Komatsu 860E-1KT Dump Truck Shop Manual CEBM022008 PDF

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Komatsu 860E-1KT Dump Truck Shop Manual CEBM022008 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 860E-1KT Dump Truck Shop Manual CEBM022008 – PDF DOWNLOAD 

Language : English
Pages : 1944
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu 860E-1KT Dump Truck Shop Manual CEBM022008 – PDF DOWNLOAD 

SERIAL NUMBERS 860E-1KT A30004 – A30030

Foreword :

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 “right,” “left,” “front,” or “rear” 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 N·m (100 ft lb). All torque specifications have ±10% 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. 960E).
• The three numbers represent the basic truck model. The letter “E” 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.
• To determine the allowable payload, fill all lubricants to the proper level and fill the fuel tank of an empty truck (which includes all accessories, body liners, tailgates, etc.), and then weigh the truck. Record this value and subtract it from the GVW. The result is the allowable payload.

TABLE OF CONTENTS:

Komatsu 860E-1KT Dump Truck Shop Manual CEBM022008 – PDF DOWNLOAD 

SERIAL NUMBERS 860E-1KT A30004 – A30030

COVER 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword, safety and general information 35
Foreword 39
How to read the shop manual 40
Composition of shop manual 40
Revision and distribution 40
Symbols 41
General safety 42
Safety rules 42
Safety features 42
Fire extinguisher and first aid kit 42
Clothing and personal items 42
Leaving the operator seat 43
Mounting and dismounting 43
Fire prevention for fuel and oil 43
Precautions with high temperature fluids 44
Asbestos dust hazard prevention 44
Prevention of injury by work equipment 44
Unauthorized modification 44
Precautions when using ROPS 44
Precautions for attachments 45
Precautions for starting the truck 45
Precautions before operating the truck 45
Safety at the worksite 45
Fire prevention 46
Ventilation in enclosed areas 46
Preparing for operation 46
Mirrors, windows and lights 46
In operator cab (before starting the engine) 46
Seat Belts 46
Precautions while operating the truck 47
When starting the engine 47
General truck operation 47
Ensuring good visibility 47
Traveling 48
Traveling in reverse 48
Traveling on slopes 48
Operating on snow or ice 48
Avoid damage to dump body 48
Driving near high voltage cables 49
When dumping 49
Working on loose ground 49
When loading 49
Parking the truck 49
Towing 50
Working near batteries 50
Battery hazard prevention 50
Starting with jumper cables 51
Jump starting with receptacles 51
Precautions before performing service 52
Warning tag 52
Stopping the engine 52
Proper tools 52
Use of tie-off anchor during maintenance and repair 53
The anchor must not be used for lifting Tie-off anchor installation 53
Securing the dump body 54
While performing maintenance 54
Keep the truck clean 54
Attachments 54
Working under the truck 55
Rotating fan and belts 55
Adding fuel or oil 55
Use of lighting 55
Radiator coolant level 55
Precautions with the battery 55
Precautions with high pressure oil 55
Handling high pressure hoses 56
Precautions when performing maintenance near high temperature or high pressure 56
Waste materials 56
Tires 56
Handling tires 56
Storing tires after removal 57
Precautions for performing repairs 58
Engine shutdown procedure after AC drive system failure 58
Jack point locations 59
Precautions for welding on the truck 60
Handling electrical equipment and hydraulic components 61
Points to remember when handling electrical equipment 61
Points to remember when handling hydraulic equipment 67
How to Read Electric Wire Code 69
Color Code and Harness Designation Tables 70
Standard torque tables 71
Effect of special lubricants on fasteners and standard torque values 71
Suggested sources for rust preventive grease 71
SAE grade 5 and grade 8 hex head capscrew and nut assemblies 72
SAE grade 9 capscrews 73
Class 10 9 capscrews and class 10 nuts 74
Standard tightening torques for fittings 74
Standard tightening torques for clamps 76
Conversion tables 77
Common conversion multipliers 77
Operating instructions 81
Preparing for operation 83
Walk around inspection 83
Engine start-up 88
After engine start-up 89
Precautions during truck operation 90
Operating on a haul road 91
Starting on a grade with a loaded truck 91
Passing 92
Loading 92
Overload speed limit function 92
Dumping 93
Raising The Dump Body 93
Lowering The Dump Body (When dumping on flat ground): 93
Lowering The Dump Body (When dumping over a berm or into a crusher): 94
Using the speed control feature 95
Safe parking procedures 95
Normal engine shutdown procedure 96
Sudden loss of engine power 97
Fuel depletion 98
Towing 98
Special Wiring Harness 98
Towing Procedure 99
Disabled truck operation 101
Steering and brake system 101
Components Required 101
Hookup 102
Disabled truck dumping procedure 103
Hookup 103
Raising the Body 104
Lowering the Body 104
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 and functions 117
Cab air conditioning 117
General information 119
Environmental impact of air conditioning 119
Air conditioning for off-highway vehicles 119
Principles of refrigeration 120
Air conditioning 120
Refrigeration – the act of cooling 120
The refrigeration cycle 120
Air conditioning system components 122
Relays 122
Fan motor and speed control 122
Cab air filter 122
Heater core 122
Actuators 122
Compressor (refrigerant pump) 124
Service valves 124
Condenser 124
Receiver-drier 124
Expansion valve 125
Accumulator 125
Evaporator core 125
Air conditioning system electrical circuit 126
Thermostat 126
Compressor clutch 126
Trinary™ switch 127
Steering circuit 129
Steering circuit operation 131
Steering circuit components 133
Steering control unit 133
High pressure filter 133
Steering accumulators 133
Bleeddown manifold 134
Steering accumulator bleeddown solenoid 137
Quick disconnect ports 137
Hoist up limit solenoid 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
Hoist limit solenoid 157
Pilot operated check valve 157
Hoist pilot valve 158
Overcenter manifold 158
Hoist pilot valve operation 159
Float position of pilot valve with truck body on frame 159
Power up operation 161
Hold operation 163
Power down operation 165
Float operation 167
Hoist cylinder wear data 169
Brake circuits 171
General information 173
Service brake circuit operation 174
Secondary braking system and auto apply 174
Rear wheel brake lock circuit operation 176
Parking brake circuit operation 178
Normal operation (key switch ON, engine on) 178
Brake lines and test ports 180
Brake warning circuit operation 181
Brake assembly wear data 183
Suspensions 185
General information 187
Front suspension wear data 187
Rear suspension wear data 188
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 207
Service 207
Sensors 207
Temperature sensors 207
Pressure sensors 208
Interface module inputs and outputs 209
Drive system 215
SR rectifier module 218
ST module (auxiliary voltage inverter) 218
Technical Data 221
SD phase modules 222
SR/ST/SD module removal 222
Inverter cabinet layout 223
Inverter cabinet water flow 223
Field regulator 224
Technical Data 224
Field regulator (discharge resistor) 224
Technical Data 224
Gate Unit 225
Technical Data 225
Technical Data 225
Technical Data 225
Control power filter 226
Technical Data 226
Filter for TCU 226
Technical Data 226
Terminal block bus bar 227
Technical Data 227
Fuses (analog sensor voltage) 228
Technical Data 228
Fuses (field regulator) 228
Technical Data 228
Fuses (fuse holder for field regulator) 228
Fuses (control power and trolley box contactor) 229
Technical Data 229
Diode modules 229
Technical Data 229
Support capacitors 230
Technical Data 230
3-Phase capacitor bank (for ST module output voltage) 230
Technical Data 230
Air-cooled inductors (for ST module) 231
Technical Data 231
3-Phase transformer (for ST module) 231
Technical Data 231
Diagnostics box 232
Diagnostic and system monitoring panel 233
Technical Data 233
Current transducers 234
Device names: 234
Technical Data 234
Technical Data 234
Current transducers (for ST module output) 235
Technical Data 235
Voltage transducers 236
Technical Data 236
Voltage transducers (for ST module output) 236
Technical Data 236
Voltage transducers (SiBAS® 24V DC bus monitoring) 237
Analog inclinometer 237
Technical Data 237
DC link capacitors 238
Technical Data 238
Ground tie capacitor 238
Technical Data 238
Low-inductance bus bar assembly 239
Free-wheeling diode for low-inductance bus bars 239
Contactor (grid box and main blower motor) 240
Technical Data 240
Contactor (control power) 240
Technical Data 240
Contactor (DC contactors) 241
Technical Data 241
Contactor (crowbar bypass) 241
Technical Data 241
Temperature probes (PT100 style) 242
Technical Data 242
Coolant inlet temperature sensor 242
Technical Data 242
Coolant outlet temperature sensor (external pad style) 243
IGBT module heat sink temperature sensor 243
Coolant outlet temperature sensor (internal style) 243
Technical Data 243
Coolant outlet temperature sensor (external pad style) 244
Technical Data 244
Circuit breakers 245
Technical Data 245
Inner circulating blower fan 245
Coolant pump 246
Technical Data 246
Motor for coolant pump 246
Technical Data 246
Coolant pressure sensor 246
Inner radiator 247
Ground voltage monitoring resistors 247
Protection thyristor assembly (crowbar) 248
Discharge reactor 248
Main blower motor 249
Technical Data 249
Grid box 249
Technical Data 249
Grid box blower motor 250
Technical Data 250
Grid box blower motor grease fittings 250
Main alternator 251
Stator 251
