Komatsu 860E-1K DUMP TRUCK Shop Manual CEBM037901 – PDF

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Komatsu 860E-1K DUMP TRUCK Shop Manual CEBM037901 – PDF DOWNLOAD

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Komatsu 860E-1K DUMP TRUCK Shop Manual CEBM037901 – PDF DOWNLOAD

Language : English
Pages : 1806
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu 860E-1K DUMP TRUCK Shop Manual CEBM037901 – PDF DOWNLOAD

• SERIAL NUMBERS 860E-1K  – A30119

Cover 1
00 Index and foreword 3
Index 3
Table of contents 6
Foreword, safety and general information 33
Foreword 37
How to read the shop manual 38
Composition of shop manual 38
Revision and distribution 38
Symbols 39
General safety 40
Safety rules 40
Safety features 40
Fire extinguisher and first aid kit 40
Clothing and personal items 40
Leaving the operator seat 41
Mounting and dismounting 41
Fire prevention for fuel and oil 41
Precautions with high temperature fluids 42
Asbestos dust hazard prevention 42
Prevention of injury by work equipment 42
Unauthorized modification 42
Precautions when using ROPS 42
Precautions for attachments 43
Precautions for starting the truck 43
Precautions before operating the truck 43
Safety at the worksite 43
Fire prevention 44
Ventilation in enclosed areas 44
Preparing for operation 44
Mirrors, windows and lights 44
In operator cab (before starting the engine) 44
Seat Belts 44
Precautions while operating the truck 45
When starting the engine 45
General truck operation 45
Ensuring good visibility 45
Traveling 46
Traveling in reverse 46
Traveling on slopes 46
Operating on snow or ice 46
Avoid damage to dump body 46
Driving near high voltage cables 47
When dumping 47
Working on loose ground 47
When loading 47
Parking the truck 47
Towing 48
Working near batteries 48
Battery hazard prevention 48
Starting with jumper cables 49
Jump starting with receptacles 49
Precautions before performing service 50
Warning tag 50
Stopping the engine 50
Proper tools 50
Use of tie-off anchor during maintenance and repair 51
The anchor must not be used for lifting Tie-off anchor installation 51
Securing the dump body 52
While performing maintenance 52
Keep the truck clean 52
Attachments 52
Working under the truck 53
Rotating fan and belts 53
Adding fuel or oil 53
Use of lighting 53
Radiator coolant level 53
Precautions with the battery 53
Precautions with high pressure oil 53
Handling high pressure hoses 54
Precautions when performing maintenance near high temperature or high pressure 54
Waste materials 54
Tires 54
Handling tires 54
Storing tires after removal 55
Precautions for performing repairs 56
Engine shutdown procedure after AC drive system failure 56
Jack point locations 57
Precautions for welding on the truck 58
Handling electrical equipment and hydraulic components 59
Points to remember when handling electrical equipment 59
Points to remember when handling hydraulic equipment 65
How to Read Electric Wire Code 67
Color Code and Harness Designation Tables 68
Standard torque tables 69
Effect of special lubricants on fasteners and standard torque values 69
Suggested sources for rust preventive grease 69
SAE grade 5 and grade 8 hex head capscrew and nut assemblies 70
SAE grade 9 capscrews 71
Class 10 9 capscrews and class 10 nuts 71
Standard tightening torques for fittings 72
Standard tightening torques for clamps 74
Conversion tables 75
Common conversion multipliers 75
01 Specification 79
Specification and technical data 79
Specification drawing 81
Specifications 82
Weight table 84
Fuel, coolant and lubricants 85
Mixing rate of water and anti-freeze 85
Suspension cylinder oil and nitrogen specifications 86
10 Structure and functions 89
Cab air conditioning 89
General information 91
Environmental impact of air conditioning 91
Air conditioning for off-highway vehicles 91
Principles of refrigeration 92
Air conditioning 92
Refrigeration – the act of cooling 92
The refrigeration cycle 92
Air conditioning system components 94
Relays 94
Fan motor and speed control 94
Cab air filter 94
Heater core 94
Actuators 94
Compressor (refrigerant pump) 96
Service valves 96
Condenser 96
Receiver-drier 96
Expansion valve 97
Accumulator 97
Evaporator core 97
Air conditioning system electrical circuit 98
Thermostat 98
Compressor clutch 98
Trinary™ switch 99
Steering circuit 101
Steering circuit operation 103
Steering circuit components 105
Steering control unit 105
High pressure filter 105
Steering accumulators 105
Bleeddown manifold 106
Steering accumulator bleeddown solenoid 109
Quick disconnect ports 109
Hoist up limit solenoid 109
Flow amplifier 109
Flow amplifier operation 110
No steer 110
Steering left 112
Steering right 114
No steer, external shock load 116
Steering/brake pump operation 119
Normal operation 119
Neutral position 120
Full pump volume 121
Half pump volume 121
Steering cylinder wear data 122
Hoist circuit 125
Hoist circuit operation 127
Hoist circuit components 128
Hydraulic tank 128
Hoist pump 128
High pressure filters 128
Hoist valve 128
Hoist limit solenoid 129
Pilot operated check valve 129
Hoist pilot valve operation 131
Float position of pilot valve with truck body on frame 131
Power up operation 133
Hold operation 135
Power down operation 137
Float operation 139
Hoist cylinder wear data 141
Brake circuits 143
General information 145
Service brake circuit operation 146
Secondary braking system and auto apply 146
Rear wheel brake lock circuit operation 148
Parking brake circuit operation 150
Normal operation (key switch ON, engine on) 150
Brake lines and test ports 152
Brake warning circuit operation 153
Brake assembly wear data 155
Electrical system, 24 volt 157
Battery supply system 159
Auxiliary control cabinet components 160
24VDC to 12VDC converter 160
Diode board – DB1 160
Power distribution terminals 160
Control power relay 161
Fuse blocks 162
Relay boards 162
Relay boards RB1, RB3, RB4, RB5 162
Relay boards RB6, RB7, RB8, RB9 164
Relay functions 164
Body position switches (With proximity switch and metal arm) 166
Body-up switch 166
Hoist limit switch 167
Body position switches (With proximity switch and magnet) 168
Proximity switch operation 168
Body-up Switch 168
Hoist limit switch 168
Drive system 171
SR rectifier module 174
ST module (auxiliary voltage inverter) 174
Technical Data 177
SD phase modules 178
SR/ST/SD module removal 178
Inverter cabinet layout 179
Inverter cabinet water flow 179
Field regulator 180
Technical Data 180
Field regulator (discharge resistor) 180
Technical Data 180
Gate Unit 181
Technical Data 181
Technical Data 181
Technical Data 181
Control power filter 182
Technical Data 182
Filter for TCU 182
Technical Data 182
Terminal block bus bar 183
Technical Data 183
Fuses (analog sensor voltage) 184
Technical Data 184
Fuses (field regulator) 184
Technical Data 184
Fuses (fuse holder for field regulator) 184
Fuses (control power and trolley box contactor) 185
Technical Data 185
Diode modules 185
Technical Data 185
Support capacitors 186
Technical Data 186
3-Phase capacitor bank (for ST module output voltage) 186
Technical Data 186
Air-cooled inductors (for ST module) 187
Technical Data 187
3-Phase transformer (for ST module) 187
Technical Data 187
Diagnostics box 188
Diagnostic and system monitoring panel 189
Technical Data 189
Current transducers 190
Device names: 190
Technical Data 190
Technical Data 190
Current transducers (for ST module output) 191
Technical Data 191
Voltage transducers 192
Technical Data 192
Voltage transducers (for ST module output) 192
Technical Data 192
Voltage transducers (SiBAS® 24V DC bus monitoring) 193
Analog inclinometer 193
Technical Data 193
DC link capacitors 194
Technical Data 194
Ground tie capacitor 194
Technical Data 194
Low-inductance bus bar assembly 195
Free-wheeling diode for low-inductance bus bars 195
Contactor (grid box and main blower motor) 196
Technical Data 196
Contactor (control power) 196
Technical Data 196
Contactor (DC contactors) 197
Technical Data 197
Contactor (crowbar bypass) 197
Technical Data 197
Temperature probes (PT100 style) 198
Technical Data 198
Coolant inlet temperature sensor 198
Technical Data 198
Coolant outlet temperature sensor (external pad style) 199
IGBT module heat sink temperature sensor 199
Coolant outlet temperature sensor (internal style) 199
Technical Data 199
Coolant outlet temperature sensor (external pad style) 200
Technical Data 200
Circuit breakers 201
Technical Data 201
Inner circulating blower fan 201
Coolant pump 202
Technical Data 202
Motor for coolant pump 202
Technical Data 202
Coolant pressure sensor 202
Inner radiator 203
Ground voltage monitoring resistors 203
Protection thyristor assembly (crowbar) 204
Discharge reactor 204
Main blower motor 205
Technical Data 205
Grid box 205
Technical Data 205
Grid box blower motor 206
Technical Data 206
Grid box blower motor grease fittings 206
Main alternator 207
Stator 207
Rotor 207
Bearings 207
Electrical connection 207
Cooling and ventilation 207
Rotating rectifier section 208
Technical Data 208
Main alternator circuit diagram 209
IGBT – inverter/chopper phase module 210
Troubleshooting information 212
Main input rectifier module 213
Internal circuit diagram 214
Upper ground tie resistor 215
Technical Data 215
Lower ground tie resistor 215
Technical Data 215
Troubleshooting – fault diagnosis 216
Speed sensor, alternator 217
Technical Data 217
Speed sensors, wheel motors 218
Technical Data 218
Traction motor 219
Technical Data 219
Grid box 220
Device name: M04 220
Technical Data 220
Step down box 223
SIBAS® IGBT rack components 225
