Komatsu 960E-2K Dump Truck Shop Manual CEBM026302 PDF

Description

Komatsu 960E-2K Dump Truck Shop Manual CEBM026302  – PDF DOWNLOAD

FILE DETAILS:

Komatsu 960E-2K Dump Truck Shop Manual CEBM026302  – PDF DOWNLOAD

Language : English
Pages : 1703
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu 960E-2K Dump Truck Shop Manual CEBM026302  – PDF DOWNLOAD

• SERIAL NUMBERS 960E-2K A50011 – A50027

00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword, safety and general information 35
Foreword 39
How to read the shop manual 40
Composition of shop manual 40
Revision and distribution 40
Symbols 41
General safety 42
Safety rules 42
Safety features 42
Fire extinguisher and first aid kit 42
Clothing and personal items 42
Leaving the operator seat 43
Mounting and dismounting 43
Fire prevention for fuel and oil 43
Precautions with high temperature fluids 44
Asbestos dust hazard prevention 44
Prevention of injury by work equipment 44
Unauthorized modification 44
Precautions when using ROPS 44
Precautions for attachments 45
Precautions for starting the truck 45
Precautions before operating the truck 45
Safety at the worksite 45
Fire prevention 46
Ventilation in enclosed areas 46
Preparing for operation 46
Mirrors, windows and lights 46
In operator cab (before starting the engine) 46
Seat Belts 46
Precautions while operating the truck 47
When starting the engine 47
General truck operation 47
Ensuring good visibility 47
Traveling 48
Traveling in reverse 48
Traveling on slopes 48
Operating on snow or ice 48
Avoid damage to dump body 48
Driving near high voltage cables 49
When dumping 49
Working on loose ground 49
When loading 49
Parking the truck 49
Towing 50
Working near batteries 50
Battery hazard prevention 50
Starting with jumper cables 51
Jump starting with receptacles 51
Precautions before performing service 52
Warning tag 52
Stopping the engine 52
Proper tools 52
Use of fall protection harness anchor during maintenance and repair 52
Securing the dump body 53
While performing maintenance 54
Keep the truck clean 54
Attachments 54
Working under the truck 54
Rotating fan and belts 54
Adding fuel or oil 54
Use of lighting 54
Radiator coolant level 55
Precautions with the battery 55
Precautions with high pressure oil 55
Handling high pressure hoses 55
Precautions when performing maintenance near high temperature or high pressure 55
Waste materials 55
Tires 56
Handling tires 56
Storing tires after removal 56
Precautions for performing repairs 57
Engine shutdown procedure after AC drive system failure 57
Jack point locations 58
Precautions for welding on the truck 59
Handling electrical equipment and hydraulic components 60
Points to remember when handling electrical equipment 60
Points to remember when handling hydraulic equipment 66
How to Read Electric Wire Code 68
Color Code and Harness Designation Tables 69
Standard torque tables 70
Effect of special lubricants on fasteners and standard torque values 70
Suggested sources for rust preventive grease 70
SAE grade 5 and grade 8 hex head capscrew and nut assemblies 71
SAE grade 9 capscrews 72
Class 10 9 capscrews and class 10 nuts 72
Standard tightening torques for fittings 73
Standard tightening torques for clamps 75
Conversion tables 76
Common conversion multipliers 76
Operating instructions 81
Preparing for operation 83
Walk around inspection 83
Engine start-up 87
After engine start-up 88
Emergency steering system 89
Operation 89
Pre-operation testing 89
Precautions during truck operation 90
Operating on a haul road 91
Starting on a grade with a loaded truck 91
Loading the dump body 92
Dumping a load 92
Raising the dump body 92
Lowering the dump body (on flat ground) 93
Lowering the dump body (over a berm or into a crusher) 94
Using the speed control feature 94
Safe parking procedure 95
Normal engine shutdown procedure 95
Sudden loss of engine power 96
Fuel depletion 96
Towing 97
Special Wiring Harness 97
Towing Procedure 98
Disabled truck operation 100
Components Required 100
Hookup 100