Rotor 251
Bearings 251
Electrical connection 251
Cooling and ventilation 251
Rotating rectifier section 252
Technical Data 252
Main alternator circuit diagram 253
IGBT – inverter/chopper phase module 254
Troubleshooting information 256
Main input rectifier module 257
Internal circuit diagram 258
Upper ground tie resistor 259
Technical Data 259
Lower ground tie resistor 259
Technical Data 259
Troubleshooting – fault diagnosis 260
Speed sensor, alternator 261
Technical Data 261
Speed sensors, wheel motors 262
Technical Data 262
Traction motor 263
Technical Data 263
Grid box 264
Device name: M04 264
Technical Data 264
Step down box 267
SIBAS® IGBT rack components 269
SiBAS®32 Traction Control Unit (TCU) 272
Overview of the SiBAS®32 systems 273
Features 273
General technical specifications, operating conditions 273
Permissible temperature range 273
Permissible limit value for air humidity 274
Permissible power supply voltage range 274
Permissible mechanical loads 274
Protection measures against electrical hazards 274
Application 274
Removing and installing the SiBAS®32 cards 277
Removal with 24V OFF! (ESD protection required) 277
Installation with 24V OFF! (ESD protection required) 277
SiBAS®32 card device names 278
Structure of SiBAS®32 card part number 279
Development status, downward compatibility 279
SiBAS®32 card interchangeability 280
Use of service interfaces 281
Connection of the service unit 281
Maintenance 281
Cleaning 282
SiBAS®32 card interactions 283
SiBAS®32 card detailed information 286
Blower subassembly 286
Device name: N/A 286
Application 286
Battery replacement 288
Rules for handling lithium batteries 288
Replacement of the battery in the fan subassembly 288
CPU card 289
Device name: G011 289
Application 290
Front panel 290
Technical data 291
DSP card 292
Device name: G019, G027 and G35 292
Application 292
Front panel 292
Technical data 293
I/O card 294
Device name: G043 294
Application 294
Front panel 295
Technical data 296
TRACO card (optional) 297
Device name: G003 297
Application 297
Front panel 298
Technical data 299
Input voltage/frequency card 300
Device name: L055, L063 and L071 300
Application 300
Technical data 301
I/O analog card 302
Device name: L079 and L087 302
Technical data 304
I/O analog card 305
Device name: L095 and L103 305
Application 305
Technical data 307
Output pulse amplifier card 308
Device name: L115, L123, L131, L139 and L147 308
Application 308
Technical data 310
Input temperature sensor card 311
Device name: L155 and L163 311
Application 311
Technical data 313
UWS card 314
Device name: G055, G063, G071 and G079 314
Application 314
Technical data 316
Digital input card 317
Device name: G103, G111, G119, G127 and G135 317
Application 317
Technical data 319
Power start-up unit card 320
Device name: G163 320
Application 320
Technical data 322
Binary output contactor drive card 323
Device name: C019, C027 and C035 323
Application 323
Technical data 325
24V / 24V power supply 326
Device name: C045, C105, C129 326
Application 326
Testing the power supply card 327
Technical data 328
24V / 15V power supply 329
Device name: C069, C087 329
Application 329
Testing the power supply card 330
Technical data 331
24V / 5V power supply 332
Device name: C153 332
Application 332
Testing the power supply card 333
Technical data 334
Reserve engine oil system 337
General information 339
Operation 340
LED monitor light 340
Remote tank fill system 341
Wheel motor transmission 343
General information 345
Transmission wear data 348
20 Standard value table 353
Standard value table 353
Standard value table for truck 355
30 Testing and adjusting 361
Service tools 361
Special tool list 363
Control cabinet 364
Cab air conditioning 367
General information 369
Service tools and equipment 370
Recovery/recycle station 370
Leak detector 370
Manifold gauge set 371
Service valves 372
Vacuum pump 372
Detecting leaks 373
System performance test 374
Checking system oil 375
System flushing 376
Installing the manifold gauge set 377
Purging air from the service hoses 378
Recovering and recycling refrigerant 379
Draining oil from previous recovery cycle 380
Recovery cycle 380
Recycling procedure 380
Evacuating the air conditioning system 381
Charging the air conditioning system 382
Steering, brake cooling and hoist hydraulic system 385
General information on system checkout 387
Steering system checkout procedures 387
Steering pump pressure control adjustments 388
Steering control valve and flow amplifier leakage test 389
Bleed down manifold leakage test 390
Shock and suction valve pressure tests 391
Steering system checkout data sheet 393
Toe-in adjustment 394
Brake cooling and hoist system checkout procedures 395
Pressure gauge locations 395
Brake cooling circuit test 396
Power up relief pressure test 396
Power down relief pressure test 397
Counterbalance valve pressure check 398
Counterbalance valve adjustment 399
Brake cooling and hoist system checkout data sheet 400
Hydraulic system flushing 401
Hydraulic system flushing procedure 401
Front suspension pressure test 408
Rear suspension pressure test 408
Steering cylinder leakage test 409
Hoist cylinder leakage test 409
Brake system 411
General information on system checkout 413
Brake circuit checkout procedure 413
Precheckout items 414
Software operation and configuration 414
Hydraulic isolation and troubleshooting 414
Truck starting procedure 414
Initial system setup 415
Brake lock / secondary braking checkout 416
Brake lock hydraulic circuit trouble shooting guide 418
Parking brake checkout 418
Park brake hydraulic circuit trouble shooting guide: 419
Service brake checkout 421
Blended braking checkout 421
Low brake accumulator pressure and auto apply checkout 422
Reapplication 423
Parking brake control logic checkout 423
Brake lock control logic checkout 425
BLENDED BRAKING CHECKOUT 429
Brake piston leakage test 438
Wet disc brake bleeding procedure 438
Parking/service brake bleeding procedure 439
Parking brake leakage test 440
Brake disc wear inspection 440
Brake valve bench test and adjustment 442
Test setup procedure 443
Brake valve output pressure adjustment 443
Final test and adjustment 444
Accumulators and suspensions 447
Accumulator charging and storage 449
Temperature during precharge 449
Bladder accumulator charging procedure 450
Precharge maintenance 452
Bladder accumulator storage procedure 452
Bladder storage 452
Installing a bladder accumulator from storage 453
Bladder accumulator leak testing 453
Piston accumulator charging procedure 454
Piston accumulator storage 457
Piston accumulator leak testing 458
Checking for improper suspension charge on operating trucks 459
Suspension oil change recommendations 460
Suspension oiling and charging procedures 461
Required equipment 461
Installing the charging kit 462
Removing the charging kit 462
Support blocks for oiling and charging dimensions 463
Front suspensions 466
TOP FILL METHOD 467
PRESSURE FILL METHOD 467
Rear suspensions 469
TOP FILL METHOD 471
PRESSURE FILL METHOD 471
Suspension pressure test 474
Payload meter 477
Payload meter initial setting procedure 479
Starting communications 479
Configure payload meter 479
Setting truck number 481
Clean truck tare 482
KOMTRAX Plus 485
KOMTRAX Plus and payload meter software 487
VHMS Tool Box Installation 487
VHMS Setting Tool Installation 487
Installing the PDM software 487
KOMTRAX Plus controller initial setting procedure 488
KOMTRAX Plus controller setup procedure 488
KOMTRAX Plus snapshot procedure 491
KOMTRAX Plus download procedure 492
KOMTRAX Plus FTP upload procedure 493
KOMTRAX Plus initialization forms 494
KOMTRAX Plus initialization check list 495
KOMTRAX Plus initialization form 497
Precautions for replacing KOMTRAX Plus controller 498
KOMTRAX Plus controller checkout procedure with optional Orbcomm communication 503
Necessary equipment 503
Preliminary 503
Checkout procedure 504
Troubleshooting 507
Machines equipped with TC301 Orbcomm terminal 509
Interface module (IM) 515
Required software and tools 517
Interface module checkout procedures 518
Initial startup 518
Checking digital inputs to the IM 518
Check analog inputs to the IM 520
Check serial interfaces to the interface module 520
Check outputs from the interface module 521
IGBT haul truck SIBAS® user manual, part 1 523
Abbreviations 526
Precautions 528
Qualified person 528
Customer monitor for SIBAS® 32 control units 528
Product description 528
Version management 529
Overview 530
Requirements 530
Installing and calling the customer monitor 531
Installation 531
Environment variables 531
Communication with the SIBAS® 32 control unit 532
Calling up the customer monitor 533
Start-up prompt 533
Monitor prompt 534
Notes on operation of the customer monitor 535
Structure of a monitor command 535
Step 1: Selecting the menu title 535
Step 2: Selecting a menu entry in the menu box 535
Step 3: Selecting a dialog box, if available 536
Step 4: Entering file or connector/signal names 536
Command buffer 537
Structure of the monitor windows 537
Window menu 538
Commands for Opening, Altering and Closing Windows 538
“Window Work open” 538
“Window Lines open” 538
“Window Tile” 538
“Window Bars open” 538
Options 538
“Window Set” 538
Options 538
“Window Cascade” 538
“Window Close” 538
“Window close All” 538
“Window Exit” 538
Set Menu 539
“Set Port” 539
Options 539
“Set Baudrate” 539
Options 539
“Set String” 540
Example 541
“Set Make” 541
Options 541
Example 1: INIT MON start-up control of the Customer Monitor 542
Example 2: Any monitor batch file with freely selectable file name (incl path) 542
“Set Execute” 543
Options 543
Example 543
“Set Record” 543
Options 543
“Set DIN-Bus” 544
“Set TCN” 544
“Set Timeout” 544
