Komatsu 860E-1KT DUMP TRUCK Shop Manual CEBM025804 – PDF DOWNLOAD

Description

Komatsu 860E-1KT DUMP TRUCK Shop Manual CEBM025804 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 860E-1KT DUMP TRUCK Shop Manual CEBM025804 – PDF DOWNLOAD

Language : English
Pages :1908
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 860E-1KT DUMP TRUCK Shop Manual CEBM025804 – PDF DOWNLOAD

SERIAL NUMBERS 860E-1KT
A30102-A30106, A30111 – A30116

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 Nm (100 ft lb).
• All torque specifications have ±10% tolerance unless otherwise 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. NOTE: Accumulations of mud, frozen material, etc, become part of the GVW and reduces the allowable payload. To maximize payload and to keep from exceeding the maximum GVW rating, these accumulations should be removed as often as practical. Exceeding the allowable payload will reduce the expected life of truck components.

TABLE OF CONTENTS:

Komatsu 860E-1KT DUMP TRUCK Shop Manual CEBM025804 – PDF DOWNLOAD

SERIAL NUMBERS 860E-1KT
A30102-A30106, A30111 – A30116

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 109 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): 94
Lowering The Dump Body (When dumping over a berm or into a crusher): 95
Trolley operating instructions 95
Operating in trolley line mode 95
Getting on line 96
Operating on trolley 96
Getting off line 97
Line status signals 97
Trolley disconnect 98
Traffic consideration for trolley line operation 98
Approaching slow moving vehicles in a trolley assisted truck 98
Operating slow moving vehicles on trolley assist ramps 99
Truck failure while on trolley 99
Using the speed control feature 100
Safe parking procedures 100
Normal engine shutdown procedure 101
Sudden loss of engine power 102
Fuel depletion 103
Towing 103
Special Wiring Harness 103
Towing Procedure 104
Disabled truck operation 106
Steering and brake system 106
Components Required 106
Hookup 107
Disabled truck dumping procedure 108
Hookup 108
Raising the Body 108
Lowering the Body 109
01 Specification 111
Specification and technical data 111
Specification drawing 113
Specifications 114
Weight table 116
Fuel, coolant and lubricants 117
Mixing rate of water and anti-freeze 117
Suspension cylinder oil and nitrogen specifications 118
10 Structure and functions 121
Cab air conditioning 121
General information 123
Environmental impact of air conditioning 123
Air conditioning for off-highway vehicles 123
Principles of refrigeration 124
Air conditioning 124
Refrigeration – the act of cooling 124
The refrigeration cycle 124
Air conditioning system components 126
Relays 126
Fan motor and speed control 126
Cab air filter 126
Heater core 126
Actuators 126
Compressor (refrigerant pump) 128
Service valves 128
Condenser 128
Receiver-drier 128
Expansion valve 129
Accumulator 129
Evaporator core 129
Air conditioning system electrical circuit 130
Thermostat 130
Compressor clutch 130
Trinary™ switch 131
Steering circuit 133
Steering circuit operation 135
Steering circuit components 137
Steering control unit 137
High pressure filter 137
Steering accumulators 137
Bleeddown manifold 138
Steering accumulator bleeddown solenoid 141
Quick disconnect ports 141
Hoist up limit solenoid 141
Flow amplifier 141
Flow amplifier operation 142
No steer 142
Steering left 144
Steering right 146
No steer, external shock load 148
Steering/brake pump operation 151
Normal operation 151
Neutral position 152
Full pump volume 153
Half pump volume 153
Steering cylinder wear data 154
Hoist circuit 157
Hoist circuit operation 159
Hoist circuit components 160
Hydraulic tank 160
Hoist pump 160
High pressure filters 160
Hoist valve 160
Hoist limit solenoid 161
Pilot operated check valve 161
Hoist pilot valve 162
Overcenter manifold 163
Hoist pilot valve operation 163
Float position of pilot valve with truck body on frame 164
Power up operation 166
Hold operation 168
Power down operation 170
Float operation 172
Hoist cylinder wear data 174
Brake circuits 177
General information 179
Service brake circuit operation 180
Secondary braking system and auto apply 180
Rear wheel brake lock circuit operation 182
Parking brake circuit operation 184
Normal operation (engine start switch ON, engine on) 184
Brake lines and test ports 186
Brake warning circuit operation 187
Brake assembly wear data 189
Suspensions 191
General information 193
Front suspension wear data 193
Rear suspension wear data 194
Electrical system, 24 volt 197
Battery supply system 199
Auxiliary control cabinet components 200
24VDC to 12VDC converter 200
Diode board – DB1 200
Power distribution terminals 200
Control power relay 201
Fuse blocks 202
Relay boards 202
Relay boards RB1, RB3, RB4, RB5 202
Relay boards RB6, RB7, RB8, RB9 204
Relay functions 204
Body position switches (With proximity switch and metal arm) 206
Body-up switch 206
Hoist limit switch 207
Body position switches (With proximity switch and magnet) 208
Proximity switch operation 208
Body-up Switch 208
Hoist limit switch 208
Interface module (IM) 211
General information 213
Service 213
Sensors 213
Temperature sensors 213
Pressure sensors 214
Interface module inputs and outputs 215
Drive system 221
SR rectifier module 224
ST module (auxiliary voltage inverter) 224
Technical Data 227
SD phase modules 228
SR/ST/SD module removal 228
Inverter cabinet layout 229
Inverter cabinet water flow 229
Field regulator 230
Technical Data 230
Field regulator (discharge resistor) 230
Technical Data 230
Gate Unit 231
Technical Data 231
Technical Data 231
Technical Data 231
Control power filter 232
Technical Data 232
Filter for TCU 232
Technical Data 232
Terminal block bus bar 233
Technical Data 233
Fuses (analog sensor voltage) 234
Technical Data 234
Fuses (field regulator) 234
Technical Data 234
Fuses (fuse holder for field regulator) 234
Fuses (control power and trolley box contactor) 235
Technical Data 235
Diode modules 235
Technical Data 235
Support capacitors 236
Technical Data 236
3-Phase capacitor bank (for ST module output voltage) 236
Technical Data 236
Air-cooled inductors (for ST module) 237
Technical Data 237
3-Phase transformer (for ST module) 237
Technical Data 237
Diagnostics box 238
Diagnostic and system monitoring panel 239
Technical Data 239
Current transducers 240
Device names: 240
Technical Data 240
Technical Data 240
Current transducers (for ST module output) 241
Technical Data 241
Voltage transducers 242
Technical Data 242
Voltage transducers (for ST module output) 242
Technical Data 242
Voltage transducers (SiBAS® 24V DC bus monitoring) 243
Analog inclinometer 243
Technical Data 243
DC link capacitors 244
Technical Data 244
Ground tie capacitor 244
Technical Data 244
Low-inductance bus bar assembly 245
Free-wheeling diode for low-inductance bus bars 245
Contactor (grid box and main blower motor) 246
Technical Data 246
Contactor (control power) 246
Technical Data 246
Contactor (DC contactors) 247
Technical Data 247
Contactor (crowbar bypass) 247
Technical Data 247
Temperature probes (PT100 style) 248
Technical Data 248
Coolant inlet temperature sensor 248
Technical Data 248
Coolant outlet temperature sensor (external pad style) 249
IGBT module heat sink temperature sensor 249
Coolant outlet temperature sensor (internal style) 249
Technical Data 249
Coolant outlet temperature sensor (external pad style) 250
Technical Data 250
Circuit breakers 251
Technical Data 251
Inner circulating blower fan 251
Coolant pump 252
Technical Data 252
Motor for coolant pump 252
Technical Data 252
Coolant pressure sensor 252
Inner radiator 253
Ground voltage monitoring resistors 253
Protection thyristor assembly (crowbar) 254
Discharge reactor 254
Main blower motor 255
Technical Data 255
Grid box 255
Technical Data 255
Grid box blower motor 256
Technical Data 256
Grid box blower motor grease fittings 256
Main alternator 257
Stator 257
Rotor 257
Bearings 257
Electrical connection 257
Cooling and ventilation 257
Rotating rectifier section 258
Technical Data 258
Main alternator circuit diagram 259
IGBT – inverter/chopper phase module 260
Troubleshooting information 262
Main input rectifier module 263
Internal circuit diagram 264
Upper ground tie resistor 265
Technical Data 265
Lower ground tie resistor 265
Technical Data 265
Troubleshooting – fault diagnosis 266
Speed sensor, alternator 267
Technical Data 267
Speed sensors, wheel motors 268
Technical Data 268
Traction motor 269
Technical Data 269
Grid box 270
Device name: M04 270
Technical Data 270
Step down box 273
SIBAS® IGBT rack components 275
SiBAS®32 Traction Control Unit (TCU) 277
Overview of the SiBAS®32 systems 278
Features 278
General technical specifications, operating conditions 278
Permissible temperature range 278
Permissible limit value for air humidity 279
Permissible power supply voltage range 279
Permissible mechanical loads 279
Protection measures against electrical hazards 279
Application 279
Removing and installing the SiBAS®32 cards 282
Removal with 24V OFF! (ESD protection required) 282
Installation with 24V OFF! (ESD protection required) 282
SiBAS®32 card device names 283
Structure of SiBAS®32 card part number 284
Development status, downward compatibility 284
SiBAS®32 card interchangeability 285
Use of service interfaces 286
Connection of the service unit 286
Maintenance 286
