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KOMATSU 860E-1KT DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30004-A30030) – PDF DOWNLOAD
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- KOMATSU 860E-1KT DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30004-A30030
- PUBLICATION NUMBER:CEBM022005
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Description
KOMATSU 860E-1KT DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30004-A30030)
KOMATSU 860E-1KT DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30004-A30030) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 860E-1KT DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30004-A30030)
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and weight of components are also explained.
90. Diagrams and drawings
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
TABLE OF CONTENTS:
KOMATSU 860E-1KT DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30004-A30030)
COVER ................................................................................................................................ 1 00 Index and foreword ................................................................................................................ 3 Index............................................................................................................................. 3 Composition of shop manual.................................................................................................... 4 Table of contents............................................................................................................. 6 Foreword, safety and general information.......................................................................................... 35 Foreword...................................................................................................................... 38 How to read the shop manual................................................................................................... 39 Composition of shop manual................................................................................................ 39 Revision and distribution................................................................................................. 39 Symbols................................................................................................................... 40 General safety................................................................................................................ 41 Safety rules.............................................................................................................. 41 Safety features........................................................................................................... 41 Fire extinguisher and first aid kit....................................................................................... 41 Clothing and personal items............................................................................................... 41 Leaving the operator seat................................................................................................. 42 Mounting and dismounting.................................................................................................. 42 Fire prevention for fuel and oil.......................................................................................... 42 Precautions with high temperature fluids.................................................................................. 43 Asbestos dust hazard prevention........................................................................................... 43 Prevention of injury by work equipment.................................................................................... 43 Unauthorized modification................................................................................................. 43 Precautions when using ROPS............................................................................................... 43 Precautions for attachments............................................................................................... 44 Precautions for starting the truck........................................................................................ 44 Precautions before operating the truck........................................................................................ 44 Safety at the worksite.................................................................................................... 44 Fire prevention........................................................................................................... 45 Ventilation in enclosed areas............................................................................................. 45 Preparing for operation................................................................................................... 45 Mirrors, windows and lights............................................................................................... 45 In operator cab (before starting the engine).............................................................................. 45 Seat Belts................................................................................................................ 45 Precautions while operating the truck......................................................................................... 46 When starting the engine.................................................................................................. 46 General truck operation................................................................................................... 46 Ensuring good visibility.................................................................................................. 46 Traveling................................................................................................................. 47 Traveling in reverse...................................................................................................... 47 Traveling on slopes....................................................................................................... 47 Operating on snow or ice.................................................................................................. 47 Avoid damage to dump body................................................................................................. 47 Driving near high voltage cables.......................................................................................... 48 When dumping.............................................................................................................. 48 Working on loose ground................................................................................................... 48 When loading.............................................................................................................. 48 Parking the truck......................................................................................................... 48 Towing.................................................................................................................... 48 Working near batteries........................................................................................................ 49 Battery hazard prevention................................................................................................. 49 Starting with booster cables.............................................................................................. 50 Jump starting with receptacles............................................................................................ 50 Precautions before performing service......................................................................................... 51 Warning tag............................................................................................................... 51 Stopping the engine....................................................................................................... 51 Proper tools.............................................................................................................. 51 Securing the dump body.................................................................................................... 51 While performing maintenance.................................................................................................. 52 Keep the truck clean...................................................................................................... 52 Attachments............................................................................................................... 52 Working under the truck................................................................................................... 52 Rotating fan and belts.................................................................................................... 52 Adding fuel or oil........................................................................................................ 52 Use of lighting........................................................................................................... 52 Radiator coolant level.................................................................................................... 53 Precautions with the battery.............................................................................................. 53 Precautions with high pressure oil........................................................................................ 53 Handling high pressure hoses.............................................................................................. 53 Precautions when performing maintenance near high temperature or high pressure............................................ 53 Waste materials........................................................................................................... 53 Tires......................................................................................................................... 54 Handling tires............................................................................................................ 54 Storing tires after removal............................................................................................... 54 Precautions for performing repairs............................................................................................ 55 Engine shutdown procedure after AC drive system failure................................................................... 55 Precautions for welding on the truck.......................................................................................... 56 Handling electrical equipment and hydraulic components........................................................................ 57 Points to remember when handling electrical equipment..................................................................... 57 Points to remember when handling hydraulic equipment...................................................................... 63 How to read electric wire code................................................................................................ 65 Standard torque tables........................................................................................................ 68 Effect of special lubricants on fasteners and standard torque values...................................................... 68 Standard tightening torques for SAE hex head cap screw and nut assemblies................................................. 69 Standard assembly torques for 12-point, grade 9 cap screws (SAE).......................................................... 70 Standard assembly torques for class 10.9 capscrews and class 10 nuts...................................................... 70 Standard tightening torques for fittings.................................................................................. 71 Conversion tables............................................................................................................. 73 Common conversion multipliers............................................................................................. 73 Operating instructions............................................................................................................ 77 Preparing for operation....................................................................................................... 79 Walk around inspection.................................................................................................... 79 Engine start-up............................................................................................................... 84 After engine start-up......................................................................................................... 85 Precautions during truck operation............................................................................................ 86 Operating on a haul road...................................................................................................... 87 Starting on a grade with a loaded truck....................................................................................... 87 Passing....................................................................................................................... 88 Loading....................................................................................................................... 88 Dumping....................................................................................................................... 88 Raising The Dump Body..................................................................................................... 88 Lowering The Dump Body (When dumping on flat ground):..................................................................... 89 Lowering The Dump Body (When dumping over a berm or into a crusher):...................................................... 90 Trolley operating instructions................................................................................................ 91 Operating in trolley line mode............................................................................................ 91 Getting on line........................................................................................................... 91 Operating on trolley...................................................................................................... 92 Getting off line.......................................................................................................... 92 Line status signals....................................................................................................... 93 Trolley disconnect........................................................................................................ 93 Traffic consideration for trolley line operation.......................................................................... 94 Approaching slow moving vehicles in a trolley assisted truck.............................................................. 94 Operating slow moving vehicles on trolley assist ramps.................................................................... 95 Truck failure while on trolley............................................................................................ 95 Using the speed control feature............................................................................................... 96 Safe parking procedures....................................................................................................... 96 Normal engine shutdown procedure.............................................................................................. 97 Sudden loss of engine power................................................................................................... 98 Fuel depletion................................................................................................................ 98 Towing........................................................................................................................ 99 Special Wiring Harness.................................................................................................... 99 Towing Procedure.......................................................................................................... 99 Disabled truck operation...................................................................................................... 102 Steering and brake system................................................................................................. 102 Components Required....................................................................................................... 102 Hookup.................................................................................................................... 103 Disabled truck dumping procedure.......................................................................................... 104 Hookup.................................................................................................................... 104 Raising the Body.......................................................................................................... 104 Lowering the Body......................................................................................................... 105 01 Specification ..................................................................................................................... 107 Specification and technical data.................................................................................................. 107 Specification drawing......................................................................................................... 109 Specifications................................................................................................................ 110 Weight table.................................................................................................................. 112 Fuel, coolant and lubricants.................................................................................................. 113 Mixing rate of water and anti-freeze...................................................................................... 113 Suspension cylinder oil and nitrogen specifications....................................................................... 114 10 Structure, functions and maintenance standard ..................................................................................... 117 Cab air conditioning.............................................................................................................. 117 General information........................................................................................................... 118 Environmental impact of air conditioning.................................................................................. 118 Air conditioning for off-highway vehicles................................................................................. 118 Principles of refrigeration................................................................................................... 119 Air conditioning.......................................................................................................... 119 Refrigeration - the act of cooling........................................................................................ 119 The refrigeration cycle................................................................................................... 119 Air conditioning system components............................................................................................ 121 Relays.................................................................................................................... 121 Fan motor and speed control............................................................................................... 121 Cab air filter............................................................................................................ 121 Heater core............................................................................................................... 121 Actuators................................................................................................................. 121 Compressor (refrigerant pump)............................................................................................. 123 Service valves............................................................................................................ 123 Condenser................................................................................................................. 123 Receiver-drier............................................................................................................ 123 Expansion valve........................................................................................................... 124 Accumulator............................................................................................................... 124 Evaporator core........................................................................................................... 124 Air conditioning system electrical circuit.................................................................................... 125 Thermostat................................................................................................................ 125 Compressor clutch......................................................................................................... 125 Trinary™ switch........................................................................................................... 126 Steering circuit.................................................................................................................. 129 Steering circuit operation.................................................................................................... 131 Steering circuit components................................................................................................... 133 Steering control unit..................................................................................................... 133 High pressure filter...................................................................................................... 133 Steering accumulators..................................................................................................... 133 Bleed down manifold....................................................................................................... 134 Steering accumulator bleed down solenoid.................................................................................. 136 Hoist up limit solenoid................................................................................................... 136 Quick disconnect ports.................................................................................................... 137 Flow amplifier............................................................................................................ 137 Flow amplifier operation...................................................................................................... 138 No steer.................................................................................................................. 138 Steering left............................................................................................................. 140 Steering right............................................................................................................ 142 No steer, external shock load............................................................................................. 144 Steering/brake pump operation................................................................................................. 147 Normal operation.......................................................................................................... 147 Neutral position.......................................................................................................... 148 Full pump volume.......................................................................................................... 149 Half pump volume.......................................................................................................... 149 Steering cylinder wear data................................................................................................... 150 Hoist circuit..................................................................................................................... 153 Hoist circuit operation....................................................................................................... 155 Hoist circuit components...................................................................................................... 156 Hydraulic tank............................................................................................................ 156 Hoist pump................................................................................................................ 156 High pressure filters..................................................................................................... 156 Hoist valve............................................................................................................... 156 Inlet sections............................................................................................................ 157 Tank ports (front) spool section.......................................................................................... 157 Work ports (rear) spool section........................................................................................... 157 Hoist pilot valve......................................................................................................... 