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KOMATSU 860E-1K DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30031 & UP) KOMATSU 860E 1K – PDF DOWNLOAD
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- KOMATSU 860E-1K DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30031 & UP
- PUBLICATION NUMBER:CEBM024202
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Description
KOMATSU 860E-1K DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30031 & UP) KOMATSU 860E 1K
KOMATSU 860E-1K DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30031 & UP) KOMATSU 860E 1K – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 860E-1K DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30031 & UP) KOMATSU 860E 1K
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and weight of components are also explained.
90. Diagrams and drawings
This section gives hydraulic circuit diagrams and electrical circuit diagrams
TABLE OF CONTENTS:
KOMATSU 860E-1K DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30031 & UP) KOMATSU 860E 1K
COVER ................................................................................................................................ 1 00 Index and foreword ................................................................................................................ 3 Index ............................................................................................................................ 3 Composition of shop manual.................................................................................................... 4 Table of contents............................................................................................................. 6 Foreword, safety and general information.......................................................................................... 35 Foreword...................................................................................................................... 38 How to read the shop manual................................................................................................... 39 Composition of shop manual................................................................................................ 39 Revision and distribution................................................................................................. 39 Symbols................................................................................................................... 40 General safety................................................................................................................ 41 Safety rules.............................................................................................................. 41 Safety features........................................................................................................... 41 Fire extinguisher and first aid kit....................................................................................... 41 Clothing and personal items............................................................................................... 41 Leaving the operator seat................................................................................................. 42 Mounting and dismounting.................................................................................................. 42 Fire prevention for fuel and oil.......................................................................................... 42 Precautions with high temperature fluids.................................................................................. 43 Asbestos dust hazard prevention........................................................................................... 43 Prevention of injury by work equipment.................................................................................... 43 Unauthorized modification................................................................................................. 43 Precautions when using ROPS............................................................................................... 43 Precautions for attachments............................................................................................... 44 Precautions for starting the truck........................................................................................ 44 Precautions before operating the truck........................................................................................ 44 Safety at the worksite.................................................................................................... 44 Fire prevention........................................................................................................... 45 Ventilation in enclosed areas............................................................................................. 45 Preparing for operation................................................................................................... 45 Mirrors, windows and lights............................................................................................... 45 In operator cab (before starting the engine).............................................................................. 45 Seat Belts................................................................................................................ 45 Precautions while operating the truck......................................................................................... 46 When starting the engine.................................................................................................. 46 General truck operation................................................................................................... 46 Ensuring good visibility.................................................................................................. 46 Traveling................................................................................................................. 47 Traveling in reverse...................................................................................................... 47 Traveling on slopes....................................................................................................... 47 Operating on snow or ice.................................................................................................. 47 Avoid damage to dump body................................................................................................. 47 Driving near high voltage cables.......................................................................................... 48 When dumping.............................................................................................................. 48 Working on loose ground................................................................................................... 48 When loading.............................................................................................................. 48 Parking the truck......................................................................................................... 48 Towing.................................................................................................................... 48 Working near batteries........................................................................................................ 49 Battery hazard prevention................................................................................................. 49 Starting with booster cables.............................................................................................. 50 Jump starting with receptacles............................................................................................ 50 Precautions before performing service......................................................................................... 51 Warning tag............................................................................................................... 51 Stopping the engine....................................................................................................... 51 Proper tools.............................................................................................................. 51 Use of Tie-Off Anchor During Maintenance and Repair....................................................................... 51 Securing the dump body.................................................................................................... 52 While performing maintenance.................................................................................................. 53 Keep the truck clean...................................................................................................... 53 Attachments............................................................................................................... 53 Working under the truck................................................................................................... 53 Rotating fan and belts.................................................................................................... 53 Adding fuel or oil........................................................................................................ 53 Use of lighting........................................................................................................... 53 Radiator coolant level.................................................................................................... 54 Precautions with the battery.............................................................................................. 54 Precautions with high pressure oil........................................................................................ 54 Handling high pressure hoses.............................................................................................. 54 Precautions when performing maintenance near high temperature or high pressure............................................ 54 Waste materials........................................................................................................... 54 Tires......................................................................................................................... 55 Handling tires............................................................................................................ 55 Storing tires after removal............................................................................................... 55 Precautions for performing repairs............................................................................................ 56 Engine shutdown procedure after AC drive system failure................................................................... 56 Precautions for welding on the truck.......................................................................................... 57 Handling electrical equipment and hydraulic components........................................................................ 58 Points to remember when handling electrical equipment..................................................................... 58 Points to remember when handling hydraulic equipment...................................................................... 64 How to read electric wire code................................................................................................ 66 Standard torque tables........................................................................................................ 69 Effect of special lubricants on fasteners and standard torque values...................................................... 69 Standard tightening torques for SAE hex head cap screw and nut assemblies................................................. 70 Standard assembly torques for 12-point, grade 9 cap screws (SAE).......................................................... 71 Standard assembly torques for class 10.9 capscrews and class 10 nuts...................................................... 71 Standard tightening torques for fittings.................................................................................. 72 Conversion tables............................................................................................................. 74 Common conversion multipliers............................................................................................. 74 Operating instructions............................................................................................................ 79 Preparing for operation....................................................................................................... 81 Walk around inspection.................................................................................................... 81 Engine start-up............................................................................................................... 86 After engine start-up......................................................................................................... 87 Precautions during truck operation............................................................................................ 88 Operating on a haul road...................................................................................................... 89 Starting on a grade with a loaded truck....................................................................................... 89 Passing....................................................................................................................... 90 Loading....................................................................................................................... 90 Dumping....................................................................................................................... 90 Raising The Dump Body..................................................................................................... 90 Lowering The Dump Body (When dumping on flat ground):..................................................................... 91 Lowering The Dump Body (When dumping over a berm or into a crusher):...................................................... 92 Using the speed control feature............................................................................................... 92 Safe parking procedures....................................................................................................... 93 Normal engine shutdown procedure.............................................................................................. 93 Sudden loss of engine power................................................................................................... 94 Fuel depletion................................................................................................................ 95 Towing........................................................................................................................ 96 Special Wiring Harness.................................................................................................... 96 Towing Procedure.......................................................................................................... 96 Disabled truck operation...................................................................................................... 99 Steering and brake system................................................................................................. 99 Components Required....................................................................................................... 99 Hookup.................................................................................................................... 100 Disabled truck dumping procedure.......................................................................................... 101 Hookup.................................................................................................................... 101 Raising the Body.......................................................................................................... 101 Lowering the Body......................................................................................................... 102 01 Specification ..................................................................................................................... 105 Specification and technical data.................................................................................................. 105 Specification drawing......................................................................................................... 107 Specifications................................................................................................................ 108 Weight table.................................................................................................................. 110 Fuel, coolant and lubricants.................................................................................................. 111 Mixing rate of water and anti-freeze...................................................................................... 111 Suspension cylinder oil and nitrogen specifications....................................................................... 112 10 Structure, functions and maintenance standard...................................................................................... 115 Cab air conditioning.............................................................................................................. 115 General information........................................................................................................... 116 Environmental impact of air conditioning.................................................................................. 116 Air conditioning for off-highway vehicles................................................................................. 116 Principles of refrigeration................................................................................................... 117 Air conditioning.......................................................................................................... 117 Refrigeration - the act of cooling........................................................................................ 117 The refrigeration cycle................................................................................................... 117 Air conditioning system components............................................................................................ 119 Relays.................................................................................................................... 119 Fan motor and speed control............................................................................................... 119 Cab air filter............................................................................................................ 119 Heater core............................................................................................................... 119 Actuators................................................................................................................. 119 Compressor (refrigerant pump)............................................................................................. 121 Service valves............................................................................................................ 121 Condenser................................................................................................................. 121 Receiver-drier............................................................................................................ 121 Expansion valve........................................................................................................... 122 Accumulator............................................................................................................... 122 Evaporator core........................................................................................................... 122 Air conditioning system electrical circuit.................................................................................... 123 Thermostat................................................................................................................ 123 Compressor clutch......................................................................................................... 123 Trinary™ switch........................................................................................................... 124 Steering circuit.................................................................................................................. 127 Steering circuit operation.................................................................................................... 129 Steering circuit components................................................................................................... 131 Steering control unit..................................................................................................... 131 High pressure filter...................................................................................................... 131 Steering accumulators..................................................................................................... 131 Bleed down manifold....................................................................................................... 132 Steering accumulator bleed down solenoid.................................................................................. 134 Hoist up limit solenoid................................................................................................... 134 Quick disconnect ports.................................................................................................... 135 Flow amplifier............................................................................................................ 135 Flow amplifier operation...................................................................................................... 136 No steer.................................................................................................................. 136 Steering left............................................................................................................. 138 Steering right............................................................................................................ 140 No steer, external shock load............................................................................................. 142 Steering/brake pump operation................................................................................................. 145 Normal operation.......................................................................................................... 145 Neutral position.......................................................................................................... 146 Full pump volume.......................................................................................................... 147 Half pump volume.......................................................................................................... 147 Steering cylinder wear data................................................................................................... 148 Hoist circuit .................................................................................................................... 151 Hoist circuit operation....................................................................................................... 153 Hoist circuit components...................................................................................................... 154 Hydraulic tank............................................................................................................ 154 Hoist pump................................................................................................................ 154 High pressure filters..................................................................................................... 154 Hoist valve............................................................................................................... 154 Inlet sections............................................................................................................ 155 Tank ports (front) spool section.......................................................................................... 155 Work ports (rear) spool section........................................................................................... 155 Hoist pilot valve......................................................................................................... 156 Bleed down manifold....................................................................................................... 156 Hoist limit solenoid...................................................................................................... 156 Pilot operated check valve................................................................................................ 156 Overcenter manifold....................................................................................................... 157 Hoist pilot valve operation................................................................................................... 158 Float position with body down............................................................................................. 158 Power up operation........................................................................................................ 160 Hold operation............................................................................................................ 162 Power down operation...................................................................................................... 164 Float operation........................................................................................................... 