SiBAS®32 Traction Control Unit (TCU) 228
Overview of the SiBAS®32 systems 229
Features 229
General technical specifications, operating conditions 229
Permissible temperature range 229
Permissible limit value for air humidity 230
Permissible power supply voltage range 230
Permissible mechanical loads 230
Protection measures against electrical hazards 230
Application 230
Removing and installing the SiBAS®32 cards 233
Removal with 24V OFF! (ESD protection required) 233
Installation with 24V OFF! (ESD protection required) 233
SiBAS®32 card device names 234
Structure of SiBAS®32 card part number 235
Development status, downward compatibility 235
SiBAS®32 card interchangeability 236
Use of service interfaces 237
Connection of the service unit 237
Maintenance 237
Cleaning 238
SiBAS®32 card interactions 239
Blower subassembly 242
Device name: N/A 242
Application 242
Battery replacement 244
Rules for handling lithium batteries 244
Replacement of the battery in the fan subassembly 244
CPU card 245
Device name: G011 245
Application 246
Front panel 246
Technical data 247
DSP card 248
Device name: G019, G027 and G35 248
Application 248
Front panel 248
Technical data 249
I/O card 250
Device name: G043 250
Application 250
Front panel 251
Technical data 252
TRACO card (optional) 253
Device name: G003 253
Application 253
Front panel 254
Technical data 255
Input voltage/frequency card 256
Device name: L055, L063 and L071 256
Application 256
Technical data 257
I/O analog card 258
Device name: L079 and L087 258
Technical data 260
I/O analog card 261
Device name: L095 and L103 261
Application 261
Technical data 263
Output pulse amplifier card 264
Device name: L115, L123, L131, L139 and L147 264
Application 264
Technical data 266
Input temperature sensor card 267
Device name: L155 and L163 267
Application 267
Technical data 269
UWS card 270
Device name: G055, G063, G071 and G079 270
Application 270
Technical data 272
Digital input card 273
Device name: G103, G111, G119, G127 and G135 273
Application 273
Technical data 275
Power start-up unit card 276
Device name: G163 276
Application 276
Technical data 278
Binary output contactor drive card 279
Device name: C019, C027 and C035 279
Application 279
Technical data 281
24V / 24V power supply 282
Device name: C045, C105, C129 282
Application 282
Testing the power supply card 283
Technical data 284
24V / 15V power supply 285
Device name: C069, C087 285
Application 285
Testing the power supply card 286
Technical data 287
24V / 5V power supply 288
Device name: C153 288
Application 288
Testing the power supply card 289
Technical data 290
Reserve engine oil system 293
General information 295
Operation 296
LED monitor light 296
Remote tank fill system 297
Wheel motor transmission 299
General information 301
Transmission wear data 304
20 Standard value table 309
Standard value table 309
Standard value table for truck 311
30 Testing and adjusting 317
Cab air conditioning 317
General information 319
Service tools and equipment 320
Recovery/recycle station 320
Leak detector 320
Manifold gauge set 321
Service valves 322
Vacuum pump 322
Detecting leaks 323
System performance test 324
Checking system oil 325
System flushing 326
Installing the manifold gauge set 327
Purging air from the service hoses 328
Recovering and recycling refrigerant 329
Draining oil from previous recovery cycle 330
Recovery cycle 330
Recycling procedure 330
Evacuating the air conditioning system 331
Charging the air conditioning system 332
Steering, brake cooling and hoist hydraulic system 335
General information on system checkout 337
Steering system checkout procedures 337
Steering pump pressure control adjustments 338
Steering control valve and flow amplifier leakage test 339
Bleed down manifold leakage test 340
Shock and suction valve pressure tests 341
Steering system checkout data sheet 343
Toe-in adjustment 344
Brake cooling and hoist system checkout procedures 345
Pressure gauge locations 345
Brake cooling circuit test 346
Power up relief pressure test 346
Power down relief pressure test 347
Counterbalance valve pressure check 348
Counterbalance valve adjustment 349
Brake cooling and hoist system checkout data sheet 350
Hydraulic system flushing procedure 351
Front suspension pressure test 358
Rear suspension pressure test 358
Steering cylinder leakage test 359
Hoist cylinder leakage test 359
Brake system 361
General information on system checkout 363
Brake circuit checkout procedure 363
Precheckout items 364
Software operation and configuration 364
Hydraulic isolation and troubleshooting 364
Truck starting procedure 364
Initial system setup 365
Brake lock / secondary braking checkout 366
Brake lock hydraulic circuit trouble shooting guide 368
Parking brake checkout 368
Park brake hydraulic circuit trouble shooting guide: 369
Service brake checkout 371
Blended braking checkout 371
Low brake accumulator pressure and auto apply checkout 372
Reapplication 373
Parking brake control logic checkout 373
Brake lock control logic checkout 375
BLENDED BRAKING CHECKOUT 379
Brake piston leakage test 388
Wet disc brake bleeding procedure 388
Parking/service brake bleeding procedure 389
Parking brake leakage test 389
Brake disc wear inspection 391
Brake valve bench test and adjustment 393
Test setup procedure 394
Brake valve output pressure adjustment 394
Final test and adjustment 395
Accumulators and suspensions 397
Accumulator charging and storage 399
Temperature during precharge 399
Bladder accumulator charging procedure 400
Precharge maintenance 402
Bladder accumulator storage procedure 402
Bladder storage 402
Installing a bladder accumulator from storage 403
Bladder accumulator leak testing 403
Piston accumulator charging procedure 404
Piston accumulator storage 407
Piston accumulator leak testing 408
Checking for improper suspension charge on operating trucks 409
Suspension oil change recommendations 410
Suspension oiling and charging procedures 411
Required equipment 411
Installing the charging kit 412
Removing the charging kit 412
Support blocks for oiling and charging dimensions 413
Front suspensions 416
TOP FILL METHOD 417
PRESSURE FILL METHOD 417
Rear suspensions 419
TOP FILL METHOD 421
PRESSURE FILL METHOD 421
Suspension pressure test 424
Payload meter IV 427
Payload meter IV software and tools 429
Payload meter IV system configuration 429
Connecting to the payload meter IV web server 429
Configuring a static IP address 429
Payload meter IV software installation 431
Inclinometer calibration and clean truck tare 432
Payload meter IV checkout procedure 432
PLM IV system checkout data sheet 438
Downloading PLM IV data and possible errors 439
KOMTRAX Plus II 443
Required software and tools 445
Ethernet connection to KOMTRAX Plus II controller 445
KOMTRAX Plus II configuration 447
GPS connection test 449
Iridium satellite system opening 451
Data download over ethernet connection for KOMTRAX Plus II initialization 454
Interface module (IM2) 457
Required tools 459
Programming the IM2 459
Updating the software 459
Configuring the IM2 460
Viewing IM2 real-time data 460
Interface module checkout procedures 461
Checking for IM fault codes 461
Checking digital inputs to the IM 461
Checking analog inputs to the IM 464
Checking serial communication to the IM 464
Checking outputs from the IM 465
IM Installation Checkout Checklist 466
IGBT haul truck SIBAS® user manual, part 1 471
Abbreviations 474
Product description 476
Version management 477
Overview 478
Requirements 478
Installation 479
Environment variables 479
Communication with the SIBAS® 32 control unit 480
Calling up the customer monitor 481
Start-up prompt 481
Monitor prompt 482
Notes on operation of the customer monitor 483
Structure of a monitor command 483
Step 1: Selecting the menu title 483
Step 2: Selecting a menu entry in the menu box 483
Step 3: Selecting a dialog box, if available 484
Step 4: Entering file or connector/signal names 484
Command buffer 485
Structure of the monitor windows 485
Commands for Opening, Altering and Closing Windows 486
“Window Work open” 486
“Window Lines open” 486
“Window Tile” 486
“Window Bars open” 486
Options 486
“Window Set” 486
Options 486
“Window Cascade” 486
“Window Close” 486
“Window close All” 486
“Window Exit” 486
“Set Port” 487
Options 487
“Set Baudrate” 487
Options 487
“Set String” 488
Example 489
“Set Make” 489
Options 489
Example 1: INIT MON start-up control of the Customer Monitor 490
Example 2: Any monitor batch file with freely selectable file name (incl path) 490
“Set Execute” 491
Options 491
Example 491
“Set Record” 491
Options 491
“Set DIN-Bus” 492
“Set TCN” 492
“Set Timeout” 492
Options 492
“Set Wait” 492
Options 492
“Set Color” 492
Options 492
“Set Info” 493
“Set comment” 493
“Set CHAR Set” 493
“Set Quit” 493
“Applic Func Package” 494
“Applic Connector” 495
Options 495
Example 496
“Applic View” 496
Options 496
Example 496
“Applic Signal” 496
“Applic Observer” 497
Options 497
Possible time slices: 497
Options 498
Two options 498
Notes on the display of connectors 500
“Applic Buffer” 501
Options 501
“Applic Report” 501
“Applic Legitimation” 501
Options 501
“Applic Menu” 502
“Applic Traco” 502
Options 502
“Applic Environment” 502
Hardware-Oriented Access via the Customer Monitor 504
“Hardw Flash” 504
Options 504
Requirements 504
Example 505
Deleting and loading 505
The EPROM for the communication drivers 505
“Hardw Clock” 505
Options 505
“Hardw DSP” 506
“Hardw BCD” 506
Options 506
Example 506
“Hardw RESET” 506
Options 506
“Hardw Info” 507
Hardware/Operating system 507