158 Bleed down manifold....................................................................................................... 158 Hoist limit solenoid...................................................................................................... 158 Pilot operated check valve................................................................................................ 158 Overcenter manifold....................................................................................................... 159 Hoist pilot valve operation................................................................................................... 160 Float position with body down............................................................................................. 160 Power up operation........................................................................................................ 162 Hold operation............................................................................................................ 164 Power down operation...................................................................................................... 166 Float operation........................................................................................................... 168 Hoist cylinder wear data...................................................................................................... 170 Brake circuits.................................................................................................................... 173 General information........................................................................................................... 175 Service brake circuit operation............................................................................................... 176 Secondary braking system and auto apply....................................................................................... 176 Rear wheel brake lock circuit operation....................................................................................... 178 Parking brake circuit operation............................................................................................... 180 Normal operation (key switch ON, engine on)............................................................................... 180 Brake warning circuit operation............................................................................................... 183 Brake assembly wear data...................................................................................................... 185 Suspensions....................................................................................................................... 187 General information........................................................................................................... 188 Front suspension wear data.................................................................................................... 188 Rear suspension wear data..................................................................................................... 189 Electrical system, 24 volt........................................................................................................ 191 Battery supply system......................................................................................................... 193 Auxiliary control cabinet components.......................................................................................... 194 24VDC to 12VDC converter.................................................................................................. 194 Diode board - DB1......................................................................................................... 194 Power distribution terminals.............................................................................................. 194 Control power relay....................................................................................................... 195 Fuse blocks............................................................................................................... 196 Relay boards.................................................................................................................. 196 Relay boards RB1, RB3, RB4, RB5........................................................................................... 196 Relay boards RB6, RB7, RB8, RB9........................................................................................... 198 Relay functions........................................................................................................... 198 Body position switches (With proximity switch and metal arm).................................................................. 200 Body-up switch............................................................................................................ 200 Hoist limit switch........................................................................................................ 201 Body position switches (With proximity switch and magnet)..................................................................... 202 Proximity switch operation................................................................................................ 202 Body-up Switch............................................................................................................ 202 Hoist limit switch........................................................................................................ 202 Interface module (IM)............................................................................................................. 205 General information........................................................................................................... 206 Sensors....................................................................................................................... 206 Temperature sensors....................................................................................................... 206 Pressure sensors.......................................................................................................... 206 Interface module inputs and outputs........................................................................................... 207 Drive system...................................................................................................................... 213 SR rectifier module........................................................................................................... 215 ST module (auxiliary voltage inverter)........................................................................................ 215 Technical Data............................................................................................................ 218 SD phase modules.............................................................................................................. 219 SR/ST/SD module removal....................................................................................................... 219 Inverter cabinet layout....................................................................................................... 220 Inverter cabinet water flow................................................................................................... 220 Field regulator............................................................................................................... 221 Technical Data............................................................................................................ 221 Field regulator (discharge resistor).......................................................................................... 221 Technical Data............................................................................................................ 221 Gate unit power supply........................................................................................................ 222 Technical Data............................................................................................................ 222 Gate unit power supply (diode)................................................................................................ 222 Technical Data............................................................................................................ 222 Gate unit power supply (tuning resistor)...................................................................................... 222 Technical Data............................................................................................................ 222 Control power filter.......................................................................................................... 222 Technical Data............................................................................................................ 222 Filter for TCU................................................................................................................ 223 Technical Data............................................................................................................ 223 Terminal block bus bar........................................................................................................ 223 Technical Data............................................................................................................ 223 Fuses (analog sensor voltage)................................................................................................. 224 Technical Data............................................................................................................ 224 Fuses (field regulator)....................................................................................................... 224 Technical Data............................................................................................................ 224 Fuses (fuse holder for field regulator)....................................................................................... 224 Technical Data............................................................................................................ 224 Fuses (control power and trolley box contactor)............................................................................... 225 Technical Data............................................................................................................ 225 Diode modules................................................................................................................. 225 Technical Data............................................................................................................ 225 Support capacitors............................................................................................................ 226 Technical Data............................................................................................................ 226 3-Phase capacitor bank (for ST module output voltage)......................................................................... 226 Technical Data............................................................................................................ 226 Air-cooled inductors (for ST module).......................................................................................... 227 Technical Data............................................................................................................ 227 3-Phase transformer (for ST module)........................................................................................... 227 Technical Data............................................................................................................ 227 Diagnostics box............................................................................................................... 228 Diagnostic and system monitoring panel........................................................................................ 229 Device name: DB101........................................................................................................ 229 Technical Data............................................................................................................ 229 Current transducers........................................................................................................... 230 Device names:............................................................................................................. 230 U101ŠU104 (Current to motor A)............................................................................................ 230 U105ŠU106 (Current to chopper A-C)........................................................................................ 230 U201ŠU204 (Current to motor B)............................................................................................ 230 U205ŠU206 (Current to chopper B-D)........................................................................................ 230 Technical Data............................................................................................................ 230 Technical Data............................................................................................................ 230 Current transducers (for ST module output).................................................................................... 231 Technical Data............................................................................................................ 231 Voltage transducers........................................................................................................... 231 Technical Data............................................................................................................ 231 Voltage transducers (for ST module output).................................................................................... 232 Technical Data............................................................................................................ 232 Voltage transducers (SiBAS® 24V DC bus monitoring)............................................................................ 232 Analog inclinometer........................................................................................................... 233 Technical Data............................................................................................................ 233 DC link capacitors............................................................................................................ 233 Technical Data............................................................................................................ 233 Ground tie capacitor.......................................................................................................... 234 Technical Data............................................................................................................ 234 Low-inductance bus bar assembly............................................................................................... 234 Free-wheeling diode for low-inductance bus bars............................................................................... 235 Contactor (grid box and main blower motor).................................................................................... 235 Technical Data............................................................................................................ 235 Contactor (control power)..................................................................................................... 236 Technical Data............................................................................................................ 236 Contactor (DC contactors)..................................................................................................... 236 Technical Data............................................................................................................ 236 Contactor (crowbar bypass).................................................................................................... 237 Technical Data............................................................................................................ 237 Temperature probes (PT100 style).............................................................................................. 237 Technical Data............................................................................................................ 237 Coolant inlet temperature sensor.............................................................................................. 237 Technical Data............................................................................................................ 238 Coolant outlet temperature sensor (external pad style)........................................................................ 238 IGBT module heat sink temperature sensor.................................................................................. 238 Device names: PT101ŠPT103 [Sensors for inverters A101ŠA103]........................................................... 238 PT201ŠPT203 [Sensors for inverters A201ŠA203]......................................................................... 238 PT104 and PT204 [Sensors for choppers 1 and 2 respectively]........................................................... 238 PT105 and PT205 [Sensors for ST module (A301) and SR module (A1) respectively]........................................ 238 Coolant outlet temperature sensor (internal style)............................................................................ 238 Technical Data............................................................................................................ 238 Coolant outlet temperature sensor (external pad style)........................................................................ 239 Technical Data............................................................................................................ 239 Circuit breakers.............................................................................................................. 239 Technical Data............................................................................................................ 239 Inner circulating blower fan.................................................................................................. 240 Coolant pump.................................................................................................................. 240 Technical Data............................................................................................................ 240 Motor for coolant pump........................................................................................................ 241 Technical Data............................................................................................................ 241 Coolant pressure sensor....................................................................................................... 241 Inner radiator................................................................................................................ 241 Ground voltage monitoring resistors........................................................................................... 242 Protection thyristor assembly (crowbar)....................................................................................... 242 Discharge reactor............................................................................................................. 243 Main blower motor............................................................................................................. 243 Technical Data............................................................................................................ 243 Grid box...................................................................................................................... 244 Technical Data............................................................................................................ 244 Grid box blower motor......................................................................................................... 244 Technical Data............................................................................................................ 244 Grid box blower motor grease fittings......................................................................................... 245 Main alternator............................................................................................................... 245 Stator.................................................................................................................... 245 Rotor..................................................................................................................... 246 Bearings.................................................................................................................. 246 Electrical connection..................................................................................................... 246 Cooling and ventilation................................................................................................... 246 Rotating rectifier section................................................................................................ 246 Technical Data............................................................................................................ 247 Main alternator circuit diagram........................................................................................... 248 IGBT Š inverter/chopper phase module...................................................................................... 249 Device names: A101ŠA103 (Inverter A section).......................................................................... 249 A201ŠA203 (Inverter B section)........................................................................................ 249 A104 (Chopper A section).............................................................................................. 249 A204 (Chopper B section).............................................................................................. 249 Troubleshooting information............................................................................................... 251 Main input rectifier module............................................................................................... 252 Device name: A1....................................................................................................... 252 Internal circuit diagram.............................................................................................. 253 Upper ground tie resistor..................................................................................................... 254 Device Name: R11.1-R11.2.................................................................................................. 254 Technical Data............................................................................................................ 254 Lower ground tie resistor..................................................................................................... 254 Device name: R11.3-R11.4.................................................................................................. 254 Technical Data............................................................................................................ 254 Troubleshooting........................................................................................................... 255 Fault diagnosis........................................................................................................... 255 Speed sensor, alternator...................................................................................................... 256 Technical Data............................................................................................................ 256 Speed sensors, wheel motors................................................................................................... 257 Technical Data............................................................................................................ 257 Traction motor................................................................................................................ 258 Device name: Motor 1 (grid box side of the truck), Motor 2 (operator cab side of the truck)............................... 258 Technical Data............................................................................................................ 258 Grid box...................................................................................................................... 259 Device name: M04.......................................................................................................... 259 Technical Data............................................................................................................ 259 SIBAS® IGBT rack components....................................................................................................... 261 SiBAS®32 Traction Control Unit (TCU).......................................................................................... 263 Overview of the SiBAS®32 systems.......................................................................................... 264 Features.............................................................................................................. 264 General technical specifications, operating conditions................................................................ 264 Permissible temperature range......................................................................................... 264 Permissible limit value for air humidity.............................................................................. 265 Permissible power supply voltage range................................................................................ 