Komatsu 860E Dump Truck Parts Manual CEBN00015-04 – PDF DOWNLOAD

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Komatsu 860E Dump Truck Parts Manual CEBN00015-04 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 860E Dump Truck Parts Manual CEBN00015-04 – PDF DOWNLOAD

Language : English
Pages : 1990
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu 860E Dump Truck Parts Manual CEBN00015-04 – PDF DOWNLOAD

• Machine model                              Serial Number
  860E-1KT                                        A30036 – A30040 ,A30043, A30047 

00 Index and foreword 1
Index 1
Composition of shop manual 2
Table of contents 4
Foreword, safety and general information 33
Foreword 37
How to read the shop manual 38
Composition of shop manual 38
Revision and distribution 38
Symbols 39
General safety 40
Safety rules 40
Safety features 40
Fire extinguisher and first aid kit 40
Clothing and personal items 40
Leaving the operator seat 41
Mounting and dismounting 41
Fire prevention for fuel and oil 41
Precautions with high temperature fluids 42
Asbestos dust hazard prevention 42
Prevention of injury by work equipment 42
Unauthorized modification 42
Precautions when using ROPS 42
Precautions for attachments 43
Precautions for starting the truck 43
Precautions before operating the truck 43
Safety at the worksite 43
Fire prevention 44
Ventilation in enclosed areas 44
Preparing for operation 44
Mirrors, windows and lights 44
In operator cab (before starting the engine) 44
Seat Belts 44
Precautions while operating the truck 45
When starting the engine 45
General truck operation 45
Ensuring good visibility 45
Traveling 46
Traveling in reverse 46
Traveling on slopes 46
Operating on snow or ice 46
Avoid damage to dump body 46
Driving near high voltage cables 47
When dumping 47
Working on loose ground 47
When loading 47
Parking the truck 47
Towing 48
Working near batteries 48
Battery hazard prevention 48
Starting with jumper cables 49
Jump starting with receptacles 49
Precautions before performing service 50
Warning tag 50
Stopping the engine 50
Proper tools 50
Use of tie-off anchor during maintenance and repair 51
The anchor must not be used for lifting Tie-off anchor installation 51
Securing the dump body 52
While performing maintenance 52
Keep the truck clean 52
Attachments 52
Working under the truck 53
Rotating fan and belts 53
Adding fuel or oil 53
Use of lighting 53
Radiator coolant level 53
Precautions with the battery 53
Precautions with high pressure oil 53
Handling high pressure hoses 54
Precautions when performing maintenance near high temperature or high pressure 54
Waste materials 54
Tires 54
Handling tires 54
Storing tires after removal 55
Precautions for performing repairs 56
Engine shutdown procedure after AC drive system failure 56
Jack point locations 57
Precautions for welding on the truck 58
Handling electrical equipment and hydraulic components 59
Points to remember when handling electrical equipment 59
Points to remember when handling hydraulic equipment 65
How to Read Electric Wire Code 67
Color Code and Harness Designation Tables 68
Standard torque tables 69
Effect of special lubricants on fasteners and standard torque values 69
Suggested sources for rust preventive grease 69
SAE grade 5 and grade 8 hex head capscrew and nut assemblies 70
SAE grade 9 capscrews 71
Class 10 9 capscrews and class 10 nuts 72
Standard tightening torques for fittings 72
Standard tightening torques for clamps 74
Conversion tables 75
Common conversion multipliers 75
Operating instructions 79
Preparing for operation 81
Walk around inspection 81
Engine start-up 86
After engine start-up 87
Precautions during truck operation 88
Operating on a haul road 89
Starting on a grade with a loaded truck 89
Passing 90
Loading 90
Overload speed limit function 90
Dumping 91
Raising The Dump Body 91
Lowering The Dump Body (When dumping on flat ground): 92
Lowering The Dump Body (When dumping over a berm or into a crusher): 93
Trolley operating instructions 93
Operating in trolley line mode 93
Getting on line 93
Operating on trolley 94
Getting off line 95
Line status signals 95
Trolley disconnect 96
Traffic consideration for trolley line operation 96
Approaching slow moving vehicles in a trolley assisted truck 96
Operating slow moving vehicles on trolley assist ramps 97
Truck failure while on trolley 97
Using the speed control feature 98
Safe parking procedures 98
Normal engine shutdown procedure 99
Sudden loss of engine power 100
Fuel depletion 101
Towing 101
Special Wiring Harness 101
Towing Procedure 102
Disabled truck operation 104
Steering and brake system 104
Components Required 104
Hookup 105
Disabled truck dumping procedure 106
Hookup 106
Raising the Body 106
Lowering the Body 107
01 Specification 109
Specification and technical data 109
Specification drawing 111
Specifications 112
Weight table 114
Fuel, coolant and lubricants 115
Mixing rate of water and anti-freeze 115
Suspension cylinder oil and nitrogen specifications 116
10 Structure and functions 119
Cab air conditioning 119
General information 121
Environmental impact of air conditioning 121
Air conditioning for off-highway vehicles 121
Principles of refrigeration 122
Air conditioning 122
Refrigeration – the act of cooling 122
The refrigeration cycle 122
Air conditioning system components 124
Relays 124
Fan motor and speed control 124
Cab air filter 124
Heater core 124
Actuators 124
Compressor (refrigerant pump) 126
Service valves 126
Condenser 126
Receiver-drier 126
Expansion valve 127
Accumulator 127
Evaporator core 127
Air conditioning system electrical circuit 128
Thermostat 128
Compressor clutch 128
Trinary™ switch 129
Steering circuit 131
Steering circuit operation 133
Steering circuit components 135
Steering control unit 135
High pressure filter 135
Steering accumulators 135
Bleeddown manifold 136
Steering accumulator bleeddown solenoid 139
Quick disconnect ports 139
Hoist up limit solenoid 139
Flow amplifier 139
Flow amplifier operation 140
No steer 140
Steering left 142
Steering right 144
No steer, external shock load 146
Steering/brake pump operation 149
Normal operation 149
Neutral position 150
Full pump volume 151
Half pump volume 151
Steering cylinder wear data 152
Hoist circuit 155
Hoist circuit operation 157
Hoist circuit components 158
Hydraulic tank 158
Hoist pump 158
High pressure filters 158
Hoist valve 158
Hoist limit solenoid 159
Pilot operated check valve 159
Hoist pilot valve 160
Overcenter manifold 160
Hoist pilot valve operation 161
Float position of pilot valve with truck body on frame 161
Power up operation 163
Hold operation 165
Power down operation 167
Float operation 169
Hoist cylinder wear data 171
Brake circuits 173
General information 175
Service brake circuit operation 176
Secondary braking system and auto apply 176
Rear wheel brake lock circuit operation 178
Parking brake circuit operation 180
Normal operation (engine start switch ON, engine on) 180
Brake lines and test ports 182
Brake warning circuit operation 183
Brake assembly wear data 185
Suspensions 187
General information 189
Front suspension wear data 189
Rear suspension wear data 190
Electrical system, 24 volt 193
Battery supply system 195
Auxiliary control cabinet components 196
24VDC to 12VDC converter 196
Diode board – DB1 196
Power distribution terminals 196
Control power relay 197
Fuse blocks 198
Relay boards 198
Relay boards RB1, RB3, RB4, RB5 198
Relay boards RB6, RB7, RB8, RB9 200
Relay functions 200
Body position switches (With proximity switch and metal arm) 202
Body-up switch 202
Hoist limit switch 203
Body position switches (With proximity switch and magnet) 204
Proximity switch operation 204
Body-up Switch 204
Hoist limit switch 204
Interface module (IM) 207
General information 209
Service 209
Sensors 209
Temperature sensors 209
Pressure sensors 210
Interface module inputs and outputs 211
Drive system 217
SR rectifier module 220
ST module (auxiliary voltage inverter) 220
Technical Data 223
SD phase modules 224
SR/ST/SD module removal 224
Inverter cabinet layout 225
Inverter cabinet water flow 225
Field regulator 226
Technical Data 226
Field regulator (discharge resistor) 226
Technical Data 226
Gate Unit 227
Technical Data 227
Technical Data 227
Technical Data 227
Control power filter 228
Technical Data 228
Filter for TCU 228
Technical Data 228
Terminal block bus bar 229
Technical Data 229
Fuses (analog sensor voltage) 230
Technical Data 230
Fuses (field regulator) 230
Technical Data 230
Fuses (fuse holder for field regulator) 230
Fuses (control power and trolley box contactor) 231
Technical Data 231
Diode modules 231
Technical Data 231