Cleaning 287
SiBAS®32 card interactions 288
Blower subassembly 291
Device name: N/A 291
Application 291
Battery replacement 293
Rules for handling lithium batteries 293
Replacement of the battery in the fan subassembly 293
CPU card 294
Device name: G011 294
Application 295
Front panel 295
Technical data 296
DSP card 297
Device name: G019, G027 and G35 297
Application 297
Front panel 297
Technical data 298
I/O card 299
Device name: G043 299
Application 299
Front panel 300
Technical data 301
TRACO card (optional) 302
Device name: G003 302
Application 302
Front panel 303
Technical data 304
Input voltage/frequency card 305
Device name: L055, L063 and L071 305
Application 305
Technical data 306
I/O analog card 307
Device name: L079 and L087 307
Technical data 309
I/O analog card 310
Device name: L095 and L103 310
Application 310
Technical data 312
Output pulse amplifier card 313
Device name: L115, L123, L131, L139 and L147 313
Application 313
Technical data 315
Input temperature sensor card 316
Device name: L155 and L163 316
Application 316
Technical data 318
UWS card 319
Device name: G055, G063, G071 and G079 319
Application 319
Technical data 321
Digital input card 322
Device name: G103, G111, G119, G127 and G135 322
Application 322
Technical data 324
Power start-up unit card 325
Device name: G163 325
Application 325
Technical data 327
Binary output contactor drive card 328
Device name: C019, C027 and C035 328
Application 328
Technical data 330
24V / 24V power supply 331
Device name: C045, C105, C129 331
Application 331
Testing the power supply card 332
Technical data 333
24V / 15V power supply 334
Device name: C069, C087 334
Application 334
Testing the power supply card 335
Technical data 336
24V / 5V power supply 337
Device name: C153 337
Application 337
Testing the power supply card 338
Technical data 339
Reserve engine oil system 341
General information 343
Operation 344
LED monitor light 344
Remote tank fill system 345
Wheel motor transmission 347
General information 349
Transmission wear data 352
20 Standard value table 357
Standard value table 357
Standard value table for truck 359
30 Testing and adjusting 365
Service tools 365
Special tool list 367
Control cabinet 368
Cab air conditioning 371
General information 373
Service tools and equipment 374
Recovery/recycle station 374
Leak detector 374
Manifold gauge set 375
Service valves 376
Vacuum pump 376
Detecting leaks 377
System performance test 378
Checking system oil 379
System flushing 380
Installing the manifold gauge set 381
Purging air from the service hoses 382
Recovering and recycling refrigerant 383
Draining oil from previous recovery cycle 384
Recovery cycle 384
Recycling procedure 384
Evacuating the air conditioning system 385
Charging the air conditioning system 386
Steering, brake cooling and hoist hydraulic system 389
General information on system checkout 391
Steering system checkout procedures 391
Steering pump pressure control adjustments 392
Steering control valve and flow amplifier leakage test 393
Bleed down manifold leakage test 394
Shock and suction valve pressure tests 395
Steering system checkout data sheet 397
Toe-in adjustment 398
Brake cooling and hoist system checkout procedures 399
Pressure gauge locations 399
Brake cooling circuit test 400
Power up relief pressure test 400
Power down relief pressure test 401
Counterbalance valve pressure check 402
Counterbalance valve adjustment 403
Brake cooling and hoist system checkout data sheet 404
Hydraulic system flushing procedure 405
Front suspension pressure test 412
Rear suspension pressure test 412
Steering cylinder leakage test 413
Hoist cylinder leakage test 413
Brake system 415
General information on system checkout 417
Brake circuit checkout procedure 417
Precheckout items 418
Software operation and configuration 418
Hydraulic isolation and troubleshooting 418
Truck starting procedure 418
Initial system setup 419
Brake lock / secondary braking checkout 420
Brake lock hydraulic circuit trouble shooting guide 422
Parking brake checkout 422
Park brake hydraulic circuit trouble shooting guide: 423
Service brake checkout 425
Blended braking checkout 425
Low brake accumulator pressure and auto apply checkout 426
Reapplication 427
Parking brake control logic checkout 427
Brake lock control logic checkout 429
BLENDED BRAKING CHECKOUT 433
Brake piston leakage test 442
Wet disc brake bleeding procedure 442
Parking/service brake bleeding procedure 443
Parking brake leakage test 444
Brake disc wear inspection 444
Brake valve bench test and adjustment 446
Test setup procedure 447
Brake valve output pressure adjustment 447
Final test and adjustment 448
Accumulators and suspensions 451
Accumulator charging and storage 453
Accumulator charging procedures 453
Precharge maintenance 456
Accumulator storage procedure 457
Accumulator leak testing 457
Checking for improper suspension charge on operating trucks 458
Suspension oil change recommendations 459
Suspension oiling and charging procedures 460
Required equipment 460
Installing the charging kit 461
Removing the charging kit 461
Support blocks for oiling and charging dimensions 462
Front suspensions 465
TOP FILL METHOD 466
PRESSURE FILL METHOD 466
Rear suspensions 468
TOP FILL METHOD 469
PRESSURE FILL METHOD 469
Suspension pressure test 472
Payload meter IV 475
Payload meter IV software and tools 477
Payload meter IV system configuration 477
Connecting to the payload meter IV web server 477
Configuring a static IP address 477
Payload meter IV software installation 479
Inclinometer calibration and clean truck tare 480
Payload meter IV checkout procedure 480
PLM IV system checkout data sheet 486
Downloading PLM IV data and possible errors 487
KOMTRAX Plus II 491
Required software and tools 493
Ethernet connection to KOMTRAX Plus II controller 493
KOMTRAX Plus II configuration 495
GPS connection test 497
Iridium satellite system opening 499
Data download over ethernet connection for KOMTRAX Plus II initialization 502
Interface module (IM1) 505
Required software and tools 507
Interface module checkout procedures 508
Initial startup 508
Checking digital inputs to the IM 508
Check analog inputs to the IM 510
Check serial interfaces to the interface module 510
Check outputs from the interface module 511
Interface module (IM2) 513
Required tools 515
Programming the IM2 515
Updating the software 515
Configuring the IM2 516
Viewing IM2 real-time data 516
Interface module checkout procedures 517
Checking for IM fault codes 517
Checking digital inputs to the IM 517
Checking analog inputs to the IM 520
Checking serial communication to the IM 520
Checking outputs from the IM 521
IM Installation Checkout Checklist 522
IGBT haul truck SIBAS® user manual, part 1 527
Abbreviations 530
Product description 532
Version management 533
Overview 534
Requirements 534
Installation 535
Environment variables 535
Communication with the SIBAS® 32 control unit 536
Calling up the customer monitor 537
Start-up prompt 537
Monitor prompt 538
Notes on operation of the customer monitor 539
Structure of a monitor command 539
Step 1: Selecting the menu title 539
Step 2: Selecting a menu entry in the menu box 539
Step 3: Selecting a dialog box, if available 540
Step 4: Entering file or connector/signal names 540
Command buffer 541
Structure of the monitor windows 541
Commands for Opening, Altering and Closing Windows 542
“Window Work open” 542
“Window Lines open” 542
“Window Tile” 542
“Window Bars open” 542
Options 542
“Window Set” 542
Options 542
“Window Cascade” 542
“Window Close” 542
“Window close All” 542
“Window Exit” 542
“Set Port” 543
Options 543
“Set Baudrate” 543
Options 543
“Set String” 544
Example 545
“Set Make” 545
Options 545
Example 1: INITMON start-up control of the Customer Monitor 546
Example 2: Any monitor batch file with freely selectable file name (incl path) 546
“Set Execute” 547
Options 547
Example 547
“Set Record” 547
Options 547
“Set DIN-Bus” 548
“Set TCN” 548
“Set Timeout” 548
Options 548
“Set Wait” 548
Options 548
“Set Color” 548
Options 548
“Set Info” 549
“Set comment” 549
“Set CHAR Set” 549
“Set Quit” 549
“Applic FuncPackage” 550
“Applic Connector” 551
Options 551
Example 552
“Applic View” 552
Options 552
Example 552
“Applic Signal” 552
“Applic Observer” 553
Options 553
Possible time slices: 553
Options 554
Two options 554
Notes on the display of connectors 556
“Applic Buffer” 557
Options 557
“Applic Report” 557
“Applic Legitimation” 557
Options 557
“Applic Menu” 558
“Applic Traco” 558
Options 558
“Applic Environment” 558
Hardware-Oriented Access via the Customer Monitor 560
“Hardw Flash” 560
Options 560
Requirements 560
Example 561
Deleting and loading 561
The EPROM for the communication drivers 561
“Hardw Clock” 561
Options 561
“Hardw DSP” 562
“Hardw BCD” 562
Options 562
Example 562
“Hardw RESET” 562
Options 562
“Hardw Info” 563
Hardware/Operating system 563
Application and tools 563
Communication module 563
Displaying the loading date 563
“Hardw User Flash” 564
Options 564
“Hardw Sys Flash” 564
Options 564
“Hardw BOOT DSP” 565
Requirements 565
DSP5600x Signal Processing Unit and TRACO 565
Inverter processing unit 567
Access to the Signal Processing Unit 567
“Hardw Flash” 567
Options 567
Requirements 567
Example 567
Deleting and loading 568
The EPROM for the communication drivers 568
User Data Flash (UDF) 568
