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KOMATSU 960E-1K DUMP TRUCK SHOP REPAIR MANUAL SN A50003 – A50010 – PDF DOWNLOAD
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KOMATSU 960E-1K DUMP TRUCK SHOP REPAIR MANUAL
SERIAL NUMBERS A50003 – A50010
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Description
KOMATSU 960E-1K DUMP TRUCK SHOP REPAIR MANUAL
FILE DETAILS:
KOMATSU 960E-1K DUMP TRUCK SHOP REPAIR MANUAL
Language : English
Pages :1752
Downloadable : Yes
File Type : PDF
Size: 46.0 MB
Book Code: CEBM022602
KOMATSU 960E-1K DUMP TRUCK SHOP REPAIR MANUAL SN A50003 – A50010 – PDF DOWNLOAD:
DESCRIPTION:
KOMATSU 960E-1K DUMP TRUCK SHOP REPAIR MANUAL
FOREWORD:
This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions should be understood and followed when operating the truck or performing repairs on the truck.
- The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example, the disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck.
- Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck. This manual shows dimensioning of U.S. standard and metric (SI) units throughout.
- All references to “right,” “left,” “front,” or “rear” are made with respect to the operator’s normal seated position unless specifically stated otherwise. When assembly instructions are provided without references to specific torque values, standard torque values should be used.
- Standard torque values are shown in torque charts later in this section. Specific torques, when provided in the text, are in bold face type, such as 135 N·m (100 ft lb). All torque specifications have ±10% tolerance unless otherwise specified.
- A product identification plate is located on the frame in front of the right side front wheel. It designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight) rating. The KOMATSU truck model designation consists of three numbers and one letter (i.e. 960E). The three numbers represent the basic truck model. The letter “E” designates an Electrical wheel motor drive system.
- The Product Identification Number (vehicle serial number) contains information which identifies several characteristics of this unit. For a more detailed explanation, refer to the Operation and Maintenance Manual. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components.
- The vehicle design and application guidelines are sensitive to the maximum GVW. GVW is total weight: empty vehicle weight + fuel & lubricants + payload. To determine the allowable payload, fill all lubricants to the proper level and fill the fuel tank of an empty truck (which includes all accessories, body liners, tailgates, etc.), and then weigh the truck. Record this value and subtract it from the GVW. The result is the allowable payload.
TABLE OF CONTENTS:
KOMATSU 960E-1K DUMP TRUCK SHOP REPAIR MANUAL
Cover................................................................................................................................. 1 00 Index and foreword................................................................................................................. 3 Index............................................................................................................................. 3 Composition of shop manual.................................................................................................... 4 Table of contents............................................................................................................. 6 Foreword, safety and general information.......................................................................................... 33 Foreword...................................................................................................................... 36 How to read the shop manual................................................................................................... 37 Composition of shop manual................................................................................................ 37 Revision and distribution................................................................................................. 37 Symbols................................................................................................................... 38 General safety................................................................................................................ 39 Safety rules.............................................................................................................. 39 Safety features........................................................................................................... 39 Fire extinguisher and first aid kit....................................................................................... 39 Clothing and personal items............................................................................................... 39 Leaving the operator seat................................................................................................. 40 Mounting and dismounting.................................................................................................. 40 Fire prevention for fuel and oil.......................................................................................... 40 Precautions with high temperature fluids.................................................................................. 41 Asbestos dust hazard prevention........................................................................................... 41 Prevention of injury by work equipment.................................................................................... 41 Unauthorized modification................................................................................................. 41 Precautions when using ROPS............................................................................................... 41 Precautions for attachments............................................................................................... 42 Precautions for starting the truck........................................................................................ 42 Precautions before operating the truck........................................................................................ 42 Safety at the worksite.................................................................................................... 42 Fire prevention........................................................................................................... 43 Ventilation in enclosed areas............................................................................................. 43 Preparing for operation................................................................................................... 43 Mirrors, windows and lights............................................................................................... 43 In operator cab (before starting the engine).............................................................................. 43 Seat Belts................................................................................................................ 43 Precautions while operating the truck......................................................................................... 44 When starting the engine.................................................................................................. 44 General truck operation................................................................................................... 44 Ensuring good visibility.................................................................................................. 44 Traveling................................................................................................................. 45 Traveling in reverse...................................................................................................... 45 Traveling on slopes....................................................................................................... 45 Operating on snow or ice.................................................................................................. 45 Avoid damage to dump body................................................................................................. 45 Driving near high voltage cables.......................................................................................... 46 When dumping.............................................................................................................. 46 Working on loose ground................................................................................................... 46 When loading.............................................................................................................. 46 Parking the truck......................................................................................................... 46 Towing.................................................................................................................... 46 Working near batteries........................................................................................................ 47 Battery hazard prevention................................................................................................. 47 Starting with booster cables.............................................................................................. 48 Jump starting with receptacles............................................................................................ 48 Precautions before performing service......................................................................................... 49 Warning tag............................................................................................................... 49 Stopping the engine....................................................................................................... 49 Proper tools.............................................................................................................. 49 Use of Tie-Off Anchor During Maintenance and Repair....................................................................... 49 Securing the dump body.................................................................................................... 50 While performing maintenance.................................................................................................. 51 Keep the truck clean...................................................................................................... 51 Attachments............................................................................................................... 51 Working under the truck................................................................................................... 51 Rotating fan and belts.................................................................................................... 51 Adding fuel or oil........................................................................................................ 51 Use of lighting........................................................................................................... 51 Radiator coolant level.................................................................................................... 52 Precautions with the battery.............................................................................................. 52 Precautions with high pressure oil........................................................................................ 52 Handling high pressure hoses.............................................................................................. 52 Precautions when performing maintenance near high temperature or high pressure............................................ 52 Waste materials........................................................................................................... 52 Tires......................................................................................................................... 53 Handling tires............................................................................................................ 53 Storing tires after removal............................................................................................... 53 Precautions for performing repairs............................................................................................ 54 Engine shutdown procedure after AC drive system failure................................................................... 54 Precautions for welding on the truck.......................................................................................... 55 Handling electrical equipment and hydraulic components........................................................................ 56 Points to remember when handling electrical equipment..................................................................... 56 Points to remember when handling hydraulic equipment...................................................................... 62 How to read electric wire code................................................................................................ 64 Standard torque tables........................................................................................................ 67 Effect of special lubricants on fasteners and standard torque values...................................................... 67 Standard tightening torques for SAE hex head cap screw and nut assemblies................................................. 68 Standard assembly torques for 12-point, grade 9 capscrews (SAE)........................................................... 69 Standard assembly torques for class 10.9 capscrews and class 10 nuts...................................................... 69 Standard tightening torques for fittings.................................................................................. 70 Conversion tables............................................................................................................. 72 Common conversion multipliers............................................................................................. 72 Operating instructions............................................................................................................ 77 Preparing for operation....................................................................................................... 79 Walk around inspection.................................................................................................... 79 Engine start-up............................................................................................................... 83 After engine start-up......................................................................................................... 84 Emergency steering system..................................................................................................... 85 Operation................................................................................................................. 85 Pre-operation testing..................................................................................................... 85 Precautions during truck operation............................................................................................ 86 Operating on a haul road...................................................................................................... 87 Starting on a grade with a loaded truck....................................................................................... 87 Loading the dump body......................................................................................................... 88 Dumping a load................................................................................................................ 88 Raising the dump body..................................................................................................... 88 Lowering the dump body (on flat ground)................................................................................... 89 Lowering the dump body (over a berm or into a crusher).................................................................... 90 Using the speed control feature............................................................................................... 90 Safe parking procedure........................................................................................................ 91 Normal engine shutdown procedure.............................................................................................. 91 Sudden loss of engine power................................................................................................... 92 Fuel depletion................................................................................................................ 92 Towing........................................................................................................................ 93 Special Wiring Harness.................................................................................................... 93 Towing Procedure.......................................................................................................... 94 Disabled truck operation...................................................................................................... 96 Components Required....................................................................................................... 96 Hookup.................................................................................................................... 96 Disabled truck dumping procedure.............................................................................................. 97 Hookup.................................................................................................................... 97 Raising the body.......................................................................................................... 98 Lowering the body......................................................................................................... 98 01 Specification...................................................................................................................... 101 Specification and technical data.................................................................................................. 101 Specification drawing......................................................................................................... 103 Specifications................................................................................................................ 104 Weight table.................................................................................................................. 106 Fuel, coolant and lubricants.................................................................................................. 107 Suspension cylinder oil and nitrogen specifications....................................................................... 108 10 Structure, functions and maintenance standard...................................................................................... 111 Steering circuit.................................................................................................................. 111 Steering circuit operation.................................................................................................... 113 Steering circuit components................................................................................................... 115 Steering control unit..................................................................................................... 115 High pressure filter...................................................................................................... 115 Steering accumulators..................................................................................................... 115 Bleeddown manifold........................................................................................................ 116 Steering accumulator bleeddown solenoid................................................................................... 118 Hoist up limit solenoid................................................................................................... 118 Quick disconnect ports.................................................................................................... 118 Flow amplifier............................................................................................................ 118 Flow amplifier operation...................................................................................................... 119 No steer.................................................................................................................. 120 Steering left............................................................................................................. 122 Steering right............................................................................................................ 124 No steer, external shock load............................................................................................. 126 Steering/brake pump operation................................................................................................. 129 Normal operation.......................................................................................................... 129 Neutral position.......................................................................................................... 130 Full pump volume.......................................................................................................... 131 Half pump volume.......................................................................................................... 131 Steering cylinder wear data................................................................................................... 132 Hoist circuit..................................................................................................................... 135 Hoist circuit operation....................................................................................................... 137 Hoist circuit components...................................................................................................... 138 Hydraulic tank............................................................................................................ 138 Hoist pump................................................................................................................ 138 High pressure filters..................................................................................................... 138 Hoist valve............................................................................................................... 138 Inlet sections............................................................................................................ 139 Tank ports (front) spool section.......................................................................................... 139 Work ports (rear) spool section........................................................................................... 139 Hoist pilot valve......................................................................................................... 140 Bleeddown manifold........................................................................................................ 140 Hoist limit solenoid...................................................................................................... 140 Pilot operated check valve................................................................................................ 140 Overcenter manifold....................................................................................................... 141 Hoist pilot valve operation................................................................................................... 142 Float position with body down............................................................................................. 142 Power up operation........................................................................................................ 144 Hold operation............................................................................................................ 146 Power down operation...................................................................................................... 148 Float operation........................................................................................................... 150 Hoist cylinder wear data...................................................................................................... 152 Brake circuits.................................................................................................................... 155 General information........................................................................................................... 157 Service brake circuit operation............................................................................................... 158 Secondary braking and auto apply.............................................................................................. 158 Parking brake circuit operation............................................................................................... 