Support capacitors 232
Technical Data 232
3-Phase capacitor bank (for ST module output voltage) 232
Technical Data 232
Air-cooled inductors (for ST module) 233
Technical Data 233
3-Phase transformer (for ST module) 233
Technical Data 233
Diagnostics box 234
Diagnostic and system monitoring panel 235
Technical Data 235
Current transducers 236
Device names: 236
Technical Data 236
Technical Data 236
Current transducers (for ST module output) 237
Technical Data 237
Voltage transducers 238
Technical Data 238
Voltage transducers (for ST module output) 238
Technical Data 238
Voltage transducers (SiBAS® 24V DC bus monitoring) 239
Analog inclinometer 239
Technical Data 239
DC link capacitors 240
Technical Data 240
Ground tie capacitor 240
Technical Data 240
Low-inductance bus bar assembly 241
Free-wheeling diode for low-inductance bus bars 241
Contactor (grid box and main blower motor) 242
Technical Data 242
Contactor (control power) 242
Technical Data 242
Contactor (DC contactors) 243
Technical Data 243
Contactor (crowbar bypass) 243
Technical Data 243
Temperature probes (PT100 style) 244
Technical Data 244
Coolant inlet temperature sensor 244
Technical Data 244
Coolant outlet temperature sensor (external pad style) 245
IGBT module heat sink temperature sensor 245
Coolant outlet temperature sensor (internal style) 245
Technical Data 245
Coolant outlet temperature sensor (external pad style) 246
Technical Data 246
Circuit breakers 247
Technical Data 247
Inner circulating blower fan 247
Coolant pump 248
Technical Data 248
Motor for coolant pump 248
Technical Data 248
Coolant pressure sensor 248
Inner radiator 249
Ground voltage monitoring resistors 249
Protection thyristor assembly (crowbar) 250
Discharge reactor 250
Main blower motor 251
Technical Data 251
Grid box 251
Technical Data 251
Grid box blower motor 252
Technical Data 252
Grid box blower motor grease fittings 252
Main alternator 253
Stator 253
Rotor 253
Bearings 253
Electrical connection 253
Cooling and ventilation 253
Rotating rectifier section 254
Technical Data 254
Main alternator circuit diagram 255
IGBT – inverter/chopper phase module 256
Troubleshooting information 258
Main input rectifier module 259
Internal circuit diagram 260
Upper ground tie resistor 261
Technical Data 261
Lower ground tie resistor 261
Technical Data 261
Troubleshooting – fault diagnosis 262
Speed sensor, alternator 263
Technical Data 263
Speed sensors, wheel motors 264
Technical Data 264
Traction motor 265
Technical Data 265
Grid box 266
Device name: M04 266
Technical Data 266
Step down box 269
SIBAS® IGBT rack components 271
SiBAS®32 Traction Control Unit (TCU) 273
Overview of the SiBAS®32 systems 274
Features 274
General technical specifications, operating conditions 274
Permissible temperature range 274
Permissible limit value for air humidity 275
Permissible power supply voltage range 275
Permissible mechanical loads 275
Protection measures against electrical hazards 275
Application 275
Removing and installing the SiBAS®32 cards 278
Removal with 24V OFF! (ESD protection required) 278
Installation with 24V OFF! (ESD protection required) 278
SiBAS®32 card device names 279
Structure of SiBAS®32 card part number 280
Development status, downward compatibility 280
SiBAS®32 card interchangeability 281
Use of service interfaces 282
Connection of the service unit 282
Maintenance 282
Cleaning 283
SiBAS®32 card interactions 284
Blower subassembly 287
Device name: N/A 287
Application 287
Battery replacement 289
Rules for handling lithium batteries 289
Replacement of the battery in the fan subassembly 289
CPU card 290
Device name: G011 290
Application 291
Front panel 291
Technical data 292
DSP card 293
Device name: G019, G027 and G35 293
Application 293
Front panel 293
Technical data 294
I/O card 295
Device name: G043 295
Application 295
Front panel 296
Technical data 297
TRACO card (optional) 298
Device name: G003 298
Application 298
Front panel 299
Technical data 300
Input voltage/frequency card 301
Device name: L055, L063 and L071 301
Application 301
Technical data 302
I/O analog card 303
Device name: L079 and L087 303
Technical data 305
I/O analog card 306
Device name: L095 and L103 306
Application 306
Technical data 308
Output pulse amplifier card 309
Device name: L115, L123, L131, L139 and L147 309
Application 309
Technical data 311
Input temperature sensor card 312
Device name: L155 and L163 312
Application 312
Technical data 314
UWS card 315
Device name: G055, G063, G071 and G079 315
Application 315
Technical data 317
Digital input card 318
Device name: G103, G111, G119, G127 and G135 318
Application 318
Technical data 320
Power start-up unit card 321
Device name: G163 321
Application 321
Technical data 323
Binary output contactor drive card 324
Device name: C019, C027 and C035 324
Application 324
Technical data 326
24V / 24V power supply 327
Device name: C045, C105, C129 327
Application 327
Testing the power supply card 328
Technical data 329
24V / 15V power supply 330
Device name: C069, C087 330
Application 330
Testing the power supply card 331
Technical data 332
24V / 5V power supply 333
Device name: C153 333
Application 333
Testing the power supply card 334
Technical data 335
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 (IM1) 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
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 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 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 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 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 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
40 Troubleshooting 671
Cab air conditioning 671
Preliminary checks 673
Diagnosis of gauge readings and system performance 673
Troubleshooting by manifold gauge set readings 674
Fuse and circuit breaker locations 681
Fuse and circuit breaker locations 683
Fuse block tables 684
Prelube motor fuse 685
Circuit breaker table 686
Troubleshooting by fault code, Part 1 689
Fault Code A001: Left front suspension pressure sensor signal high 692
Related circuit diagram 692
Fault Code A002: Left front suspension pressure sensor signal low 693
Related circuit diagram 693
Fault Code A003: Right front suspension pressure sensor signal high 694
Related circuit diagram 694
Fault Code A004: Right front suspension pressure sensor signal low 695
Related circuit diagram 695
Fault Code A005: Left rear suspension pressure sensor signal high 696
Related circuit diagram 696
Fault Code A006: Left rear suspension pressure sensor signal low 697
Related circuit diagram 697
Fault Code A007: Right rear suspension pressure sensor signal high 698
Related circuit diagram 698
Fault Code A008: Right rear suspension pressure sensor signal low 699
Related circuit diagram 699
Fault Code A009: Incline sensor signal high 700
Related circuit diagram 700
Fault Code A010: Incline sensor signal low 701
Related circuit diagram 701
Fault Code A011: Payload meter speed sensor signal has failed 702
Related circuit diagram 702
Fault Code A013: Body up switch has failed 703
Related circuit diagram 703
Fault Code A014: Payload meter checksum computation has failed 704
Related circuit diagram 704
Fault Code A016: Payload meter write to flash memory has failed 705
Related circuit diagram 705
Fault Code A017: Payload meter flash memory read has failed 706
Related circuit diagram 706
Fault Code A018: Right rear flat suspension cylinder warning 707
Related circuit diagram 708
Fault Code A019: Left rear flat suspension cylinder warning 709
Related circuit diagram 710
Fault Code A022: Carryback load excessive 711
Related circuit diagram 712
Fault Code A100: An open circuit breaker has been detected on a relay board 713
Related circuit diagram 713
Fault Code A101: High pressure detected across an hydraulic pump filter 714
Related circuit diagram 716
Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level 717
Related circuit diagram 718
Fault Code A111: Low steering pressure warning for storage by KOMTRAX Plus 719
Related circuit diagram 719
Fault Code A115: Low steering precharge pressure detected 720
Related circuit diagram 721
Fault Code A117: Low brake accumulator pressure warning for storage by KOMTRAX Plus 722
Related circuit diagram 722
Fault Code A118: Brake pressure is low while in brake lock 723
Related circuit diagram 724
Fault Code A126: Oil level in the hydraulic tank is low 725
Related circuit diagram 725
Fault Code A127: IM-furnished +5 volt output for sensors is low 726
Related circuit diagram 727
Fault Code A128: IM-furnished +5 volt output for sensors is high 728
Related circuit diagram 729
