Komatsu 860E-1K Dump Truck Shop Manual CEBM024206 PDF

Description

Komatsu 860E-1K Dump Truck Shop Manual CEBM024206  – PDF DOWNLOAD

FILE DETAILS:

Komatsu 860E-1K Dump Truck Shop Manual CEBM024206  – PDF DOWNLOAD

Language : English
Pages : 1844
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu 860E-1K Dump Truck Shop Manual CEBM024206  – PDF DOWNLOAD’

• SERIAL NUMBERS 860E-1K A30031 – A30118

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 39
How to read the shop manual 40
Composition of shop manual 40
Revision and distribution 40
Symbols 41
General safety 42
Safety rules 42
Safety features 42
Fire extinguisher and first aid kit 42
Clothing and personal items 42
Leaving the operator seat 43
Mounting and dismounting 43
Fire prevention for fuel and oil 43
Precautions with high temperature fluids 44
Asbestos dust hazard prevention 44
Prevention of injury by work equipment 44
Unauthorized modification 44
Precautions when using ROPS 44
Precautions for attachments 45
Precautions for starting the truck 45
Precautions before operating the truck 45
Safety at the worksite 45
Fire prevention 46
Ventilation in enclosed areas 46
Preparing for operation 46
Mirrors, windows and lights 46
In operator cab (before starting the engine) 46
Seat Belts 46
Precautions while operating the truck 47
When starting the engine 47
General truck operation 47
Ensuring good visibility 47
Traveling 48
Traveling in reverse 48
Traveling on slopes 48
Operating on snow or ice 48
Avoid damage to dump body 48
Driving near high voltage cables 49
When dumping 49
Working on loose ground 49
When loading 49
Parking the truck 49
Towing 50
Working near batteries 50
Battery hazard prevention 50
Starting with jumper cables 51
Jump starting with receptacles 51
Precautions before performing service 52
Warning tag 52
Stopping the engine 52
Proper tools 52
Use of tie-off anchor during maintenance and repair 53
The anchor must not be used for lifting Tie-off anchor installation 53
Securing the dump body 54
While performing maintenance 54
Keep the truck clean 54
Attachments 54
Working under the truck 55
Rotating fan and belts 55
Adding fuel or oil 55
Use of lighting 55
Radiator coolant level 55
Precautions with the battery 55
Precautions with high pressure oil 55
Handling high pressure hoses 56
Precautions when performing maintenance near high temperature or high pressure 56
Waste materials 56
Tires 56
Handling tires 56
Storing tires after removal 57
Precautions for performing repairs 58
Engine shutdown procedure after AC drive system failure 58
Jack point locations 59
Precautions for welding on the truck 60
Handling electrical equipment and hydraulic components 61
Points to remember when handling electrical equipment 61
Points to remember when handling hydraulic equipment 67
How to Read Electric Wire Code 69
Color Code and Harness Designation Tables 70
Standard torque tables 71
Effect of special lubricants on fasteners and standard torque values 71
Suggested sources for rust preventive grease 71
SAE grade 5 and grade 8 hex head capscrew and nut assemblies 72
SAE grade 9 capscrews 73
Class 10 9 capscrews and class 10 nuts 74
Standard tightening torques for fittings 74
Standard tightening torques for clamps 76
Conversion tables 77
Common conversion multipliers 77
01 Specification 81
Specification and technical data 81
Specification drawing 83
Specifications 84
Weight table 86
Fuel, coolant and lubricants 87
Mixing rate of water and anti-freeze 87
Suspension cylinder oil and nitrogen specifications 88
10 Structure and functions 91
Cab air conditioning 91
General information 93
Environmental impact of air conditioning 93
Air conditioning for off-highway vehicles 93
Principles of refrigeration 94
Air conditioning 94
Refrigeration – the act of cooling 94
The refrigeration cycle 94
Air conditioning system components 96
Relays 96
Fan motor and speed control 96
Cab air filter 96
Heater core 96
Actuators 96
Compressor (refrigerant pump) 98
Service valves 98
Condenser 98
Receiver-drier 98
Expansion valve 99
Accumulator 99
Evaporator core 99
Air conditioning system electrical circuit 100
Thermostat 100
Compressor clutch 100
Trinary™ switch 101
Steering circuit 103
Steering circuit operation 105
Steering circuit components 107
Steering control unit 107
High pressure filter 107
Steering accumulators 107
Bleeddown manifold 108
Steering accumulator bleeddown solenoid 111
Quick disconnect ports 111
Hoist up limit solenoid 111
Flow amplifier 111
Flow amplifier operation 112
No steer 112
Steering left 114
Steering right 116
No steer, external shock load 118
Steering/brake pump operation 121
Normal operation 121
Neutral position 122
Full pump volume 123
Half pump volume 123
Steering cylinder wear data 124
Hoist circuit 127
Hoist circuit operation 129
Hoist circuit components 130
Hydraulic tank 130
Hoist pump 130
High pressure filters 130
Hoist valve 130
Hoist limit solenoid 131
Pilot operated check valve 131
Hoist pilot valve 132
Overcenter manifold 132
Hoist pilot valve operation 133
Float position of pilot valve with truck body on frame 133
Power up operation 135
Hold operation 137
Power down operation 139
Float operation 141
Hoist cylinder wear data 143
Brake circuits 145
General information 147
Service brake circuit operation 148
Secondary braking system and auto apply 148
Rear wheel brake lock circuit operation 150
Parking brake circuit operation 152
Normal operation (key switch ON, engine on) 152
Brake lines and test ports 154
Brake warning circuit operation 155
Brake assembly wear data 157
Suspensions 159
General information 161
Front suspension wear data 161
Rear suspension wear data 162
Electrical system, 24 volt 165
Battery supply system 167
Auxiliary control cabinet components 168
24VDC to 12VDC converter 168
Diode board – DB1 168
Power distribution terminals 168
Control power relay 169
Fuse blocks 170
Relay boards 170
Relay boards RB1, RB3, RB4, RB5 170
Relay boards RB6, RB7, RB8, RB9 172
Relay functions 172
Body position switches (With proximity switch and metal arm) 174
Body-up switch 174
Hoist limit switch 175
Body position switches (With proximity switch and magnet) 176
Proximity switch operation 176
Body-up Switch 176
Hoist limit switch 176
Interface module (IM) 179
General information 181
Service 181
Sensors 181
Temperature sensors 181
Pressure sensors 182
Interface module inputs and outputs 183
Drive system 189
SR rectifier module 192
ST module (auxiliary voltage inverter) 192
Technical Data 195
SD phase modules 196
SR/ST/SD module removal 196
Inverter cabinet layout 197
Inverter cabinet water flow 197
Field regulator 198
Technical Data 198
Field regulator (discharge resistor) 198
Technical Data 198
Gate Unit 199
Technical Data 199
Technical Data 199
Technical Data 199
Control power filter 200
Technical Data 200
Filter for TCU 200
Technical Data 200
Terminal block bus bar 201
Technical Data 201
Fuses (analog sensor voltage) 202
Technical Data 202
Fuses (field regulator) 202
Technical Data 202
Fuses (fuse holder for field regulator) 202
Fuses (control power and trolley box contactor) 203
Technical Data 203
Diode modules 203
Technical Data 203
Support capacitors 204
Technical Data 204
3-Phase capacitor bank (for ST module output voltage) 204
Technical Data 204
Air-cooled inductors (for ST module) 205
Technical Data 205
3-Phase transformer (for ST module) 205
Technical Data 205
Diagnostics box 206
Diagnostic and system monitoring panel 207
Technical Data 207
Current transducers 208
Device names: 208
Technical Data 208
Technical Data 208
Current transducers (for ST module output) 209
Technical Data 209
Voltage transducers 210
Technical Data 210
Voltage transducers (for ST module output) 210
Technical Data 210
Voltage transducers (SiBAS® 24V DC bus monitoring) 211
Analog inclinometer 211
Technical Data 211
DC link capacitors 212
Technical Data 212
Ground tie capacitor 212
Technical Data 212
Low-inductance bus bar assembly 213
Free-wheeling diode for low-inductance bus bars 213
Contactor (grid box and main blower motor) 214
Technical Data 214
Contactor (control power) 214
Technical Data 214
Contactor (DC contactors) 215
Technical Data 215
Contactor (crowbar bypass) 215
Technical Data 215
Temperature probes (PT100 style) 216
Technical Data 216
Coolant inlet temperature sensor 216
Technical Data 216
Coolant outlet temperature sensor (external pad style) 217
IGBT module heat sink temperature sensor 217
Coolant outlet temperature sensor (internal style) 217
Technical Data 217
Coolant outlet temperature sensor (external pad style) 218
Technical Data 218
Circuit breakers 219
Technical Data 219
Inner circulating blower fan 219
Coolant pump 220
Technical Data 220
Motor for coolant pump 220
Technical Data 220
Coolant pressure sensor 220
Inner radiator 221
Ground voltage monitoring resistors 221
Protection thyristor assembly (crowbar) 222
Discharge reactor 222
Main blower motor 223
Technical Data 223
Grid box 223
Technical Data 223
Grid box blower motor 224
Technical Data 224
Grid box blower motor grease fittings 224
Main alternator 225
Stator 225
Rotor 225
Bearings 225
Electrical connection 225
Cooling and ventilation 225
Rotating rectifier section 226
Technical Data 226
Main alternator circuit diagram 227
IGBT – inverter/chopper phase module 228
Troubleshooting information 230
Main input rectifier module 231
Internal circuit diagram 232
Upper ground tie resistor 233
Technical Data 233
Lower ground tie resistor 233
Technical Data 233
Troubleshooting – fault diagnosis 234
Speed sensor, alternator 235
Technical Data 235
Speed sensors, wheel motors 236
Technical Data 236
Traction motor 237