160 Normal operation (key switch ON, engine on)............................................................................... 160 Wheel brake lock circuit operation............................................................................................ 161 Brake warning circuit operation............................................................................................... 161 Brake assembly wear data...................................................................................................... 163 Suspensions....................................................................................................................... 165 General information........................................................................................................... 167 Front suspension wear data.................................................................................................... 167 Rear suspension wear data..................................................................................................... 168 Electrical system, 24 volt........................................................................................................ 171 Battery supply system......................................................................................................... 173 Auxiliary control cabinet components.......................................................................................... 174 24VDC to 12VDC converter.................................................................................................. 174 Diode board - DB1......................................................................................................... 174 Power distribution terminals.............................................................................................. 174 Control power relay....................................................................................................... 175 Fuse blocks............................................................................................................... 176 Relay boards.................................................................................................................. 176 Relay boards RB1, RB3, RB4, RB5........................................................................................... 176 Relay boards RB6, RB7, RB8, RB9........................................................................................... 178 Relay functions........................................................................................................... 178 Body position switches (With proximity switch and metal arm).................................................................. 180 Body-up switch............................................................................................................ 180 Hoist limit switch........................................................................................................ 181 Body position switches (With proximity switch and magnet)..................................................................... 182 Proximity switch operation................................................................................................ 182 Body-up Switch............................................................................................................ 182 Hoist limit switch........................................................................................................ 182 Interface module (IM)............................................................................................................. 185 General information........................................................................................................... 186 Sensors....................................................................................................................... 186 Temperature sensors....................................................................................................... 186 Pressure sensors.......................................................................................................... 186 Interface module inputs and outputs........................................................................................... 187 Drive system...................................................................................................................... 193 SR rectifier module........................................................................................................... 195 ST module (auxiliary voltage inverter)........................................................................................ 195 Technical Data............................................................................................................ 198 SD phase modules.............................................................................................................. 199 SR/ST/SD module removal....................................................................................................... 199 Inverter cabinet layout....................................................................................................... 200 Inverter cabinet water flow................................................................................................... 200 Field regulator............................................................................................................... 201 Technical Data............................................................................................................ 201 Field regulator (discharge resistor).......................................................................................... 201 Technical Data............................................................................................................ 201 Gate unit power supply........................................................................................................ 202 Technical Data............................................................................................................ 202 Gate unit power supply (diode)................................................................................................ 202 Technical Data............................................................................................................ 202 Gate unit power supply (tuning resistor)...................................................................................... 202 Technical Data............................................................................................................ 202 Control power filter.......................................................................................................... 202 Technical Data............................................................................................................ 202 Filter for TCU................................................................................................................ 203 Technical Data............................................................................................................ 203 Terminal block bus bar........................................................................................................ 203 Technical Data............................................................................................................ 203 Fuses (analog sensor voltage)................................................................................................. 204 Technical Data............................................................................................................ 204 Fuses (field regulator)....................................................................................................... 204 Technical Data............................................................................................................ 204 Fuses (fuse holder for field regulator)....................................................................................... 204 Technical Data............................................................................................................ 204 Fuses (control power and trolley box contactor)............................................................................... 205 Technical Data............................................................................................................ 205 Diode modules................................................................................................................. 205 Technical Data............................................................................................................ 205 Support capacitors............................................................................................................ 206 Technical Data............................................................................................................ 206 3-Phase capacitor bank (for ST module output voltage)......................................................................... 206 Technical Data............................................................................................................ 206 Air-cooled inductors (for ST module).......................................................................................... 207 Technical Data............................................................................................................ 207 3-Phase transformer (for ST module)........................................................................................... 207 Technical Data............................................................................................................ 207 Diagnostics box............................................................................................................... 208 Diagnostic and system monitoring panel........................................................................................ 209 Device name: DB101........................................................................................................ 209 Technical Data............................................................................................................ 209 Current transducers........................................................................................................... 210 Device names:............................................................................................................. 210 U101ŠU104 (Current to motor A)............................................................................................ 210 U105ŠU106 (Current to chopper A-C)........................................................................................ 210 U201ŠU204 (Current to motor B)............................................................................................ 210 U205ŠU206 (Current to chopper B-D)........................................................................................ 210 Technical Data............................................................................................................ 210 Technical Data............................................................................................................ 210 Current transducers (for ST module output).................................................................................... 211 Technical Data............................................................................................................ 211 Voltage transducers........................................................................................................... 211 Technical Data............................................................................................................ 211 Voltage transducers (for ST module output).................................................................................... 212 Technical Data............................................................................................................ 212 Voltage transducers (SiBASØ 24V DC bus monitoring)............................................................................ 212 Analog inclinometer........................................................................................................... 213 Technical Data............................................................................................................ 213 DC link capacitors............................................................................................................ 213 Technical Data............................................................................................................ 213 Ground tie capacitor.......................................................................................................... 214 Technical Data............................................................................................................ 214 Low-inductance bus bar assembly............................................................................................... 214 Free-wheeling diode for low-inductance bus bars............................................................................... 215 Contactor (grid box and main blower motor).................................................................................... 215 Technical Data............................................................................................................ 215 Contactor (control power)..................................................................................................... 216 Technical Data............................................................................................................ 216 Contactor (DC contactors)..................................................................................................... 216 Technical Data............................................................................................................ 216 Contactor (crowbar bypass).................................................................................................... 217 Technical Data............................................................................................................ 217 Temperature probes (PT100 style).............................................................................................. 217 Technical Data............................................................................................................ 217 Coolant inlet temperature sensor.............................................................................................. 217 Technical Data............................................................................................................ 218 Coolant outlet temperature sensor (external pad style)........................................................................ 218 IGBT module heat sink temperature sensor...................................................................................... 218 Device names: PT101ŠPT103 [Sensors for inverters A101ŠA103]............................................................... 218 PT201ŠPT203 [Sensors for inverters A201ŠA203]............................................................................. 218 PT104 and PT204 [Sensors for choppers 1 and 2 respectively]............................................................... 218 PT105 and PT205 [Sensors for ST module (A301) and SR module (A1) respectively]............................................ 218 Coolant outlet temperature sensor (internal style)............................................................................ 218 Technical Data............................................................................................................ 218 Coolant outlet temperature sensor (external pad style)........................................................................ 219 Technical Data............................................................................................................ 219 Circuit breakers.............................................................................................................. 219 Technical Data............................................................................................................ 219 Inner circulating blower fan.................................................................................................. 220 Coolant pump.................................................................................................................. 220 Technical Data............................................................................................................ 220 Motor for coolant pump........................................................................................................ 221 Technical Data............................................................................................................ 221 Coolant pressure sensor....................................................................................................... 221 Inner radiator................................................................................................................ 221 Ground voltage monitoring resistors........................................................................................... 222 Protection thyristor assembly (crowbar)....................................................................................... 222 Discharge reactor............................................................................................................. 223 Main blower motor............................................................................................................. 223 Technical Data............................................................................................................ 223 Grid box...................................................................................................................... 224 Technical Data............................................................................................................ 224 Grid box blower motor......................................................................................................... 224 Technical Data............................................................................................................ 224 Grid box blower motor grease fittings......................................................................................... 225 Main alternator............................................................................................................... 225 Stator.................................................................................................................... 225 Rotor..................................................................................................................... 226 Bearings.................................................................................................................. 226 Electrical connection..................................................................................................... 226 Cooling and ventilation................................................................................................... 226 Rotating rectifier section................................................................................................ 226 Technical Data............................................................................................................ 227 Main alternator circuit diagram........................................................................................... 228 IGBT Š inverter/chopper phase module.......................................................................................... 229 Device names: A101ŠA103 (Inverter A section).............................................................................. 229 A201ŠA203 (Inverter B section)............................................................................................ 229 A104 (Chopper A section).................................................................................................. 229 A204 (Chopper B section).................................................................................................. 229 Troubleshooting information................................................................................................... 231 Main input rectifier module................................................................................................... 232 Device name: A1........................................................................................................... 232 Internal circuit diagram.................................................................................................. 233 Upper ground tie resistor..................................................................................................... 234 Device Name: R11.1-R11.2.................................................................................................. 234 Technical Data............................................................................................................ 234 Lower ground tie resistor..................................................................................................... 234 Device name: R11.3-R11.4.................................................................................................. 234 Technical Data............................................................................................................ 234 Troubleshooting............................................................................................................... 235 Fault diagnosis............................................................................................................... 235 Speed sensor, alternator...................................................................................................... 236 Technical Data............................................................................................................ 236 Speed sensors, wheel motors................................................................................................... 237 Technical Data............................................................................................................ 237 Traction motor................................................................................................................ 238 Device name: Motor 1 (grid box side of the truck), Motor 2 (operator cab side of the truck)............................... 238 Technical Data............................................................................................................ 238 Grid box...................................................................................................................... 239 Device name: M04.......................................................................................................... 239 Technical Data............................................................................................................ 239 Cab air conditioning.............................................................................................................. 241 General information........................................................................................................... 242 Environmental impact of air conditioning.................................................................................. 242 Air conditioning for off-highway vehicles................................................................................. 242 Principles of refrigeration................................................................................................... 243 Air conditioning.......................................................................................................... 243 Refrigeration - the act of cooling........................................................................................ 243 The refrigeration cycle................................................................................................... 243 Air conditioning system components............................................................................................ 245 Relays.................................................................................................................... 245 Fan motor and speed control............................................................................................... 245 Cab air filter............................................................................................................ 245 Heater core............................................................................................................... 245 Actuators................................................................................................................. 245 Compressor (refrigerant pump)............................................................................................. 247 Service valves............................................................................................................ 247 Condenser................................................................................................................. 247 Receiver-drier............................................................................................................ 247 Expansion valve........................................................................................................... 