Fault Code A139: Low fuel warning for storage by KOMTRAX Plus and for use by A310 730
Related circuit diagram 731
Troubleshooting by fault code, part 2 733
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil 736
Related circuit diagram 737
Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil 738
Related circuit diagram 739
Fault Code A152: Starter failure 740
Related circuit diagram 741
Fault Code A153: Battery voltage is low with the truck in operation 742
Related circuit diagram 743
Fault Code A154: Battery charging voltage is excessive 744
Related circuit diagram 744
Fault Code A155: Battery charging voltage is low 745
Related circuit diagram 745
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 746
Related circuit diagram 747
Fault Code A159: (A30003 only) The battery 12 Volt circuit sensing is producing low readings 748
Related circuit diagram 748
Fault Code A164: (A30003 only) The battery 12 Volt circuit sensing is producing high readings 749
Related Circuit Diagram 749
Fault Code A166: Left rear hydraulic oil temperature sensor is low 750
Related circuit diagram 751
Fault Code A167: Right rear hydraulic oil temperature sensor is low 752
Related circuit diagram 753
Fault Code A168: Left front hydraulic oil temperature sensor is low 754
Related circuit diagram 755
Fault Code A169: Right front hydraulic oil temperature sensor is low 756
Related circuit diagram 757
Fault Code A170: Left rear hydraulic oil temperature sensor is high 758
Related circuit diagram 758
Fault Code A171: Right rear hydraulic oil temperature sensor is high 759
Related circuit diagram 759
Fault Code A172: Left front hydraulic oil temperature sensor is high 760
Related circuit diagram 760
Fault Code A173: Right front hydraulic oil temperature sensor is high 761
Related circuit diagram 761
Fault Code A182: (A30003 only) The battery 12 Volt battery tap has high voltage 762
Related circuit diagram 763
Fault Code A183: (A30003 only) The battery 12 Volt battery tap has low voltage 764
Related circuit diagram 765
Fault Code A184: J1939 data link is not connected 766
Related circuit diagram 767
Fault Code A190: (A30003 only) The automatic lubrication system has announced a fault 768
Fault Code A190: (A30004 & Up) Auto lube control has detected an incomplete lube cycle 770
Related circuit diagram 771
Fault Code A194: Left front hydraulic oil temperature is high 772
Related circuit diagram 772
Fault Code A195: Right front hydraulic oil temperature is high 773
Related circuit diagram 773
Fault Code A196: Left rear hydraulic oil temperature is high 774
Related circuit diagram 774
Fault Code A197: Right rear hydraulic oil temperature is high 775
Related circuit diagram 775
Fault Code A198: Hoist pressure 1 sensor is high 776
Related circuit diagram 776
Fault Code A199: Hoist pressure 2 sensor is high 777
Related circuit diagram 777
Fault Code A200: Steering pressure sensor is high 778
Related circuit diagram 778
Fault Code A201: Brake pressure sensor is high 779
Related circuit diagram 779
Fault Code A202: Hoist pressure 1 sensor is low 780
Related circuit diagram 780
Fault Code A203: Hoist pressure 2 sensor is low 781
Related circuit diagram 781
Fault Code A204: Steering pressure sensor is low 782
Related circuit diagram 782
Fault Code A205: Brake pressure sensor is low 783
Related circuit diagram 783
Fault Code A206: Ambient temperature sensor is high 784
Related circuit diagram 784
Fault Code A207: Ambient temperature sensor is low 785
Related circuit diagram 785
Troubleshooting by fault code, part 3 787
Fault Code A213: Parking brake should have applied but is detected as not having applied 790
Related circuit diagram 793
Fault Code A214: Parking brake should have released but is detected as not having released 794
Related circuit diagram 796
Fault Code A215: Brake auto apply valve circuit is defective 797
Related circuit diagram 798
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 799
Related circuit diagram 800
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted 801
Related circuit diagram 802
Fault Code A230: Parking brake has been requested while truck still moving 803
Related circuit diagram 804
Fault Code A231: The body is up while traveling or with selector in forward or neutral 805
Fault Code A233: Drive System Control Link is not connected 807
Related circuit diagram 809
Fault Code A235: Steering accumulator is in the process of being bled down 810
Related circuit diagram 811
Fault Code A236: The steering accumulator has not properly bled down after 90 seconds 812
Related circuit diagram 813
Fault Code A237: The CAN/RPC connection to the display is open 814
Related circuit diagram 815
Fault Code A238: Drive System and IM are reporting different park brake status 816
Related circuit diagram 818
Fault Code A239: The Drive System and IM are reporting different brake lock status 819
Related circuit diagram 820
Fault Code A240: The keyswitch input to the Interface Module is open 821
Related circuit diagram 821
Fault Code A242: Fuel gauge within the dash display panel is defective 822
Related circuit diagram 822
Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective 823
Related circuit diagram 823
Fault Code A244: Drive system temperature gauge within the dash display panel is defective 824
Related circuit diagram 824
Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective 825
Related circuit diagram 825
Fault Code A246: Payload meter reports truck overload 826
Related circuit diagram 826
Fault Code A247: Low steering pressure warning for display to operator 827
Related circuit diagram 827
Fault Code A248: Status module within the dash display panel is defective 828
Related circuit diagram 828
Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted 829
Related circuit diagram 829
Fault Code A250: Battery voltage is low with the truck parked 830
Related circuit diagram 831
Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground 832
Related circuit diagram 833
Fault Code A252: Start enable output circuit is either open or shorted to ground 834
Related circuit diagram 835
Fault Code A253: Steering bleed circuit is not open while running 836
Related circuit diagram 837
Fault Code A254: (A30003 Only) The 5 minute idle circuit is either open or shorted to ground 838
Related circuit diagram 838
Fault Code A256: Red warning lamp in the dash display (driven by IM) is open 839
Related circuit diagram 839
Fault Code A257: Payload CAN/RPC is not connected 840
Related circuit diagram 841
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 842
Related circuit diagram 842
Troubleshooting by fault code, part 4 845
Fault Code A260: Park brake failure 848
Related circuit diagram 849
Fault Code A261: Low brake accumulator pressure warning for display to operator 850
Related circuit diagram 850
Fault Code A262: Steering bleed valve circuit open during shutdown 851
Related circuit diagram 852
Fault Code A264: Park brake relay circuit is defective 853
Related circuit diagram 854
Fault Code A265: Service brake failure 855
Related circuit diagram 856
Fault Code A266: Selector switch was not in park while attempting to crank engine 857
Related circuit diagram 858
Fault Code A267: Park brake was not set while attempting to crank engine 859
Related circuit diagram 860
Fault Code A268: Secondary engine shutdown while cranking 861
Related circuit diagram 861
Fault Code A270: Brake lock switch power supply is not on when required 862
Related circuit diagram 864
Fault Code A271: Shifter not in gear 865
Related circuit diagram 866
Fault Code A272: Brake lock switch power supply is not off when required 867
Related circuit diagram 868
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit 869
Related circuit diagram 869
Fault Code A274: A brake setting fault has been detected 870
Related circuit diagram 871
Fault Code A275: A starter has been detected as engaged without a cranking attempt 872
Related circuit diagram 873
Fault Code A277: Park brake applied while loading 874
Related circuit diagram 875
Fault Code A278: Service brake applied while loading 876
Related circuit diagram 877
Fault Code A279: Low Steering Pressure Switch bad 878
Related circuit diagram 878
Fault Code A280: Steering accumulator bled switch bad 879
Related circuit diagram 879
Fault Code A281: Brake lock degrade switch bad 880
Related circuit diagram 881
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 882
Related circuit diagram 883
Fault Code A283: (A30004 & Up) An engine shutdown delay was aborted because the parking brake was not set 884
Related circuit diagram 885