Disabled truck dumping procedure 101
Hookup 101
Raising the body 102
Lowering the body 102
01 Specification 105
Specification and technical data 105
Specification drawing 107
Specifications 108
Weight table 110
Fuel, coolant and lubricants 111
Suspension cylinder oil and nitrogen specifications 112
10 Structure and functions 115
Steering circuit 115
Steering circuit operation 117
Steering circuit components 119
Steering control unit 119
High pressure filter 119
Steering accumulators 119
Bleeddown manifold 120
Steering accumulator bleeddown solenoid 122
Hoist up limit solenoid 122
Quick disconnect ports 122
Flow amplifier 122
Flow amplifier operation 123
No steer 124
Steering left 126
Steering right 128
No steer, external shock load 130
Steering/brake pump operation 133
Normal operation 133
Neutral position 135
Full pump volume 136
Half pump volume 136
Steering cylinder wear data 137
Hoist circuit 139
Hoist circuit operation 141
Hoist circuit components 142
Hydraulic tank 142
Hoist pump 142
High pressure filters 142
Hoist valve 142
Inlet sections 143
Tank ports (front) spool section 143
Work ports (rear) spool section 143
Hoist pilot valve 144
Bleeddown manifold 144
Hoist limit solenoid 144
Pilot operated check valve 144
Overcenter manifold 145
Hoist pilot valve operation 146
Float position with body down 146
Power up operation 148
Hold operation 150
Power down operation 152
Float operation 154
Hoist cylinder wear data 156
Brake circuits 159
General information 161
Service brake circuit operation 162
Secondary braking and auto apply 162
Parking brake circuit operation 164
Normal operation (key switch ON, engine on) 164
Wheel brake lock circuit operation 165
Brake warning circuit operation 165
Brake assembly wear data 167
Suspensions 169
General information 171
Front suspension wear data 171
Rear suspension wear data 172
Electrical system, 24 volt 175
Battery supply system 177
24VDC Battery Charging Alternator 177
Batteries 177
Engine Start Relays 177
24VDC Auxiliary Battery Receptacles 177
Battery Disconnect Switches 178
Auxiliary control cabinet components 178
24VDC to 12VDC converter 178
Diode board – DB1 178
Power distribution terminals 178
Control power relay 179
Fuse blocks 180
Relay boards 180
Relay boards RB1, RB3, RB4, RB5 180
Relay boards RB6, RB7, RB8, RB9 182
Relay functions 182
Body position switches (With proximity switch and magnet) 184
Proximity switch operation 184
Body-up Switch 185
Hoist limit switch 186
Interface module (IM) 189
General information 190
Sensors 190
Temperature sensors 190
Pressure sensors 190
Interface module inputs and outputs 191
Drive system 197
SR rectifier module 199
ST module (auxiliary voltage inverter) 199
Technical Data 202
SD phase modules 203
SR/ST/SD module removal 203
Inverter cabinet layout 204
Inverter cabinet water flow 204
Field regulator 205
Technical Data 205
Field regulator discharge resistor 205
Technical Data 205
Gate unit power supply 206
Technical Data 206
Gate unit power supply (diode) 206
Technical Data 206
Gate unit power supply (tuning resistor) 206
Technical Data 206
Control power filter 206
Technical Data 206
Filter for TCU 207
Technical Data 207
Terminal block bus bar 207
Technical Data 207
Fuses (analog sensor voltage) 208
Technical Data 208
Fuses (field regulator) 208
Technical Data 208
Fuse holder for field regulator 208
Fuses (control power and trolley box contactor) 209
Technical Data 209
Diode modules 209
Technical Data 209
Support capacitors 210
Technical Data 210
Three-phase capacitor bank (for ST module output voltage) 210
Technical Data 210
Air-cooled inductors (for ST module) 211
Technical Data 211
Three-phase transformer (for ST module) 211
Technical Data 211
Diagnostics box 212
Diagnostic and system monitoring panel 213
Device name: DB101 213
Technical Data 213
Current transducers 214
Device names: 214
U101-U104 (Current to motor A) 214
U105-U106 (Current to chopper A-C) 214
U201-U204 (Current to motor B) 214
U205-U206 (Current to chopper B-D) 214
Technical Data 214