248 Accumulator............................................................................................................... 248 Evaporator core........................................................................................................... 248 Air conditioning system electrical circuit.................................................................................... 249 Thermostat................................................................................................................ 249 Compressor clutch......................................................................................................... 249 Trinary™ switch........................................................................................................... 250 Reserve engine oil system......................................................................................................... 253 General information........................................................................................................... 255 Operation..................................................................................................................... 256 LED monitor light......................................................................................................... 256 Remote tank fill system....................................................................................................... 257 SIBAS® IGBT rack components....................................................................................................... 259 SiBAS®32 Traction Control Unit (TCU).......................................................................................... 261 Overview of the SiBAS®32 systems.............................................................................................. 262 Features.................................................................................................................. 262 General technical specifications, operating conditions.................................................................... 262 Permissible temperature range............................................................................................. 262 Permissible limit value for air humidity.................................................................................. 263 Permissible power supply voltage range.................................................................................... 263 Permissible mechanical loads.............................................................................................. 263 Protection measures against electrical hazards............................................................................ 263 Application............................................................................................................... 263 Removing and installing the SiBAS®32 cards.................................................................................... 266 Removal with 24V OFF! (ESD protection required)........................................................................... 266 Installation with 24V OFF! (ESD protection required)...................................................................... 266 SiBAS®32 card device names.................................................................................................... 267 Structure of SiBAS®32 card part number........................................................................................ 268 Development status, downward compatibility................................................................................ 268 SiBAS®32 card interchangeability.............................................................................................. 269 Use of service interfaces................................................................................................. 270 Connection of the service unit............................................................................................ 270 Maintenance............................................................................................................... 270 Cleaning.................................................................................................................. 271 SiBAS®32 card interactions.................................................................................................... 272 SiBAS®32 card detailed information............................................................................................ 275 Blower subassembly............................................................................................................ 275 Device name: N/A.......................................................................................................... 275 Application............................................................................................................... 275 Battery replacement....................................................................................................... 277 Rules for handling lithium batteries...................................................................................... 277 Replacement of the battery in the fan subassembly......................................................................... 277 CPU card...................................................................................................................... 278 Device name: G011......................................................................................................... 278 Application............................................................................................................... 279 Front panel............................................................................................................... 279 Technical data............................................................................................................ 280 DSP card...................................................................................................................... 281 Device name: G019, G027 and G35........................................................................................... 281 Application............................................................................................................... 281 Front panel............................................................................................................... 281 Technical data............................................................................................................ 282 I/O card...................................................................................................................... 283 Device name: G043......................................................................................................... 283 Application............................................................................................................... 283 Front panel............................................................................................................... 284 Technical data............................................................................................................ 285 TRACO card (optional)......................................................................................................... 286 Device name: G003......................................................................................................... 286 Application............................................................................................................... 286 Front panel............................................................................................................... 287 Technical data............................................................................................................ 288 Input voltage/frequency card.................................................................................................. 289 Device name: L055, L063 and L071.......................................................................................... 289 Application............................................................................................................... 289 Technical data............................................................................................................ 290 I/O analog card............................................................................................................... 291 Device name: L079 and L087................................................................................................ 291 Technical data............................................................................................................ 293 I/O analog card............................................................................................................... 294 Device name: L095 and L103................................................................................................ 294 Application............................................................................................................... 294 Technical data............................................................................................................ 296 Output pulse amplifier card................................................................................................... 297 Device name: L115, L123, L131, L139 and L147.............................................................................. 297 Application............................................................................................................... 297 Technical data............................................................................................................ 299 Input temperature sensor card................................................................................................. 300 Device name: L155 and L163................................................................................................ 300 Application............................................................................................................... 300 Technical data............................................................................................................ 302 UWS card...................................................................................................................... 303 Device name: G055, G063, G071 and G079.................................................................................... 303 Application............................................................................................................... 303 Technical data............................................................................................................ 305 Digital input card............................................................................................................ 306 Device name: G103, G111, G119, G127 and G135.............................................................................. 306 Application............................................................................................................... 306 Technical data............................................................................................................ 308 Power start-up unit card...................................................................................................... 309 Device name: G163......................................................................................................... 309 Application............................................................................................................... 309 Technical data............................................................................................................ 311 Binary output contactor drive card............................................................................................ 312 Device name: C019, C027 and C035.......................................................................................... 312 Application............................................................................................................... 312 Technical data............................................................................................................ 314 24V / 24V power supply........................................................................................................ 315 Device name: C045, C105, C129............................................................................................. 315 Application............................................................................................................... 315 Testing the power supply card............................................................................................. 316 Technical data............................................................................................................ 317 24V / 15V power supply........................................................................................................ 318 Device name: C069, C087................................................................................................... 318 Application............................................................................................................... 318 Testing the power supply card............................................................................................. 319 Technical data............................................................................................................ 320 24V / 5V power supply......................................................................................................... 321 Device name: C153......................................................................................................... 321 Application............................................................................................................... 321 Testing the power supply card............................................................................................. 322 Technical data............................................................................................................ 323 20 Standard value table............................................................................................................... 331 Standard value table for truck.................................................................................................... 333 Standard value table.......................................................................................................... 331 30 Testing and adjusting.............................................................................................................. 339 General information............................................................................................................... 339 Special tool list............................................................................................................. 341 Steering, brake cooling and hoist hydraulic system................................................................................ 343 General information on system checkout........................................................................................ 345 Steering system checkout procedures........................................................................................... 345 Steering pump pressure control adjustments................................................................................ 346 Steering control valve and flow amplifier leakage test.................................................................... 347 Bleeddown manifold leakage test........................................................................................... 348 Shock and suction valve pressure tests.................................................................................... 349 Steering system checkout data sheet........................................................................................... 351 Toe-in adjustment............................................................................................................. 352 Brake cooling and hoist system checkout procedures............................................................................ 353 Pressure gauge locations.................................................................................................. 353 Brake cooling circuit test................................................................................................ 354 Power up relief pressure test............................................................................................. 354 Power down relief pressure test........................................................................................... 355 Counterbalance valve pressure check....................................................................................... 356 Counterbalance valve adjustment........................................................................................... 357 Brake cooling and hoist system checkout data sheet............................................................................ 358 Hoist cylinder leakage test................................................................................................... 359 Hydraulic system flushing procedure........................................................................................... 359 Brake system...................................................................................................................... 367 General information on system checkout........................................................................................ 369 Brake circuit checkout procedure.............................................................................................. 369 Initial system setup...................................................................................................... 371 Brake lock / secondary braking checkout................................................................................... 372 Parking brake checkout.................................................................................................... 373 Service brake checkout.................................................................................................... 373 Low brake accumulator pressure and auto apply checkout.................................................................... 374 Parking brake control logic checkout...................................................................................... 376 Brake lock control logic checkout......................................................................................... 377 Brake system checkout data sheet.............................................................................................. 380 Brake piston leakage test..................................................................................................... 385 Brake seal pressure test...................................................................................................... 385 Wet disc brake bleeding procedure............................................................................................. 386 Parking brake bleeding procedure.............................................................................................. 386 Brake disc wear inspection.................................................................................................... 387 Brake valve bench test and adjustment......................................................................................... 390 Test setup procedure...................................................................................................... 391 Brake valve output pressure adjustment.................................................................................... 391 Final test and adjustment................................................................................................. 392 Dual relay valve bench test and adjustment.................................................................................... 393 Test setup procedure...................................................................................................... 394 Relay valve output pressure adjustment.................................................................................... 394 Accumulators and suspensions...................................................................................................... 397 Accumulator charging and storage.............................................................................................. 399 Accumulator charging procedures........................................................................................... 399 Precharge maintenance..................................................................................................... 402 Accumulator storage procedure............................................................................................. 403 Bladder storage........................................................................................................... 403 Installing a bladder accumulator from storage............................................................................. 403 Accumulator leak testing...................................................................................................... 404 Suspension oiling and charging procedures..................................................................................... 406 Equipment list............................................................................................................ 406 Installing the charging kit............................................................................................... 406 Removing the charging kit................................................................................................. 407 Support blocks for oiling and charging dimensions......................................................................... 407 Front suspension oiling................................................................................................... 408 Front suspension nitrogen charging........................................................................................ 409 Rear suspension oiling.................................................................................................... 410 Rear suspension nitrogen charging......................................................................................... 412 Suspension pressure test...................................................................................................... 413 Cab air conditioning.............................................................................................................. 415 General information........................................................................................................... 416 Service tools and equipment................................................................................................... 417 Recovery/recycle station.................................................................................................. 417 Leak detector............................................................................................................. 417 Manifold gauge set........................................................................................................ 418 Service valves............................................................................................................ 419 Vacuum pump............................................................................................................... 419 Detecting leaks............................................................................................................... 420 System performance test....................................................................................................... 421 Checking system oil........................................................................................................... 422 System flushing............................................................................................................... 423 Installing the manifold gauge set............................................................................................. 424 Purging air from the service hoses........................................................................................ 424 Recovering and recycling refrigerant.......................................................................................... 425 Draining oil from previous recovery cycle................................................................................. 426 Recovery cycle............................................................................................................ 426 Recycling procedure....................................................................................................... 426 Evacuating the air conditioning system........................................................................................ 427 Charging the air conditioning system.......................................................................................... 428 A/C drive belt checkout procedure............................................................................................. 429 Pulley alignment.......................................................................................................... 