Fault Code A284: (A30004 & Up) An engine shutdown delay was aborted because the secondary shutdown switch was operated 886
Related circuit diagram 887
Fault Code A285: (A30004 & Up) The park brake was not set when the keyswitch was turned off 888
Related circuit diagram 889
Fault Code A286: (A30004 & Up) A fault was detected in the shutdown delay relay circuit 890
Related circuit diagram 891
Fault Code A292: (A30004 & Up) The shutdown delay relay has remained on after the latched keyswitch circuit is off 892
Related circuit diagram 893
Fault Code A295: The right front park brake is not setting up 894
Related circuit diagram 894
Fault Code A296: The left front park brake is not setting up 895
Related circuit diagram 895
Fault Code A297:The right rear park brake is not setting up 896
Related circuit diagram 896
Fault Code A298: The left rear park brake is not setting up 897
Related circuit diagram 897
Fault Code A299: The right front park brake is not releasing 898
Related circuit diagram 898
Fault Code A300: The left front park brake is not releasing 899
Related circuit diagram 899
Fault Code A301: The right rear park brake is not releasing 900
Related circuit diagram 900
Fault Code A302: The left rear park brake is not releasing 901
Related circuit diagram 901
Troubleshooting by fault code, part 5 903
Fault Code A303: Shifter is defective 906
Related circuit diagram 907
Fault Code A304: (A30004 & Up) Auto lube grease level fault 908
Related circuit diagram 908
Fault Code A305: (A30004 & Up) Auto lube circuit is defective 909
Related circuit diagram 910
Fault Code A309: No brakes applied when expected 911
Related circuit diagram 912
Fault Code A310: Low fuel warning 913
Related circuit diagram 914
Fault Code A311: Brake lock switch is on when it should not be 915
Related circuit diagram 916
Fault Code A312: (A30004 & Up) DCDC converter 12 volt circuit sensing is producing low readings 917
Related circuit diagram 917
Fault Code A313: (A30004 & Up) DCDC converter 12 volt circuit sensing is producing high readings 918
Related circuit diagram 918
Fault Code A315: (A30004 & Up) DCDC converter 12 volt circuit is low 919
Related circuit diagram 920
Fault Code A316: Starter engagement has been attempted with engine running 921
Related circuit diagram 922
Fault Code A317: Operation of brake auto apply valve without a detected response 923
Related circuit diagram 925
Fault Code A318: Unexpected power loss to Interface Module 926
Related circuit diagram 926
Fault Code A328: Drive system not powered up 927
Related circuit diagram 927
Fault Code A335: Manual/Auto Apply Pressure Fault 928
Fault Code A350: Overload on output 1B 929
Related circuit diagram 929
Fault Code A351: Overload on output 1E 930
Related circuit diagram 931
Fault Code A352: (A30003) Overload on output 1H 932
Related circuit diagram 932
Fault Code A352: (A30004 & Up) Overload on output 1H 933
Related circuit diagram 933
Fault Code A353: Overload on output 1J 934
Related circuit diagram 934
Fault Code A354: Overload on output 1K 935
Related circuit diagram 935
Fault Code A355: Overload on output 1L 936
Related circuit diagram 936
Fault Code A356: Overload on output 1M 937
Related circuit diagram 937
Fault Code A357: Overload on output 1N 938
Related circuit diagram 938
Fault Code A358: Overload on output 1P 939
Related circuit diagram 939
Fault Code A359: Overload on output 1R 940
Related circuit diagram 941
Fault Code A360: Overload on output 1S 942
Related circuit diagram 942
Fault Code A361: (A30003) Overload on output 1T 943
Related circuit diagram 943
None 943
Fault Code A361: (A30004 & Up) Overload on output 1T 944
Related circuit diagram 945
Fault Code A362: Overload on output 1U 946
Related circuit diagram 946
Fault Code A363: Overload on output 1X 947
Related circuit diagram 947
Fault Code A364: Overload on output 1Y 948
Related circuit diagram 948
Fault Code A365: Overload on output 1Z 949
Related circuit diagram 949
Fault Code A368: Siemens Brake Test Active 950
Related circuit diagram 950
Fault Code A369: Siemens Brake Test Incomplete 951
Related circuit diagram 951
Fault Code A370: Siemens Brake Test Torque Achieved for Park Brake 952
Related circuit diagram 952
Fault Code A371: Siemens Brake Test Torque Achieved for Service Brake 953
Related circuit diagram 953
Fault Code A372: Siemens Brake Test Torque Not Achieved for Park Brake 954
Related circuit diagram 954
Fault Code A373: Siemens Brake Test Torque Not Achieved for Service Brake 955
Related circuit diagram 955
Drive system fault code table, part 1 957
Summary 960
How to use this document 960
Event code and diagnosis message 960
Description 960
Threshold 960
Detection by 960
Possible reasons 960
Action to reset 960
Action to repair 961
Operator displayed code 961
Note 961
Protection reactions 961
Event classification 962
Level 1: Warning 962
Level 2: Minor purposes 962
Level 3: Severe 962
1 L3C SYS: Time slice overflow CPU T1 963
2 L3C SYS: Time slice overflow CPU T2 963
3 L3C SYS: Time slice overflow CPU T3 963
4 L3C SYS: Time slice overflow CPU T4 963
5 L3C SYS: Time slice overflow CPU T5 963
6 L3C SYS: Time slice overflow CPU T6 963
7 L3C SYS: Time slice overflow CPU T7 963
8 L3C SYS: Time slice overflow CPU T8 963
10 L2A SYS: Pulse inhibit/asa inhibit PSU–ONLINE 964
11 L3D SYS: Pulse inhibit/asa inhibit PSU-Start-up 964
12 L1A SYS: SIBAS® blower fault 965
13 L1B SYS: Undervoltage in SIBAS® battery for BRAM 965
14 L3C SYS: SIBAS® power supply failure 24V for pulse amplifier 966
15 L3C SYS: SIBAS® power supply failure +5V 967
16 L3C SYS: SIBAS® power supply failure +15V 968
17 L3C SYS: SIBAS® power supply failure –15V 969
18 L3C SYS: SIBAS® power supply failure +24V 970
19 L3C SYS: SIBAS® power supply failure –24V 971
20 L3C SYS: SIBAS® power supply failure primary 972
21 L3C SYS: FPGA clock missing for PSU 972
22 L3C SYS: Pulse inhibit by reset in PSU from CPU 973
24 L3C SYS: General protection error (G10) 973
25 L3C SYS: Total block 974
26 L1B SYS: Permanent inhibit fault active 975
27 L1B SYS: Regular inhibit fault active 975
28 L1A SYS: GW Test stopped by A/D converter faulty 976
30 L3C DSP A: Initialization fault detected by DSP 976
31 L3C DSP A: SW-WatchdoG 977
32 L3C DSP A: Initialization fault detected by CPU 978
33 L1B DSP A: SW-Traco triggered 978
34 L1B DSP A: SW-Traco full 979
35 L3C DSP A: Time slice overflow T1 980
36 L3C DSP A: Time slice overflow T2 980
37 L3C DSP A: Time slice overflow T3 980
38 L3C DSP A: Time slice overflow T4 980
39 L1A DSP A: Communication HSCX data from DSP B missing 981
40 L1A DSP A: Communication HSCX data from DSP T missing 981
41 L3C DSP A: Current offset during pulse block 982
42 L3C DSP A: Current offset during no pulse block 982
43 L3A DSP A: Overcurrent fault 983
44 L3C DSP A: Current transducer defective phase U 984
45 L3C DSP A: Current transducer defective phase W 985
48 L1A DSP A: Modulation software fault 985
49 L3A DSP A: Active current controller at limit 986
Drive system fault code table, part 2 989
50 L3A DSP A: Active current reference at limit 992
51 L1A DSP A: Braking chopper controller at limit 992
52 L3C DSP A: Phase unbalance too large 993
53 L3A DSP A: Pulse block by DSP software 994
54 L3C DSP A: U/F Card defective 994
55 L3C DSP A: Difference in current of phase U over limit 995
56 L3C DSP A: Difference in current of phase W over limit 995
60 L3C DSP B: Initialization fault detected by DSP 996
61 L3C DSP B: SW-Watchdog 996
62 L3C DSP B: Initialization fault detected by CPU 997
63 L1B DSP B: SW-Traco triggered 997
64 L1B DSP B: SW-Traco full 998
65 L3C DSP B: Time slice overflow T1 998
69 L1A DSP B: Communication HSCX data from DSP A missing 999
70 L1A DSP B: Communication HSCX data from DSP T missing 999
71 L3C DSP B: Current offset during pulse block 1000
72 L3C DSP B: Current offset during no pulse block 1000
73 L3A DSP B: Overcurrent fault 1001
74 L3C DSP B: Current transducer defective phase V 1002
75 L3C DSP B: Current transducer defective phase W 1003
78 L1A DSP B: Modulation software fault 1003
79 L3A DSP B: Active current controller at limit 1004
80 L3A DSP B: Active current reference at limit 1004
81 L1A DSP B: Braking chopper controller at limit 1004
82 L3C DSP B: Phase unbalance too large 1005
83 L3A DSP B: Pulse block by DSP software 1005
84 L3C DSP B: U/F Card defective 1006
85 L3C DSP B: Difference in current of phase V over limit 1006
86 L3C DSP B: Difference in current of phase W over limit 1007
90 L3C DSP T: Initialization fault detected by DSP 1007
91 L3C DSP T: SW-Watchdog 1008
92 L3C DSP T: Initialization fault detected by CPU 1009
93 L1B DSP T: SW-Traco triggered 1009
94 L1B DSP T: SW-Traco full 1010
95 L3C DSP T: Time slice overflow T1 1010