“Hardw RESET” 568
Options 568
“Hardw ZR” 569
“Hardw BOOT ZR” 569
The following procedure is necessary: 569
Commands for Displaying Line Graphics 570
“Graphic Load” 570
Options 570
“Graphic Position” 570
Options 570
“Graphic Time/Div” 571
Options 571
“Graphic Unit/Div” 571
Options 571
“Graphic Display” 571
Options 571
“Graphic Color” 572
Options 572
“Graphic Format” 572
Options 572
IGBT haul truck SIBAS® user manual, part 2 575
Traco Menu 578
HW-Traco 578
Options 579
SW-Traco 580
Options 581
ZR traco basic parameters: 581
ZR traco record signal table: 581
DAC_Traco 584
Options 585
Events Menu 586
STatistics 587
History 588
LEL:Last EvL 589
LES:Last EvS 591
DLL:DC,LastL 592
DLS:DC,LastS 593
DAL:DC,All L 594
DAS:DC,All S 595
ML:Memory L 596
MS:Memory S 597
CN:Clear Norm 598
CA:Clear All 598
Test-Code 598
DS:Diag-Strc 599
User Menu 600
DAC_IO 601
Options 601
Options 602
OperatData 603
Acc test 610
Engine_Test 610
X_Test_Inx 613
STate intern 614
Header: 614
Vehicle Number: 614
Powering system: 614
TCU Operation Mode: 614
Component status listings: 615
Field regulator status: 615
Status gate unit power supply A: 615
Status gate unit power supply B: 615
ST inverter status 615
Vehicle status 616
Drive status: 616
Operation status: 616
Pedal calib 617
Language 618
OFFline-test 618
Options 618
Variables 620
Examples: 620
IV:Vehic-ID 621
Commands 622
Discharge Dc link / Fire crowbar 622
Limp mode commands 622
Settings 623
Parameters 624
Temp_prot 626
Appendix 628
Background commands 628
Monitor commands for the central processing unit 630
Monitor commands for the signal processing unit 630
Installing ZR / DSP software 633
Monitor Program – Loading software into the SIBAS® 635
Loading software into the DSP procedure 635
Loading a DSP program Inverter A 640
Loading software into the CPU procedure 647
Loading ZR software Prog jumpers Reset 654
Loading the proper pgm file 656
Setting the system up After loading a new pgm 656
24V electrical system 659
Body position switches (with proximity switches and metal arms) 661
Body up switch adjustment 661
Hoist limit switch adjustment 662
Service 662
Body position switches (with proximity switches and magnets) 663
Body up switch adjustment 663
Hoist limit switch adjustment 663
Service 663
Automatic lubrication (auto lube) system 667
Priming the system 669
Checkout procedure 671
Adjusting the lubrication cycle timing 672
Trucks with Interface Module 1 672
Trucks with Interface Module 2 672
40 Troubleshooting 675
Cab air conditioning 675
Preliminary checks 677
Diagnosis of gauge readings and system performance 677
Troubleshooting by manifold gauge set readings 678
Fuse and circuit breaker locations 685
Fuse and circuit breaker locations 687
Fuse block tables 688
Prelube motor fuse 689
Circuit breaker table 690
Troubleshooting by fault code, Part 1 693
Fault Code A001: Left front suspension pressure sensor signal high 696
Related circuit diagram 696
Fault Code A002: Left front suspension pressure sensor signal low 697
Related circuit diagram 697
Fault Code A003: Right front suspension pressure sensor signal high 698
Related circuit diagram 698
Fault Code A004: Right front suspension pressure sensor signal low 699
Related circuit diagram 699
Fault Code A005: Left rear suspension pressure sensor signal high 700
Related circuit diagram 700
Fault Code A006: Left rear suspension pressure sensor signal low 701
Related circuit diagram 701
Fault Code A007: Right rear suspension pressure sensor signal high 702
Related circuit diagram 702
Fault Code A008: Right rear suspension pressure sensor signal low 703
Related circuit diagram 703
Fault Code A009: Incline sensor signal high 704
Related circuit diagram 704
Fault Code A010: Incline sensor signal low 705
Related circuit diagram 705
Fault Code A011: Payload meter speed sensor signal has failed 706
Related circuit diagram 706
Fault Code A013: Body up switch has failed 707
Related circuit diagram 707
Fault Code A014: Payload meter checksum computation has failed 708
Related circuit diagram 708
Fault Code A016: Payload meter write to flash memory has failed 709
Related circuit diagram 709
Fault Code A017: Payload meter flash memory read has failed 710
Related circuit diagram 710
Fault Code A018: Right rear flat suspension cylinder warning 711
Related circuit diagram 712
Fault Code A019: Left rear flat suspension cylinder warning 713
Related circuit diagram 714
Fault Code A022: Carryback load excessive 715
Related circuit diagram 716
Fault Code A100: An open circuit breaker has been detected on a relay board 717
Related circuit diagram 717
Fault Code A101: High pressure detected across an hydraulic pump filter 718
Related circuit diagram 720
Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level 721
Related circuit diagram 722
Fault Code A111: Low steering pressure warning for storage by KOMTRAX Plus 723
Related circuit diagram 723
Fault Code A115: Low steering precharge pressure detected 724
Related circuit diagram 725
Fault Code A117: Low brake accumulator pressure warning for storage by KOMTRAX Plus 726
Related circuit diagram 726
Fault Code A118: Brake pressure is low while in brake lock 727
Related circuit diagram 728
Fault Code A126: Oil level in the hydraulic tank is low 729
Related circuit diagram 729
Fault Code A127: IM-furnished +5 volt output for sensors is low 730
Related circuit diagram 731
Fault Code A128: IM-furnished +5 volt output for sensors is high 732
Related circuit diagram 733
Fault Code A139: Low fuel warning for storage by KOMTRAX Plus and for use by A310 734
Related circuit diagram 735
Troubleshooting by fault code, part 2 737
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil 740
Related circuit diagram 741
Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil 742
Related circuit diagram 743
Fault Code A152: Starter failure 744
Related circuit diagram 745
Fault Code A153: Battery voltage is low with the truck in operation 746
Related circuit diagram 747
Fault Code A154: Battery charging voltage is excessive 748
Related circuit diagram 748
Fault Code A155: Battery charging voltage is low 749
Related circuit diagram 749
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 750
Related circuit diagram 751
Fault Code A159: (A30003 only) The battery 12 Volt circuit sensing is producing low readings 752
Related circuit diagram 752
Fault Code A164: (A30003 only) The battery 12 Volt circuit sensing is producing high readings 753
Related Circuit Diagram 753
Fault Code A166: Left rear hydraulic oil temperature sensor is low 754
Related circuit diagram 755
Fault Code A167: Right rear hydraulic oil temperature sensor is low 756
Related circuit diagram 757
Fault Code A168: Left front hydraulic oil temperature sensor is low 758
Related circuit diagram 759
Fault Code A169: Right front hydraulic oil temperature sensor is low 760
Related circuit diagram 761
Fault Code A170: Left rear hydraulic oil temperature sensor is high 762
Related circuit diagram 762
Fault Code A171: Right rear hydraulic oil temperature sensor is high 763
Related circuit diagram 763
Fault Code A172: Left front hydraulic oil temperature sensor is high 764
Related circuit diagram 764
Fault Code A173: Right front hydraulic oil temperature sensor is high 765
Related circuit diagram 765
Fault Code A182: (A30003 only) The battery 12 Volt battery tap has high voltage 766
Related circuit diagram 767
Fault Code A183: (A30003 only) The battery 12 Volt battery tap has low voltage 768
Related circuit diagram 769
Fault Code A184: J1939 data link is not connected 770
Related circuit diagram 771
Fault Code A190: (A30003 only) The automatic lubrication system has announced a fault 772
Fault Code A190: (A30004 & Up) Auto lube control has detected an incomplete lube cycle 774
Related circuit diagram 775
Fault Code A194: Left front hydraulic oil temperature is high 776
Related circuit diagram 776
Fault Code A195: Right front hydraulic oil temperature is high 777
Related circuit diagram 777
Fault Code A196: Left rear hydraulic oil temperature is high 778
Related circuit diagram 778
Fault Code A197: Right rear hydraulic oil temperature is high 779
Related circuit diagram 779
Fault Code A198: Hoist pressure 1 sensor is high 780
Related circuit diagram 780
Fault Code A199: Hoist pressure 2 sensor is high 781
Related circuit diagram 781
Fault Code A200: Steering pressure sensor is high 782
Related circuit diagram 782
Fault Code A201: Brake pressure sensor is high 783
Related circuit diagram 783
Fault Code A202: Hoist pressure 1 sensor is low 784
Related circuit diagram 784
Fault Code A203: Hoist pressure 2 sensor is low 785
Related circuit diagram 785
Fault Code A204: Steering pressure sensor is low 786
Related circuit diagram 786
Fault Code A205: Brake pressure sensor is low 787
Related circuit diagram 787
Fault Code A206: Ambient temperature sensor is high 788
Related circuit diagram 788
Fault Code A207: Ambient temperature sensor is low 789
Related circuit diagram 789
Troubleshooting by fault code, part 3 791
Fault Code A213: Parking brake should have applied but is detected as not having applied 794
Related circuit diagram 797
Fault Code A214: Parking brake should have released but is detected as not having released 798
Related circuit diagram 800
Fault Code A215: Brake auto apply valve circuit is defective 801