429 Belt tension check........................................................................................................ 429 Interface module (IM)............................................................................................................. 433 Interface module software..................................................................................................... 434 Flashburn program installation............................................................................................ 434 Interface module application code installation............................................................................ 435 Interface module realtime data monitor software installation.............................................................. 435 Interface module checkout procedures.......................................................................................... 436 Necessary equipment....................................................................................................... 436 Preliminary............................................................................................................... 437 Check digital inputs to the interface module.............................................................................. 438 Check analog inputs to the interface module............................................................................... 441 Check serial interfaces to the interface module........................................................................... 442 Check outputs from the interface module................................................................................... 442 IGBT haul truck SIBAS® user manual, part 1........................................................................................ 445 Abbreviations................................................................................................................. 447 Precautions................................................................................................................... 449 Qualified person.............................................................................................................. 449 Customer monitor for SIBAS® 32 control units.................................................................................. 449 Product description....................................................................................................... 449 Version management........................................................................................................ 450 Overview.................................................................................................................. 451 Requirements.............................................................................................................. 451 Installing and calling the customer monitor................................................................................... 452 Installation.................................................................................................................. 452 Environment variables..................................................................................................... 452 Communication with the SIBAS® 32 control unit................................................................................. 453 Calling up the customer monitor............................................................................................... 454 Start-up prompt........................................................................................................... 454 Monitor prompt............................................................................................................ 455 Notes on operation of the customer monitor.................................................................................... 456 Structure of a monitor command................................................................................................ 456 Step 1: Selecting the menu title.......................................................................................... 456 Step 2: Selecting a menu entry in the menu box............................................................................ 456 Step 3: Selecting a dialog box, if available.............................................................................. 457 Step 4: Entering file or connector/signal names........................................................................... 457 Command buffer................................................................................................................ 458 Structure of the monitor windows.............................................................................................. 458 Window menu................................................................................................................... 459 Commands for Opening, Altering and Closing Windows........................................................................ 459 "Window Work open"............................................................................................................ 459 "Window Lines open"........................................................................................................... 459 "Window Tile"................................................................................................................. 459 "Window Bars open"............................................................................................................ 459 Options................................................................................................................... 459 "Window Set".................................................................................................................. 459 Options................................................................................................................... 459 "Window Cascade".............................................................................................................. 459 "Window Close"................................................................................................................ 459 "Window close All"............................................................................................................ 459 "Window Exit"................................................................................................................. 459 Set Menu...................................................................................................................... 460 "Set Port".................................................................................................................... 460 Options................................................................................................................... 460 "Set Baudrate"................................................................................................................ 460 Options................................................................................................................... 460 "Set String".................................................................................................................. 461 Example................................................................................................................... 462 "Set Make".................................................................................................................... 462 Options................................................................................................................... 462 Example 1: INIT.MON start-up control of the Customer Monitor.............................................................. 463 Example 2: Any monitor batch file with freely selectable file name (incl. path)........................................... 463 "Set Execute"................................................................................................................. 464 Options................................................................................................................... 464 Example................................................................................................................... 464 "Set Record".................................................................................................................. 464 Options................................................................................................................... 464 "Set DIN-Bus"................................................................................................................. 465 "Set TCN"..................................................................................................................... 465 "Set Timeout"................................................................................................................. 465 Options................................................................................................................... 465 "Set Wait".................................................................................................................... 465 Options................................................................................................................... 465 "Set Color"................................................................................................................... 465 Options................................................................................................................... 465 "Set Info".................................................................................................................... 466 "Set comment"................................................................................................................. 466 "Set CHAR Set"................................................................................................................ 466 "Set Quit".................................................................................................................... 466 Applic. Menu.................................................................................................................. 467 "Applic. Func.Package"........................................................................................................ 467 "Applic. Connector"........................................................................................................... 468 Options................................................................................................................... 468 Example................................................................................................................... 469 "Applic. View"................................................................................................................ 469 Options................................................................................................................... 469 Example................................................................................................................... 469 "Applic. Signal".............................................................................................................. 469 "Applic. Observer"............................................................................................................ 470 Options................................................................................................................... 470 Possible time slices:..................................................................................................... 470 Options................................................................................................................... 471 Two options............................................................................................................... 471 Notes on the display of connectors........................................................................................ 473 "Applic. Buffer".............................................................................................................. 474 Options................................................................................................................... 474 "Applic. Report".............................................................................................................. 474 "Applic. Legitimation"........................................................................................................ 474 Options................................................................................................................... 474 "Applic. Menu"................................................................................................................ 475 "Applic. Traco"............................................................................................................... 475 Options................................................................................................................... 475 "Applic. Environment"......................................................................................................... 475 Hardw. Menu................................................................................................................... 477 Hardware-Oriented Access via the Customer Monitor......................................................................... 477 "Hardw. Flash"................................................................................................................ 477 Options................................................................................................................... 477 Requirements.............................................................................................................. 477 Example................................................................................................................... 478 Deleting and loading...................................................................................................... 478 The EPROM for the communication drivers................................................................................... 478 "Hardw. Clock"................................................................................................................ 478 Options................................................................................................................... 478 "Hardw. DSP".................................................................................................................. 479 "Hardw. BCD".................................................................................................................. 479 Options................................................................................................................... 479 Example................................................................................................................... 479 "Hardw. RESET"................................................................................................................ 479 Options................................................................................................................... 479 "Hardw. Info"................................................................................................................. 480 Hardware/Operating system................................................................................................. 480 Application and tools..................................................................................................... 480 Communication module...................................................................................................... 480 Displaying the loading date............................................................................................... 480 "Hardw. User Flash"........................................................................................................... 481 Options................................................................................................................... 481 "Hardw. Sys. Flash"........................................................................................................... 481 Options................................................................................................................... 481 "Hardw. BOOT DSP"............................................................................................................. 482 Requirements.............................................................................................................. 482 DSP5600x Signal Processing Unit and TRACO................................................................................. 482 Inverter processing unit.................................................................................................. 484 Access to the Signal Processing Unit...................................................................................... 484 "Hardw. Flash"................................................................................................................ 484 Options................................................................................................................... 484 Requirements.............................................................................................................. 484 Example................................................................................................................... 484 Deleting and loading...................................................................................................... 485 The EPROM for the communication drivers................................................................................... 485 User Data Flash (UDF)..................................................................................................... 485 "Hardw. RESET"................................................................................................................ 485 Options................................................................................................................... 485 "Hardw. ZR"................................................................................................................... 486 "Hardw. BOOT ZR".............................................................................................................. 486 The following procedure is necessary:..................................................................................... 486 Graphic Menu.................................................................................................................. 487 Commands for Displaying Line Graphics..................................................................................... 487 "Graphic Load"................................................................................................................ 487 Options................................................................................................................... 487 "Graphic Position"............................................................................................................ 487 Options................................................................................................................... 487 "Graphic Time/Div"............................................................................................................ 488 Options................................................................................................................... 488 "Graphic Unit/Div"............................................................................................................ 488 Options................................................................................................................... 488 "Graphic Display"............................................................................................................. 488 Options................................................................................................................... 488 "Graphic Color"............................................................................................................... 489 Options................................................................................................................... 489 "Graphic Format".............................................................................................................. 489 Options................................................................................................................... 489 IGBT haul truck SIBAS® user manual, part 2........................................................................................ 491 Traco Menu.................................................................................................................... 493 HW-Traco...................................................................................................................... 493 Options................................................................................................................... 494 SW-Traco...................................................................................................................... 495 Options................................................................................................................... 496 ZR traco basic parameters:................................................................................................ 496 ZR traco record signal table:............................................................................................. 496 DAC_Traco..................................................................................................................... 499 Options................................................................................................................... 500 Events Menu................................................................................................................... 501 STatistics.................................................................................................................... 502 History....................................................................................................................... 503 LEL:Last EvL.................................................................................................................. 504 LES:Last EvS.................................................................................................................. 506 DLL:DC,LastL.................................................................................................................. 507 DLS:DC,LastS.................................................................................................................. 508 DAL:DC,All L.................................................................................................................. 509 DAS:DC,All S.................................................................................................................. 510 ML:Memory L................................................................................................................... 511 MS:Memory S................................................................................................................... 512 CN:Clear Norm................................................................................................................. 513 CA:Clear All.................................................................................................................. 513 Test-Code..................................................................................................................... 513 DS:Diag-Strc.................................................................................................................. 514 User Menu..................................................................................................................... 515 DAC_IO........................................................................................................................ 516 Options................................................................................................................... 516 Options................................................................................................................... 517 Operat.Data............................................................................................................... 518 Acc test...................................................................................................................... 525 Engine_Test................................................................................................................... 525 X_Test_Inx.................................................................................................................... 528 STate intern.................................................................................................................. 529 Header:................................................................................................................... 529 Vehicle Number:........................................................................................................... 529 Powering system:.......................................................................................................... 529 TCU Operation Mode:....................................................................................................... 