Application and tools 507
Communication module 507
Displaying the loading date 507
“Hardw User Flash” 508
Options 508
“Hardw Sys Flash” 508
Options 508
“Hardw BOOT DSP” 509
Requirements 509
DSP5600x Signal Processing Unit and TRACO 509
Inverter processing unit 511
Access to the Signal Processing Unit 511
“Hardw Flash” 511
Options 511
Requirements 511
Example 511
Deleting and loading 512
The EPROM for the communication drivers 512
User Data Flash (UDF) 512
“Hardw RESET” 512
Options 512
“Hardw ZR” 513
“Hardw BOOT ZR” 513
The following procedure is necessary: 513
Commands for Displaying Line Graphics 514
“Graphic Load” 514
Options 514
“Graphic Position” 514
Options 514
“Graphic Time/Div” 515
Options 515
“Graphic Unit/Div” 515
Options 515
“Graphic Display” 515
Options 515
“Graphic Color” 516
Options 516
“Graphic Format” 516
Options 516
IGBT haul truck SIBAS® user manual, part 2 519
Traco Menu 522
HW-Traco 522
Options 523
SW-Traco 524
Options 525
ZR traco basic parameters: 525
ZR traco record signal table: 525
DAC_Traco 528
Options 529
Events Menu 530
STatistics 531
History 532
LEL:Last EvL 533
LES:Last EvS 535
DLL:DC,LastL 536
DLS:DC,LastS 537
DAL:DC,All L 538
DAS:DC,All S 539
ML:Memory L 540
MS:Memory S 541
CN:Clear Norm 542
CA:Clear All 542
Test-Code 542
DS:Diag-Strc 543
User Menu 544
DAC_IO 545
Options 545
Options 546
Operat Data 547
Acc test 554
Engine_Test 554
X_Test_Inx 557
STate intern 558
Header: 558
Vehicle Number: 558
Powering system: 558
TCU Operation Mode: 558
Component status listings: 559
Field regulator status: 559
Status gate unit power supply A: 559
Status gate unit power supply B: 559
ST inverter status 559
Vehicle status 560
Drive status: 560
Operation status: 560
Pedal calib 561
Language 562
OFFline-test 562
Options 562
Variables 564
Examples: 564
IV:Vehic-ID 565
Commands 566
Discharge Dc link / Fire crowbar 566
Limp mode commands 566
Settings 567
Parameters 568
Temp_prot 570
Appendix 572
Background commands 572
Monitor commands for the central processing unit 574
Monitor commands for the signal processing unit 574
Installing ZR / DSP software 577
Monitor Program – Loading software into the SIBAS® 579
Loading software into the DSP procedure 579
Loading a DSP program Inverter A 584
Loading software into the CPU procedure 591
Loading ZR software Prog jumpers Reset 598
Loading the proper pgm file 600
Setting the system up After loading a new pgm 600
24V electrical system 603
Body position switches (with proximity switches and metal arms) 605
Body up switch adjustment 605
Hoist limit switch adjustment 606
Service 606
Body position switches (with proximity switches and magnets) 607
Body up switch adjustment 607
Hoist limit switch adjustment 607
Service 607
Automatic lubrication (auto lube) system 611
Priming the system 613
Checkout procedure 615
Adjusting the lubrication cycle timing 616
Trucks with Interface Module 1 616
Trucks with Interface Module 2 616
40 Troubleshooting 619
Fuse and circuit breaker locations 619
Fuse and circuit breaker locations 621
Fuse block tables 622
Prelube motor fuse 623
Circuit breaker table 624
Troubleshooting by fault code, Part 1 627
Fault Code A001: Left front suspension pressure sensor signal high 630
Related circuit diagram 630
Fault Code A002: Left front suspension pressure sensor signal low 631
Related circuit diagram 631
Fault Code A003: Right front suspension pressure sensor signal high 632
Related circuit diagram 632
Fault Code A004: Right front suspension pressure sensor signal low 633
Related circuit diagram 633
Fault Code A005: Left rear suspension pressure sensor signal high 634
Related circuit diagram 634
Fault Code A006: Left rear suspension pressure sensor signal low 635
Related circuit diagram 635
Fault Code A007: Right rear suspension pressure sensor signal high 636
Related circuit diagram 636
Fault Code A008: Right rear suspension pressure sensor signal low 637
Related circuit diagram 637
Fault Code A009: Incline sensor signal high 638
Related circuit diagram 638
Fault Code A010: Incline sensor signal low 639
Related circuit diagram 639
Fault Code A011: Payload meter speed sensor signal has failed 640
Related circuit diagram 640
Fault Code A013: Body up switch has failed 641
Related circuit diagram 641
Fault Code A014: Payload meter checksum computation has failed 642
Related circuit diagram 642
Fault Code A016: Payload meter write to flash memory has failed 643
Related circuit diagram 643
Fault Code A017: Payload meter flash memory read has failed 644
Related circuit diagram 644
Fault Code A018: Right rear flat suspension cylinder warning 645
Related circuit diagram 646
Fault Code A019: Left rear flat suspension cylinder warning 647
Related circuit diagram 648
Fault Code A022: Carryback load excessive 649
Related circuit diagram 650
Fault Code A100: An open circuit breaker has been detected on a relay board 651
Related circuit diagram 651
Fault Code A101: High pressure detected across an hydraulic pump filter 652
Related circuit diagram 654
Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level 655
Related circuit diagram 656
Fault Code A111: Low steering pressure warning for storage by KOMTRAX Plus 657
Related circuit diagram 657
Fault Code A115: Low steering precharge pressure detected 658
Related circuit diagram 659
Fault Code A117: Low brake accumulator pressure warning for storage by KOMTRAX Plus 660
Related circuit diagram 660
Fault Code A118: Brake pressure is low while in brake lock 661
Related circuit diagram 662
Fault Code A126: Oil level in the hydraulic tank is low 663
Related circuit diagram 663
Fault Code A127: IM-furnished +5 volt output for sensors is low 664
Related circuit diagram 665
Fault Code A128: IM-furnished +5 volt output for sensors is high 666
Related circuit diagram 667
Fault Code A139: Low fuel warning for storage by KOMTRAX Plus and for use by A310 668
Related circuit diagram 669
Troubleshooting by fault code, part 2 671
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil 674
Related circuit diagram 675
Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil 676
Related circuit diagram 677
Fault Code A152: Starter failure 678
Related circuit diagram 679
Fault Code A153: Battery voltage is low with the truck in operation 680
Related circuit diagram 681
Fault Code A154: Battery charging voltage is excessive 682
Related circuit diagram 682
Fault Code A155: Battery charging voltage is low 683
Related circuit diagram 683
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 684
Related circuit diagram 685
Fault Code A159: (A30003 only) The battery 12 Volt circuit sensing is producing low readings 686
Related circuit diagram 686
Fault Code A164: (A30003 only) The battery 12 Volt circuit sensing is producing high readings 687
Related Circuit Diagram 687
Fault Code A166: Left rear hydraulic oil temperature sensor is low 688
Related circuit diagram 689
Fault Code A167: Right rear hydraulic oil temperature sensor is low 690
Related circuit diagram 691
Fault Code A168: Left front hydraulic oil temperature sensor is low 692
Related circuit diagram 693
Fault Code A169: Right front hydraulic oil temperature sensor is low 694
Related circuit diagram 695
Fault Code A170: Left rear hydraulic oil temperature sensor is high 696
Related circuit diagram 696
Fault Code A171: Right rear hydraulic oil temperature sensor is high 697
Related circuit diagram 697
Fault Code A172: Left front hydraulic oil temperature sensor is high 698
Related circuit diagram 698
Fault Code A173: Right front hydraulic oil temperature sensor is high 699
Related circuit diagram 699
Fault Code A182: (A30003 only) The battery 12 Volt battery tap has high voltage 700
Related circuit diagram 701
Fault Code A183: (A30003 only) The battery 12 Volt battery tap has low voltage 702
Related circuit diagram 703
Fault Code A184: J1939 data link is not connected 704
Related circuit diagram 705
Fault Code A190: (A30003 only) The automatic lubrication system has announced a fault 706
Fault Code A190: (A30004 & Up) Auto lube control has detected an incomplete lube cycle 708
Related circuit diagram 709
Fault Code A194: Left front hydraulic oil temperature is high 710
Related circuit diagram 710
Fault Code A195: Right front hydraulic oil temperature is high 711
Related circuit diagram 711
Fault Code A196: Left rear hydraulic oil temperature is high 712
Related circuit diagram 712
Fault Code A197: Right rear hydraulic oil temperature is high 713
Related circuit diagram 713
Fault Code A198: Hoist pressure 1 sensor is high 714
Related circuit diagram 714
Fault Code A199: Hoist pressure 2 sensor is high 715
Related circuit diagram 715
Fault Code A200: Steering pressure sensor is high 716
Related circuit diagram 716
Fault Code A201: Brake pressure sensor is high 717
Related circuit diagram 717
Fault Code A202: Hoist pressure 1 sensor is low 718
Related circuit diagram 718
Fault Code A203: Hoist pressure 2 sensor is low 719
Related circuit diagram 719
Fault Code A204: Steering pressure sensor is low 720
Related circuit diagram 720
Fault Code A205: Brake pressure sensor is low 721
Related circuit diagram 721
Fault Code A206: Ambient temperature sensor is high 722
Related circuit diagram 722
Fault Code A207: Ambient temperature sensor is low 723
Related circuit diagram 723
Troubleshooting by fault code, part 3 725
Fault Code A213: Parking brake should have applied but is detected as not having applied 728
Related circuit diagram 731
Fault Code A214: Parking brake should have released but is detected as not having released 732