Options 544
“Set Wait” 544
Options 544
“Set Color” 544
Options 544
“Set Info” 545
“Set comment” 545
“Set CHAR Set” 545
“Set Quit” 545
Applic Menu 546
“Applic Func Package” 546
“Applic Connector” 547
Options 547
Example 548
“Applic View” 548
Options 548
Example 548
“Applic Signal” 548
“Applic Observer” 549
Options 549
Possible time slices: 549
Options 550
Two options 550
Notes on the display of connectors 552
“Applic Buffer” 553
Options 553
“Applic Report” 553
“Applic Legitimation” 553
Options 553
“Applic Menu” 554
“Applic Traco” 554
Options 554
“Applic Environment” 554
Hardw Menu 556
Hardware-Oriented Access via the Customer Monitor 556
“Hardw Flash” 556
Options 556
Requirements 556
Example 557
Deleting and loading 557
The EPROM for the communication drivers 557
“Hardw Clock” 557
Options 557
“Hardw DSP” 558
“Hardw BCD” 558
Options 558
Example 558
“Hardw RESET” 558
Options 558
“Hardw Info” 559
Hardware/Operating system 559
Application and tools 559
Communication module 559
Displaying the loading date 559
“Hardw User Flash” 560
Options 560
“Hardw Sys Flash” 560
Options 560
“Hardw BOOT DSP” 561
Requirements 561
DSP5600x Signal Processing Unit and TRACO 561
Inverter processing unit 563
Access to the Signal Processing Unit 563
“Hardw Flash” 563
Options 563
Requirements 563
Example 563
Deleting and loading 564
The EPROM for the communication drivers 564
User Data Flash (UDF) 564
“Hardw RESET” 564
Options 564
“Hardw ZR” 565
“Hardw BOOT ZR” 565
The following procedure is necessary: 565
Graphic Menu 566
Commands for Displaying Line Graphics 566
“Graphic Load” 566
Options 566
“Graphic Position” 566
Options 566
“Graphic Time/Div” 567
Options 567
“Graphic Unit/Div” 567
Options 567
“Graphic Display” 567
Options 567
“Graphic Color” 568
Options 568
“Graphic Format” 568
Options 568
IGBT haul truck SIBAS® user manual, part 2 571
Traco Menu 574
HW-Traco 574
Options 575
SW-Traco 576
Options 577
ZR traco basic parameters: 577
ZR traco record signal table: 577
DAC_Traco 580
Options 581
Events Menu 582
STatistics 583
History 584
LEL:Last EvL 585
LES:Last EvS 587
DLL:DC,LastL 588
DLS:DC,LastS 589
DAL:DC,All L 590
DAS:DC,All S 591
ML:Memory L 592
MS:Memory S 593
CN:Clear Norm 594
CA:Clear All 594
Test-Code 594
DS:Diag-Strc 595
User Menu 596
DAC_IO 597
Options 597
Options 598
Operat Data 599
Acc test 606
Engine_Test 606
X_Test_Inx 609
STate intern 610
Header: 610
Vehicle Number: 610
Powering system: 610
TCU Operation Mode: 610
Component status listings: 611
Field regulator status: 611
Status gate unit power supply A: 611
Status gate unit power supply B: 611
ST inverter status 611
Vehicle status 612
Drive status: 612
Operation status: 612
Pedal calib 613
Language 614
OFFline-test 614
Options 614
Variables 616
Examples: 616
IV:Vehic-ID 617
Commands 618
Discharge Dc link / Fire crowbar 618
Limp mode commands 618
Settings 619
Parameters 620
Temp_prot 622
Appendix 624
Background commands 624
Monitor commands for the central processing unit 626
Monitor commands for the signal processing unit 626
Installing ZR / DSP software 629
Monitor Program – Loading software into the SIBAS® 631
Loading software into the DSP procedure 631
Loading a DSP program Inverter A 636
Loading software into the CPU procedure 643
Loading ZR software Prog jumpers Reset 650
Loading the proper pgm file 652
Setting the system up After loading a new pgm 652
24V electrical system 655
Body position switches (with proximity switches and metal arms) 657
Body up switch adjustment 657
Hoist limit switch adjustment 658
Service 658
Body position switches (with proximity switches and magnets) 659
Body up switch adjustment 659
Hoist limit switch adjustment 659
Service 659
Automatic lubrication system checkout 663
System checkout 665
Pump priming procedure 665
System priming procedure 666
Lubrication cycle operation 667
40 Troubleshooting 669
Cab air conditioning 669
Preliminary checks 671
Diagnosis of gauge readings and system performance 671
Troubleshooting by manifold gauge set readings 672
Fuse and circuit breaker locations 679
Fuse and circuit breaker locations 681
Fuse block tables 682
Prelube motor fuse 683
Circuit breaker table 684
Troubleshooting by fault code, Part 1 687
Fault Code A001: Left front suspension pressure sensor signal high 690
Related circuit diagram 690
Fault Code A002: Left front suspension pressure sensor signal low 691
Related circuit diagram 691
Fault Code A003: Right front suspension pressure sensor signal high 692
Related circuit diagram 692
Fault Code A004: Right front suspension pressure sensor signal low 693
Related circuit diagram 693
Fault Code A005: Left rear suspension pressure sensor signal high 694
Related circuit diagram 694
Fault Code A006: Left rear suspension pressure sensor signal low 695
Related circuit diagram 695
Fault Code A007: Right rear suspension pressure sensor signal high 696
Related circuit diagram 696
Fault Code A008: Right rear suspension pressure sensor signal low 697
Related circuit diagram 697
Fault Code A009: Incline sensor signal high 698
Related circuit diagram 698
Fault Code A010: Incline sensor signal low 699
Related circuit diagram 699
Fault Code A011: Payload meter speed sensor signal has failed 700
Related circuit diagram 700
Fault Code A013: Body up switch has failed 701
Related circuit diagram 701
Fault Code A014: Payload meter checksum computation has failed 702
Related circuit diagram 702
Fault Code A016: Payload meter write to flash memory has failed 703
Related circuit diagram 703
Fault Code A017: Payload meter flash memory read has failed 704
Related circuit diagram 704
Fault Code A018: Right rear flat suspension cylinder warning 705
Related circuit diagram 706
Fault Code A019: Left rear flat suspension cylinder warning 707
Related circuit diagram 708
Fault Code A022: Carryback load excessive 709
Related circuit diagram 710
Fault Code A100: An open circuit breaker has been detected on a relay board 711
Related circuit diagram 711
Fault Code A101: High pressure detected across an hydraulic pump filter 712
Related circuit diagram 714
Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level 715
Related circuit diagram 716
Fault Code A111: Low steering pressure warning for storage by KOMTRAX Plus 717
Related circuit diagram 717
Fault Code A115: Low steering precharge pressure detected 718
Related circuit diagram 719
Fault Code A117: Low brake accumulator pressure warning for storage by KOMTRAX Plus 720
Related circuit diagram 720
Fault Code A118: Brake pressure is low while in brake lock 721
Related circuit diagram 722
Fault Code A126: Oil level in the hydraulic tank is low 723
Related circuit diagram 723
Fault Code A127: IM-furnished +5 volt output for sensors is low 724
Related circuit diagram 725
Fault Code A128: IM-furnished +5 volt output for sensors is high 726
Related circuit diagram 727
Fault Code A139: Low fuel warning for storage by KOMTRAX Plus and for use by A310 728
Related circuit diagram 729
Troubleshooting by fault code, part 2 731
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil 734
Related circuit diagram 735
Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil 736
Related circuit diagram 737
Fault Code A152: Starter failure 738
Related circuit diagram 739
Fault Code A153: Battery voltage is low with the truck in operation 740
Related circuit diagram 741
Fault Code A154: Battery charging voltage is excessive 742
Related circuit diagram 742
Fault Code A155: Battery charging voltage is low 743
Related circuit diagram 743
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 744
Related circuit diagram 745
Fault Code A159: (A30003 only) The battery 12 Volt circuit sensing is producing low readings 746
Related circuit diagram 746
Fault Code A164: (A30003 only) The battery 12 Volt circuit sensing is producing high readings 747
Related Circuit Diagram 747
Fault Code A166: Left rear hydraulic oil temperature sensor is low 748
Related circuit diagram 749
Fault Code A167: Right rear hydraulic oil temperature sensor is low 750
Related circuit diagram 751
Fault Code A168: Left front hydraulic oil temperature sensor is low 752
Related circuit diagram 753
Fault Code A169: Right front hydraulic oil temperature sensor is low 754
Related circuit diagram 755
Fault Code A170: Left rear hydraulic oil temperature sensor is high 756
Related circuit diagram 756
Fault Code A171: Right rear hydraulic oil temperature sensor is high 757
Related circuit diagram 757
Fault Code A172: Left front hydraulic oil temperature sensor is high 758
Related circuit diagram 758
Fault Code A173: Right front hydraulic oil temperature sensor is high 759
Related circuit diagram 759
Fault Code A182: (A30003 only) The battery 12 Volt battery tap has high voltage 760
Related circuit diagram 761
Fault Code A183: (A30003 only) The battery 12 Volt battery tap has low voltage 762
Related circuit diagram 763
Fault Code A184: J1939 data link is not connected 764
Related circuit diagram 765
Fault Code A190: (A30003 only) The automatic lubrication system has announced a fault 766
Fault Code A190: (A30004 & Up) Auto lube control has detected an incomplete lube cycle 768
Related circuit diagram 769
Fault Code A194: Left front hydraulic oil temperature is high 770
Related circuit diagram 770
Fault Code A195: Right front hydraulic oil temperature is high 771
Related circuit diagram 771
Fault Code A196: Left rear hydraulic oil temperature is high 772
Related circuit diagram 772
Fault Code A197: Right rear hydraulic oil temperature is high 773
Related circuit diagram 773
Fault Code A198: Hoist pressure 1 sensor is high 774
Related circuit diagram 774
Fault Code A199: Hoist pressure 2 sensor is high 775
Related circuit diagram 775