166 Hoist cylinder wear data...................................................................................................... 168 Brake circuit .................................................................................................................... 171 General information........................................................................................................... 173 Service brake circuit operation............................................................................................... 174 Secondary braking system and auto apply....................................................................................... 174 Rear wheel brake lock circuit operation....................................................................................... 176 Parking brake circuit operation............................................................................................... 178 Normal operation (key switch ON, engine on)............................................................................... 178 Brake lines and test ports.................................................................................................... 180 Brake warning circuit operation............................................................................................... 181 Brake assembly wear data...................................................................................................... 183 Suspensions ...................................................................................................................... 185 General information........................................................................................................... 186 Front suspension wear data.................................................................................................... 186 Rear suspension wear data..................................................................................................... 187 Electrical system, 24 volt........................................................................................................ 189 Battery supply system......................................................................................................... 191 Auxiliary control cabinet components.......................................................................................... 192 24VDC to 12VDC converter.................................................................................................. 192 Diode board - DB1......................................................................................................... 192 Power distribution terminals.............................................................................................. 192 Control power relay....................................................................................................... 193 Fuse blocks............................................................................................................... 194 Relay boards.................................................................................................................. 194 Relay boards RB1, RB3, RB4, RB5........................................................................................... 194 Relay boards RB6, RB7, RB8, RB9........................................................................................... 196 Relay functions........................................................................................................... 196 Body position switches (With proximity switch and metal arm).................................................................. 198 Body-up switch............................................................................................................ 198 Hoist limit switch........................................................................................................ 199 Body position switches (With proximity switch and magnet)..................................................................... 200 Proximity switch operation................................................................................................ 200 Body-up Switch............................................................................................................ 200 Hoist limit switch........................................................................................................ 200 Interface module (IM)............................................................................................................. 203 General information........................................................................................................... 204 Sensors....................................................................................................................... 204 Temperature sensors....................................................................................................... 204 Pressure sensors.......................................................................................................... 204 Interface module inputs and outputs........................................................................................... 205 Drive system ..................................................................................................................... 211 SR rectifier module........................................................................................................... 213 ST module (auxiliary voltage inverter)........................................................................................ 213 Technical Data............................................................................................................ 216 SD phase modules.............................................................................................................. 217 SR/ST/SD module removal....................................................................................................... 217 Inverter cabinet layout....................................................................................................... 218 Inverter cabinet water flow................................................................................................... 218 Field regulator............................................................................................................... 219 Technical Data............................................................................................................ 219 Field regulator (discharge resistor).......................................................................................... 219 Technical Data............................................................................................................ 219 Gate unit power supply........................................................................................................ 220 Technical Data............................................................................................................ 220 Gate unit power supply (diode)................................................................................................ 220 Technical Data............................................................................................................ 220 Gate unit power supply (tuning resistor)...................................................................................... 220 Technical Data............................................................................................................ 220 Control power filter.......................................................................................................... 220 Technical Data............................................................................................................ 220 Filter for TCU................................................................................................................ 221 Technical Data............................................................................................................ 221 Terminal block bus bar........................................................................................................ 221 Technical Data............................................................................................................ 221 Fuses (analog sensor voltage)................................................................................................. 222 Technical Data............................................................................................................ 222 Fuses (field regulator)....................................................................................................... 222 Technical Data............................................................................................................ 222 Fuses (fuse holder for field regulator)....................................................................................... 222 Technical Data............................................................................................................ 222 Fuses (control power and trolley box contactor)............................................................................... 223 Technical Data............................................................................................................ 223 Diode modules................................................................................................................. 223 Technical Data............................................................................................................ 223 Support capacitors............................................................................................................ 224 Technical Data............................................................................................................ 224 3-Phase capacitor bank (for ST module output voltage)......................................................................... 224 Technical Data............................................................................................................ 224 Air-cooled inductors (for ST module).......................................................................................... 225 Technical Data............................................................................................................ 225 3-Phase transformer (for ST module)........................................................................................... 225 Technical Data............................................................................................................ 225 Diagnostics box............................................................................................................... 226 Diagnostic and system monitoring panel........................................................................................ 227 Device name: DB101........................................................................................................ 227 Technical Data............................................................................................................ 227 Current transducers........................................................................................................... 228 Device names:............................................................................................................. 228 U101ŠU104 (Current to motor A)............................................................................................ 228 U105ŠU106 (Current to chopper A-C)........................................................................................ 228 U201ŠU204 (Current to motor B)............................................................................................ 228 U205ŠU206 (Current to chopper B-D)........................................................................................ 228 Technical Data............................................................................................................ 228 Technical Data............................................................................................................ 228 Current transducers (for ST module output).................................................................................... 229 Technical Data............................................................................................................ 229 Voltage transducers........................................................................................................... 229 Technical Data............................................................................................................ 229 Voltage transducers (for ST module output).................................................................................... 230 Technical Data............................................................................................................ 230 Voltage transducers (SiBAS® 24V DC bus monitoring)............................................................................ 230 Analog inclinometer........................................................................................................... 231 Technical Data............................................................................................................ 231 DC link capacitors............................................................................................................ 231 Technical Data............................................................................................................ 231 Ground tie capacitor.......................................................................................................... 232 Technical Data............................................................................................................ 232 Low-inductance bus bar assembly............................................................................................... 232 Free-wheeling diode for low-inductance bus bars............................................................................... 233 Contactor (grid box and main blower motor).................................................................................... 233 Technical Data............................................................................................................ 233 Contactor (control power)..................................................................................................... 234 Technical Data............................................................................................................ 234 Contactor (DC contactors)..................................................................................................... 234 Technical Data............................................................................................................ 234 Contactor (crowbar bypass).................................................................................................... 235 Technical Data............................................................................................................ 235 Temperature probes (PT100 style).............................................................................................. 235 Technical Data............................................................................................................ 235 Coolant inlet temperature sensor.............................................................................................. 235 Technical Data............................................................................................................ 236 Coolant outlet temperature sensor (external pad style)........................................................................ 236 IGBT module heat sink temperature sensor.................................................................................. 236 Device names: PT101ŠPT103 [Sensors for inverters A101ŠA103]........................................................... 236 PT201ŠPT203 [Sensors for inverters A201ŠA203]......................................................................... 236 PT104 and PT204 [Sensors for choppers 1 and 2 respectively]........................................................... 236 PT105 and PT205 [Sensors for ST module (A301) and SR module (A1) respectively]........................................ 236 Coolant outlet temperature sensor (internal style)............................................................................ 236 Technical Data............................................................................................................ 236 Coolant outlet temperature sensor (external pad style)........................................................................ 237 Technical Data............................................................................................................ 237 Circuit breakers.............................................................................................................. 237 Technical Data............................................................................................................ 237 Inner circulating blower fan.................................................................................................. 238 Coolant pump.................................................................................................................. 238 Technical Data............................................................................................................ 238 Motor for coolant pump........................................................................................................ 239 Technical Data............................................................................................................ 239 Coolant pressure sensor....................................................................................................... 239 Inner radiator................................................................................................................ 239 Ground voltage monitoring resistors........................................................................................... 240 Protection thyristor assembly (crowbar)....................................................................................... 240 Discharge reactor............................................................................................................. 241 Main blower motor............................................................................................................. 241 Technical Data............................................................................................................ 241 Grid box...................................................................................................................... 242 Technical Data............................................................................................................ 242 Grid box blower motor......................................................................................................... 242 Technical Data............................................................................................................ 242 Grid box blower motor grease fittings......................................................................................... 243 Main alternator............................................................................................................... 243 Stator.................................................................................................................... 243 Rotor..................................................................................................................... 244 Bearings.................................................................................................................. 244 Electrical connection..................................................................................................... 244 Cooling and ventilation................................................................................................... 244 Rotating rectifier section................................................................................................ 244 Technical Data............................................................................................................ 245 Main alternator circuit diagram........................................................................................... 246 IGBT Š inverter/chopper phase module...................................................................................... 247 Device names: A101ŠA103 (Inverter A section).......................................................................... 247 A201ŠA203 (Inverter B section)........................................................................................ 247 A104 (Chopper A section).............................................................................................. 247 A204 (Chopper B section).............................................................................................. 247 Troubleshooting information............................................................................................... 249 Main input rectifier module............................................................................................... 250 Device name: A1....................................................................................................... 250 Internal circuit diagram.............................................................................................. 251 Upper ground tie resistor..................................................................................................... 252 Device Name: R11.1-R11.2.................................................................................................. 252 Technical Data............................................................................................................ 252 Lower ground tie resistor..................................................................................................... 252 Device name: R11.3-R11.4.................................................................................................. 252 Technical Data............................................................................................................ 252 Troubleshooting........................................................................................................... 253 Fault diagnosis........................................................................................................... 253 Speed sensor, alternator...................................................................................................... 254 Technical Data............................................................................................................ 254 Speed sensors, wheel motors................................................................................................... 255 Technical Data............................................................................................................ 255 Traction motor................................................................................................................ 256 Device name: Motor 1 (grid box side of the truck), Motor 2 (operator cab side of the truck)............................... 256 Technical Data............................................................................................................ 256 Grid box...................................................................................................................... 257 Device name: M04.......................................................................................................... 257 Technical Data............................................................................................................ 257 SIBAS® IGBT rack components....................................................................................................... 259 SiBAS®32 Traction Control Unit (TCU).......................................................................................... 261 Overview of the SiBAS®32 systems.............................................................................................. 262 Features.................................................................................................................. 262 General technical specifications, operating conditions.................................................................... 262 Permissible temperature range............................................................................................. 262 Permissible limit value for air humidity.................................................................................. 263 Permissible power supply voltage range.................................................................................... 263 Permissible mechanical loads.............................................................................................. 263 Protection measures against electrical hazards............................................................................ 263 Application............................................................................................................... 263 Removing and installing the SiBAS®32 cards.................................................................................... 266 Removal with 24V OFF! (ESD protection required)........................................................................... 266 Installation with 24V OFF! (ESD protection required)...................................................................... 266 SiBAS®32 card device names.................................................................................................... 267 Structure of SiBAS®32 card part number........................................................................................ 268 Development status, downward compatibility................................................................................ 268 SiBAS®32 card interchangeability.............................................................................................. 