plug this connector with a 7N9738 Housing and tie this breakout back out of the way.
6. Connect EUI Retro harness console connection for the service meter and clip connector with existing inline sure seal clip assembly.
307-OR to S Terminal of Key Switch, 308-YL to R Terminal of Key Switch, 105-BR to B Terminal of Key Switch,
7. Connect additional leads to the key switch by loosening the screws and placing 307-OR, 308-YL and 105-BR leads under the screws and tighten. Make sure to match existing wire codes and color.
8. Clip EPTC-II data link extension of EUI Retro harness (used for EPTC II) with 3T3048 clip assembly.
9. Remove existing console panel located towards rear of console directly above transmission control box (EPTC).
1053652 Panel Group. 1. 1052038 Plate. 2. 1052484 Film. 3. 6T6066 Switch Assembly. 4. Two 6T6329 Bezel. 5. Four 5P7590 Bolt. 6. 6T3990 Switch Assembly. 7. Four 3E8043 Screw. 8. 8C6354 Cap. 9. Four 5P1075 Washer. 10. 7T0493 Plug. 11. Four 6V8801 Nut. 12. Two 3T0304 Base. 13. Two 7N1996 Lamp. 14. Two 6T7058 Lens. 15. Two 6T2774 Clip. 16. Four 6B4540 Nut. 17. Four 6D3033 Screw. 18. Four 6V9497 Washer. 19. 1049543 Harness Assembly. 20. 1052045 Panel. 1 10. Assemble the 1053652 Panel Group as shown in the illustrations above.
1049543 Harness Assembly
11. Connect the harness and individual wires as shown. Clip 1049543 Harness to the panel with 8M2773 Clip.
12. Connect the EUI Retro harness to 1049543 Harness Assembly. Clip the connection with a 3T3046 Clip Assembly. Position the panel group back in place on the console with the existing hardware.
Cab EUI Retrofit Harness (Front of Cab)
A major portion of the EUI Retro harness will extend through the tunnel to the front of the cab where connections must be made to the:
- * Overspeed warning light
- * Throttle pedal
- * Warning horn
- * Throttle pedal
Overspeed warning light
Route the front portion of the Retro Harness through the tunnel under the cab. The plate under the cab may be removed for easier access.
All trucks after 9ZC133 were equipped with an engine overspeed control module located in the front of the cab. This function is now handled by the EUI-Electronic Control Module. Part of this old system (8W0584 Wiring Group-Cab) must be disconnected and removed.
Remove the following items.
8W0584 Wiring Group. 1. 8W7193 Harness Assembly. 2. 7T3821 Control Group. 3. 9D3721 Switch. 4. Two 7N8419 Terminals. 5. Three 4M5282 Bolts. 6. Three 5P4115 Washers.
Overspeed Warning Group
All trucks with PINS 9ZC1 thru 9ZC132, a Special Instruction SEHS8863 Installation of Off-Highway Truck Engine Overspeed Warning Indicator Group was available to update these trucks with the stand alone engine overspeed system.
This Special Instruction should be used for all trucks within this PIN range.
- * Trucks that was not retro-fitted with engine overspeed.
- * Trucks that had been retro-fitted with Special Instruction SEHS8863.
Trucks That Was Not Retro-fitted
Install just the items given in the following chart on these trucks.
The 12 items in the chart above must be installed to complete the EUI Retro-fit on those trucks that had no overspeed warning installed. The following Steps were taken from Special Instruction SEHS8863.
NOTE: The following Steps are similar to the Steps in SEHS8863. Do only those things that are spelled out in these 12 Steps, which were taken from SEHS8863.
1. Disconnect the batteries.
2. Remove the cover from the front of the cab.
3. Remove the instrument panel and the plastic dash. See the Service Manual for correct procedure.
As seen from inside of cab
4. Drill hole (A) at the dimensions shown in the illustration above.
5. Cut an opening (B) in the lower part of the metal dash, to the dimensions shown with a 3 mm (.12 in) radius at each corner.
6. Install a 8F9836 Lug (2) with a 3 mm (.12 in) fillet weld at the dimensions shown on the left side of the steering tunnel on the dash assembly. This lug will be used to mount the 9G9813 Alarm Group.
7. Drill only hole (E), 26 ± 0.5 mm (1.02 ± .08 in) diameter, at the location shown in the illustration.
8. Install the plastic dash.
9. Install 8C7535 Film (10), 3T0304 Indicator Light Base (8), 7N1996 Lamp and 6T7058 Lens in dash as shown.
12. Place the wires from the alarm group through the hole drilled in Step 4 in the dash assembly and install a 4V5091 Grommet (13).
Trucks That Was Retro-fitted
Remove the items installed with SEHS8863 that is given in the following chart.
Throttle Pedal (8X7946 Acceleration Control Group)
1. 1M0437 Spring. 2. 8X7985 Plate Assembly. 3. 2K8467 Pin. 4. 8T7566 Pin. 5. 8X7980 Pedal. 6. 8D7052 Spring. 7. 8X8590 Pin. 8. 8T0277 Spring. 9. 3E5400 Control Group. 10. Two 2N7456 Screw. 11. Two 4B4274 Washer. 12. 6H4006 Grommet. 13. 4D7794 Clip. 14. Three 4M0061 Bolt. 15. Three 8T4224 Washer. 16. 9R5616 Plug.
4. Insert harness through floor and place 6H4006 Grommet around hole.
5. Fasten harness to plate assembly with 4D7794 Clip, 4M0061 Bolt and 8T4224 Washer. Install the remaining two bolts and washers. Snap 9R5616 Plug in the bottom of the tube.
6. Connect the breakout from EUI Retro harness to throttle pedal control group extension. Secure this extension and tie excess wiring.
7. Connect the breakout of EUI Retro harness to warning horn harness. Use 9G9150 Clip.
8. Connect 998-BR and B948-BR wires to overspeed warning lamp. Use 8M3839 Button to plug switch opening if needed
Outside Cab Wall
1. Fasten EUI engine harness to the cab wall and tighten the anchor screws.
2. Extent cab EUI Retro harness outside extensions through the cab wall using the 9P0719 Grommet. Connect EUI Engine harness to cab EUI Retro harness at 109-OR breakout using a 3T3047 Clip Assembly.
3. Connect 200-BK ring terminal of Cab EUI Retro Harness (and 200-BK ring terminal of battery cable where applicable) to the ground boss located on the platform near the cab wall. Make sure to include all other existing ground connections. Secure with existing hardware.
4. Connect existing chassis harness to Cab EUI Retro harness at the 446-PU, 451-BR, 450-YL, 481-GN (4 pin) sure seal breakout using a 3T3045 Clip Assembly. Connect at the 777-PU (power sure seal) using a 3T3047 Clip Assembly
5. Clip 201-BK (2 pin) sure seal breakout with a 3T3048 Clip Assembly and tie back. (Not used on this truck).
6. Connect battery cable to Cab EUI Retro Harness at 101-RD and 315-GN using two 9G9154 Clips. Connect 310-PU, 203-BK and 311-WH using one 9G9152 Clip. Secure these three clips to the existing boss and hardware.
7. Clip plugged 113-OR (2 pin) sure seal with 3T3048 Clip Assembly and tie back or connect to existing shutter attachment harness.
8. This completes the cab portion of the EUI Retrofit.
9. Clean and paint all welded areas.
10. Secure all harnesses with tie wraps that may be hanging loose.
11. Check all areas that were modified or changed.
12. Connect the batteries.