Related circuit diagram 802
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 803
Related circuit diagram 804
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted 805
Related circuit diagram 806
Fault Code A230: Parking brake has been requested while truck still moving 807
Related circuit diagram 808
Fault Code A231: The body is up while traveling or with selector in forward or neutral 809
Fault Code A233: Drive System Control Link is not connected 811
Related circuit diagram 813
Fault Code A235: Steering accumulator is in the process of being bled down 814
Related circuit diagram 815
Fault Code A236: The steering accumulator has not properly bled down after 90 seconds 816
Related circuit diagram 817
Fault Code A237: The CAN/RPC connection to the display is open 818
Related circuit diagram 819
Fault Code A238: Drive System and IM are reporting different park brake status 820
Related circuit diagram 822
Fault Code A239: The Drive System and IM are reporting different brake lock status 823
Related circuit diagram 824
Fault Code A240: The keyswitch input to the Interface Module is open 825
Related circuit diagram 825
Fault Code A242: Fuel gauge within the dash display panel is defective 826
Related circuit diagram 826
Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective 827
Related circuit diagram 827
Fault Code A244: Drive system temperature gauge within the dash display panel is defective 828
Related circuit diagram 828
Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective 829
Related circuit diagram 829
Fault Code A246: Payload meter reports truck overload 830
Related circuit diagram 830
Fault Code A247: Low steering pressure warning for display to operator 831
Related circuit diagram 831
Fault Code A248: Status module within the dash display panel is defective 832
Related circuit diagram 832
Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted 833
Related circuit diagram 833
Fault Code A250: Battery voltage is low with the truck parked 834
Related circuit diagram 835
Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground 836
Related circuit diagram 837
Fault Code A252: Start enable output circuit is either open or shorted to ground 838
Related circuit diagram 839
Fault Code A253: Steering bleed circuit is not open while running 840
Related circuit diagram 841
Fault Code A254: (A30003 Only) The 5 minute idle circuit is either open or shorted to ground 842
Related circuit diagram 842
Fault Code A256: Red warning lamp in the dash display (driven by IM) is open 843
Related circuit diagram 843
Fault Code A257: Payload CAN/RPC is not connected 844
Related circuit diagram 845
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 846
Related circuit diagram 846
Troubleshooting by fault code, part 4 849
Fault Code A260: Park brake failure 852
Related circuit diagram 853
Fault Code A261: Low brake accumulator pressure warning for display to operator 854
Related circuit diagram 854
Fault Code A262: Steering bleed valve circuit open during shutdown 855
Related circuit diagram 856
Fault Code A264: Park brake relay circuit is defective 857
Related circuit diagram 858
Fault Code A265: Service brake failure 859
Related circuit diagram 860
Fault Code A266: Selector switch was not in park while attempting to crank engine 861
Related circuit diagram 862
Fault Code A267: Park brake was not set while attempting to crank engine 863
Related circuit diagram 864
Fault Code A268: Secondary engine shutdown while cranking 865
Related circuit diagram 865
Fault Code A270: Brake lock switch power supply is not on when required 866
Related circuit diagram 868
Fault Code A271: Shifter not in gear 869
Related circuit diagram 870
Fault Code A272: Brake lock switch power supply is not off when required 871
Related circuit diagram 872
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit 873
Related circuit diagram 873
Fault Code A274: A brake setting fault has been detected 874
Related circuit diagram 875
Fault Code A275: A starter has been detected as engaged without a cranking attempt 876
Related circuit diagram 877
Fault Code A277: Park brake applied while loading 878
Related circuit diagram 879
Fault Code A278: Service brake applied while loading 880
Related circuit diagram 881
Fault Code A279: Low Steering Pressure Switch bad 882
Related circuit diagram 882
Fault Code A280: Steering accumulator bled switch bad 883
Related circuit diagram 883
Fault Code A281: Brake lock degrade switch bad 884
Related circuit diagram 885
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 886
Related circuit diagram 887
Fault Code A283: (A30004 & Up) An engine shutdown delay was aborted because the parking brake was not set 888
Related circuit diagram 889
Fault Code A284: (A30004 & Up) An engine shutdown delay was aborted because the secondary shutdown switch was operated 890
Related circuit diagram 891
Fault Code A285: (A30004 & Up) The park brake was not set when the keyswitch was turned off 892
Related circuit diagram 893
Fault Code A286: (A30004 & Up) A fault was detected in the shutdown delay relay circuit 894
Related circuit diagram 895
Fault Code A292: (A30004 & Up) The shutdown delay relay has remained on after the latched keyswitch circuit is off 896
Related circuit diagram 897
Fault Code A295: The right front park brake is not setting up 898
Related circuit diagram 898
Fault Code A296: The left front park brake is not setting up 899
Related circuit diagram 899
Fault Code A297:The right rear park brake is not setting up 900
Related circuit diagram 900
Fault Code A298: The left rear park brake is not setting up 901
Related circuit diagram 901
Fault Code A299: The right front park brake is not releasing 902
Related circuit diagram 902
Fault Code A300: The left front park brake is not releasing 903
Related circuit diagram 903
Fault Code A301: The right rear park brake is not releasing 904
Related circuit diagram 904
Fault Code A302: The left rear park brake is not releasing 905
Related circuit diagram 905
Troubleshooting by fault code, part 5 907
Fault Code A303: Shifter is defective 910
Related circuit diagram 911
Fault Code A304: (A30004 & Up) Auto lube grease level fault 912
Related circuit diagram 912
Fault Code A305: (A30004 & Up) Auto lube circuit is defective 913
Related circuit diagram 914
Fault Code A309: No brakes applied when expected 915
Related circuit diagram 916
Fault Code A310: Low fuel warning 917
Related circuit diagram 918
Fault Code A311: Brake lock switch is on when it should not be 919
Related circuit diagram 920
Fault Code A312: (A30004 & Up) DCDC converter 12 volt circuit sensing is producing low readings 921
Related circuit diagram 921
Fault Code A313: (A30004 & Up) DCDC converter 12 volt circuit sensing is producing high readings 922
Related circuit diagram 922
Fault Code A315: (A30004 & Up) DCDC converter 12 volt circuit is low 923
Related circuit diagram 924
Fault Code A316: Starter engagement has been attempted with engine running 925
Related circuit diagram 926
Fault Code A317: Operation of brake auto apply valve without a detected response 927
Related circuit diagram 929
Fault Code A318: Unexpected power loss to Interface Module 930
Related circuit diagram 930
Fault Code A328: Drive system not powered up 931
Related circuit diagram 931
Fault Code A335: Manual/Auto Apply Pressure Fault 932
Fault Code A350: Overload on output 1B 933
Related circuit diagram 933
Fault Code A351: Overload on output 1E 934
Related circuit diagram 935
Fault Code A352: (A30003) Overload on output 1H 936
Related circuit diagram 936
Fault Code A352: (A30004 & Up) Overload on output 1H 937
Related circuit diagram 937
Fault Code A353: Overload on output 1J 938
Related circuit diagram 938
Fault Code A354: Overload on output 1K 939
Related circuit diagram 939
Fault Code A355: Overload on output 1L 940
Related circuit diagram 940
Fault Code A356: Overload on output 1M 941
Related circuit diagram 941
Fault Code A357: Overload on output 1N 942
Related circuit diagram 942
Fault Code A358: Overload on output 1P 943
Related circuit diagram 943
Fault Code A359: Overload on output 1R 944
Related circuit diagram 945
Fault Code A360: Overload on output 1S 946
Related circuit diagram 946
Fault Code A361: (A30003) Overload on output 1T 947
Related circuit diagram 947
None 947
Fault Code A361: (A30004 & Up) Overload on output 1T 948
Related circuit diagram 949
Fault Code A362: Overload on output 1U 950
Related circuit diagram 950
Fault Code A363: Overload on output 1X 951
Related circuit diagram 951
Fault Code A364: Overload on output 1Y 952
Related circuit diagram 952
Fault Code A365: Overload on output 1Z 953
Related circuit diagram 953
Fault Code A368: Siemens Brake Test Active 954
Related circuit diagram 954
Fault Code A369: Siemens Brake Test Incomplete 955
Related circuit diagram 955
Fault Code A370: Siemens Brake Test Torque Achieved for Park Brake 956
Related circuit diagram 956
Fault Code A371: Siemens Brake Test Torque Achieved for Service Brake 957
Related circuit diagram 957
Fault Code A372: Siemens Brake Test Torque Not Achieved for Park Brake 958
Related circuit diagram 958
Fault Code A373: Siemens Brake Test Torque Not Achieved for Service Brake 959
Related circuit diagram 959
Drive system fault code table, part 1 961
Summary 964
How to use this document 964