269 Use of service interfaces................................................................................................. 270 Connection of the service unit............................................................................................ 270 Maintenance............................................................................................................... 270 Cleaning.................................................................................................................. 271 SiBAS®32 card interactions.................................................................................................... 272 SiBAS®32 card detailed information............................................................................................ 275 Blower subassembly............................................................................................................ 275 Device name: N/A.......................................................................................................... 275 Application............................................................................................................... 275 Battery replacement....................................................................................................... 277 Rules for handling lithium batteries...................................................................................... 277 Replacement of the battery in the fan subassembly......................................................................... 277 CPU card...................................................................................................................... 278 Device name: G011......................................................................................................... 278 Application............................................................................................................... 279 Front panel............................................................................................................... 279 Technical data............................................................................................................ 280 DSP card...................................................................................................................... 281 Device name: G019, G027 and G35........................................................................................... 281 Application............................................................................................................... 281 Front panel............................................................................................................... 281 Technical data............................................................................................................ 282 I/O card...................................................................................................................... 283 Device name: G043......................................................................................................... 283 Application............................................................................................................... 283 Front panel............................................................................................................... 284 Technical data............................................................................................................ 285 TRACO card (optional)......................................................................................................... 286 Device name: G003......................................................................................................... 286 Application............................................................................................................... 286 Front panel............................................................................................................... 287 Technical data............................................................................................................ 288 Input voltage/frequency card.................................................................................................. 289 Device name: L055, L063 and L071.......................................................................................... 289 Application............................................................................................................... 289 Technical data............................................................................................................ 290 I/O analog card............................................................................................................... 291 Device name: L079 and L087................................................................................................ 291 Technical data............................................................................................................ 293 I/O analog card............................................................................................................... 294 Device name: L095 and L103................................................................................................ 294 Application............................................................................................................... 294 Technical data............................................................................................................ 296 Output pulse amplifier card................................................................................................... 297 Device name: L115, L123, L131, L139 and L147.............................................................................. 297 Application............................................................................................................... 297 Technical data............................................................................................................ 299 Input temperature sensor card................................................................................................. 300 Device name: L155 and L163................................................................................................ 300 Application............................................................................................................... 300 Technical data............................................................................................................ 302 UWS card...................................................................................................................... 303 Device name: G055, G063, G071 and G079.................................................................................... 303 Application............................................................................................................... 303 Technical data............................................................................................................ 305 Digital input card............................................................................................................ 306 Device name: G103, G111, G119, G127 and G135.............................................................................. 306 Application............................................................................................................... 306 Technical data............................................................................................................ 308 Power start-up unit card...................................................................................................... 309 Device name: G163......................................................................................................... 309 Application............................................................................................................... 309 Technical data............................................................................................................ 311 Binary output contactor drive card............................................................................................ 312 Device name: C019, C027 and C035.......................................................................................... 312 Application............................................................................................................... 312 Technical data............................................................................................................ 314 24V / 24V power supply........................................................................................................ 315 Device name: C045, C105, C129............................................................................................. 315 Application............................................................................................................... 315 Testing the power supply card............................................................................................. 316 Technical data............................................................................................................ 317 24V / 15V power supply........................................................................................................ 318 Device name: C069, C087................................................................................................... 318 Application............................................................................................................... 318 Testing the power supply card............................................................................................. 319 Technical data............................................................................................................ 320 24V / 5V power supply......................................................................................................... 321 Device name: C153......................................................................................................... 321 Application............................................................................................................... 321 Testing the power supply card............................................................................................. 322 Technical data............................................................................................................ 323 Reserve engine oil system......................................................................................................... 325 General information........................................................................................................... 327 Operation..................................................................................................................... 328 LED monitor light......................................................................................................... 328 Remote tank fill system....................................................................................................... 329 Wheel motor transmission ......................................................................................................... 331 General information........................................................................................................... 332 Transmission wear data........................................................................................................ 335 20 Standard value table .............................................................................................................. 339 Standard value table ............................................................................................................. 339 Standard value table for truck................................................................................................ 340 30 Testing and adjusting ............................................................................................................. 345 General information .............................................................................................................. 345 Special tool list............................................................................................................. 346 Cab air conditioning.............................................................................................................. 349 General information........................................................................................................... 350 Service tools and equipment................................................................................................... 351 Recovery/recycle station.................................................................................................. 351 Leak detector............................................................................................................. 351 Manifold gauge set........................................................................................................ 352 Service valves............................................................................................................ 353 Vacuum pump............................................................................................................... 353 Detecting leaks............................................................................................................... 354 System performance test....................................................................................................... 355 Checking system oil........................................................................................................... 356 System flushing............................................................................................................... 357 Installing the manifold gauge set............................................................................................. 358 Purging air from the service hoses........................................................................................ 358 Recovering and recycling refrigerant.......................................................................................... 359 Draining oil from previous recovery cycle................................................................................. 360 Recovery cycle............................................................................................................ 360 Recycling procedure....................................................................................................... 360 Evacuating the air conditioning system........................................................................................ 361 Charging the air conditioning system.......................................................................................... 362 Steering, brake cooling and hoist hydraulic system ............................................................................... 365 General information on system checkout........................................................................................ 367 Steering system checkout procedures........................................................................................... 367 Steering pump pressure control adjustments................................................................................ 368 Steering control valve and flow amplifier leakage test.................................................................... 369 Bleed down manifold leakage test.......................................................................................... 370 Shock and suction valve pressure tests.................................................................................... 371 Steering system checkout data sheet........................................................................................... 373 Toe-in adjustment............................................................................................................. 374 Brake cooling and hoist system checkout procedures............................................................................ 375 Pressure gauge locations.................................................................................................. 375 Brake cooling circuit test................................................................................................ 376 Power up relief pressure test............................................................................................. 376 Power down relief pressure test........................................................................................... 377 Counterbalance valve pressure check....................................................................................... 378 Counterbalance valve adjustment........................................................................................... 379 Brake cooling and hoist system checkout data sheet............................................................................ 380 Hydraulic system flushing..................................................................................................... 381 Hydraulic System Flushing Procedure....................................................................................... 381 Front suspension pressure test................................................................................................ 388 Rear suspension pressure test................................................................................................. 388 Steering cylinder leakage test................................................................................................ 389 Hoist cylinder leakage test................................................................................................... 389 Brake system ..................................................................................................................... 391 General information on system checkout........................................................................................ 392 Brake circuit checkout procedure.............................................................................................. 392 Initial system setup...................................................................................................... 393 Brake lock / secondary braking checkout................................................................................... 394 Parking brake checkout.................................................................................................... 396 Service brake checkout.................................................................................................... 399 Blended braking checkout.................................................................................................. 399 Low brake accumulator pressure and auto apply checkout.................................................................... 400 Parking brake control logic checkout...................................................................................... 402 Auto apply solenoid hydraulic circuit troubleshooting..................................................................... 403 Brake lock control logic checkout......................................................................................... 404 Brake system checkout data sheet.............................................................................................. 407 Brake piston leakage test..................................................................................................... 412 Wet disc brake bleeding procedure............................................................................................. 412 Parking brake bleeding procedure.............................................................................................. 413 Parking brake leakage test.................................................................................................... 413 Brake valve bench test and adjustment......................................................................................... 414 Test setup procedure...................................................................................................... 415 Brake valve output pressure adjustment.................................................................................... 415 Final test and adjustment................................................................................................. 416 Dual relay valve bench test and adjustment.................................................................................... 417 Test setup procedure...................................................................................................... 418 Relay valve output pressure adjustment.................................................................................... 418 Accumulators and suspensions ..................................................................................................... 421 Accumulator charging and storage.............................................................................................. 423 Accumulator charging procedures........................................................................................... 423 Precharge maintenance..................................................................................................... 426 Accumulator storage procedure............................................................................................. 427 Bladder storage........................................................................................................... 427 Installing a bladder accumulator from storage............................................................................. 427 Accumulator leak testing...................................................................................................... 428 Suspension oiling and charging procedures..................................................................................... 430 Equipment list............................................................................................................ 430 Installing the charging kit............................................................................................... 430 Removing the charging kit................................................................................................. 431 Support blocks for oiling and charging dimensions......................................................................... 431 Front suspension oiling................................................................................................... 432 Front suspension nitrogen charging........................................................................................ 433 Rear suspension oiling.................................................................................................... 435 Rear suspension nitrogen charging......................................................................................... 437 Suspension pressure test...................................................................................................... 438 Payload meter .................................................................................................................... 441 Payload meter initial setting procedure....................................................................................... 443 Starting communications................................................................................................... 443 Configure payload meter................................................................................................... 443 Setting truck number...................................................................................................... 445 Clean truck tare.......................................................................................................... 446 Inclinometer calibration.................................................................................................. 446 KOMTRAX Plus...................................................................................................................... 449 KOMTRAX Plus and payload meter software....................................................................................... 451 VHMS Tool Box Installation................................................................................................ 451 VHMS Setting Tool Installation............................................................................................ 451 Installing the PDM software............................................................................................... 451 KOMTRAX Plus controller initial setting procedure............................................................................. 452 KOMTRAX Plus controller setup procedure................................................................................... 452 KOMTRAX Plus snapshot procedure........................................................................................... 455 KOMTRAX Plus download procedure........................................................................................... 456 KOMTRAX Plus FTP upload procedure......................................................................................... 457 KOMTRAX Plus initialization forms......................................................................................... 458 KOMTRAX Plus initialization check list........................................................................................ 459 KOMTRAX Plus initialization form.............................................................................................. 461 Precautions for replacing KOMTRAX Plus controller............................................................................. 462 KOMTRAX Plus controller checkout procedure.................................................................................... 467 Necessary equipment....................................................................................................... 467 Preliminary............................................................................................................... 