Current transducers (for ST module output) 215
Technical Data 215
Voltage transducers 215
Technical Data 215
Voltage transducers (for ST module output) 216
Technical Data 216
Voltage transducers (SiBAS 24V DC bus monitoring) 216
Analog inclinometer 217
Technical Data 217
DC link capacitors 217
Technical Data 217
Ground tie capacitor 218
Technical Data 218
Low-inductance bus bar assembly 218
Free-wheeling diode for low-inductance bus bars 219
Contactor (grid box and main blower motor) 219
Technical Data 219
Contactor (control power) 220
Technical Data 220
Contactor (DC contactors) 220
Technical Data 220
Contactor (crowbar bypass) 221
Technical Data 221
Temperature probes (PT100 style) 221
Technical Data 221
Coolant inlet temperature sensor 222
Technical Data 222
Coolant outlet temperature sensor (external pad style) 222
Technical Data 222
Coolant outlet temperature sensor (internal style) 223
Technical Data 223
IGBT module heat sink temperature sensor 223
Device names: 223
Circuit breakers 224
Technical Data 224
Inner circulating blower fan 224
Coolant pump 225
Technical Data 225
Motor for coolant pump 225
Technical Data 225
Coolant pressure sensor 225
Inner radiator 226
Ground voltage monitoring resistors 226
Protection thyristor assembly (crowbar) 227
Discharge reactor 227
Main blower motor 228
Technical Data 228
Grid box 228
Technical Data 228
Grid box blower motor 229
Technical Data 229
Grid box blower motor grease fittings 229
Main alternator 230
Stator 230
Rotor 230
Bearings 230
Electrical connection 230
Cooling and ventilation 230
Rotating rectifier section 231
Technical Data 231
Main alternator circuit diagram 232
IGBT – inverter/chopper phase module 233
Device names: A101-A103 (Inverter A section) 233
A201-A203 (Inverter B section) 233
A104 (Chopper A section) 233
A204 (Chopper B section) 233
Troubleshooting information 235
Main input rectifier module 236
Device name: A1 236
Internal circuit diagram 237
Ground tie resistor, upper 238
Device Name: R11 1-R11 2 238
Technical Data 238
Ground tie resistor, lower 238
Device name: R11 3-R11 4 238
Technical Data 238
Troubleshooting 239
Fault diagnosis 239
Speed sensor, alternator 240
Technical Data 240
Speed sensors, wheel motors 241
Technical Data 241
Traction motor 242
Device name: Motor 1 (grid box side of the truck) Motor 2 (operator cab side of the truck) 242
Technical Data 242
Retarding grid 243
Device name: M04 243
Technical Data 243
Cab air conditioning 245
General information 247
Environmental impact of air conditioning 247
Air conditioning for off-highway vehicles 247
Principles of refrigeration 248
Air conditioning 248
Refrigeration – the act of cooling 248
The refrigeration cycle 248
Air conditioning system components 250
Relays 250
Fan motor and speed control 250
Cab air filter 250
Heater core 250
Actuators 250
Compressor (refrigerant pump) 252
Service valves 252
Condenser 252
Receiver-drier 252
Expansion valve 253
Accumulator 253
Evaporator core 253
Air conditioning system electrical circuit 254
Thermostat 254
Compressor clutch 254
Trinary™ switch 255
Reserve engine oil system 257
General information 259
Operation 260
LED monitor light 260
Remote tank fill system 261
SIBAS® IGBT rack components 263
SiBAS®32 Traction Control Unit (TCU) 266
Overview of the SiBAS®32 systems 267
Features 267
General technical specifications, operating conditions 267
Permissible temperature range 267
Permissible limit value for air humidity 268
Permissible power supply voltage range 268
Permissible mechanical loads 268
Protection measures against electrical hazards 268
Application 268
Removing and installing the SiBAS®32 cards 271
Removal with 24V OFF! (ESD protection required) 271
Installation with 24V OFF! (ESD protection required) 271
SiBAS®32 card device names 272
Structure of SiBAS®32 card part number 273
Development status, downward compatibility 273
SiBAS®32 card interchangeability 274
Use of service interfaces 275
Connection of the service unit 275
Maintenance 275
Cleaning 276