Related circuit diagram 734
Fault Code A215: Brake auto apply valve circuit is defective 735
Related circuit diagram 736
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 737
Related circuit diagram 738
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted 739
Related circuit diagram 740
Fault Code A230: Parking brake has been requested while truck still moving 741
Related circuit diagram 742
Fault Code A231: The body is up while traveling or with selector in forward or neutral 743
Fault Code A233: Drive System Control Link is not connected 745
Related circuit diagram 747
Fault Code A235: Steering accumulator is in the process of being bled down 748
Related circuit diagram 749
Fault Code A236: The steering accumulator has not properly bled down after 90 seconds 750
Related circuit diagram 751
Fault Code A237: The CAN/RPC connection to the display is open 752
Related circuit diagram 753
Fault Code A238: Drive System and IM are reporting different park brake status 754
Related circuit diagram 756
Fault Code A239: The Drive System and IM are reporting different brake lock status 757
Related circuit diagram 758
Fault Code A240: The keyswitch input to the Interface Module is open 759
Related circuit diagram 759
Fault Code A242: Fuel gauge within the dash display panel is defective 760
Related circuit diagram 760
Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective 761
Related circuit diagram 761
Fault Code A244: Drive system temperature gauge within the dash display panel is defective 762
Related circuit diagram 762
Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective 763
Related circuit diagram 763
Fault Code A246: Payload meter reports truck overload 764
Related circuit diagram 764
Fault Code A247: Low steering pressure warning for display to operator 765
Related circuit diagram 765
Fault Code A248: Status module within the dash display panel is defective 766
Related circuit diagram 766
Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted 767
Related circuit diagram 767
Fault Code A250: Battery voltage is low with the truck parked 768
Related circuit diagram 769
Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground 770
Related circuit diagram 771
Fault Code A252: Start enable output circuit is either open or shorted to ground 772
Related circuit diagram 773
Fault Code A253: Steering bleed circuit is not open while running 774
Related circuit diagram 775
Fault Code A254: (A30003 Only) The 5 minute idle circuit is either open or shorted to ground 776
Related circuit diagram 776
Fault Code A256: Red warning lamp in the dash display (driven by IM) is open 777
Related circuit diagram 777
Fault Code A257: Payload CAN/RPC is not connected 778
Related circuit diagram 779
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 780
Related circuit diagram 780
Troubleshooting by fault code, part 4 783
Fault Code A260: Park brake failure 786
Related circuit diagram 787
Fault Code A261: Low brake accumulator pressure warning for display to operator 788
Related circuit diagram 788
Fault Code A262: Steering bleed valve circuit open during shutdown 789
Related circuit diagram 790
Fault Code A264: Park brake relay circuit is defective 791
Related circuit diagram 792
Fault Code A265: Service brake failure 793
Related circuit diagram 794
Fault Code A266: Selector switch was not in park while attempting to crank engine 795
Related circuit diagram 796
Fault Code A267: Park brake was not set while attempting to crank engine 797
Related circuit diagram 798
Fault Code A268: Secondary engine shutdown while cranking 799
Related circuit diagram 799
Fault Code A270: Brake lock switch power supply is not on when required 800
Related circuit diagram 802
Fault Code A271: Shifter not in gear 803
Related circuit diagram 804
Fault Code A272: Brake lock switch power supply is not off when required 805
Related circuit diagram 806
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit 807
Related circuit diagram 807
Fault Code A274: A brake setting fault has been detected 808
Related circuit diagram 809
Fault Code A275: A starter has been detected as engaged without a cranking attempt 810
Related circuit diagram 811
Fault Code A277: Park brake applied while loading 812
Related circuit diagram 813
Fault Code A278: Service brake applied while loading 814
Related circuit diagram 815
Fault Code A279: Low Steering Pressure Switch bad 816
Related circuit diagram 816
Fault Code A280: Steering accumulator bled switch bad 817
Related circuit diagram 817
Fault Code A281: Brake lock degrade switch bad 818
Related circuit diagram 819
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 820
Related circuit diagram 821
Fault Code A283: (A30004 & Up) An engine shutdown delay was aborted because the parking brake was not set 822
Related circuit diagram 823
Fault Code A284: (A30004 & Up) An engine shutdown delay was aborted because the secondary shutdown switch was operated 824
Related circuit diagram 825
Fault Code A285: (A30004 & Up) The park brake was not set when the keyswitch was turned off 826
Related circuit diagram 827
Fault Code A286: (A30004 & Up) A fault was detected in the shutdown delay relay circuit 828
Related circuit diagram 829
Fault Code A292: (A30004 & Up) The shutdown delay relay has remained on after the latched keyswitch circuit is off 830
Related circuit diagram 831
Fault Code A295: The right front park brake is not setting up 832
Related circuit diagram 832
Fault Code A296: The left front park brake is not setting up 833
Related circuit diagram 833
Fault Code A297:The right rear park brake is not setting up 834
Related circuit diagram 834
Fault Code A298: The left rear park brake is not setting up 835
Related circuit diagram 835
Fault Code A299: The right front park brake is not releasing 836
Related circuit diagram 836
Fault Code A300: The left front park brake is not releasing 837
Related circuit diagram 837
Fault Code A301: The right rear park brake is not releasing 838
Related circuit diagram 838
Fault Code A302: The left rear park brake is not releasing 839
Related circuit diagram 839
Troubleshooting by fault code, part 5 841
Fault Code A303: Shifter is defective 844
Related circuit diagram 845
Fault Code A304: (A30004 & Up) Auto lube grease level fault 846
Related circuit diagram 846
Fault Code A305: (A30004 & Up) Auto lube circuit is defective 847
Related circuit diagram 848
Fault Code A309: No brakes applied when expected 849
Related circuit diagram 850
Fault Code A310: Low fuel warning 851
Related circuit diagram 852
Fault Code A311: Brake lock switch is on when it should not be 853
Related circuit diagram 854
Fault Code A312: (A30004 & Up) DCDC converter 12 volt circuit sensing is producing low readings 855
Related circuit diagram 855
Fault Code A313: (A30004 & Up) DCDC converter 12 volt circuit sensing is producing high readings 856
Related circuit diagram 856
Fault Code A315: (A30004 & Up) DCDC converter 12 volt circuit is low 857
Related circuit diagram 858
Fault Code A316: Starter engagement has been attempted with engine running 859
Related circuit diagram 860
Fault Code A317: Operation of brake auto apply valve without a detected response 861
Related circuit diagram 863
Fault Code A318: Unexpected power loss to Interface Module 864
Related circuit diagram 864
Fault Code A328: Drive system not powered up 865
Related circuit diagram 865
Fault Code A335: Manual/Auto Apply Pressure Fault 866
Fault Code A350: Overload on output 1B 867
Related circuit diagram 867
Fault Code A351: Overload on output 1E 868
Related circuit diagram 869
Fault Code A352: (A30003) Overload on output 1H 870
Related circuit diagram 870
Fault Code A352: (A30004 & Up) Overload on output 1H 871
Related circuit diagram 871
Fault Code A353: Overload on output 1J 872
Related circuit diagram 872
Fault Code A354: Overload on output 1K 873
Related circuit diagram 873
Fault Code A355: Overload on output 1L 874
Related circuit diagram 874
Fault Code A356: Overload on output 1M 875
Related circuit diagram 875
Fault Code A357: Overload on output 1N 876
Related circuit diagram 876
Fault Code A358: Overload on output 1P 877
Related circuit diagram 877
Fault Code A359: Overload on output 1R 878
Related circuit diagram 879
Fault Code A360: Overload on output 1S 880
Related circuit diagram 880
Fault Code A361: (A30003) Overload on output 1T 881
Related circuit diagram 881
None 881
Fault Code A361: (A30004 & Up) Overload on output 1T 882
Related circuit diagram 883
Fault Code A362: Overload on output 1U 884
Related circuit diagram 884
Fault Code A363: Overload on output 1X 885
Related circuit diagram 885
Fault Code A364: Overload on output 1Y 886
Related circuit diagram 886
Fault Code A365: Overload on output 1Z 887
Related circuit diagram 887
Fault Code A368: Siemens Brake Test Active 888
Related circuit diagram 888
Fault Code A369: Siemens Brake Test Incomplete 889
Related circuit diagram 889
Fault Code A370: Siemens Brake Test Torque Achieved for Park Brake 890
Related circuit diagram 890
Fault Code A371: Siemens Brake Test Torque Achieved for Service Brake 891
Related circuit diagram 891
Fault Code A372: Siemens Brake Test Torque Not Achieved for Park Brake 892
Related circuit diagram 892
Fault Code A373: Siemens Brake Test Torque Not Achieved for Service Brake 893
Related circuit diagram 893
Drive system fault code table, part 1 895
Summary 898
How to use this document 898
Event code and diagnosis message 898
Description 898
Threshold 898
Detection by 898
Possible reasons 898
Action to reset 898
Action to repair 899