Event code and diagnosis message 964
Description 964
Threshold 964
Detection by 964
Possible reasons 964
Action to reset 964
Action to repair 965
Operator displayed code 965
Note 965
Protection reactions 965
Event classification 966
Level 1: Warning 966
Level 2: Minor purposes 966
Level 3: Severe 966
1 L3C SYS: Time slice overflow CPU T1 967
2 L3C SYS: Time slice overflow CPU T2 967
3 L3C SYS: Time slice overflow CPU T3 967
4 L3C SYS: Time slice overflow CPU T4 967
5 L3C SYS: Time slice overflow CPU T5 967
6 L3C SYS: Time slice overflow CPU T6 967
7 L3C SYS: Time slice overflow CPU T7 967
8 L3C SYS: Time slice overflow CPU T8 967
10 L2A SYS: Pulse inhibit/asa inhibit PSU–ONLINE 968
11 L3D SYS: Pulse inhibit/asa inhibit PSU-Start-up 968
12 L1A SYS: SIBAS® blower fault 969
13 L1B SYS: Undervoltage in SIBAS® battery for BRAM 969
14 L3C SYS: SIBAS® power supply failure 24V for pulse amplifier 970
15 L3C SYS: SIBAS® power supply failure +5V 971
16 L3C SYS: SIBAS® power supply failure +15V 972
17 L3C SYS: SIBAS® power supply failure –15V 973
18 L3C SYS: SIBAS® power supply failure +24V 974
19 L3C SYS: SIBAS® power supply failure –24V 975
20 L3C SYS: SIBAS® power supply failure primary 976
21 L3C SYS: FPGA clock missing for PSU 976
22 L3C SYS: Pulse inhibit by reset in PSU from CPU 977
24 L3C SYS: General protection error (G10) 977
25 L3C SYS: Total block 978
26 L1B SYS: Permanent inhibit fault active 979
27 L1B SYS: Regular inhibit fault active 979
28 L1A SYS: GW Test stopped by A/D converter faulty 980
30 L3C DSP A: Initialization fault detected by DSP 980
31 L3C DSP A: SW-WatchdoG 981
32 L3C DSP A: Initialization fault detected by CPU 982
33 L1B DSP A: SW-Traco triggered 982
34 L1B DSP A: SW-Traco full 983
35 L3C DSP A: Time slice overflow T1 984
36 L3C DSP A: Time slice overflow T2 984
37 L3C DSP A: Time slice overflow T3 984
38 L3C DSP A: Time slice overflow T4 984
39 L1A DSP A: Communication HSCX data from DSP B missing 985
40 L1A DSP A: Communication HSCX data from DSP T missing 985
41 L3C DSP A: Current offset during pulse block 986
42 L3C DSP A: Current offset during no pulse block 986
43 L3A DSP A: Overcurrent fault 987
44 L3C DSP A: Current transducer defective phase U 988
45 L3C DSP A: Current transducer defective phase W 989
48 L1A DSP A: Modulation software fault 989
49 L3A DSP A: Active current controller at limit 990
Drive system fault code table, part 2 993
50 L3A DSP A: Active current reference at limit 996
51 L1A DSP A: Braking chopper controller at limit 996
52 L3C DSP A: Phase unbalance too large 997
53 L3A DSP A: Pulse block by DSP software 998
54 L3C DSP A: U/F Card defective 998
55 L3C DSP A: Difference in current of phase U over limit 999
56 L3C DSP A: Difference in current of phase W over limit 999
60 L3C DSP B: Initialization fault detected by DSP1000
61 L3C DSP B: SW-Watchdog1000
62 L3C DSP B: Initialization fault detected by CPU1001
63 L1B DSP B: SW-Traco triggered1001
64 L1B DSP B: SW-Traco full1002
65 L3C DSP B: Time slice overflow T11002
69 L1A DSP B: Communication HSCX data from DSP A missing1003
70 L1A DSP B: Communication HSCX data from DSP T missing1003
71 L3C DSP B: Current offset during pulse block1004
72 L3C DSP B: Current offset during no pulse block1004
73 L3A DSP B: Overcurrent fault1005
74 L3C DSP B: Current transducer defective phase V1006
75 L3C DSP B: Current transducer defective phase W1007
78 L1A DSP B: Modulation software fault1007
79 L3A DSP B: Active current controller at limit1008
80 L3A DSP B: Active current reference at limit1008
81 L1A DSP B: Braking chopper controller at limit1008
82 L3C DSP B: Phase unbalance too large1009
83 L3A DSP B: Pulse block by DSP software1009
84 L3C DSP B: U/F Card defective1010
85 L3C DSP B: Difference in current of phase V over limit1010
86 L3C DSP B: Difference in current of phase W over limit1011
90 L3C DSP T: Initialization fault detected by DSP1011
91 L3C DSP T: SW-Watchdog1012
92 L3C DSP T: Initialization fault detected by CPU1013
93 L1B DSP T: SW-Traco triggered1013
94 L1B DSP T: SW-Traco full1014
95 L3C DSP T: Time slice overflow T11014
96 L3C DSP T: Time slice overflow T21014
97 L3C DSP T: Time slice overflow T31014
98 L3C DSP T: Time slice overflow T41014
99 L1A DSP T: Communication HSCX data from DSP A missing1015
Drive system fault code table, part 31017
100 L1A DSP T: Communication HSCX data from DSP B missing1020
101 L3C DSP T: Current offset during pulse block1020
102 L3C DSP T: Current offset during no pulse block1021
103 L3A DSP T: Overcurrent fault1022
104 L3C DSP T: Current transducer defective phase U1023
105 L3C DSP T: Current transducer defective phase V1024
106 L3C DSP T: Current transducer defective phase W1025
107 L3C DSP T: Sum of output current not equal zero1026
108 L1A DSP T: Modulation software fault1026
109 L1A DSP T: Voltage controller at limit1027
112 L3C DSP T: Phase unbalance too large1027
113 L3A DSP T: Pulse block by DSP software1028
114 L3C DSP T: U/F Card defective1028
117 L3C DSP T: Crowbar fired by DSP T1029
119 L1C DSP T: Voltage transducer U34 not ok1030
120 L3C IO: Supervision bus clock1030
121 L3C IO: Supervision I/O clock1031
122 L3C IO: Incorrect FPGA version identifier1031
123 L3C IO: Incorrect FPGA application version identifier1032
124 L3C IO: Incorrect module version identifier1032
125 L3C/L1A IO: AD Converter faulty1033
126 L3C IO: GW Comparator faulty during start-up test1033
127 L3C IO: Test voltage not equal zero1034
128 L1A IO: SIBAS® Temperature out of range1034
129 L3C IO: Incorrect EBIN card identifier1035
130 L3C IO: Front plug monitoring1036
131 L3C IO: CPU Watchdog triggered1037
132 L3C IO: DSP A Watchdog triggered1037
133 L3C IO: DSP B Watchdog triggered1038
134 L3C IO: DSP T Watchdog triggered1038
135 L3C IO: CPU Reset triggered1039
138 L1B IO: CPU Traco triggered1039
146 L3A IO: Pulse block from I/O1040
150 L3A IO: DC link voltage A level 1 exceeded1040
151 L3A IO: DC link voltage B level 1 exceeded1041
152 L3C IO: Trolley line overvoltage1042
154 L3B IO: Trolley line overcurrent1043
155 L2B IO: Trolley line current transducer faulty1043
156 L2B IO: Trolley line voltage transducer faulty1044
160 L3A IO: Throttle pedal out of range1044
161 L3A IO: Retard pedal out of range1045
162 L1A IO: Cruise speed control module out of range1045
180 L3C UWSA1: Supervision bus clock1046
181 L3C UWSA1: Supervision module clock1046
182 L3C UWSA1: Incorrect FPGA version identifier1047
183 L3C UWSA1: Incorrect FPGA project identifier1047
184 L3C UWSA1: GW Comparator faulty during start-up test1048
185 L1A UWSA1: ADC Faulty1048
186 L3C UWSA1: Configuration failure1049
187 L1A UWSA1: Hardware failure counter / processor1049
188 L3A UWSA1: Peak current protection active1050
189 L3D UWSA1: Peak current protection pulse start1051
190 L3D UWSA1: Number of peak current protection >limit1052
191 L3D UWSA1: Supervision switching frequency1053
193 L1A UWSA1: Overvoltage level 1 exceeded1053
196 L3D UWSA1: Limit 5 overcurrent phase U1054
197 L3D UWSA1: Limit 5 overcurrent phase V1054
198 L3D UWSA1: Limit 5 overcurrent phase W1054
199 L3D UWSA1: Limit 5 overvoltage DC bus1055
Drive system fault code table, part 41057
201 L3D UWSA1: Checkback INVA1 L1U faulty1061
202 L3D UWSA1: Checkback INVA1 L1L faulty1061
203 L3D UWSA1: Checkback INVA1 L2U faulty1061
204 L3D UWSA1: Checkback INVA1 L2L faulty1061
205 L3D UWSA1: Checkback INVA1 L3U faulty1061
206 L3D UWSA1: Checkback INVA1 L3L faulty1061
207 L3D UWSA1: Checkback chopper A faulty1061
210 L3C UWSB1: Supervision bus clock1062
211 L3C UWSB1: Supervision module clock1062
212 L3C UWSB1: Incorrect FPGA version identifier1063
213 L3C UWSB1: Incorrect FPGA project identifier1063
214 L3C UWSB1: GW Comparator faulty during start-up test1064
215 L1A UWSB1: ADC Faulty1064
216 L3C UWSB1: Configuration failure1065
217 L1A UWSB1: Hardware failure counter / processor1065
218 L3A UWSB1: Peak current protection active1066
219 L3D UWSB1: Peak current protection pulse start1067
220 L3D UWSB1: Number of peak current protection >limit1068
221 L3D UWSB1: Supervision switching frequency1069
223 L1A UWSB1: Overvoltage level 1 exceeded1069
226 L3D UWSB1: Limit 5 overcurrent phase V1070
227 L3D UWSB1: Limit 5 overcurrent phase U1070
228 L3D UWSB1: Limit 5 overcurrent phase W1070
229 L3D UWSB1: Limit 5 overvoltage DC bus1071
231 L3D UWSB1: Checkback INVB1 L1U Faulty1072
232 L3D UWSB1: Checkback INVB1 L1L Faulty1072
233 L3D UWSB1: Checkback INVB1 L2U Faulty1072
234 L3D UWSB1: Checkback INVB1 L2L Faulty1072
235 L3D UWSB1: Checkback INVB1 L3U Faulty1072
236 L3D UWSB1: Checkback INVB1 L3L Faulty1072
237 L3D UWSB1: Checkback chopper B Faulty1072
240 L3C UWSA2: Supervision bus clock1073
241 L3C UWSA2: Supervision module clock1073
242 L3C UWSA2: Incorrect FPGA version identifier1074
243 L3C UWSA2: Incorrect FPGA project identifier1074
244 L3C UWSA2: GW Comparator faulty during start-up test1075
245 L1A UWSA2: ADC Faulty1075
246 L3C UWSA2: Configuration failure1076
247 L1A UWSA2: Hardware failure counter / processor1076
248 L3A UWSA2: Peak current protection active1077
249 L3D UWSA2: Peak current protection pulse start1078
250 L3D UWSA2: Number of peak current protection >limit1079
251 L3D UWSA2: Supervision switching frequency1080
253 L1A UWSA2: Overvoltage level 1 exceeded1080
256 L3D UWSA2: Limit 5 overcurrent phase U11081