265 Permissible mechanical loads.......................................................................................... 265 Protection measures against electrical hazards........................................................................ 265 Application........................................................................................................... 265 Removing and installing the SiBAS®32 cards................................................................................ 268 Removal with 24V OFF! (ESD protection required)....................................................................... 268 Installation with 24V OFF! (ESD protection required).................................................................. 268 SiBAS®32 card device names................................................................................................ 269 Structure of SiBAS®32 card part number.................................................................................... 270 Development status, downward compatibility............................................................................ 270 SiBAS®32 card interchangeability.......................................................................................... 271 Use of service interfaces............................................................................................. 272 Connection of the service unit........................................................................................ 272 Maintenance........................................................................................................... 272 Cleaning.............................................................................................................. 273 SiBAS®32 card interactions................................................................................................ 274 SiBAS®32 card detailed information........................................................................................ 277 Blower subassembly.................................................................................................... 277 Device name: N/A.................................................................................................. 277 Application....................................................................................................... 277 Battery replacement............................................................................................... 279 Rules for handling lithium batteries.............................................................................. 279 Replacement of the battery in the fan subassembly................................................................. 279 CPU card.............................................................................................................. 280 Device name: G011................................................................................................. 280 Application....................................................................................................... 281 Front panel....................................................................................................... 281 Technical data.................................................................................................... 282 DSP card.............................................................................................................. 283 Device name: G019, G027 and G35................................................................................... 283 Application....................................................................................................... 283 Front panel....................................................................................................... 283 Technical data.................................................................................................... 284 I/O card.............................................................................................................. 285 Device name: G043................................................................................................. 285 Application....................................................................................................... 285 Front panel....................................................................................................... 286 Technical data.................................................................................................... 287 TRACO card (optional)................................................................................................. 288 Device name: G003................................................................................................. 288 Application....................................................................................................... 288 Front panel....................................................................................................... 289 Technical data.................................................................................................... 290 Input voltage/frequency card.......................................................................................... 291 Device name: L055, L063 and L071.................................................................................. 291 Application....................................................................................................... 291 Technical data.................................................................................................... 292 I/O analog card....................................................................................................... 293 Device name: L079 and L087........................................................................................ 293 Technical data.................................................................................................... 295 I/O analog card....................................................................................................... 296 Device name: L095 and L103........................................................................................ 296 Application....................................................................................................... 296 Technical data.................................................................................................... 298 Output pulse amplifier card........................................................................................... 299 Device name: L115, L123, L131, L139 and L147...................................................................... 299 Application....................................................................................................... 299 Technical data.................................................................................................... 301 Input temperature sensor card......................................................................................... 302 Device name: L155 and L163........................................................................................ 302 Application....................................................................................................... 302 Technical data.................................................................................................... 304 UWS card.............................................................................................................. 305 Device name: G055, G063, G071 and G079............................................................................ 305 Application....................................................................................................... 305 Technical data.................................................................................................... 307 Digital input card.................................................................................................... 308 Device name: G103, G111, G119, G127 and G135...................................................................... 308 Application....................................................................................................... 308 Technical data.................................................................................................... 310 Power start-up unit card.............................................................................................. 311 Device name: G163................................................................................................. 311 Application....................................................................................................... 311 Technical data.................................................................................................... 313 Binary output contactor drive card.................................................................................... 314 Device name: C019, C027 and C035.................................................................................. 314 Application....................................................................................................... 314 Technical data.................................................................................................... 316 24V / 24V power supply................................................................................................ 317 Device name: C045, C105, C129..................................................................................... 317 Application....................................................................................................... 317 Testing the power supply card..................................................................................... 318 Technical data.................................................................................................... 319 24V / 15V power supply................................................................................................ 320 Device name: C069, C087........................................................................................... 320 Application....................................................................................................... 320 Testing the power supply card..................................................................................... 321 Technical data.................................................................................................... 322 24V / 5V power supply................................................................................................. 323 Device name: C153................................................................................................. 323 Application....................................................................................................... 323 Testing the power supply card..................................................................................... 324 Technical data.................................................................................................... 325 Reserve engine oil system......................................................................................................... 327 General information........................................................................................................... 329 Operation..................................................................................................................... 330 LED monitor light......................................................................................................... 330 Remote tank fill system....................................................................................................... 331 Wheel motor transmission.......................................................................................................... 333 General information........................................................................................................... 334 Transmission wear data........................................................................................................ 337 20 Standard value table ............................................................................................................. 341 Standard value table.............................................................................................................. 341 Standard value table for truck................................................................................................ 342 30 Testing and adjusting ............................................................................................................. 347 General information............................................................................................................... 347 Special tool list............................................................................................................. 348 Cab air conditioning.............................................................................................................. 351 General information........................................................................................................... 352 Service tools and equipment................................................................................................... 353 Recovery/recycle station.................................................................................................. 353 Leak detector............................................................................................................. 353 Manifold gauge set........................................................................................................ 354 Service valves............................................................................................................ 355 Vacuum pump............................................................................................................... 355 Detecting leaks............................................................................................................... 356 System performance test....................................................................................................... 357 Checking system oil........................................................................................................... 358 System flushing............................................................................................................... 359 Installing the manifold gauge set............................................................................................. 360 Purging air from the service hoses........................................................................................ 360 Recovering and recycling refrigerant.......................................................................................... 361 Draining oil from previous recovery cycle................................................................................. 362 Recovery cycle............................................................................................................ 362 Recycling procedure....................................................................................................... 362 Evacuating the air conditioning system........................................................................................ 363 Charging the air conditioning system.......................................................................................... 364 A/C drive belt checkout procedure............................................................................................. 365 Pulley alignment.......................................................................................................... 365 Belt tension check........................................................................................................ 365 Steering, brake cooling and hoist hydraulic system................................................................................ 369 General information on system checkout........................................................................................ 371 Steering system checkout procedures........................................................................................... 371 Steering pump pressure control adjustments................................................................................ 372 Steering control valve and flow amplifier leakage test.................................................................... 373 Bleed down manifold leakage test.......................................................................................... 374 Shock and suction valve pressure tests.................................................................................... 375 Steering system checkout data sheet........................................................................................... 377 Toe-in adjustment............................................................................................................. 378 Brake cooling and hoist system checkout procedures............................................................................ 379 Pressure gauge locations.................................................................................................. 379 Brake cooling circuit test................................................................................................ 380 Power up relief pressure test............................................................................................. 380 Power down relief pressure test........................................................................................... 381 Counterbalance valve pressure check....................................................................................... 382 Counterbalance valve adjustment........................................................................................... 383 Brake cooling and hoist system checkout data sheet............................................................................ 384 Hydraulic system flushing..................................................................................................... 385 Hydraulic System Flushing Procedure....................................................................................... 385 Front suspension pressure test............................................................................................ 392 Rear suspension pressure test............................................................................................. 392 Steering cylinder leakage test............................................................................................ 393 Hoist cylinder leakage test............................................................................................... 393 Brake system...................................................................................................................... 395 General information on system checkout........................................................................................ 396 Brake circuit checkout procedure.............................................................................................. 396 Initial system setup...................................................................................................... 397 Brake lock / secondary braking checkout................................................................................... 398 Parking brake checkout.................................................................................................... 400 Service brake checkout.................................................................................................... 403 Blended braking checkout.................................................................................................. 403 Low brake accumulator pressure and auto apply checkout.................................................................... 404 Parking brake control logic checkout...................................................................................... 406 Auto apply solenoid hydraulic circuit troubleshooting..................................................................... 407 Brake lock control logic checkout......................................................................................... 408 Brake system checkout data sheet.............................................................................................. 411 Brake piston leakage test..................................................................................................... 416 Wet disc brake bleeding procedure............................................................................................. 416 Parking brake bleeding procedure.............................................................................................. 417 Parking brake leakage test.................................................................................................... 417 Brake valve bench test and adjustment......................................................................................... 418 Test setup procedure...................................................................................................... 419 Brake valve output pressure adjustment.................................................................................... 419 Final test and adjustment................................................................................................. 420 Dual relay valve bench test and adjustment.................................................................................... 421 Test setup procedure...................................................................................................... 422 Relay valve output pressure adjustment.................................................................................... 422 Accumulators and suspensions...................................................................................................... 425 Accumulator charging and storage.............................................................................................. 427 Accumulator charging procedures........................................................................................... 427 Precharge maintenance..................................................................................................... 430 Accumulator storage procedure............................................................................................. 431 Bladder storage........................................................................................................... 431 Installing a bladder accumulator from storage............................................................................. 431 Accumulator leak testing...................................................................................................... 432 Suspension oiling and charging procedures..................................................................................... 434 Equipment list............................................................................................................ 434 Installing the charging kit............................................................................................... 434 Removing the charging kit................................................................................................. 435 Support blocks for oiling and charging dimensions......................................................................... 435 Front suspension oiling................................................................................................... 436 Front suspension nitrogen charging........................................................................................ 437 Rear suspension oiling.................................................................................................... 439 Rear suspension nitrogen charging......................................................................................... 441 Suspension pressure test...................................................................................................... 442 Payload meter..................................................................................................................... 445 Payload meter initial setting procedure....................................................................................... 447 Starting communications................................................................................................... 447 Configure payload meter................................................................................................... 447 Setting truck number...................................................................................................... 449 Clean truck tare.......................................................................................................... 450 Inclinometer calibration.................................................................................................. 450 KOMTRAX Plus...................................................................................................................... 453 KOMTRAX Plus and payload meter software....................................................................................... 455 VHMS Tool Box Installation................................................................................................ 455 VHMS Setting Tool Installation............................................................................................ 455 Installing the PDM software............................................................................................... 455 KOMTRAX Plus controller initial setting procedure............................................................................. 456 KOMTRAX Plus controller setup procedure................................................................................... 