Technical Data 237
Grid box 238
Device name: M04 238
Technical Data 238
Step down box 241
SIBAS® IGBT rack components 243
SiBAS®32 Traction Control Unit (TCU) 246
Overview of the SiBAS®32 systems 247
Features 247
General technical specifications, operating conditions 247
Permissible temperature range 247
Permissible limit value for air humidity 248
Permissible power supply voltage range 248
Permissible mechanical loads 248
Protection measures against electrical hazards 248
Application 248
Removing and installing the SiBAS®32 cards 251
Removal with 24V OFF! (ESD protection required) 251
Installation with 24V OFF! (ESD protection required) 251
SiBAS®32 card device names 252
Structure of SiBAS®32 card part number 253
Development status, downward compatibility 253
SiBAS®32 card interchangeability 254
Use of service interfaces 255
Connection of the service unit 255
Maintenance 255
Cleaning 256
SiBAS®32 card interactions 257
Blower subassembly 260
Device name: N/A 260
Application 260
Battery replacement 262
Rules for handling lithium batteries 262
Replacement of the battery in the fan subassembly 262
CPU card 263
Device name: G011 263
Application 264
Front panel 264
Technical data 265
DSP card 266
Device name: G019, G027 and G35 266
Application 266
Front panel 266
Technical data 267
I/O card 268
Device name: G043 268
Application 268
Front panel 269
Technical data 270
TRACO card (optional) 271
Device name: G003 271
Application 271
Front panel 272
Technical data 273
Input voltage/frequency card 274
Device name: L055, L063 and L071 274
Application 274
Technical data 275
I/O analog card 276
Device name: L079 and L087 276
Technical data 278
I/O analog card 279
Device name: L095 and L103 279
Application 279
Technical data 281
Output pulse amplifier card 282
Device name: L115, L123, L131, L139 and L147 282
Application 282
Technical data 284
Input temperature sensor card 285
Device name: L155 and L163 285
Application 285
Technical data 287
UWS card 288
Device name: G055, G063, G071 and G079 288
Application 288
Technical data 290
Digital input card 291
Device name: G103, G111, G119, G127 and G135 291
Application 291
Technical data 293
Power start-up unit card 294
Device name: G163 294
Application 294
Technical data 296
Binary output contactor drive card 297
Device name: C019, C027 and C035 297
Application 297
Technical data 299
24V / 24V power supply 300
Device name: C045, C105, C129 300
Application 300
Testing the power supply card 301
Technical data 302
24V / 15V power supply 303
Device name: C069, C087 303
Application 303
Testing the power supply card 304
Technical data 305
24V / 5V power supply 306
Device name: C153 306
Application 306
Testing the power supply card 307
Technical data 308
Reserve engine oil system 311
General information 313
Operation 314
LED monitor light 314
Remote tank fill system 315
Wheel motor transmission 317
General information 319
Transmission wear data 322
20 Standard value table 327
Standard value table 327
Standard value table for truck 329
30 Testing and adjusting 335
Service tools 335
Special tool list 337
Control cabinet 338
Cab air conditioning 341
General information 343
Service tools and equipment 344
Recovery/recycle station 344
Leak detector 344
Manifold gauge set 345
Service valves 346
Vacuum pump 346
Detecting leaks 347
System performance test 348
Checking system oil 349
System flushing 350
Installing the manifold gauge set 351
Purging air from the service hoses 352
Recovering and recycling refrigerant 353
Draining oil from previous recovery cycle 354
Recovery cycle 354
Recycling procedure 354
Evacuating the air conditioning system 355
Charging the air conditioning system 356
Steering, brake cooling and hoist hydraulic system 359
General information on system checkout 361
Steering system checkout procedures 361
Steering pump pressure control adjustments 362
Steering control valve and flow amplifier leakage test 363
Bleed down manifold leakage test 364
Shock and suction valve pressure tests 365
Steering system checkout data sheet 367
Toe-in adjustment 368
Brake cooling and hoist system checkout procedures 369
Pressure gauge locations 369
Brake cooling circuit test 370
Power up relief pressure test 370
Power down relief pressure test 371
Counterbalance valve pressure check 372
Counterbalance valve adjustment 373
Brake cooling and hoist system checkout data sheet 374
Hydraulic system flushing procedure 375
Front suspension pressure test 382
Rear suspension pressure test 382
Steering cylinder leakage test 383
Hoist cylinder leakage test 383
Brake system 385
General information on system checkout 387
Brake circuit checkout procedure 387
Precheckout items 388
Software operation and configuration 388
Hydraulic isolation and troubleshooting 388
Truck starting procedure 388
Initial system setup 389
Brake lock / secondary braking checkout 390
Brake lock hydraulic circuit trouble shooting guide 392
Parking brake checkout 392
Park brake hydraulic circuit trouble shooting guide: 393
Service brake checkout 395
Blended braking checkout 395
Low brake accumulator pressure and auto apply checkout 396
Reapplication 397
Parking brake control logic checkout 397
Brake lock control logic checkout 399
BLENDED BRAKING CHECKOUT 403
Brake piston leakage test 412
Wet disc brake bleeding procedure 412
Parking/service brake bleeding procedure 413
Parking brake leakage test 414
Brake disc wear inspection 414
Brake valve bench test and adjustment 416
Test setup procedure 417
Brake valve output pressure adjustment 417
Final test and adjustment 418
Accumulators and suspensions 421
Accumulator charging and storage 423
Temperature during precharge 423
Bladder accumulator charging procedure 424
Precharge maintenance 426
Bladder accumulator storage procedure 426
Bladder storage 426
Installing a bladder accumulator from storage 427
Bladder accumulator leak testing 427
Piston accumulator charging procedure 428
Piston accumulator storage 431
Piston accumulator leak testing 432
Checking for improper suspension charge on operating trucks 433
Suspension oil change recommendations 434
Suspension oiling and charging procedures 435
Required equipment 435
Installing the charging kit 436
Removing the charging kit 436
Support blocks for oiling and charging dimensions 437
Front suspensions 440
TOP FILL METHOD 441
PRESSURE FILL METHOD 441
Rear suspensions 443
TOP FILL METHOD 445
PRESSURE FILL METHOD 445
Suspension pressure test 448
Payload meter IV 451
Payload meter IV software and tools 453
Payload meter IV system configuration 453
Connecting to the payload meter IV web server 453
Configuring a static IP address 453
Payload meter IV software installation 455
Inclinometer calibration and clean truck tare 456
Payload meter IV checkout procedure 456
PLM IV system checkout data sheet 462
Downloading PLM IV data and possible errors 463
KOMTRAX Plus II 467
Required software and tools 469
Ethernet connection to KOMTRAX Plus II controller 469
KOMTRAX Plus II configuration 471
GPS connection test 473
Iridium satellite system opening 475
Data download over ethernet connection for KOMTRAX Plus II initialization 478
Interface module (IM) 481
Required software and tools 483
Interface module checkout procedures 484
Initial startup 484
Checking digital inputs to the IM 484
Check analog inputs to the IM 486
Check serial interfaces to the interface module 486
Check outputs from the interface module 487
Interface module (IM2) 489
Required tools 491
Programming the IM2 491
Updating the software 491
Configuring the IM2 492
Viewing IM2 real-time data 492
Interface module checkout procedures 493
Checking for IM fault codes 493
Checking digital inputs to the IM 493
Checking analog inputs to the IM 496
Checking serial communication to the IM 496
Checking outputs from the IM 497
IM Installation Checkout Checklist 498
IGBT haul truck SIBAS® user manual, part 1 503
Abbreviations 506
Product description 508
Version management 509
Overview 510
Requirements 510
Installation 511
Environment variables 511
Communication with the SIBAS® 32 control unit 512
Calling up the customer monitor 513
Start-up prompt 513
Monitor prompt 514
Notes on operation of the customer monitor 515
Structure of a monitor command 515
Step 1: Selecting the menu title 515
Step 2: Selecting a menu entry in the menu box 515
Step 3: Selecting a dialog box, if available 516
Step 4: Entering file or connector/signal names 516
Command buffer 517
Structure of the monitor windows 517
Commands for Opening, Altering and Closing Windows 518
“Window Work open” 518
“Window Lines open” 518
“Window Tile” 518
“Window Bars open” 518
Options 518
“Window Set” 518
Options 518
“Window Cascade” 518
“Window Close” 518
“Window close All” 518
“Window Exit” 518
“Set Port” 519
Options 519
“Set Baudrate” 519
Options 519
“Set String” 520
Example 521
“Set Make” 521
Options 521
Example 1: INIT MON start-up control of the Customer Monitor 522
Example 2: Any monitor batch file with freely selectable file name (incl path) 522
“Set Execute” 523
Options 523
Example 523
“Set Record” 523
Options 523
“Set DIN-Bus” 524
“Set TCN” 524
“Set Timeout” 524
Options 524
“Set Wait” 524
Options 524
“Set Color” 524
Options 524
“Set Info” 525
“Set comment” 525
“Set CHAR Set” 525
“Set Quit” 525
“Applic Func Package” 526
“Applic Connector” 527
Options 527
Example 528
“Applic View” 528
Options 528
Example 528
“Applic Signal” 528
“Applic Observer” 529
Options 529
Possible time slices: 529
Options 530
Two options 530
Notes on the display of connectors 532
“Applic Buffer” 533
Options 533
“Applic Report” 533
“Applic Legitimation” 533
Options 533
“Applic Menu” 534