SiBAS®32 card interactions 277
SiBAS®32 card detailed information 280
Blower subassembly 280
Device name: N/A 280
Application 280
Battery replacement 282
Rules for handling lithium batteries 282
Replacement of the battery in the fan subassembly 282
CPU card 283
Device name: G011 283
Application 284
Front panel 284
Technical data 285
DSP card 286
Device name: G019, G027 and G35 286
Application 286
Front panel 286
Technical data 287
I/O card 288
Device name: G043 288
Application 288
Front panel 289
Technical data 290
TRACO card (optional) 291
Device name: G003 291
Application 291
Front panel 292
Technical data 293
Input voltage/frequency card 294
Device name: L055, L063 and L071 294
Application 294
Technical data 295
I/O analog card 296
Device name: L079 and L087 296
Technical data 298
I/O analog card 299
Device name: L095 and L103 299
Application 299
Technical data 301
Output pulse amplifier card 302
Device name: L115, L123, L131, L139 and L147 302
Application 302
Technical data 304
Input temperature sensor card 305
Device name: L155 and L163 305
Application 305
Technical data 307
UWS card 308
Device name: G055, G063, G071 and G079 308
Application 308
Technical data 310
Digital input card 311
Device name: G103, G111, G119, G127 and G135 311
Application 311
Technical data 313
Power start-up unit card 314
Device name: G163 314
Application 314
Technical data 316
Binary output contactor drive card 317
Device name: C019, C027 and C035 317
Application 317
Technical data 319
24V / 24V power supply 320
Device name: C045, C105, C129 320
Application 320
Testing the power supply card 321
Technical data 322
24V / 15V power supply 323
Device name: C069, C087 323
Application 323
Testing the power supply card 324
Technical data 325
24V / 5V power supply 326
Device name: C153 326
Application 326
Testing the power supply card 327
Technical data 328
Wheel motor transmission 331
Structure 332
Maintenance standard 333
20 Standard value table 337
Standard value table 337
Standard value table for truck 339
30 Testing and adjusting 345
General information 345
Special tool list 347
Steering, brake cooling and hoist hydraulic system 349
General information on system checkout 351
Steering system checkout procedures 351
Steering pump pressure control adjustments on steering pumps with a pressure compensator 352
Steering pump pressure control adjustments on steering pumps without a pressure compensator 353
Steering control valve and flow amplifier leakage test 354
Bleeddown manifold leakage test 355
Shock and suction valve pressure tests on steering pumps with a pressure compensator 356
Shock and suction valve pressure tests on steering pumps without a pressure compensator 358
Steering system checkout data sheet 360
Toe-in adjustment 361
Brake cooling and hoist system checkout procedures 362
Pressure gauge locations 362
Brake cooling circuit test 363
Power up relief pressure test 363
Power down relief pressure test 364
Counterbalance valve pressure check 365
Counterbalance valve adjustment 366
Brake cooling and hoist system checkout data sheet 367
Hoist cylinder leakage test 368
Hydraulic system flushing procedure 368
Brake system 377
General information on system checkout 379
Brake circuit checkout procedure 379
Initial system setup 381
Brake lock / secondary braking checkout 382
Brake Lock Hydraulic Circuit Trouble Shooting Guide 383
Park Brake 383
Park Brake Hydraulic Circuit Troubleshooting Guide: 384
Service brake system 384
Low Brake Pressure and Auto Apply 385
Reapplications 386
Park Brake Control Logic Check 386
Park Brake and Auto Apply sequencing: 386
Auto Apply Solenoid Hydraulic Circuit Trouble Shooting Guide: 387
Brake Lock Control Logic Check 388
Brake system checkout data sheet 391
Brake piston leakage test 401
Brake seal pressure test 401
Wet disc brake bleeding procedure 402
Parking brake bleeding procedure 402
Service brake disc wear inspection 403
Parking brake disc wear inspection 405
Brake valve bench test and adjustment 406
Test setup procedure 407