Fault Code A200: Steering pressure sensor is high 776
Related circuit diagram 776
Fault Code A201: Brake pressure sensor is high 777
Related circuit diagram 777
Fault Code A202: Hoist pressure 1 sensor is low 778
Related circuit diagram 778
Fault Code A203: Hoist pressure 2 sensor is low 779
Related circuit diagram 779
Fault Code A204: Steering pressure sensor is low 780
Related circuit diagram 780
Fault Code A205: Brake pressure sensor is low 781
Related circuit diagram 781
Fault Code A206: Ambient temperature sensor is high 782
Related circuit diagram 782
Fault Code A207: Ambient temperature sensor is low 783
Related circuit diagram 783
Troubleshooting by fault code, part 3 785
Fault Code A213: Parking brake should have applied but is detected as not having applied 788
Related circuit diagram 791
Fault Code A214: Parking brake should have released but is detected as not having released 792
Related circuit diagram 794
Fault Code A215: Brake auto apply valve circuit is defective 795
Related circuit diagram 796
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 797
Related circuit diagram 798
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted 799
Related circuit diagram 800
Fault Code A230: Parking brake has been requested while truck still moving 801
Related circuit diagram 802
Fault Code A231: The body is up while traveling or with selector in forward or neutral 803
Fault Code A233: Drive System Control Link is not connected 805
Related circuit diagram 807
Fault Code A235: Steering accumulator is in the process of being bled down 808
Related circuit diagram 809
Fault Code A236: The steering accumulator has not properly bled down after 90 seconds 810
Related circuit diagram 811
Fault Code A237: The CAN/RPC connection to the display is open 812
Related circuit diagram 813
Fault Code A238: Drive System and IM are reporting different park brake status 814
Related circuit diagram 816
Fault Code A239: The Drive System and IM are reporting different brake lock status 817
Related circuit diagram 818
Fault Code A240: The keyswitch input to the Interface Module is open 819
Related circuit diagram 819
Fault Code A242: Fuel gauge within the dash display panel is defective 820
Related circuit diagram 820
Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective 821
Related circuit diagram 821
Fault Code A244: Drive system temperature gauge within the dash display panel is defective 822
Related circuit diagram 822
Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective 823
Related circuit diagram 823
Fault Code A246: Payload meter reports truck overload 824
Related circuit diagram 824
Fault Code A247: Low steering pressure warning for display to operator 825
Related circuit diagram 825
Fault Code A248: Status module within the dash display panel is defective 826
Related circuit diagram 826
Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted 827
Related circuit diagram 827
Fault Code A250: Battery voltage is low with the truck parked 828
Related circuit diagram 829
Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground 830
Related circuit diagram 831
Fault Code A252: Start enable output circuit is either open or shorted to ground 832
Related circuit diagram 833
Fault Code A253: Steering bleed circuit is not open while running 834
Related circuit diagram 835
Fault Code A254: (A30003 Only) The 5 minute idle circuit is either open or shorted to ground 836
Related circuit diagram 836
Fault Code A256: Red warning lamp in the dash display (driven by IM) is open 837
Related circuit diagram 837
Fault Code A257: Payload CAN/RPC is not connected 838
Related circuit diagram 839
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 840
Related circuit diagram 840
Troubleshooting by fault code, part 4 843
Fault Code A260: Park brake failure 846
Related circuit diagram 847
Fault Code A261: Low brake accumulator pressure warning for display to operator 848
Related circuit diagram 848
Fault Code A262: Steering bleed valve circuit open during shutdown 849
Related circuit diagram 850
Fault Code A264: Park brake relay circuit is defective 851
Related circuit diagram 852
Fault Code A265: Service brake failure 853
Related circuit diagram 854
Fault Code A266: Selector switch was not in park while attempting to crank engine 855
Related circuit diagram 856
Fault Code A267: Park brake was not set while attempting to crank engine 857
Related circuit diagram 858
Fault Code A268: Secondary engine shutdown while cranking 859
Related circuit diagram 859
Fault Code A270: Brake lock switch power supply is not on when required 860
Related circuit diagram 862
Fault Code A271: Shifter not in gear 863
Related circuit diagram 864
Fault Code A272: Brake lock switch power supply is not off when required 865
Related circuit diagram 866
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit 867
Related circuit diagram 867
Fault Code A274: A brake setting fault has been detected 868
Related circuit diagram 869
Fault Code A275: A starter has been detected as engaged without a cranking attempt 870
Related circuit diagram 871
Fault Code A277: Park brake applied while loading 872
Related circuit diagram 873
Fault Code A278: Service brake applied while loading 874
Related circuit diagram 875
Fault Code A279: Low Steering Pressure Switch bad 876
Related circuit diagram 876
Fault Code A280: Steering accumulator bled switch bad 877
Related circuit diagram 877
Fault Code A281: Brake lock degrade switch bad 878
Related circuit diagram 879
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 880
Related circuit diagram 881
Fault Code A283: (A30004 & Up) An engine shutdown delay was aborted because the parking brake was not set 882
Related circuit diagram 883
Fault Code A284: (A30004 & Up) An engine shutdown delay was aborted because the secondary shutdown switch was operated 884
Related circuit diagram 885
Fault Code A285: (A30004 & Up) The park brake was not set when the keyswitch was turned off 886
Related circuit diagram 887
Fault Code A286: (A30004 & Up) A fault was detected in the shutdown delay relay circuit 888
Related circuit diagram 889
Fault Code A292: (A30004 & Up) The shutdown delay relay has remained on after the latched keyswitch circuit is off 890
Related circuit diagram 891
Fault Code A295: The right front park brake is not setting up 892
Related circuit diagram 892
Fault Code A296: The left front park brake is not setting up 893
Related circuit diagram 893
Fault Code A297:The right rear park brake is not setting up 894
Related circuit diagram 894
Fault Code A298: The left rear park brake is not setting up 895
Related circuit diagram 895
Fault Code A299: The right front park brake is not releasing 896
Related circuit diagram 896
Fault Code A300: The left front park brake is not releasing 897
Related circuit diagram 897
Fault Code A301: The right rear park brake is not releasing 898
Related circuit diagram 898
Fault Code A302: The left rear park brake is not releasing 899
Related circuit diagram 899
Troubleshooting by fault code, part 5 901
Fault Code A303: Shifter is defective 904
Related circuit diagram 905
Fault Code A304: (A30004 & Up) Auto lube grease level fault 906
Related circuit diagram 906
Fault Code A305: (A30004 & Up) Auto lube circuit is defective 907
Related circuit diagram 908
Fault Code A309: No brakes applied when expected 909
Related circuit diagram 910
Fault Code A310: Low fuel warning 911
Related circuit diagram 912
Fault Code A311: Brake lock switch is on when it should not be 913
Related circuit diagram 914
Fault Code A312: (A30004 & Up) DCDC converter 12 volt circuit sensing is producing low readings 915
Related circuit diagram 915
Fault Code A313: (A30004 & Up) DCDC converter 12 volt circuit sensing is producing high readings 916
Related circuit diagram 916
Fault Code A315: (A30004 & Up) DCDC converter 12 volt circuit is low 917
Related circuit diagram 918
Fault Code A316: Starter engagement has been attempted with engine running 919
Related circuit diagram 920
Fault Code A317: Operation of brake auto apply valve without a detected response 921
Related circuit diagram 923
Fault Code A318: Unexpected power loss to Interface Module 924
Related circuit diagram 924
Fault Code A328: Drive system not powered up 925
Related circuit diagram 925
Fault Code A335: Manual/Auto Apply Pressure Fault 926
Fault Code A350: Overload on output 1B 927
Related circuit diagram 927
Fault Code A351: Overload on output 1E 928
Related circuit diagram 929
Fault Code A352: (A30003) Overload on output 1H 930
Related circuit diagram 930
Fault Code A352: (A30004 & Up) Overload on output 1H 931
Related circuit diagram 931
Fault Code A353: Overload on output 1J 932
Related circuit diagram 932
Fault Code A354: Overload on output 1K 933
Related circuit diagram 933
Fault Code A355: Overload on output 1L 934
Related circuit diagram 934
Fault Code A356: Overload on output 1M 935
Related circuit diagram 935
Fault Code A357: Overload on output 1N 936
Related circuit diagram 936
Fault Code A358: Overload on output 1P 937
Related circuit diagram 937
Fault Code A359: Overload on output 1R 938
Related circuit diagram 939
Fault Code A360: Overload on output 1S 940
Related circuit diagram 940
Fault Code A361: (A30003) Overload on output 1T 941
Related circuit diagram 941
None 941
Fault Code A361: (A30004 & Up) Overload on output 1T 942
Related circuit diagram 943
Fault Code A362: Overload on output 1U 944
Related circuit diagram 944
Fault Code A363: Overload on output 1X 945
Related circuit diagram 945
Fault Code A364: Overload on output 1Y 946
Related circuit diagram 946
Fault Code A365: Overload on output 1Z 947
Related circuit diagram 947
Fault Code A368: Siemens Brake Test Active 948