“Applic Traco” 534
Options 534
“Applic Environment” 534
Hardware-Oriented Access via the Customer Monitor 536
“Hardw Flash” 536
Options 536
Requirements 536
Example 537
Deleting and loading 537
The EPROM for the communication drivers 537
“Hardw Clock” 537
Options 537
“Hardw DSP” 538
“Hardw BCD” 538
Options 538
Example 538
“Hardw RESET” 538
Options 538
“Hardw Info” 539
Hardware/Operating system 539
Application and tools 539
Communication module 539
Displaying the loading date 539
“Hardw User Flash” 540
Options 540
“Hardw Sys Flash” 540
Options 540
“Hardw BOOT DSP” 541
Requirements 541
DSP5600x Signal Processing Unit and TRACO 541
Inverter processing unit 543
Access to the Signal Processing Unit 543
“Hardw Flash” 543
Options 543
Requirements 543
Example 543
Deleting and loading 544
The EPROM for the communication drivers 544
User Data Flash (UDF) 544
“Hardw RESET” 544
Options 544
“Hardw ZR” 545
“Hardw BOOT ZR” 545
The following procedure is necessary: 545
Commands for Displaying Line Graphics 546
“Graphic Load” 546
Options 546
“Graphic Position” 546
Options 546
“Graphic Time/Div” 547
Options 547
“Graphic Unit/Div” 547
Options 547
“Graphic Display” 547
Options 547
“Graphic Color” 548
Options 548
“Graphic Format” 548
Options 548
IGBT haul truck SIBAS® user manual, part 2 551
Traco Menu 554
HW-Traco 554
Options 555
SW-Traco 556
Options 557
ZR traco basic parameters: 557
ZR traco record signal table: 557
DAC_Traco 560
Options 561
Events Menu 562
STatistics 563
History 564
LEL:Last EvL 565
LES:Last EvS 567
DLL:DC,LastL 568
DLS:DC,LastS 569
DAL:DC,All L 570
DAS:DC,All S 571
ML:Memory L 572
MS:Memory S 573
CN:Clear Norm 574
CA:Clear All 574
Test-Code 574
DS:Diag-Strc 575
User Menu 576
DAC_IO 577
Options 577
Options 578
Operat Data 579
Acc test 586
Engine_Test 586
X_Test_Inx 589
STate intern 590
Header: 590
Vehicle Number: 590
Powering system: 590
TCU Operation Mode: 590
Component status listings: 591
Field regulator status: 591
Status gate unit power supply A: 591
Status gate unit power supply B: 591
ST inverter status 591
Vehicle status 592
Drive status: 592
Operation status: 592
Pedal calib 593
Language 594
OFFline-test 594
Options 594
Variables 596
Examples: 596
IV:Vehic-ID 597
Commands 598
Discharge Dc link / Fire crowbar 598
Limp mode commands 598
Settings 599
Parameters 600
Temp_prot 602
Appendix 604
Background commands 604
Monitor commands for the central processing unit 606
Monitor commands for the signal processing unit 606
Installing ZR / DSP software 609
Monitor Program – Loading software into the SIBAS® 611
Loading software into the DSP procedure 611
Loading a DSP program Inverter A 616
Loading software into the CPU procedure 623
Loading ZR software Prog jumpers Reset 630
Loading the proper pgm file 632
Setting the system up After loading a new pgm 632
24V electrical system 635
Body position switches (with proximity switches and metal arms) 637
Body up switch adjustment 637
Hoist limit switch adjustment 638
Service 638
Body position switches (with proximity switches and magnets) 639
Body up switch adjustment 639
Hoist limit switch adjustment 639
Service 639
Automatic lubrication (auto lube) system 643
Priming the system 645
Checkout procedure 647
Adjusting the lubrication cycle timing 648
Trucks with Interface Module 1 648
Trucks with Interface Module 2 648
40 Troubleshooting 651
Fuse and circuit breaker locations 651
Fuse and circuit breaker locations 653
Fuse block tables 654
Prelube motor fuse 655
Circuit breaker table 656
Troubleshooting by fault code, Part 1 659
Fault Code A001: Left front suspension pressure sensor signal high 662
Related circuit diagram 662
Fault Code A002: Left front suspension pressure sensor signal low 663
Related circuit diagram 663
Fault Code A003: Right front suspension pressure sensor signal high 664
Related circuit diagram 664
Fault Code A004: Right front suspension pressure sensor signal low 665
Related circuit diagram 665
Fault Code A005: Left rear suspension pressure sensor signal high 666
Related circuit diagram 666
Fault Code A006: Left rear suspension pressure sensor signal low 667
Related circuit diagram 667
Fault Code A007: Right rear suspension pressure sensor signal high 668
Related circuit diagram 668
Fault Code A008: Right rear suspension pressure sensor signal low 669
Related circuit diagram 669
Fault Code A009: Incline sensor signal high 670
Related circuit diagram 670
Fault Code A010: Incline sensor signal low 671
Related circuit diagram 671
Fault Code A011: Payload meter speed sensor signal has failed 672
Related circuit diagram 672
Fault Code A013: Body up switch has failed 673
Related circuit diagram 673
Fault Code A014: Payload meter checksum computation has failed 674
Related circuit diagram 674
Fault Code A016: Payload meter write to flash memory has failed 675
Related circuit diagram 675
Fault Code A017: Payload meter flash memory read has failed 676
Related circuit diagram 676
Fault Code A018: Right rear flat suspension cylinder warning 677
Related circuit diagram 678
Fault Code A019: Left rear flat suspension cylinder warning 679
Related circuit diagram 680
Fault Code A022: Carryback load excessive 681
Related circuit diagram 682
Fault Code A100: An open circuit breaker has been detected on a relay board 683
Related circuit diagram 683
Fault Code A101: High pressure detected across an hydraulic pump filter 684
Related circuit diagram 686
Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level 687
Related circuit diagram 688
Fault Code A111: Low steering pressure warning for storage by KOMTRAX Plus 689
Related circuit diagram 689
Fault Code A115: Low steering precharge pressure detected 690
Related circuit diagram 691
Fault Code A117: Low brake accumulator pressure warning for storage by KOMTRAX Plus 692
Related circuit diagram 692
Fault Code A118: Brake pressure is low while in brake lock 693
Related circuit diagram 694
Fault Code A126: Oil level in the hydraulic tank is low 695
Related circuit diagram 695
Fault Code A127: IM-furnished +5 volt output for sensors is low 696
Related circuit diagram 697
Fault Code A128: IM-furnished +5 volt output for sensors is high 698
Related circuit diagram 699
Fault Code A139: Low fuel warning for storage by KOMTRAX Plus and for use by A310 700
Related circuit diagram 701
Troubleshooting by fault code, part 2 703
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil 706
Related circuit diagram 707
Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil 708
Related circuit diagram 709
Fault Code A152: Starter failure 710
Related circuit diagram 711
Fault Code A153: Battery voltage is low with the truck in operation 712
Related circuit diagram 713
Fault Code A154: Battery charging voltage is excessive 714
Related circuit diagram 714
Fault Code A155: Battery charging voltage is low 715
Related circuit diagram 715
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 716
Related circuit diagram 717
Fault Code A159: (A30003 only) The battery 12 Volt circuit sensing is producing low readings 718
Related circuit diagram 718
Fault Code A164: (A30003 only) The battery 12 Volt circuit sensing is producing high readings 719
Related Circuit Diagram 719
Fault Code A166: Left rear hydraulic oil temperature sensor is low 720
Related circuit diagram 721
Fault Code A167: Right rear hydraulic oil temperature sensor is low 722
Related circuit diagram 723
Fault Code A168: Left front hydraulic oil temperature sensor is low 724
Related circuit diagram 725
Fault Code A169: Right front hydraulic oil temperature sensor is low 726
Related circuit diagram 727
Fault Code A170: Left rear hydraulic oil temperature sensor is high 728
Related circuit diagram 728
Fault Code A171: Right rear hydraulic oil temperature sensor is high 729
Related circuit diagram 729
Fault Code A172: Left front hydraulic oil temperature sensor is high 730
Related circuit diagram 730
Fault Code A173: Right front hydraulic oil temperature sensor is high 731
Related circuit diagram 731
Fault Code A182: (A30003 only) The battery 12 Volt battery tap has high voltage 732
Related circuit diagram 733
Fault Code A183: (A30003 only) The battery 12 Volt battery tap has low voltage 734
Related circuit diagram 735
Fault Code A184: J1939 data link is not connected 736
Related circuit diagram 737
Fault Code A190: (A30003 only) The automatic lubrication system has announced a fault 738
Fault Code A190: (A30004 & Up) Auto lube control has detected an incomplete lube cycle 740
Related circuit diagram 741
Fault Code A194: Left front hydraulic oil temperature is high 742
Related circuit diagram 742
Fault Code A195: Right front hydraulic oil temperature is high 743
Related circuit diagram 743
Fault Code A196: Left rear hydraulic oil temperature is high 744
Related circuit diagram 744
Fault Code A197: Right rear hydraulic oil temperature is high 745
Related circuit diagram 745
Fault Code A198: Hoist pressure 1 sensor is high 746
Related circuit diagram 746
Fault Code A199: Hoist pressure 2 sensor is high 747
Related circuit diagram 747
Fault Code A200: Steering pressure sensor is high 748
Related circuit diagram 748
Fault Code A201: Brake pressure sensor is high 749
Related circuit diagram 749
Fault Code A202: Hoist pressure 1 sensor is low 750
Related circuit diagram 750
Fault Code A203: Hoist pressure 2 sensor is low 751
Related circuit diagram 751
Fault Code A204: Steering pressure sensor is low 752
Related circuit diagram 752
Fault Code A205: Brake pressure sensor is low 753
Related circuit diagram 753
Fault Code A206: Ambient temperature sensor is high 754
Related circuit diagram 754