467 Checkout procedure........................................................................................................ 468 Interface module ................................................................................................................. 471 Interface module software..................................................................................................... 472 Flashburn program installation............................................................................................ 472 Interface module application code installation............................................................................ 473 Interface module realtime data monitor software installation.............................................................. 473 Interface module checkout procedures.......................................................................................... 474 Necessary equipment....................................................................................................... 474 Preliminary............................................................................................................... 475 Check digital inputs to the interface module.............................................................................. 476 Check analog inputs to the interface module............................................................................... 479 Check serial interfaces to the interface module........................................................................... 480 Check outputs from the interface module................................................................................... 480 IGBT haul truck SIBAS® user manual, part 1........................................................................................ 483 Abbreviations................................................................................................................. 485 Precautions................................................................................................................... 487 Qualified person.............................................................................................................. 487 Customer monitor for SIBAS® 32 control units.................................................................................. 487 Product description....................................................................................................... 487 Version management........................................................................................................ 488 Overview.................................................................................................................. 489 Requirements.............................................................................................................. 489 Installing and calling the customer monitor................................................................................... 490 Installation.................................................................................................................. 490 Environment variables..................................................................................................... 490 Communication with the SIBAS® 32 control unit................................................................................. 491 Calling up the customer monitor............................................................................................... 492 Start-up prompt........................................................................................................... 492 Monitor prompt............................................................................................................ 493 Notes on operation of the customer monitor.................................................................................... 494 Structure of a monitor command................................................................................................ 494 Step 1: Selecting the menu title.......................................................................................... 494 Step 2: Selecting a menu entry in the menu box............................................................................ 494 Step 3: Selecting a dialog box, if available.............................................................................. 495 Step 4: Entering file or connector/signal names........................................................................... 495 Command buffer................................................................................................................ 496 Structure of the monitor windows.............................................................................................. 496 Window menu................................................................................................................... 497 Commands for Opening, Altering and Closing Windows........................................................................ 497 "Window Work open"............................................................................................................ 497 "Window Lines open"........................................................................................................... 497 "Window Tile"................................................................................................................. 497 "Window Bars open"............................................................................................................ 497 Options................................................................................................................... 497 "Window Set".................................................................................................................. 497 Options................................................................................................................... 497 "Window Cascade".............................................................................................................. 497 "Window Close"................................................................................................................ 497 "Window close All"............................................................................................................ 497 "Window Exit"................................................................................................................. 497 Set Menu...................................................................................................................... 498 "Set Port".................................................................................................................... 498 Options................................................................................................................... 498 "Set Baudrate"................................................................................................................ 498 Options................................................................................................................... 498 "Set String".................................................................................................................. 499 Example................................................................................................................... 500 "Set Make".................................................................................................................... 500 Options................................................................................................................... 500 Example 1: INIT.MON start-up control of the Customer Monitor.............................................................. 501 Example 2: Any monitor batch file with freely selectable file name (incl. path)........................................... 501 "Set Execute"................................................................................................................. 502 Options................................................................................................................... 502 Example................................................................................................................... 502 "Set Record".................................................................................................................. 502 Options................................................................................................................... 502 "Set DIN-Bus"................................................................................................................. 503 "Set TCN"..................................................................................................................... 503 "Set Timeout"................................................................................................................. 503 Options................................................................................................................... 503 "Set Wait".................................................................................................................... 503 Options................................................................................................................... 503 "Set Color"................................................................................................................... 503 Options................................................................................................................... 503 "Set Info".................................................................................................................... 504 "Set comment"................................................................................................................. 504 "Set CHAR Set"................................................................................................................ 504 "Set Quit".................................................................................................................... 504 Applic. Menu.................................................................................................................. 505 "Applic. Func.Package"........................................................................................................ 505 "Applic. Connector"........................................................................................................... 506 Options................................................................................................................... 506 Example................................................................................................................... 507 "Applic. View"................................................................................................................ 507 Options................................................................................................................... 507 Example................................................................................................................... 507 "Applic. Signal".............................................................................................................. 507 "Applic. Observer"............................................................................................................ 508 Options................................................................................................................... 508 Possible time slices:..................................................................................................... 508 Options................................................................................................................... 509 Two options............................................................................................................... 509 Notes on the display of connectors........................................................................................ 511 "Applic. Buffer".............................................................................................................. 512 Options................................................................................................................... 512 "Applic. Report".............................................................................................................. 512 "Applic. Legitimation"........................................................................................................ 512 Options................................................................................................................... 512 "Applic. Menu"................................................................................................................ 513 "Applic. Traco"............................................................................................................... 513 Options................................................................................................................... 513 "Applic. Environment"......................................................................................................... 513 Hardw. Menu................................................................................................................... 515 Hardware-Oriented Access via the Customer Monitor......................................................................... 515 "Hardw. Flash"................................................................................................................ 515 Options................................................................................................................... 515 Requirements.............................................................................................................. 515 Example................................................................................................................... 516 Deleting and loading...................................................................................................... 516 The EPROM for the communication drivers................................................................................... 516 "Hardw. Clock"................................................................................................................ 516 Options................................................................................................................... 516 "Hardw. DSP".................................................................................................................. 517 "Hardw. BCD".................................................................................................................. 517 Options................................................................................................................... 517 Example................................................................................................................... 517 "Hardw. RESET"................................................................................................................ 517 Options................................................................................................................... 517 "Hardw. Info"................................................................................................................. 518 Hardware/Operating system................................................................................................. 518 Application and tools..................................................................................................... 518 Communication module...................................................................................................... 518 Displaying the loading date............................................................................................... 518 "Hardw. User Flash"........................................................................................................... 519 Options................................................................................................................... 519 "Hardw. Sys. Flash"........................................................................................................... 519 Options................................................................................................................... 519 "Hardw. BOOT DSP"............................................................................................................. 520 Requirements.............................................................................................................. 520 DSP5600x Signal Processing Unit and TRACO................................................................................. 520 Inverter processing unit.................................................................................................. 522 Access to the Signal Processing Unit...................................................................................... 522 "Hardw. Flash"................................................................................................................ 522 Options................................................................................................................... 522 Requirements.............................................................................................................. 522 Example................................................................................................................... 522 Deleting and loading...................................................................................................... 523 The EPROM for the communication drivers................................................................................... 523 User Data Flash (UDF)..................................................................................................... 523 "Hardw. RESET"................................................................................................................ 523 Options................................................................................................................... 523 "Hardw. ZR"................................................................................................................... 524 "Hardw. BOOT ZR".............................................................................................................. 524 The following procedure is necessary:..................................................................................... 524 Graphic Menu.................................................................................................................. 525 Commands for Displaying Line Graphics..................................................................................... 525 "Graphic Load"................................................................................................................ 525 Options................................................................................................................... 525 "Graphic Position"............................................................................................................ 525 Options................................................................................................................... 525 "Graphic Time/Div"............................................................................................................ 526 Options................................................................................................................... 526 "Graphic Unit/Div"............................................................................................................ 526 Options................................................................................................................... 526 "Graphic Display"............................................................................................................. 526 Options................................................................................................................... 526 "Graphic Color"............................................................................................................... 527 Options................................................................................................................... 527 "Graphic Format".............................................................................................................. 527 Options................................................................................................................... 527 IGBT haul truck SIBAS® user manual, part 2........................................................................................ 529 Traco Menu.................................................................................................................... 531 HW-Traco...................................................................................................................... 531 Options................................................................................................................... 532 SW-Traco...................................................................................................................... 533 Options................................................................................................................... 534 ZR traco basic parameters:................................................................................................ 534 ZR traco record signal table:............................................................................................. 534 DAC_Traco..................................................................................................................... 537 Options................................................................................................................... 538 Events Menu................................................................................................................... 539 STatistics.................................................................................................................... 540 History....................................................................................................................... 541 LEL:Last EvL.................................................................................................................. 542 LES:Last EvS.................................................................................................................. 544 DLL:DC,LastL.................................................................................................................. 545 DLS:DC,LastS.................................................................................................................. 546 DAL:DC,All L.................................................................................................................. 547 DAS:DC,All S.................................................................................................................. 548 ML:Memory L................................................................................................................... 549 MS:Memory S................................................................................................................... 550 CN:Clear Norm................................................................................................................. 551 CA:Clear All.................................................................................................................. 551 Test-Code..................................................................................................................... 551 DS:Diag-Strc.................................................................................................................. 552 User Menu..................................................................................................................... 553 DAC_IO........................................................................................................................ 554 Options................................................................................................................... 554 Options................................................................................................................... 555 Operat.Data............................................................................................................... 556 Acc test...................................................................................................................... 563 Engine_Test................................................................................................................... 563 X_Test_Inx.................................................................................................................... 566 STate intern.................................................................................................................. 567 Header:................................................................................................................... 567 Vehicle Number:........................................................................................................... 567 Powering system:.......................................................................................................... 567 TCU Operation Mode:....................................................................................................... 567 Component status listings:................................................................................................ 568 Field regulator status:................................................................................................... 568 Status gate unit power supply A:.......................................................................................... 568 Status gate unit power supply B:.......................................................................................... 568 ST inverter status........................................................................................................ 