96 L3C DSP T: Time slice overflow T2 1010
97 L3C DSP T: Time slice overflow T3 1010
98 L3C DSP T: Time slice overflow T4 1010
99 L1A DSP T: Communication HSCX data from DSP A missing 1011
Drive system fault code table, part 3 1013
100 L1A DSP T: Communication HSCX data from DSP B missing 1016
101 L3C DSP T: Current offset during pulse block 1016
102 L3C DSP T: Current offset during no pulse block 1017
103 L3A DSP T: Overcurrent fault 1018
104 L3C DSP T: Current transducer defective phase U 1019
105 L3C DSP T: Current transducer defective phase V 1020
106 L3C DSP T: Current transducer defective phase W 1021
107 L3C DSP T: Sum of output current not equal zero 1022
108 L1A DSP T: Modulation software fault 1022
109 L1A DSP T: Voltage controller at limit 1023
112 L3C DSP T: Phase unbalance too large 1023
113 L3A DSP T: Pulse block by DSP software 1024
114 L3C DSP T: U/F Card defective 1024
117 L3C DSP T: Crowbar fired by DSP T 1025
119 L1C DSP T: Voltage transducer U34 not ok 1026
120 L3C IO: Supervision bus clock 1026
121 L3C IO: Supervision I/O clock 1027
122 L3C IO: Incorrect FPGA version identifier 1027
123 L3C IO: Incorrect FPGA application version identifier 1028
124 L3C IO: Incorrect module version identifier 1028
125 L3C/L1A IO: AD Converter faulty 1029
126 L3C IO: GW Comparator faulty during start-up test 1029
127 L3C IO: Test voltage not equal zero 1030
128 L1A IO: SIBAS® Temperature out of range 1030
129 L3C IO: Incorrect EBIN card identifier 1031
130 L3C IO: Front plug monitoring 1032
131 L3C IO: CPU Watchdog triggered 1033
132 L3C IO: DSP A Watchdog triggered 1033
133 L3C IO: DSP B Watchdog triggered 1034
134 L3C IO: DSP T Watchdog triggered 1034
135 L3C IO: CPU Reset triggered 1035
138 L1B IO: CPU Traco triggered 1035
146 L3A IO: Pulse block from I/O 1036
150 L3A IO: DC link voltage A level 1 exceeded 1036
151 L3A IO: DC link voltage B level 1 exceeded 1037
152 L3C IO: Trolley line overvoltage 1038
154 L3B IO: Trolley line overcurrent 1039
155 L2B IO: Trolley line current transducer faulty 1039
156 L2B IO: Trolley line voltage transducer faulty 1040
160 L3A IO: Throttle pedal out of range 1040
161 L3A IO: Retard pedal out of range 1041
162 L1A IO: Cruise speed control module out of range 1041
180 L3C UWSA1: Supervision bus clock 1042
181 L3C UWSA1: Supervision module clock 1042
182 L3C UWSA1: Incorrect FPGA version identifier 1043
183 L3C UWSA1: Incorrect FPGA project identifier 1043
184 L3C UWSA1: GW Comparator faulty during start-up test 1044
185 L1A UWSA1: ADC Faulty 1044
186 L3C UWSA1: Configuration failure 1045
187 L1A UWSA1: Hardware failure counter / processor 1045
188 L3A UWSA1: Peak current protection active 1046
189 L3D UWSA1: Peak current protection pulse start 1047
190 L3D UWSA1: Number of peak current protection >limit 1048
191 L3D UWSA1: Supervision switching frequency 1049
193 L1A UWSA1: Overvoltage level 1 exceeded 1049
196 L3D UWSA1: Limit 5 overcurrent phase U 1050
197 L3D UWSA1: Limit 5 overcurrent phase V 1050
198 L3D UWSA1: Limit 5 overcurrent phase W 1050
199 L3D UWSA1: Limit 5 overvoltage DC bus 1051
Drive system fault code table, part 4 1053
201 L3D UWSA1: Checkback INVA1 L1U faulty 1057
202 L3D UWSA1: Checkback INVA1 L1L faulty 1057
203 L3D UWSA1: Checkback INVA1 L2U faulty 1057
204 L3D UWSA1: Checkback INVA1 L2L faulty 1057
205 L3D UWSA1: Checkback INVA1 L3U faulty 1057
206 L3D UWSA1: Checkback INVA1 L3L faulty 1057
207 L3D UWSA1: Checkback chopper A faulty 1057
210 L3C UWSB1: Supervision bus clock 1058
211 L3C UWSB1: Supervision module clock 1058
212 L3C UWSB1: Incorrect FPGA version identifier 1059
213 L3C UWSB1: Incorrect FPGA project identifier 1059
214 L3C UWSB1: GW Comparator faulty during start-up test 1060
215 L1A UWSB1: ADC Faulty 1060
216 L3C UWSB1: Configuration failure 1061
217 L1A UWSB1: Hardware failure counter / processor 1061
218 L3A UWSB1: Peak current protection active 1062
219 L3D UWSB1: Peak current protection pulse start 1063
220 L3D UWSB1: Number of peak current protection >limit 1064
221 L3D UWSB1: Supervision switching frequency 1065
223 L1A UWSB1: Overvoltage level 1 exceeded 1065
226 L3D UWSB1: Limit 5 overcurrent phase V 1066
227 L3D UWSB1: Limit 5 overcurrent phase U 1066
228 L3D UWSB1: Limit 5 overcurrent phase W 1066
229 L3D UWSB1: Limit 5 overvoltage DC bus 1067
231 L3D UWSB1: Checkback INVB1 L1U Faulty 1068
232 L3D UWSB1: Checkback INVB1 L1L Faulty 1068
233 L3D UWSB1: Checkback INVB1 L2U Faulty 1068
234 L3D UWSB1: Checkback INVB1 L2L Faulty 1068
235 L3D UWSB1: Checkback INVB1 L3U Faulty 1068
236 L3D UWSB1: Checkback INVB1 L3L Faulty 1068
237 L3D UWSB1: Checkback chopper B Faulty 1068
240 L3C UWSA2: Supervision bus clock 1069
241 L3C UWSA2: Supervision module clock 1069
242 L3C UWSA2: Incorrect FPGA version identifier 1070
243 L3C UWSA2: Incorrect FPGA project identifier 1070
244 L3C UWSA2: GW Comparator faulty during start-up test 1071
245 L1A UWSA2: ADC Faulty 1071
246 L3C UWSA2: Configuration failure 1072
247 L1A UWSA2: Hardware failure counter / processor 1072
248 L3A UWSA2: Peak current protection active 1073
249 L3D UWSA2: Peak current protection pulse start 1074
250 L3D UWSA2: Number of peak current protection >limit 1075
251 L3D UWSA2: Supervision switching frequency 1076
253 L1A UWSA2: Overvoltage level 1 exceeded 1076
256 L3D UWSA2: Limit 5 overcurrent phase U1 1077
257 L3D UWSA2: Limit 5 overcurrent phase V1 1077
258 L3D UWSA2: Limit 5 overcurrent phase W1 1077
259 L3D UWSA2: Limit 5 overvoltage DC bus 1078
261 L3D UWSA2: Checkback INVA2 L1U faulty 1079
262 L3D UWSA2: Checkback INVA2 L1L faulty 1079
263 L3D UWSA2: Checkback INVA2 L2U faulty 1079
264 L3D UWSA2: Checkback INVA2 L2L faulty 1079
265 L3D UWSA2: Checkback INVA2 L3U faulty 1079
266 L3D UWSA2: Checkback INVA2 L3L faulty 1079
267 L3D UWSA2: Checkback chopper C faulty 1079
270 L3C UWSB2: Supervision bus clock 1080
271 L3C UWSB2: Supervision module clock 1080
272 L3C UWSB2: Incorrect FPGA version identifier 1081
273 L3C UWSB2: Incorrect FPGA project identifier 1081
274 L3C UWSB2: GW Comparator faulty during start-up test 1082
275 L1A UWSB2: ADC Faulty 1082
276 L3C UWSB2: Configuration failure 1083
277 L1A UWSB2: Hardware failure counter / processor 1083
278 L3A UWSB2: Peak current protection active 1084
279 L3D UWSB2: Peak current protection pulse start 1085
280 L3D UWSB2: Number of peak current protection >limit 1086
281 L3D UWSB2: Supervision switching frequency 1087
283 L1A UWSB2: Overvoltage level 1 exceeded 1087
286 L3D UWSB2: Limit 5 overcurrent phase V1 1088
287 L3D UWSB2: Limit 5 overcurrent phase U1 1088
288 L3D UWSB2: Limit 5 overcurrent phase W1 1088
289 L3D UWSB2: Limit 5 overvoltage DC bus 1089
291 L3D UWSB2: Checkback INVB2 L1U Faulty 1090
292 L3D UWSB2: Checkback INVB2 L1L Faulty 1090
293 L3D UWSB2: Checkback INVB2 L2U Faulty 1090
294 L3D UWSB2: Checkback INVB2 L2L Faulty 1090
295 L3D UWSB2: Checkback INVB2 L3U Faulty 1090
296 L3D UWSB2: Checkback INVB2 L3L Faulty 1090
297 L3D UWSB2: Checkback chopper D Faulty 1090
Drive system fault code table, part 5 1093
300 L3C UWSST: Supervision bus clock 1097
301 L3C UWSST: Supervision module clock 1097
302 L3C UWSST: Incorrect FPGA version identifier 1098
303 L3C UWSST: Incorrect FPGA project identifieR 1098
304 L3C UWSST: GW Comparator faulty during start-up test 1099
305 L1A UWSST: ADC Faulty 1099
306 L3C UWSST: Configuration failure 1100
307 L1A UWSST: Hardware failure counter / processor 1100
308 L3A UWSST: Peak current protection active 1101
310 L3D UWSST: Number of peak current protection >limit 1102
311 L3D UWSST: Supervision switching frequency 1103
314 L3C UWSST: Crowbar is fired without command 1104
319 L3D UWSST: Limit 5 overvoltage DC bus 1106
321 L3D UWSST: Checkback INVST L1U Faulty 1107
322 L3D UWSST: Checkback INVST L1L Faulty 1107
323 L3D UWSST: Checkback INVST L2U Faulty 1107
324 L3D UWSST: Checkback INVST L2L Faulty 1107
325 L3D UWSST: Checkback INVST L3U Faulty 1107
326 L3D UWSST: Checkback INVST L3L Faulty 1107
327 L3C UWSST: Checkback crowbar faulty 1108
330 L1A BUS: CAN Communication failure 1109
331 L1A BUS: Serial link communication failure 1109
332 L1A BUS: Truck is over loaded 1109
333 L1B TR: Transient traco is triggered 1110
334 L1B TR: Transient traco is full 1110
340 L1A ETM: ADC Failure for ETM1 1110
341 L1A ETM: ADC Failure for ETM2 1111
342 L1A ETM: ADC Failure for ETM3 1111
343 L1A ETM: ADC Failure for ETM4 1111
344 L1A MEFA: ADC Failure 1112
345 L3C HL: Gate unit power supply A defective 1112
346 L3C HL: Gate unit power supply B defective 1113
351 L1A DRZ: LIMP Mode A active 1114
352 L1A DRZ: Limp mode B active 1114
353 L1A DRZ: Low battery voltage 1115