Fault Code A207: Ambient temperature sensor is low 755
Related circuit diagram 755
Troubleshooting by fault code, part 3 757
Fault Code A213: Parking brake should have applied but is detected as not having applied 760
Related circuit diagram 763
Fault Code A214: Parking brake should have released but is detected as not having released 764
Related circuit diagram 766
Fault Code A215: Brake auto apply valve circuit is defective 767
Related circuit diagram 768
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 769
Related circuit diagram 770
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted 771
Related circuit diagram 772
Fault Code A230: Parking brake has been requested while truck still moving 773
Related circuit diagram 774
Fault Code A231: The body is up while traveling or with selector in forward or neutral 775
Fault Code A233: Drive System Control Link is not connected 777
Related circuit diagram 779
Fault Code A235: Steering accumulator is in the process of being bled down 780
Related circuit diagram 781
Fault Code A236: The steering accumulator has not properly bled down after 90 seconds 782
Related circuit diagram 783
Fault Code A237: The CAN/RPC connection to the display is open 784
Related circuit diagram 785
Fault Code A238: Drive System and IM are reporting different park brake status 786
Related circuit diagram 788
Fault Code A239: The Drive System and IM are reporting different brake lock status 789
Related circuit diagram 790
Fault Code A240: The keyswitch input to the Interface Module is open 791
Related circuit diagram 791
Fault Code A242: Fuel gauge within the dash display panel is defective 792
Related circuit diagram 792
Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective 793
Related circuit diagram 793
Fault Code A244: Drive system temperature gauge within the dash display panel is defective 794
Related circuit diagram 794
Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective 795
Related circuit diagram 795
Fault Code A246: Payload meter reports truck overload 796
Related circuit diagram 796
Fault Code A247: Low steering pressure warning for display to operator 797
Related circuit diagram 797
Fault Code A248: Status module within the dash display panel is defective 798
Related circuit diagram 798
Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted 799
Related circuit diagram 799
Fault Code A250: Battery voltage is low with the truck parked 800
Related circuit diagram 801
Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground 802
Related circuit diagram 803
Fault Code A252: Start enable output circuit is either open or shorted to ground 804
Related circuit diagram 805
Fault Code A253: Steering bleed circuit is not open while running 806
Related circuit diagram 807
Fault Code A254: (A30003 Only) The 5 minute idle circuit is either open or shorted to ground 808
Related circuit diagram 808
Fault Code A256: Red warning lamp in the dash display (driven by IM) is open 809
Related circuit diagram 809
Fault Code A257: Payload CAN/RPC is not connected 810
Related circuit diagram 811
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 812
Related circuit diagram 812
Troubleshooting by fault code, part 4 815
Fault Code A260: Park brake failure 818
Related circuit diagram 819
Fault Code A261: Low brake accumulator pressure warning for display to operator 820
Related circuit diagram 820
Fault Code A262: Steering bleed valve circuit open during shutdown 821
Related circuit diagram 822
Fault Code A264: Park brake relay circuit is defective 823
Related circuit diagram 824
Fault Code A265: Service brake failure 825
Related circuit diagram 826
Fault Code A266: Selector switch was not in park while attempting to crank engine 827
Related circuit diagram 828
Fault Code A267: Park brake was not set while attempting to crank engine 829
Related circuit diagram 830
Fault Code A268: Secondary engine shutdown while cranking 831
Related circuit diagram 831
Fault Code A270: Brake lock switch power supply is not on when required 832
Related circuit diagram 834
Fault Code A271: Shifter not in gear 835
Related circuit diagram 836
Fault Code A272: Brake lock switch power supply is not off when required 837
Related circuit diagram 838
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit 839
Related circuit diagram 839
Fault Code A274: A brake setting fault has been detected 840
Related circuit diagram 841
Fault Code A275: A starter has been detected as engaged without a cranking attempt 842
Related circuit diagram 843
Fault Code A277: Park brake applied while loading 844
Related circuit diagram 845
Fault Code A278: Service brake applied while loading 846
Related circuit diagram 847
Fault Code A279: Low Steering Pressure Switch bad 848
Related circuit diagram 848
Fault Code A280: Steering accumulator bled switch bad 849
Related circuit diagram 849
Fault Code A281: Brake lock degrade switch bad 850
Related circuit diagram 851
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 852
Related circuit diagram 853
Fault Code A283: (A30004 & Up) An engine shutdown delay was aborted because the parking brake was not set 854
Related circuit diagram 855
Fault Code A284: (A30004 & Up) An engine shutdown delay was aborted because the secondary shutdown switch was operated 856
Related circuit diagram 857
Fault Code A285: (A30004 & Up) The park brake was not set when the keyswitch was turned off 858
Related circuit diagram 859
Fault Code A286: (A30004 & Up) A fault was detected in the shutdown delay relay circuit 860
Related circuit diagram 861
Fault Code A292: (A30004 & Up) The shutdown delay relay has remained on after the latched keyswitch circuit is off 862
Related circuit diagram 863
Fault Code A295: The right front park brake is not setting up 864
Related circuit diagram 864
Fault Code A296: The left front park brake is not setting up 865
Related circuit diagram 865
Fault Code A297:The right rear park brake is not setting up 866
Related circuit diagram 866
Fault Code A298: The left rear park brake is not setting up 867
Related circuit diagram 867
Fault Code A299: The right front park brake is not releasing 868
Related circuit diagram 868
Fault Code A300: The left front park brake is not releasing 869
Related circuit diagram 869
Fault Code A301: The right rear park brake is not releasing 870
Related circuit diagram 870
Fault Code A302: The left rear park brake is not releasing 871
Related circuit diagram 871
Troubleshooting by fault code, part 5 873
Fault Code A303: Shifter is defective 876
Related circuit diagram 877
Fault Code A304: (A30004 & Up) Auto lube grease level fault 878
Related circuit diagram 878
Fault Code A305: (A30004 & Up) Auto lube circuit is defective 879
Related circuit diagram 880
Fault Code A309: No brakes applied when expected 881
Related circuit diagram 882
Fault Code A310: Low fuel warning 883
Related circuit diagram 884
Fault Code A311: Brake lock switch is on when it should not be 885
Related circuit diagram 886
Fault Code A312: (A30004 & Up) DCDC converter 12 volt circuit sensing is producing low readings 887
Related circuit diagram 887
Fault Code A313: (A30004 & Up) DCDC converter 12 volt circuit sensing is producing high readings 888
Related circuit diagram 888
Fault Code A315: (A30004 & Up) DCDC converter 12 volt circuit is low 889
Related circuit diagram 890
Fault Code A316: Starter engagement has been attempted with engine running 891
Related circuit diagram 892
Fault Code A317: Operation of brake auto apply valve without a detected response 893
Related circuit diagram 895
Fault Code A318: Unexpected power loss to Interface Module 896
Related circuit diagram 896
Fault Code A328: Drive system not powered up 897
Related circuit diagram 897
Fault Code A335: Manual/Auto Apply Pressure Fault 898
Fault Code A350: Overload on output 1B 899
Related circuit diagram 899
Fault Code A351: Overload on output 1E 900
Related circuit diagram 901
Fault Code A352: (A30003) Overload on output 1H 902
Related circuit diagram 902
Fault Code A352: (A30004 & Up) Overload on output 1H 903
Related circuit diagram 903
Fault Code A353: Overload on output 1J 904
Related circuit diagram 904
Fault Code A354: Overload on output 1K 905
Related circuit diagram 905
Fault Code A355: Overload on output 1L 906
Related circuit diagram 906
Fault Code A356: Overload on output 1M 907
Related circuit diagram 907
Fault Code A357: Overload on output 1N 908
Related circuit diagram 908
Fault Code A358: Overload on output 1P 909
Related circuit diagram 909
Fault Code A359: Overload on output 1R 910
Related circuit diagram 911
Fault Code A360: Overload on output 1S 912
Related circuit diagram 912
Fault Code A361: (A30003) Overload on output 1T 913
Related circuit diagram 913
None 913
Fault Code A361: (A30004 & Up) Overload on output 1T 914
Related circuit diagram 915
Fault Code A362: Overload on output 1U 916
Related circuit diagram 916
Fault Code A363: Overload on output 1X 917
Related circuit diagram 917
Fault Code A364: Overload on output 1Y 918
Related circuit diagram 918
Fault Code A365: Overload on output 1Z 919
Related circuit diagram 919
Fault Code A368: Siemens Brake Test Active 920
Related circuit diagram 920
Fault Code A369: Siemens Brake Test Incomplete 921
Related circuit diagram 921
Fault Code A370: Siemens Brake Test Torque Achieved for Park Brake 922
Related circuit diagram 922
Fault Code A371: Siemens Brake Test Torque Achieved for Service Brake 923
Related circuit diagram 923
Fault Code A372: Siemens Brake Test Torque Not Achieved for Park Brake 924
Related circuit diagram 924
Fault Code A373: Siemens Brake Test Torque Not Achieved for Service Brake 925