569 Vehicle status............................................................................................................ 569 Drive status:............................................................................................................. 569 Operation status:......................................................................................................... 570 Pedal calib................................................................................................................... 571 Language...................................................................................................................... 572 OFFline-test.................................................................................................................. 572 Options................................................................................................................... 572 Variables..................................................................................................................... 573 Examples:................................................................................................................. 573 IV:Vehic-ID................................................................................................................... 575 Commands...................................................................................................................... 575 Discharge Dc link / Fire crowbar.......................................................................................... 576 Limp mode commands........................................................................................................ 576 Settings...................................................................................................................... 577 Parameters.................................................................................................................... 578 Temp_prot..................................................................................................................... 580 Appendix...................................................................................................................... 582 Background commands........................................................................................................... 582 Monitor commands for the central processing unit.............................................................................. 583 Monitor commands for the signal processing unit............................................................................... 583 Installing ZR / DSP software...................................................................................................... 585 Monitor Program – Loading software into the SIBAS®............................................................................ 586 Loading software into the DSP procedure....................................................................................... 586 Loading a DSP program Inverter A.............................................................................................. 591 Loading ZR software Prog. jumpers Reset....................................................................................... 605 24V electrical system ............................................................................................................ 609 Body position switches (with proximity switches and metal arms)............................................................... 610 Body up switch adjustment................................................................................................. 610 Hoist limit switch adjustment............................................................................................. 611 Service................................................................................................................... 611 Body position switches (with proximity switches and magnets).................................................................. 612 Body up switch adjustment................................................................................................. 612 Hoist limit switch adjustment............................................................................................. 612 Service................................................................................................................... 612 40 Troubleshooting.................................................................................................................... 617 Cab air conditioning.............................................................................................................. 617 Preliminary checks............................................................................................................ 619 Diagnosis of gauge readings and system performance............................................................................ 619 Troubleshooting by manifold gauge set readings................................................................................ 620 Fuse and circuit breaker locations................................................................................................ 627 Fuse and circuit breaker locations............................................................................................ 628 Troubleshooting by fault code, part 1............................................................................................. 633 Fault Code A001: Left front suspension pressure sensor signal high............................................................ 635 Related circuit diagram................................................................................................... 635 Fault Code A002: Left front suspension pressure sensor signal low............................................................. 636 Related circuit diagram................................................................................................... 636 Fault Code A003: Right front suspension pressure sensor signal high........................................................... 637 Related circuit diagram................................................................................................... 637 Fault Code A004: Right front suspension pressure sensor signal low............................................................ 638 Related circuit diagram................................................................................................... 638 Fault Code A005: Left rear suspension pressure sensor signal high............................................................. 639 Related circuit diagram................................................................................................... 639 Fault Code A006: Left rear suspension pressure sensor signal low.............................................................. 640 Related circuit diagram................................................................................................... 640 Fault Code A007: Right rear suspension pressure sensor signal high............................................................ 641 Related circuit diagram................................................................................................... 641 Fault Code A008: Right rear suspension pressure sensor signal low............................................................. 642 Related circuit diagram................................................................................................... 642 Fault Code A009: Incline sensor signal high................................................................................... 643 Related circuit diagram................................................................................................... 643 Fault Code A010: Incline sensor signal low.................................................................................... 644 Related circuit diagram................................................................................................... 644 Fault Code A011: Payload meter speed sensor signal has failed................................................................. 645 Related circuit diagram................................................................................................... 645 Fault Code A013: Body up switch has failed.................................................................................... 646 Related circuit diagram................................................................................................... 646 Fault Code A014: Payload meter checksum computation has failed................................................................ 647 Related circuit diagram................................................................................................... 647 Fault Code A016: Payload meter write to flash memory has failed............................................................... 648 Related circuit diagram................................................................................................... 648 Fault Code A017: Payload meter flash memory read has failed................................................................... 649 Related circuit diagram................................................................................................... 649 Fault Code A018: Right rear flat suspension cylinder warning.................................................................. 650 Related circuit diagram................................................................................................... 651 Fault Code A019: Left rear flat suspension cylinder warning................................................................... 652 Related circuit diagram................................................................................................... 653 Fault Code A022: Carryback load excessive..................................................................................... 654 Related circuit diagram................................................................................................... 655 Fault Code A100: An open circuit breaker has been detected on a relay board................................................... 657 Related circuit diagram................................................................................................... 657 Fault Code A101: High pressure detected across an hydraulic pump filter....................................................... 658 Related circuit diagram................................................................................................... 659 Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level...................................... 660 Related circuit diagram................................................................................................... 661 Fault Code A111: Low steering pressure warning for storage by VHMS............................................................ 662 Related circuit diagram................................................................................................... 662 Fault Code A115: Low steering precharge pressure detected..................................................................... 664 Related circuit diagram................................................................................................... 665 Fault Code A117: Low brake accumulator pressure warning for storage by VHMS................................................... 666 Related circuit diagram................................................................................................... 666 Fault Code A118: Brake pressure is low while in brake lock.................................................................... 668 Related circuit diagram................................................................................................... 669 Fault Code A126: Oil level in the hydraulic tank is low....................................................................... 670 Related circuit diagram................................................................................................... 670 Fault Code A127: IM-furnished +5 volt output for sensors is low............................................................... 672 Related circuit diagram................................................................................................... 673 Fault Code A128: IM-furnished +5 volt output for sensors is high.............................................................. 674 Related circuit diagram................................................................................................... 675 Fault Code A139: Low fuel warning for storage by VHMS and for use by A310..................................................... 676 Related circuit diagram................................................................................................... 677 Troubleshooting by fault code, part 2............................................................................................. 679 Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil.... 682 Related circuit diagram................................................................................................... 683 Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil.... 684 Related circuit diagram................................................................................................... 685 Fault Code A152: Starter failure.............................................................................................. 686 Related circuit diagram................................................................................................... 687 Fault Code A153: Battery voltage is low with the truck in operation........................................................... 688 Related circuit diagram................................................................................................... 689 Fault Code A154: Battery charging voltage is excessive........................................................................ 690 Related circuit diagram................................................................................................... 690 Fault Code A155: Battery charging voltage is low.............................................................................. 691 Related circuit diagram................................................................................................... 691 Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level................................. 692 Related circuit diagram................................................................................................... 693 Fault Code A159: (A30003 only) The battery 12 Volt circuit sensing is producing low readings.................................. 694 Related circuit diagram................................................................................................... 694 Fault Code A164: (A30003 only) The battery 12 Volt circuit sensing is producing high readings................................. 695 Related Circuit Diagram................................................................................................... 695 Fault Code A166: Left rear hydraulic oil temperature sensor is low............................................................ 696 Related circuit diagram................................................................................................... 697 Fault Code A167: Right rear hydraulic oil temperature sensor is low........................................................... 698 Related circuit diagram................................................................................................... 699 Fault Code A168: Left front hydraulic oil temperature sensor is low........................................................... 700 Related circuit diagram................................................................................................... 701 Fault Code A169: Right front hydraulic oil temperature sensor is low.......................................................... 702 Related circuit diagram................................................................................................... 703 Fault Code A170: Left rear hydraulic oil temperature sensor is high........................................................... 704 Related circuit diagram................................................................................................... 704 Fault Code A171: Right rear hydraulic oil temperature sensor is high.......................................................... 705 Related circuit diagram................................................................................................... 705 Fault Code A172: Left front hydraulic oil temperature sensor is high.......................................................... 706 Related circuit diagram................................................................................................... 706 Fault Code A173: Right front hydraulic oil temperature sensor is high......................................................... 707 Related circuit diagram................................................................................................... 707 Fault Code A182: (A30003 only) The battery 12 Volt battery tap has high voltage............................................... 708 Related circuit diagram................................................................................................... 709 Fault Code A183: (A30003 only) The battery 12 Volt battery tap has low voltage................................................ 710 Related circuit diagram................................................................................................... 711 Fault Code A184: J1939 data link is not connected............................................................................. 712 Related circuit diagram................................................................................................... 713 Fault Code A190: (A30003 only) The automatic lubrication system has announced a fault......................................... 714 Fault Code A190: (A30004 & Up) Auto lube control has detected an incomplete lube cycle........................................ 716 Related circuit diagram................................................................................................... 717 Fault Code A194: Left front hydraulic oil temperature is high................................................................. 718 Related circuit diagram................................................................................................... 718 Fault Code A195: Right front hydraulic oil temperature is high................................................................ 719 Related circuit diagram................................................................................................... 719 Fault Code A196: Left rear hydraulic oil temperature is high.................................................................. 720 Related circuit diagram................................................................................................... 720 Fault Code A197: Right rear hydraulic oil temperature is high................................................................. 721 Related circuit diagram................................................................................................... 721 Fault Code A198: Hoist pressure 1 sensor is high.............................................................................. 722 Related circuit diagram................................................................................................... 722 Fault Code A199: Hoist pressure 2 sensor is high.............................................................................. 723 Related circuit diagram................................................................................................... 723 Fault Code A200: Steering pressure sensor is high............................................................................. 724 Related circuit diagram................................................................................................... 724 Fault Code A201: Brake pressure sensor is high................................................................................ 725 Related circuit diagram................................................................................................... 725 Fault Code A202: Hoist pressure 1 sensor is low............................................................................... 726 Related circuit diagram................................................................................................... 726 Fault Code A203: Hoist pressure 2 sensor is low............................................................................... 727 Related circuit diagram................................................................................................... 727 Fault Code A204: Steering pressure sensor is low.............................................................................. 728 Related circuit diagram................................................................................................... 728 Fault Code A205: Brake pressure sensor is low................................................................................. 729 Related circuit diagram................................................................................................... 729 Fault Code A206: Ambient temperature sensor is high........................................................................... 730 Related circuit diagram................................................................................................... 730 Fault Code A207: Ambient temperature sensor is low............................................................................ 731 Related circuit diagram................................................................................................... 731 Troubleshooting by fault code, Part 3............................................................................................. 733 Fault Code A213: Parking brake should have applied but is detected as not having applied...................................... 735 Related circuit diagram................................................................................................... 738 Fault Code A214: Parking brake should have released but is detected as not having released.................................... 740 Related circuit diagram................................................................................................... 742 Fault Code A215: Brake auto apply valve circuit is defective.................................................................. 744 Related circuit diagram................................................................................................... 745 Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit...................... 746 Related circuit diagram................................................................................................... 747 Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted.................................... 748 Related circuit diagram................................................................................................... 749 Fault Code A230: Parking brake has been requested while truck still moving.................................................... 750 Related circuit diagram................................................................................................... 751 Fault Code A231: The body is up while traveling or with selector in forward or neutral........................................ 752 Fault Code A233: Drive System Control Link is not connected................................................................... 754 Related circuit diagram................................................................................................... 755 Fault Code A235: Steering accumulator is in the process of being bled down.................................................... 756 Related circuit diagram................................................................................................... 757 Fault Code A236: The steering accumulator has not properly bled down after 90 seconds......................................... 758 Related circuit diagram................................................................................................... 759 Fault Code A237: The CAN/RPC connection to the display is open................................................................ 760 Related circuit diagram................................................................................................... 761 Fault Code A238: Drive System and IM are reporting different park brake status................................................ 762 Related circuit diagram................................................................................................... 763 Fault Code A239: The Drive System and IM are reporting different brake lock status............................................ 764 Related circuit diagram................................................................................................... 765 Fault Code A240: The keyswitch input to the Interface Module is open.......................................................... 766 Related circuit diagram................................................................................................... 766 Fault Code A242: Fuel gauge within the dash display panel is defective........................................................ 767 Related circuit diagram................................................................................................... 767 Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective.................................. 768 Related circuit diagram................................................................................................... 768 Fault Code A244: Drive system temperature gauge within the dash display panel is defective.................................... 769 Related circuit diagram................................................................................................... 