456 KOMTRAX Plus snapshot procedure........................................................................................... 459 KOMTRAX Plus download procedure........................................................................................... 460 KOMTRAX Plus FTP upload procedure......................................................................................... 461 KOMTRAX Plus initialization forms......................................................................................... 462 KOMTRAX Plus initialization check list........................................................................................ 463 KOMTRAX Plus initialization form.............................................................................................. 465 Precautions for replacing KOMTRAX Plus controller............................................................................. 466 KOMTRAX Plus controller checkout procedure.................................................................................... 471 Necessary equipment....................................................................................................... 471 Preliminary............................................................................................................... 471 Checkout procedure........................................................................................................ 472 Interface module (IM)............................................................................................................. 475 Interface module software..................................................................................................... 476 Flashburn program installation............................................................................................ 476 Interface module application code installation............................................................................ 477 Interface module realtime data monitor software installation.............................................................. 477 Interface module checkout procedures.......................................................................................... 478 Necessary equipment....................................................................................................... 478 Preliminary............................................................................................................... 479 Check digital inputs to the interface module.............................................................................. 480 Check analog inputs to the interface module............................................................................... 483 Check serial interfaces to the interface module........................................................................... 484 Check outputs from the interface module................................................................................... 484 IGBT haul truck SIBAS® user manual, part 1........................................................................................ 487 Abbreviations................................................................................................................. 489 Precautions................................................................................................................... 491 Qualified person.............................................................................................................. 491 Customer monitor for SIBAS® 32 control units.................................................................................. 491 Product description....................................................................................................... 491 Version management........................................................................................................ 492 Overview.................................................................................................................. 493 Requirements.............................................................................................................. 493 Installing and calling the customer monitor................................................................................... 494 Installation.............................................................................................................. 494 Environment variables................................................................................................. 494 Communication with the SIBAS® 32 control unit............................................................................. 495 Calling up the customer monitor........................................................................................... 496 Start-up prompt....................................................................................................... 496 Monitor prompt........................................................................................................ 497 Notes on operation of the customer monitor................................................................................ 498 Structure of a monitor command............................................................................................ 498 Step 1: Selecting the menu title...................................................................................... 498 Step 2: Selecting a menu entry in the menu box........................................................................ 498 Step 3: Selecting a dialog box, if available.......................................................................... 499 Step 4: Entering file or connector/signal names....................................................................... 499 Command buffer............................................................................................................ 500 Structure of the monitor windows.......................................................................................... 500 Window menu................................................................................................................... 501 Commands for Opening, Altering and Closing Windows........................................................................ 501 "Window Work open"........................................................................................................ 501 "Window Lines open"....................................................................................................... 501 "Window Tile"............................................................................................................. 501 "Window Bars open"........................................................................................................ 501 Options............................................................................................................... 501 "Window Set".............................................................................................................. 501 Options............................................................................................................... 501 "Window Cascade".......................................................................................................... 501 "Window Close"............................................................................................................ 501 "Window close All"........................................................................................................ 501 "Window Exit"............................................................................................................. 501 Set Menu...................................................................................................................... 502 "Set Port"................................................................................................................ 502 Options............................................................................................................... 502 "Set Baudrate"............................................................................................................ 502 Options............................................................................................................... 502 "Set String".............................................................................................................. 503 Example............................................................................................................... 504 "Set Make"................................................................................................................ 504 Options............................................................................................................... 504 Example 1: INIT.MON start-up control of the Customer Monitor.......................................................... 505 Example 2: Any monitor batch file with freely selectable file name (incl. path)....................................... 505 "Set Execute"............................................................................................................. 506 Options............................................................................................................... 506 Example............................................................................................................... 506 "Set Record".............................................................................................................. 506 Options............................................................................................................... 506 "Set DIN-Bus"............................................................................................................. 507 "Set TCN"................................................................................................................. 507 "Set Timeout"............................................................................................................. 507 Options............................................................................................................... 507 "Set Wait"................................................................................................................ 507 Options............................................................................................................... 507 "Set Color"............................................................................................................... 507 Options............................................................................................................... 507 "Set Info"................................................................................................................ 508 "Set comment"............................................................................................................. 508 "Set CHAR Set"............................................................................................................ 508 "Set Quit"................................................................................................................ 508 Applic. Menu.................................................................................................................. 509 "Applic. Func.Package".................................................................................................... 509 "Applic. Connector"....................................................................................................... 510 Options............................................................................................................... 510 Example............................................................................................................... 511 "Applic. View"............................................................................................................ 511 Options............................................................................................................... 511 Example............................................................................................................... 511 "Applic. Signal".......................................................................................................... 511 "Applic. Observer"........................................................................................................ 512 Options............................................................................................................... 512 Possible time slices:................................................................................................. 512 Options............................................................................................................... 513 Two options........................................................................................................... 513 Notes on the display of connectors.................................................................................... 515 "Applic. Buffer".......................................................................................................... 516 Options............................................................................................................... 516 "Applic. Report".......................................................................................................... 516 "Applic. Legitimation".................................................................................................... 516 Options............................................................................................................... 516 "Applic. Menu"............................................................................................................ 517 "Applic. Traco"........................................................................................................... 517 Options............................................................................................................... 517 "Applic. Environment"..................................................................................................... 517 Hardw. Menu................................................................................................................... 519 Hardware-Oriented Access via the Customer Monitor......................................................................... 519 "Hardw. Flash"............................................................................................................ 519 Options............................................................................................................... 519 Requirements.......................................................................................................... 519 Example............................................................................................................... 520 Deleting and loading.................................................................................................. 520 The EPROM for the communication drivers............................................................................... 520 "Hardw. Clock"............................................................................................................ 520 Options............................................................................................................... 520 "Hardw. DSP".............................................................................................................. 521 "Hardw. BCD".............................................................................................................. 521 Options............................................................................................................... 521 Example............................................................................................................... 521 "Hardw. RESET"............................................................................................................ 521 Options............................................................................................................... 521 "Hardw. Info"............................................................................................................. 522 Hardware/Operating system............................................................................................. 522 Application and tools................................................................................................. 522 Communication module.................................................................................................. 522 Displaying the loading date........................................................................................... 522 "Hardw. User Flash"....................................................................................................... 523 Options............................................................................................................... 523 "Hardw. Sys. Flash"....................................................................................................... 523 Options............................................................................................................... 523 "Hardw. BOOT DSP"......................................................................................................... 524 Requirements.......................................................................................................... 524 DSP5600x Signal Processing Unit and TRACO............................................................................. 524 Inverter processing unit.............................................................................................. 526 Access to the Signal Processing Unit.................................................................................. 526 "Hardw. Flash"............................................................................................................ 526 Options............................................................................................................... 526 Requirements.......................................................................................................... 526 Example............................................................................................................... 526 Deleting and loading.................................................................................................. 527 The EPROM for the communication drivers............................................................................... 527 User Data Flash (UDF)................................................................................................. 527 "Hardw. RESET"............................................................................................................ 527 Options............................................................................................................... 527 "Hardw. ZR"............................................................................................................... 528 "Hardw. BOOT ZR".......................................................................................................... 528 The following procedure is necessary:................................................................................. 528 Graphic Menu.................................................................................................................. 529 Commands for Displaying Line Graphics..................................................................................... 529 "Graphic Load"............................................................................................................ 529 Options............................................................................................................... 529 "Graphic Position"........................................................................................................ 529 Options............................................................................................................... 529 "Graphic Time/Div"........................................................................................................ 530 Options............................................................................................................... 530 "Graphic Unit/Div"........................................................................................................ 530 Options............................................................................................................... 530 "Graphic Display"......................................................................................................... 530 Options............................................................................................................... 530 "Graphic Color"........................................................................................................... 531 Options............................................................................................................... 531 "Graphic Format".......................................................................................................... 531 Options............................................................................................................... 531 IGBT haul truck SIBAS® user manual, part 2........................................................................................ 533 Traco Menu.................................................................................................................... 535 HW-Traco.................................................................................................................. 535 Options............................................................................................................... 536 SW-Traco.................................................................................................................. 537 Options............................................................................................................... 538 ZR traco basic parameters:............................................................................................ 538 ZR traco record signal table:......................................................................................... 538 DAC_Traco................................................................................................................. 541 Options............................................................................................................... 542 Events Menu................................................................................................................... 543 STatistics................................................................................................................ 544 History................................................................................................................... 545 LEL:Last EvL.............................................................................................................. 546 LES:Last EvS.............................................................................................................. 548 DLL:DC,LastL.............................................................................................................. 549 DLS:DC,LastS.............................................................................................................. 550 DAL:DC,All L.............................................................................................................. 551 DAS:DC,All S.............................................................................................................. 552 ML:Memory L............................................................................................................... 553 MS:Memory S............................................................................................................... 554 CN:Clear Norm............................................................................................................. 555 CA:Clear All.............................................................................................................. 555 Test-Code................................................................................................................. 555 DS:Diag-Strc.............................................................................................................. 556 User Menu..................................................................................................................... 557 DAC_IO.................................................................................................................... 558 Options............................................................................................................... 558 Options............................................................................................................... 559 Operat.Data........................................................................................................... 560 Acc test.................................................................................................................. 567 Engine_Test............................................................................................................... 567 X_Test_Inx................................................................................................................ 570 STate intern.............................................................................................................. 571 Header:............................................................................................................... 571 Vehicle Number:....................................................................................................... 571 Powering system:...................................................................................................... 571 TCU Operation Mode:................................................................................................... 