Related circuit diagram 925
Drive system fault code table, part 1 927
Summary 930
How to use this document 930
Event code and diagnosis message 930
Description 930
Threshold 930
Detection by 930
Possible reasons 930
Action to reset 930
Action to repair 931
Operator displayed code 931
Note 931
Protection reactions 931
Event classification 932
Level 1: Warning 932
Level 2: Minor purposes 932
Level 3: Severe 932
1 L3C SYS: Time slice overflow CPU T1 933
2 L3C SYS: Time slice overflow CPU T2 933
3 L3C SYS: Time slice overflow CPU T3 933
4 L3C SYS: Time slice overflow CPU T4 933
5 L3C SYS: Time slice overflow CPU T5 933
6 L3C SYS: Time slice overflow CPU T6 933
7 L3C SYS: Time slice overflow CPU T7 933
8 L3C SYS: Time slice overflow CPU T8 933
10 L2A SYS: Pulse inhibit/asa inhibit PSU–ONLINE 934
11 L3D SYS: Pulse inhibit/asa inhibit PSU-Start-up 934
12 L1A SYS: SIBAS® blower fault 935
13 L1B SYS: Undervoltage in SIBAS® battery for BRAM 935
14 L3C SYS: SIBAS® power supply failure 24V for pulse amplifier 936
15 L3C SYS: SIBAS® power supply failure +5V 937
16 L3C SYS: SIBAS® power supply failure +15V 938
17 L3C SYS: SIBAS® power supply failure –15V 939
18 L3C SYS: SIBAS® power supply failure +24V 940
19 L3C SYS: SIBAS® power supply failure –24V 941
20 L3C SYS: SIBAS® power supply failure primary 942
21 L3C SYS: FPGA clock missing for PSU 942
22 L3C SYS: Pulse inhibit by reset in PSU from CPU 943
24 L3C SYS: General protection error (G10) 943
25 L3C SYS: Total block 944
26 L1B SYS: Permanent inhibit fault active 945
27 L1B SYS: Regular inhibit fault active 945
28 L1A SYS: GW Test stopped by A/D converter faulty 946
30 L3C DSP A: Initialization fault detected by DSP 946
31 L3C DSP A: SW-WatchdoG 947
32 L3C DSP A: Initialization fault detected by CPU 948
33 L1B DSP A: SW-Traco triggered 948
34 L1B DSP A: SW-Traco full 949
35 L3C DSP A: Time slice overflow T1 950
36 L3C DSP A: Time slice overflow T2 950
37 L3C DSP A: Time slice overflow T3 950
38 L3C DSP A: Time slice overflow T4 950
39 L1A DSP A: Communication HSCX data from DSP B missing 951
40 L1A DSP A: Communication HSCX data from DSP T missing 951
41 L3C DSP A: Current offset during pulse block 952
42 L3C DSP A: Current offset during no pulse block 952
43 L3A DSP A: Overcurrent fault 953
44 L3C DSP A: Current transducer defective phase U 954
45 L3C DSP A: Current transducer defective phase W 955
48 L1A DSP A: Modulation software fault 955
49 L3A DSP A: Active current controller at limit 956
Drive system fault code table, part 2 959
50 L3A DSP A: Active current reference at limit 962
51 L1A DSP A: Braking chopper controller at limit 962
52 L3C DSP A: Phase unbalance too large 963
53 L3A DSP A: Pulse block by DSP software 964
54 L3C DSP A: U/F Card defective 964
55 L3C DSP A: Difference in current of phase U over limit 965
56 L3C DSP A: Difference in current of phase W over limit 965
60 L3C DSP B: Initialization fault detected by DSP 966
61 L3C DSP B: SW-Watchdog 966
62 L3C DSP B: Initialization fault detected by CPU 967
63 L1B DSP B: SW-Traco triggered 967
64 L1B DSP B: SW-Traco full 968
65 L3C DSP B: Time slice overflow T1 968
69 L1A DSP B: Communication HSCX data from DSP A missing 969
70 L1A DSP B: Communication HSCX data from DSP T missing 969
71 L3C DSP B: Current offset during pulse block 970
72 L3C DSP B: Current offset during no pulse block 970
73 L3A DSP B: Overcurrent fault 971
74 L3C DSP B: Current transducer defective phase V 972
75 L3C DSP B: Current transducer defective phase W 973
78 L1A DSP B: Modulation software fault 973
79 L3A DSP B: Active current controller at limit 974
80 L3A DSP B: Active current reference at limit 974
81 L1A DSP B: Braking chopper controller at limit 974
82 L3C DSP B: Phase unbalance too large 975
83 L3A DSP B: Pulse block by DSP software 975
84 L3C DSP B: U/F Card defective 976
85 L3C DSP B: Difference in current of phase V over limit 976
86 L3C DSP B: Difference in current of phase W over limit 977
90 L3C DSP T: Initialization fault detected by DSP 977
91 L3C DSP T: SW-Watchdog 978
92 L3C DSP T: Initialization fault detected by CPU 979
93 L1B DSP T: SW-Traco triggered 979
94 L1B DSP T: SW-Traco full 980
95 L3C DSP T: Time slice overflow T1 980
96 L3C DSP T: Time slice overflow T2 980
97 L3C DSP T: Time slice overflow T3 980
98 L3C DSP T: Time slice overflow T4 980
99 L1A DSP T: Communication HSCX data from DSP A missing 981
Drive system fault code table, part 3 983
100 L1A DSP T: Communication HSCX data from DSP B missing 986
101 L3C DSP T: Current offset during pulse block 986
102 L3C DSP T: Current offset during no pulse block 987
103 L3A DSP T: Overcurrent fault 988
104 L3C DSP T: Current transducer defective phase U 989
105 L3C DSP T: Current transducer defective phase V 990
106 L3C DSP T: Current transducer defective phase W 991
107 L3C DSP T: Sum of output current not equal zero 992
108 L1A DSP T: Modulation software fault 992
109 L1A DSP T: Voltage controller at limit 993
112 L3C DSP T: Phase unbalance too large 993
113 L3A DSP T: Pulse block by DSP software 994
114 L3C DSP T: U/F Card defective 994
117 L3C DSP T: Crowbar fired by DSP T 995
119 L1C DSP T: Voltage transducer U34 not ok 996
120 L3C IO: Supervision bus clock 996
121 L3C IO: Supervision I/O clock 997
122 L3C IO: Incorrect FPGA version identifier 997
123 L3C IO: Incorrect FPGA application version identifier 998
124 L3C IO: Incorrect module version identifier 998
125 L3C/L1A IO: AD Converter faulty 999
126 L3C IO: GW Comparator faulty during start-up test 999
127 L3C IO: Test voltage not equal zero 1000
128 L1A IO: SIBAS® Temperature out of range 1000
129 L3C IO: Incorrect EBIN card identifier 1001
130 L3C IO: Front plug monitoring 1002
131 L3C IO: CPU Watchdog triggered 1003
132 L3C IO: DSP A Watchdog triggered 1003
133 L3C IO: DSP B Watchdog triggered 1004
134 L3C IO: DSP T Watchdog triggered 1004
135 L3C IO: CPU Reset triggered 1005
138 L1B IO: CPU Traco triggered 1005
146 L3A IO: Pulse block from I/O 1006
150 L3A IO: DC link voltage A level 1 exceeded 1006
151 L3A IO: DC link voltage B level 1 exceeded 1007
152 L3C IO: Trolley line overvoltage 1008
154 L3B IO: Trolley line overcurrent 1009
155 L2B IO: Trolley line current transducer faulty 1009
156 L2B IO: Trolley line voltage transducer faulty 1010
160 L3A IO: Throttle pedal out of range 1010
161 L3A IO: Retard pedal out of range 1011
162 L1A IO: Cruise speed control module out of range 1011
180 L3C UWSA1: Supervision bus clock 1012
181 L3C UWSA1: Supervision module clock 1012
182 L3C UWSA1: Incorrect FPGA version identifier 1013
183 L3C UWSA1: Incorrect FPGA project identifier 1013
184 L3C UWSA1: GW Comparator faulty during start-up test 1014
185 L1A UWSA1: ADC Faulty 1014
186 L3C UWSA1: Configuration failure 1015
187 L1A UWSA1: Hardware failure counter / processor 1015
188 L3A UWSA1: Peak current protection active 1016
189 L3D UWSA1: Peak current protection pulse start 1017
190 L3D UWSA1: Number of peak current protection >limit 1018
191 L3D UWSA1: Supervision switching frequency 1019
193 L1A UWSA1: Overvoltage level 1 exceeded 1019
196 L3D UWSA1: Limit 5 overcurrent phase U 1020
197 L3D UWSA1: Limit 5 overcurrent phase V 1020
198 L3D UWSA1: Limit 5 overcurrent phase W 1020
199 L3D UWSA1: Limit 5 overvoltage DC bus 1021
Drive system fault code table, part 4 1023
201 L3D UWSA1: Checkback INVA1 L1U faulty 1027
202 L3D UWSA1: Checkback INVA1 L1L faulty 1027
203 L3D UWSA1: Checkback INVA1 L2U faulty 1027
204 L3D UWSA1: Checkback INVA1 L2L faulty 1027
205 L3D UWSA1: Checkback INVA1 L3U faulty 1027
206 L3D UWSA1: Checkback INVA1 L3L faulty 1027
207 L3D UWSA1: Checkback chopper A faulty 1027
210 L3C UWSB1: Supervision bus clock 1028
211 L3C UWSB1: Supervision module clock 1028
212 L3C UWSB1: Incorrect FPGA version identifier 1029
213 L3C UWSB1: Incorrect FPGA project identifier 1029
214 L3C UWSB1: GW Comparator faulty during start-up test 1030
215 L1A UWSB1: ADC Faulty 1030
216 L3C UWSB1: Configuration failure 1031
217 L1A UWSB1: Hardware failure counter / processor 1031
218 L3A UWSB1: Peak current protection active 1032
219 L3D UWSB1: Peak current protection pulse start 1033
220 L3D UWSB1: Number of peak current protection >limit 1034
221 L3D UWSB1: Supervision switching frequency 1035
223 L1A UWSB1: Overvoltage level 1 exceeded 1035
226 L3D UWSB1: Limit 5 overcurrent phase V 1036
227 L3D UWSB1: Limit 5 overcurrent phase U 1036
228 L3D UWSB1: Limit 5 overcurrent phase W 1036
229 L3D UWSB1: Limit 5 overvoltage DC bus 1037
231 L3D UWSB1: Checkback INVB1 L1U Faulty 1038
232 L3D UWSB1: Checkback INVB1 L1L Faulty 1038
233 L3D UWSB1: Checkback INVB1 L2U Faulty 1038
234 L3D UWSB1: Checkback INVB1 L2L Faulty 1038
235 L3D UWSB1: Checkback INVB1 L3U Faulty 1038
236 L3D UWSB1: Checkback INVB1 L3L Faulty 1038
237 L3D UWSB1: Checkback chopper B Faulty 1038
240 L3C UWSA2: Supervision bus clock 1039
241 L3C UWSA2: Supervision module clock 1039
242 L3C UWSA2: Incorrect FPGA version identifier 1040
243 L3C UWSA2: Incorrect FPGA project identifier 1040
244 L3C UWSA2: GW Comparator faulty during start-up test 1041
245 L1A UWSA2: ADC Faulty 1041
246 L3C UWSA2: Configuration failure 1042
247 L1A UWSA2: Hardware failure counter / processor 1042
248 L3A UWSA2: Peak current protection active 1043
249 L3D UWSA2: Peak current protection pulse start 1044
250 L3D UWSA2: Number of peak current protection >limit 1045
251 L3D UWSA2: Supervision switching frequency 1046
253 L1A UWSA2: Overvoltage level 1 exceeded 1046
256 L3D UWSA2: Limit 5 overcurrent phase U1 1047
257 L3D UWSA2: Limit 5 overcurrent phase V1 1047
