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KOMATSU 860E-1KT DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30036 & UP) KOMATSU 860E 1KT – PDF DOWNLOAD
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- KOMATSU 860E-1KT DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30036 & UP
- PUBLICATION NUMBER:CEBM025801
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KOMATSU 860E-1KT DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30036 & UP) KOMATSU 860E 1KT
KOMATSU 860E-1KT DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30036 & UP) KOMATSU 860E 1KT – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 860E-1KT DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30036 & UP) KOMATSU 860E 1KT
- This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions should be understood and followed when operating the truck or performing repairs on the truck.
- The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example, the disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs.
- The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck.
- This manual shows dimensioning of U.S. standard and metric (SI) units throughout. All references to โright,โ โleft,โ โfront,โ or โrearโ are made with respect to the operator’s normal seated position unless specifically stated otherwise.
- When assembly instructions are provided without references to specific torque values, standard torque values should be used. Standard torque values are shown in torque charts later in this section. Specific torques, when provided in the text, are in bold face type, such as 135 Nm (100 ft lb). All torque specifications have ยฑ10% tolerance unless otherwise specified.
- A product identification plate is located on the frame in front of the right side front wheel. It designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight) rating.
- The KOMATSU truck model designation consists of three numbers and one letter (i.e. 930E). The three numbers represent the basic truck model. The letter โEโ designates an Electrical wheel motor drive system.
- The Product Identification Number (vehicle serial number) contains information which identifies several characteristics of this unit. For a more detailed explanation, refer to the Operation and Maintenance Manual.
- The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the maximum GVW. GVW is total weight: empty vehicle weight + fuel & lubricants + payload.
TABLE OF CONTENTS:
KOMATSU 860E-1KT DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30036 & UP) KOMATSU 860E 1KT
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 Trinaryโข 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 circuit .................................................................................................................... 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 lines and test ports.................................................................................................... 182 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 U101ล U104 (Current to motor A)............................................................................................ 230 U105ล U106 (Current to chopper A-C)........................................................................................ 230 U201ล U204 (Current to motor B)............................................................................................ 230 U205ล U206 (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 (SiBASยฎ 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: PT101ล PT103 [Sensors for inverters A101ล A103]........................................................... 238 PT201ล PT203 [Sensors for inverters A201ล A203]......................................................................... 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 ล inverter/chopper phase module...................................................................................... 249 Device names: A101ล A103 (Inverter A section).......................................................................... 249 A201ล A203 (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 SIBASยฎ IGBT rack components....................................................................................................... 261 SiBASยฎ32 Traction Control Unit (TCU).......................................................................................... 263 Overview of the SiBASยฎ32 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 SiBASยฎ32 cards.................................................................................... 268 Removal with 24V OFF! (ESD protection required)........................................................................... 268 Installation with 24V OFF! (ESD protection required)...................................................................... 268 SiBASยฎ32 card device names.................................................................................................... 269 Structure of SiBASยฎ32 card part number........................................................................................ 270 Development status, downward compatibility................................................................................ 270 SiBASยฎ32 card interchangeability.............................................................................................. 271 Use of service interfaces................................................................................................. 272 Connection of the service unit............................................................................................ 272 Maintenance............................................................................................................... 272 Cleaning.................................................................................................................. 273 SiBASยฎ32 card interactions.................................................................................................... 274 SiBASยฎ32 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 Steering, brake cooling and hoist hydraulic system ............................................................................... 367 General information on system checkout........................................................................................ 369 Steering system checkout procedures........................................................................................... 369 Steering pump pressure control adjustments................................................................................ 370 Steering control valve and flow amplifier leakage test.................................................................... 371 Bleed down manifold leakage test.......................................................................................... 372 Shock and suction valve pressure tests.................................................................................... 373 Steering system checkout data sheet........................................................................................... 375 Toe-in adjustment............................................................................................................. 376 Brake cooling and hoist system checkout procedures............................................................................ 377 Pressure gauge locations.................................................................................................. 377 Brake cooling circuit test................................................................................................ 378 Power up relief pressure test............................................................................................. 378 Power down relief pressure test........................................................................................... 379 Counterbalance valve pressure check....................................................................................... 380 Counterbalance valve adjustment........................................................................................... 381 Brake cooling and hoist system checkout data sheet............................................................................ 382 Hydraulic system flushing..................................................................................................... 383 Hydraulic System Flushing Procedure....................................................................................... 383 Front suspension pressure test................................................................................................ 390 Rear suspension pressure test................................................................................................. 390 Steering cylinder leakage test................................................................................................ 391 Hoist cylinder leakage test................................................................................................... 391 Brake system ..................................................................................................................... 393 General information on system checkout........................................................................................ 394 Brake circuit checkout procedure.............................................................................................. 394 Initial system setup...................................................................................................... 395 Brake lock / secondary braking checkout................................................................................... 396 Parking brake checkout.................................................................................................... 398 Service brake checkout.................................................................................................... 401 Blended braking checkout.................................................................................................. 401 Low brake accumulator pressure and auto apply checkout.................................................................... 402 Parking brake control logic checkout...................................................................................... 404 Auto apply solenoid hydraulic circuit troubleshooting..................................................................... 405 Brake lock control logic checkout......................................................................................... 406 Brake system checkout data sheet.............................................................................................. 409 Brake piston leakage test..................................................................................................... 414 Wet disc brake bleeding procedure............................................................................................. 414 Parking brake bleeding procedure.............................................................................................. 415 Parking brake leakage test.................................................................................................... 415 Brake valve bench test and adjustment......................................................................................... 416 Test setup procedure...................................................................................................... 417 Brake valve output pressure adjustment.................................................................................... 417 Final test and adjustment................................................................................................. 418 Dual relay valve bench test and adjustment.................................................................................... 419 Test setup procedure...................................................................................................... 420 Relay valve output pressure adjustment.................................................................................... 420 Accumulators and suspensions ..................................................................................................... 423 Accumulator charging and storage.............................................................................................. 425 Accumulator charging procedures........................................................................................... 425 Precharge maintenance..................................................................................................... 428 Accumulator storage procedure............................................................................................. 429 Bladder storage........................................................................................................... 429 Installing a bladder accumulator from storage............................................................................. 429 Accumulator leak testing...................................................................................................... 430 Suspension oiling and charging procedures..................................................................................... 432 Equipment list............................................................................................................ 432 Installing the charging kit............................................................................................... 432 Removing the charging kit................................................................................................. 433 Support blocks for oiling and charging dimensions......................................................................... 433 Front suspension oiling................................................................................................... 434 Front suspension nitrogen charging........................................................................................ 435 Rear suspension oiling.................................................................................................... 437 Rear suspension nitrogen charging......................................................................................... 439 Suspension pressure test...................................................................................................... 440 Payload meter .................................................................................................................... 443 Payload meter initial setting procedure....................................................................................... 445 Starting communications................................................................................................... 445 Configure payload meter................................................................................................... 445 Setting truck number...................................................................................................... 447 Clean truck tare.......................................................................................................... 448 Inclinometer calibration.................................................................................................. 448 KOMTRAX Plus...................................................................................................................... 451 KOMTRAX Plus and payload meter software....................................................................................... 453 VHMS Tool Box Installation................................................................................................ 453 VHMS Setting Tool Installation............................................................................................ 453 Installing the PDM software............................................................................................... 453 KOMTRAX Plus controller initial setting procedure............................................................................. 454 KOMTRAX Plus controller setup procedure................................................................................... 454 KOMTRAX Plus snapshot procedure........................................................................................... 457 KOMTRAX Plus download procedure........................................................................................... 458 KOMTRAX Plus FTP upload procedure......................................................................................... 459 KOMTRAX Plus initialization forms......................................................................................... 460 KOMTRAX Plus initialization check list........................................................................................ 461 KOMTRAX Plus initialization form.............................................................................................. 463 Precautions for replacing KOMTRAX Plus controller............................................................................. 464 KOMTRAX Plus controller checkout procedure.................................................................................... 469 Necessary equipment....................................................................................................... 469 Preliminary............................................................................................................... 469 Checkout procedure........................................................................................................ 470 Interface module ................................................................................................................. 473 Interface module software..................................................................................................... 474 Flashburn program installation............................................................................................ 474 Interface module application code installation............................................................................ 475 Interface module realtime data monitor software installation.............................................................. 475 Interface module checkout procedures.......................................................................................... 476 Necessary equipment....................................................................................................... 