769 Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective................................... 770 Related circuit diagram................................................................................................... 770 Fault Code A246: Payload meter reports truck overload......................................................................... 771 Related circuit diagram................................................................................................... 771 Fault Code A247: Low steering pressure warning for display to operator........................................................ 772 Related circuit diagram................................................................................................... 772 Fault Code A248: Status module within the dash display panel is defective..................................................... 773 Related circuit diagram................................................................................................... 773 Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted........................................... 774 Related circuit diagram................................................................................................... 774 Fault Code A250: Battery voltage is low with the truck parked................................................................. 775 Related circuit diagram................................................................................................... 776 Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground.............................. 777 Related circuit diagram................................................................................................... 778 Fault Code A252: Start enable output circuit is either open or shorted to ground.............................................. 779 Related circuit diagram................................................................................................... 779 Fault Code A253: Steering bleed circuit is not open while running............................................................. 780 Related circuit diagram................................................................................................... 781 Fault Code A254: (A30003 Only) The 5 minute idle circuit is either open or shorted to ground.................................. 782 Related circuit diagram................................................................................................... 782 Fault Code A256: Red warning lamp in the dash display (driven by IM) is open.................................................. 783 Related circuit diagram................................................................................................... 783 Fault Code A257: Payload CAN/RPC is not connected............................................................................. 784 Related circuit diagram................................................................................................... 785 Fault Code A258: Steering accumulator bleed pressure switch circuit is defective.............................................. 786 Related circuit diagram................................................................................................... 786 Troubleshooting by fault code, Part 4............................................................................................. 789 Fault Code A260: Park brake failure........................................................................................... 792 Related circuit diagram................................................................................................... 793 Fault Code A261: Low brake accumulator pressure warning for display to operator............................................... 794 Related circuit diagram................................................................................................... 794 Fault Code A262: Steering bleed valve circuit open during shutdown............................................................ 796 Related circuit diagram................................................................................................... 797 Fault Code A264: Park brake relay circuit is defective........................................................................ 798 Related circuit diagram................................................................................................... 799 Fault Code A265: Service brake failure........................................................................................ 800 Related circuit diagram................................................................................................... 801 Fault Code A266: Selector switch was not in park while attempting to crank engine............................................. 802 Related circuit diagram................................................................................................... 802 Fault Code A267: Park brake was not set while attempting to crank engine...................................................... 803 Related circuit diagram................................................................................................... 803 Fault Code A268: Secondary engine shutdown while cranking..................................................................... 804 Related circuit diagram................................................................................................... 804 Fault Code A270: Brake lock switch power supply is not on when required....................................................... 806 Related circuit diagram................................................................................................... 807 Fault Code A271: Shifter not in gear.......................................................................................... 808 Related circuit diagram................................................................................................... 809 Fault Code A272: Brake lock switch power supply is not off when required...................................................... 810 Related circuit diagram................................................................................................... 811 Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit....................... 812 Related circuit diagram................................................................................................... 812 Fault Code A274: A brake setting fault has been detected...................................................................... 814 Related circuit diagram................................................................................................... 815 Fault Code A275: A starter has been detected as engaged without a cranking attempt............................................ 816 Related circuit diagram................................................................................................... 817 Fault Code A277: Park brake applied while loading............................................................................. 818 Related circuit diagram................................................................................................... 819 Fault Code A278: Service brake applied while loading.......................................................................... 820 Related circuit diagram................................................................................................... 821 Fault Code A279: Low Steering Pressure Switch bad............................................................................. 822 Related circuit diagram................................................................................................... 822 Fault Code A280: Steering accumulator bled switch bad......................................................................... 823 Related circuit diagram................................................................................................... 823 Fault Code A281: Brake lock degrade switch bad................................................................................ 824 Related circuit diagram................................................................................................... 825 Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7............. 826 Related circuit diagram................................................................................................... 827 Fault Code A283: (A30004 & Up) An engine shutdown delay was aborted because the parking brake was not set..................... 828 Related circuit diagram................................................................................................... 829 Fault Code A284: (A30004 & Up) An engine shutdown delay was aborted because the secondary shutdown switch was operated........ 830 Related circuit diagram................................................................................................... 831 Fault Code A285: (A30004 & Up) The park brake was not set when the keyswitch was turned off................................... 832 Related circuit diagram................................................................................................... 833 Fault Code A286: (A30004 & Up) A fault was detected in the shutdown delay relay circuit....................................... 834 Related circuit diagram................................................................................................... 835 Fault Code A292: (A30004 & Up) The shutdown delay relay has remained on after the latched keyswitch circuit is off............ 836 Related circuit diagram................................................................................................... 837 Fault Code A295: The right front park brake is not setting up................................................................. 838 Related circuit diagram................................................................................................... 838 Fault Code A296: The left front park brake is not setting up.................................................................. 839 Related circuit diagram................................................................................................... 839 Fault Code A297:The right rear park brake is not setting up................................................................... 840 Related circuit diagram................................................................................................... 840 Fault Code A298: The left rear park brake is not setting up................................................................... 841 Related circuit diagram................................................................................................... 841 Fault Code A299: The right front park brake is not releasing.................................................................. 842 Related circuit diagram................................................................................................... 842 Fault Code A300: The left front park brake is not releasing................................................................... 843 Related circuit diagram................................................................................................... 843 Fault Code A301: The right rear park brake is not releasing................................................................... 844 Related circuit diagram................................................................................................... 844 Fault Code A302: The left rear park brake is not releasing.................................................................... 845 Related circuit diagram................................................................................................... 845 Troubleshooting by fault code, part 5............................................................................................. 847 Fault Code A303: Shifter is defective......................................................................................... 850 Related circuit diagram................................................................................................... 851 Fault Code A304: (A30004 & Up) Auto lube grease level fault................................................................... 852 Related circuit diagram................................................................................................... 852 Fault Code A305: (A30004 & Up) Auto lube circuit is defective................................................................. 854 Related circuit diagram................................................................................................... 855 Fault Code A309: No brakes applied when expected.............................................................................. 856 Related circuit diagram................................................................................................... 857 Fault Code A310: Low fuel warning............................................................................................. 858 Related circuit diagram................................................................................................... 859 Fault Code A311: Brake lock switch is on when it should not be................................................................ 860 Related circuit diagram................................................................................................... 861 Fault Code A312: (A30004 & Up) DCDC converter 12 volt circuit sensing is producing low readings............................... 862 Related circuit diagram................................................................................................... 862 Fault Code A313: (A30004 & Up) DCDC converter 12 volt circuit sensing is producing high readings.............................. 863 Related circuit diagram................................................................................................... 863 Fault Code A315: (A30004 & Up) DCDC converter 12 volt circuit is low.......................................................... 864 Related circuit diagram................................................................................................... 865 Fault Code A316: Starter engagement has been attempted with engine running.................................................... 866 Related circuit diagram................................................................................................... 867 Fault Code A317: Operation of brake auto apply valve without a detected response.............................................. 868 Related circuit diagram................................................................................................... 869 Fault Code A318: Unexpected power loss to Interface Module.................................................................... 870 Related circuit diagram................................................................................................... 870 Fault Code A328: Drive system not powered up.................................................................................. 871 Related circuit diagram................................................................................................... 871 Fault Code A350: Overload on output 1B........................................................................................ 872 Related circuit diagram................................................................................................... 872 Fault Code A351: Overload on output 1E........................................................................................ 874 Related circuit diagram................................................................................................... 875 Fault Code A352: (A30003) Overload on output 1H............................................................................... 876 Related circuit diagram................................................................................................... 876 Fault Code A352: (A30004 & Up) Overload on output 1H.......................................................................... 877 Related circuit diagram................................................................................................... 877 Fault Code A353: Overload on output 1J........................................................................................ 878 Related circuit diagram................................................................................................... 878 Fault Code A354: Overload on output 1K........................................................................................ 879 Related circuit diagram................................................................................................... 879 Fault Code A355: Overload on output 1L........................................................................................ 880 Related circuit diagram................................................................................................... 880 Fault Code A356: Overload on output 1M........................................................................................ 881 Related circuit diagram................................................................................................... 881 Fault Code A357: Overload on output 1N........................................................................................ 882 Related circuit diagram................................................................................................... 882 Fault Code A358: Overload on output 1P........................................................................................ 883 Related circuit diagram................................................................................................... 883 Fault Code A359: Overload on output 1R........................................................................................ 884 Related circuit diagram................................................................................................... 885 Fault Code A360: Overload on output 1S........................................................................................ 886 Related circuit diagram................................................................................................... 886 Fault Code A361: (A30003) Overload on output 1T............................................................................... 887 Related circuit diagram................................................................................................... 887 None...................................................................................................................... 887 Fault Code A361: (A30004 & Up) Overload on output 1T.......................................................................... 888 Related circuit diagram................................................................................................... 889 Fault Code A362: Overload on output 1U........................................................................................ 890 Related circuit diagram................................................................................................... 890 Fault Code A363: Overload on output 1X........................................................................................ 891 Related circuit diagram................................................................................................... 891 Fault Code A364: Overload on output 1Y........................................................................................ 892 Related circuit diagram................................................................................................... 892 Fault Code A365: Overload on output 1Z........................................................................................ 893 Related circuit diagram................................................................................................... 893 Drive system fault code table, Part 1............................................................................................. 895 Summary....................................................................................................................... 897 How to use this document...................................................................................................... 897 Event code and diagnosis message.............................................................................................. 897 Description................................................................................................................... 897 Threshold..................................................................................................................... 897 Detection by.................................................................................................................. 897 Possible reasons.............................................................................................................. 897 Action to reset............................................................................................................... 897 Action to repair.............................................................................................................. 898 Operator displayed code....................................................................................................... 898 Note.......................................................................................................................... 898 Protection reactions.......................................................................................................... 898 EVENT CLASSIFICATION.......................................................................................................... 898 Level 1: Warning.............................................................................................................. 899 Level 2: Minor purposes....................................................................................................... 899 Level 3: Severe............................................................................................................... 899 Drive system fault code table, Part 2............................................................................................. 935 Drive system fault code table, Part 3............................................................................................. 