571 Component status listings:............................................................................................ 572 Field regulator status:............................................................................................... 572 Status gate unit power supply A:...................................................................................... 572 Status gate unit power supply B:...................................................................................... 572 ST inverter status.................................................................................................... 573 Vehicle status........................................................................................................ 573 Drive status:......................................................................................................... 573 Operation status:..................................................................................................... 574 Pedal calib............................................................................................................... 575 Language.................................................................................................................. 576 OFFline-test.............................................................................................................. 576 Options............................................................................................................... 576 Variables................................................................................................................. 577 Examples:............................................................................................................. 577 IV:Vehic-ID............................................................................................................... 579 Commands.................................................................................................................. 579 Discharge Dc link / Fire crowbar...................................................................................... 580 Limp mode commands.................................................................................................... 580 Settings.................................................................................................................. 581 Parameters................................................................................................................ 582 Temp_prot................................................................................................................. 584 Appendix...................................................................................................................... 586 Background commands....................................................................................................... 586 Monitor commands for the central processing unit.......................................................................... 587 Monitor commands for the signal processing unit........................................................................... 587 Installing ZR / DSP software...................................................................................................... 589 Monitor Program – Loading software into the SIBAS®............................................................................ 590 Loading software into the DSP procedure....................................................................................... 590 Loading a DSP program Inverter A.............................................................................................. 595 Loading ZR software Prog. jumpers Reset....................................................................................... 609 24V electrical system............................................................................................................. 613 Body position switches (with proximity switches and metal arms)............................................................... 614 Body up switch adjustment................................................................................................. 614 Hoist limit switch adjustment............................................................................................. 615 Service................................................................................................................... 615 Body position switches (with proximity switches and magnets).................................................................. 616 Body up switch adjustment................................................................................................. 616 Hoist limit switch adjustment............................................................................................. 616 Service................................................................................................................... 616 40 Troubleshooting ................................................................................................................... 621 Cab air conditioning.............................................................................................................. 621 Preliminary checks............................................................................................................ 623 Diagnosis of gauge readings and system performance............................................................................ 623 Troubleshooting by manifold gauge set readings................................................................................ 624 Fuse and circuit breaker locations................................................................................................ 631 Fuse and circuit breaker locations............................................................................................ 632 Troubleshooting by fault code, part 1............................................................................................. 637 Fault Code A001: Left front suspension pressure sensor signal high............................................................ 639 Related circuit diagram................................................................................................... 639 Fault Code A002: Left front suspension pressure sensor signal low............................................................. 640 Related circuit diagram................................................................................................... 640 Fault Code A003: Right front suspension pressure sensor signal high........................................................... 641 Related circuit diagram................................................................................................... 641 Fault Code A004: Right front suspension pressure sensor signal low............................................................ 642 Related circuit diagram................................................................................................... 642 Fault Code A005: Left rear suspension pressure sensor signal high............................................................. 643 Related circuit diagram................................................................................................... 643 Fault Code A006: Left rear suspension pressure sensor signal low.............................................................. 644 Related circuit diagram................................................................................................... 644 Fault Code A007: Right rear suspension pressure sensor signal high............................................................ 645 Related circuit diagram................................................................................................... 645 Fault Code A008: Right rear suspension pressure sensor signal low............................................................. 646 Related circuit diagram................................................................................................... 646 Fault Code A009: Incline sensor signal high................................................................................... 647 Related circuit diagram................................................................................................... 647 Fault Code A010: Incline sensor signal low.................................................................................... 648 Related circuit diagram................................................................................................... 648 Fault Code A011: Payload meter speed sensor signal has failed................................................................. 649 Related circuit diagram................................................................................................... 649 Fault Code A013: Body up switch has failed.................................................................................... 650 Related circuit diagram................................................................................................... 650 Fault Code A014: Payload meter checksum computation has failed................................................................ 651 Related circuit diagram................................................................................................... 651 Fault Code A016: Payload meter write to flash memory has failed............................................................... 652 Related circuit diagram................................................................................................... 652 Fault Code A017: Payload meter flash memory read has failed................................................................... 653 Related circuit diagram................................................................................................... 653 Fault Code A018: Right rear flat suspension cylinder warning.................................................................. 654 Related circuit diagram................................................................................................... 655 Fault Code A019: Left rear flat suspension cylinder warning................................................................... 656 Related circuit diagram................................................................................................... 657 Fault Code A022: Carryback load excessive..................................................................................... 658 Related circuit diagram................................................................................................... 659 Fault Code A100: An open circuit breaker has been detected on a relay board................................................... 661 Related circuit diagram................................................................................................... 661 Fault Code A101: High pressure detected across an hydraulic pump filter....................................................... 662 Related circuit diagram................................................................................................... 663 Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level...................................... 664 Related circuit diagram................................................................................................... 665 Fault Code A111: Low steering pressure warning for storage by VHMS............................................................ 666 Related circuit diagram................................................................................................... 666 Fault Code A115: Low steering precharge pressure detected..................................................................... 668 Related circuit diagram................................................................................................... 669 Fault Code A117: Low brake accumulator pressure warning for storage by VHMS................................................... 670 Related circuit diagram................................................................................................... 670 Fault Code A118: Brake pressure is low while in brake lock.................................................................... 672 Related circuit diagram................................................................................................... 673 Fault Code A126: Oil level in the hydraulic tank is low....................................................................... 674 Related circuit diagram................................................................................................... 674 Fault Code A127: IM-furnished +5 volt output for sensors is low............................................................... 676 Related circuit diagram................................................................................................... 677 Fault Code A128: IM-furnished +5 volt output for sensors is high.............................................................. 678 Related circuit diagram................................................................................................... 679 Fault Code A139: Low fuel warning for storage by VHMS and for use by A310..................................................... 680 Related circuit diagram................................................................................................... 681 Troubleshooting by fault code, part 2............................................................................................. 683 Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil.... 686 Related circuit diagram................................................................................................... 687 Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil.... 688 Related circuit diagram................................................................................................... 689 Fault Code A152: Starter failure.............................................................................................. 690 Related circuit diagram................................................................................................... 691 Fault Code A153: Battery voltage is low with the truck in operation........................................................... 692 Related circuit diagram................................................................................................... 693 Fault Code A154: Battery charging voltage is excessive........................................................................ 694 Related circuit diagram................................................................................................... 694 Fault Code A155: Battery charging voltage is low.............................................................................. 695 Related circuit diagram................................................................................................... 695 Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level................................. 696 Related circuit diagram................................................................................................... 697 Fault Code A159: (A30003 only) The battery 12 Volt circuit sensing is producing low readings.................................. 698 Related circuit diagram................................................................................................... 698 Fault Code A164: (A30003 only) The battery 12 Volt circuit sensing is producing high readings................................. 699 Related Circuit Diagram................................................................................................... 699 Fault Code A166: Left rear hydraulic oil temperature sensor is low............................................................ 700 Related circuit diagram................................................................................................... 701 Fault Code A167: Right rear hydraulic oil temperature sensor is low........................................................... 702 Related circuit diagram................................................................................................... 703 Fault Code A168: Left front hydraulic oil temperature sensor is low........................................................... 704 Related circuit diagram................................................................................................... 705 Fault Code A169: Right front hydraulic oil temperature sensor is low.......................................................... 706 Related circuit diagram................................................................................................... 707 Fault Code A170: Left rear hydraulic oil temperature sensor is high........................................................... 708 Related circuit diagram................................................................................................... 708 Fault Code A171: Right rear hydraulic oil temperature sensor is high.......................................................... 709 Related circuit diagram................................................................................................... 709 Fault Code A172: Left front hydraulic oil temperature sensor is high.......................................................... 710 Related circuit diagram................................................................................................... 710 Fault Code A173: Right front hydraulic oil temperature sensor is high......................................................... 711 Related circuit diagram................................................................................................... 711 Fault Code A182: (A30003 only) The battery 12 Volt battery tap has high voltage............................................... 712 Related circuit diagram................................................................................................... 713 Fault Code A183: (A30003 only) The battery 12 Volt battery tap has low voltage................................................ 714 Related circuit diagram................................................................................................... 715 Fault Code A184: J1939 data link is not connected............................................................................. 716 Related circuit diagram................................................................................................... 717 Fault Code A190: (A30003 only) The automatic lubrication system has announced a fault......................................... 718 Fault Code A190: (A30004 & Up) Auto lube control has detected an incomplete lube cycle........................................ 720 Related circuit diagram................................................................................................... 721 Fault Code A194: Left front hydraulic oil temperature is high................................................................. 722 Related circuit diagram................................................................................................... 722 Fault Code A195: Right front hydraulic oil temperature is high................................................................ 723 Related circuit diagram................................................................................................... 723 Fault Code A196: Left rear hydraulic oil temperature is high.................................................................. 724 Related circuit diagram................................................................................................... 724 Fault Code A197: Right rear hydraulic oil temperature is high................................................................. 725 Related circuit diagram................................................................................................... 725 Fault Code A198: Hoist pressure 1 sensor is high.............................................................................. 726 Related circuit diagram................................................................................................... 726 Fault Code A199: Hoist pressure 2 sensor is high.............................................................................. 727 Related circuit diagram................................................................................................... 727 Fault Code A200: Steering pressure sensor is high............................................................................. 728 Related circuit diagram................................................................................................... 728 Fault Code A201: Brake pressure sensor is high................................................................................ 729 Related circuit diagram................................................................................................... 729 Fault Code A202: Hoist pressure 1 sensor is low............................................................................... 730 Related circuit diagram................................................................................................... 730 Fault Code A203: Hoist pressure 2 sensor is low............................................................................... 731 Related circuit diagram................................................................................................... 731 Fault Code A204: Steering pressure sensor is low.............................................................................. 732 Related circuit diagram................................................................................................... 732 Fault Code A205: Brake pressure sensor is low................................................................................. 733 Related circuit diagram................................................................................................... 733 Fault Code A206: Ambient temperature sensor is high........................................................................... 734 Related circuit diagram................................................................................................... 734 Fault Code A207: Ambient temperature sensor is low............................................................................ 735 Related circuit diagram................................................................................................... 735 Troubleshooting by fault code, Part 3............................................................................................. 737 Fault Code A213: Parking brake should have applied but is detected as not having applied...................................... 739 Related circuit diagram................................................................................................... 742 Fault Code A214: Parking brake should have released but is detected as not having released.................................... 744 Related circuit diagram................................................................................................... 746 Fault Code A215: Brake auto apply valve circuit is defective.................................................................. 748 Related circuit diagram................................................................................................... 749 Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit...................... 750 Related circuit diagram................................................................................................... 751 Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted.................................... 752 Related circuit diagram................................................................................................... 753 Fault Code A230: Parking brake has been requested while truck still moving.................................................... 754 Related circuit diagram................................................................................................... 755 Fault Code A231: The body is up while traveling or with selector in forward or neutral........................................ 756 Fault Code A233: Drive System Control Link is not connected................................................................... 758 Related circuit diagram................................................................................................... 759 Fault Code A235: Steering accumulator is in the process of being bled down.................................................... 760 Related circuit diagram................................................................................................... 761 Fault Code A236: The steering accumulator has not properly bled down after 90 seconds......................................... 762 Related circuit diagram................................................................................................... 763 Fault Code A237: The CAN/RPC connection to the display is open................................................................ 764 Related circuit diagram................................................................................................... 765 Fault Code A238: Drive System and IM are reporting different park brake status................................................ 766 Related circuit diagram................................................................................................... 767 Fault Code A239: The Drive System and IM are reporting different brake lock status............................................ 768 Related circuit diagram................................................................................................... 769 Fault Code A240: The keyswitch input to the Interface Module is open.......................................................... 770 Related circuit diagram................................................................................................... 