258 L3D UWSA2: Limit 5 overcurrent phase W1 1047
259 L3D UWSA2: Limit 5 overvoltage DC bus 1048
261 L3D UWSA2: Checkback INVA2 L1U faulty 1049
262 L3D UWSA2: Checkback INVA2 L1L faulty 1049
263 L3D UWSA2: Checkback INVA2 L2U faulty 1049
264 L3D UWSA2: Checkback INVA2 L2L faulty 1049
265 L3D UWSA2: Checkback INVA2 L3U faulty 1049
266 L3D UWSA2: Checkback INVA2 L3L faulty 1049
267 L3D UWSA2: Checkback chopper C faulty 1049
270 L3C UWSB2: Supervision bus clock 1050
271 L3C UWSB2: Supervision module clock 1050
272 L3C UWSB2: Incorrect FPGA version identifier 1051
273 L3C UWSB2: Incorrect FPGA project identifier 1051
274 L3C UWSB2: GW Comparator faulty during start-up test 1052
275 L1A UWSB2: ADC Faulty 1052
276 L3C UWSB2: Configuration failure 1053
277 L1A UWSB2: Hardware failure counter / processor 1053
278 L3A UWSB2: Peak current protection active 1054
279 L3D UWSB2: Peak current protection pulse start 1055
280 L3D UWSB2: Number of peak current protection >limit 1056
281 L3D UWSB2: Supervision switching frequency 1057
283 L1A UWSB2: Overvoltage level 1 exceeded 1057
286 L3D UWSB2: Limit 5 overcurrent phase V1 1058
287 L3D UWSB2: Limit 5 overcurrent phase U1 1058
288 L3D UWSB2: Limit 5 overcurrent phase W1 1058
289 L3D UWSB2: Limit 5 overvoltage DC bus 1059
291 L3D UWSB2: Checkback INVB2 L1U Faulty 1060
292 L3D UWSB2: Checkback INVB2 L1L Faulty 1060
293 L3D UWSB2: Checkback INVB2 L2U Faulty 1060
294 L3D UWSB2: Checkback INVB2 L2L Faulty 1060
295 L3D UWSB2: Checkback INVB2 L3U Faulty 1060
296 L3D UWSB2: Checkback INVB2 L3L Faulty 1060
297 L3D UWSB2: Checkback chopper D Faulty 1060
Drive system fault code table, part 5 1063
300 L3C UWSST: Supervision bus clock 1067
301 L3C UWSST: Supervision module clock 1067
302 L3C UWSST: Incorrect FPGA version identifier 1068
303 L3C UWSST: Incorrect FPGA project identifieR 1068
304 L3C UWSST: GW Comparator faulty during start-up test 1069
305 L1A UWSST: ADC Faulty 1069
306 L3C UWSST: Configuration failure 1070
307 L1A UWSST: Hardware failure counter / processor 1070
308 L3A UWSST: Peak current protection active 1071
310 L3D UWSST: Number of peak current protection >limit 1072
311 L3D UWSST: Supervision switching frequency 1073
314 L3C UWSST: Crowbar is fired without command 1074
319 L3D UWSST: Limit 5 overvoltage DC bus 1076
321 L3D UWSST: Checkback INVST L1U Faulty 1077
322 L3D UWSST: Checkback INVST L1L Faulty 1077
323 L3D UWSST: Checkback INVST L2U Faulty 1077
324 L3D UWSST: Checkback INVST L2L Faulty 1077
325 L3D UWSST: Checkback INVST L3U Faulty 1077
326 L3D UWSST: Checkback INVST L3L Faulty 1077
327 L3C UWSST: Checkback crowbar faulty 1078
330 L1A BUS: CAN Communication failure 1079
331 L1A BUS: Serial link communication failure 1079
332 L1A BUS: Truck is over loaded 1079
333 L1B TR: Transient traco is triggered 1080
334 L1B TR: Transient traco is full 1080
340 L1A ETM: ADC Failure for ETM1 1080
341 L1A ETM: ADC Failure for ETM2 1081
342 L1A ETM: ADC Failure for ETM3 1081
343 L1A ETM: ADC Failure for ETM4 1081
344 L1A MEFA: ADC Failure 1082
345 L3C HL: Gate unit power supply A defective 1082
346 L3C HL: Gate unit power supply B defective 1083
351 L1A DRZ: LIMP Mode A active 1084
352 L1A DRZ: Limp mode B active 1084
353 L1A DRZ: Low battery voltage 1085
354 L1B BUS: Engine floor input increasing minimum engine speed 1085
355 L1B DM: Data store switch pressed 1086
356 L1B DM: Diagnosis memory configuration failure 1086
357 L1B DM: Diagnosis memory occupation > 75% 1086
358 L1B DM: Diagnosis memory full 1087
359 L1B DM: Test event 1087
360 L2A EXT: Main blower air flow supervision 1088
361 L2A EXT: Minimum engine speed supervision 1089
362 L1A EXT: Main blower pressure switch malfunction 1090
363 L1A EXT: Shift lever supervision 1091
364 L2A EXT: Engine derate protection active 1092
365 L1A EXT: Truck external plug monitoring 1092
367 L3A EXT: DC Power off mod request (rest switch on) 1093
369 L1A EXT: Doppler sensor defective 1095
370 L1A EXT: Auto lube control defective 1096
372 L1A EXT: Service brake pressed at high speeD 1096
373 L1A EXT: Service brake on above speed limit 1097
374 L1A EXT: Anti-roll control malfunction 1097
375 L3B BEF: CB301 Circuit breaker defective 1098
376 L3B BEF: K303/K304 Contactor defective 1099
377 L3C STP: Voltage reading incorrect between trolley line and voltage in stepdown box 1100
382 L3B BEF: K103 Feedback defective 1101
383 L3B BEF: K105 Feedback defective 1101
384 L1A BEF: K107 Feedback defective 1102
385 L1A BEF: K109 Feedback defective 1102
386 L1A BEF: K111 Feedback defective 1103
387 L1A BEF: Limp mode selector defective 1103
388 L2B BEF: CB113 Tripped 1104
390 L3D IUW: Output current supervision INV A 1104
391 L3D IUW: Output current supervision INV B 1105
392 L3B IUW: Precharge supervision 1 1106
393 L3B IUW: Precharge supervision 2 1107
394 L3A IUW: DC Link undervoltage 1108
395 L2B IUW: Trolley line undervoltage 1109
397 L3B IUW: Field regulator current setpoint supervision 1110
398 L2B IUW: Field regulator output current supervision 1111
399 L3B IUW: Alternator overcurrent protection 1112
Drive system fault code table, part 6 1115
400 L2C IUW: Alternator overload warning 1118
401 L2B IUW: Alternator overload protection 1118
402 L3C IUW: Alternator AC current sensor faulty 1119
403 L2A IUW: DC Link voltage out of range in propel 1120
404 L3A IUW: DC Link voltage out of range retard 1121
405 L3A IUW: DC Link voltage out of range for ST operation 1122
406 L3B IUW: DC Link controller supervision 1123
407 L2C IUW: Motor torque square T supervision 1124
408 L2C IUW: Motor current square T supervision 1124
409 L1A IUW: DC Link discharge time exceeded limit 1125
410 L2B IUW: Ground fault at positive DC link detected 1126
411 L2B IUW: Ground fault at negative DC link detected 1127
412 L2B IUW: Ground fault at AC side detected 1128
413 L2B IUW: Ground fault 1129
414 L3C IUW: Chopper A current supervision 1130
415 L3C IUW: Chopper B current supervision 1131
416 L3C IUW: Chopper C current supervision 1132
417 L3C IUW: Chopper D current supervision 1133
418 L3D IUW: Output current supervision INV ST 1134
419 L2A IUW: Vehicle overspeed supervisioN 1135
420 L1A IUW: DC Link voltage sensor A faulty 1136
421 L1A IUW: DC Link voltage sensor B faulty 1137
422 L3C IUW: ST Inverter failure 1138
423 L3B IUW: DC Grid fan circuit failure 1138
424 L2B IUW: Cooling water pressure out of range 1139
425 L2B IUW: Cooling water level out of range 1140
426 L1A IUW: Water pump motor overtemperature 1141
427 L1A IUW: Retard limit supervision 1141
428 L1A DRZ: Front wheel A speed sensor supervision 1142
429 L1A DRZ: Front wheel B speed sensor supervision 1143
430 L3D DRZ: Motor A speed sensor supervision 1144
431 L3D DRZ: Motor B speed sensor supervision 1145
432 L3C DRZ: Alternator speed sensor supervision 1146
433 L2A DRZ: Motor A maximum speed exceeded 1147
434 L2A DRZ: Motor B maximum speed exceeded 1147
435 L1A DRZ: Alternator maximum speed exceeded 1148
436 L3A DRZ: Motor A/B rotation inconsistency 1149
437 L3A DRZ: Motor A torque supervision 1150
438 L3A DRZ: Motor B torque supervision 1151
439 L3C SIV: Start-up sequence can’t pass due to GUPS failure 1152
440 L3C SIV: Start-up sequence can’t pass due to K103/K105 failure 1153
441 L3C SIV: Start-up sequence can’t pass due to IGBT failure 1154
442 L3C SIV: Start-up sequence can’t pass due to CB301 OR K303 failure 1155
443 L3C SIV: Start-up sequence can’t pass due to crowbar failure 1156
447 L1A SIV: Direct trolley engage sequence supervision 1157
448 L1A SIV: Direct trolley disengage sequence supervision 1158
Drive system fault code table, part 7 1161
450 L1A TMP: SIBAS® Temperature < low limit 1165
451 L1A TMP: SIBAS® Temperature > warning limit 1165
452 L3B TMP: SIBAS® Temperature > shutdown limit 1166
453 L3A TMP: IGBT Module A101 temperature < low limit 1167
454 L2C TMP: IGBT Module A101 temperature > APRS limit 1168
455 L3A TMP: IGBT Module A101 temperature > shutdown limit 1169
456 L3A TMP: IGBT Module A102 temperature < low limit 1170
457 L2C TMP: IGBT Module A102 temperature > APRS limit 1171
458 L3A TMP: IGBT Module A102 temperature > shutdown limit 1172
459 L3A TMP: IGBT ModulE A201 temperature < low limit 1173
460 L2C TMP: IGBT Module A201 temperature > APRS limit 1174
461 L3A TMP: IGBT Module A201 temperature > shutdown limit 1175
462 L3A TMP: IGBT Module A202 temperature < low limit 1176
463 L2C TMP: IGBT Module A202 temperature > APRS limit 1177
464 L3A TMP: IGBT Module A202 temperature >shutdown limit 1178
465 L3A TMP: ST Module temperature < low limit 1179
466 L2C TMP: ST Module temperature > warning limit 1180
467 L3A TMP: ST Module temperature > shutdown limit 1181
468 L2B TMP: SR Module temperature < low limit 1182
469 L2C TMP: SR Module temperature > warning limit 1183
470 L2B TMP: SR Module temperature > shutdown limit 1184
471 L2C TMP: Wheel motor A stator temperature > APRS limit 1185
472 L3A TMP: Wheel motor A stator temperature > shutdown limit 1186
473 L2C TMP: Wheel motor B Stator temperature > APRS limit 1187
474 L3A TMP: Wheel motor B stator temperature shutdown limit 1188
475 L2C TMP: Wheel motor A, DE bearing temperature > warning limit 1189
476 L3A TMP: Wheel motor A, DE bearing temperature > shutdown limit 1190
477 L2C TMP: Wheel motor A NDE bearing temperature > warning limit 1191
478 L3A TMP: Wheel motor A NDE bearing temperature > shutdown limit 1192
479 L2C TMP: Wheel motor B DE bearing temperature > warning limit 1193
480 L3A TMP: Wheel motor B DE bearing temperature > shutdown limit 1194
481 L2C TMP: Wheel motor B NDE bearing temperature > warning limit 1195
482 L3A TMP: Wheel motor B NDE bearing temperature > shutdown limit 1196