257 L3D UWSA2: Limit 5 overcurrent phase V11081
258 L3D UWSA2: Limit 5 overcurrent phase W11081
259 L3D UWSA2: Limit 5 overvoltage DC bus1082
261 L3D UWSA2: Checkback INVA2 L1U faulty1083
262 L3D UWSA2: Checkback INVA2 L1L faulty1083
263 L3D UWSA2: Checkback INVA2 L2U faulty1083
264 L3D UWSA2: Checkback INVA2 L2L faulty1083
265 L3D UWSA2: Checkback INVA2 L3U faulty1083
266 L3D UWSA2: Checkback INVA2 L3L faulty1083
267 L3D UWSA2: Checkback chopper C faulty1083
270 L3C UWSB2: Supervision bus clock1084
271 L3C UWSB2: Supervision module clock1084
272 L3C UWSB2: Incorrect FPGA version identifier1085
273 L3C UWSB2: Incorrect FPGA project identifier1085
274 L3C UWSB2: GW Comparator faulty during start-up test1086
275 L1A UWSB2: ADC Faulty1086
276 L3C UWSB2: Configuration failure1087
277 L1A UWSB2: Hardware failure counter / processor1087
278 L3A UWSB2: Peak current protection active1088
279 L3D UWSB2: Peak current protection pulse start1089
280 L3D UWSB2: Number of peak current protection >limit1090
281 L3D UWSB2: Supervision switching frequency1091
283 L1A UWSB2: Overvoltage level 1 exceeded1091
286 L3D UWSB2: Limit 5 overcurrent phase V11092
287 L3D UWSB2: Limit 5 overcurrent phase U11092
288 L3D UWSB2: Limit 5 overcurrent phase W11092
289 L3D UWSB2: Limit 5 overvoltage DC bus1093
291 L3D UWSB2: Checkback INVB2 L1U Faulty1094
292 L3D UWSB2: Checkback INVB2 L1L Faulty1094
293 L3D UWSB2: Checkback INVB2 L2U Faulty1094
294 L3D UWSB2: Checkback INVB2 L2L Faulty1094
295 L3D UWSB2: Checkback INVB2 L3U Faulty1094
296 L3D UWSB2: Checkback INVB2 L3L Faulty1094
297 L3D UWSB2: Checkback chopper D Faulty1094
Drive system fault code table, part 51097
300 L3C UWSST: Supervision bus clock1101
301 L3C UWSST: Supervision module clock1101
302 L3C UWSST: Incorrect FPGA version identifier1102
303 L3C UWSST: Incorrect FPGA project identifieR1102
304 L3C UWSST: GW Comparator faulty during start-up test1103
305 L1A UWSST: ADC Faulty1103
306 L3C UWSST: Configuration failure1104
307 L1A UWSST: Hardware failure counter / processor1104
308 L3A UWSST: Peak current protection active1105
310 L3D UWSST: Number of peak current protection >limit1106
311 L3D UWSST: Supervision switching frequency1107
314 L3C UWSST: Crowbar is fired without command1108
319 L3D UWSST: Limit 5 overvoltage DC bus1110
321 L3D UWSST: Checkback INVST L1U Faulty1111
322 L3D UWSST: Checkback INVST L1L Faulty1111
323 L3D UWSST: Checkback INVST L2U Faulty1111
324 L3D UWSST: Checkback INVST L2L Faulty1111
325 L3D UWSST: Checkback INVST L3U Faulty1111
326 L3D UWSST: Checkback INVST L3L Faulty1111
327 L3C UWSST: Checkback crowbar faulty1112
330 L1A BUS: CAN Communication failure1113
331 L1A BUS: Serial link communication failure1113
332 L1A BUS: Truck is over loaded1113
333 L1B TR: Transient traco is triggered1114
334 L1B TR: Transient traco is full1114
340 L1A ETM: ADC Failure for ETM11114
341 L1A ETM: ADC Failure for ETM21115
342 L1A ETM: ADC Failure for ETM31115
343 L1A ETM: ADC Failure for ETM41115
344 L1A MEFA: ADC Failure1116
345 L3C HL: Gate unit power supply A defective1116
346 L3C HL: Gate unit power supply B defective1117
351 L1A DRZ: LIMP Mode A active1118
352 L1A DRZ: Limp mode B active1118
353 L1A DRZ: Low battery voltage1119
354 L1B BUS: Engine floor input increasing minimum engine speed1119
355 L1B DM: Data store switch pressed1120
356 L1B DM: Diagnosis memory configuration failure1120
357 L1B DM: Diagnosis memory occupation > 75%1120
358 L1B DM: Diagnosis memory full1121
359 L1B DM: Test event1121
360 L2A EXT: Main blower air flow supervision1122
361 L2A EXT: Minimum engine speed supervision1123
362 L1A EXT: Main blower pressure switch malfunction1124
363 L1A EXT: Shift lever supervision1125
364 L2A EXT: Engine derate protection active1126
365 L1A EXT: Truck external plug monitoring1126
367 L3A EXT: DC Power off mod request (rest switch on)1127
369 L1A EXT: Doppler sensor defective1129
370 L1A EXT: Auto lube control defective1130
372 L1A EXT: Service brake pressed at high speeD1130
373 L1A EXT: Service brake on above speed limit1131
374 L1A EXT: Anti-roll control malfunction1131
375 L3B BEF: CB301 Circuit breaker defective1132
376 L3B BEF: K303/K304 Contactor defective1133
377 L3C STP: Voltage reading incorrect between trolley line and voltage in stepdown box1134
382 L3B BEF: K103 Feedback defective1135
383 L3B BEF: K105 Feedback defective1135
384 L1A BEF: K107 Feedback defective1136
385 L1A BEF: K109 Feedback defective1136
386 L1A BEF: K111 Feedback defective1137
387 L1A BEF: Limp mode selector defective1137
388 L2B BEF: CB113 Tripped1138
390 L3D IUW: Output current supervision INV A1138
391 L3D IUW: Output current supervision INV B1139
392 L3B IUW: Precharge supervision 11140
393 L3B IUW: Precharge supervision 21141
394 L3A IUW: DC Link undervoltage1142
395 L2B IUW: Trolley line undervoltage1143
397 L3B IUW: Field regulator current setpoint supervision1144
398 L2B IUW: Field regulator output current supervision1145
399 L3B IUW: Alternator overcurrent protection1146
Drive system fault code table, part 61149
400 L2C IUW: Alternator overload warning1152
401 L2B IUW: Alternator overload protection1152
402 L3C IUW: Alternator AC current sensor faulty1153
403 L2A IUW: DC Link voltage out of range in propel1154
404 L3A IUW: DC Link voltage out of range retard1155
405 L3A IUW: DC Link voltage out of range for ST operation1156
406 L3B IUW: DC Link controller supervision1157
407 L2C IUW: Motor torque square T supervision1158
408 L2C IUW: Motor current square T supervision1158
409 L1A IUW: DC Link discharge time exceeded limit1159
410 L2B IUW: Ground fault at positive DC link detected1160
411 L2B IUW: Ground fault at negative DC link detected1161
412 L2B IUW: Ground fault at AC side detected1162
413 L2B IUW: Ground fault1163
414 L3C IUW: Chopper A current supervision1164
415 L3C IUW: Chopper B current supervision1165
416 L3C IUW: Chopper C current supervision1166
417 L3C IUW: Chopper D current supervision1167
418 L3D IUW: Output current supervision INV ST1168
419 L2A IUW: Vehicle overspeed supervisioN1169
420 L1A IUW: DC Link voltage sensor A faulty1170
421 L1A IUW: DC Link voltage sensor B faulty1171
422 L3C IUW: ST Inverter failure1172
423 L3B IUW: DC Grid fan circuit failure1172
424 L2B IUW: Cooling water pressure out of range1173
425 L2B IUW: Cooling water level out of range1174
426 L1A IUW: Water pump motor overtemperature1175
427 L1A IUW: Retard limit supervision1175
428 L1A DRZ: Front wheel A speed sensor supervision1176
429 L1A DRZ: Front wheel B speed sensor supervision1177
430 L3D DRZ: Motor A speed sensor supervision1178
431 L3D DRZ: Motor B speed sensor supervision1179
432 L3C DRZ: Alternator speed sensor supervision1180
433 L2A DRZ: Motor A maximum speed exceeded1181
434 L2A DRZ: Motor B maximum speed exceeded1181
435 L1A DRZ: Alternator maximum speed exceeded1182
436 L3A DRZ: Motor A/B rotation inconsistency1183
437 L3A DRZ: Motor A torque supervision1184
438 L3A DRZ: Motor B torque supervision1185
439 L3C SIV: Start-up sequence can’t pass due to GUPS failure1186
440 L3C SIV: Start-up sequence can’t pass due to K103/K105 failure1187
441 L3C SIV: Start-up sequence can’t pass due to IGBT failure1188
442 L3C SIV: Start-up sequence can’t pass due to CB301 OR K303 failure1189
443 L3C SIV: Start-up sequence can’t pass due to crowbar failure1190
447 L1A SIV: Direct trolley engage sequence supervision1191
448 L1A SIV: Direct trolley disengage sequence supervision1192
Drive system fault code table, part 71195
450 L1A TMP: SIBAS® Temperature < low limit1199
451 L1A TMP: SIBAS® Temperature > warning limit1199
452 L3B TMP: SIBAS® Temperature > shutdown limit1200
453 L3A TMP: IGBT Module A101 temperature < low limit1201
454 L2C TMP: IGBT Module A101 temperature > APRS limit1202
455 L3A TMP: IGBT Module A101 temperature > shutdown limit1203
456 L3A TMP: IGBT Module A102 temperature < low limit1204
457 L2C TMP: IGBT Module A102 temperature > APRS limit1205
458 L3A TMP: IGBT Module A102 temperature > shutdown limit1206
459 L3A TMP: IGBT ModulE A201 temperature < low limit1207
460 L2C TMP: IGBT Module A201 temperature > APRS limit1208
461 L3A TMP: IGBT Module A201 temperature > shutdown limit1209
462 L3A TMP: IGBT Module A202 temperature < low limit1210
463 L2C TMP: IGBT Module A202 temperature > APRS limit1211
464 L3A TMP: IGBT Module A202 temperature >shutdown limit1212
465 L3A TMP: ST Module temperature < low limit1213
466 L2C TMP: ST Module temperature > warning limit1214
467 L3A TMP: ST Module temperature > shutdown limit1215
468 L2B TMP: SR Module temperature < low limit1216
469 L2C TMP: SR Module temperature > warning limit1217
470 L2B TMP: SR Module temperature > shutdown limit1218
471 L2C TMP: Wheel motor A stator temperature > APRS limit1219
472 L3A TMP: Wheel motor A stator temperature > shutdown limit1220
473 L2C TMP: Wheel motor B Stator temperature > APRS limit1221
474 L3A TMP: Wheel motor B stator temperature shutdown limit1222
475 L2C TMP: Wheel motor A, DE bearing temperature > warning limit1223
476 L3A TMP: Wheel motor A, DE bearing temperature > shutdown limit1224
477 L2C TMP: Wheel motor A NDE bearing temperature > warning limit1225
478 L3A TMP: Wheel motor A NDE bearing temperature > shutdown limit1226
479 L2C TMP: Wheel motor B DE bearing temperature > warning limit1227
480 L3A TMP: Wheel motor B DE bearing temperature > shutdown limit1228