476 Preliminary............................................................................................................... 477 Check digital inputs to the interface module.............................................................................. 478 Check analog inputs to the interface module............................................................................... 481 Check serial interfaces to the interface module........................................................................... 482 Check outputs from the interface module................................................................................... 482 IGBT haul truck SIBASยฎ user manual, part 1........................................................................................ 485 Abbreviations................................................................................................................. 487 Precautions................................................................................................................... 489 Qualified person.............................................................................................................. 489 Customer monitor for SIBASยฎ 32 control units.................................................................................. 489 Product description....................................................................................................... 489 Version management........................................................................................................ 490 Overview.................................................................................................................. 491 Requirements.............................................................................................................. 491 Installing and calling the customer monitor................................................................................... 492 Installation.................................................................................................................. 492 Environment variables..................................................................................................... 492 Communication with the SIBASยฎ 32 control unit................................................................................. 493 Calling up the customer monitor............................................................................................... 494 Start-up prompt........................................................................................................... 494 Monitor prompt............................................................................................................ 495 Notes on operation of the customer monitor.................................................................................... 496 Structure of a monitor command................................................................................................ 496 Step 1: Selecting the menu title.......................................................................................... 496 Step 2: Selecting a menu entry in the menu box............................................................................ 496 Step 3: Selecting a dialog box, if available.............................................................................. 497 Step 4: Entering file or connector/signal names........................................................................... 497 Command buffer................................................................................................................ 498 Structure of the monitor windows.............................................................................................. 498 Window menu................................................................................................................... 499 Commands for Opening, Altering and Closing Windows........................................................................ 499 "Window Work open"............................................................................................................ 499 "Window Lines open"........................................................................................................... 499 "Window Tile"................................................................................................................. 499 "Window Bars open"............................................................................................................ 499 Options................................................................................................................... 499 "Window Set".................................................................................................................. 499 Options................................................................................................................... 499 "Window Cascade".............................................................................................................. 499 "Window Close"................................................................................................................ 499 "Window close All"............................................................................................................ 499 "Window Exit"................................................................................................................. 499 Set Menu...................................................................................................................... 500 "Set Port".................................................................................................................... 500 Options................................................................................................................... 500 "Set Baudrate"................................................................................................................ 500 Options................................................................................................................... 500 "Set String".................................................................................................................. 501 Example................................................................................................................... 502 "Set Make".................................................................................................................... 502 Options................................................................................................................... 502 Example 1: INIT.MON start-up control of the Customer Monitor.............................................................. 503 Example 2: Any monitor batch file with freely selectable file name (incl. path)........................................... 503 "Set Execute"................................................................................................................. 504 Options................................................................................................................... 504 Example................................................................................................................... 504 "Set Record".................................................................................................................. 504 Options................................................................................................................... 504 "Set DIN-Bus"................................................................................................................. 505 "Set TCN"..................................................................................................................... 505 "Set Timeout"................................................................................................................. 505 Options................................................................................................................... 505 "Set Wait".................................................................................................................... 505 Options................................................................................................................... 505 "Set Color"................................................................................................................... 505 Options................................................................................................................... 505 "Set Info".................................................................................................................... 506 "Set comment"................................................................................................................. 506 "Set CHAR Set"................................................................................................................ 506 "Set Quit".................................................................................................................... 506 Applic. Menu.................................................................................................................. 507 "Applic. Func.Package"........................................................................................................ 507 "Applic. Connector"........................................................................................................... 508 Options................................................................................................................... 508 Example................................................................................................................... 509 "Applic. View"................................................................................................................ 509 Options................................................................................................................... 509 Example................................................................................................................... 509 "Applic. Signal".............................................................................................................. 509 "Applic. Observer"............................................................................................................ 510 Options................................................................................................................... 510 Possible time slices:..................................................................................................... 510 Options................................................................................................................... 511 Two options............................................................................................................... 511 Notes on the display of connectors........................................................................................ 513 "Applic. Buffer".............................................................................................................. 514 Options................................................................................................................... 514 "Applic. Report".............................................................................................................. 514 "Applic. Legitimation"........................................................................................................ 514 Options................................................................................................................... 514 "Applic. Menu"................................................................................................................ 515 "Applic. Traco"............................................................................................................... 515 Options................................................................................................................... 515 "Applic. Environment"......................................................................................................... 515 Hardw. Menu................................................................................................................... 517 Hardware-Oriented Access via the Customer Monitor......................................................................... 517 "Hardw. Flash"................................................................................................................ 517 Options................................................................................................................... 517 Requirements.............................................................................................................. 517 Example................................................................................................................... 518 Deleting and loading...................................................................................................... 518 The EPROM for the communication drivers................................................................................... 518 "Hardw. Clock"................................................................................................................ 518 Options................................................................................................................... 518 "Hardw. DSP".................................................................................................................. 519 "Hardw. BCD".................................................................................................................. 519 Options................................................................................................................... 519 Example................................................................................................................... 519 "Hardw. RESET"................................................................................................................ 519 Options................................................................................................................... 519 "Hardw. Info"................................................................................................................. 520 Hardware/Operating system................................................................................................. 520 Application and tools..................................................................................................... 520 Communication module...................................................................................................... 520 Displaying the loading date............................................................................................... 520 "Hardw. User Flash"........................................................................................................... 521 Options................................................................................................................... 521 "Hardw. Sys. Flash"........................................................................................................... 521 Options................................................................................................................... 521 "Hardw. BOOT DSP"............................................................................................................. 522 Requirements.............................................................................................................. 522 DSP5600x Signal Processing Unit and TRACO................................................................................. 522 Inverter processing unit.................................................................................................. 524 Access to the Signal Processing Unit...................................................................................... 524 "Hardw. Flash"................................................................................................................ 524 Options................................................................................................................... 524 Requirements.............................................................................................................. 524 Example................................................................................................................... 524 Deleting and loading...................................................................................................... 525 The EPROM for the communication drivers................................................................................... 525 User Data Flash (UDF)..................................................................................................... 525 "Hardw. RESET"................................................................................................................ 525 Options................................................................................................................... 525 "Hardw. ZR"................................................................................................................... 526 "Hardw. BOOT ZR".............................................................................................................. 526 The following procedure is necessary:..................................................................................... 526 Graphic Menu.................................................................................................................. 527 Commands for Displaying Line Graphics..................................................................................... 527 "Graphic Load"................................................................................................................ 527 Options................................................................................................................... 527 "Graphic Position"............................................................................................................ 527 Options................................................................................................................... 527 "Graphic Time/Div"............................................................................................................ 