483 L2C TMP: Alternator stator temperature > APRS limit 1197
484 L2B TMP: Alternator stator temperature > shutdown limit 1198
485 L2C TMP: Alternator bearing temperature > warning limit 1199
486 L2B TMP: Alternator bearing temperature > shutdown limit 1200
487 L1A TMP: Cooling water inlet temperature < low limit 1201
488 L2C TMP: Cooling water inlet temperature > warning limit 1202
489 L2B TMP: Cooling water inlet temperature > shutdown limit 1203
490 L1A TMP: Cooling water outlet temperature < low limit 1204
491 L2C TMP: Cooling water outlet temperature > warning limit 1205
492 L2B TMP: Cooling water outlet temperature > shutdown limit 1206
493 L1A TMP: Cooling water delta T too high 1207
495 L2C TMP: Inverter cab temperature > warning limit 1208
496 L2B TMP: Inverter cab temperature > shutdown limit 1209
497 L2C TMP: Inside cooler outlet temperature > warning limit 1210
498 L2B TMP: Inside cooler outlet temperature > shutdown limit 1211
499 L1A TMP: Main blower motor stator temperature > warning limit 1212
500 L1A TMP: Main blower motor stator temperature > shutdown limit 1213
505 L1A TMP: Wheel motor A rotor temperature > limit 1214
506 L1A TMP: Wheel motor B rotor temperature > limit 1215
508 L1A ETM1: Alternator PT100 open circuit 1216
509 L1A ETM1: Main blower stator PT100 open circuit 1216
510 L1A ETM1: Grid blower statoR PT100 open circuit 1216
511 L1A ETM1: Inverter CAB PT100 open circuit 1216
512 L1A ETM1: Ambient PT100 open circuit 1216
513 L1A ETM1: Heater exchanger PT100 open circuit 1216
514 L1A ETM1: Cooling water inlet PT100 open circuit 1216
515 L1A ETM1: Cooling water outlet PT100 open circuit 1216
516 L1A ETM2: Motor A NDE Bearing PT100 open circuit 1217
517 L1A ETM2: Motor A DE Bearing PT100 open circuit 1217
518 L1A ETM2: Motor B NDE Bearing PT100 open circuit 1217
519 L1A ETM2: Motor B DE Bearing PT100 open circuit 1217
520 L1A ETM2: Alternator Bearing PT100 open circuit 1217
521 L1A ETM2: Motor A stator PT100 open circuit 1217
522 L1A ETM2: Motor B stator PT100 open circuit 1217
523 L1A ETM2: Motor inlet air PT100 open circuit 1217
524 L1A ETM3: IGBT Module A101 PT100 open circuit 1218
525 L1A ETM3: IGBT Module A102 PT100 open circuit 1218
526 L1A ETM3: IGBT Module A103 PT100 open circuit 1218
527 L1A ETM3: IGBT Module A104 PT100 open circuit 1218
528 L1A ETM3: IGBT Module A201 PT100 open circuit 1218
529 L1A ETM3: IGBT Module A202 PT100 open circuit 1218
530 L1A ETM3: IGBT Module A203 PT100 open circuit 1218
531 L1A ETM3: IGBT Module A204 PT100 open circuit 1218
532 L1A ETM3: ST Module PT100 open circuit 1219
533 L1A ETM3: SR Module PT100 open circuit 1219
534 L1A ETM3: Channel 7 PT100 open circuit 1219
535 L1A ETM3: Channel 8 PT100 open circuit 1219
536 L1A ETM4: Channel 1 PT100 open circuit 1220
537 L1A ETM4: Channel 2 PT100 open circuit 1220
538 L1A ETM4: Channel 3 PT100 open circuit 1220
539 L1A ETM4: Channel 4 PT100 open circuit 1220
540 L1A ETM4: Channel 5 PT100 open circuit 1220
541 L1A ETM4: Channel 6 PT100 open circuit 1220
542 L1A ETM4: Channel 7 PT100 open circuit 1220
543 L1A ETM4: Channel 8 PT100 open circuit 1220
544 L1A ETM4: SR Module PT100 open circuit 1220
550 L3A TMP: Inverter A module temperature < low limit 1221
551 L2C TMP: Inverter A module temperature > APRS limit 1222
552 L3A TMP: Inverter A module temperature > shutdown limit 1223
553 L3A TMP: Inverter B module temperature < low limit 1224
554 L2C TMP: Inverter B module temperature > APRS limit 1225
555 L3A TMP: Inverter B module temperature > shutdown limit 1226
556 L3A TMP: Chopper A module temperature < low limit 1227
557 L2C TMP: Chopper A module temperature > APRS limit 1228
558 L3A TMP: Chopper A module temperature > shutdown limit 1229
559 L3A TMP: Chopper B module temperature < low limit 1230
560 L2C TMP: Chopper B module temperature > APRS limit 1231
561 L3A TMP: Chopper B module temperature > shutdown limit 1232
Payload meter scoreboard 1235
Display messages 1237
LED lights 1237
Processor LED (2, Figure 50-1) 1237
Data Receive LED (3, Figure 50-1) 1237
Option switches 1238
SWITCH 1 – TEST (Displays “888”) 1238
SWITCH 2 – COUNT 1238
SWITCH 9 – TRANSMIT CUT 1238
SWITCH 10 – HIGH IMPEDANCE LISTEN 1238
Troubleshooting 1239
Troubleshooting chart 1239
Symptom 1239
Possible Cause 1239
Remedy 1239
Electric wheel motor 1241
Fault table 1243
Steering system 1251
Steering circuit troubleshooting chart 1253
Steering circuit troubleshooting guidelines 1255
Basic hydraulic system checks 1256
System leakage check 1257
Steering pump troubleshooting guide 1259
Pump pressure control checks 1262
To verify pump unload pressure 1262
To verify pump reloading 1262
Pump fails to unload 1263
Pump fails to develop pressure 1263
Pump slow in developing pressure 1264
Pump control valve inspection and trouble shooting 1265
Pump case drain check 1267
Definitions: 1268
Adjustment 1268
Cab air conditioning 1271
Preliminary checks 1273
Diagnosis of gauge readings and system performance 1273
Troubleshooting by manifold gauge set readings 1274
Automatic lubrication (auto lube) system 1281
Autolube troubleshooting chart 1283
Reserve engine oil system 1287
Pumping unit LED signals 1289
Circuit fuses 1289
50 Disassembly and assembly 1291
Service tools 1291
Special tool list 1293
Additional tool list 1293
Wheel motor rebuild tools 1294
Control cabinet 1294
Cab air conditioning 1297
Replacement of air conditioning system components 1299
Hoses and fittings 1299
Lines 1299
Expansion valve 1299
Receiver-drier 1299
Thermostat 1299
Compressor 1300
Accumulator 1300
Clutch 1300
Wheels, spindles and rear axle 1303
General precautions for tires and rims 1305
Wheel stud maintenance 1306
Front tires and rims 1307
Removal 1307
Installation 1308
Rear tires and rims 1308
Removal 1308
Installation 1309
Rim components 1311
Smart Rim Component Layout 1311
Rim and tire service 1312
Lubricants 1312
Tire Inflation 1312
Lock Ring Retainer Installation 1312
Remove Smart Lock Ring from Inside Position of Outer Dual and Outside Position of Inner Dual 1313
Install Smart Lock Ring to Inside Position of Outer Dual and Outside Position of Inner Dual 1314
Removal (5-Piece Standard Rim) 1315
Removal (7-Piece Smart Rim) 1318
Removal (5-Piece Smart Rim) 1320
Preparation Before Assembly 1322
Installation (5-Piece Standard Rim) 1322
Installation – Horizontal Mount (Smart Rim) 1324
Installation – Vertical Mount (5-Piece Smart Rim) 1326
Installation – Vertical Mount (7-Piece Smart Rim) 1328
Removal and installation of front wheel hub and spindle 1329
Removal 1329
Spindle Removal Procedure (off of the truck) 1332
Installation 1335
Disassembly and assembly of front wheel hub and spindle 1336
Disassembly 1336
Cleaning and inspection 1336
Assembly 1338
Wheel bearing adjustment 1338
Seal assembly gap check and adjustment 1339
Floating seal installation 1340
Floating seal test procedure 1347
Speed sensor installation and adjustment 1348
Removal and installation of wheel motor 1348
Preparation 1348
Removal 1349
Cleaning and inspection 1350
Installation 1350
Removal and installation of rear axle 1353
Removal 1353
Cleaning and inspection 1355
Installation 1355
Removal and installation of anti-sway bar 1356
Removal 1356
Installation 1356
Removal and installation of pivot pin 1357
Removal 1357
Installation 1357
Pivot eye and bearing service 1358
Bearing inspection 1358
Bearing removal 1359
Bearing installation 1360
Pivot eye repair 1360
Removal and installation of electric motor 1361
Removal 1361
Installation 1362
Disassembly and assembly of wheel motor transmission 1363
Disassembly 1363
Cleaning and inspection 1370
Assembly 1370
Disassembly and assembly of low speed carrier 1382
Disassembly 1382
Inspection 1383
Assembly 1384
Disassembly and assembly of high speed carrier 1387
Disassembly 1387
Inspection 1388
Assembly 1389
Brake system 1393
Removal and installation of brake valve 1395
Removal 1395
Installation 1396
Disassembly and assembly of brake valve/pedal assembly 1396
Disassembly 1396
Assembly 1397
Removal and installation of dual relay valve 1399
Removal 1399
Installation 1400
Removal and installation of brake manifold 1401
Removal 1401
Installation 1401
Disassembly and assembly of brake manifold 1402
Disassembly 1402
Assembly 1402
Removal and installation of brake accumulator (piston style) 1403
Removal 1403
Installation 1405
Disassembly and assembly of brake accumulator (piston style) 1405
Disassembly 1405
Cleaning and inspection 1407
Piston seal replacement 1408
Assembly 1408
Removal and installation of brake accumulators (bladder style) 1409
Removal 1409
Installation 1410
Disassembly and assembly of brake accumulator (bladder style) 1411
Disassembly 1411
Cleaning and inspection 1412
Assembly 1413
Disassembly and assembly of wheel brake 1414
Disassembly 1415
Cleaning and inspection 1418
Assembly 1419
Floating ring seal assembly and installation 1425
Removal and installation of rear brake assembly 1433
Removal 1433
Installation 1433
Steering system 1439
Removal and installation of steering control unit 1441
Removal 1441
Installation 1442
Disassembly and assembly of steering control unit 1443
Disassembly 1443
Assembly 1445
Removal and installation of steering column 1448
Removal 1448
Inspection 1448
Installation 1449
Removal and installation of steering wheel 1450
Removal 1450
Installation 1450
Removal and installation of bleeddown manifold 1452
Removal 1452
Installation 1452
Removal and installation of flow amplifier 1454
Removal 1454
Installation 1454
Removal and installation of steering cylinder 1454
Removal 1454
Bearing replacement 1454
Installation 1455