Related circuit diagram 948
Fault Code A369: Siemens Brake Test Incomplete 949
Related circuit diagram 949
Fault Code A370: Siemens Brake Test Torque Achieved for Park Brake 950
Related circuit diagram 950
Fault Code A371: Siemens Brake Test Torque Achieved for Service Brake 951
Related circuit diagram 951
Fault Code A372: Siemens Brake Test Torque Not Achieved for Park Brake 952
Related circuit diagram 952
Fault Code A373: Siemens Brake Test Torque Not Achieved for Service Brake 953
Related circuit diagram 953
Drive system fault code table, part 1 955
Summary 958
How to use this document 958
Event code and diagnosis message 958
Description 958
Threshold 958
Detection by 958
Possible reasons 958
Action to reset 958
Action to repair 959
Operator displayed code 959
Note 959
Protection reactions 959
Event classification 960
Level 1: Warning 960
Level 2: Minor purposes 960
Level 3: Severe 960
1 L3C SYS: Time slice overflow CPU T1 961
2 L3C SYS: Time slice overflow CPU T2 961
3 L3C SYS: Time slice overflow CPU T3 961
4 L3C SYS: Time slice overflow CPU T4 961
5 L3C SYS: Time slice overflow CPU T5 961
6 L3C SYS: Time slice overflow CPU T6 961
7 L3C SYS: Time slice overflow CPU T7 961
8 L3C SYS: Time slice overflow CPU T8 961
10 L2A SYS: Pulse inhibit/asa inhibit PSU–ONLINE 962
11 L3D SYS: Pulse inhibit/asa inhibit PSU-Start-up 962
12 L1A SYS: SIBAS® blower fault 963
13 L1B SYS: Undervoltage in SIBAS® battery for BRAM 963
14 L3C SYS: SIBAS® power supply failure 24V for pulse amplifier 964
15 L3C SYS: SIBAS® power supply failure +5V 965
16 L3C SYS: SIBAS® power supply failure +15V 966
17 L3C SYS: SIBAS® power supply failure –15V 967
18 L3C SYS: SIBAS® power supply failure +24V 968
19 L3C SYS: SIBAS® power supply failure –24V 969
20 L3C SYS: SIBAS® power supply failure primary 970
21 L3C SYS: FPGA clock missing for PSU 970
22 L3C SYS: Pulse inhibit by reset in PSU from CPU 971
24 L3C SYS: General protection error (G10) 971
25 L3C SYS: Total block 972
26 L1B SYS: Permanent inhibit fault active 973
27 L1B SYS: Regular inhibit fault active 973
28 L1A SYS: GW Test stopped by A/D converter faulty 974
30 L3C DSP A: Initialization fault detected by DSP 974
31 L3C DSP A: SW-WatchdoG 975
32 L3C DSP A: Initialization fault detected by CPU 976
33 L1B DSP A: SW-Traco triggered 976
34 L1B DSP A: SW-Traco full 977
35 L3C DSP A: Time slice overflow T1 978
36 L3C DSP A: Time slice overflow T2 978
37 L3C DSP A: Time slice overflow T3 978
38 L3C DSP A: Time slice overflow T4 978
39 L1A DSP A: Communication HSCX data from DSP B missing 979
40 L1A DSP A: Communication HSCX data from DSP T missing 979
41 L3C DSP A: Current offset during pulse block 980
42 L3C DSP A: Current offset during no pulse block 980
43 L3A DSP A: Overcurrent fault 981
44 L3C DSP A: Current transducer defective phase U 982
45 L3C DSP A: Current transducer defective phase W 983
48 L1A DSP A: Modulation software fault 983
49 L3A DSP A: Active current controller at limit 984
Drive system fault code table, part 2 987
50 L3A DSP A: Active current reference at limit 990
51 L1A DSP A: Braking chopper controller at limit 990
52 L3C DSP A: Phase unbalance too large 991
53 L3A DSP A: Pulse block by DSP software 992
54 L3C DSP A: U/F Card defective 992
55 L3C DSP A: Difference in current of phase U over limit 993
56 L3C DSP A: Difference in current of phase W over limit 993
60 L3C DSP B: Initialization fault detected by DSP 994
61 L3C DSP B: SW-Watchdog 994
62 L3C DSP B: Initialization fault detected by CPU 995
63 L1B DSP B: SW-Traco triggered 995
64 L1B DSP B: SW-Traco full 996
65 L3C DSP B: Time slice overflow T1 996
69 L1A DSP B: Communication HSCX data from DSP A missing 997
70 L1A DSP B: Communication HSCX data from DSP T missing 997
71 L3C DSP B: Current offset during pulse block 998
72 L3C DSP B: Current offset during no pulse block 998
73 L3A DSP B: Overcurrent fault 999
74 L3C DSP B: Current transducer defective phase V 1000
75 L3C DSP B: Current transducer defective phase W 1001
78 L1A DSP B: Modulation software fault 1001
79 L3A DSP B: Active current controller at limit 1002
80 L3A DSP B: Active current reference at limit 1002
81 L1A DSP B: Braking chopper controller at limit 1002
82 L3C DSP B: Phase unbalance too large 1003
83 L3A DSP B: Pulse block by DSP software 1003
84 L3C DSP B: U/F Card defective 1004
85 L3C DSP B: Difference in current of phase V over limit 1004
86 L3C DSP B: Difference in current of phase W over limit 1005
90 L3C DSP T: Initialization fault detected by DSP 1005
91 L3C DSP T: SW-Watchdog 1006
92 L3C DSP T: Initialization fault detected by CPU 1007
93 L1B DSP T: SW-Traco triggered 1007
94 L1B DSP T: SW-Traco full 1008
95 L3C DSP T: Time slice overflow T1 1008
96 L3C DSP T: Time slice overflow T2 1008
97 L3C DSP T: Time slice overflow T3 1008
98 L3C DSP T: Time slice overflow T4 1008
99 L1A DSP T: Communication HSCX data from DSP A missing 1009
Drive system fault code table, part 3 1011
100 L1A DSP T: Communication HSCX data from DSP B missing 1014
101 L3C DSP T: Current offset during pulse block 1014
102 L3C DSP T: Current offset during no pulse block 1015
103 L3A DSP T: Overcurrent fault 1016
104 L3C DSP T: Current transducer defective phase U 1017
105 L3C DSP T: Current transducer defective phase V 1018
106 L3C DSP T: Current transducer defective phase W 1019
107 L3C DSP T: Sum of output current not equal zero 1020
108 L1A DSP T: Modulation software fault 1020
109 L1A DSP T: Voltage controller at limit 1021
112 L3C DSP T: Phase unbalance too large 1021
113 L3A DSP T: Pulse block by DSP software 1022
114 L3C DSP T: U/F Card defective 1022
117 L3C DSP T: Crowbar fired by DSP T 1023
119 L1C DSP T: Voltage transducer U34 not ok 1024
120 L3C IO: Supervision bus clock 1024
121 L3C IO: Supervision I/O clock 1025
122 L3C IO: Incorrect FPGA version identifier 1025
123 L3C IO: Incorrect FPGA application version identifier 1026
124 L3C IO: Incorrect module version identifier 1026
125 L3C/L1A IO: AD Converter faulty 1027
126 L3C IO: GW Comparator faulty during start-up test 1027
127 L3C IO: Test voltage not equal zero 1028
128 L1A IO: SIBAS® Temperature out of range 1028
129 L3C IO: Incorrect EBIN card identifier 1029
130 L3C IO: Front plug monitoring 1030
131 L3C IO: CPU Watchdog triggered 1031
132 L3C IO: DSP A Watchdog triggered 1031
133 L3C IO: DSP B Watchdog triggered 1032
134 L3C IO: DSP T Watchdog triggered 1032
135 L3C IO: CPU Reset triggered 1033
138 L1B IO: CPU Traco triggered 1033
146 L3A IO: Pulse block from I/O 1034
150 L3A IO: DC link voltage A level 1 exceeded 1034
151 L3A IO: DC link voltage B level 1 exceeded 1035
152 L3C IO: Trolley line overvoltage 1036
154 L3B IO: Trolley line overcurrent 1037
155 L2B IO: Trolley line current transducer faulty 1037
156 L2B IO: Trolley line voltage transducer faulty 1038
160 L3A IO: Throttle pedal out of range 1038
161 L3A IO: Retard pedal out of range 1039
162 L1A IO: Cruise speed control module out of range 1039
180 L3C UWSA1: Supervision bus clock 1040
181 L3C UWSA1: Supervision module clock 1040
182 L3C UWSA1: Incorrect FPGA version identifier 1041
183 L3C UWSA1: Incorrect FPGA project identifier 1041
184 L3C UWSA1: GW Comparator faulty during start-up test 1042
185 L1A UWSA1: ADC Faulty 1042
186 L3C UWSA1: Configuration failure 1043
187 L1A UWSA1: Hardware failure counter / processor 1043
188 L3A UWSA1: Peak current protection active 1044
189 L3D UWSA1: Peak current protection pulse start 1045
190 L3D UWSA1: Number of peak current protection >limit 1046
191 L3D UWSA1: Supervision switching frequency 1047
193 L1A UWSA1: Overvoltage level 1 exceeded 1047
196 L3D UWSA1: Limit 5 overcurrent phase U 1048
197 L3D UWSA1: Limit 5 overcurrent phase V 1048
198 L3D UWSA1: Limit 5 overcurrent phase W 1048
199 L3D UWSA1: Limit 5 overvoltage DC bus 1049
Drive system fault code table, part 4 1051
201 L3D UWSA1: Checkback INVA1 L1U faulty 1055
202 L3D UWSA1: Checkback INVA1 L1L faulty 1055
203 L3D UWSA1: Checkback INVA1 L2U faulty 1055
204 L3D UWSA1: Checkback INVA1 L2L faulty 1055
205 L3D UWSA1: Checkback INVA1 L3U faulty 1055
206 L3D UWSA1: Checkback INVA1 L3L faulty 1055
207 L3D UWSA1: Checkback chopper A faulty 1055
210 L3C UWSB1: Supervision bus clock 1056
211 L3C UWSB1: Supervision module clock 1056
212 L3C UWSB1: Incorrect FPGA version identifier 1057
213 L3C UWSB1: Incorrect FPGA project identifier 1057
214 L3C UWSB1: GW Comparator faulty during start-up test 1058
215 L1A UWSB1: ADC Faulty 1058
216 L3C UWSB1: Configuration failure 1059
217 L1A UWSB1: Hardware failure counter / processor 1059
218 L3A UWSB1: Peak current protection active 1060
219 L3D UWSB1: Peak current protection pulse start 1061
220 L3D UWSB1: Number of peak current protection >limit 1062
221 L3D UWSB1: Supervision switching frequency 1063
223 L1A UWSB1: Overvoltage level 1 exceeded 1063
226 L3D UWSB1: Limit 5 overcurrent phase V 1064
227 L3D UWSB1: Limit 5 overcurrent phase U 1064
228 L3D UWSB1: Limit 5 overcurrent phase W 1064
229 L3D UWSB1: Limit 5 overvoltage DC bus 1065
231 L3D UWSB1: Checkback INVB1 L1U Faulty 1066
232 L3D UWSB1: Checkback INVB1 L1L Faulty 1066
233 L3D UWSB1: Checkback INVB1 L2U Faulty 1066
234 L3D UWSB1: Checkback INVB1 L2L Faulty 1066
235 L3D UWSB1: Checkback INVB1 L3U Faulty 1066
236 L3D UWSB1: Checkback INVB1 L3L Faulty 1066
237 L3D UWSB1: Checkback chopper B Faulty 1066
240 L3C UWSA2: Supervision bus clock 1067
241 L3C UWSA2: Supervision module clock 1067
242 L3C UWSA2: Incorrect FPGA version identifier 1068
243 L3C UWSA2: Incorrect FPGA project identifier 1068
244 L3C UWSA2: GW Comparator faulty during start-up test 1069
245 L1A UWSA2: ADC Faulty 1069
246 L3C UWSA2: Configuration failure 1070