528 Options................................................................................................................... 528 "Graphic Unit/Div"............................................................................................................ 528 Options................................................................................................................... 528 "Graphic Display"............................................................................................................. 528 Options................................................................................................................... 528 "Graphic Color"............................................................................................................... 529 Options................................................................................................................... 529 "Graphic Format".............................................................................................................. 529 Options................................................................................................................... 529 IGBT haul truck SIBASยฎ user manual, part 2........................................................................................ 531 Traco Menu.................................................................................................................... 533 HW-Traco...................................................................................................................... 533 Options................................................................................................................... 534 SW-Traco...................................................................................................................... 535 Options................................................................................................................... 536 ZR traco basic parameters:................................................................................................ 536 ZR traco record signal table:............................................................................................. 536 DAC_Traco..................................................................................................................... 539 Options................................................................................................................... 540 Events Menu................................................................................................................... 541 STatistics.................................................................................................................... 542 History....................................................................................................................... 543 LEL:Last EvL.................................................................................................................. 544 LES:Last EvS.................................................................................................................. 546 DLL:DC,LastL.................................................................................................................. 547 DLS:DC,LastS.................................................................................................................. 548 DAL:DC,All L.................................................................................................................. 549 DAS:DC,All S.................................................................................................................. 550 ML:Memory L................................................................................................................... 551 MS:Memory S................................................................................................................... 552 CN:Clear Norm................................................................................................................. 553 CA:Clear All.................................................................................................................. 553 Test-Code..................................................................................................................... 553 DS:Diag-Strc.................................................................................................................. 554 User Menu..................................................................................................................... 555 DAC_IO........................................................................................................................ 556 Options................................................................................................................... 556 Options................................................................................................................... 557 Operat.Data............................................................................................................... 558 Acc test...................................................................................................................... 565 Engine_Test................................................................................................................... 565 X_Test_Inx.................................................................................................................... 568 STate intern.................................................................................................................. 569 Header:................................................................................................................... 569 Vehicle Number:........................................................................................................... 569 Powering system:.......................................................................................................... 569 TCU Operation Mode:....................................................................................................... 569 Component status listings:................................................................................................ 570 Field regulator status:................................................................................................... 570 Status gate unit power supply A:.......................................................................................... 570 Status gate unit power supply B:.......................................................................................... 570 ST inverter status........................................................................................................ 571 Vehicle status............................................................................................................ 571 Drive status:............................................................................................................. 571 Operation status:......................................................................................................... 572 Pedal calib................................................................................................................... 573 Language...................................................................................................................... 574 OFFline-test.................................................................................................................. 574 Options................................................................................................................... 574 Variables..................................................................................................................... 575 Examples:................................................................................................................. 575 IV:Vehic-ID................................................................................................................... 577 Commands...................................................................................................................... 577 Discharge Dc link / Fire crowbar.......................................................................................... 578 Limp mode commands........................................................................................................ 578 Settings...................................................................................................................... 579 Parameters.................................................................................................................... 580 Temp_prot..................................................................................................................... 582 Appendix...................................................................................................................... 584 Background commands........................................................................................................... 584 Monitor commands for the central processing unit.............................................................................. 585 Monitor commands for the signal processing unit............................................................................... 585 Installing ZR / DSP software...................................................................................................... 587 Monitor Program โ Loading software into the SIBASยฎ............................................................................ 588 Loading software into the DSP procedure....................................................................................... 588 Loading a DSP program Inverter A.............................................................................................. 593 Loading ZR software Prog. jumpers Reset....................................................................................... 607 24V electrical system ............................................................................................................ 611 Body position switches (with proximity switches and metal arms)............................................................... 612 Body up switch adjustment................................................................................................. 612 Hoist limit switch adjustment............................................................................................. 613 Service................................................................................................................... 613 Body position switches (with proximity switches and magnets).................................................................. 614 Body up switch adjustment................................................................................................. 614 Hoist limit switch adjustment............................................................................................. 614 Service................................................................................................................... 614 40 Troubleshooting.................................................................................................................... 619 Cab air conditioning.............................................................................................................. 619 Preliminary checks............................................................................................................ 621 Diagnosis of gauge readings and system performance............................................................................ 621 Troubleshooting by manifold gauge set readings................................................................................ 622 Fuse and circuit breaker locations................................................................................................ 629 Fuse and circuit breaker locations............................................................................................ 630 Troubleshooting by fault code, part 1............................................................................................. 635 Fault Code A001: Left front suspension pressure sensor signal high............................................................ 637 Related circuit diagram................................................................................................... 637 Fault Code A002: Left front suspension pressure sensor signal low............................................................. 638 Related circuit diagram................................................................................................... 638 Fault Code A003: Right front suspension pressure sensor signal high........................................................... 639 Related circuit diagram................................................................................................... 639 Fault Code A004: Right front suspension pressure sensor signal low............................................................ 640 Related circuit diagram................................................................................................... 640 Fault Code A005: Left rear suspension pressure sensor signal high............................................................. 641 Related circuit diagram................................................................................................... 641 Fault Code A006: Left rear suspension pressure sensor signal low.............................................................. 642 Related circuit diagram................................................................................................... 642 Fault Code A007: Right rear suspension pressure sensor signal high............................................................ 643 Related circuit diagram................................................................................................... 643 Fault Code A008: Right rear suspension pressure sensor signal low............................................................. 644 Related circuit diagram................................................................................................... 644 Fault Code A009: Incline sensor signal high................................................................................... 645 Related circuit diagram................................................................................................... 645 Fault Code A010: Incline sensor signal low.................................................................................... 646 Related circuit diagram................................................................................................... 646 Fault Code A011: Payload meter speed sensor signal has failed................................................................. 647 Related circuit diagram................................................................................................... 647 Fault Code A013: Body up switch has failed.................................................................................... 648 Related circuit diagram................................................................................................... 648 Fault Code A014: Payload meter checksum computation has failed................................................................ 649 Related circuit diagram................................................................................................... 649 Fault Code A016: Payload meter write to flash memory has failed............................................................... 650 Related circuit diagram................................................................................................... 650 Fault Code A017: Payload meter flash memory read has failed................................................................... 651 Related circuit diagram................................................................................................... 651 Fault Code A018: Right rear flat suspension cylinder warning.................................................................. 652 Related circuit diagram................................................................................................... 653 Fault Code A019: Left rear flat suspension cylinder warning................................................................... 654 Related circuit diagram................................................................................................... 655 Fault Code A022: Carryback load excessive..................................................................................... 656 Related circuit diagram................................................................................................... 657 Fault Code A100: An open circuit breaker has been detected on a relay board................................................... 659 Related circuit diagram................................................................................................... 659 Fault Code A101: High pressure detected across an hydraulic pump filter....................................................... 660 Related circuit diagram................................................................................................... 661 Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level...................................... 662 Related circuit diagram................................................................................................... 663 Fault Code A111: Low steering pressure warning for storage by VHMS............................................................ 664 Related circuit diagram................................................................................................... 664 Fault Code A115: Low steering precharge pressure detected..................................................................... 666 Related circuit diagram................................................................................................... 667 Fault Code A117: Low brake accumulator pressure warning for storage by VHMS................................................... 668 Related circuit diagram................................................................................................... 668 Fault Code A118: Brake pressure is low while in brake lock.................................................................... 670 Related circuit diagram................................................................................................... 