Operator displayed code 899
Note 899
Protection reactions 899
Event classification 900
Level 1: Warning 900
Level 2: Minor purposes 900
Level 3: Severe 900
1 L3C SYS: Time slice overflow CPU T1 901
2 L3C SYS: Time slice overflow CPU T2 901
3 L3C SYS: Time slice overflow CPU T3 901
4 L3C SYS: Time slice overflow CPU T4 901
5 L3C SYS: Time slice overflow CPU T5 901
6 L3C SYS: Time slice overflow CPU T6 901
7 L3C SYS: Time slice overflow CPU T7 901
8 L3C SYS: Time slice overflow CPU T8 901
10 L2A SYS: Pulse inhibit/asa inhibit PSU–ONLINE 902
11 L3D SYS: Pulse inhibit/asa inhibit PSU-Start-up 902
12 L1A SYS: SIBAS® blower fault 903
13 L1B SYS: Undervoltage in SIBAS® battery for BRAM 903
14 L3C SYS: SIBAS® power supply failure 24V for pulse amplifier 904
15 L3C SYS: SIBAS® power supply failure +5V 905
16 L3C SYS: SIBAS® power supply failure +15V 906
17 L3C SYS: SIBAS® power supply failure –15V 907
18 L3C SYS: SIBAS® power supply failure +24V 908
19 L3C SYS: SIBAS® power supply failure –24V 909
20 L3C SYS: SIBAS® power supply failure primary 910
21 L3C SYS: FPGA clock missing for PSU 910
22 L3C SYS: Pulse inhibit by reset in PSU from CPU 911
24 L3C SYS: General protection error (G10) 911
25 L3C SYS: Total block 912
26 L1B SYS: Permanent inhibit fault active 913
27 L1B SYS: Regular inhibit fault active 913
28 L1A SYS: GW Test stopped by A/D converter faulty 914
30 L3C DSP A: Initialization fault detected by DSP 914
31 L3C DSP A: SW-WatchdoG 915
32 L3C DSP A: Initialization fault detected by CPU 916
33 L1B DSP A: SW-Traco triggered 916
34 L1B DSP A: SW-Traco full 917
35 L3C DSP A: Time slice overflow T1 918
36 L3C DSP A: Time slice overflow T2 918
37 L3C DSP A: Time slice overflow T3 918
38 L3C DSP A: Time slice overflow T4 918
39 L1A DSP A: Communication HSCX data from DSP B missing 919
40 L1A DSP A: Communication HSCX data from DSP T missing 919
41 L3C DSP A: Current offset during pulse block 920
42 L3C DSP A: Current offset during no pulse block 920
43 L3A DSP A: Overcurrent fault 921
44 L3C DSP A: Current transducer defective phase U 922
45 L3C DSP A: Current transducer defective phase W 923
48 L1A DSP A: Modulation software fault 923
49 L3A DSP A: Active current controller at limit 924
Drive system fault code table, part 2 927
50 L3A DSP A: Active current reference at limit 930
51 L1A DSP A: Braking chopper controller at limit 930
52 L3C DSP A: Phase unbalance too large 931
53 L3A DSP A: Pulse block by DSP software 932
54 L3C DSP A: U/F Card defective 932
55 L3C DSP A: Difference in current of phase U over limit 933
56 L3C DSP A: Difference in current of phase W over limit 933
60 L3C DSP B: Initialization fault detected by DSP 934
61 L3C DSP B: SW-Watchdog 934
62 L3C DSP B: Initialization fault detected by CPU 935
63 L1B DSP B: SW-Traco triggered 935
64 L1B DSP B: SW-Traco full 936
65 L3C DSP B: Time slice overflow T1 936
69 L1A DSP B: Communication HSCX data from DSP A missing 937
70 L1A DSP B: Communication HSCX data from DSP T missing 937
71 L3C DSP B: Current offset during pulse block 938
72 L3C DSP B: Current offset during no pulse block 938
73 L3A DSP B: Overcurrent fault 939
74 L3C DSP B: Current transducer defective phase V 940
75 L3C DSP B: Current transducer defective phase W 941
78 L1A DSP B: Modulation software fault 941
79 L3A DSP B: Active current controller at limit 942
80 L3A DSP B: Active current reference at limit 942
81 L1A DSP B: Braking chopper controller at limit 942
82 L3C DSP B: Phase unbalance too large 943
83 L3A DSP B: Pulse block by DSP software 943
84 L3C DSP B: U/F Card defective 944
85 L3C DSP B: Difference in current of phase V over limit 944
86 L3C DSP B: Difference in current of phase W over limit 945
90 L3C DSP T: Initialization fault detected by DSP 945
91 L3C DSP T: SW-Watchdog 946
92 L3C DSP T: Initialization fault detected by CPU 947
93 L1B DSP T: SW-Traco triggered 947
94 L1B DSP T: SW-Traco full 948
95 L3C DSP T: Time slice overflow T1 948
96 L3C DSP T: Time slice overflow T2 948
97 L3C DSP T: Time slice overflow T3 948
98 L3C DSP T: Time slice overflow T4 948
99 L1A DSP T: Communication HSCX data from DSP A missing 949
Drive system fault code table, part 3 951
100 L1A DSP T: Communication HSCX data from DSP B missing 954
101 L3C DSP T: Current offset during pulse block 954
102 L3C DSP T: Current offset during no pulse block 955
103 L3A DSP T: Overcurrent fault 956
104 L3C DSP T: Current transducer defective phase U 957
105 L3C DSP T: Current transducer defective phase V 958
106 L3C DSP T: Current transducer defective phase W 959
107 L3C DSP T: Sum of output current not equal zero 960
108 L1A DSP T: Modulation software fault 960
109 L1A DSP T: Voltage controller at limit 961
112 L3C DSP T: Phase unbalance too large 961
113 L3A DSP T: Pulse block by DSP software 962
114 L3C DSP T: U/F Card defective 962
117 L3C DSP T: Crowbar fired by DSP T 963
119 L1C DSP T: Voltage transducer U34 not ok 964
120 L3C IO: Supervision bus clock 964
121 L3C IO: Supervision I/O clock 965
122 L3C IO: Incorrect FPGA version identifier 965
123 L3C IO: Incorrect FPGA application version identifier 966
124 L3C IO: Incorrect module version identifier 966
125 L3C/L1A IO: AD Converter faulty 967
126 L3C IO: GW Comparator faulty during start-up test 967
127 L3C IO: Test voltage not equal zero 968
128 L1A IO: SIBAS® Temperature out of range 968
129 L3C IO: Incorrect EBIN card identifier 969
130 L3C IO: Front plug monitoring 970
131 L3C IO: CPU Watchdog triggered 971
132 L3C IO: DSP A Watchdog triggered 971
133 L3C IO: DSP B Watchdog triggered 972
134 L3C IO: DSP T Watchdog triggered 972
135 L3C IO: CPU Reset triggered 973
138 L1B IO: CPU Traco triggered 973
146 L3A IO: Pulse block from I/O 974
150 L3A IO: DC link voltage A level 1 exceeded 974
151 L3A IO: DC link voltage B level 1 exceeded 975
152 L3C IO: Trolley line overvoltage 976
154 L3B IO: Trolley line overcurrent 977
155 L2B IO: Trolley line current transducer faulty 977
156 L2B IO: Trolley line voltage transducer faulty 978
160 L3A IO: Throttle pedal out of range 978
161 L3A IO: Retard pedal out of range 979
162 L1A IO: Cruise speed control module out of range 979
180 L3C UWSA1: Supervision bus clock 980
181 L3C UWSA1: Supervision module clock 980
182 L3C UWSA1: Incorrect FPGA version identifier 981
183 L3C UWSA1: Incorrect FPGA project identifier 981
184 L3C UWSA1: GW Comparator faulty during start-up test 982
185 L1A UWSA1: ADC Faulty 982
186 L3C UWSA1: Configuration failure 983
187 L1A UWSA1: Hardware failure counter / processor 983
188 L3A UWSA1: Peak current protection active 984
189 L3D UWSA1: Peak current protection pulse start 985
190 L3D UWSA1: Number of peak current protection >limit 986
191 L3D UWSA1: Supervision switching frequency 987
193 L1A UWSA1: Overvoltage level 1 exceeded 987
196 L3D UWSA1: Limit 5 overcurrent phase U 988
197 L3D UWSA1: Limit 5 overcurrent phase V 988
198 L3D UWSA1: Limit 5 overcurrent phase W 988
199 L3D UWSA1: Limit 5 overvoltage DC bus 989
Drive system fault code table, part 4 991
201 L3D UWSA1: Checkback INVA1 L1U faulty 995
202 L3D UWSA1: Checkback INVA1 L1L faulty 995
203 L3D UWSA1: Checkback INVA1 L2U faulty 995
204 L3D UWSA1: Checkback INVA1 L2L faulty 995
205 L3D UWSA1: Checkback INVA1 L3U faulty 995
206 L3D UWSA1: Checkback INVA1 L3L faulty 995
207 L3D UWSA1: Checkback chopper A faulty 995
210 L3C UWSB1: Supervision bus clock 996
211 L3C UWSB1: Supervision module clock 996
212 L3C UWSB1: Incorrect FPGA version identifier 997
213 L3C UWSB1: Incorrect FPGA project identifier 997
214 L3C UWSB1: GW Comparator faulty during start-up test 998
215 L1A UWSB1: ADC Faulty 998
216 L3C UWSB1: Configuration failure 999
217 L1A UWSB1: Hardware failure counter / processor 999
218 L3A UWSB1: Peak current protection active 1000
219 L3D UWSB1: Peak current protection pulse start 1001
220 L3D UWSB1: Number of peak current protection >limit 1002
221 L3D UWSB1: Supervision switching frequency 1003
223 L1A UWSB1: Overvoltage level 1 exceeded 1003
226 L3D UWSB1: Limit 5 overcurrent phase V 1004
227 L3D UWSB1: Limit 5 overcurrent phase U 1004
228 L3D UWSB1: Limit 5 overcurrent phase W 1004
229 L3D UWSB1: Limit 5 overvoltage DC bus 1005
231 L3D UWSB1: Checkback INVB1 L1U Faulty 1006
232 L3D UWSB1: Checkback INVB1 L1L Faulty 1006
233 L3D UWSB1: Checkback INVB1 L2U Faulty 1006
234 L3D UWSB1: Checkback INVB1 L2L Faulty 1006
235 L3D UWSB1: Checkback INVB1 L3U Faulty 1006
236 L3D UWSB1: Checkback INVB1 L3L Faulty 1006
237 L3D UWSB1: Checkback chopper B Faulty 1006
240 L3C UWSA2: Supervision bus clock 1007
241 L3C UWSA2: Supervision module clock 1007
242 L3C UWSA2: Incorrect FPGA version identifier 1008
243 L3C UWSA2: Incorrect FPGA project identifier 1008
244 L3C UWSA2: GW Comparator faulty during start-up test 1009
245 L1A UWSA2: ADC Faulty 1009
246 L3C UWSA2: Configuration failure 1010
247 L1A UWSA2: Hardware failure counter / processor 1010
248 L3A UWSA2: Peak current protection active 1011
249 L3D UWSA2: Peak current protection pulse start 1012
250 L3D UWSA2: Number of peak current protection >limit 1013
251 L3D UWSA2: Supervision switching frequency 1014
253 L1A UWSA2: Overvoltage level 1 exceeded 1014
256 L3D UWSA2: Limit 5 overcurrent phase U1 1015
257 L3D UWSA2: Limit 5 overcurrent phase V1 1015
258 L3D UWSA2: Limit 5 overcurrent phase W1 1015
259 L3D UWSA2: Limit 5 overvoltage DC bus 1016
261 L3D UWSA2: Checkback INVA2 L1U faulty 1017
262 L3D UWSA2: Checkback INVA2 L1L faulty 1017
263 L3D UWSA2: Checkback INVA2 L2U faulty 1017
264 L3D UWSA2: Checkback INVA2 L2L faulty 1017