770 Fault Code A242: Fuel gauge within the dash display panel is defective........................................................ 771 Related circuit diagram................................................................................................... 771 Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective.................................. 772 Related circuit diagram................................................................................................... 772 Fault Code A244: Drive system temperature gauge within the dash display panel is defective.................................... 773 Related circuit diagram................................................................................................... 773 Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective................................... 774 Related circuit diagram................................................................................................... 774 Fault Code A246: Payload meter reports truck overload......................................................................... 775 Related circuit diagram................................................................................................... 775 Fault Code A247: Low steering pressure warning for display to operator........................................................ 776 Related circuit diagram................................................................................................... 776 Fault Code A248: Status module within the dash display panel is defective..................................................... 777 Related circuit diagram................................................................................................... 777 Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted........................................... 778 Related circuit diagram................................................................................................... 778 Fault Code A250: Battery voltage is low with the truck parked................................................................. 779 Related circuit diagram................................................................................................... 780 Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground.............................. 781 Related circuit diagram................................................................................................... 782 Fault Code A252: Start enable output circuit is either open or shorted to ground.............................................. 783 Related circuit diagram................................................................................................... 783 Fault Code A253: Steering bleed circuit is not open while running............................................................. 784 Related circuit diagram................................................................................................... 785 Fault Code A254: (A30003 Only) The 5 minute idle circuit is either open or shorted to ground.................................. 786 Related circuit diagram................................................................................................... 786 Fault Code A256: Red warning lamp in the dash display (driven by IM) is open.................................................. 787 Related circuit diagram................................................................................................... 787 Fault Code A257: Payload CAN/RPC is not connected............................................................................. 788 Related circuit diagram................................................................................................... 789 Fault Code A258: Steering accumulator bleed pressure switch circuit is defective.............................................. 790 Related circuit diagram................................................................................................... 790 Troubleshooting by fault code, Part 4............................................................................................. 793 Fault Code A260: Park brake failure........................................................................................... 796 Related circuit diagram................................................................................................... 797 Fault Code A261: Low brake accumulator pressure warning for display to operator............................................... 798 Related circuit diagram................................................................................................... 798 Fault Code A262: Steering bleed valve circuit open during shutdown............................................................ 800 Related circuit diagram................................................................................................... 801 Fault Code A264: Park brake relay circuit is defective........................................................................ 802 Related circuit diagram................................................................................................... 803 Fault Code A265: Service brake failure........................................................................................ 804 Related circuit diagram................................................................................................... 805 Fault Code A266: Selector switch was not in park while attempting to crank engine............................................. 806 Related circuit diagram................................................................................................... 806 Fault Code A267: Park brake was not set while attempting to crank engine...................................................... 807 Related circuit diagram................................................................................................... 807 Fault Code A268: Secondary engine shutdown while cranking..................................................................... 808 Related circuit diagram................................................................................................... 808 Fault Code A270: Brake lock switch power supply is not on when required....................................................... 810 Related circuit diagram................................................................................................... 811 Fault Code A271: Shifter not in gear.......................................................................................... 812 Related circuit diagram................................................................................................... 813 Fault Code A272: Brake lock switch power supply is not off when required...................................................... 814 Related circuit diagram................................................................................................... 815 Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit....................... 816 Related circuit diagram................................................................................................... 816 Fault Code A274: A brake setting fault has been detected...................................................................... 818 Related circuit diagram................................................................................................... 819 Fault Code A275: A starter has been detected as engaged without a cranking attempt............................................ 820 Related circuit diagram................................................................................................... 821 Fault Code A277: Park brake applied while loading............................................................................. 822 Related circuit diagram................................................................................................... 823 Fault Code A278: Service brake applied while loading.......................................................................... 824 Related circuit diagram................................................................................................... 825 Fault Code A279: Low Steering Pressure Switch bad............................................................................. 826 Related circuit diagram................................................................................................... 826 Fault Code A280: Steering accumulator bled switch bad......................................................................... 827 Related circuit diagram................................................................................................... 827 Fault Code A281: Brake lock degrade switch bad................................................................................ 828 Related circuit diagram................................................................................................... 829 Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7............. 830 Related circuit diagram................................................................................................... 831 Fault Code A283: (A30004 & Up) An engine shutdown delay was aborted because the parking brake was not set..................... 832 Related circuit diagram................................................................................................... 833 Fault Code A284: (A30004 & Up) An engine shutdown delay was aborted because the secondary shutdown switch was operated........ 834 Related circuit diagram................................................................................................... 835 Fault Code A285: (A30004 & Up) The park brake was not set when the keyswitch was turned off................................... 836 Related circuit diagram................................................................................................... 837 Fault Code A286: (A30004 & Up) A fault was detected in the shutdown delay relay circuit....................................... 838 Related circuit diagram................................................................................................... 839 Fault Code A292: (A30004 & Up) The shutdown delay relay has remained on after the latched keyswitch circuit is off............ 840 Related circuit diagram................................................................................................... 841 Fault Code A295: The right front park brake is not setting up................................................................. 842 Related circuit diagram................................................................................................... 842 Fault Code A296: The left front park brake is not setting up.................................................................. 843 Related circuit diagram................................................................................................... 843 Fault Code A297:The right rear park brake is not setting up................................................................... 844 Related circuit diagram................................................................................................... 844 Fault Code A298: The left rear park brake is not setting up................................................................... 845 Related circuit diagram................................................................................................... 845 Fault Code A299: The right front park brake is not releasing.................................................................. 846 Related circuit diagram................................................................................................... 846 Fault Code A300: The left front park brake is not releasing................................................................... 847 Related circuit diagram................................................................................................... 847 Fault Code A301: The right rear park brake is not releasing................................................................... 848 Related circuit diagram................................................................................................... 848 Fault Code A302: The left rear park brake is not releasing.................................................................... 849 Related circuit diagram................................................................................................... 849 Troubleshooting by fault code, part 5............................................................................................. 851 Fault Code A303: Shifter is defective......................................................................................... 854 Related circuit diagram................................................................................................... 855 Fault Code A304: (A30004 & Up) Auto lube grease level fault................................................................... 856 Related circuit diagram................................................................................................... 856 Fault Code A305: (A30004 & Up) Auto lube circuit is defective................................................................. 858 Related circuit diagram................................................................................................... 859 Fault Code A309: No brakes applied when expected.............................................................................. 860 Related circuit diagram................................................................................................... 861 Fault Code A310: Low fuel warning............................................................................................. 862 Related circuit diagram................................................................................................... 863 Fault Code A311: Brake lock switch is on when it should not be................................................................ 864 Related circuit diagram................................................................................................... 865 Fault Code A312: (A30004 & Up) DCDC converter 12 volt circuit sensing is producing low readings............................... 866 Related circuit diagram................................................................................................... 866 Fault Code A313: (A30004 & Up) DCDC converter 12 volt circuit sensing is producing high readings.............................. 867 Related circuit diagram................................................................................................... 867 Fault Code A315: (A30004 & Up) DCDC converter 12 volt circuit is low.......................................................... 868 Related circuit diagram................................................................................................... 869 Fault Code A316: Starter engagement has been attempted with engine running.................................................... 870 Related circuit diagram................................................................................................... 871 Fault Code A317: Operation of brake auto apply valve without a detected response.............................................. 872 Related circuit diagram................................................................................................... 873 Fault Code A318: Unexpected power loss to Interface Module.................................................................... 874 Related circuit diagram................................................................................................... 874 Fault Code A328: Drive system not powered up.................................................................................. 875 Related circuit diagram................................................................................................... 875 Fault Code A350: Overload on output 1B........................................................................................ 876 Related circuit diagram................................................................................................... 876 Fault Code A351: Overload on output 1E........................................................................................ 878 Related circuit diagram................................................................................................... 879 Fault Code A352: (A30003) Overload on output 1H............................................................................... 880 Related circuit diagram................................................................................................... 880 Fault Code A352: (A30004 & Up) Overload on output 1H.......................................................................... 881 Related circuit diagram................................................................................................... 881 Fault Code A353: Overload on output 1J........................................................................................ 882 Related circuit diagram................................................................................................... 882 Fault Code A354: Overload on output 1K........................................................................................ 883 Related circuit diagram................................................................................................... 883 Fault Code A355: Overload on output 1L........................................................................................ 884 Related circuit diagram................................................................................................... 884 Fault Code A356: Overload on output 1M........................................................................................ 885 Related circuit diagram................................................................................................... 885 Fault Code A357: Overload on output 1N........................................................................................ 886 Related circuit diagram................................................................................................... 886 Fault Code A358: Overload on output 1P........................................................................................ 887 Related circuit diagram................................................................................................... 887 Fault Code A359: Overload on output 1R........................................................................................ 888 Related circuit diagram................................................................................................... 889 Fault Code A360: Overload on output 1S........................................................................................ 890 Related circuit diagram................................................................................................... 890 Fault Code A361: (A30003) Overload on output 1T............................................................................... 891 Related circuit diagram................................................................................................... 891 None...................................................................................................................... 891 Fault Code A361: (A30004 & Up) Overload on output 1T.......................................................................... 892 Related circuit diagram................................................................................................... 893 Fault Code A362: Overload on output 1U........................................................................................ 894 Related circuit diagram................................................................................................... 894 Fault Code A363: Overload on output 1X........................................................................................ 895 Related circuit diagram................................................................................................... 895 Fault Code A364: Overload on output 1Y........................................................................................ 896 Related circuit diagram................................................................................................... 896 Fault Code A365: Overload on output 1Z........................................................................................ 897 Related circuit diagram................................................................................................... 897 Drive system fault code table, Part 1............................................................................................. 899 Summary....................................................................................................................... 901 How to use this document.................................................................................................. 901 Event code and diagnosis message.......................................................................................... 901 Description............................................................................................................... 901 Threshold................................................................................................................. 901 Detection by.............................................................................................................. 901 Possible reasons.......................................................................................................... 901 Action to reset........................................................................................................... 901 Action to repair.......................................................................................................... 902 Operator displayed code................................................................................................... 902 Note...................................................................................................................... 902 Protection reactions...................................................................................................... 902 EVENT CLASSIFICATION.......................................................................................................... 902 Level 1: Warning.......................................................................................................... 903 Level 2: Minor purposes................................................................................................... 903 Level 3: Severe........................................................................................................... 903 Drive system fault code table, Part 2............................................................................................. 939 Drive system fault code table, Part 3............................................................................................. 