671 Fault Code A126: Oil level in the hydraulic tank is low....................................................................... 672 Related circuit diagram................................................................................................... 672 Fault Code A127: IM-furnished +5 volt output for sensors is low............................................................... 674 Related circuit diagram................................................................................................... 675 Fault Code A128: IM-furnished +5 volt output for sensors is high.............................................................. 676 Related circuit diagram................................................................................................... 677 Fault Code A139: Low fuel warning for storage by VHMS and for use by A310..................................................... 678 Related circuit diagram................................................................................................... 679 Troubleshooting by fault code, part 2............................................................................................. 681 Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil.... 684 Related circuit diagram................................................................................................... 685 Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil.... 686 Related circuit diagram................................................................................................... 687 Fault Code A152: Starter failure.............................................................................................. 688 Related circuit diagram................................................................................................... 689 Fault Code A153: Battery voltage is low with the truck in operation........................................................... 690 Related circuit diagram................................................................................................... 691 Fault Code A154: Battery charging voltage is excessive........................................................................ 692 Related circuit diagram................................................................................................... 692 Fault Code A155: Battery charging voltage is low.............................................................................. 693 Related circuit diagram................................................................................................... 693 Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level................................. 694 Related circuit diagram................................................................................................... 695 Fault Code A159: (A30003 only) The battery 12 Volt circuit sensing is producing low readings.................................. 696 Related circuit diagram................................................................................................... 696 Fault Code A164: (A30003 only) The battery 12 Volt circuit sensing is producing high readings................................. 697 Related Circuit Diagram................................................................................................... 697 Fault Code A166: Left rear hydraulic oil temperature sensor is low............................................................ 698 Related circuit diagram................................................................................................... 699 Fault Code A167: Right rear hydraulic oil temperature sensor is low........................................................... 700 Related circuit diagram................................................................................................... 701 Fault Code A168: Left front hydraulic oil temperature sensor is low........................................................... 702 Related circuit diagram................................................................................................... 703 Fault Code A169: Right front hydraulic oil temperature sensor is low.......................................................... 704 Related circuit diagram................................................................................................... 705 Fault Code A170: Left rear hydraulic oil temperature sensor is high........................................................... 706 Related circuit diagram................................................................................................... 706 Fault Code A171: Right rear hydraulic oil temperature sensor is high.......................................................... 707 Related circuit diagram................................................................................................... 707 Fault Code A172: Left front hydraulic oil temperature sensor is high.......................................................... 708 Related circuit diagram................................................................................................... 708 Fault Code A173: Right front hydraulic oil temperature sensor is high......................................................... 709 Related circuit diagram................................................................................................... 709 Fault Code A182: (A30003 only) The battery 12 Volt battery tap has high voltage............................................... 710 Related circuit diagram................................................................................................... 711 Fault Code A183: (A30003 only) The battery 12 Volt battery tap has low voltage................................................ 712 Related circuit diagram................................................................................................... 713 Fault Code A184: J1939 data link is not connected............................................................................. 714 Related circuit diagram................................................................................................... 715 Fault Code A190: (A30003 only) The automatic lubrication system has announced a fault......................................... 716 Fault Code A190: (A30004 & Up) Auto lube control has detected an incomplete lube cycle........................................ 718 Related circuit diagram................................................................................................... 719 Fault Code A194: Left front hydraulic oil temperature is high................................................................. 720 Related circuit diagram................................................................................................... 720 Fault Code A195: Right front hydraulic oil temperature is high................................................................ 721 Related circuit diagram................................................................................................... 721 Fault Code A196: Left rear hydraulic oil temperature is high.................................................................. 722 Related circuit diagram................................................................................................... 722 Fault Code A197: Right rear hydraulic oil temperature is high................................................................. 723 Related circuit diagram................................................................................................... 723 Fault Code A198: Hoist pressure 1 sensor is high.............................................................................. 724 Related circuit diagram................................................................................................... 724 Fault Code A199: Hoist pressure 2 sensor is high.............................................................................. 725 Related circuit diagram................................................................................................... 725 Fault Code A200: Steering pressure sensor is high............................................................................. 726 Related circuit diagram................................................................................................... 726 Fault Code A201: Brake pressure sensor is high................................................................................ 727 Related circuit diagram................................................................................................... 727 Fault Code A202: Hoist pressure 1 sensor is low............................................................................... 728 Related circuit diagram................................................................................................... 728 Fault Code A203: Hoist pressure 2 sensor is low............................................................................... 729 Related circuit diagram................................................................................................... 729 Fault Code A204: Steering pressure sensor is low.............................................................................. 730 Related circuit diagram................................................................................................... 730 Fault Code A205: Brake pressure sensor is low................................................................................. 731 Related circuit diagram................................................................................................... 731 Fault Code A206: Ambient temperature sensor is high........................................................................... 732 Related circuit diagram................................................................................................... 732 Fault Code A207: Ambient temperature sensor is low............................................................................ 733 Related circuit diagram................................................................................................... 733 Troubleshooting by fault code, Part 3............................................................................................. 735 Fault Code A213: Parking brake should have applied but is detected as not having applied...................................... 737 Related circuit diagram................................................................................................... 740 Fault Code A214: Parking brake should have released but is detected as not having released.................................... 742 Related circuit diagram................................................................................................... 744 Fault Code A215: Brake auto apply valve circuit is defective.................................................................. 746 Related circuit diagram................................................................................................... 747 Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit...................... 748 Related circuit diagram................................................................................................... 749 Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted.................................... 750 Related circuit diagram................................................................................................... 751 Fault Code A230: Parking brake has been requested while truck still moving.................................................... 752 Related circuit diagram................................................................................................... 753 Fault Code A231: The body is up while traveling or with selector in forward or neutral........................................ 754 Fault Code A233: Drive System Control Link is not connected................................................................... 756 Related circuit diagram................................................................................................... 757 Fault Code A235: Steering accumulator is in the process of being bled down.................................................... 758 Related circuit diagram................................................................................................... 759 Fault Code A236: The steering accumulator has not properly bled down after 90 seconds......................................... 760 Related circuit diagram................................................................................................... 761 Fault Code A237: The CAN/RPC connection to the display is open................................................................ 762 Related circuit diagram................................................................................................... 763 Fault Code A238: Drive System and IM are reporting different park brake status................................................ 764 Related circuit diagram................................................................................................... 765 Fault Code A239: The Drive System and IM are reporting different brake lock status............................................ 766 Related circuit diagram................................................................................................... 767 Fault Code A240: The keyswitch input to the Interface Module is open.......................................................... 768 Related circuit diagram................................................................................................... 768 Fault Code A242: Fuel gauge within the dash display panel is defective........................................................ 769 Related circuit diagram................................................................................................... 769 Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective.................................. 770 Related circuit diagram................................................................................................... 770 Fault Code A244: Drive system temperature gauge within the dash display panel is defective.................................... 771 Related circuit diagram................................................................................................... 771 Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective................................... 772 Related circuit diagram................................................................................................... 772 Fault Code A246: Payload meter reports truck overload......................................................................... 773 Related circuit diagram................................................................................................... 773 Fault Code A247: Low steering pressure warning for display to operator........................................................ 774 Related circuit diagram................................................................................................... 774 Fault Code A248: Status module within the dash display panel is defective..................................................... 775 Related circuit diagram................................................................................................... 775 Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted........................................... 776 Related circuit diagram................................................................................................... 776 Fault Code A250: Battery voltage is low with the truck parked................................................................. 777 Related circuit diagram................................................................................................... 778 Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground.............................. 779 Related circuit diagram................................................................................................... 780 Fault Code A252: Start enable output circuit is either open or shorted to ground.............................................. 781 Related circuit diagram................................................................................................... 781 Fault Code A253: Steering bleed circuit is not open while running............................................................. 782 Related circuit diagram................................................................................................... 783 Fault Code A254: (A30003 Only) The 5 minute idle circuit is either open or shorted to ground.................................. 784 Related circuit diagram................................................................................................... 784 Fault Code A256: Red warning lamp in the dash display (driven by IM) is open.................................................. 785 Related circuit diagram................................................................................................... 785 Fault Code A257: Payload CAN/RPC is not connected............................................................................. 786 Related circuit diagram................................................................................................... 787 Fault Code A258: Steering accumulator bleed pressure switch circuit is defective.............................................. 788 Related circuit diagram................................................................................................... 788 Troubleshooting by fault code, Part 4............................................................................................. 791 Fault Code A260: Park brake failure........................................................................................... 794 Related circuit diagram................................................................................................... 795 Fault Code A261: Low brake accumulator pressure warning for display to operator............................................... 796 Related circuit diagram................................................................................................... 796 Fault Code A262: Steering bleed valve circuit open during shutdown............................................................ 