247 L1A UWSA2: Hardware failure counter / processor 1070
248 L3A UWSA2: Peak current protection active 1071
249 L3D UWSA2: Peak current protection pulse start 1072
250 L3D UWSA2: Number of peak current protection >limit 1073
251 L3D UWSA2: Supervision switching frequency 1074
253 L1A UWSA2: Overvoltage level 1 exceeded 1074
256 L3D UWSA2: Limit 5 overcurrent phase U1 1075
257 L3D UWSA2: Limit 5 overcurrent phase V1 1075
258 L3D UWSA2: Limit 5 overcurrent phase W1 1075
259 L3D UWSA2: Limit 5 overvoltage DC bus 1076
261 L3D UWSA2: Checkback INVA2 L1U faulty 1077
262 L3D UWSA2: Checkback INVA2 L1L faulty 1077
263 L3D UWSA2: Checkback INVA2 L2U faulty 1077
264 L3D UWSA2: Checkback INVA2 L2L faulty 1077
265 L3D UWSA2: Checkback INVA2 L3U faulty 1077
266 L3D UWSA2: Checkback INVA2 L3L faulty 1077
267 L3D UWSA2: Checkback chopper C faulty 1077
270 L3C UWSB2: Supervision bus clock 1078
271 L3C UWSB2: Supervision module clock 1078
272 L3C UWSB2: Incorrect FPGA version identifier 1079
273 L3C UWSB2: Incorrect FPGA project identifier 1079
274 L3C UWSB2: GW Comparator faulty during start-up test 1080
275 L1A UWSB2: ADC Faulty 1080
276 L3C UWSB2: Configuration failure 1081
277 L1A UWSB2: Hardware failure counter / processor 1081
278 L3A UWSB2: Peak current protection active 1082
279 L3D UWSB2: Peak current protection pulse start 1083
280 L3D UWSB2: Number of peak current protection >limit 1084
281 L3D UWSB2: Supervision switching frequency 1085
283 L1A UWSB2: Overvoltage level 1 exceeded 1085
286 L3D UWSB2: Limit 5 overcurrent phase V1 1086
287 L3D UWSB2: Limit 5 overcurrent phase U1 1086
288 L3D UWSB2: Limit 5 overcurrent phase W1 1086
289 L3D UWSB2: Limit 5 overvoltage DC bus 1087
291 L3D UWSB2: Checkback INVB2 L1U Faulty 1088
292 L3D UWSB2: Checkback INVB2 L1L Faulty 1088
293 L3D UWSB2: Checkback INVB2 L2U Faulty 1088
294 L3D UWSB2: Checkback INVB2 L2L Faulty 1088
295 L3D UWSB2: Checkback INVB2 L3U Faulty 1088
296 L3D UWSB2: Checkback INVB2 L3L Faulty 1088
297 L3D UWSB2: Checkback chopper D Faulty 1088
Drive system fault code table, part 5 1091
300 L3C UWSST: Supervision bus clock 1095
301 L3C UWSST: Supervision module clock 1095
302 L3C UWSST: Incorrect FPGA version identifier 1096
303 L3C UWSST: Incorrect FPGA project identifieR 1096
304 L3C UWSST: GW Comparator faulty during start-up test 1097
305 L1A UWSST: ADC Faulty 1097
306 L3C UWSST: Configuration failure 1098
307 L1A UWSST: Hardware failure counter / processor 1098
308 L3A UWSST: Peak current protection active 1099
310 L3D UWSST: Number of peak current protection >limit 1100
311 L3D UWSST: Supervision switching frequency 1101
314 L3C UWSST: Crowbar is fired without command 1102
319 L3D UWSST: Limit 5 overvoltage DC bus 1104
321 L3D UWSST: Checkback INVST L1U Faulty 1105
322 L3D UWSST: Checkback INVST L1L Faulty 1105
323 L3D UWSST: Checkback INVST L2U Faulty 1105
324 L3D UWSST: Checkback INVST L2L Faulty 1105
325 L3D UWSST: Checkback INVST L3U Faulty 1105
326 L3D UWSST: Checkback INVST L3L Faulty 1105
327 L3C UWSST: Checkback crowbar faulty 1106
330 L1A BUS: CAN Communication failure 1107
331 L1A BUS: Serial link communication failure 1107
332 L1A BUS: Truck is over loaded 1107
333 L1B TR: Transient traco is triggered 1108
334 L1B TR: Transient traco is full 1108
340 L1A ETM: ADC Failure for ETM1 1108
341 L1A ETM: ADC Failure for ETM2 1109
342 L1A ETM: ADC Failure for ETM3 1109
343 L1A ETM: ADC Failure for ETM4 1109
344 L1A MEFA: ADC Failure 1110
345 L3C HL: Gate unit power supply A defective 1110
346 L3C HL: Gate unit power supply B defective 1111
351 L1A DRZ: LIMP Mode A active 1112
352 L1A DRZ: Limp mode B active 1112
353 L1A DRZ: Low battery voltage 1113
354 L1B BUS: Engine floor input increasing minimum engine speed 1113
355 L1B DM: Data store switch pressed 1114
356 L1B DM: Diagnosis memory configuration failure 1114
357 L1B DM: Diagnosis memory occupation > 75% 1114
358 L1B DM: Diagnosis memory full 1115
359 L1B DM: Test event 1115
360 L2A EXT: Main blower air flow supervision 1116
361 L2A EXT: Minimum engine speed supervision 1117
362 L1A EXT: Main blower pressure switch malfunction 1118
363 L1A EXT: Shift lever supervision 1119
364 L2A EXT: Engine derate protection active 1120
365 L1A EXT: Truck external plug monitoring 1120
367 L3A EXT: DC Power off mod request (rest switch on) 1121
369 L1A EXT: Doppler sensor defective 1123
370 L1A EXT: Auto lube control defective 1124
372 L1A EXT: Service brake pressed at high speeD 1124
373 L1A EXT: Service brake on above speed limit 1125
374 L1A EXT: Anti-roll control malfunction 1125
375 L3B BEF: CB301 Circuit breaker defective 1126
376 L3B BEF: K303/K304 Contactor defective 1127
377 L3C STP: Voltage reading incorrect between trolley line and voltage in stepdown box 1128
382 L3B BEF: K103 Feedback defective 1129
383 L3B BEF: K105 Feedback defective 1129
384 L1A BEF: K107 Feedback defective 1130
385 L1A BEF: K109 Feedback defective 1130
386 L1A BEF: K111 Feedback defective 1131
387 L1A BEF: Limp mode selector defective 1131
388 L2B BEF: CB113 Tripped 1132
390 L3D IUW: Output current supervision INV A 1132
391 L3D IUW: Output current supervision INV B 1133
392 L3B IUW: Precharge supervision 1 1134
393 L3B IUW: Precharge supervision 2 1135
394 L3A IUW: DC Link undervoltage 1136
395 L2B IUW: Trolley line undervoltage 1137
397 L3B IUW: Field regulator current setpoint supervision 1138
398 L2B IUW: Field regulator output current supervision 1139
399 L3B IUW: Alternator overcurrent protection 1140
Drive system fault code table, part 6 1143
400 L2C IUW: Alternator overload warning 1146
401 L2B IUW: Alternator overload protection 1146
402 L3C IUW: Alternator AC current sensor faulty 1147
403 L2A IUW: DC Link voltage out of range in propel 1148
404 L3A IUW: DC Link voltage out of range retard 1149
405 L3A IUW: DC Link voltage out of range for ST operation 1150
406 L3B IUW: DC Link controller supervision 1151
407 L2C IUW: Motor torque square T supervision 1152
408 L2C IUW: Motor current square T supervision 1152
409 L1A IUW: DC Link discharge time exceeded limit 1153
410 L2B IUW: Ground fault at positive DC link detected 1154
411 L2B IUW: Ground fault at negative DC link detected 1155
412 L2B IUW: Ground fault at AC side detected 1156
413 L2B IUW: Ground fault 1157
414 L3C IUW: Chopper A current supervision 1158
415 L3C IUW: Chopper B current supervision 1159
416 L3C IUW: Chopper C current supervision 1160
417 L3C IUW: Chopper D current supervision 1161
418 L3D IUW: Output current supervision INV ST 1162
419 L2A IUW: Vehicle overspeed supervisioN 1163
420 L1A IUW: DC Link voltage sensor A faulty 1164
421 L1A IUW: DC Link voltage sensor B faulty 1165
422 L3C IUW: ST Inverter failure 1166
423 L3B IUW: DC Grid fan circuit failure 1166
424 L2B IUW: Cooling water pressure out of range 1167
425 L2B IUW: Cooling water level out of range 1168
426 L1A IUW: Water pump motor overtemperature 1169
427 L1A IUW: Retard limit supervision 1169
428 L1A DRZ: Front wheel A speed sensor supervision 1170
429 L1A DRZ: Front wheel B speed sensor supervision 1171
430 L3D DRZ: Motor A speed sensor supervision 1172
431 L3D DRZ: Motor B speed sensor supervision 1173
432 L3C DRZ: Alternator speed sensor supervision 1174
433 L2A DRZ: Motor A maximum speed exceeded 1175
434 L2A DRZ: Motor B maximum speed exceeded 1175
435 L1A DRZ: Alternator maximum speed exceeded 1176
436 L3A DRZ: Motor A/B rotation inconsistency 1177
437 L3A DRZ: Motor A torque supervision 1178
438 L3A DRZ: Motor B torque supervision 1179
439 L3C SIV: Start-up sequence can’t pass due to GUPS failure 1180
440 L3C SIV: Start-up sequence can’t pass due to K103/K105 failure 1181
441 L3C SIV: Start-up sequence can’t pass due to IGBT failure 1182
442 L3C SIV: Start-up sequence can’t pass due to CB301 OR K303 failure 1183
443 L3C SIV: Start-up sequence can’t pass due to crowbar failure 1184
447 L1A SIV: Direct trolley engage sequence supervision 1185
448 L1A SIV: Direct trolley disengage sequence supervision 1186
Drive system fault code table, part 7 1189
450 L1A TMP: SIBAS® Temperature < low limit 1193
451 L1A TMP: SIBAS® Temperature > warning limit 1193
452 L3B TMP: SIBAS® Temperature > shutdown limit 1194
453 L3A TMP: IGBT Module A101 temperature < low limit 1195
454 L2C TMP: IGBT Module A101 temperature > APRS limit 1196
455 L3A TMP: IGBT Module A101 temperature > shutdown limit 1197
456 L3A TMP: IGBT Module A102 temperature < low limit 1198
457 L2C TMP: IGBT Module A102 temperature > APRS limit 1199
458 L3A TMP: IGBT Module A102 temperature > shutdown limit 1200
459 L3A TMP: IGBT ModulE A201 temperature < low limit 1201
460 L2C TMP: IGBT Module A201 temperature > APRS limit 1202
461 L3A TMP: IGBT Module A201 temperature > shutdown limit 1203
462 L3A TMP: IGBT Module A202 temperature < low limit 1204
463 L2C TMP: IGBT Module A202 temperature > APRS limit 1205
464 L3A TMP: IGBT Module A202 temperature >shutdown limit 1206
465 L3A TMP: ST Module temperature < low limit 1207
466 L2C TMP: ST Module temperature > warning limit 1208
467 L3A TMP: ST Module temperature > shutdown limit 1209
468 L2B TMP: SR Module temperature < low limit 1210
469 L2C TMP: SR Module temperature > warning limit 1211
470 L2B TMP: SR Module temperature > shutdown limit 1212
471 L2C TMP: Wheel motor A stator temperature > APRS limit 1213
472 L3A TMP: Wheel motor A stator temperature > shutdown limit 1214
473 L2C TMP: Wheel motor B Stator temperature > APRS limit 1215
474 L3A TMP: Wheel motor B stator temperature shutdown limit 1216
475 L2C TMP: Wheel motor A, DE bearing temperature > warning limit 1217
476 L3A TMP: Wheel motor A, DE bearing temperature > shutdown limit 1218
477 L2C TMP: Wheel motor A NDE bearing temperature > warning limit 1219