529 Component status listings:................................................................................................ 530 Field regulator status:................................................................................................... 530 Status gate unit power supply A:.......................................................................................... 530 Status gate unit power supply B:.......................................................................................... 530 ST inverter status........................................................................................................ 531 Vehicle status............................................................................................................ 531 Drive status:............................................................................................................. 531 Operation status:......................................................................................................... 532 Pedal calib................................................................................................................... 533 Language...................................................................................................................... 534 OFFline-test.................................................................................................................. 534 Options................................................................................................................... 534 Variables..................................................................................................................... 535 Examples:................................................................................................................. 535 IV:Vehic-ID................................................................................................................... 537 Commands...................................................................................................................... 537 Discharge Dc link / Fire crowbar.......................................................................................... 538 Limp mode commands........................................................................................................ 538 Settings...................................................................................................................... 539 Parameters.................................................................................................................... 540 Temp_prot..................................................................................................................... 542 Appendix...................................................................................................................... 544 Background commands........................................................................................................... 544 Monitor commands for the central processing unit.............................................................................. 545 Monitor commands for the signal processing unit............................................................................... 545 Installing ZR / DSP software...................................................................................................... 547 Monitor Program – Loading software into the SIBAS®............................................................................ 548 Loading software into the DSP procedure....................................................................................... 548 Loading a DSP program Inverter A.............................................................................................. 553 Loading ZR software Prog. jumpers Reset....................................................................................... 567 40 Troubleshooting.................................................................................................................... 571 Fuse and circuit breaker locations................................................................................................ 571 Fuse and circuit breaker locations............................................................................................ 572 Troubleshooting by fault code, part 1............................................................................................. 577 Fault Code A001: Left front suspension pressure sensor signal high............................................................ 579 Related circuit diagram................................................................................................... 579 Fault Code A002: Left front suspension pressure sensor signal low............................................................. 580 Related circuit diagram................................................................................................... 580 Fault Code A003: Right front suspension pressure sensor signal high........................................................... 581 Related circuit diagram................................................................................................... 581 Fault Code A004: Right front suspension pressure sensor signal low............................................................ 582 Related circuit diagram................................................................................................... 582 Fault Code A005: Left rear suspension pressure sensor signal high............................................................. 583 Related circuit diagram................................................................................................... 583 Fault Code A006: Left rear suspension pressure sensor signal low.............................................................. 584 Related circuit diagram................................................................................................... 584 Fault Code A007: Right rear suspension pressure sensor signal high............................................................ 585 Related circuit diagram................................................................................................... 585 Fault Code A008: Right rear suspension pressure sensor signal low............................................................. 586 Related circuit diagram................................................................................................... 586 Fault Code A009: Incline sensor signal high................................................................................... 587 Related circuit diagram................................................................................................... 587 Fault Code A010: Incline sensor signal low.................................................................................... 588 Related circuit diagram................................................................................................... 588 Fault Code A011: Payload meter speed sensor signal has failed................................................................. 589 Related circuit diagram................................................................................................... 589 Fault Code A013: Body up switch has failed.................................................................................... 590 Related circuit diagram................................................................................................... 590 Fault Code A014: Payload meter checksum computation has failed................................................................ 591 Related circuit diagram................................................................................................... 591 Fault Code A016: Payload meter write to flash memory has failed............................................................... 592 Related circuit diagram................................................................................................... 592 Fault Code A017: Payload meter flash memory read has failed................................................................... 593 Related circuit diagram................................................................................................... 593 Fault Code A018: Right rear flat suspension cylinder warning.................................................................. 594 Related circuit diagram................................................................................................... 595 Fault Code A019: Left rear flat suspension cylinder warning................................................................... 596 Related circuit diagram................................................................................................... 597 Fault Code A022: Carryback load excessive..................................................................................... 598 Related circuit diagram................................................................................................... 599 Fault Code A100: An open circuit breaker has been detected on a relay board................................................... 601 Related circuit diagram................................................................................................... 601 Fault Code A101: High pressure detected across an hydraulic pump filter....................................................... 602 Related circuit diagram................................................................................................... 603 Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level...................................... 604 Related circuit diagram................................................................................................... 605 Fault Code A111: Low steering pressure warning for storage by KOMTRAX Plus.................................................... 606 Related circuit diagram................................................................................................... 606 Fault Code A115: Low steering precharge pressure detected..................................................................... 608 Related circuit diagram................................................................................................... 609 Fault Code A117: Low brake accumulator pressure warning for storage by KOMTRAX Plus........................................... 610 Related circuit diagram................................................................................................... 610 Fault Code A118: Brake pressure is low while in brake lock.................................................................... 612 Related circuit diagram................................................................................................... 613 Fault Code A126: Oil level in the hydraulic tank is low....................................................................... 614 Related circuit diagram................................................................................................... 614 Fault Code A127: IM-furnished +5 volt output for sensors is low............................................................... 616 Related circuit diagram................................................................................................... 617 Fault Code A128: IM-furnished +5 volt output for sensors is high.............................................................. 618 Related circuit diagram................................................................................................... 619 Fault Code A139: Low fuel warning for storage by KOMTRAX Plus and for use by A310............................................. 620 Related circuit diagram................................................................................................... 621 Troubleshooting by fault code, part 2............................................................................................. 623 Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil.... 626 Related circuit diagram................................................................................................... 627 Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil.... 628 Related circuit diagram................................................................................................... 629 Fault Code A152: Starter failure.............................................................................................. 630 Related circuit diagram................................................................................................... 631 Fault Code A153: Battery voltage is low with the truck in operation........................................................... 632 Related circuit diagram................................................................................................... 633 Fault Code A154: Battery charging voltage is excessive........................................................................ 634 Related circuit diagram................................................................................................... 634 Fault Code A155: Battery charging voltage is low.............................................................................. 635 Related circuit diagram................................................................................................... 635 Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level................................. 636 Related circuit diagram................................................................................................... 637 Fault Code A166: Left rear hydraulic oil temperature sensor is low............................................................ 638 Related circuit diagram................................................................................................... 639 Fault Code A167: Right rear hydraulic oil temperature sensor is low........................................................... 640 Related circuit diagram................................................................................................... 641 Fault Code A168: Left front hydraulic oil temperature sensor is low........................................................... 642 Related circuit diagram................................................................................................... 643 Fault Code A169: Right front hydraulic oil temperature sensor is low.......................................................... 644 Related circuit diagram................................................................................................... 645 Fault Code A170: Left rear hydraulic oil temperature sensor is high........................................................... 646 Related circuit diagram................................................................................................... 646 Fault Code A171: Right rear hydraulic oil temperature sensor is high.......................................................... 647 Related circuit diagram................................................................................................... 647 Fault Code A172: Left front hydraulic oil temperature sensor is high.......................................................... 648 Related circuit diagram................................................................................................... 648 Fault Code A173: Right front hydraulic oil temperature sensor is high......................................................... 649 Related circuit diagram................................................................................................... 649 Fault Code A184: J1939 data link is not connected............................................................................. 650 Related circuit diagram................................................................................................... 651 Fault Code A190: Auto lube control has detected an incomplete lube cycle...................................................... 652 Related circuit diagram................................................................................................... 653 Fault Code A194: Left front hydraulic oil temperature is high................................................................. 654 Related circuit diagram................................................................................................... 654 Fault Code A195: Right front hydraulic oil temperature is high................................................................ 655 Related circuit diagram................................................................................................... 655 Fault Code A196: Left rear hydraulic oil temperature is high.................................................................. 656 Related circuit diagram................................................................................................... 656 Fault Code A197: Right rear hydraulic oil temperature is high................................................................. 657 Related circuit diagram................................................................................................... 657 Fault Code A198: Hoist pressure 1 sensor is high.............................................................................. 658 Related circuit diagram................................................................................................... 658 Fault Code A199: Hoist pressure 2 sensor is high.............................................................................. 659 Related circuit diagram................................................................................................... 659 Fault Code A200: Steering pressure sensor is high............................................................................. 660 Related circuit diagram................................................................................................... 660 Fault Code A201: Brake pressure sensor is high................................................................................ 661 Related circuit diagram................................................................................................... 661 Fault Code A202: Hoist pressure 1 sensor is low............................................................................... 662 Related circuit diagram................................................................................................... 662 Fault Code A203: Hoist pressure 2 sensor is low............................................................................... 663 Related circuit diagram................................................................................................... 663 Fault Code A204: Steering pressure sensor is low.............................................................................. 664 Related circuit diagram................................................................................................... 664 Fault Code A205: Brake pressure sensor is low................................................................................. 665 Related circuit diagram................................................................................................... 665 Fault Code A206: Ambient temperature sensor is high........................................................................... 666 Related circuit diagram................................................................................................... 666 Fault Code A207: Ambient temperature sensor is low............................................................................ 667 Related circuit diagram................................................................................................... 667 Troubleshooting by fault code, Part 3............................................................................................. 669 Fault Code A213: Parking brake should have applied but is detected as not having applied...................................... 671 Related circuit diagram................................................................................................... 673 Fault Code A214: Parking brake should have released but is detected as not having released.................................... 675 Related circuit diagram................................................................................................... 677 Fault Code A215: Brake auto apply valve circuit is defective.................................................................. 678 Related circuit diagram................................................................................................... 679 Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit...................... 680 Related circuit diagram................................................................................................... 681 Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted.................................... 682 Related circuit diagram................................................................................................... 683 Fault Code A230: Parking brake has been requested while truck still moving.................................................... 684 Related circuit diagram................................................................................................... 685 Fault Code A231: The body is up while traveling or with selector in forward or neutral........................................ 686 Fault Code A233: Drive System Control Link is not connected................................................................... 688 Related circuit diagram................................................................................................... 689 Fault Code A235: Steering accumulator is in the process of being bled down.................................................... 690 Related circuit diagram................................................................................................... 691 Fault Code A236: The steering accumulator has not properly bled down after 90 seconds......................................... 692 Related circuit diagram................................................................................................... 693 Fault Code A237: The CAN/RPC connection to the display is open................................................................ 694 Related circuit diagram................................................................................................... 695 Fault Code A238: Drive System and IM are reporting different park brake status................................................ 696 Related circuit diagram................................................................................................... 697 Fault Code A239: The Drive System and IM are reporting different brake lock status............................................ 698 Related circuit diagram................................................................................................... 699 Fault Code A240: The keyswitch input to the Interface Module is open.......................................................... 700 Related circuit diagram................................................................................................... 700 Fault Code A242: Fuel gauge within the dash display panel is defective........................................................ 701 Related circuit diagram................................................................................................... 701 Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective.................................. 702 Related circuit diagram................................................................................................... 702 Fault Code A244: Drive system temperature gauge within the dash display panel is defective.................................... 703 Related circuit diagram................................................................................................... 703 Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective................................... 704 Related circuit diagram................................................................................................... 704 Fault Code A246: Payload meter reports truck overload......................................................................... 705 Related circuit diagram................................................................................................... 705 Fault Code A247: Low steering pressure warning for display to operator........................................................ 707 Related circuit diagram................................................................................................... 707 Fault Code A248: Status module within the dash display panel is defective..................................................... 708 Related circuit diagram................................................................................................... 708 Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted........................................... 709 Related circuit diagram................................................................................................... 709 Fault Code A250: Battery voltage is low with the truck parked................................................................. 