798 Related circuit diagram................................................................................................... 799 Fault Code A264: Park brake relay circuit is defective........................................................................ 800 Related circuit diagram................................................................................................... 801 Fault Code A265: Service brake failure........................................................................................ 802 Related circuit diagram................................................................................................... 803 Fault Code A266: Selector switch was not in park while attempting to crank engine............................................. 804 Related circuit diagram................................................................................................... 804 Fault Code A267: Park brake was not set while attempting to crank engine...................................................... 805 Related circuit diagram................................................................................................... 805 Fault Code A268: Secondary engine shutdown while cranking..................................................................... 806 Related circuit diagram................................................................................................... 806 Fault Code A270: Brake lock switch power supply is not on when required....................................................... 808 Related circuit diagram................................................................................................... 809 Fault Code A271: Shifter not in gear.......................................................................................... 810 Related circuit diagram................................................................................................... 811 Fault Code A272: Brake lock switch power supply is not off when required...................................................... 812 Related circuit diagram................................................................................................... 813 Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit....................... 814 Related circuit diagram................................................................................................... 814 Fault Code A274: A brake setting fault has been detected...................................................................... 816 Related circuit diagram................................................................................................... 817 Fault Code A275: A starter has been detected as engaged without a cranking attempt............................................ 818 Related circuit diagram................................................................................................... 819 Fault Code A277: Park brake applied while loading............................................................................. 820 Related circuit diagram................................................................................................... 821 Fault Code A278: Service brake applied while loading.......................................................................... 822 Related circuit diagram................................................................................................... 823 Fault Code A279: Low Steering Pressure Switch bad............................................................................. 824 Related circuit diagram................................................................................................... 824 Fault Code A280: Steering accumulator bled switch bad......................................................................... 825 Related circuit diagram................................................................................................... 825 Fault Code A281: Brake lock degrade switch bad................................................................................ 826 Related circuit diagram................................................................................................... 827 Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7............. 828 Related circuit diagram................................................................................................... 829 Fault Code A283: (A30004 & Up) An engine shutdown delay was aborted because the parking brake was not set..................... 830 Related circuit diagram................................................................................................... 831 Fault Code A284: (A30004 & Up) An engine shutdown delay was aborted because the secondary shutdown switch was operated........ 832 Related circuit diagram................................................................................................... 833 Fault Code A285: (A30004 & Up) The park brake was not set when the keyswitch was turned off................................... 834 Related circuit diagram................................................................................................... 835 Fault Code A286: (A30004 & Up) A fault was detected in the shutdown delay relay circuit....................................... 836 Related circuit diagram................................................................................................... 837 Fault Code A292: (A30004 & Up) The shutdown delay relay has remained on after the latched keyswitch circuit is off............ 838 Related circuit diagram................................................................................................... 839 Fault Code A295: The right front park brake is not setting up................................................................. 840 Related circuit diagram................................................................................................... 840 Fault Code A296: The left front park brake is not setting up.................................................................. 841 Related circuit diagram................................................................................................... 841 Fault Code A297:The right rear park brake is not setting up................................................................... 842 Related circuit diagram................................................................................................... 842 Fault Code A298: The left rear park brake is not setting up................................................................... 843 Related circuit diagram................................................................................................... 843 Fault Code A299: The right front park brake is not releasing.................................................................. 844 Related circuit diagram................................................................................................... 844 Fault Code A300: The left front park brake is not releasing................................................................... 845 Related circuit diagram................................................................................................... 845 Fault Code A301: The right rear park brake is not releasing................................................................... 846 Related circuit diagram................................................................................................... 846 Fault Code A302: The left rear park brake is not releasing.................................................................... 847 Related circuit diagram................................................................................................... 847 Troubleshooting by fault code, part 5............................................................................................. 849 Fault Code A303: Shifter is defective......................................................................................... 852 Related circuit diagram................................................................................................... 853 Fault Code A304: (A30004 & Up) Auto lube grease level fault................................................................... 854 Related circuit diagram................................................................................................... 854 Fault Code A305: (A30004 & Up) Auto lube circuit is defective................................................................. 856 Related circuit diagram................................................................................................... 857 Fault Code A309: No brakes applied when expected.............................................................................. 858 Related circuit diagram................................................................................................... 859 Fault Code A310: Low fuel warning............................................................................................. 860 Related circuit diagram................................................................................................... 861 Fault Code A311: Brake lock switch is on when it should not be................................................................ 862 Related circuit diagram................................................................................................... 863 Fault Code A312: (A30004 & Up) DCDC converter 12 volt circuit sensing is producing low readings............................... 864 Related circuit diagram................................................................................................... 864 Fault Code A313: (A30004 & Up) DCDC converter 12 volt circuit sensing is producing high readings.............................. 865 Related circuit diagram................................................................................................... 865 Fault Code A315: (A30004 & Up) DCDC converter 12 volt circuit is low.......................................................... 866 Related circuit diagram................................................................................................... 867 Fault Code A316: Starter engagement has been attempted with engine running.................................................... 868 Related circuit diagram................................................................................................... 869 Fault Code A317: Operation of brake auto apply valve without a detected response.............................................. 870 Related circuit diagram................................................................................................... 871 Fault Code A318: Unexpected power loss to Interface Module.................................................................... 872 Related circuit diagram................................................................................................... 872 Fault Code A328: Drive system not powered up.................................................................................. 873 Related circuit diagram................................................................................................... 873 Fault Code A350: Overload on output 1B........................................................................................ 874 Related circuit diagram................................................................................................... 874 Fault Code A351: Overload on output 1E........................................................................................ 876 Related circuit diagram................................................................................................... 877 Fault Code A352: (A30003) Overload on output 1H............................................................................... 878 Related circuit diagram................................................................................................... 878 Fault Code A352: (A30004 & Up) Overload on output 1H.......................................................................... 879 Related circuit diagram................................................................................................... 879 Fault Code A353: Overload on output 1J........................................................................................ 880 Related circuit diagram................................................................................................... 880 Fault Code A354: Overload on output 1K........................................................................................ 881 Related circuit diagram................................................................................................... 881 Fault Code A355: Overload on output 1L........................................................................................ 882 Related circuit diagram................................................................................................... 882 Fault Code A356: Overload on output 1M........................................................................................ 883 Related circuit diagram................................................................................................... 883 Fault Code A357: Overload on output 1N........................................................................................ 884 Related circuit diagram................................................................................................... 884 Fault Code A358: Overload on output 1P........................................................................................ 885 Related circuit diagram................................................................................................... 885 Fault Code A359: Overload on output 1R........................................................................................ 886 Related circuit diagram................................................................................................... 887 Fault Code A360: Overload on output 1S........................................................................................ 888 Related circuit diagram................................................................................................... 888 Fault Code A361: (A30003) Overload on output 1T............................................................................... 889 Related circuit diagram................................................................................................... 889 None...................................................................................................................... 889 Fault Code A361: (A30004 & Up) Overload on output 1T.......................................................................... 890 Related circuit diagram................................................................................................... 891 Fault Code A362: Overload on output 1U........................................................................................ 892 Related circuit diagram................................................................................................... 892 Fault Code A363: Overload on output 1X........................................................................................ 893 Related circuit diagram................................................................................................... 893 Fault Code A364: Overload on output 1Y........................................................................................ 894 Related circuit diagram................................................................................................... 894 Fault Code A365: Overload on output 1Z........................................................................................ 895 Related circuit diagram................................................................................................... 895 Drive system fault code table, Part 1............................................................................................. 897 Summary....................................................................................................................... 899 How to use this document...................................................................................................... 899 Event code and diagnosis message.............................................................................................. 899 Description................................................................................................................... 899 Threshold..................................................................................................................... 899 Detection by.................................................................................................................. 899 Possible reasons.............................................................................................................. 899 Action to reset............................................................................................................... 899 Action to repair.............................................................................................................. 900 Operator displayed code....................................................................................................... 900 Note.......................................................................................................................... 900 Protection reactions.......................................................................................................... 900 EVENT CLASSIFICATION.......................................................................................................... 900 Level 1: Warning.............................................................................................................. 901 Level 2: Minor purposes....................................................................................................... 901 Level 3: Severe............................................................................................................... 901 Drive system fault code table, Part 2............................................................................................. 937 Drive system fault code table, Part 3............................................................................................. 