478 L3A TMP: Wheel motor A NDE bearing temperature > shutdown limit 1220
479 L2C TMP: Wheel motor B DE bearing temperature > warning limit 1221
480 L3A TMP: Wheel motor B DE bearing temperature > shutdown limit 1222
481 L2C TMP: Wheel motor B NDE bearing temperature > warning limit 1223
482 L3A TMP: Wheel motor B NDE bearing temperature > shutdown limit 1224
483 L2C TMP: Alternator stator temperature > APRS limit 1225
484 L2B TMP: Alternator stator temperature > shutdown limit 1226
485 L2C TMP: Alternator bearing temperature > warning limit 1227
486 L2B TMP: Alternator bearing temperature > shutdown limit 1228
487 L1A TMP: Cooling water inlet temperature < low limit 1229
488 L2C TMP: Cooling water inlet temperature > warning limit 1230
489 L2B TMP: Cooling water inlet temperature > shutdown limit 1231
490 L1A TMP: Cooling water outlet temperature < low limit 1232
491 L2C TMP: Cooling water outlet temperature > warning limit 1233
492 L2B TMP: Cooling water outlet temperature > shutdown limit 1234
493 L1A TMP: Cooling water delta T too high 1235
495 L2C TMP: Inverter cab temperature > warning limit 1236
496 L2B TMP: Inverter cab temperature > shutdown limit 1237
497 L2C TMP: Inside cooler outlet temperature > warning limit 1238
498 L2B TMP: Inside cooler outlet temperature > shutdown limit 1239
499 L1A TMP: Main blower motor stator temperature > warning limit 1240
500 L1A TMP: Main blower motor stator temperature > shutdown limit 1241
505 L1A TMP: Wheel motor A rotor temperature > limit 1242
506 L1A TMP: Wheel motor B rotor temperature > limit 1243
508 L1A ETM1: Alternator PT100 open circuit 1244
509 L1A ETM1: Main blower stator PT100 open circuit 1244
510 L1A ETM1: Grid blower statoR PT100 open circuit 1244
511 L1A ETM1: Inverter CAB PT100 open circuit 1244
512 L1A ETM1: Ambient PT100 open circuit 1244
513 L1A ETM1: Heater exchanger PT100 open circuit 1244
514 L1A ETM1: Cooling water inlet PT100 open circuit 1244
515 L1A ETM1: Cooling water outlet PT100 open circuit 1244
516 L1A ETM2: Motor A NDE Bearing PT100 open circuit 1245
517 L1A ETM2: Motor A DE Bearing PT100 open circuit 1245
518 L1A ETM2: Motor B NDE Bearing PT100 open circuit 1245
519 L1A ETM2: Motor B DE Bearing PT100 open circuit 1245
520 L1A ETM2: Alternator Bearing PT100 open circuit 1245
521 L1A ETM2: Motor A stator PT100 open circuit 1245
522 L1A ETM2: Motor B stator PT100 open circuit 1245
523 L1A ETM2: Motor inlet air PT100 open circuit 1245
524 L1A ETM3: IGBT Module A101 PT100 open circuit 1246
525 L1A ETM3: IGBT Module A102 PT100 open circuit 1246
526 L1A ETM3: IGBT Module A103 PT100 open circuit 1246
527 L1A ETM3: IGBT Module A104 PT100 open circuit 1246
528 L1A ETM3: IGBT Module A201 PT100 open circuit 1246
529 L1A ETM3: IGBT Module A202 PT100 open circuit 1246
530 L1A ETM3: IGBT Module A203 PT100 open circuit 1246
531 L1A ETM3: IGBT Module A204 PT100 open circuit 1246
532 L1A ETM3: ST Module PT100 open circuit 1247
533 L1A ETM3: SR Module PT100 open circuit 1247
534 L1A ETM3: Channel 7 PT100 open circuit 1247
535 L1A ETM3: Channel 8 PT100 open circuit 1247
536 L1A ETM4: Channel 1 PT100 open circuit 1248
537 L1A ETM4: Channel 2 PT100 open circuit 1248
538 L1A ETM4: Channel 3 PT100 open circuit 1248
539 L1A ETM4: Channel 4 PT100 open circuit 1248
540 L1A ETM4: Channel 5 PT100 open circuit 1248
541 L1A ETM4: Channel 6 PT100 open circuit 1248
542 L1A ETM4: Channel 7 PT100 open circuit 1248
543 L1A ETM4: Channel 8 PT100 open circuit 1248
544 L1A ETM4: SR Module PT100 open circuit 1248
550 L3A TMP: Inverter A module temperature < low limit 1249
551 L2C TMP: Inverter A module temperature > APRS limit 1250
552 L3A TMP: Inverter A module temperature > shutdown limit 1251
553 L3A TMP: Inverter B module temperature < low limit 1252
554 L2C TMP: Inverter B module temperature > APRS limit 1253
555 L3A TMP: Inverter B module temperature > shutdown limit 1254
556 L3A TMP: Chopper A module temperature < low limit 1255
557 L2C TMP: Chopper A module temperature > APRS limit 1256
558 L3A TMP: Chopper A module temperature > shutdown limit 1257
559 L3A TMP: Chopper B module temperature < low limit 1258
560 L2C TMP: Chopper B module temperature > APRS limit 1259
561 L3A TMP: Chopper B module temperature > shutdown limit 1260
Payload meter scoreboard 1263
Display messages 1265
LED lights 1265
Processor LED (2, Figure 50-1) 1265
Data Receive LED (3, Figure 50-1) 1265
Option switches 1266
SWITCH 1 – TEST (Displays “888”) 1266
SWITCH 2 – COUNT 1266
SWITCH 9 – TRANSMIT CUT 1266
SWITCH 10 – HIGH IMPEDANCE LISTEN 1266
Troubleshooting 1267
Troubleshooting chart 1267
Symptom 1267
Possible Cause 1267
Remedy 1267
Electric wheel motor 1269
Fault table 1271
Reserve engine oil system 1279
Pumping unit LED signals 1281
Circuit fuses 1281
Steering system 1283
Steering circuit troubleshooting chart 1285
Steering circuit troubleshooting guidelines 1287
Basic hydraulic system checks 1288
System leakage check 1289
Steering pump troubleshooting guide 1291
Pump pressure control checks 1294
To verify pump unload pressure 1294
To verify pump reloading 1294
Pump fails to unload 1295
Pump fails to develop pressure 1295
Pump slow in developing pressure 1296
Pump control valve inspection and trouble shooting 1297
Pump case drain check 1299
Definitions: 1300
Adjustment 1300
Automatic lubrication (auto lube) system 1303
Autolube troubleshooting chart 1305
50 Disassembly and assembly 1309
Service tools 1309
Special tool list 1311
Additional tool list 1311
Wheel motor rebuild tools 1312
Control cabinet 1312
Cab air conditioning 1315
Replacement of air conditioning system components 1317
Hoses and fittings 1317
Lines 1317
Expansion valve 1317
Receiver-drier 1317
Thermostat 1317
Compressor 1318
Accumulator 1318
Clutch 1318
Wheels, spindles and rear axle 1321
General precautions for tires and rims 1323
Wheel stud maintenance 1324
Front tires and rims 1325
Removal 1325
Installation 1326
Rear tires and rims 1326
Removal 1326
Installation 1327
Rim components 1329
Smart Rim Component Layout 1329
Rim and tire service 1330
Lubricants 1330
Tire Inflation 1330
Lock Ring Retainer Installation 1330
Remove Smart Lock Ring from Inside Position of Outer Dual and Outside Position of Inner Dual 1331
Install Smart Lock Ring to Inside Position of Outer Dual and Outside Position of Inner Dual 1332
Removal (5-Piece Standard Rim) 1333
Removal (7-Piece Smart Rim) 1336
Removal (5-Piece Smart Rim) 1338
Preparation Before Assembly 1340
Installation (5-Piece Standard Rim) 1340
Installation – Horizontal Mount (Smart Rim) 1342
Installation – Vertical Mount (5-Piece Smart Rim) 1344
Installation – Vertical Mount (7-Piece Smart Rim) 1346
Removal and installation of front wheel hub and spindle 1347
Removal 1347
Spindle Removal Procedure (off of the truck) 1350
Installation 1353
Disassembly and assembly of front wheel hub and spindle 1354
Disassembly 1354
Cleaning and inspection 1354
Assembly 1356
Wheel bearing adjustment 1356
Seal assembly gap check and adjustment 1357
Floating seal installation 1358
Floating seal test procedure 1365
Speed sensor installation and adjustment 1366
Removal and installation of wheel motor 1366
Preparation 1366
Removal 1367
Cleaning and inspection 1368
Installation 1368
Removal and installation of rear axle 1371
Removal 1371
Cleaning and inspection 1373
Installation 1373
Removal and installation of anti-sway bar 1374
Removal 1374
Installation 1374
Removal and installation of pivot pin 1375
Removal 1375
Installation 1375
Pivot eye and bearing service 1376
Bearing inspection 1376
Bearing removal 1377
Bearing installation 1378
Pivot eye repair 1378
Removal and installation of electric motor 1379
Removal 1379
Installation 1380
Disassembly and assembly of wheel motor transmission 1381
Disassembly 1381
Cleaning and inspection 1388
Assembly 1388
Disassembly and assembly of low speed carrier 1400
Disassembly 1400
Inspection 1401
Assembly 1402
Disassembly and assembly of high speed carrier 1405
Disassembly 1405
Inspection 1406
Assembly 1407
Brake system 1411
Removal and installation of brake valve 1413
Removal 1413
Installation 1414
Disassembly and assembly of brake valve/pedal assembly 1414
Disassembly 1414
Assembly 1415
Removal and installation of dual relay valve 1417
Removal 1417
Installation 1418
Removal and installation of brake manifold 1419
Removal 1419
Installation 1419
Disassembly and assembly of brake manifold 1420
Disassembly 1420
Assembly 1420
Removal and installation of brake accumulator (piston style) 1421
Removal 1421
Installation 1423
Disassembly and assembly of brake accumulator (piston style) 1423
Disassembly 1423
Cleaning and inspection 1425
Piston seal replacement 1426
Assembly 1426
Removal and installation of brake accumulators (bladder style) 1427
Removal 1427
Installation 1428
Disassembly and assembly of brake accumulator (bladder style) 1429
Disassembly 1429
Cleaning and inspection 1430
Assembly 1431
Disassembly and assembly of wheel brake 1432
Disassembly 1433
Cleaning and inspection 1436
Assembly 1437
Floating ring seal assembly and installation 1443
Removal and installation of rear brake assembly 1451
Removal 1451
Installation 1451
Steering system 1457
Removal and installation of steering control unit 1459
Removal 1459
Installation 1460
Disassembly and assembly of steering control unit 1461
Disassembly 1461
Assembly 1463
Removal and installation of steering column 1466
Removal 1466
Inspection 1466
Installation 1467
Removal and installation of steering wheel 1468
Removal 1468
Installation 1468
Removal and installation of bleeddown manifold 1470
Removal 1470
Installation 1470
Removal and installation of flow amplifier 1472
Removal 1472
Installation 1472
Removal and installation of steering cylinder 1472