481 L2C TMP: Wheel motor B NDE bearing temperature > warning limit1229
482 L3A TMP: Wheel motor B NDE bearing temperature > shutdown limit1230
483 L2C TMP: Alternator stator temperature > APRS limit1231
484 L2B TMP: Alternator stator temperature > shutdown limit1232
485 L2C TMP: Alternator bearing temperature > warning limit1233
486 L2B TMP: Alternator bearing temperature > shutdown limit1234
487 L1A TMP: Cooling water inlet temperature < low limit1235
488 L2C TMP: Cooling water inlet temperature > warning limit1236
489 L2B TMP: Cooling water inlet temperature > shutdown limit1237
490 L1A TMP: Cooling water outlet temperature < low limit1238
491 L2C TMP: Cooling water outlet temperature > warning limit1239
492 L2B TMP: Cooling water outlet temperature > shutdown limit1240
493 L1A TMP: Cooling water delta T too high1241
495 L2C TMP: Inverter cab temperature > warning limit1242
496 L2B TMP: Inverter cab temperature > shutdown limit1243
497 L2C TMP: Inside cooler outlet temperature > warning limit1244
498 L2B TMP: Inside cooler outlet temperature > shutdown limit1245
499 L1A TMP: Main blower motor stator temperature > warning limit1246
500 L1A TMP: Main blower motor stator temperature > shutdown limit1247
505 L1A TMP: Wheel motor A rotor temperature > limit1248
506 L1A TMP: Wheel motor B rotor temperature > limit1249
508 L1A ETM1: Alternator PT100 open circuit1250
509 L1A ETM1: Main blower stator PT100 open circuit1250
510 L1A ETM1: Grid blower statoR PT100 open circuit1250
511 L1A ETM1: Inverter CAB PT100 open circuit1250
512 L1A ETM1: Ambient PT100 open circuit1250
513 L1A ETM1: Heater exchanger PT100 open circuit1250
514 L1A ETM1: Cooling water inlet PT100 open circuit1250
515 L1A ETM1: Cooling water outlet PT100 open circuit1250
516 L1A ETM2: Motor A NDE Bearing PT100 open circuit1251
517 L1A ETM2: Motor A DE Bearing PT100 open circuit1251
518 L1A ETM2: Motor B NDE Bearing PT100 open circuit1251
519 L1A ETM2: Motor B DE Bearing PT100 open circuit1251
520 L1A ETM2: Alternator Bearing PT100 open circuit1251
521 L1A ETM2: Motor A stator PT100 open circuit1251
522 L1A ETM2: Motor B stator PT100 open circuit1251
523 L1A ETM2: Motor inlet air PT100 open circuit1251
524 L1A ETM3: IGBT Module A101 PT100 open circuit1252
525 L1A ETM3: IGBT Module A102 PT100 open circuit1252
526 L1A ETM3: IGBT Module A103 PT100 open circuit1252
527 L1A ETM3: IGBT Module A104 PT100 open circuit1252
528 L1A ETM3: IGBT Module A201 PT100 open circuit1252
529 L1A ETM3: IGBT Module A202 PT100 open circuit1252
530 L1A ETM3: IGBT Module A203 PT100 open circuit1252
531 L1A ETM3: IGBT Module A204 PT100 open circuit1252
532 L1A ETM3: ST Module PT100 open circuit1253
533 L1A ETM3: SR Module PT100 open circuit1253
534 L1A ETM3: Channel 7 PT100 open circuit1253
535 L1A ETM3: Channel 8 PT100 open circuit1253
536 L1A ETM4: Channel 1 PT100 open circuit1254
537 L1A ETM4: Channel 2 PT100 open circuit1254
538 L1A ETM4: Channel 3 PT100 open circuit1254
539 L1A ETM4: Channel 4 PT100 open circuit1254
540 L1A ETM4: Channel 5 PT100 open circuit1254
541 L1A ETM4: Channel 6 PT100 open circuit1254
542 L1A ETM4: Channel 7 PT100 open circuit1254
543 L1A ETM4: Channel 8 PT100 open circuit1254
544 L1A ETM4: SR Module PT100 open circuit1254
550 L3A TMP: Inverter A module temperature < low limit1255
551 L2C TMP: Inverter A module temperature > APRS limit1256
552 L3A TMP: Inverter A module temperature > shutdown limit1257
553 L3A TMP: Inverter B module temperature < low limit1258
554 L2C TMP: Inverter B module temperature > APRS limit1259
555 L3A TMP: Inverter B module temperature > shutdown limit1260
556 L3A TMP: Chopper A module temperature < low limit1261
557 L2C TMP: Chopper A module temperature > APRS limit1262
558 L3A TMP: Chopper A module temperature > shutdown limit1263
559 L3A TMP: Chopper B module temperature < low limit1264
560 L2C TMP: Chopper B module temperature > APRS limit1265
561 L3A TMP: Chopper B module temperature > shutdown limit1266
Payload meter scoreboard1269
Display messages1271
LED lights1271
Processor LED (2, Figure 50-1)1271
Data Receive LED (3, Figure 50-1)1271
Option switches1272
SWITCH 1 – TEST (Displays “888”)1272
SWITCH 2 – COUNT1272
SWITCH 9 – TRANSMIT CUT1272
SWITCH 10 – HIGH IMPEDANCE LISTEN1272
Troubleshooting1273
Troubleshooting chart1273
Symptom1273
Possible Cause1273
Remedy1273
Electric wheel motor1275
Fault table1277
Reserve engine oil system1285
Pumping unit LED signals1287
Circuit fuses1287
Steering system1289
Steering circuit troubleshooting chart1291
Steering circuit troubleshooting guidelines1293
Basic hydraulic system checks1294
System leakage check1295
Steering pump troubleshooting guide1297
Pump pressure control checks1300
To verify pump unload pressure1300
To verify pump reloading1300
Pump fails to unload1301
Pump fails to develop pressure1301
Pump slow in developing pressure1302
Pump control valve inspection and trouble shooting1303
Pump case drain check1305
Definitions:1306
Adjustment1306
Automatic lubrication (auto lube) system1309
Autolube troubleshooting chart1311
50 Disassembly and assembly1315
Service tools1315
Special tool list1317
Additional tool list1317
Wheel motor rebuild tools1318
Control cabinet1318
Cab air conditioning1321
Replacement of air conditioning system components1323
Hoses and fittings1323
Lines1323
Expansion valve1323
Receiver-drier1323
Thermostat1323
Compressor1324
Accumulator1324
Clutch1324
Wheels, spindles and rear axle1327
General precautions for tires and rims1329
Wheel stud maintenance1330
Front tires and rims1331
Removal1331
Installation1332
Rear tires and rims1332
Removal1332
Installation1333
Rim components1335
Smart Rim Component Layout1335
Rim and tire service1336
Lubricants1336
Tire Inflation1336
Lock Ring Retainer Installation1336
Remove Smart Lock Ring from Inside Position of Outer Dual and Outside Position of Inner Dual1337
Install Smart Lock Ring to Inside Position of Outer Dual and Outside Position of Inner Dual1338
Removal (5-Piece Standard Rim)1339
Removal (7-Piece Smart Rim)1342
Removal (5-Piece Smart Rim)1344
Preparation Before Assembly1346
Installation (5-Piece Standard Rim)1346
Installation – Horizontal Mount (Smart Rim)1348
Installation – Vertical Mount (5-Piece Smart Rim)1350
Installation – Vertical Mount (7-Piece Smart Rim)1352
Removal and installation of front wheel hub and spindle1353
Removal1353
Spindle Removal Procedure (off of the truck)1357
Disassembly and assembly of front wheel hub and spindle1360
Disassembly1360
Cleaning and inspection1360
Assembly1363
Wheel bearing adjustment1363
Seal assembly gap check and adjustment1364
Floating seal installation1365
Floating seal test procedure1372
Speed sensor installation and adjustment1373
Removal and installation of wheel motor1373
Preparation1373
Removal1374
Cleaning and inspection1375
Installation1375
Removal and installation of rear axle1378
Removal1378
Cleaning and inspection1380
Installation1380
Removal and installation of anti-sway bar1381
Removal1381
Installation1381
Removal and installation of pivot pin1382
Removal1382
Installation1382
Pivot eye and bearing service1383
Bearing removal1383
Bearing installation1383
Pivot eye repair1384
Removal and installation of electric motor1385
Removal1385
Installation1385
Disassembly and assembly of wheel motor transmission1386
Disassembly1387
Cleaning and inspection1393
Assembly1394
Disassembly and assembly of low speed carrier1405
Disassembly1405
Inspection1407
Assembly1408
Disassembly and assembly of high speed carrier1411
Disassembly1411
Inspection1413
Assembly1413
Brake system1419
Removal and installation of brake valve1421
Installation1422
Disassembly and assembly of brake valve/pedal assembly1423
Disassembly1423
Assembly1424
Removal and installation of dual relay valve1426
Removal1426
Installation1427
Removal and installation of brake manifold1427
Removal1427
Installation1428
Disassembly and assembly of brake manifold1428
Disassembly1428
Assembly1428
Removal and installation of brake accumulator1429
Removal1429
Installation1431
Disassembly and assembly of brake accumulator1431
Cleaning and Inspection1433
Piston seals replacement1434
Assembly1434
Piston accumulator storage1435
Brake accumulator charging procedure1436
Temperature during precharge1438
Disassembly and assembly of wheel brake1439
Disassembly1440
Cleaning and inspection1443
Assembly1444
Floating ring seal assembly and installation1450
Removal and installation of rear brake assembly1458
Removal1458
Installation1458
Seal Leakage Test1460
Steering system1463
Removal and installation of steering control unit1465
Removal1465
Installation1466
Disassembly and assembly of steering control unit1467
Disassembly1467
Assembly1469
Removal and installation of steering column1472
Removal1472
Inspection1472
Installation1473
Removal and installation of steering wheel1474
Removal1474
Installation1474
Removal and installation of bleeddown manifold1476
Removal1476
Installation1476
Removal and installation of flow amplifier1478
Removal1478
Installation1478
Disassembly and assembly of flow amplifier1478
Disassembly1478
Assembly1480
Removal and installation of steering cylinder1481
Removal1481
Bearing replacement1481
Installation1482
Disassembly and assembly of steering cylinders1483
Disassembly1483
Assembly1483
Removal and installation of tie rod1485