977 Drive system fault code table, Part 4.............................................................................................1037 Drive system fault code table, Part 5.............................................................................................1091 Drive system fault code table, Part 6.............................................................................................1165 Drive system fault code table, Part 7.............................................................................................1215 Troubleshooting electric wheel motor..............................................................................................1289 FAULT TABLE...................................................................................................................1290 Reserve engine oil system.........................................................................................................1299 Pumping unit LED signals......................................................................................................1301 Circuit fuses.............................................................................................................1301 50 Disassembly and assembly...........................................................................................................1303 General information ..............................................................................................................1303 Special tool list.............................................................................................................1304 Cab air conditioning..............................................................................................................1313 Replacement of air conditioning system components.............................................................................1315 Hoses and fittings........................................................................................................1315 Lines.....................................................................................................................1315 Expansion valve...........................................................................................................1315 Receiver-drier............................................................................................................1315 Thermostat................................................................................................................1315 Compressor................................................................................................................1316 Accumulator...............................................................................................................1316 Clutch....................................................................................................................1316 Wheels, spindles and rear axle....................................................................................................1321 General information for tires and rims........................................................................................1323 Storage and handling......................................................................................................1323 Wheel stud maintenance........................................................................................................1324 Front wheel studs.........................................................................................................1324 Rear wheel studs..........................................................................................................1324 Removal and installation of front wheel.......................................................................................1326 Removal...................................................................................................................1326 Installation..............................................................................................................1326 Removal and installation of rear wheels.......................................................................................1328 Removal...................................................................................................................1328 Installation..............................................................................................................1329 Removal and installation of tires.............................................................................................1330 Removal...................................................................................................................1330 Installation..............................................................................................................1331 Removal and installation of front wheel hub and spindle.......................................................................1333 Removal...................................................................................................................1334 Spindle Removal Procedure (off of the truck)..............................................................................1337 Installation..............................................................................................................1339 Disassembly and assembly of front wheel hub and spindle.......................................................................1340 Disassembly...............................................................................................................1340 Cleaning and inspection...................................................................................................1341 Assembly..................................................................................................................1343 Wheel bearing adjustment..................................................................................................1343 Seal assembly gap check and adjustment....................................................................................1344 Floating seal installation................................................................................................1345 Speed sensor installation and adjustment..................................................................................1347 Removal and installation of wheel motor.......................................................................................1348 Preparation...............................................................................................................1348 Removal...................................................................................................................1348 Cleaning and inspection...................................................................................................1349 Installation..............................................................................................................1350 Removal and installation of rear axle.........................................................................................1353 Removal...................................................................................................................1353 Cleaning and inspection...................................................................................................1354 Installation..............................................................................................................1355 Removal and installation of anti-sway bar.....................................................................................1355 Removal...................................................................................................................1355 Installation..............................................................................................................1356 Removal and installation of pivot pin.........................................................................................1357 Removal...................................................................................................................1357 Installation..............................................................................................................1357 Pivot eye and bearing service.................................................................................................1358 Bearing removal...........................................................................................................1358 Bearing installation......................................................................................................1358 Pivot eye repair..........................................................................................................1359 Removal and installation of electric motor....................................................................................1360 Removal...................................................................................................................1360 Installation..............................................................................................................1360 Disassembly and assembly of wheel motor transmission..........................................................................1361 Disassembly...............................................................................................................1361 Cleaning and inspection...................................................................................................1367 Assembly..................................................................................................................1368 Disassembly and assembly of low speed carrier.................................................................................1379 Disassembly...............................................................................................................1379 Inspection................................................................................................................1380 Assembly..................................................................................................................1381 Disassembly and assembly of high speed carrier................................................................................1384 Disassembly...............................................................................................................1384 Inspection................................................................................................................1385 Assembly..................................................................................................................1386 Brake System .....................................................................................................................1391 Removal and installation of brake valve.......................................................................................1393 Removal...................................................................................................................1393 Installation..............................................................................................................1394 Disassembly and assembly of brake valve.......................................................................................1394 Disassembly...............................................................................................................1394 Cleaning and inspection...................................................................................................1398 Assembly..................................................................................................................1398 Removal and installation of dual relay valve..................................................................................1402 Removal...................................................................................................................1402 Installation..............................................................................................................1403 Disassembly and assembly of dual relay valve..................................................................................1403 Disassembly...............................................................................................................1403 Cleaning and inspection...................................................................................................1404 Assembly..................................................................................................................1404 Removal and installation of brake manifold....................................................................................1405 Removal...................................................................................................................1405 Installation..............................................................................................................1406 Disassembly and assembly of brake manifold....................................................................................1406 Disassembly...............................................................................................................1406 Assembly..................................................................................................................1406 Removal and installation of brake accumulator.................................................................................1407 Removal...................................................................................................................1407 Installation..............................................................................................................1408 Disassembly and assembly of brake accumulator.................................................................................1408 Disassembly...............................................................................................................1408 Cleaning and inspection...................................................................................................1410 Assembly..................................................................................................................1410 Disassembly and assembly of wheel brake.......................................................................................1412 Disassembly...............................................................................................................1413 Cleaning and inspection...................................................................................................1416 Assembly..................................................................................................................1417 Floating ring seal assembly and installation..............................................................................1423 Removal and installation of rear brake assembly...............................................................................1427 Removal...................................................................................................................1427 Installation..............................................................................................................1427 Steering system ..................................................................................................................1433 Removal and installation of steering control unit.............................................................................1435 Removal...................................................................................................................1435 Installation..............................................................................................................1436 Disassembly and assembly of steering control unit.............................................................................1437 Disassembly...............................................................................................................1437 Assembly..................................................................................................................1439 Removal and installation of steering column...................................................................................1442 Removal...................................................................................................................1442 Inspection................................................................................................................1442 Installation..............................................................................................................1443 Removal and installation of steering wheel....................................................................................1444 Removal...................................................................................................................1444 Installation..............................................................................................................1444 Removal and installation of bleed down manifold...............................................................................1446 Removal...................................................................................................................1446 Installation..............................................................................................................1446 Removal and installation of flow amplifier....................................................................................1448 Removal...................................................................................................................1448 Installation..............................................................................................................1448 Disassembly and assembly of flow amplifier....................................................................................1448 Disassembly...............................................................................................................1448 Assembly..................................................................................................................1450 Removal and installation of steering cylinders and tie rod....................................................................1451 Removal...................................................................................................................1451 Bearing