710 Related circuit diagram................................................................................................... 711 Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground.............................. 712 Related circuit diagram................................................................................................... 712 Fault Code A252: Start enable output circuit is either open or shorted to ground.............................................. 713 Related circuit diagram................................................................................................... 713 Fault Code A253: Steering bleed circuit is not open while running............................................................. 714 Related circuit diagram................................................................................................... 715 Fault Code A256: Red warning lamp in the dash display (driven by IM) is open.................................................. 717 Related circuit diagram................................................................................................... 717 Fault Code A257: Payload CAN/RPC is not connected............................................................................. 718 Related circuit diagram................................................................................................... 719 Fault Code A258: Steering accumulator bleed pressure switch circuit is defective.............................................. 720 Related circuit diagram................................................................................................... 720 Troubleshooting by fault code, Part 4............................................................................................. 723 Fault Code A260: Parking brake failure........................................................................................ 726 Related circuit diagram................................................................................................... 727 Fault Code A261: Low brake accumulator pressure warning for display to operator............................................... 728 Related circuit diagram................................................................................................... 728 Fault Code A262: Steering bleed valve circuit open during shutdown............................................................ 730 Related circuit diagram................................................................................................... 731 Fault Code A264: Parking brake relay circuit is defective..................................................................... 732 Related circuit diagram................................................................................................... 733 Fault Code A265: Service brake failure........................................................................................ 734 Related circuit diagram................................................................................................... 735 Fault Code A266: Selector switch was not in park while attempting to crank engine............................................. 736 Related circuit diagram................................................................................................... 736 Fault Code A267: Parking brake was not set while attempting to crank engine................................................... 737 Related circuit diagram................................................................................................... 737 Fault Code A268: Secondary engine shutdown while cranking..................................................................... 738 Related circuit diagram................................................................................................... 738 Fault Code A270: Brake lock switch power supply is not on when required....................................................... 740 Related circuit diagram................................................................................................... 741 Fault Code A271: Shifter not in gear.......................................................................................... 742 Related circuit diagram................................................................................................... 743 Fault Code A272: Brake lock switch power supply is not off when required...................................................... 744 Related circuit diagram................................................................................................... 745 Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit....................... 746 Related circuit diagram................................................................................................... 746 Fault Code A274: A brake setting fault has been detected...................................................................... 748 Related circuit diagram................................................................................................... 749 Fault Code A275: A starter has been detected as engaged without a cranking attempt............................................ 750 Related circuit diagram................................................................................................... 751 Fault Code A277: Parking brake applied while loading.......................................................................... 752 Related circuit diagram................................................................................................... 753 Fault Code A278: Service brake applied while loading.......................................................................... 754 Related circuit diagram................................................................................................... 755 Fault Code A279: Low steering pressure switch is defective.................................................................... 756 Related circuit diagram................................................................................................... 756 Fault Code A280: Steering accumulator bleeddown switch is defective........................................................... 757 Related circuit diagram................................................................................................... 757 Fault Code A281: Brake lock degrade switch is defective....................................................................... 758 Related circuit diagram................................................................................................... 759 Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7............. 760 Related circuit diagram................................................................................................... 761 Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set................................... 762 Related circuit diagram................................................................................................... 763 Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated...................... 764 Related circuit diagram................................................................................................... 765 Fault Code A285: The parking brake was not set when the keyswitch was turned off.............................................. 766 Related circuit diagram................................................................................................... 767 Fault Code A286: A fault was detected in the shutdown delay relay circuit..................................................... 768 Related circuit diagram................................................................................................... 769 Fault Code A292: The shutdown delay relay has remained on after the latched keyswitch circuit is off.......................... 770 Related circuit diagram................................................................................................... 771 Troubleshooting by fault code, part 5............................................................................................. 773 Fault Code A303: Shifter is defective......................................................................................... 776 Related circuit diagram................................................................................................... 777 Fault Code A304: Auto lube grease level fault................................................................................. 778 Related circuit diagram................................................................................................... 778 Fault Code A305: Auto lube circuit is defective............................................................................... 780 Related circuit diagram................................................................................................... 781 Fault Code A309: No brakes applied when expected.............................................................................. 782 Related circuit diagram................................................................................................... 783 Fault Code A310: Low fuel warning............................................................................................. 784 Related circuit diagram................................................................................................... 785 Fault Code A311: Brake lock switch is on when it should not be................................................................ 786 Related circuit diagram................................................................................................... 787 Fault Code A312: DCDC converter 12 volt circuit sensing is producing low readings............................................. 788 Related circuit diagram................................................................................................... 788 Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings............................................ 789 Related circuit diagram................................................................................................... 789 Fault Code A315: DCDC converter 12 volt circuit is low........................................................................ 790 Related circuit diagram................................................................................................... 791 Fault Code A316: Starter engagement has been attempted with engine running.................................................... 792 Related circuit diagram................................................................................................... 793 Fault Code A317: Operation of brake auto apply valve without a detected response.............................................. 794 Related circuit diagram................................................................................................... 795 Fault Code A318: Unexpected power loss to Interface Module.................................................................... 796 Related circuit diagram................................................................................................... 796 Fault Code A328: Drive system not powered up.................................................................................. 797 Related circuit diagram................................................................................................... 797 Fault Code A350: Overload on output 1B........................................................................................ 798 Related circuit diagram................................................................................................... 798 Fault Code A351: Overload on output 1E........................................................................................ 800 Related circuit diagram................................................................................................... 801 Fault Code A352: Overload on output 1H........................................................................................ 802 Related circuit diagram................................................................................................... 802 Fault Code A353: Overload on output 1J........................................................................................ 803 Related circuit diagram................................................................................................... 803 Fault Code A354: Overload on output 1K........................................................................................ 804 Related circuit diagram................................................................................................... 804 Fault Code A355: Overload on output 1L........................................................................................ 805 Related circuit diagram................................................................................................... 805 Fault Code A356: Overload on output 1M........................................................................................ 806 Related circuit diagram................................................................................................... 806 Fault Code A357: Overload on output 1N........................................................................................ 807 Related circuit diagram................................................................................................... 807 Fault Code A358: Overload on output 1P........................................................................................ 808 Related circuit diagram................................................................................................... 808 Fault Code A359: Overload on output 1R........................................................................................ 809 Related circuit diagram................................................................................................... 809 Fault Code A360: Overload on output 1S........................................................................................ 810 Related circuit diagram................................................................................................... 810 Fault Code A361: Overload on output 1T........................................................................................ 812 Related circuit diagram................................................................................................... 813 Fault Code A362: Overload on output 1U........................................................................................ 814 Related circuit diagram................................................................................................... 814 Fault Code A363: Overload on output 1X........................................................................................ 815 Related circuit diagram................................................................................................... 815 Fault Code A364: Overload on output 1Y........................................................................................ 816 Related circuit diagram................................................................................................... 816 Fault Code A365: Overload on output 1Z........................................................................................ 817 Related circuit diagram................................................................................................... 817 Drive system fault code table, Part 1............................................................................................. 819 Summary....................................................................................................................... 821 How to use this document...................................................................................................... 821 Event code and diagnosis message.............................................................................................. 821 Description................................................................................................................... 821 Threshold..................................................................................................................... 821 Detection by.................................................................................................................. 821 Possible reasons.............................................................................................................. 821 Action to reset............................................................................................................... 821 Action to repair.............................................................................................................. 822 Operator displayed code....................................................................................................... 822 Note.......................................................................................................................... 822 Protection reactions.......................................................................................................... 822 EVENT CLASSIFICATION.......................................................................................................... 822 Level 1: Warning.............................................................................................................. 823 Level 2: Minor purposes....................................................................................................... 823 Level 3: Severe............................................................................................................... 823 Drive system fault code table, Part 2............................................................................................. 859 Drive system fault code table, Part 3............................................................................................. 899 Drive system fault code table, Part 4............................................................................................. 959 Drive system fault code table, Part 5.............................................................................................1013 Drive system fault code table, Part 6.............................................................................................1087 Drive system fault code table, Part 7.............................................................................................1137 Cab air conditioning..............................................................................................................1211 Preliminary checks............................................................................................................1213 Diagnosis of gauge readings and system performance............................................................................1213 Troubleshooting by manifold gauge set readings................................................................................1214 Reserve engine oil system.........................................................................................................1221 Pumping unit LED signals......................................................................................................1223 Circuit fuses.............................................................................................................1223 Steering system...................................................................................................................1225 Steering circuit..............................................................................................................1226 Steering pump.................................................................................................................1228 Basic Hydraulic System Checks.............................................................................................1229 System Leakage Check......................................................................................................1230 Steering Pump Troubleshooting Guide.......................................................................................1231 Pump Pressure Control Checks..............................................................................................1235 Pump fails to unload......................................................................................................1235 Pump fails to develop pressure............................................................................................1236 Pump slow in developing pressure..........................................................................................1236 Pump control valve inspection and trouble shooting........................................................................1237 Pump case drain check.....................................................................................................1238 Setting pump pressure controls............................................................................................1240 Definitions:..............................................................................................................1240 Adjustment................................................................................................................1241 50 Disassembly and assembly...............................................................................................1243 50 Disassembly and assembly...........................................................................................................1251 General information...............................................................................................................1243 Special tool list.............................................................................................................1245 Wheels, spindles and rear axle....................................................................................................1251 General information for tires and rims........................................................................................1253 Storage and handling......................................................................................................1253 Wheel stud maintenance....................................................................................................1254 Removal and installation of front wheel.......................................................................................1254 Removal...................................................................................................................1254 Installation..............................................................................................................1255 Removal and installation of rear wheel........................................................................................1256 Removal...................................................................................................................1256 Installation..............................................................................................................1257 Removal and installation of tires.............................................................................................1258 Removal...................................................................................................................1259 Installation..............................................................................................................1259 Removal and installation of front wheel hub and spindle.......................................................................1261 Removal...................................................................................................................1261 Installation..............................................................................................................1264 Disassembly and assembly of front wheel hub and spindle.......................................................................1265 Disassembly...............................................................................................................1265 Cleaning and inspection...................................................................................................1265 Assembly..................................................................................................................1267 Wheel bearing adjustment..................................................................................................1267 Seal assembly gap check and adjustment....................................................................................1268 Brake installation........................................................................................................1269 Speed sensor installation and adjustment..................................................................................1269 Removal and installation of wheel motor.......................................................................................1270 Preparation...............................................................................................................1270 Removal...................................................................................................................1270 Cleaning and inspection...................................................................................................1272 