265 L3D UWSA2: Checkback INVA2 L3U faulty 1017
266 L3D UWSA2: Checkback INVA2 L3L faulty 1017
267 L3D UWSA2: Checkback chopper C faulty 1017
270 L3C UWSB2: Supervision bus clock 1018
271 L3C UWSB2: Supervision module clock 1018
272 L3C UWSB2: Incorrect FPGA version identifier 1019
273 L3C UWSB2: Incorrect FPGA project identifier 1019
274 L3C UWSB2: GW Comparator faulty during start-up test 1020
275 L1A UWSB2: ADC Faulty 1020
276 L3C UWSB2: Configuration failure 1021
277 L1A UWSB2: Hardware failure counter / processor 1021
278 L3A UWSB2: Peak current protection active 1022
279 L3D UWSB2: Peak current protection pulse start 1023
280 L3D UWSB2: Number of peak current protection >limit 1024
281 L3D UWSB2: Supervision switching frequency 1025
283 L1A UWSB2: Overvoltage level 1 exceeded 1025
286 L3D UWSB2: Limit 5 overcurrent phase V1 1026
287 L3D UWSB2: Limit 5 overcurrent phase U1 1026
288 L3D UWSB2: Limit 5 overcurrent phase W1 1026
289 L3D UWSB2: Limit 5 overvoltage DC bus 1027
291 L3D UWSB2: Checkback INVB2 L1U Faulty 1028
292 L3D UWSB2: Checkback INVB2 L1L Faulty 1028
293 L3D UWSB2: Checkback INVB2 L2U Faulty 1028
294 L3D UWSB2: Checkback INVB2 L2L Faulty 1028
295 L3D UWSB2: Checkback INVB2 L3U Faulty 1028
296 L3D UWSB2: Checkback INVB2 L3L Faulty 1028
297 L3D UWSB2: Checkback chopper D Faulty 1028
Drive system fault code table, part 5 1031
300 L3C UWSST: Supervision bus clock 1035
301 L3C UWSST: Supervision module clock 1035
302 L3C UWSST: Incorrect FPGA version identifier 1036
303 L3C UWSST: Incorrect FPGA project identifieR 1036
304 L3C UWSST: GW Comparator faulty during start-up test 1037
305 L1A UWSST: ADC Faulty 1037
306 L3C UWSST: Configuration failure 1038
307 L1A UWSST: Hardware failure counter / processor 1038
308 L3A UWSST: Peak current protection active 1039
310 L3D UWSST: Number of peak current protection >limit 1040
311 L3D UWSST: Supervision switching frequency 1041
314 L3C UWSST: Crowbar is fired without command 1042
319 L3D UWSST: Limit 5 overvoltage DC bus 1044
321 L3D UWSST: Checkback INVST L1U Faulty 1045
322 L3D UWSST: Checkback INVST L1L Faulty 1045
323 L3D UWSST: Checkback INVST L2U Faulty 1045
324 L3D UWSST: Checkback INVST L2L Faulty 1045
325 L3D UWSST: Checkback INVST L3U Faulty 1045
326 L3D UWSST: Checkback INVST L3L Faulty 1045
327 L3C UWSST: Checkback crowbar faulty 1046
330 L1A BUS: CAN Communication failure 1047
331 L1A BUS: Serial link communication failure 1047
332 L1A BUS: Truck is over loaded 1047
333 L1B TR: Transient traco is triggered 1048
334 L1B TR: Transient traco is full 1048
340 L1A ETM: ADC Failure for ETM1 1048
341 L1A ETM: ADC Failure for ETM2 1049
342 L1A ETM: ADC Failure for ETM3 1049
343 L1A ETM: ADC Failure for ETM4 1049
344 L1A MEFA: ADC Failure 1050
345 L3C HL: Gate unit power supply A defective 1050
346 L3C HL: Gate unit power supply B defective 1051
351 L1A DRZ: LIMP Mode A active 1052
352 L1A DRZ: Limp mode B active 1052
353 L1A DRZ: Low battery voltage 1053
354 L1B BUS: Engine floor input increasing minimum engine speed 1053
355 L1B DM: Data store switch pressed 1054
356 L1B DM: Diagnosis memory configuration failure 1054
357 L1B DM: Diagnosis memory occupation > 75% 1054
358 L1B DM: Diagnosis memory full 1055
359 L1B DM: Test event 1055
360 L2A EXT: Main blower air flow supervision 1056
361 L2A EXT: Minimum engine speed supervision 1057
362 L1A EXT: Main blower pressure switch malfunction 1058
363 L1A EXT: Shift lever supervision 1059
364 L2A EXT: Engine derate protection active 1060
365 L1A EXT: Truck external plug monitoring 1060
367 L3A EXT: DC Power off mod request (rest switch on) 1061
369 L1A EXT: Doppler sensor defective 1063
370 L1A EXT: Auto lube control defective 1064
372 L1A EXT: Service brake pressed at high speeD 1064
373 L1A EXT: Service brake on above speed limit 1065
374 L1A EXT: Anti-roll control malfunction 1065
375 L3B BEF: CB301 Circuit breaker defective 1066
376 L3B BEF: K303/K304 Contactor defective 1067
377 L3C STP: Voltage reading incorrect between trolley line and voltage in stepdown box 1068
382 L3B BEF: K103 Feedback defective 1069
383 L3B BEF: K105 Feedback defective 1069
384 L1A BEF: K107 Feedback defective 1070
385 L1A BEF: K109 Feedback defective 1070
386 L1A BEF: K111 Feedback defective 1071
387 L1A BEF: Limp mode selector defective 1071
388 L2B BEF: CB113 Tripped 1072
390 L3D IUW: Output current supervision INV A 1072
391 L3D IUW: Output current supervision INV B 1073
392 L3B IUW: Precharge supervision 1 1074
393 L3B IUW: Precharge supervision 2 1075
394 L3A IUW: DC Link undervoltage 1076
395 L2B IUW: Trolley line undervoltage 1077
397 L3B IUW: Field regulator current setpoint supervision 1078
398 L2B IUW: Field regulator output current supervision 1079
399 L3B IUW: Alternator overcurrent protection 1080
Drive system fault code table, part 6 1083
400 L2C IUW: Alternator overload warning 1086
401 L2B IUW: Alternator overload protection 1086
402 L3C IUW: Alternator AC current sensor faulty 1087
403 L2A IUW: DC Link voltage out of range in propel 1088
404 L3A IUW: DC Link voltage out of range retard 1089
405 L3A IUW: DC Link voltage out of range for ST operation 1090
406 L3B IUW: DC Link controller supervision 1091
407 L2C IUW: Motor torque square T supervision 1092
408 L2C IUW: Motor current square T supervision 1092
409 L1A IUW: DC Link discharge time exceeded limit 1093
410 L2B IUW: Ground fault at positive DC link detected 1094
411 L2B IUW: Ground fault at negative DC link detected 1095
412 L2B IUW: Ground fault at AC side detected 1096
413 L2B IUW: Ground fault 1097
414 L3C IUW: Chopper A current supervision 1098
415 L3C IUW: Chopper B current supervision 1099
416 L3C IUW: Chopper C current supervision 1100
417 L3C IUW: Chopper D current supervision 1101
418 L3D IUW: Output current supervision INV ST 1102
419 L2A IUW: Vehicle overspeed supervisioN 1103
420 L1A IUW: DC Link voltage sensor A faulty 1104
421 L1A IUW: DC Link voltage sensor B faulty 1105
422 L3C IUW: ST Inverter failure 1106
423 L3B IUW: DC Grid fan circuit failure 1106
424 L2B IUW: Cooling water pressure out of range 1107
425 L2B IUW: Cooling water level out of range 1108
426 L1A IUW: Water pump motor overtemperature 1109
427 L1A IUW: Retard limit supervision 1109
428 L1A DRZ: Front wheel A speed sensor supervision 1110
429 L1A DRZ: Front wheel B speed sensor supervision 1111
430 L3D DRZ: Motor A speed sensor supervision 1112
431 L3D DRZ: Motor B speed sensor supervision 1113
432 L3C DRZ: Alternator speed sensor supervision 1114
433 L2A DRZ: Motor A maximum speed exceeded 1115
434 L2A DRZ: Motor B maximum speed exceeded 1115
435 L1A DRZ: Alternator maximum speed exceeded 1116
436 L3A DRZ: Motor A/B rotation inconsistency 1117
437 L3A DRZ: Motor A torque supervision 1118
438 L3A DRZ: Motor B torque supervision 1119
439 L3C SIV: Start-up sequence can’t pass due to GUPS failure 1120
440 L3C SIV: Start-up sequence can’t pass due to K103/K105 failure 1121
441 L3C SIV: Start-up sequence can’t pass due to IGBT failure 1122
442 L3C SIV: Start-up sequence can’t pass due to CB301 OR K303 failure 1123
443 L3C SIV: Start-up sequence can’t pass due to crowbar failure 1124
447 L1A SIV: Direct trolley engage sequence supervision 1125
448 L1A SIV: Direct trolley disengage sequence supervision 1126
Drive system fault code table, part 7 1129
450 L1A TMP: SIBAS® Temperature < low limit 1133
451 L1A TMP: SIBAS® Temperature > warning limit 1133
452 L3B TMP: SIBAS® Temperature > shutdown limit 1134
453 L3A TMP: IGBT Module A101 temperature < low limit 1135
454 L2C TMP: IGBT Module A101 temperature > APRS limit 1136
455 L3A TMP: IGBT Module A101 temperature > shutdown limit 1137
456 L3A TMP: IGBT Module A102 temperature < low limit 1138
457 L2C TMP: IGBT Module A102 temperature > APRS limit 1139
458 L3A TMP: IGBT Module A102 temperature > shutdown limit 1140
459 L3A TMP: IGBT ModulE A201 temperature < low limit 1141
460 L2C TMP: IGBT Module A201 temperature > APRS limit 1142
461 L3A TMP: IGBT Module A201 temperature > shutdown limit 1143
462 L3A TMP: IGBT Module A202 temperature < low limit 1144
463 L2C TMP: IGBT Module A202 temperature > APRS limit 1145
464 L3A TMP: IGBT Module A202 temperature >shutdown limit 1146
465 L3A TMP: ST Module temperature < low limit 1147
466 L2C TMP: ST Module temperature > warning limit 1148
467 L3A TMP: ST Module temperature > shutdown limit 1149
468 L2B TMP: SR Module temperature < low limit 1150
469 L2C TMP: SR Module temperature > warning limit 1151
470 L2B TMP: SR Module temperature > shutdown limit 1152
471 L2C TMP: Wheel motor A stator temperature > APRS limit 1153
472 L3A TMP: Wheel motor A stator temperature > shutdown limit 1154
473 L2C TMP: Wheel motor B Stator temperature > APRS limit 1155
474 L3A TMP: Wheel motor B stator temperature shutdown limit 1156
475 L2C TMP: Wheel motor A, DE bearing temperature > warning limit 1157
476 L3A TMP: Wheel motor A, DE bearing temperature > shutdown limit 1158
477 L2C TMP: Wheel motor A NDE bearing temperature > warning limit 1159
478 L3A TMP: Wheel motor A NDE bearing temperature > shutdown limit 1160
479 L2C TMP: Wheel motor B DE bearing temperature > warning limit 1161
480 L3A TMP: Wheel motor B DE bearing temperature > shutdown limit 1162
481 L2C TMP: Wheel motor B NDE bearing temperature > warning limit 1163
482 L3A TMP: Wheel motor B NDE bearing temperature > shutdown limit 1164
483 L2C TMP: Alternator stator temperature > APRS limit 1165
484 L2B TMP: Alternator stator temperature > shutdown limit 1166
485 L2C TMP: Alternator bearing temperature > warning limit 1167