replacement.......................................................................................................1451 Installation..............................................................................................................1451 Disassembly and assembly of steering cylinders................................................................................1453 Disassembly...............................................................................................................1453 Assembly..................................................................................................................1453 Removal and installation of steering/brake pump...............................................................................1454 Removal...................................................................................................................1454 Installation..............................................................................................................1455 Disassembly and assembly of steering/brake pump...............................................................................1457 Disassembly...............................................................................................................1457 Inspection................................................................................................................1460 Assembly..................................................................................................................1463 Driveshaft group..........................................................................................................1464 Rotating group............................................................................................................1464 Removal and installation of steering accumulators.............................................................................1467 Removal Use vacuum pump kit (XB0887) to hold the oil back in the tank.....................................................1467 Installation..............................................................................................................1468 Disassembly and assembly of steering accumulators.............................................................................1468 Disassembly...............................................................................................................1468 Cleaning and Inspection...................................................................................................1470 Assembly..................................................................................................................1470 Suspensions ......................................................................................................................1475 Removal and installation of front suspension..................................................................................1477 Removal...................................................................................................................1477 Installation..............................................................................................................1478 Inspection................................................................................................................1483 Minor front suspension repairs (lower bearing and seals)......................................................................1484 Lower bearing retainer removal............................................................................................1484 Lower bearing retainer installation.......................................................................................1484 Major front suspension rebuild................................................................................................1485 Disassembly...............................................................................................................1485 Assembly..................................................................................................................1486 Removal and installation of rear suspension...................................................................................1488 Removal...................................................................................................................1489 Installation..............................................................................................................1490 Disassembly and assembly of rear suspension...................................................................................1491 Disassembly...............................................................................................................1491 Cleaning and Inspection...................................................................................................1492 Assembly..................................................................................................................1492 Hoist circuit ....................................................................................................................1495 Removal and installation of hoist pump........................................................................................1497 Removal...................................................................................................................1497 Installation..............................................................................................................1498 Disassembly and assembly of hoist pump........................................................................................1499 Disassembly...............................................................................................................1499 Inspection................................................................................................................1502 Assembly..................................................................................................................1502 Removal and installation of hoist valve.......................................................................................1507 Removal...................................................................................................................1507 Installation..............................................................................................................1508 Disassembly and assembly of hoist valve.......................................................................................1508 O-ring replacement........................................................................................................1508 Disassembly of inlet section..............................................................................................1509 Assembly of inlet section.................................................................................................1510 Disassembly of rear spool section.........................................................................................1511 Assembly of rear spool section............................................................................................1513 Disassembly of front spool section........................................................................................1514 Assembly of front spool section...........................................................................................1515 Overcenter valve manifold service.............................................................................................1515 Removal and installation of hoist pilot valve.................................................................................1516 Removal...................................................................................................................1516 Installation..............................................................................................................1516 Disassembly and assembly of hoist pilot valve.................................................................................1517 Disassembly...............................................................................................................1517 Cleaning and inspection...................................................................................................1518 Assembly..................................................................................................................1518 Removal and installation of hoist cylinders...................................................................................1519 Removal...................................................................................................................1519 Installation..............................................................................................................1519 Disassembly and assembly of hoist cylinders...................................................................................1521 Disassembly...............................................................................................................1521 Cleaning and inspection...................................................................................................1523 Installation of the quill.................................................................................................1524 Assembly..................................................................................................................1526 Operator cab .....................................................................................................................1529 Removal and installation of operator cab......................................................................................1531 Removal...................................................................................................................1532 Installation..............................................................................................................1533 Removal and installation of cab door..........................................................................................1535 Removal...................................................................................................................1535 Installation..............................................................................................................1535 Disassembly and assembly of cab door..........................................................................................1535 Removing door panel.......................................................................................................1535 Installing door panel.....................................................................................................1536 Replacing door window regulator...........................................................................................1536 Replacing door handle or latch assembly...................................................................................1537 Replacing door assembly seal and door hinge seal..........................................................................1538 Replacing door opening seal...............................................................................................1538 Removing door glass.......................................................................................................1539 Installing door glass.....................................................................................................1540 Adjustment of cab door........................................................................................................1542 Door jamb bolt adjustment.................................................................................................1542 Door handle plunger adjustment............................................................................................1543 Removal and installation of side window glass.................................................................................1544 Recommended tools and supplies............................................................................................1544 Removal...................................................................................................................1545 Installation..............................................................................................................1545 Removal and installation of windshield and rear window glass..................................................................1546 Removal...................................................................................................................1546 Installation..............................................................................................................1546 Removal and installation of windshield wiper motor............................................................................1547 Removal...................................................................................................................1547 Installation..............................................................................................................1547 Removal and installation of windshield wiper arm..............................................................................1548 Removal...................................................................................................................1548 Installation..............................................................................................................1548 Removal and installation of windshield wiper linkage..........................................................................1549 Removal...................................................................................................................1549 Installation..............................................................................................................1549 Removal and installation of operator seat.....................................................................................1550 Inspection................................................................................................................1550 Removal...................................................................................................................1550 Installation..............................................................................................................1550 Removal and installation of passenger seat....................................................................................1551 Removal...................................................................................................................1551 Installation..............................................................................................................1551 Removal and installation of seat belts (standard seats).......................................................................1552 Removal...................................................................................................................1552 Installation..............................................................................................................1552 Removal and installation of seat belts (optional seats).......................................................................1554 General...................................................................................................................1554 Removal...................................................................................................................1554 Installation..............................................................................................................1556 Body and structures ..............................................................................................................1561 Removal and installation of dump body.........................................................................................1563 Removal...................................................................................................................1563 Inspection................................................................................................................1564 Installation..............................................................................................................1565 Removal and installation of body pads.........................................................................................1565 Removal...................................................................................................................1565 Installation..............................................................................................................1566 Adjustment................................................................................................................1566 Removal and installation of diagonal ladder/ hood and grille assembly.........................................................1568 Removal...................................................................................................................1568 Installation..............................................................................................................1568 Removal and installation of right deck........................................................................................1569 Removal...................................................................................................................1569 Installation..............................................................................................................1570 Removal and installation of left deck.........................................................................................1572 Removal...................................................................................................................1572 Installation..............................................................................................................1572 Removal and installation of fuel tank.........................................................................................1574 Removal...................................................................................................................1574 Cleaning and inspection...................................................................................................1574 Installation..............................................................................................................1576 