354 L1B BUS: Engine floor input increasing minimum engine speed 1115
355 L1B DM: Data store switch pressed 1116
356 L1B DM: Diagnosis memory configuration failure 1116
357 L1B DM: Diagnosis memory occupation > 75% 1116
358 L1B DM: Diagnosis memory full 1117
359 L1B DM: Test event 1117
360 L2A EXT: Main blower air flow supervision 1118
361 L2A EXT: Minimum engine speed supervision 1119
362 L1A EXT: Main blower pressure switch malfunction 1120
363 L1A EXT: Shift lever supervision 1121
364 L2A EXT: Engine derate protection active 1122
365 L1A EXT: Truck external plug monitoring 1122
367 L3A EXT: DC Power off mod request (rest switch on) 1123
369 L1A EXT: Doppler sensor defective 1125
370 L1A EXT: Auto lube control defective 1126
372 L1A EXT: Service brake pressed at high speeD 1126
373 L1A EXT: Service brake on above speed limit 1127
374 L1A EXT: Anti-roll control malfunction 1127
375 L3B BEF: CB301 Circuit breaker defective 1128
376 L3B BEF: K303/K304 Contactor defective 1129
377 L3C STP: Voltage reading incorrect between trolley line and voltage in stepdown box 1130
382 L3B BEF: K103 Feedback defective 1131
383 L3B BEF: K105 Feedback defective 1131
384 L1A BEF: K107 Feedback defective 1132
385 L1A BEF: K109 Feedback defective 1132
386 L1A BEF: K111 Feedback defective 1133
387 L1A BEF: Limp mode selector defective 1133
388 L2B BEF: CB113 Tripped 1134
390 L3D IUW: Output current supervision INV A 1134
391 L3D IUW: Output current supervision INV B 1135
392 L3B IUW: Precharge supervision 1 1136
393 L3B IUW: Precharge supervision 2 1137
394 L3A IUW: DC Link undervoltage 1138
395 L2B IUW: Trolley line undervoltage 1139
397 L3B IUW: Field regulator current setpoint supervision 1140
398 L2B IUW: Field regulator output current supervision 1141
399 L3B IUW: Alternator overcurrent protection 1142
Drive system fault code table, part 6 1145
400 L2C IUW: Alternator overload warning 1148
401 L2B IUW: Alternator overload protection 1148
402 L3C IUW: Alternator AC current sensor faulty 1149
403 L2A IUW: DC Link voltage out of range in propel 1150
404 L3A IUW: DC Link voltage out of range retard 1151
405 L3A IUW: DC Link voltage out of range for ST operation 1152
406 L3B IUW: DC Link controller supervision 1153
407 L2C IUW: Motor torque square T supervision 1154
408 L2C IUW: Motor current square T supervision 1154
409 L1A IUW: DC Link discharge time exceeded limit 1155
410 L2B IUW: Ground fault at positive DC link detected 1156
411 L2B IUW: Ground fault at negative DC link detected 1157
412 L2B IUW: Ground fault at AC side detected 1158
413 L2B IUW: Ground fault 1159
414 L3C IUW: Chopper A current supervision 1160
415 L3C IUW: Chopper B current supervision 1161
416 L3C IUW: Chopper C current supervision 1162
417 L3C IUW: Chopper D current supervision 1163
418 L3D IUW: Output current supervision INV ST 1164
419 L2A IUW: Vehicle overspeed supervisioN 1165
420 L1A IUW: DC Link voltage sensor A faulty 1166
421 L1A IUW: DC Link voltage sensor B faulty 1167
422 L3C IUW: ST Inverter failure 1168
423 L3B IUW: DC Grid fan circuit failure 1168
424 L2B IUW: Cooling water pressure out of range 1169
425 L2B IUW: Cooling water level out of range 1170
426 L1A IUW: Water pump motor overtemperature 1171
427 L1A IUW: Retard limit supervision 1171
428 L1A DRZ: Front wheel A speed sensor supervision 1172
429 L1A DRZ: Front wheel B speed sensor supervision 1173
430 L3D DRZ: Motor A speed sensor supervision 1174
431 L3D DRZ: Motor B speed sensor supervision 1175
432 L3C DRZ: Alternator speed sensor supervision 1176
433 L2A DRZ: Motor A maximum speed exceeded 1177
434 L2A DRZ: Motor B maximum speed exceeded 1177
435 L1A DRZ: Alternator maximum speed exceeded 1178
436 L3A DRZ: Motor A/B rotation inconsistency 1179
437 L3A DRZ: Motor A torque supervision 1180
438 L3A DRZ: Motor B torque supervision 1181
439 L3C SIV: Start-up sequence can’t pass due to GUPS failure 1182
440 L3C SIV: Start-up sequence can’t pass due to K103/K105 failure 1183
441 L3C SIV: Start-up sequence can’t pass due to IGBT failure 1184
442 L3C SIV: Start-up sequence can’t pass due to CB301 OR K303 failure 1185
443 L3C SIV: Start-up sequence can’t pass due to crowbar failure 1186
447 L1A SIV: Direct trolley engage sequence supervision 1187
448 L1A SIV: Direct trolley disengage sequence supervision 1188
Drive system fault code table, part 7 1191
450 L1A TMP: SIBAS® Temperature < low limit 1195
451 L1A TMP: SIBAS® Temperature > warning limit 1195
452 L3B TMP: SIBAS® Temperature > shutdown limit 1196
453 L3A TMP: IGBT Module A101 temperature < low limit 1197
454 L2C TMP: IGBT Module A101 temperature > APRS limit 1198
455 L3A TMP: IGBT Module A101 temperature > shutdown limit 1199
456 L3A TMP: IGBT Module A102 temperature < low limit 1200
457 L2C TMP: IGBT Module A102 temperature > APRS limit 1201
458 L3A TMP: IGBT Module A102 temperature > shutdown limit 1202
459 L3A TMP: IGBT ModulE A201 temperature < low limit 1203
460 L2C TMP: IGBT Module A201 temperature > APRS limit 1204
461 L3A TMP: IGBT Module A201 temperature > shutdown limit 1205
462 L3A TMP: IGBT Module A202 temperature < low limit 1206
463 L2C TMP: IGBT Module A202 temperature > APRS limit 1207
464 L3A TMP: IGBT Module A202 temperature >shutdown limit 1208
465 L3A TMP: ST Module temperature < low limit 1209
466 L2C TMP: ST Module temperature > warning limit 1210
467 L3A TMP: ST Module temperature > shutdown limit 1211
468 L2B TMP: SR Module temperature < low limit 1212
469 L2C TMP: SR Module temperature > warning limit 1213
470 L2B TMP: SR Module temperature > shutdown limit 1214
471 L2C TMP: Wheel motor A stator temperature > APRS limit 1215
472 L3A TMP: Wheel motor A stator temperature > shutdown limit 1216
473 L2C TMP: Wheel motor B Stator temperature > APRS limit 1217
474 L3A TMP: Wheel motor B stator temperature shutdown limit 1218
475 L2C TMP: Wheel motor A, DE bearing temperature > warning limit 1219
476 L3A TMP: Wheel motor A, DE bearing temperature > shutdown limit 1220
477 L2C TMP: Wheel motor A NDE bearing temperature > warning limit 1221
478 L3A TMP: Wheel motor A NDE bearing temperature > shutdown limit 1222
479 L2C TMP: Wheel motor B DE bearing temperature > warning limit 1223
480 L3A TMP: Wheel motor B DE bearing temperature > shutdown limit 1224
481 L2C TMP: Wheel motor B NDE bearing temperature > warning limit 1225
482 L3A TMP: Wheel motor B NDE bearing temperature > shutdown limit 1226
483 L2C TMP: Alternator stator temperature > APRS limit 1227
484 L2B TMP: Alternator stator temperature > shutdown limit 1228
485 L2C TMP: Alternator bearing temperature > warning limit 1229
486 L2B TMP: Alternator bearing temperature > shutdown limit 1230
487 L1A TMP: Cooling water inlet temperature < low limit 1231
488 L2C TMP: Cooling water inlet temperature > warning limit 1232
489 L2B TMP: Cooling water inlet temperature > shutdown limit 1233
490 L1A TMP: Cooling water outlet temperature < low limit 1234
491 L2C TMP: Cooling water outlet temperature > warning limit 1235
492 L2B TMP: Cooling water outlet temperature > shutdown limit 1236
493 L1A TMP: Cooling water delta T too high 1237
495 L2C TMP: Inverter cab temperature > warning limit 1238
496 L2B TMP: Inverter cab temperature > shutdown limit 1239
497 L2C TMP: Inside cooler outlet temperature > warning limit 1240
498 L2B TMP: Inside cooler outlet temperature > shutdown limit 1241
499 L1A TMP: Main blower motor stator temperature > warning limit 1242
500 L1A TMP: Main blower motor stator temperature > shutdown limit 1243
505 L1A TMP: Wheel motor A rotor temperature > limit 1244
506 L1A TMP: Wheel motor B rotor temperature > limit 1245
508 L1A ETM1: Alternator PT100 open circuit 1246
509 L1A ETM1: Main blower stator PT100 open circuit 1246
510 L1A ETM1: Grid blower statoR PT100 open circuit 1246
511 L1A ETM1: Inverter CAB PT100 open circuit 1246
512 L1A ETM1: Ambient PT100 open circuit 1246
513 L1A ETM1: Heater exchanger PT100 open circuit 1246
514 L1A ETM1: Cooling water inlet PT100 open circuit 1246
515 L1A ETM1: Cooling water outlet PT100 open circuit 1246
516 L1A ETM2: Motor A NDE Bearing PT100 open circuit 1247
517 L1A ETM2: Motor A DE Bearing PT100 open circuit 1247
518 L1A ETM2: Motor B NDE Bearing PT100 open circuit 1247
519 L1A ETM2: Motor B DE Bearing PT100 open circuit 1247
520 L1A ETM2: Alternator Bearing PT100 open circuit 1247
521 L1A ETM2: Motor A stator PT100 open circuit 1247
522 L1A ETM2: Motor B stator PT100 open circuit 1247
523 L1A ETM2: Motor inlet air PT100 open circuit 1247
524 L1A ETM3: IGBT Module A101 PT100 open circuit 1248
525 L1A ETM3: IGBT Module A102 PT100 open circuit 1248