486 L2B TMP: Alternator bearing temperature > shutdown limit 1168
487 L1A TMP: Cooling water inlet temperature < low limit 1169
488 L2C TMP: Cooling water inlet temperature > warning limit 1170
489 L2B TMP: Cooling water inlet temperature > shutdown limit 1171
490 L1A TMP: Cooling water outlet temperature < low limit 1172
491 L2C TMP: Cooling water outlet temperature > warning limit 1173
492 L2B TMP: Cooling water outlet temperature > shutdown limit 1174
493 L1A TMP: Cooling water delta T too high 1175
495 L2C TMP: Inverter cab temperature > warning limit 1176
496 L2B TMP: Inverter cab temperature > shutdown limit 1177
497 L2C TMP: Inside cooler outlet temperature > warning limit 1178
498 L2B TMP: Inside cooler outlet temperature > shutdown limit 1179
499 L1A TMP: Main blower motor stator temperature > warning limit 1180
500 L1A TMP: Main blower motor stator temperature > shutdown limit 1181
505 L1A TMP: Wheel motor A rotor temperature > limit 1182
506 L1A TMP: Wheel motor B rotor temperature > limit 1183
508 L1A ETM1: Alternator PT100 open circuit 1184
509 L1A ETM1: Main blower stator PT100 open circuit 1184
510 L1A ETM1: Grid blower statoR PT100 open circuit 1184
511 L1A ETM1: Inverter CAB PT100 open circuit 1184
512 L1A ETM1: Ambient PT100 open circuit 1184
513 L1A ETM1: Heater exchanger PT100 open circuit 1184
514 L1A ETM1: Cooling water inlet PT100 open circuit 1184
515 L1A ETM1: Cooling water outlet PT100 open circuit 1184
516 L1A ETM2: Motor A NDE Bearing PT100 open circuit 1185
517 L1A ETM2: Motor A DE Bearing PT100 open circuit 1185
518 L1A ETM2: Motor B NDE Bearing PT100 open circuit 1185
519 L1A ETM2: Motor B DE Bearing PT100 open circuit 1185
520 L1A ETM2: Alternator Bearing PT100 open circuit 1185
521 L1A ETM2: Motor A stator PT100 open circuit 1185
522 L1A ETM2: Motor B stator PT100 open circuit 1185
523 L1A ETM2: Motor inlet air PT100 open circuit 1185
524 L1A ETM3: IGBT Module A101 PT100 open circuit 1186
525 L1A ETM3: IGBT Module A102 PT100 open circuit 1186
526 L1A ETM3: IGBT Module A103 PT100 open circuit 1186
527 L1A ETM3: IGBT Module A104 PT100 open circuit 1186
528 L1A ETM3: IGBT Module A201 PT100 open circuit 1186
529 L1A ETM3: IGBT Module A202 PT100 open circuit 1186
530 L1A ETM3: IGBT Module A203 PT100 open circuit 1186
531 L1A ETM3: IGBT Module A204 PT100 open circuit 1186
532 L1A ETM3: ST Module PT100 open circuit 1187
533 L1A ETM3: SR Module PT100 open circuit 1187
534 L1A ETM3: Channel 7 PT100 open circuit 1187
535 L1A ETM3: Channel 8 PT100 open circuit 1187
536 L1A ETM4: Channel 1 PT100 open circuit 1188
537 L1A ETM4: Channel 2 PT100 open circuit 1188
538 L1A ETM4: Channel 3 PT100 open circuit 1188
539 L1A ETM4: Channel 4 PT100 open circuit 1188
540 L1A ETM4: Channel 5 PT100 open circuit 1188
541 L1A ETM4: Channel 6 PT100 open circuit 1188
542 L1A ETM4: Channel 7 PT100 open circuit 1188
543 L1A ETM4: Channel 8 PT100 open circuit 1188
544 L1A ETM4: SR Module PT100 open circuit 1188
550 L3A TMP: Inverter A module temperature < low limit 1189
551 L2C TMP: Inverter A module temperature > APRS limit 1190
552 L3A TMP: Inverter A module temperature > shutdown limit 1191
553 L3A TMP: Inverter B module temperature < low limit 1192
554 L2C TMP: Inverter B module temperature > APRS limit 1193
555 L3A TMP: Inverter B module temperature > shutdown limit 1194
556 L3A TMP: Chopper A module temperature < low limit 1195
557 L2C TMP: Chopper A module temperature > APRS limit 1196
558 L3A TMP: Chopper A module temperature > shutdown limit 1197
559 L3A TMP: Chopper B module temperature < low limit 1198
560 L2C TMP: Chopper B module temperature > APRS limit 1199
561 L3A TMP: Chopper B module temperature > shutdown limit 1200
Payload meter scoreboard 1203
Display messages 1205
LED lights 1205
Processor LED (2, Figure 50-1) 1205
Data Receive LED (3, Figure 50-1) 1205
Option switches 1206
SWITCH 1 – TEST (Displays “888”) 1206
SWITCH 2 – COUNT 1206
SWITCH 9 – TRANSMIT CUT 1206
SWITCH 10 – HIGH IMPEDANCE LISTEN 1206
Troubleshooting 1207
Troubleshooting chart 1207
Symptom 1207
Possible Cause 1207
Remedy 1207
Electric wheel motor 1209
Fault table 1211
Steering system 1219
Steering circuit troubleshooting chart 1221
Steering circuit troubleshooting guidelines 1223
Basic hydraulic system checks 1224
System leakage check 1225
Steering pump troubleshooting guide 1227
Pump pressure control checks 1230
To verify pump unload pressure 1230
To verify pump reloading 1230
Pump fails to unload 1231
Pump fails to develop pressure 1231
Pump slow in developing pressure 1232
Pump control valve inspection and trouble shooting 1233
Pump case drain check 1235
Adjustment 1236
Cab air conditioning 1239
Preliminary checks 1241
Diagnosis of gauge readings and system performance 1241
Troubleshooting by manifold gauge set readings 1242
Automatic lubrication (auto lube) system 1249
Autolube troubleshooting chart 1251
Reserve engine oil system 1255
Pumping unit LED signals 1257
Circuit fuses 1257
50 Disassembly and assembly 1259
Service tools 1259
Special tool list 1261
Additional tool list 1261
Wheel motor rebuild tools 1262
Control cabinet 1262
Cab air conditioning 1265
Replacement of air conditioning system components 1267
Hoses and fittings 1267
Lines 1267
Expansion valve 1267
Receiver-drier 1267
Thermostat 1267
Compressor 1268
Accumulator 1268
Clutch 1268
Wheels, spindles and rear axle 1271
General precautions for tires and rims 1273
Wheel stud maintenance 1274
Front tires and rims 1275
Removal 1275
Rear tires and rims 0
Installation 1277
Rim components 1279
Smart Rim Component Layout 1279
Rim and tire service 1280
Lubricants 1280
Tire Inflation 1280
Lock Ring Retainer Installation 1280
Remove Smart Lock Ring from Inside Position of Outer Dual and Outside Position of Inner Dual 1281
Install Smart Lock Ring to Inside Position of Outer Dual and Outside Position of Inner Dual 1282
Removal (5-Piece Standard Rim) 1283
Removal (7-Piece Smart Rim) 1286
Removal (5-Piece Smart Rim) 1288
Preparation Before Assembly 1290
Installation (5-Piece Standard Rim) 1290
Installation – Horizontal Mount (Smart Rim) 1292
Installation – Vertical Mount (5-Piece Smart Rim) 1294
Installation – Vertical Mount (7-Piece Smart Rim) 1296
Removal and installation of front wheel hub and spindle 1297
Removal 1297
Spindle Removal Procedure (off of the truck) 1300
Installation 1303
Disassembly and assembly of front wheel hub and spindle 1304
Disassembly 1304
Cleaning and inspection 1304
Assembly 1306
Wheel bearing adjustment 1306
Seal assembly gap check and adjustment 1307
Floating seal installation 1308
Floating seal test procedure 1315
Speed sensor installation and adjustment 1316
Removal and installation of wheel motor 1316
Preparation 1316
Removal 1317
Cleaning and inspection 1318
Installation 1318
Removal and installation of rear axle 1321
Removal 1321
Cleaning and inspection 1323
Installation 1323
Removal and installation of anti-sway bar 1324
Removal 1324
Installation 1324
Removal and installation of pivot pin 1325
Removal 1325
Installation 1325
Pivot eye and bearing service 1326
Bearing inspection 1326
Bearing removal 1327
Bearing installation 1328
Pivot eye repair 1328
Removal and installation of electric motor 1329
Removal 1329
Installation 1330
Disassembly and assembly of wheel motor transmission 1331
Disassembly 1331
Cleaning and inspection 1338
Assembly 1338
Disassembly and assembly of low speed carrier 1350
Disassembly 1350
Inspection 1351
Assembly 1352
Disassembly and assembly of high speed carrier 1355
Disassembly 1355
Inspection 1356
Assembly 1357
Brake system 1361
Removal and installation of brake valve 1363
Removal 1363
Installation 1364
Disassembly and assembly of brake valve/pedal assembly 1364
Disassembly 1364
Assembly 1365
Removal and installation of dual relay valve 1367
Removal 1367
Installation 1368
Removal and installation of brake manifold 1369
Removal 1369
Installation 1369
Disassembly and assembly of brake manifold 1370
Disassembly 1370
Assembly 1370
Removal and installation of brake accumulator (piston style) 1371
Removal 1371
Installation 1373
Disassembly and assembly of brake accumulator (piston style) 1373
Disassembly 1373
Cleaning and inspection 1375
Piston seal replacement 1376
Assembly 1376
Removal and installation of brake accumulators (bladder style) 1377
Removal 1377
Installation 1378
Disassembly and assembly of brake accumulator (bladder style) 1379
Disassembly 1379
Cleaning and inspection 1380
Assembly 1381
Disassembly and assembly of wheel brake 1382
Disassembly 1383
Cleaning and inspection 1386
Assembly 1387
Floating ring seal assembly and installation 1393
Removal and installation of rear brake assembly 1401
Removal 1401
Installation 1401
Steering system 1407
Removal and installation of steering control unit 1409
Removal 1409
Installation 1410
Disassembly and assembly of steering control unit 1411
Disassembly 1411
Assembly 1413
Removal and installation of steering column 1416
Removal 1416
Inspection 1416
Installation 1417
Removal and installation of steering wheel 1418
Removal 1418
Installation 1418
Removal and installation of bleeddown manifold 1420
Removal 1420
Installation 1420
Removal and installation of flow amplifier 1422
Removal 1422
Installation 1422
Removal and installation of steering cylinder 1422
Removal 1422
Bearing replacement 1422
Installation 1423
Disassembly and assembly of steering cylinders 1424
Disassembly 1424
Assembly 1424
Removal and installation of tie rod 1425
Removal 1425
Installation 1426
Removal and installation of steering/brake pump 1426