979 Drive system fault code table, Part 4.............................................................................................1039 Drive system fault code table, Part 5.............................................................................................1093 Drive system fault code table, Part 6.............................................................................................1167 Drive system fault code table, Part 7.............................................................................................1217 Troubleshooting electric wheel motor..............................................................................................1291 FAULT TABLE...................................................................................................................1292 Reserve engine oil system.........................................................................................................1301 Pumping unit LED signals......................................................................................................1303 Circuit fuses.............................................................................................................1303 50 Disassembly and assembly ..........................................................................................................1305 General information...............................................................................................................1305 Special tool list.............................................................................................................1306 Cab air conditioning..............................................................................................................1315 Replacement of air conditioning system components.............................................................................1317 Hoses and fittings........................................................................................................1317 Lines.....................................................................................................................1317 Expansion valve...........................................................................................................1317 Receiver-drier............................................................................................................1317 Thermostat................................................................................................................1317 Compressor................................................................................................................1318 Accumulator...............................................................................................................1318 Clutch....................................................................................................................1318 Diasassembly and assembly of compressor clutch................................................................................1319 Removal of the clutch assembly............................................................................................1319 Removal of the pulley.....................................................................................................1321 Installation of the pulley................................................................................................1321 Installation of the clutch assembly.......................................................................................1322 Wheels, spindles and rear axle....................................................................................................1325 General information for tires and rims........................................................................................1327 Storage and handling......................................................................................................1327 Wheel stud maintenance........................................................................................................1328 Front wheel studs.........................................................................................................1328 Rear wheel studs..........................................................................................................1328 Removal and installation of front wheel.......................................................................................1330 Removal...................................................................................................................1330 Installation..............................................................................................................1330 Removal and installation of rear wheels.......................................................................................1332 Removal...................................................................................................................1332 Installation..............................................................................................................1333 Removal and installation of tires.............................................................................................1334 Removal...................................................................................................................1334 Installation..............................................................................................................1335 Removal and installation of front wheel hub and spindle.......................................................................1337 Removal...................................................................................................................1338 Spindle Removal Procedure (off of the truck)..............................................................................1341 Installation..............................................................................................................1343 Disassembly and assembly of front wheel hub and spindle.......................................................................1344 Disassembly...............................................................................................................1344 Cleaning and inspection...................................................................................................1345 Assembly..................................................................................................................1347 Wheel bearing adjustment..................................................................................................1347 Seal assembly gap check and adjustment....................................................................................1348 Floating seal installation................................................................................................1349 Speed sensor installation and adjustment..................................................................................1351 Removal and installation of wheel motor.......................................................................................1352 Preparation...............................................................................................................1352 Removal...................................................................................................................1352 Cleaning and inspection...................................................................................................1353 Installation..............................................................................................................1354 Removal and installation of rear axle.........................................................................................1357 Removal...................................................................................................................1357 Cleaning and inspection...................................................................................................1358 Installation..............................................................................................................1359 Removal and installation of anti-sway bar.....................................................................................1359 Removal...................................................................................................................1359 Installation..............................................................................................................1360 Removal and installation of pivot pin.........................................................................................1361 Removal...................................................................................................................1361 Installation..............................................................................................................1361 Pivot eye and bearing service.................................................................................................1362 Bearing removal...........................................................................................................1362 Bearing installation......................................................................................................1362 Pivot eye repair..........................................................................................................1363 Removal and installation of electric motor....................................................................................1364 Removal...................................................................................................................1364 Installation..............................................................................................................1364 Disassembly and assembly of wheel motor transmission..........................................................................1365 Disassembly...............................................................................................................1365 Cleaning and inspection...................................................................................................1371 Assembly..................................................................................................................1372 Disassembly and assembly of low speed carrier.................................................................................1383 Disassembly...............................................................................................................1383 Inspection................................................................................................................1384 Assembly..................................................................................................................1385 Disassembly and assembly of high speed carrier................................................................................1388 Disassembly...............................................................................................................1388 Inspection................................................................................................................1389 Assembly..................................................................................................................1390 Brake system......................................................................................................................1395 Removal and installation of brake valve.......................................................................................1397 Removal...................................................................................................................1397 Installation..............................................................................................................1398 Disassembly and assembly of brake valve.......................................................................................1398 Disassembly...............................................................................................................1398 Cleaning and inspection...................................................................................................1402 Assembly..................................................................................................................1402 Removal and installation of dual relay valve..................................................................................1406 Removal...................................................................................................................1406 Installation..............................................................................................................1407 Disassembly and assembly of dual relay valve..................................................................................1407 Disassembly...............................................................................................................1407 Cleaning and inspection...................................................................................................1408 Assembly..................................................................................................................1408 Removal and installation of brake manifold....................................................................................1409 Removal...................................................................................................................1409 Installation..............................................................................................................1410 Disassembly and assembly of brake manifold....................................................................................1410 Disassembly...............................................................................................................1410 Assembly..................................................................................................................1410 Removal and installation of brake accumulator.................................................................................1411 Removal...................................................................................................................1411 Installation..............................................................................................................1412 Disassembly and assembly of brake accumulator.................................................................................1412 Disassembly...............................................................................................................1412 Cleaning and inspection...................................................................................................1414 Assembly..................................................................................................................1414 Disassembly and assembly of wheel brake.......................................................................................1416 Disassembly...............................................................................................................1417 Cleaning and inspection...................................................................................................1420 Assembly..................................................................................................................1421 Floating ring seal assembly and installation..............................................................................1427 Removal and installation of rear brake assembly...............................................................................1431 Removal...................................................................................................................1431 Installation..............................................................................................................1431 Steering system...................................................................................................................1437 Removal and installation of steering control unit.............................................................................1439 Removal...................................................................................................................1439 Installation..............................................................................................................1440 Disassembly and assembly of steering control unit.............................................................................1441 Disassembly...............................................................................................................1441 Assembly..................................................................................................................1443 Removal and installation of steering column...................................................................................1446 Removal...................................................................................................................1446 Inspection................................................................................................................1446 Installation..............................................................................................................1447 Removal and installation of steering wheel....................................................................................1448 Removal...................................................................................................................1448 Installation..............................................................................................................1448 Removal and installation of bleed down manifold...............................................................................1450 Removal...................................................................................................................1450 Installation..............................................................................................................1450 Removal and installation of flow amplifier....................................................................................1452 Removal...................................................................................................................1452 Installation..............................................................................................................1452 Disassembly and assembly of flow amplifier....................................................................................1452 Disassembly...............................................................................................................1452 Assembly..................................................................................................................1454 Removal and installation of steering cylinders and tie rod....................................................................1455 Removal...................................................................................................................1455 Bearing replacement.......................................................................................................1455 Installation..............................................................................................................1455 Disassembly and assembly of steering cylinders................................................................................1457 Disassembly...............................................................................................................1457 Assembly..................................................................................................................1457 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.............................................................................1471 Removal Use vacuum pump kit (XB0887) to hold the oil back in the tank.....................................................1471 Installation..............................................................................................................1472 Disassembly and assembly of steering accumulators.............................................................................1472 Disassembly...............................................................................................................1472 Cleaning and Inspection...................................................................................................1474 Assembly..................................................................................................................1474 Suspensions.......................................................................................................................1479 Removal and installation of front suspension..................................................................................1481 Removal...................................................................................................................1481 Installation..............................................................................................................1482 Inspection................................................................................................................1487 Minor front suspension repairs (lower bearing and seals)......................................................................1488 Lower bearing retainer removal............................................................................................1488 Lower bearing retainer installation.......................................................................................1488 Major front suspension rebuild................................................................................................1489 Disassembly...............................................................................................................1489 Assembly..................................................................................................................1490 Removal and installation of rear suspension...................................................................................1492 Removal...................................................................................................................1493 Installation..............................................................................................................1494 Disassembly and assembly of rear suspension...................................................................................1495 Disassembly...............................................................................................................1495 Cleaning and Inspection...................................................................................................1496 Assembly..................................................................................................................1496 Hoist circuit.....................................................................................................................1499 Removal and installation of hoist pump........................................................................................1501 Removal...................................................................................................................1501 Installation..............................................................................................................1502 Disassembly and assembly of hoist pump........................................................................................1503 Disassembly...............................................................................................................1503 Inspection................................................................................................................1506 Assembly..................................................................................................................1506 Removal and installation of hoist valve.......................................................................................1511 Removal...................................................................................................................1511 Installation..............................................................................................................1512 Disassembly and assembly of hoist valve.......................................................................................1512 O-ring replacement........................................................................................................1512 Disassembly of inlet section..............................................................................................1513 Assembly of inlet section.................................................................................................1514 Disassembly of rear spool section.........................................................................................1515 Assembly of rear spool section............................................................................................1517 Disassembly of front spool section........................................................................................1518 Assembly of front spool section...........................................................................................1519 Overcenter valve manifold service.............................................................................................1519 Removal and installation of hoist pilot valve.................................................................................1520 Removal...................................................................................................................1520 Installation..............................................................................................................1520 Disassembly and assembly of hoist pilot valve.................................................................................1521 Disassembly...............................................................................................................1521 Cleaning and inspection...................................................................................................1522 Assembly..................................................................................................................1522 Removal and installation of hoist cylinders...................................................................................1523 Removal...................................................................................................................1523 Installation..............................................................................................................1523 Disassembly and assembly of hoist cylinders...................................................................................1525 Disassembly...............................................................................................................1525 Cleaning and inspection...................................................................................................1527 Installation of the quill.................................................................................................1528 Assembly..................................................................................................................1530 Operator cab......................................................................................................................1533 Removal and installation of operator cab......................................................................................1535 Removal...................................................................................................................1536 Installation..............................................................................................................1537 Removal and installation of cab door..........................................................................................1539 Removal...................................................................................................................1539 Installation..............................................................................................................1539 Disassembly and assembly of cab door..........................................................................................1539 Removing door panel.......................................................................................................1539 Installing door panel.....................................................................................................1540 Replacing door window regulator...........................................................................................1540 Replacing door handle or latch assembly...................................................................................1541 