Installation..............................................................................................................1272 Removal and installation of electric motor....................................................................................1276 Removal...................................................................................................................1276 Installation..............................................................................................................1276 Disassembly and assembly of wheel motor transmission..........................................................................1276 Disassembly...............................................................................................................1276 Cleaning and inspection...................................................................................................1284 Assembly..................................................................................................................1284 Disassembly and assembly of low speed carrier.................................................................................1296 Disassembly...............................................................................................................1296 Inspection................................................................................................................1297 Assembly..................................................................................................................1298 Disassembly and assembly of high speed carrier................................................................................1301 Disassembly...............................................................................................................1301 Inspection................................................................................................................1302 Assembly..................................................................................................................1303 Removal and installation of rear axle.........................................................................................1305 Removal...................................................................................................................1305 Cleaning and inspection...................................................................................................1306 Installation..............................................................................................................1307 Removal and installation of anti-sway bar.....................................................................................1307 Removal...................................................................................................................1307 Installation..............................................................................................................1308 Removal and installation of pivot pin.........................................................................................1309 Removal...................................................................................................................1309 Installation..............................................................................................................1309 Pivot eye and bearing service.................................................................................................1310 Bearing removal...........................................................................................................1310 Bearing installation......................................................................................................1310 Pivot eye repair..........................................................................................................1311 Brake system......................................................................................................................1313 Removal and installation of brake valve.......................................................................................1315 Removal...................................................................................................................1315 Installation..............................................................................................................1316 Disassembly and assembly of brake valve.......................................................................................1316 Disassembly...............................................................................................................1316 Cleaning and inspection...................................................................................................1320 Assembly..................................................................................................................1320 Removal and installation of dual relay valve..................................................................................1323 Removal...................................................................................................................1323 Installation..............................................................................................................1324 Disassembly and assembly of dual relay valve..................................................................................1325 Disassembly...............................................................................................................1325 Cleaning and inspection...................................................................................................1326 Assembly..................................................................................................................1326 Removal and installation of brake manifold....................................................................................1327 Removal...................................................................................................................1327 Installation..............................................................................................................1327 Disassembly and assembly of brake manifold....................................................................................1328 Disassembly...............................................................................................................1328 Assembly..................................................................................................................1328 Removal and installation of brake accumulator.................................................................................1329 Removal...................................................................................................................1329 Installation..............................................................................................................1329 Disassembly and assembly of brake accumulator.................................................................................1330 Disassembly...............................................................................................................1330 Cleaning and inspection...................................................................................................1331 Assembly..................................................................................................................1332 Disassembly and assembly of wheel brake.......................................................................................1333 Disassembly...............................................................................................................1334 Cleaning and inspection...................................................................................................1337 Assembly..................................................................................................................1338 Floating ring seal assembly and installation..............................................................................1341 Removal and installation of rear brake assembly...............................................................................1349 Removal...................................................................................................................1349 Installation..............................................................................................................1349 Removal and installation of parking brake.....................................................................................1351 Removal...................................................................................................................1351 Installation..............................................................................................................1353 Disassembly and assembly of parking brake.....................................................................................1353 Disassembly...............................................................................................................1353 Cleaning and inspection...................................................................................................1354 Assembly..................................................................................................................1356 Cleaning and inspecting new discs.........................................................................................1358 Steering system...................................................................................................................1361 Removal and installation of steering control unit.............................................................................1363 Removal...................................................................................................................1363 Installation..............................................................................................................1364 Disassembly and assembly of steering control unit.............................................................................1365 Disassembly...............................................................................................................1365 Assembly..................................................................................................................1367 Removal and installation of steering column...................................................................................1370 Removal...................................................................................................................1370 Inspection................................................................................................................1370 Installation..............................................................................................................1371 Removal and installation of steering wheel....................................................................................1371 Removal...................................................................................................................1371 Installation..............................................................................................................1372 Removal and installation of bleeddown manifold................................................................................1373 Removal...................................................................................................................1373 Installation..............................................................................................................1374 Removal and installation of flow amplifier....................................................................................1375 Removal...................................................................................................................1375 Installation..............................................................................................................1375 Disassembly and assembly of flow amplifier....................................................................................1375 Disassembly...............................................................................................................1375 Assembly..................................................................................................................1377 Removal and installation of steering cylinders and tie rod....................................................................1378 Removal...................................................................................................................1378 Bearing replacement.......................................................................................................1378 Installation..............................................................................................................1378 Disassembly and assembly of steering cylinders................................................................................1380 Disassembly...............................................................................................................1380 Assembly..................................................................................................................1381 Removal and installation of steering/brake pump...............................................................................1381 Removal...................................................................................................................1381 Installation..............................................................................................................1382 Disassembly and assembly of steering/brake pump...............................................................................1384 Disassembly...............................................................................................................1384 Inspection................................................................................................................1387 Assembly..................................................................................................................1390 Driveshaft group..........................................................................................................1390 Rotating group............................................................................................................1391 Removal and installation of steering accumulators.............................................................................1394 Removal...................................................................................................................1394 Installation..............................................................................................................1395 Disassembly and assembly of steering accumulators.............................................................................1395 Disassembly...............................................................................................................1395 Cleaning and Inspection...................................................................................................1396 Assembly..................................................................................................................1397 Suspensions.......................................................................................................................1401 Removal and installation of front suspension..................................................................................1403 Removal...................................................................................................................1403 Installation..............................................................................................................1404 Inspection................................................................................................................1407 Minor front suspension repairs (lower bearing and seals)......................................................................1410 Lower bearing retainer removal............................................................................................1410 Lower bearing retainer installation.......................................................................................1410 Major front suspension rebuild................................................................................................1411 Disassembly...............................................................................................................1411 Assembly..................................................................................................................1412 Removal and installation of rear suspension...................................................................................1414 Removal...................................................................................................................1415 Installation..............................................................................................................1417 Disassembly and assembly of rear suspension...................................................................................1417 Disassembly...............................................................................................................1417 Cleaning and Inspection...................................................................................................1418 Assembly..................................................................................................................1418 Hoist circuit.....................................................................................................................1421 Removal and installation of hoist pump........................................................................................1423 Removal...................................................................................................................1423 Installation..............................................................................................................1424 Disassembly and assembly of hoist pump........................................................................................1425 Disassembly...............................................................................................................1425 Inspection................................................................................................................1428 Assembly..................................................................................................................1428 Removal and installation of hoist valve.......................................................................................1433 Removal...................................................................................................................1433 Installation..............................................................................................................1434 Disassembly and assembly of hoist valve.......................................................................................1434 O-ring replacement........................................................................................................1434 Disassembly of inlet section..............................................................................................1435 Assembly of inlet section.................................................................................................1436 Disassembly of rear spool section.........................................................................................1436 Assembly of rear spool section............................................................................................1439 Disassembly of front spool section........................................................................................1440 Assembly of front spool section...........................................................................................1441 Overcenter valve manifold service.............................................................................................1441 Removal and installation of hoist pilot valve.................................................................................1442 Removal...................................................................................................................1442 Installation..............................................................................................................1442 Disassembly and assembly of hoist pilot valve.................................................................................1443 Disassembly...............................................................................................................1443 Cleaning and inspection...................................................................................................1444 Assembly..................................................................................................................1444 Removal and installation of hoist cylinders...................................................................................1445 Removal...................................................................................................................1445 Installation..............................................................................................................1446 Disassembly and assembly of hoist cylinders...................................................................................1447 Disassembly...............................................................................................................1447 Cleaning and inspection...................................................................................................1449 Installation of the quill.................................................................................................1450 Assembly..................................................................................................................1452 Operator cab......................................................................................................................1455 Removal and installation of operator cab......................................................................................1457 Removal...................................................................................................................1458 Installation..............................................................................................................1459 Removal and installation of cab door..........................................................................................1460 Removal...................................................................................................................1460 Installation..............................................................................................................1460 Disassembly and assembly of cab door..........................................................................................1460 Removing door panel.......................................................................................................1460 Installing door panel.....................................................................................................1461 Replacing the door window regulator.......................................................................................1461 Replacing door handle or latch assembly...................................................................................1462 Replacing door assembly seal and door hinge seal..........................................................................1463 Replacing door opening seal...............................................................................................1463 Removing door glass.......................................................................................................1464 Installing door glass.....................................................................................................1466 Adjustment of cab door........................................................................................................1467 Door jamb bolt adjustment.................................................................................................1467 Door handle plunger adjustment............................................................................................1469 Removal and installation of side window glass.................................................................................1470 Recommended tools and supplies............................................................................................1470 Removal...................................................................................................................1470 Installation..............................................................................................................1470 Removal and installation of windshield and rear window glass..................................................................1471 Removal...................................................................................................................1471 Installation..............................................................................................................1471 Removal and installation of