Brake valve output pressure adjustment 407
Final test and adjustment 408
Dual relay valve bench test and adjustment 409
Test setup procedure 410
Relay valve output pressure adjustment 410
Accumulators and suspensions 413
Accumulator charging and storage 415
Accumulator charging procedures 415
Precharge maintenance 418
Bladder accumulator storage procedure 419
Bladder storage 419
Installing a bladder accumulator from storage 419
Accumulator leak testing 420
Piston accumulator 422
Piston accumulator storage procedure 422
Piston accumulator storage 422
Piston accumulator testing 422
Steering accumulator charging procedure 423
Checking for improper suspension charge 424
Suspension oiling and charging procedures 425
Required equipment 425
Installing the charging kit 426
Removing the charging kit 426
Support blocks for oiling and charging dimensions 427
Front suspensions 428
Rear suspensions 431
Suspension pressure test 434
Payload meter IV 437
Payload meter IV software and tools 439
Payload meter IV system configuration 439
Connecting to the payload meter IV web server 439
Configuring a static IP address 439
Payload meter IV software installation 441
Payload meter IV checkout procedure 442
PLM IV system checkout data sheet 448
Downloading PLM IV data and possible errors 449
Cab air conditioning 453
General information 455
Service tools and equipment 456
Recovery/recycle station 456
Leak detector 456
Manifold gauge set 457
Service valves 458
Vacuum pump 458
Detecting leaks 459
System performance test 460
Checking system oil 461
System flushing 462
Installing the manifold gauge set 463
Purging air from the service hoses 463
Recovering and recycling refrigerant 464
Draining oil from previous recovery cycle 465
Recovery cycle 465
Recycling procedure 465
Evacuating the air conditioning system 466
Charging the air conditioning system 467
Interface module (IM) 469
Interface module software 470
Flashburn program installation 470
Interface module application code installation 471
Interface module realtime data monitor software installation 471
Interface module checkout procedures 472
Necessary equipment 472
Preliminary 473
Check digital inputs to the interface module 474
Check analog inputs to the interface module 477
Check serial interfaces to the interface module 478
Check outputs from the interface module 479
IGBT haul truck SIBAS® user manual, part 1 481
Abbreviations 484
Precautions 486
Qualified person 486
Customer monitor for SIBAS® 32 control units 486
Product description 486
Version management 487
Overview 488
Requirements 488
Installing and calling the customer monitor 489
Installation 489
Environment variables 489
Communication with the SIBAS® 32 control unit 490
Calling up the customer monitor 491
Start-up prompt 491
Monitor prompt 492
Notes on operation of the customer monitor 493
Structure of a monitor command 493
Step 1: Selecting the menu title 493
Step 2: Selecting a menu entry in the menu box 493
Step 3: Selecting a dialog box, if available 494
Step 4: Entering file or connector/signal names 494
Command buffer 495
Structure of the monitor windows 495
Window menu 496
Commands for Opening, Altering and Closing Windows 496
“Window Work open” 496
“Window Lines open” 496
“Window Tile” 496
“Window Bars open” 496
Options 496
“Window Set” 496
Options 496
“Window Cascade” 496
“Window Close” 496
“Window close All” 496
“Window Exit” 496
Set Menu 497
“Set Port” 497
Options 497
“Set Baudrate” 497
Options 497
“Set String” 498
Example 499
“Set Make” 499
Options 499
Example 1: INIT MON start-up control of the Customer Monitor 500
Example 2: Any monitor batch file with freely selectable file name (incl path) 500
“Set Execute” 501
Options 501
Example 501
“Set Record” 501
Options 501
“Set DIN-Bus” 502
“Set TCN” 502
“Set Timeout” 502
Options 502
“Set Wait” 502
Options 502
“Set Color” 502
Options 502
“Set Info” 503
“Set comment” 503
“Set CHAR Set” 503
“Set Quit” 503
Applic Menu 504
“Applic Func Package” 504
“Applic Connector” 505
Options 505
Example 506