Removal1485
Installation1485
Disassembly and assembly of tie rod1486
Disassembly1486
Assembly1486
Removal and installation of steering/brake pump1488
Removal1488
Installation1489
Disassembly and assembly of steering/brake pump1490
Disassembly1490
Inspection1494
Assembly1497
Driveshaft group1498
Rotating group1498
Removal and installation of steering accumulators1501
Removal1501
Installation1502
Disassembly and assembly of steering accumulator1503
Cleaning and Inspection1504
Piston seals replacement1505
Assembly1505
Piston accumulator storage1506
Steering accumulator charging procedure1507
Temperature during precharge1509
Suspensions1511
Removal and installation of front suspension1513
Removal1513
Installation1515
Inspection1520
Minor front suspension repairs (lower bearing and seals)1521
Lower bearing retainer removal1521
Lower bearing retainer installation1521
Major front suspension rebuild1522
Disassembly1522
Assembly1523
Removal and installation of rear suspension1525
Removal1526
Installation1527
Disassembly and assembly of rear suspension1528
Disassembly1528
Cleaning and Inspection1529
Assembly1529
Hoist circuit1533
Removal and installation of hoist pump1535
Removal1535
Installation1536
Disassembly and assembly of hoist pump1538
Disassembly1538
Inspection1543
Assembly1544
Removal and installation of hoist valve1547
Removal1547
Installation1548
Disassembly and assembly of hoist valve1548
O-ring replacement1548
Disassembly of inlet section1550
Assembly of inlet section1551
Disassembly of rear spool section1552
Assembly of rear spool section1554
Disassembly of front spool section1555
Assembly of front spool section1556
Overcenter manifold service1556
Removal and installation of hoist pilot valve1557
Removal1557
Installation1557
Disassembly and assembly of hoist pilot valve1558
Disassembly1558
Cleaning and inspection1559
Assembly1559
Removal and installation of hoist cylinders1560
Removal1560
Installation1561
Disassembly and assembly of hoist cylinders1563
Disassembly1563
Cleaning and inspection1565
Installation of the quill1566
Assembly1568
Replacement of hoist circuit filter1570
Filter element replacement1571
Operator cab1573
Removal and installation of operator cab1575
Removal1576
Installation1577
Removal and installation of cab door1579
Removal1579
Installation1579
Disassembly and assembly of cab door1579
Removing door panel1579
Installing door panel1580
Replacing door window regulator1580
Replacing door handle or latch assembly1581
Replacing door assembly seal and door hinge seal1582
Replacing door opening seal1582
Removing door glass1583
Installing door glass1584
Adjustment of cab door1586
Door jamb bolt adjustment1586
Door handle plunger adjustment1587
Removal and installation of side window glass1588
Recommended tools and supplies1588
Removal1589
Installation1589
Removal and installation of windshield and rear window glass1590
Removal1590
Installation1590
Removal and installation of windshield wiper motor1591
Removal1591
Installation1591
Removal and installation of windshield wiper arm1592
Removal1592
Installation1592
Removal and installation of windshield wiper linkage1593
Removal1593
Installation1593
Removal and installation of operator seat (standard seat)1594
Adjustment1594
Inspection1595
Removal1595
Installation1595
Replacing the Seat Compressor1596
Removal and installation of passenger seat (standard seat)1601
Adjustment1601
Inspection1602
Removal1602
Installation1602
Removal and installation of seat belts (standard seat)1603
Removal1603
Installation1603
Operator seat (optional seat)1604
Seat Belts1604
Adjustment1604
Passenger seat (optional seat)1606
Seat Belts1606
Adjustment1606
Removal and installation of seat belts (optional seat)1607
General1607
Removal1607
Installation1609
Body and structures1613
Removal and installation of dump body1615
Removal1615
Inspection1616
Installation1617
Removal and installation of body pads1617
Removal1617
Installation1618
Body pad shimming procedure1618
Removal and installation of diagonal ladder/ hood and grille assembly1619
Removal1619
Installation1619
Removal and installation of right deck1620
Removal1620
Installation1622
Removal and installation of left deck1623
Removal1623
Installation1623
Removal and installation of fuel tank1625
Removal1625
Cleaning and inspection1625
Installation1627
Removal and installation of horizontally mounted fuel gauge sender1627
Removal1627
Installation1627
Removal and installation of vertically mounted fuel gauge sender1627
Installation1627
Disassembly and assembly of fuel tank breather1629
Disassembly1629
Assembly1629
Removal and installation of hydraulic tank1630
Removal1630
Installation1630
Three phase wheel motor1633
Motor1637
Transport1638
Storage of new motors1639
Storage of used motors1640
Safety guidelines1641
Checking for external damage1642
Checking the connections1643
Regreasing the bearings1643
Applying grease to the bearings1643
Checking the interior of the motor for water1644
Pressing off the coupling1646
Disassembly1647
Rotor1647
Removing the rubber seals and the air baffles1652
Bearing and labyrinth ring1653
Removal1653
Stator Inspection1654
Rotor Inspection1654
Testing the insulation1655
High-voltage test1655
Work on the bearings1656
Assembling the rubber seals and the air baffles1658
Assembly after special repair work1660
Bearing installation1661
Preparatory measures for assembling the bearing (Figure 50-20 must be observed):1664
Assemble the bearing1665
Cover installation1666
Assembling the bearing shield (N-end) at the stator frame1667
Bearing installation1669
Rotor installation1671
Labyrinth ring1673
Installation1673
Installing accessories (D- and N-end)1675
Running in the bearings1679
Coupling1680
Installation1680
Assembly conditions and instructions1681
Tests1681
Replacing defective connecting leads1682
Repairing the stator winding insulation1683
Recommended consumables1683
Chemical cleaning agents1683
Chemical cleaning agents for outdoor use and for cleaning mechanical parts1683
Chemical cleaning agents for flange faces1683
Chemical cleaning agents for windings1684
Chemical cleaning agents for windings1684
Chemical cleaning agents for windings with severe damage and for oily windings1684
Rolling-contact bearing grease1684
Assembly/disassembly agents for bearing seat1684
Sealants for joining parts or gaps1684
Locking agents for connecting elements1684
Anti-corrosion agent1684
Assembly paste for temperature sensors1684
Mounting devices for inserting and withdrawing the rotor horizontally1685
Press for expanding the coupling1685
Compression devices for pressing on or for support while pressing off1686
Pulling units with cross beam or disk1688
Aids1688
Extraction devices1689
Paints for refinishing the painted parts or touching up damaged parts1689
Power module1691
Removal and installation of power module1693
General1693
Preparation1693
Removal1694
Installation1699
Exhaust tube installation1701
Exhaust blanket installation1701
Removal and installation of alternator1702
Removal1702
Installation1704
Engine flywheel adapter face runout1704
Engine crankshaft endplay1705
Engine flywheel to flywheel housing adapter – measurement “C”1705
Alternator housing to rotor – measurement “A”1706
Measurements after joining the alternator and engine1708
Flywheel housing face runout1709
Flywheel housing radial runout1709
Flywheel/flexplate face runout1710
Flywheel/flexplate radial runout1710
Rotor shaft radial runout (assembled)1711
Joining the alternator and engine1712
Removal and installation of engine1714
Removal1714
Service1714
Installation1714
Removal and installation of radiator1714
Removal1714
Installation1716
Repairing the radiator1718
Internal inspection1718
External cleaning1718
Disassembly1718
Cleaning and inspection1719
Assembly1720
Pressure testing1721
Auto lubrication system1723
Lubrication system priming1725
Removal and installation of lubrication pump1725
Removal1725
Installation1725
Disassembly and assembly of lubrication pump1727
Disassembly1727
Cleaning and Inspection1730
Assembly1730
Main blower1733
Removing the main blower motor1735
Disassembling the main blower motor1741
Assembling the main blower motor1743
Installing the main blower motor1746
Retarding grid1753
Removing the grid blower motor1755
Disassembling the grid blower motor1757
Assembling the grid blower motor1759
Installing the grid blower motor1761
Removing a grid element1766
Control cabinet1769
Removing the SIBAC Inverter Module1771
Required tools/materials1771
Removal1774
Installing the SIBAC Inverter Module1778
Draining and filling the IGBT coolant system1779
Required tools/materials1779
Coolant mixture specification (distilled water: Antifrogen® N)1779
Draining and filling the coolant1781
Removing and installing the IGBT coolant pump assembly1784
Required tools/materials1784
Removal1785
90 Diagrams and drawings1789
Hydraulic circuit diagrams1789
Steering, hoist and brake cooling hydraulic circuit – EM13741791
Brake hydraulic circuit diagram – EM62981792
Electrical circuit diagrams – 24V system1795
Electrical circuit diagram – 58C-06-003841797
Electrical circuit diagram – 58C-06-013001815
Electrical circuit diagram – 58C-06-013011831
Electrical circuit diagrams – drive system1849
Electrical circuit diagrams – drive system – 58C-06-007301797

IMAGES PREVIEW OF THE MANUAL:

S.M 21/12/24