Replacing door assembly seal and door hinge seal..........................................................................1542 Replacing door opening seal...............................................................................................1542 Removing door glass.......................................................................................................1543 Installing door glass.....................................................................................................1544 Adjustment of cab door........................................................................................................1546 Door jamb bolt adjustment.................................................................................................1546 Door handle plunger adjustment............................................................................................1547 Removal and installation of side window glass.................................................................................1548 Recommended tools and supplies............................................................................................1548 Removal...................................................................................................................1549 Installation..............................................................................................................1549 Removal and installation of windshield and rear window glass..................................................................1550 Removal...................................................................................................................1550 Installation..............................................................................................................1550 Removal and installation of windshield wiper motor............................................................................1551 Removal...................................................................................................................1551 Installation..............................................................................................................1551 Removal and installation of windshield wiper arm..............................................................................1552 Removal...................................................................................................................1552 Installation..............................................................................................................1552 Removal and installation of windshield wiper linkage..........................................................................1553 Removal...................................................................................................................1553 Installation..............................................................................................................1553 Removal and installation of operator seat.....................................................................................1554 Inspection................................................................................................................1554 Removal...................................................................................................................1554 Installation..............................................................................................................1554 Removal and installation of passenger seat....................................................................................1555 Removal...................................................................................................................1555 Installation..............................................................................................................1555 Removal and installation of seat belts (standard seats).......................................................................1556 Removal...................................................................................................................1556 Installation..............................................................................................................1556 Removal and installation of seat belts (optional seats).......................................................................1558 General...................................................................................................................1558 Removal...................................................................................................................1558 Installation..............................................................................................................1560 Body and structures...............................................................................................................1565 Removal and installation of dump body.........................................................................................1567 Removal...................................................................................................................1567 Inspection................................................................................................................1568 Installation..............................................................................................................1569 Removal and installation of body pads.........................................................................................1569 Removal...................................................................................................................1569 Installation..............................................................................................................1570 Adjustment................................................................................................................1570 Removal and installation of diagonal ladder/ hood and grille assembly.........................................................1572 Removal...................................................................................................................1572 Installation..............................................................................................................1572 Removal and installation of right deck........................................................................................1573 Removal...................................................................................................................1573 Installation..............................................................................................................1574 Removal and installation of left deck.........................................................................................1576 Removal...................................................................................................................1576 Installation..............................................................................................................1576 Removal and installation of fuel tank.........................................................................................1578 Removal...................................................................................................................1578 Cleaning and inspection...................................................................................................1578 Installation..............................................................................................................1580 Removal and installation of fuel gauge sender.................................................................................1580 Removal...................................................................................................................1580 Installation..............................................................................................................1580 Disassembly and assembly of fuel tank breather................................................................................1581 Disassembly...............................................................................................................1581 Assembly..................................................................................................................1581 Removal and installation of hydraulic tank....................................................................................1582 Removal...................................................................................................................1582 Installation..............................................................................................................1582 Three phase wheel motor...........................................................................................................1585 Qualified personnel...........................................................................................................1586 General.......................................................................................................................1586 General safety information................................................................................................1586 Handling......................................................................................................................1587 Motor.....................................................................................................................1587 Transport.................................................................................................................1588 Storage...................................................................................................................1589 Storage of new motors.....................................................................................................1589 Storage of used motors....................................................................................................1590 Maintenance...................................................................................................................1590 General note:.............................................................................................................1590 Motor.........................................................................................................................1590 General...................................................................................................................1590 Safety guidelines.........................................................................................................1591 Maintenance intervals.........................................................................................................1592 Maintenance work on the installed motor.......................................................................................1592 Checking for external damage..............................................................................................1592 Checking the connections..................................................................................................1593 Regreasing the bearings...................................................................................................1593 Applying grease to the bearings:..........................................................................................1593 Checking the interior of the motor for water..............................................................................1594 Disassembly...................................................................................................................1595 Pressing off the coupling.................................................................................................1596 Disassembly...............................................................................................................1597 Rotor.................................................................................................................1597 Removing the rubber seals and the air baffles.............................................................................1601 Bearing and labyrinth ring................................................................................................1602 Removal...............................................................................................................1602 Maintenance work..............................................................................................................1603 Stator Inspection.........................................................................................................1603 Rotor Inspection..........................................................................................................1603 Testing the insulation....................................................................................................1604 High-voltage test.....................................................................................................1604 Work on the bearings......................................................................................................1605 Assembly......................................................................................................................1606 Assembling the rubber seals and the air baffles...........................................................................1607 Assembly after special repair work........................................................................................1609 Bearing installation..................................................................................................1610 Assemble the bearing..................................................................................................1614 Cover installation....................................................................................................1615 Assembling the bearing shield (N-end) at the stator frame.................................................................1616 Bearing installation......................................................................................................1618 Rotor installation........................................................................................................1620 Labyrinth ring............................................................................................................1622 Installation..........................................................................................................1622 Installing accessories (D- and N-end).....................................................................................1624 Running in the bearings...................................................................................................1628 Coupling..................................................................................................................1629 Installation..........................................................................................................1629 Assembly conditions and instructions......................................................................................1630 Tests.....................................................................................................................1630 Repair work...................................................................................................................1631 Replacing defective connecting leads......................................................................................1631 Repairing the stator winding insulation...................................................................................1632 Recommended consumables...................................................................................................1632 Chemical cleaning agents..................................................................................................1632 Chemical cleaning agents for outdoor use and for cleaning mechanical parts............................................1632 Chemical cleaning agents for flange faces.............................................................................1632 Chemical cleaning agents for windings.....................................................................................1633 Chemical cleaning agents for windings.................................................................................1633 Chemical cleaning agents for windings with severe damage and for oily windings........................................1633 Rolling-contact bearing grease............................................................................................1633 Assembly/disassembly agents for bearing seat..............................................................................1633 Sealants for joining parts or gaps........................................................................................1633 Locking agents for connecting elements....................................................................................1633 Anti-corrosion agent......................................................................................................1633 Assembly paste for temperature sensors....................................................................................1633 List of tools.................................................................................................................1634 Mounting devices for inserting and withdrawing the rotor horizontally.....................................................1634 Press for expanding the coupling..........................................................................................1634 Compression devices for pressing on or for support while pressing off.....................................................1635 Pulling units with cross beam or disk.....................................................................................1637 Aids......................................................................................................................1637 Extraction devices........................................................................................................1638 Repair parts list.............................................................................................................1638 Paints for refinishing the painted parts or touching up damaged parts.....................................................1638 Power module......................................................................................................................1641 Removal and installation of power module......................................................................................1643 General...................................................................................................................1643 Preparation...............................................................................................................1643 Removal...................................................................................................................1644 Installation..............................................................................................................1649 Removal and installation of alternator........................................................................................1651 Removal...................................................................................................................1651 Installation..............................................................................................................1653 Removal and installation of engine............................................................................................1656 Removal...................................................................................................................1656 Service...................................................................................................................1657 Installation..............................................................................................................1657 Removal and installation of radiator..........................................................................................1657 Removal...................................................................................................................1657 Installation..............................................................................................................1659 Repairing the radiator........................................................................................................1660 Internal inspection.......................................................................................................1660 External cleaning.........................................................................................................1660 Disassembly...............................................................................................................1661 Cleaning and inspection...................................................................................................1662 Assembly..................................................................................................................1662 Pressure testing..........................................................................................................1663 Auto lubrication system...........................................................................................................1665 Lubrication system priming....................................................................................................1666 Disassembly and assembly of lubrication pump..................................................................................1666 Disassembly...............................................................................................................1666 Cleaning and Inspection...................................................................................................1668 Assembly..................................................................................................................1668 Main blower.......................................................................................................................1671 Removing the main blower motor................................................................................................1672 Disassembling the main blower motor...........................................................................................1678 Assembling the main blower motor..............................................................................................1680 Installing the main blower motor..............................................................................................1683 Retarding grid....................................................................................................................1691 Removing the grid blower motor................................................................................................1692 Disassembling the grid blower motor...........................................................................................1694 Assembling the grid blower motor..............................................................................................1696 Installing the grid blower motor..............................................................................................1698 Removing a grid element.......................................................................................................1701 Control cabinet...................................................................................................................1705 Draining and filling the IGBT coolant system..................................................................................1707 Required tools/materials..................................................................................................1707 Coolant mixture specification (distilled water : Antifrogen N)............................................................1707 Draining and filling the coolant..........................................................................................1708 Removing and installing the IGBT coolant pump assembly........................................................................1711 Required tools/materials..................................................................................................1711 Removal...................................................................................................................1712 90 Diagrams and drawings .............................................................................................................1715 Hydraulic circuit diagrams........................................................................................................1715 EM1374 Hydraulic schematic ...................................................................................................1717 EM6298 Brake schematic .......................................................................................................1718 Electrical circuit diagrams.......................................................................................................1719 XS6701 Electric schematic ....................................................................................................1723 HE488 Connector table and arrangment .........................................................................................1761 Electrical circuit diagrams - drive system........................................................................................1762 HE486 Electric schematic .....................................................................................................1766 XS3381 Electric schematic ....................................................................................................1813
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