975 Drive system fault code table, Part 4.............................................................................................1035 Drive system fault code table, Part 5.............................................................................................1089 Drive system fault code table, Part 6.............................................................................................1163 Drive system fault code table, Part 7.............................................................................................1213 Troubleshooting electric wheel motor..............................................................................................1287 FAULT TABLE...................................................................................................................1288 Reserve engine oil system.........................................................................................................1297 Pumping unit LED signals......................................................................................................1299 Circuit fuses.............................................................................................................1299 50 Disassembly and assembly...........................................................................................................1301 General information ..............................................................................................................1301 Special tool list.............................................................................................................1302 Cab air conditioning..............................................................................................................1311 Replacement of air conditioning system components.............................................................................1313 Hoses and fittings........................................................................................................1313 Lines.....................................................................................................................1313 Expansion valve...........................................................................................................1313 Receiver-drier............................................................................................................1313 Thermostat................................................................................................................1313 Compressor................................................................................................................1314 Accumulator...............................................................................................................1314 Clutch....................................................................................................................1314 Wheels, spindles and rear axle....................................................................................................1319 General information for tires and rims........................................................................................1321 Storage and handling......................................................................................................1321 Wheel stud maintenance........................................................................................................1322 Front wheel studs.........................................................................................................1322 Rear wheel studs..........................................................................................................1322 Removal and installation of front wheel.......................................................................................1324 Removal...................................................................................................................1324 Installation..............................................................................................................1324 Removal and installation of rear wheels.......................................................................................1326 Removal...................................................................................................................1326 Installation..............................................................................................................1327 Removal and installation of tires.............................................................................................1328 Removal...................................................................................................................1328 Installation..............................................................................................................1329 Removal and installation of front wheel hub and spindle.......................................................................1331 Removal...................................................................................................................1332 Spindle Removal Procedure (off of the truck)..............................................................................1335 Installation..............................................................................................................1337 Disassembly and assembly of front wheel hub and spindle.......................................................................1338 Disassembly...............................................................................................................1338 Cleaning and inspection...................................................................................................1339 Assembly..................................................................................................................1341 Wheel bearing adjustment..................................................................................................1341 Seal assembly gap check and adjustment....................................................................................1342 Floating seal installation................................................................................................1343 Speed sensor installation and adjustment..................................................................................1345 Removal and installation of wheel motor.......................................................................................1346 Preparation...............................................................................................................1346 Removal...................................................................................................................1346 Cleaning and inspection...................................................................................................1347 Installation..............................................................................................................1348 Removal and installation of rear axle.........................................................................................1351 Removal...................................................................................................................1351 Cleaning and inspection...................................................................................................1352 Installation..............................................................................................................1353 Removal and installation of anti-sway bar.....................................................................................1353 Removal...................................................................................................................1353 Installation..............................................................................................................1354 Removal and installation of pivot pin.........................................................................................1355 Removal...................................................................................................................1355 Installation..............................................................................................................1355 Pivot eye and bearing service.................................................................................................1356 Bearing removal...........................................................................................................1356 Bearing installation......................................................................................................1356 Pivot eye repair..........................................................................................................1357 Removal and installation of electric motor....................................................................................1358 Removal...................................................................................................................1358 Installation..............................................................................................................1358 Disassembly and assembly of wheel motor transmission..........................................................................1359 Disassembly...............................................................................................................1359 Cleaning and inspection...................................................................................................1365 Assembly..................................................................................................................1366 Disassembly and assembly of low speed carrier.................................................................................1377 Disassembly...............................................................................................................1377 Inspection................................................................................................................1378 Assembly..................................................................................................................1379 Disassembly and assembly of high speed carrier................................................................................1382 Disassembly...............................................................................................................1382 Inspection................................................................................................................1383 Assembly..................................................................................................................1384 Brake System .....................................................................................................................1389 Removal and installation of brake valve.......................................................................................1391 Removal...................................................................................................................1391 Installation..............................................................................................................1392 Disassembly and assembly of brake valve.......................................................................................1392 Disassembly...............................................................................................................1392 Cleaning and inspection...................................................................................................1396 Assembly..................................................................................................................1396 Removal and installation of dual relay valve..................................................................................1400 Removal...................................................................................................................1400 Installation..............................................................................................................1401 Disassembly and assembly of dual relay valve..................................................................................1401 Disassembly...............................................................................................................1401 Cleaning and inspection...................................................................................................1402 Assembly..................................................................................................................1402 Removal and installation of brake manifold....................................................................................1403 Removal...................................................................................................................1403 Installation..............................................................................................................1404 Disassembly and assembly of brake manifold....................................................................................1404 Disassembly...............................................................................................................1404 Assembly..................................................................................................................1404 Removal and installation of brake accumulator.................................................................................1405 Removal...................................................................................................................1405 Installation..............................................................................................................1406 Disassembly and assembly of brake accumulator.................................................................................1406 Disassembly...............................................................................................................1406 Cleaning and inspection...................................................................................................1408 Assembly..................................................................................................................1408 Disassembly and assembly of wheel brake.......................................................................................1410 Disassembly...............................................................................................................1411 Cleaning and inspection...................................................................................................1414 Assembly..................................................................................................................1415 Floating ring seal assembly and installation..............................................................................1421 Removal and installation of rear brake assembly...............................................................................1425 Removal...................................................................................................................1425 Installation..............................................................................................................1425 Steering System ..................................................................................................................1431 Removal and installation of steering control unit.............................................................................1433 Removal...................................................................................................................1433 Installation..............................................................................................................1434 Disassembly and assembly of steering control unit.............................................................................1435 Disassembly...............................................................................................................1435 Assembly..................................................................................................................1437 Removal and installation of steering column...................................................................................1440 Removal...................................................................................................................1440 Inspection................................................................................................................1440 Installation..............................................................................................................1441 Removal and installation of steering wheel....................................................................................1442 Removal...................................................................................................................1442 Installation..............................................................................................................1442 Removal and installation of bleed down manifold...............................................................................1444 Removal...................................................................................................................1444 Installation..............................................................................................................1444 Removal and installation of flow amplifier....................................................................................1446 Removal...................................................................................................................1446 Installation..............................................................................................................1446 Disassembly and assembly of flow amplifier....................................................................................1446 Disassembly...............................................................................................................1446 Assembly..................................................................................................................1448 Removal and installation of steering cylinder.................................................................................1449 Removal...................................................................................................................1449 Bearing replacement.......................................................................................................1449 Installation..............................................................................................................1450 Disassembly and assembly of steering cylinders................................................................................1451 Disassembly...............................................................................................................1451 Assembly..................................................................................................................1451 Removal and installation of tie rod...........................................................................................1452 Removal...................................................................................................................1452 Installation..............................................................................................................1453 Disassembly and assembly of tie rod...........................................................................................1453 Disassembly...............................................................................................................1453 Assembly..................................................................................................................1453 Removal and installation of steering/brake pump...............................................................................1454 Removal...................................................................................................................1454 Installation..............................................................................................................1455 Disassembly and assembly of steering/brake pump...............................................................................1456 Disassembly...............................................................................................................1456 Inspection................................................................................................................1460 Assembly..................................................................................................................1463 Driveshaft group..........................................................................................................1464 Rotating group............................................................................................................1464 Removal and installation of steering accumulators.............................................................................1467 Removal Use vacuum pump kit (XB0887) to hold the oil back in the tank.....................................................1467 Installation..............................................................................................................1468 Disassembly and assembly of steering accumulators.............................................................................1468 Disassembly...............................................................................................................1468 Cleaning and Inspection...................................................................................................1470 Assembly..................................................................................................................1470 Suspensions ......................................................................................................................1475 Removal and installation of front suspension..................................................................................1477 Removal...................................................................................................................1477 Installation..............................................................................................................1478 Inspection................................................................................................................1483 Minor front suspension repairs (lower bearing and seals)......................................................................1484 Lower bearing retainer removal............................................................................................1484 Lower bearing retainer installation.......................................................................................1484 Major front suspension rebuild................................................................................................1485 Disassembly...............................................................................................................1485 Assembly..................................................................................................................1486 Removal and installation of rear suspension...................................................................................1488 Removal...................................................................................................................1489 Installation..............................................................................................................1490 Disassembly and assembly of rear suspension...................................................................................1491 Disassembly...............................................................................................................1491 Cleaning and Inspection...................................................................................................1492 Assembly..................................................................................................................1492 Hoist circuit ....................................................................................................................1495 Removal and installation of hoist pump........................................................................................1497 Removal...................................................................................................................1497 Installation..............................................................................................................1498 Disassembly and assembly of hoist pump........................................................................................1499 Disassembly...............................................................................................................1499 Inspection................................................................................................................1502 Assembly..................................................................................................................1502 Removal and installation of hoist valve.......................................................................................1507 Removal...................................................................................................................1507 Installation..............................................................................................................1508 Disassembly and assembly of hoist valve.......................................................................................1508 O-ring replacement........................................................................................................1508 Disassembly of inlet section..............................................................................................1509 Assembly of inlet section.................................................................................................1510 Disassembly of rear spool section.........................................................................................1511 Assembly of rear spool section............................................................................................1513 Disassembly of front spool section........................................................................................1514 Assembly of front spool section...........................................................................................1515 Overcenter valve manifold service.............................................................................................1515 Removal and installation of hoist pilot valve.................................................................................1516 Removal...................................................................................................................1516 Installation..............................................................................................................1516 Disassembly and assembly of hoist pilot valve.................................................................................1517 Disassembly...............................................................................................................1517 Cleaning and inspection...................................................................................................1518 Assembly..................................................................................................................1518 Removal and installation of hoist cylinders...................................................................................1519 Removal...................................................................................................................1519 Installation..............................................................................................................1519 Disassembly and assembly of hoist cylinders...................................................................................1521 Disassembly...............................................................................................................1521 Cleaning and inspection...................................................................................................1523 Installation of the quill.................................................................................................1524 Assembly..................................................................................................................1526 Operator cab .....................................................................................................................1529 Removal and installation of operator cab......................................................................................1531 Removal...................................................................................................................1532 Installation..............................................................................................................1533 Removal and installation of cab door..........................................................................................1535 Removal...................................................................................................................1535 Installation..............................................................................................................1535 Disassembly and assembly of cab door..........................................................................................1535 Removing door panel.......................................................................................................1535 Installing door