Removal 1426
Installation 1427
Disassembly and assembly of steering/brake pump 1429
Disassembly 1429
Inspection 1432
Assembly 1435
Driveshaft group 1436
Rotating group 1436
Removal and installation of steering accumulators (piston style) 1439
Removal 1439
Installation 1441
Disassembly and assembly of steering accumulator (piston style) 1441
Cleaning and Inspection 1443
Piston seals replacement 1443
Assembly 1444
Removal and installation of steering accumulators (bladder style) 1445
Removal 1445
Installation 1446
Disassembly and assembly of steering accumulator (bladder style) 1446
Disassembly 1446
Cleaning and Inspection 1447
Assembly 1448
Suspensions 1451
Removal and installation of front suspension 1453
General information 1453
Removal 1453
Installation 1455
Upper mounting joint – 60° advance 1459
Inspection 1460
Minor front suspension repairs (lower bearing and seals) 1461
Lower bearing retainer removal 1461
Lower bearing retainer installation 1461
Major front suspension rebuild 0
Assembly 1463
Removal and installation of rear suspension 1465
General information 1465
Removal 1465
Installation 1468
Disassembly and assembly of rear suspension 1469
Disassembly 1469
Cleaning and Inspection 1469
Assembly 1470
Hoist circuit 1473
Removal and installation of hoist pump 1475
Removal 1475
Installation 1476
Disassembly and assembly of hoist pump 1478
Disassembly 1478
Inspection 1483
Assembly 1484
Removal and installation of hoist valve 1487
Removal 1487
Installation 1488
Disassembly and assembly of hoist valve 1488
O-ring replacement 1488
Disassembly of inlet section 1490
Assembly of inlet section 1491
Disassembly of rear spool section 1492
Assembly of rear spool section 1494
Disassembly of front spool section 1495
Assembly of front spool section 1496
Overcenter manifold service 1496
Removal and installation of hoist pilot valve 1497
Removal 1497
Installation 1497
Disassembly and assembly of hoist pilot valve 1498
Disassembly 1498
Cleaning and inspection 1499
Assembly 1499
Removal and installation of hoist cylinders 1500
Removal 1500
Installation 1501
Disassembly and assembly of hoist cylinders 1503
Disassembly 1503
Cleaning and inspection 1505
Installation of the quill 1506
Assembly 1508
Replacement of hoist circuit filter 1510
Filter element replacement 1511
Operator cab 1513
Removal and installation of operator cab 1515
Removal 1516
Installation 1517
Removal and installation of cab door 1519
Removal 1519
Installation 1519
Disassembly and assembly of cab door 1519
Removing door panel 1519
Installing door panel 1520
Replacing door window regulator 1520
Replacing door handle or latch assembly 1521
Replacing door assembly seal and door hinge seal 1522
Replacing door opening seal 1522
Removing door glass 1523
Installing door glass 1524
Adjustment of cab door 1526
Door jamb bolt adjustment 1526
Door handle plunger adjustment 1527
Removal and installation of side window glass 1528
Recommended tools and supplies 1528
Removal 1529
Installation 1529
Removal and installation of windshield and rear window glass 1530
Removal 1530
Installation 1530
Removal and installation of windshield wiper motor 1531
Removal 1531
Installation 1531
Removal and installation of windshield wiper arm 1532
Removal 1532
Installation 1532
Removal and installation of windshield wiper linkage 1533
Removal 1533
Installation 1533
Removal and installation of operator seat (standard seat) 1534
Adjustment 1534
Inspection 1535
Removal 1535
Installation 1535
Replacing the Seat Compressor 1536
Removal and installation of passenger seat (standard seat) 1541
Adjustment 1541
Inspection 1542
Removal 1542
Installation 1542
Removal and installation of seat belts (standard seat) 1543
Removal 1543
Installation 1543
Operator seat (optional seat) 1544
Seat Belts 1544
Adjustment 1544
Passenger seat (optional seat) 1546
Seat Belts 1546
Adjustment 1546
Removal and installation of seat belts (optional seat) 1547
General 1547
Removal 1547
Installation 1549
Body and structures 1553
Removal and installation of dump body 1555
Removal 1555
Inspection 1556
Installation 1557
Removal and installation of body pads 1557
Removal 1557
Installation 1558
Adjustment 1558
Removal and installation of diagonal ladder/ hood and grille assembly 1560
Removal 1560
Installation 1560
Removal and installation of right deck 1561
Removal 1561
Installation 1563
Removal and installation of left deck 1564
Removal 1564
Installation 1564
Removal and installation of fuel tank 1566
Removal 1566
Cleaning and inspection 1566
Installation 1568
Removal and installation of horizontally mounted fuel gauge sender 1568
Removal 1568
Installation 1568
Removal and installation of vertically mounted fuel gauge sender 1568
Installation 1568
Disassembly and assembly of fuel tank breather 1570
Disassembly 1570
Assembly 1570
Removal and installation of hydraulic tank 1571
Removal 1571
Installation 1571
Three phase wheel motor 1573
Motor 1577
Transport 1578
Storage of new motors 1579
Storage of used motors 1580
Safety guidelines 1581
Checking for external damage 1582
Checking the connections 1583
Regreasing the bearings 1583
Applying grease to the bearings 1583
Checking the interior of the motor for water 1584
Pressing off the coupling 1586
Disassembly 1587
Rotor 1587
Removing the rubber seals and the air baffles 1592
Bearing and labyrinth ring 1593
Removal 1593
Stator Inspection 1594
Rotor Inspection 1594
Testing the insulation 1595
High-voltage test 1595
Work on the bearings 1596
Assembling the rubber seals and the air baffles 1598
Assembly after special repair work 1600
Bearing installation 1601
Preparatory measures for assembling the bearing (Figure 50-20 must be observed): 1604
Assemble the bearing 1605
Cover installation 1606
Assembling the bearing shield (N-end) at the stator frame 1607
Bearing installation 1609
Rotor installation 1611
Labyrinth ring 1613
Installation 1613
Installing accessories (D- and N-end) 1615
Running in the bearings 1619
Coupling 1620
Installation 1620
Assembly conditions and instructions 1621
Tests 1621
Replacing defective connecting leads 1622
Repairing the stator winding insulation 1623
Recommended consumables 1623
Chemical cleaning agents 1623
Chemical cleaning agents for outdoor use and for cleaning mechanical parts 1623
Chemical cleaning agents for flange faces 1623
Chemical cleaning agents for windings 1624
Chemical cleaning agents for windings 1624
Chemical cleaning agents for windings with severe damage and for oily windings 1624
Rolling-contact bearing grease 1624
Assembly/disassembly agents for bearing seat 1624
Sealants for joining parts or gaps 1624
Locking agents for connecting elements 1624
Anti-corrosion agent 1624
Assembly paste for temperature sensors 1624
Mounting devices for inserting and withdrawing the rotor horizontally 1625
Press for expanding the coupling 1625
Compression devices for pressing on or for support while pressing off 1626
Pulling units with cross beam or disk 1628
Aids 1628
Extraction devices 1629
Paints for refinishing the painted parts or touching up damaged parts 1629
Power module 1631
Removal and installation of power module 1633
General 1633
Preparation 1633
Removal 1634
Installation 1639
Exhaust tube installation 1641
Exhaust blanket installation 1641
Removal and installation of alternator 1642
Removal 1642
Installation 1644
Engine flywheel adapter face runout 1644
Engine crankshaft endplay 1645
Engine flywheel to flywheel housing adapter – measurement “C” 1645
Alternator housing to rotor – measurement “A” 1646
Measurements after joining the alternator and engine 1648
Flywheel housing face runout 1649
Flywheel housing radial runout 1649
Flywheel/flexplate face runout 1650
Flywheel/flexplate radial runout 1650
Rotor shaft radial runout (assembled) 1651
Joining the alternator and engine 1652
Removal and installation of engine 1654
Removal 1654
Service 1654
Installation 1654
Removal and installation of radiator 1654
Removal 1654
Installation 1656
Repairing the radiator 1658
Internal inspection 1658
External cleaning 1658
Disassembly 1658
Cleaning and inspection 1659
Assembly 1660
Pressure testing 1661
Main blower 1663
Removing the main blower motor 1665
Disassembling the main blower motor 1671
Assembling the main blower motor 1673
Installing the main blower motor 1676
Retarding grid 1683
Removing the grid blower motor 1685
Disassembling the grid blower motor 1687
Assembling the grid blower motor 1689
Installing the grid blower motor 1691
Removing a grid element 1696
Control cabinet 1699
Removing the SIBAC Inverter Module 1701
Required tools/materials 1701
Removal 1704
Installing the SIBAC Inverter Module 1708
Draining and filling the IGBT coolant system 1709
Required tools/materials 1709
Coolant mixture specification (distilled water: Antifrogen® N) 1709
Draining and filling the coolant 1711
Removing and installing the IGBT coolant pump assembly 1714
Required tools/materials 1714
Removal 1715
90 Diagrams and drawings 1719
Hydraulic circuit diagrams 1719
Electrical circuit diagrams – 24V system 1725
Electrical circuit diagrams – drive system 1747

DESCRIPTION:

Komatsu 860E-1K DUMP TRUCK Shop Manual CEBM037901 – PDF DOWNLOAD

• SERIAL NUMBERS 860E-1K  – A30119

Composition of shop manual:
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 judgment 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 judgment 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.
Revision and distribution
Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-todate
information before you start any work.

G.B 20/12/24