Removal 1472
Bearing replacement 1472
Installation 1473
Disassembly and assembly of steering cylinders 1474
Disassembly 1474
Assembly 1474
Removal and installation of tie rod 1475
Removal 1475
Installation 1476
Removal and installation of steering/brake pump 1476
Removal 1476
Installation 1477
Disassembly and assembly of steering/brake pump 1479
Disassembly 1479
Inspection 1482
Assembly 1485
Driveshaft group 1486
Rotating group 1486
Removal and installation of steering accumulators (piston style) 1489
Removal 1489
Installation 1491
Disassembly and assembly of steering accumulator (piston style) 1491
Cleaning and Inspection 1493
Piston seals replacement 1493
Assembly 1494
Removal and installation of steering accumulators (bladder style) 1495
Removal 1495
Installation 1496
Disassembly and assembly of steering accumulator (bladder style) 1496
Disassembly 1496
Cleaning and Inspection 1497
Assembly 1498
Suspensions 1501
Removal and installation of front suspension 1503
General information 1503
Removal 1503
Installation 1505
Upper mounting joint – 60° advance 1509
Inspection 1510
Minor front suspension repairs (lower bearing and seals) 1511
Lower bearing retainer removal 1511
Lower bearing retainer installation 1511
Major front suspension rebuild 1512
Disassembly 1512
Assembly 1513
Removal and installation of rear suspension 1515
General information 1515
Removal 1515
Installation 1518
Disassembly and assembly of rear suspension 1519
Disassembly 1519
Cleaning and Inspection 1519
Assembly 1520
Hoist circuit 1523
Removal and installation of hoist pump 1525
Removal 1525
Installation 1526
Disassembly and assembly of hoist pump 1528
Disassembly 1528
Inspection 1533
Assembly 1534
Removal and installation of hoist valve 1537
Removal 1537
Installation 1538
Disassembly and assembly of hoist valve 1538
O-ring replacement 1538
Disassembly of inlet section 1540
Assembly of inlet section 1541
Disassembly of rear spool section 1542
Assembly of rear spool section 1544
Disassembly of front spool section 1545
Assembly of front spool section 1546
Overcenter manifold service 1546
Removal and installation of hoist pilot valve 1547
Removal 1547
Installation 1547
Disassembly and assembly of hoist pilot valve 1548
Disassembly 1548
Cleaning and inspection 1549
Assembly 1549
Removal and installation of hoist cylinders 1550
Removal 1550
Installation 1551
Disassembly and assembly of hoist cylinders 1553
Disassembly 1553
Cleaning and inspection 1555
Installation of the quill 1556
Assembly 1558
Replacement of hoist circuit filter 1560
Filter element replacement 1561
Operator cab 1563
Removal and installation of operator cab 1565
Removal 1566
Installation 1567
Removal and installation of cab door 1569
Removal 1569
Installation 1569
Disassembly and assembly of cab door 1569
Removing door panel 1569
Installing door panel 1570
Replacing door window regulator 1570
Replacing door handle or latch assembly 1571
Replacing door assembly seal and door hinge seal 1572
Replacing door opening seal 1572
Removing door glass 1573
Installing door glass 1574
Adjustment of cab door 1576
Door jamb bolt adjustment 1576
Door handle plunger adjustment 1577
Removal and installation of side window glass 1578
Recommended tools and supplies 1578
Removal 1579
Installation 1579
Removal and installation of windshield and rear window glass 1580
Removal 1580
Installation 1580
Removal and installation of windshield wiper motor 1581
Removal 1581
Installation 1581
Removal and installation of windshield wiper arm 1582
Removal 1582
Installation 1582
Removal and installation of windshield wiper linkage 1583
Removal 1583
Installation 1583
Removal and installation of operator seat (standard seat) 1584
Adjustment 1584
Inspection 1585
Removal 1585
Installation 1585
Replacing the Seat Compressor 1586
Removal and installation of passenger seat (standard seat) 1591
Adjustment 1591
Inspection 1592
Removal 1592
Installation 1592
Removal and installation of seat belts (standard seat) 1593
Removal 1593
Installation 1593
Operator seat (optional seat) 1594
Seat Belts 1594
Adjustment 1594
Passenger seat (optional seat) 1596
Seat Belts 1596
Adjustment 1596
Removal and installation of seat belts (optional seat) 1597
General 1597
Removal 1597
Installation 1599
Body and structures 1603
Removal and installation of dump body 1605
Removal 1605
Inspection 1606
Installation 1607
Removal and installation of body pads 1607
Removal 1607
Installation 1608
Body pad shimming procedure 1608
Removal and installation of diagonal ladder/ hood and grille assembly 1609
Removal 1609
Installation 1609
Removal and installation of right deck 1610
Removal 1610
Installation 1612
Removal and installation of left deck 1613
Removal 1613
Installation 1613
Removal and installation of fuel tank 1615
Removal 1615
Cleaning and inspection 1615
Installation 1617
Removal and installation of horizontally mounted fuel gauge sender 1617
Removal 1617
Installation 1617
Removal and installation of vertically mounted fuel gauge sender 1617
Installation 1617
Disassembly and assembly of fuel tank breather 1619
Disassembly 1619
Assembly 1619
Removal and installation of hydraulic tank 1620
Removal 1620
Installation 1620
Three phase wheel motor 1623
Qualified personnel 1626
General safety information 1626
Handling 1627
Motor 1627
Transport 1628
Storage 1629
Storage of new motors 1629
Storage of used motors 1630
Maintenance 1630
Motor 1630
Safety guidelines 1631
Maintenance intervals 1632
Maintenance work on the installed motor 1632
Checking for external damage 1632
Checking the connections 1633
Regreasing the bearings 1633
Applying grease to the bearings 1633
Checking the interior of the motor for water 1634
Disassembly 1635
Pressing off the coupling 1636
Disassembly 1637
Rotor 1637
Removing the rubber seals and the air baffles 1642
Bearing and labyrinth ring 1643
Removal 1643
Maintenance work 1644
Stator Inspection 1644
Rotor Inspection 1644
Testing the insulation 1645
High-voltage test 1645
Work on the bearings 1646
Assembly 1647
Assembling the rubber seals and the air baffles 1648
Assembly after special repair work 1650
Bearing installation 1651
Preparatory measures for assembling the bearing (Figure 50-20 must be observed): 1654
Assemble the bearing 1655
Cover installation 1656
Assembling the bearing shield (N-end) at the stator frame 1657
Bearing installation 1659
Rotor installation 1661
Labyrinth ring 1663
Installation 1663
Installing accessories (D- and N-end) 1665
Running in the bearings 1669
Coupling 1670
Installation 1670
Assembly conditions and instructions 1671
Tests 1671
Repair work 1672
Replacing defective connecting leads 1672
Repairing the stator winding insulation 1673
Recommended consumables 1673
Chemical cleaning agents 1673
Chemical cleaning agents for outdoor use and for cleaning mechanical parts 1673
Chemical cleaning agents for flange faces 1673
Chemical cleaning agents for windings 1674
Chemical cleaning agents for windings 1674
Chemical cleaning agents for windings with severe damage and for oily windings 1674
Rolling-contact bearing grease 1674
Assembly/disassembly agents for bearing seat 1674
Sealants for joining parts or gaps 1674
Locking agents for connecting elements 1674
Anti-corrosion agent 1674
Assembly paste for temperature sensors 1674
List of tools 1675
Mounting devices for inserting and withdrawing the rotor horizontally 1675
Press for expanding the coupling 1675
Compression devices for pressing on or for support while pressing off 1676
Pulling units with cross beam or disk 1678
Aids 1678
Extraction devices 1679
Repair parts list 1679
Paints for refinishing the painted parts or touching up damaged parts 1679
Power module 1681
Removal and installation of power module 1683
General 1683
Preparation 1683
Removal 1684
Installation 1689
Exhaust tube installation 1691
Exhaust blanket installation 1691
Removal and installation of alternator 1692
Removal 1692
Installation 1694
Engine flywheel adapter face runout 1694
Engine crankshaft endplay 1695
Engine flywheel to flywheel housing adapter – measurement “C” 1695
Alternator housing to rotor – measurement “A” 1696
Measurements after joining the alternator and engine 1698
Flywheel housing face runout 1699
Flywheel housing radial runout 1699
Flywheel/flexplate face runout 1700
Flywheel/flexplate radial runout 1700
Rotor shaft radial runout (assembled) 1701
Joining the alternator and engine 1702
Removal and installation of engine 1704
Removal 1704
Service 1704
Installation 1704
Removal and installation of radiator 1704
Removal 1704
Installation 1706
Repairing the radiator 1708
Internal inspection 1708
External cleaning 1708
Disassembly 1708
Cleaning and inspection 1709
Assembly 1710
Pressure testing 1711
Main blower 1713
Removing the main blower motor 1715
Disassembling the main blower motor 1721
Assembling the main blower motor 1723
Installing the main blower motor 1726
Retarding grid 1733
Removing the grid blower motor 1735
Disassembling the grid blower motor 1737
Assembling the grid blower motor 1739
Installing the grid blower motor 1741
Removing a grid element 1746
Control cabinet 1749
Removing the SIBAC Inverter Module 1751
Required tools/materials 1751
Removal 1754
Installing the SIBAC Inverter Module 1758
Draining and filling the IGBT coolant system 1759
Required tools/materials 1759
Coolant mixture specification (distilled water: Antifrogen® N) 1759
Draining and filling the coolant 1761
Removing and installing the IGBT coolant pump assembly 1764
Required tools/materials 1764
Removal 1765
90 Diagrams and drawings 1769
Hydraulic circuit diagrams 1769
Electrical circuit diagrams – 24V system 1775
Electrical circuit diagrams – drive system 1833

S.V 16/12/24