Disassembly and assembly of steering cylinders 1456
Disassembly 1456
Assembly 1456
Removal and installation of tie rod 1457
Removal 1457
Installation 1458
Removal and installation of steering/brake pump 1458
Removal 1458
Installation 1459
Disassembly and assembly of steering/brake pump 1461
Disassembly 1461
Inspection 1464
Assembly 1467
Driveshaft group 1468
Rotating group 1468
Removal and installation of steering accumulators (piston style) 1471
Removal 1471
Installation 1473
Disassembly and assembly of steering accumulator (piston style) 1473
Cleaning and Inspection 1475
Piston seals replacement 1475
Assembly 1476
Removal and installation of steering accumulators (bladder style) 1477
Removal 1477
Installation 1478
Disassembly and assembly of steering accumulator (bladder style) 1478
Disassembly 1478
Cleaning and Inspection 1479
Assembly 1480
Suspensions 1483
Removal and installation of front suspension 1485
General information 1485
Removal 1485
Installation 1487
Upper mounting joint – 60° advance 1491
Inspection 1492
Minor front suspension repairs (lower bearing and seals) 1493
Lower bearing retainer removal 1493
Lower bearing retainer installation 1493
Major front suspension rebuild 1494
Disassembly 1494
Assembly 1495
Removal and installation of rear suspension 1497
General information 1497
Removal 1497
Installation 1500
Disassembly and assembly of rear suspension 1501
Disassembly 1501
Cleaning and Inspection 1501
Assembly 1502
Hoist circuit 1505
Removal and installation of hoist pump 1507
Removal 1507
Installation 1508
Disassembly and assembly of hoist pump 1510
Disassembly 1510
Inspection 1515
Assembly 1516
Removal and installation of hoist valve 1519
Removal 1519
Installation 1520
Disassembly and assembly of hoist valve 1520
O-ring replacement 1520
Disassembly of inlet section 1522
Assembly of inlet section 1523
Disassembly of rear spool section 1524
Assembly of rear spool section 1526
Disassembly of front spool section 1527
Assembly of front spool section 1528
Overcenter manifold service 1528
Removal and installation of hoist pilot valve 1529
Removal 1529
Installation 1529
Disassembly and assembly of hoist pilot valve 1530
Disassembly 1530
Cleaning and inspection 1531
Assembly 1531
Removal and installation of hoist cylinders 1532
Removal 1532
Installation 1533
Disassembly and assembly of hoist cylinders 1535
Disassembly 1535
Cleaning and inspection 1537
Installation of the quill 1538
Assembly 1540
Replacement of hoist circuit filter 1542
Filter element replacement 1543
Operator cab 1545
Removal and installation of operator cab 1547
Removal 1548
Installation 1549
Removal and installation of cab door 1551
Removal 1551
Installation 1551
Disassembly and assembly of cab door 1551
Removing door panel 1551
Installing door panel 1552
Replacing door window regulator 1552
Replacing door handle or latch assembly 1553
Replacing door assembly seal and door hinge seal 1554
Replacing door opening seal 1554
Removing door glass 1555
Installing door glass 1556
Adjustment of cab door 1558
Door jamb bolt adjustment 1558
Door handle plunger adjustment 1559
Removal and installation of side window glass 1560
Recommended tools and supplies 1560
Removal 1561
Installation 1561
Removal and installation of windshield and rear window glass 1562
Removal 1562
Installation 1562
Removal and installation of windshield wiper motor 1563
Removal 1563
Installation 1563
Removal and installation of windshield wiper arm 1564
Removal 1564
Installation 1564
Removal and installation of windshield wiper linkage 1565
Removal 1565
Installation 1565
Removal and installation of operator seat (standard seat) 1566
Adjustment 1566
Inspection 1567
Removal 1567
Installation 1567
Replacing the Seat Compressor 1568
Removal and installation of passenger seat (standard seat) 1573
Adjustment 1573
Inspection 1574
Removal 1574
Installation 1574
Removal and installation of seat belts (standard seat) 1575
Removal 1575
Installation 1575
Operator seat (optional seat) 1576
Seat Belts 1576
Adjustment 1576
Passenger seat (optional seat) 1578
Seat Belts 1578
Adjustment 1578
Removal and installation of seat belts (optional seat) 1579
General 1579
Removal 1579
Installation 1581
Body and structures 1585
Removal and installation of dump body 1587
Removal 1587
Inspection 1588
Installation 1589
Removal and installation of body pads 1589
Removal 1589
Installation 1590
Adjustment 1590
Removal and installation of diagonal ladder/ hood and grille assembly 1592
Removal 1592
Installation 1592
Removal and installation of right deck 1593
Removal 1593
Installation 1595
Removal and installation of left deck 1596
Removal 1596
Installation 1596
Removal and installation of fuel tank 1598
Removal 1598
Cleaning and inspection 1598
Installation 1600
Removal and installation of horizontally mounted fuel gauge sender 1600
Removal 1600
Installation 1600
Removal and installation of vertically mounted fuel gauge sender 1600
Installation 1600
Disassembly and assembly of fuel tank breather 1602
Disassembly 1602
Assembly 1602
Removal and installation of hydraulic tank 1603
Removal 1603
Installation 1603
Three phase wheel motor 1605
Motor 1609
Transport 1610
Storage of new motors 1611
Storage of used motors 1612
Safety guidelines 1613
Checking for external damage 1614
Checking the connections 1615
Regreasing the bearings 1615
Applying grease to the bearings 1615
Checking the interior of the motor for water 1616
Pressing off the coupling 1618
Disassembly 1619
Rotor 1619
Removing the rubber seals and the air baffles 1624
Bearing and labyrinth ring 1625
Removal 1625
Stator Inspection 1626
Rotor Inspection 1626
Testing the insulation 1627
High-voltage test 1627
Work on the bearings 1628
Assembling the rubber seals and the air baffles 1630
Assembly after special repair work 1632
Bearing installation 1633
Preparatory measures for assembling the bearing (Figure 50-20 must be observed): 1636
Assemble the bearing 1637
Cover installation 1638
Assembling the bearing shield (N-end) at the stator frame 1639
Bearing installation 1641
Rotor installation 1643
Labyrinth ring 1645
Installation 1645
Installing accessories (D- and N-end) 1647
Running in the bearings 1651
Coupling 1652
Installation 1652
Assembly conditions and instructions 1653
Tests 1653
Replacing defective connecting leads 1654
Repairing the stator winding insulation 1655
Recommended consumables 1655
Chemical cleaning agents 1655
Chemical cleaning agents for outdoor use and for cleaning mechanical parts 1655
Chemical cleaning agents for flange faces 1655
Chemical cleaning agents for windings 1656
Chemical cleaning agents for windings 1656
Chemical cleaning agents for windings with severe damage and for oily windings 1656
Rolling-contact bearing grease 1656
Assembly/disassembly agents for bearing seat 1656
Sealants for joining parts or gaps 1656
Locking agents for connecting elements 1656
Anti-corrosion agent 1656
Assembly paste for temperature sensors 1656
Mounting devices for inserting and withdrawing the rotor horizontally 1657
Press for expanding the coupling 1657
Compression devices for pressing on or for support while pressing off 1658
Pulling units with cross beam or disk 1660
Aids 1660
Extraction devices 1661
Paints for refinishing the painted parts or touching up damaged parts 1661
Power module 1663
Removal and installation of power module 1665
General 1665
Preparation 1665
Removal 1666
Installation 1671
Exhaust tube installation 1673
Exhaust blanket installation 1673
Removal and installation of alternator 1674
Removal 1674
Installation 1676
Engine flywheel adapter face runout 1676
Engine crankshaft endplay 1677
Engine flywheel to flywheel housing adapter – measurement “C” 1677
Alternator housing to rotor – measurement “A” 1678
Measurements after joining the alternator and engine 1680
Flywheel housing face runout 1681
Flywheel housing radial runout 1681
Flywheel/flexplate face runout 1682
Flywheel/flexplate radial runout 1682
Rotor shaft radial runout (assembled) 1683
Joining the alternator and engine 1684
Removal and installation of engine 1686
Removal 1686
Service 1686
Installation 1686
Removal and installation of radiator 1686
Removal 1686
Installation 1688
Repairing the radiator 1690
Internal inspection 1690
External cleaning 1690
Disassembly 1690
Cleaning and inspection 1691
Assembly 1692
Pressure testing 1693
Automatic lubrication (autolube) system 1695
Lubrication system priming 1697
Disassembly and assembly of lubrication pump 1697
Disassembly 1697
Cleaning and Inspection 1700
Assembly 1700
Main blower 1703
Removing the main blower motor 1705
Disassembling the main blower motor 1711
Assembling the main blower motor 1713
Installing the main blower motor 1716
Retarding grid 1723
Removing the grid blower motor 1725
Disassembling the grid blower motor 1727
Assembling the grid blower motor 1729
Installing the grid blower motor 1731
Removing a grid element 1736
Control cabinet 1739
Removing the SIBAC Inverter Module 1741
Required tools/materials 1741
Removal 1744
Installing the SIBAC Inverter Module 1748
Draining and filling the IGBT coolant system 1749
Required tools/materials 1749
Coolant mixture specification (distilled water: Antifrogen® N) 1749
Draining and filling the coolant 1751
Removing and installing the IGBT coolant pump assembly 1754
Required tools/materials 1754
Removal 1755
90 Diagrams and drawings 1759
Hydraulic circuit diagrams 1759
Electrical circuit diagrams – 24V system 1765
Electrical circuit diagrams – drive system 1785

DESCRIPTION:

Komatsu 860E-1K Dump Truck Shop Manual CEBM024206  – PDF DOWNLOAD

• SERIAL NUMBERS 860E-1K A30031 – A30118

G.B 20/12/24