“Applic View” 506
Options 506
Example 506
“Applic Signal” 506
“Applic Observer” 507
Options 507
Possible time slices: 507
Options 508
Two options 508
Notes on the display of connectors 510
“Applic Buffer” 511
Options 511
“Applic Report” 511
“Applic Legitimation” 511
Options 511
“Applic Menu” 512
“Applic Traco” 512
Options 512
“Applic Environment” 512
Hardw Menu 514
Hardware-Oriented Access via the Customer Monitor 514
“Hardw Flash” 514
Options 514
Requirements 514
Example 515
Deleting and loading 515
The EPROM for the communication drivers 515
“Hardw Clock” 515
Options 515
“Hardw DSP” 516
“Hardw BCD” 516
Options 516
Example 516
“Hardw RESET” 516
Options 516
“Hardw Info” 517
Hardware/Operating system 517
Application and tools 517
Communication module 517
Displaying the loading date 517
“Hardw User Flash” 518
Options 518
“Hardw Sys Flash” 518
Options 518
“Hardw BOOT DSP” 519
Requirements 519
DSP5600x Signal Processing Unit and TRACO 519
Inverter processing unit 521
Access to the Signal Processing Unit 521
“Hardw Flash” 521
Options 521
Requirements 521
Example 521
Deleting and loading 522
The EPROM for the communication drivers 522
User Data Flash (UDF) 522
“Hardw RESET” 522
Options 522
“Hardw ZR” 523
“Hardw BOOT ZR” 523
The following procedure is necessary: 523
Graphic Menu 524
Commands for Displaying Line Graphics 524
“Graphic Load” 524
Options 524
“Graphic Position” 524
Options 524
“Graphic Time/Div” 525
Options 525
“Graphic Unit/Div” 525
Options 525
“Graphic Display” 525
Options 525
“Graphic Color” 526
Options 526
“Graphic Format” 526
Options 526
IGBT haul truck SIBAS® user manual, part 2 529
Traco Menu 532
HW-Traco 532
Options 533
SW-Traco 534
Options 535
ZR traco basic parameters: 535
ZR traco record signal table: 535
DAC_Traco 538
Options 539
Events Menu 540
STatistics 541
History 542
LEL:Last EvL 543
LES:Last EvS 545
DLL:DC,LastL 546
DLS:DC,LastS 547
DAL:DC,All L 548
DAS:DC,All S 549
ML:Memory L 550
MS:Memory S 551
CN:Clear Norm 552
CA:Clear All 552
Test-Code 552
DS:Diag-Strc 553
User Menu 554
DAC_IO 555
Options 555
Options 556
Operat Data 557
Acc test 564
Engine_Test 564
X_Test_Inx 567
STate intern 568
Header: 568
Vehicle Number: 568
Powering system: 568
TCU Operation Mode: 568
Component status listings: 569
Field regulator status: 569
Status gate unit power supply A: 569
Status gate unit power supply B: 569
ST inverter status 569
Vehicle status 570
Drive status: 570
Operation status: 570
Pedal calib 571
Language 572
OFFline-test 572
Options 572
Variables 574
Examples: 574
IV:Vehic-ID 575
Commands 576
Discharge Dc link / Fire crowbar 576
Limp mode commands 576
Settings 577
Parameters 578
Temp_prot 580
Appendix 582
Background commands 582
Monitor commands for the central processing unit 584
Monitor commands for the signal processing unit 584
Installing ZR / DSP software 587
Monitor Program – Loading software into the SIBAS® 589
Loading software into the DSP procedure 589
Loading a DSP program Inverter A 594
Loading software into the CPU procedure 601
Loading ZR software Prog jumpers Reset 608
Loading the proper pgm file 610
Setting the system up After loading a new pgm 610
40 Troubleshooting 613
Fuse and circuit breaker locations 613
Fuse and circuit breaker locations 615
Fuse block tables 616
Prelube motor fuse 617
Circuit breaker table 618
Troubleshooting by fault code, Part 1 621
Fault Code A001: Left front suspension pressure sensor signal high 624
Related circuit diagram 624
Fault Code A002: Left front suspension pressure sensor signal low 625
Related circuit diagram 625
Fault Code A003: Right front suspension pressure sensor signal high 626
Related circuit diagram 626
Fault Code A004: Right front suspension pressure sensor signal low 627
Related circuit diagram 627
Fault Code A005: Left rear suspension pressure sensor signal high 628
Related circuit diagram 628
Fault Code A006: Left rear suspension pressure sensor signal low 629
Related circuit diagram 629
Fault Code A007: Right rear suspension pressure sensor signal high 630