panel.....................................................................................................1536 Replacing door window regulator...........................................................................................1536 Replacing door handle or latch assembly...................................................................................1537 Replacing door assembly seal and door hinge seal..........................................................................1538 Replacing door opening seal...............................................................................................1538 Removing door glass.......................................................................................................1539 Installing door glass.....................................................................................................1540 Adjustment of cab door........................................................................................................1542 Door jamb bolt adjustment.................................................................................................1542 Door handle plunger adjustment............................................................................................1543 Removal and installation of side window glass.................................................................................1544 Recommended tools and supplies............................................................................................1544 Removal...................................................................................................................1545 Installation..............................................................................................................1545 Removal and installation of windshield and rear window glass..................................................................1546 Removal...................................................................................................................1546 Installation..............................................................................................................1546 Removal and installation of windshield wiper motor............................................................................1547 Removal...................................................................................................................1547 Installation..............................................................................................................1547 Removal and installation of windshield wiper arm..............................................................................1548 Removal...................................................................................................................1548 Installation..............................................................................................................1548 Removal and installation of windshield wiper linkage..........................................................................1549 Removal...................................................................................................................1549 Installation..............................................................................................................1549 Removal and installation of operator seat.....................................................................................1550 Inspection................................................................................................................1550 Removal...................................................................................................................1550 Installation..............................................................................................................1550 Removal and installation of passenger seat....................................................................................1551 Removal...................................................................................................................1551 Installation..............................................................................................................1551 Removal and installation of seat belts (standard seats).......................................................................1552 Removal...................................................................................................................1552 Installation..............................................................................................................1552 Removal and installation of seat belts (optional seats).......................................................................1554 General...................................................................................................................1554 Removal...................................................................................................................1554 Installation..............................................................................................................1556 Body and structures ..............................................................................................................1561 Removal and installation of dump body.........................................................................................1563 Removal...................................................................................................................1563 Inspection................................................................................................................1564 Installation..............................................................................................................1565 Removal and installation of body pads.........................................................................................1565 Removal...................................................................................................................1565 Installation..............................................................................................................1566 Adjustment................................................................................................................1566 Removal and installation of diagonal ladder/ hood and grille assembly.........................................................1568 Removal...................................................................................................................1568 Installation..............................................................................................................1568 Removal and installation of right deck........................................................................................1569 Removal...................................................................................................................1569 Installation..............................................................................................................1570 Removal and installation of left deck.........................................................................................1572 Removal...................................................................................................................1572 Installation..............................................................................................................1572 Removal and installation of fuel tank.........................................................................................1574 Removal...................................................................................................................1574 Cleaning and inspection...................................................................................................1574 Installation..............................................................................................................1576 Removal and installation of fuel gauge sender.................................................................................1576 Removal...................................................................................................................1576 Installation..............................................................................................................1576 Disassembly and assembly of fuel tank breather................................................................................1577 Disassembly...............................................................................................................1577 Assembly..................................................................................................................1577 Removal and installation of hydraulic tank....................................................................................1578 Removal...................................................................................................................1578 Installation..............................................................................................................1578 Three phase wheel motor ..........................................................................................................1581 Qualified personnel...........................................................................................................1582 General.......................................................................................................................1582 General safety information................................................................................................1582 Handling......................................................................................................................1583 Motor.....................................................................................................................1583 Transport.................................................................................................................1584 Storage...................................................................................................................1585 Storage of new motors.....................................................................................................1585 Storage of used motors....................................................................................................1586 Maintenance...............................................................................................................1586 General note:.........................................................................................................1586 Motor.....................................................................................................................1586 General...............................................................................................................1586 Safety guidelines.....................................................................................................1587 Maintenance intervals.........................................................................................................1588 Maintenance work on the installed motor.......................................................................................1588 Checking for external damage..............................................................................................1588 Checking the connections..................................................................................................1589 Regreasing the bearings...................................................................................................1589 Applying grease to the bearings:..........................................................................................1589 Checking the interior of the motor for water..............................................................................1590 Disassembly...................................................................................................................1591 Pressing off the coupling.................................................................................................1592 Disassembly...............................................................................................................1593 Rotor.................................................................................................................1593 Removing the rubber seals and the air baffles.............................................................................1597 Bearing and labyrinth ring................................................................................................1598 Removal...............................................................................................................1598 Maintenance work..............................................................................................................1599 Stator Inspection.........................................................................................................1599 Rotor Inspection..........................................................................................................1599 Testing the insulation....................................................................................................1600 High-voltage test.....................................................................................................1600 Work on the bearings......................................................................................................1601 Assembly......................................................................................................................1602 Assembling the rubber seals and the air baffles...........................................................................1603 Assembly after special repair work........................................................................................1605 Bearing installation..................................................................................................1606 Assemble the bearing..................................................................................................1610 Cover installation....................................................................................................1611 Assembling the bearing shield (N-end) at the stator frame.................................................................1612 Bearing installation......................................................................................................1614 Rotor installation........................................................................................................1616 Labyrinth ring............................................................................................................1618 Installation..........................................................................................................1618 Installing accessories (D- and N-end).....................................................................................1620 Running in the bearings...................................................................................................1624 Coupling..................................................................................................................1625 Installation..........................................................................................................1625 Assembly conditions and instructions......................................................................................1626 Tests.....................................................................................................................1626 Repair work...................................................................................................................1627 Replacing defective connecting leads......................................................................................1627 Repairing the stator winding insulation...................................................................................1628 Recommended consumables...................................................................................................1628 Chemical cleaning agents..................................................................................................1628 Chemical cleaning agents for outdoor use and for cleaning mechanical parts............................................1628 Chemical cleaning agents for flange faces.............................................................................1628 Chemical cleaning agents for windings.....................................................................................1629 Chemical cleaning agents for windings.................................................................................1629 Chemical cleaning agents for windings with severe damage and for oily windings........................................1629 Rolling-contact bearing grease............................................................................................1629 Assembly/disassembly agents for bearing seat..............................................................................1629 Sealants for joining parts or gaps........................................................................................1629 Locking agents for connecting elements....................................................................................1629 Anti-corrosion agent......................................................................................................1629 Assembly paste for temperature sensors....................................................................................1629 List of tools.................................................................................................................1630 Mounting devices for inserting and withdrawing the rotor horizontally.....................................................1630 Press for expanding the coupling..........................................................................................1630 Compression devices for pressing on or for support while pressing off.....................................................1631 Pulling units with cross beam or disk.....................................................................................1633 Aids......................................................................................................................1633 Extraction devices........................................................................................................1634 Repair parts list.............................................................................................................1634 Paints for refinishing the painted parts or touching up damaged parts.....................................................1634 Power module .....................................................................................................................1637 Removal and installation of power module......................................................................................1639 General...................................................................................................................1639 Preparation...............................................................................................................1639 Removal...................................................................................................................1640 Installation..............................................................................................................1645 Removal and installation of alternator........................................................................................1647 Removal...................................................................................................................1647 Installation..............................................................................................................1649 Removal and installation of engine............................................................................................1652 Removal...................................................................................................................1652 Service...................................................................................................................1653 Installation..............................................................................................................1653 Removal and installation of radiator..........................................................................................1653 Removal...................................................................................................................1653 Installation..............................................................................................................1655 Repairing the radiator........................................................................................................1656 Internal inspection.......................................................................................................1656 External cleaning.........................................................................................................1656 Disassembly...............................................................................................................1657 Cleaning and inspection...................................................................................................1658 Assembly..................................................................................................................1658 Pressure testing..........................................................................................................1659 Auto lubrication system ..........................................................................................................1661 Lubrication system priming....................................................................................................1662 Disassembly and assembly of lubrication pump..................................................................................1662 Disassembly...............................................................................................................1662 Cleaning and Inspection...................................................................................................1664 Assembly..................................................................................................................1664 Main blower.......................................................................................................................1667 Removing the main blower motor................................................................................................1668 Disassembling the main blower motor...........................................................................................1674 Assembling the main blower motor..............................................................................................1676 Installing the main blower motor..............................................................................................1679 Retarding grid....................................................................................................................1687 Removing the grid blower motor................................................................................................1688 Disassembling the grid blower motor...........................................................................................1690 Assembling the grid blower motor..............................................................................................1692 Installing the grid blower motor..............................................................................................1694 Removing a grid element.......................................................................................................1697 Control cabinet...................................................................................................................1701 Draining and filling the IGBT coolant system..................................................................................1703 Required tools/materials..................................................................................................1703 Coolant mixture specification (distilled water : Antifrogen N)............................................................1703 Draining and filling the coolant..........................................................................................1704 Removing and installing the IGBT coolant pump assembly........................................................................1707 Required tools/materials..................................................................................................1707 Removal...................................................................................................................1708 90 Diagrams and drawings .............................................................................................................1711 Hydraulic circuit diagrams .......................................................................................................1711 EM1374 Hydraulic schematic ...................................................................................................1713 EM6298 Hydraulic brake schematic..............................................................................................1714 Electrical circuit diagrams ......................................................................................................1715 EM6700 Electric schematic ....................................................................................................1719 HE488 Connector locater .....................................................................................................1757 Electrical circuit diagrams - drive system........................................................................................1758 HE486 Electric schematic .....................................................................................................1762
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