Removal and installation of fuel gauge sender.................................................................................1576 Removal...................................................................................................................1576 Installation..............................................................................................................1576 Disassembly and assembly of fuel tank breather................................................................................1577 Disassembly...............................................................................................................1577 Assembly..................................................................................................................1577 Removal and installation of hydraulic tank....................................................................................1578 Removal...................................................................................................................1578 Installation..............................................................................................................1578 Three phase wheel motor ..........................................................................................................1581 Qualified personnel...........................................................................................................1582 General.......................................................................................................................1582 General safety information................................................................................................1582 Handling......................................................................................................................1583 Motor.....................................................................................................................1583 Transport.................................................................................................................1584 Storage...................................................................................................................1585 Storage of new motors.....................................................................................................1585 Storage of used motors....................................................................................................1586 Maintenance...............................................................................................................1586 General note:.........................................................................................................1586 Motor.....................................................................................................................1586 General...............................................................................................................1586 Safety guidelines.....................................................................................................1587 Maintenance intervals.........................................................................................................1588 Maintenance work on the installed motor.......................................................................................1588 Checking for external damage..............................................................................................1588 Checking the connections..................................................................................................1589 Regreasing the bearings...................................................................................................1589 Applying grease to the bearings:..........................................................................................1589 Checking the interior of the motor for water..............................................................................1590 Disassembly...................................................................................................................1591 Pressing off the coupling.................................................................................................1592 Disassembly...............................................................................................................1593 Rotor.................................................................................................................1593 Removing the rubber seals and the air baffles.............................................................................1597 Bearing and labyrinth ring................................................................................................1598 Removal...............................................................................................................1598 Maintenance work..............................................................................................................1599 Stator Inspection.........................................................................................................1599 Rotor Inspection..........................................................................................................1599 Testing the insulation....................................................................................................1600 High-voltage test.....................................................................................................1600 Work on the bearings......................................................................................................1601 Assembly......................................................................................................................1602 Assembling the rubber seals and the air baffles...........................................................................1603 Assembly after special repair work........................................................................................1605 Bearing installation..................................................................................................1606 Assemble the bearing..................................................................................................1610 Cover installation....................................................................................................1611 Assembling the bearing shield (N-end) at the stator frame.................................................................1612 Bearing installation......................................................................................................1614 Rotor installation........................................................................................................1616 Labyrinth ring............................................................................................................1618 Installation..........................................................................................................1618 Installing accessories (D- and N-end).....................................................................................1620 Running in the bearings...................................................................................................1624 Coupling..................................................................................................................1625 Installation..........................................................................................................1625 Assembly conditions and instructions......................................................................................1626 Tests.....................................................................................................................1626 Repair work...................................................................................................................1627 Replacing defective connecting leads......................................................................................1627 Repairing the stator winding insulation...................................................................................1628 Recommended consumables...................................................................................................1628 Chemical cleaning agents..................................................................................................1628 Chemical cleaning agents for outdoor use and for cleaning mechanical parts............................................1628 Chemical cleaning agents for flange faces.............................................................................1628 Chemical cleaning agents for windings.....................................................................................1629 Chemical cleaning agents for windings.................................................................................1629 Chemical cleaning agents for windings with severe damage and for oily windings........................................1629 Rolling-contact bearing grease............................................................................................1629 Assembly/disassembly agents for bearing seat..............................................................................1629 Sealants for joining parts or gaps........................................................................................1629 Locking agents for connecting elements....................................................................................1629 Anti-corrosion agent......................................................................................................1629 Assembly paste for temperature sensors....................................................................................1629 List of tools.................................................................................................................1630 Mounting devices for inserting and withdrawing the rotor horizontally.....................................................1630 Press for expanding the coupling..........................................................................................1630 Compression devices for pressing on or for support while pressing off.....................................................1631 Pulling units with cross beam or disk.....................................................................................1633 Aids......................................................................................................................1633 Extraction devices........................................................................................................1634 Repair parts list.............................................................................................................1634 Paints for refinishing the painted parts or touching up damaged parts.....................................................1634 Power module .....................................................................................................................1637 Removal and installation of power module......................................................................................1639 General...................................................................................................................1639 Preparation...............................................................................................................1639 Removal...................................................................................................................1640 Installation..............................................................................................................1645 Removal and installation of alternator........................................................................................1647 Removal...................................................................................................................1647 Installation..............................................................................................................1649 Removal and installation of engine............................................................................................1652 Removal...................................................................................................................1652 Service...................................................................................................................1653 Installation..............................................................................................................1653 Removal and installation of radiator..........................................................................................1653 Removal...................................................................................................................1653 Installation..............................................................................................................1655 Repairing the radiator........................................................................................................1656 Internal inspection.......................................................................................................1656 External cleaning.........................................................................................................1656 Disassembly...............................................................................................................1657 Cleaning and inspection...................................................................................................1658 Assembly..................................................................................................................1658 Pressure testing..........................................................................................................1659 Auto lubrication system ..........................................................................................................1661 Lubrication system priming....................................................................................................1662 Disassembly and assembly of lubrication pump..................................................................................1662 Disassembly...............................................................................................................1662 Cleaning and Inspection...................................................................................................1664 Assembly..................................................................................................................1664 Main blower.......................................................................................................................1667 Removing the main blower motor................................................................................................1668 Disassembling the main blower motor...........................................................................................1674 Assembling the main blower motor..............................................................................................1676 Installing the main blower motor..............................................................................................1679 Retarding grid....................................................................................................................1687 Removing the grid blower motor................................................................................................1688 Disassembling the grid blower motor...........................................................................................1690 Assembling the grid blower motor..............................................................................................1692 Installing the grid blower motor..............................................................................................1694 Removing a grid element.......................................................................................................1697 Control cabinet...................................................................................................................1701 Draining and filling the IGBT coolant system..................................................................................1703 Required tools/materials..................................................................................................1703 Coolant mixture specification (distilled water : Antifrogen N)............................................................1703 Draining and filling the coolant..........................................................................................1704 Removing and installing the IGBT coolant pump assembly........................................................................1707 Required tools/materials..................................................................................................1707 Removal...................................................................................................................1708 90 Diagrams and drawings .............................................................................................................1711 Hydraulic circuit diagrams .......................................................................................................1711 EM1374 Hydraulic schematic ...................................................................................................1713 EM6298 Hydraulic brake schematic..............................................................................................1714 Electrical circuit diagrams ......................................................................................................1715 EM6700 Electric schematic ....................................................................................................1719 HE488 Connector locater .....................................................................................................1757 Electrical circuit diagrams - drive system........................................................................................1758 HE486 Electric schematic .....................................................................................................1762 XS3380 Electric trolley schematic ............................................................................................1809
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