526 L1A ETM3: IGBT Module A103 PT100 open circuit 1248
527 L1A ETM3: IGBT Module A104 PT100 open circuit 1248
528 L1A ETM3: IGBT Module A201 PT100 open circuit 1248
529 L1A ETM3: IGBT Module A202 PT100 open circuit 1248
530 L1A ETM3: IGBT Module A203 PT100 open circuit 1248
531 L1A ETM3: IGBT Module A204 PT100 open circuit 1248
532 L1A ETM3: ST Module PT100 open circuit 1249
533 L1A ETM3: SR Module PT100 open circuit 1249
534 L1A ETM3: Channel 7 PT100 open circuit 1249
535 L1A ETM3: Channel 8 PT100 open circuit 1249
536 L1A ETM4: Channel 1 PT100 open circuit 1250
537 L1A ETM4: Channel 2 PT100 open circuit 1250
538 L1A ETM4: Channel 3 PT100 open circuit 1250
539 L1A ETM4: Channel 4 PT100 open circuit 1250
540 L1A ETM4: Channel 5 PT100 open circuit 1250
541 L1A ETM4: Channel 6 PT100 open circuit 1250
542 L1A ETM4: Channel 7 PT100 open circuit 1250
543 L1A ETM4: Channel 8 PT100 open circuit 1250
544 L1A ETM4: SR Module PT100 open circuit 1250
550 L3A TMP: Inverter A module temperature < low limit 1251
551 L2C TMP: Inverter A module temperature > APRS limit 1252
552 L3A TMP: Inverter A module temperature > shutdown limit 1253
553 L3A TMP: Inverter B module temperature < low limit 1254
554 L2C TMP: Inverter B module temperature > APRS limit 1255
555 L3A TMP: Inverter B module temperature > shutdown limit 1256
556 L3A TMP: Chopper A module temperature < low limit 1257
557 L2C TMP: Chopper A module temperature > APRS limit 1258
558 L3A TMP: Chopper A module temperature > shutdown limit 1259
559 L3A TMP: Chopper B module temperature < low limit 1260
560 L2C TMP: Chopper B module temperature > APRS limit 1261
561 L3A TMP: Chopper B module temperature > shutdown limit 1262
Payload meter scoreboard 1265
Display messages 1267
LED lights 1267
Processor LED (2, Figure 50-1) 1267
Data Receive LED (3, Figure 50-1) 1267
Option switches 1268
SWITCH 1 – TEST (Displays “888”) 1268
SWITCH 2 – COUNT 1268
SWITCH 9 – TRANSMIT CUT 1268
SWITCH 10 – HIGH IMPEDANCE LISTEN 1268
Troubleshooting 1269
Troubleshooting chart 1269
Symptom 1269
Possible Cause 1269
Remedy 1269
Electric wheel motor 1271
Fault table 1273
Reserve engine oil system 1281
Pumping unit LED signals 1283
Circuit fuses 1283
Steering system 1285
Steering circuit troubleshooting chart 1287
Steering circuit troubleshooting guidelines 1289
Basic hydraulic system checks 1290
System leakage check 1291
Steering pump troubleshooting guide 1293
Pump pressure control checks 1296
To verify pump unload pressure 1296
To verify pump reloading 1296
Pump fails to unload 1297
Pump fails to develop pressure 1297
Pump slow in developing pressure 1298
Pump control valve inspection and trouble shooting 1299
Pump case drain check 1301
Definitions: 1302
Adjustment 1302
Automatic lubrication (auto lube) system 1305
Autolube troubleshooting chart 1307
50 Disassembly and assembly 1311
Service tools 1311
Special tool list 1313
Additional tool list 1313
Wheel motor rebuild tools 1314
Control cabinet 1314
Cab air conditioning 1317
Replacement of air conditioning system components 1319
Hoses and fittings 1319
Lines 1319
Expansion valve 1319
Receiver-drier 1319
Thermostat 1319
Compressor 1320
Accumulator 1320
Clutch 1320
Wheels, spindles and rear axle 1323
General precautions for tires and rims 1325
Wheel stud maintenance 1326
Front tires and rims 1327
Removal 1327
Installation 1328
Rear tires and rims 1328
Removal 1328
Installation 1329
Rim components 1331
Smart Rim Component Layout 1331
Rim and tire service 1332
Lubricants 1332
Tire Inflation 1332
Lock Ring Retainer Installation 1332
Remove Smart Lock Ring from Inside Position of Outer Dual and Outside Position of Inner Dual 1333
Install Smart Lock Ring to Inside Position of Outer Dual and Outside Position of Inner Dual 1334
Removal (5-Piece Standard Rim) 1335
Removal (7-Piece Smart Rim) 1338
Removal (5-Piece Smart Rim) 1340
Preparation Before Assembly 1342
Installation (5-Piece Standard Rim) 1342
Installation – Horizontal Mount (Smart Rim) 1344
Installation – Vertical Mount (5-Piece Smart Rim) 1346
Installation – Vertical Mount (7-Piece Smart Rim) 1348
Removal and installation of front wheel hub and spindle 1349
Removal 1349
Spindle Removal Procedure (off of the truck) 1352
Installation 1355
Disassembly and assembly of front wheel hub and spindle 1356
Disassembly 1356
Cleaning and inspection 1356
Assembly 1358
Wheel bearing adjustment 1358
Seal assembly gap check and adjustment 1359
Floating seal installation 1360
Floating seal test procedure 1367
Speed sensor installation and adjustment 1368
Removal and installation of wheel motor 1368
Preparation 1368
Removal 1369
Cleaning and inspection 1370
Installation 1370
Removal and installation of rear axle 1373
Removal 1373
Cleaning and inspection 1375
Installation 1375
Removal and installation of anti-sway bar 1376
Removal 1376
Installation 1376
Removal and installation of pivot pin 1377
Removal 1377
Installation 1377
Pivot eye and bearing service 1378
Bearing inspection 1378
Bearing removal 1379
Bearing installation 1380
Pivot eye repair 1380
Removal and installation of electric motor 1381
Removal 1381
Installation 1382
Disassembly and assembly of wheel motor transmission 1383
Disassembly 1383
Cleaning and inspection 1390
Assembly 1390
Disassembly and assembly of low speed carrier 1402
Disassembly 1402
Inspection 1403
Assembly 1404
Disassembly and assembly of high speed carrier 1407
Disassembly 1407
Inspection 1408
Assembly 1409
Brake system 1413
Removal and installation of brake valve 1415
Removal 1415
Installation 1416
Disassembly and assembly of brake valve/pedal assembly 1416
Disassembly 1416
Assembly 1417
Removal and installation of dual relay valve 1419
Removal 1419
Installation 1420
Removal and installation of brake manifold 1421
Removal 1421
Installation 1421
Disassembly and assembly of brake manifold 1422
Disassembly 1422
Assembly 1422
Removal and installation of brake accumulator (piston style) 1423
Removal 1423
Installation 1425
Disassembly and assembly of brake accumulator (piston style) 1425
Disassembly 1425
Cleaning and inspection 1427
Piston seal replacement 1428
Assembly 1428
Removal and installation of brake accumulators (bladder style) 1429
Removal 1429
Installation 1430
Disassembly and assembly of brake accumulator (bladder style) 1431
Disassembly 1431
Cleaning and inspection 1432
Assembly 1433
Disassembly and assembly of wheel brake 1434
Disassembly 1435
Cleaning and inspection 1438
Assembly 1439
Floating ring seal assembly and installation 1445
Removal and installation of rear brake assembly 1453
Removal 1453
Installation 1453
Steering system 1459
Removal and installation of steering control unit 1461
Removal 1461
Installation 1462
Disassembly and assembly of steering control unit 1463
Disassembly 1463
Assembly 1465
Removal and installation of steering column 1468
Removal 1468
Inspection 1468
Installation 1469
Removal and installation of steering wheel 1470
Removal 1470
Installation 1470
Removal and installation of bleeddown manifold 1472
Removal 1472
Installation 1472
Removal and installation of flow amplifier 1474
Removal 1474
Installation 1474
Removal and installation of steering cylinder 1474
Removal 1474
Bearing replacement 1474
Installation 1475
Disassembly and assembly of steering cylinders 1476
Disassembly 1476
Assembly 1476
Removal and installation of tie rod 1477
Removal 1477
Installation 1478
Removal and installation of steering/brake pump 1478
Removal 1478
Installation 1479
Disassembly and assembly of steering/brake pump 1481
Disassembly 1481
Inspection 1484
Assembly 1487
Driveshaft group 1488
Rotating group 1488
Removal and installation of steering accumulators (piston style) 1491
Removal 1491
Installation 1493
Disassembly and assembly of steering accumulator (piston style) 1493
Cleaning and Inspection 1495
Piston seals replacement 1495
Assembly 1496
Removal and installation of steering accumulators (bladder style) 1497
Removal 1497
Installation 1498
Disassembly and assembly of steering accumulator (bladder style) 1498
Disassembly 1498
Cleaning and Inspection 1499
Assembly 1500
Suspensions 1503
Removal and installation of front suspension 1505
General information 1505
Removal 1505
Installation 1507
Upper mounting joint – 60° advance 1511
Inspection 1512
Minor front suspension repairs (lower bearing and seals) 1513
Lower bearing retainer removal 1513
Lower bearing retainer installation 1513
Major front suspension rebuild 1514
Disassembly 1514
Assembly 1515
Removal and installation of rear suspension 1517
General information 1517
Removal 1517
Installation 1520
Disassembly and assembly of rear suspension 1521
Disassembly 1521
Cleaning and Inspection 1521
Assembly 1522