windshield wiper motor............................................................................1473 Removal...................................................................................................................1473 Installation..............................................................................................................1473 Removal and installation of windshield wiper arm..............................................................................1474 Removal...................................................................................................................1474 Installation..............................................................................................................1474 Removal and installation of windshield wiper linkage..........................................................................1474 Removal...................................................................................................................1474 Installation..............................................................................................................1475 Removal and installation of operator seat.....................................................................................1475 Inspection................................................................................................................1475 Removal...................................................................................................................1475 Installation..............................................................................................................1475 Replacing the Seat Compressor.............................................................................................1476 Removal and installation of passenger seat....................................................................................1481 Removal...................................................................................................................1481 Installation..............................................................................................................1481 Removal and installation of seat belts (standard seats).......................................................................1482 Removal...................................................................................................................1482 Installation..............................................................................................................1482 Removal and installation of seat belts (optional seats).......................................................................1484 General...................................................................................................................1484 Removal...................................................................................................................1484 Installation..............................................................................................................1486 Body and structures...............................................................................................................1489 Removal and installation of dump body.........................................................................................1491 Removal...................................................................................................................1491 Inspection................................................................................................................1492 Installation..............................................................................................................1493 Removal and installation of body pads.........................................................................................1493 Removal...................................................................................................................1493 Installation..............................................................................................................1494 Body pad shimming procedure...............................................................................................1495 Removal and installation of diagonal ladder/hood and grille assembly..........................................................1496 Removal...................................................................................................................1496 Installation..............................................................................................................1496 Removal and installation of right deck........................................................................................1497 Removal...................................................................................................................1497 Installation..............................................................................................................1498 Removal and installation of left deck.........................................................................................1499 Removal...................................................................................................................1499 Installation..............................................................................................................1499 Removal and installation of fuel tank.........................................................................................1501 Removal...................................................................................................................1501 Cleaning and inspection...................................................................................................1501 Installation..............................................................................................................1503 Removal and installation of fuel gauge sender (S/N A50003 - A50011)...........................................................1503 Removal...................................................................................................................1503 Installation..............................................................................................................1503 Removal and installation of fuel gauge sender (S/N A50012 & up)...............................................................1503 Removal...................................................................................................................1503 Installation..............................................................................................................1503 Disassembly and assembly of fuel tank breather................................................................................1504 Disassembly...............................................................................................................1504 Assembly..................................................................................................................1504 Removal and installation of hydraulic tank....................................................................................1505 Removal...................................................................................................................1505 Installation..............................................................................................................1505 Cab air conditioning..............................................................................................................1507 Replacement of air conditioning system components.............................................................................1509 Hoses and fittings........................................................................................................1509 Lines.....................................................................................................................1509 Expansion valve...........................................................................................................1509 Receiver-drier............................................................................................................1509 Thermostat................................................................................................................1509 Compressor................................................................................................................1510 Accumulator...............................................................................................................1510 Clutch....................................................................................................................1510 Diasassembly and assembly of compressor clutch................................................................................1511 Removal of the clutch assembly............................................................................................1511 Removal of the pulley.....................................................................................................1513 Installation of the pulley................................................................................................1513 Installation of the clutch assembly.......................................................................................1514 Power module......................................................................................................................1517 Removal and installation of power module......................................................................................1519 General...................................................................................................................1519 Preparation...............................................................................................................1519 Removal...................................................................................................................1520 Installation..............................................................................................................1525 Removal and installation of alternator........................................................................................1527 Removal...................................................................................................................1527 Installation..............................................................................................................1529 Removal and installation of engine............................................................................................1532 Removal...................................................................................................................1532 Service...................................................................................................................1533 Installation..............................................................................................................1533 Removal and installation of radiator..........................................................................................1533 Removal...................................................................................................................1533 Installation..............................................................................................................1535 Repairing the radiator........................................................................................................1537 Internal inspection.......................................................................................................1537 External cleaning.........................................................................................................1537 Disassembly...............................................................................................................1537 Cleaning and inspection...................................................................................................1538 Assembly..................................................................................................................1539 Pressure testing..........................................................................................................1540 Auto lubrication system...........................................................................................................1543 Lubrication system priming....................................................................................................1544 Disassembly and assembly of lubrication pump..................................................................................1544 Disassembly...............................................................................................................1544 Cleaning and Inspection...................................................................................................1546 Assembly..................................................................................................................1546 Three phase wheel motor...........................................................................................................1549 General safety information....................................................................................................1550 Handling the motor............................................................................................................1551 Transport.....................................................................................................................1552 Storage.......................................................................................................................1553 Storage of new motors.....................................................................................................1553 Storage of used motors....................................................................................................1553 Motor description.............................................................................................................1554 Maintenance...................................................................................................................1555 Safety guidelines.............................................................................................................1555 Maintenance intervals.........................................................................................................1556 Maintenance work on the installed motor.......................................................................................1556 Checking for external damage..............................................................................................1556 Checking the connections..................................................................................................1556 Checking the interior of the motor for water..............................................................................1556 Regreasing the bearings.......................................................................................................1557 Applying grease to the bearings...............................................................................................1557 Checking the interior of the motor for water..................................................................................1558 Disassembling the motor.......................................................................................................1559 Removing the coupling.........................................................................................................1560 Disassembling the rotor.......................................................................................................1562 Removing the rubber seals and the air baffles.................................................................................1567 Removing the bearing and labyrinth ring.......................................................................................1568 Maintenance work..............................................................................................................1569 Cleaning......................................................................................................................1569 Stator inspection.............................................................................................................1569 Rotor inspection..............................................................................................................1569 Testing the insulation........................................................................................................1570 High-voltage test.........................................................................................................1570 Work on the bearings..........................................................................................................1571 Assembling the motor..........................................................................................................1572 Important general instructions................................................................................................1572 Assembling the rubber seals and the air baffles...............................................................................1573 Assembly after special repair work............................................................................................1575 Bearing installation (D-end)..................................................................................................1576 Assembling the bearing....................................................................................................1576 Installing the cover......................................................................................................1578 Bearing installation (N-end)..................................................................................................1579 Assembling the bearing....................................................................................................1579 Installing the cover......................................................................................................1581 Assembling the bearing shield (N-end) at the stator frame.....................................................................1582 Installing the bearing........................................................................................................1584 Installing the rotor..........................................................................................................1586 Installing the labyrinth ring.................................................................................................1588 Installing accessories (D- and N-end).........................................................................................1590 Running in the bearings.......................................................................................................1594 Installing the gear wheel.....................................................................................................1595 Installing the coupling.......................................................................................................1596 Assembly conditions and instructions..........................................................................................1597 Repairing the motor...........................................................................................................1598 Replacing defective connecting leads..........................................................................................1598 Repairing the stator winding insulation.......................................................................................1599 Recommended consumables.......................................................................................................1599 Chemical cleaning agents......................................................................................................1599 Generally approved cleaning agents........................................................................................1599 Chemical cleaning agents for outdoor use and for cleaning mechanical parts................................................1600 Chemical cleaning agents for flange faces.................................................................................1600 Chemical cleaning agents for windings.....................................................................................1600 Chemical cleaning agents for windings with severe damage and for oily windings............................................1600 Rolling-contact bearing grease................................................................................................1601 Assembly/disassembly agents for bearing seat..................................................................................1601 Sealants for joining parts or gaps............................................................................................1601 Locking agents for connecting elements........................................................................................1601 Anti-corrosion agent..........................................................................................................1601 Assembly paste for temperature sensors........................................................................................1601 Paints for refinishing the painted parts or touching up damaged parts.........................................................1601 Special tools.................................................................................................................1602 Mounting devices for inserting and withdrawing the rotor horizontally.........................................................1602 Press for expanding the coupling..............................................................................................1602 Compression devices for pressing on or for support while pressing off.........................................................1603 Pulling units with cross beam or disk.........................................................................................1605 Aids..........................................................................................................................1605 Extraction devices............................................................................................................1605 Main blower...................................................................................................................1607 Removing the main blower motor............................................................................................1608 Disassembling the main blower motor.......................................................................................1614 Assembling the main blower motor..........................................................................................1616 Installing the main blower motor..........................................................................................1619 Retarding grid................................................................................................................1627 Removing the grid blower motor............................................................................................1628 Disassembling the grid blower motor.......................................................................................1630 Assembling the grid blower motor..........................................................................................1632 Installing the grid blower motor..........................................................................................1634 Removing a grid element...................................................................................................1637 Control cabinet...............................................................................................................1641 Draining and filling the IGBT coolant system..............................................................................1643 Required tools/materials..............................................................................................1643 Coolant mixture specification (distilled water : Antifrogen N)........................................................1643 Draining and filling the coolant......................................................................................1644 Removing and installing the IGBT coolant pump assembly....................................................................1647 Required tools/materials..............................................................................................1647 Removal...............................................................................................................1648 90 Diagrams and drawings..............................................................................................................1651 Hydraulic circuit diagrams........................................................................................................1651 Electrical circuit diagrams.......................................................................................................1657 Electrical circuit diagrams - drive system........................................................................................1698
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