Hoist circuit 1525
Removal and installation of hoist pump 1527
Removal 1527
Installation 1528
Disassembly and assembly of hoist pump 1530
Disassembly 1530
Inspection 1535
Assembly 1536
Removal and installation of hoist valve 1539
Removal 1539
Installation 1540
Disassembly and assembly of hoist valve 1540
O-ring replacement 1540
Disassembly of inlet section 1542
Assembly of inlet section 1543
Disassembly of rear spool section 1544
Assembly of rear spool section 1546
Disassembly of front spool section 1547
Assembly of front spool section 1548
Overcenter manifold service 1548
Removal and installation of hoist pilot valve 1549
Removal 1549
Installation 1549
Disassembly and assembly of hoist pilot valve 1550
Disassembly 1550
Cleaning and inspection 1551
Assembly 1551
Removal and installation of hoist cylinders 1552
Removal 1552
Installation 1553
Disassembly and assembly of hoist cylinders 1555
Disassembly 1555
Cleaning and inspection 1557
Installation of the quill 1558
Assembly 1560
Replacement of hoist circuit filter 1562
Filter element replacement 1563
Operator cab 1565
Removal and installation of operator cab 1567
Removal 1568
Installation 1569
Removal and installation of cab door 1571
Removal 1571
Installation 1571
Disassembly and assembly of cab door 1571
Removing door panel 1571
Installing door panel 1572
Replacing door window regulator 1572
Replacing door handle or latch assembly 1573
Replacing door assembly seal and door hinge seal 1574
Replacing door opening seal 1574
Removing door glass 1575
Installing door glass 1576
Adjustment of cab door 1578
Door jamb bolt adjustment 1578
Door handle plunger adjustment 1579
Removal and installation of side window glass 1580
Recommended tools and supplies 1580
Removal 1581
Installation 1581
Removal and installation of windshield and rear window glass 1582
Removal 1582
Installation 1582
Removal and installation of windshield wiper motor 1583
Removal 1583
Installation 1583
Removal and installation of windshield wiper arm 1584
Removal 1584
Installation 1584
Removal and installation of windshield wiper linkage 1585
Removal 1585
Installation 1585
Removal and installation of operator seat (standard seat) 1586
Adjustment 1586
Inspection 1587
Removal 1587
Installation 1587
Replacing the Seat Compressor 1588
Removal and installation of passenger seat (standard seat) 1593
Adjustment 1593
Inspection 1594
Removal 1594
Installation 1594
Removal and installation of seat belts (standard seat) 1595
Removal 1595
Installation 1595
Operator seat (optional seat) 1596
Seat Belts 1596
Adjustment 1596
Passenger seat (optional seat) 1598
Seat Belts 1598
Adjustment 1598
Removal and installation of seat belts (optional seat) 1599
General 1599
Removal 1599
Installation 1601
Body and structures 1605
Removal and installation of dump body 1607
Removal 1607
Inspection 1608
Installation 1609
Removal and installation of body pads 1609
Removal 1609
Installation 1610
Body pad shimming procedure 1610
Removal and installation of diagonal ladder/ hood and grille assembly 1611
Removal 1611
Installation 1611
Removal and installation of right deck 1612
Removal 1612
Installation 1614
Removal and installation of left deck 1615
Removal 1615
Installation 1615
Removal and installation of fuel tank 1617
Removal 1617
Cleaning and inspection 1617
Installation 1619
Removal and installation of horizontally mounted fuel gauge sender 1619
Removal 1619
Installation 1619
Removal and installation of vertically mounted fuel gauge sender 1619
Installation 1619
Disassembly and assembly of fuel tank breather 1621
Disassembly 1621
Assembly 1621
Removal and installation of hydraulic tank 1622
Removal 1622
Installation 1622
Three phase wheel motor 1625
Motor 1629
Transport 1630
Handling 1629
Storage of new motors 1631
Storage of used motors 1632
Safety guidelines 1633
Checking for external damage 1634
Checking the connections 1635
Regreasing the bearings 1635
Applying grease to the bearings 1635
Checking the interior of the motor for water 1636
Pressing off the coupling 1638
Disassembly 1639
Rotor 1639
Removing the rubber seals and the air baffles 1644
Bearing and labyrinth ring 1645
Removal 1645
Stator Inspection 1646
Rotor Inspection 1646
Testing the insulation 1647
High-voltage test 1647
Assembling the rubber seals and the air baffles 1650
Assembly after special repair work 1652
Bearing installation 1653
Preparatory measures for assembling the bearing (Figure 50-20 must be observed): 1656
Assemble the bearing 1657
Cover installation 1658
Assembling the bearing shield (N-end) at the stator frame 1659
Bearing installation 1661
Rotor installation 1663
Labyrinth ring 1665
Installation 1665
Installing accessories (D- and N-end) 1667
Running in the bearings 1671
Coupling 1672
Installation 1672
Assembly conditions and instructions 1673
Tests 1673
Replacing defective connecting leads 1674
Repairing the stator winding insulation 1675
Recommended consumables 1675
Chemical cleaning agents 1675
Chemical cleaning agents for outdoor use and for cleaning mechanical parts 1675
Chemical cleaning agents for flange faces 1675
Chemical cleaning agents for windings 1676
Chemical cleaning agents for windings 1676
Chemical cleaning agents for windings with severe damage and for oily windings 1676
Rolling-contact bearing grease 1676
Assembly/disassembly agents for bearing seat 1676
Sealants for joining parts or gaps 1676
Locking agents for connecting elements 1676
Anti-corrosion agent 1676
Assembly paste for temperature sensors 1676
Mounting devices for inserting and withdrawing the rotor horizontally 1677
Press for expanding the coupling 1677
Compression devices for pressing on or for support while pressing off 1678
Pulling units with cross beam or disk 1680
Aids 1680
Extraction devices 1681
Paints for refinishing the painted parts or touching up damaged parts 1681
Power module 1683
Removal and installation of power module 1685
General 1685
Preparation 1685
Removal 1686
Installation 1691
Exhaust tube installation 1693
Exhaust blanket installation 1693
Removal and installation of alternator 1694
Removal 1694
Installation 1696
Engine flywheel adapter face runout 1696
Engine crankshaft endplay 1697
Engine flywheel to flywheel housing adapter – measurement “C” 1697
Alternator housing to rotor – measurement “A” 1698
Measurements after joining the alternator and engine 1700
Flywheel housing face runout 1701
Flywheel housing radial runout 1701
Flywheel/flexplate face runout 1702
Flywheel/flexplate radial runout 1702
Rotor shaft radial runout (assembled) 1703
Joining the alternator and engine 1704
Removal and installation of engine 1706
Removal 1706
Service 1706
Installation 1706
Removal and installation of radiator 1706
Removal 1706
Installation 1708
Repairing the radiator 1710
Internal inspection 1710
External cleaning 1710
Disassembly 1710
Cleaning and inspection 1711
Assembly 1712
Pressure testing 1713
Main blower 1715
Removing the main blower motor 1717
Disassembling the main blower motor 1723
Assembling the main blower motor 1725
Installing the main blower motor 1728
Retarding grid 1735
Removing the grid blower motor 1737
Disassembling the grid blower motor 1739
Assembling the grid blower motor 1741
Installing the grid blower motor 1743
Removing a grid element 1748
Control cabinet 1751
Removing the SIBAC Inverter Module 1753
Required tools/materials 1753
Removal 1756
Installing the SIBAC Inverter Module 1760
Draining and filling the IGBT coolant system 1761
Required tools/materials 1761
Coolant mixture specification (distilled water: Antifrogen® N) 1761
Draining and filling the coolant 1763
Removing and installing the IGBT coolant pump assembly 1766
Required tools/materials 1766
Removal 1767
90 Diagrams and drawings 1771
Hydraulic circuit diagrams 1771
Steering, hoist and brake cooling hydraulic circuit diagram – EM1374 1773
Brake hydraulic circuit diagram – EM6298 1774
Electrical circuit diagrams – 24V system 1777
Electrical circuit diagram – XS6700 1779
Electrical circuit diagram – HE488 1816
Electrical circuit diagram – 58C-06-00383 1817
Electrical circuit diagrams – drive system 1835
Electrical circuit diagram – AC drive system – 58C-06-00730 1837
Electrical circuit diagram – AC trolley drive system – XS3380 1893

DESCRIPTION:

Komatsu 860E Dump Truck Parts Manual CEBN00015-04 – PDF DOWNLOAD

• Machine model                              Serial Number
  860E-1KT                                        A30036 – A30040 ,A30043, A30047 
  A30100
• 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 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.
• 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.

G.B 18/12/24