Related circuit diagram 630
Fault Code A008: Right rear suspension pressure sensor signal low 631
Related circuit diagram 631
Fault Code A009: Incline sensor signal high 632
Related circuit diagram 632
Fault Code A010: Incline sensor signal low 633
Related circuit diagram 633
Fault Code A011: Payload meter speed sensor signal has failed 634
Related circuit diagram 634
Fault Code A013: Body up switch has failed 635
Related circuit diagram 635
Fault Code A014: Payload meter checksum computation has failed 636
Related circuit diagram 636
Fault Code A016: Payload meter write to flash memory has failed 637
Related circuit diagram 637
Fault Code A017: Payload meter flash memory read has failed 638
Related circuit diagram 638
Fault Code A018: Right rear flat suspension cylinder warning 639
Related circuit diagram 640
Fault Code A019: Left rear flat suspension cylinder warning 641
Related circuit diagram 642
Fault Code A022: Carryback load excessive 643
Related circuit diagram 644
Fault Code A100: An open circuit breaker has been detected on a relay board 645
Related circuit diagram 645
Fault Code A101: High pressure detected across an hydraulic pump filter 646
Related circuit diagram 648
Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level 649
Related circuit diagram 650
Fault Code A111: Low steering pressure warning for storage by KOMTRAX Plus 651
Related circuit diagram 651
Fault Code A115: Low steering precharge pressure detected 652
Related circuit diagram 653
Fault Code A117: Low brake accumulator pressure warning for storage by KOMTRAX Plus 654
Related circuit diagram 654
Fault Code A118: Brake pressure is low while in brake lock 655
Related circuit diagram 656
Fault Code A126: Oil level in the hydraulic tank is low 657
Related circuit diagram 657
Fault Code A127: IM-furnished +5 volt output for sensors is low 658
Related circuit diagram 659
Fault Code A128: IM-furnished +5 volt output for sensors is high 660
Related circuit diagram 661
Fault Code A139: Low fuel warning for storage by KOMTRAX Plus and for use by A310 662
Related circuit diagram 663
Troubleshooting by fault code, part 2 665
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil 668
Related circuit diagram 669
Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil 670
Related circuit diagram 671
Fault Code A152: Starter failure 672
Related circuit diagram 673
Fault Code A153: Battery voltage is low with the truck in operation 674
Related circuit diagram 675
Fault Code A154: Battery charging voltage is excessive 676
Related circuit diagram 676
Fault Code A155: Battery charging voltage is low 677
Related circuit diagram 677
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 678
Related circuit diagram 679
Fault Code A166: Left rear hydraulic oil temperature sensor is low 680
Related circuit diagram 681
Fault Code A167: Right rear hydraulic oil temperature sensor is low 682
Related circuit diagram 683
Fault Code A168: Left front hydraulic oil temperature sensor is low 684
Related circuit diagram 685
Fault Code A169: Right front hydraulic oil temperature sensor is low 686
Related circuit diagram 687
Fault Code A170: Left rear hydraulic oil temperature sensor is high 688
Related circuit diagram 688
Fault Code A171: Right rear hydraulic oil temperature sensor is high 689
Related circuit diagram 689
Fault Code A172: Left front hydraulic oil temperature sensor is high 690
Related circuit diagram 690
Fault Code A173: Right front hydraulic oil temperature sensor is high 691
Related circuit diagram 691
Fault Code A184: J1939 data link is not connected 692
Related circuit diagram 693
Fault Code A190: Auto lube control has detected an incomplete lube cycle 694
Related circuit diagram 695
Fault Code A194: Left front hydraulic oil temperature is high 696
Related circuit diagram 696
Fault Code A195: Right front hydraulic oil temperature is high 697
Related circuit diagram 697
Fault Code A196: Left rear hydraulic oil temperature is high 698
Related circuit diagram 698
Fault Code A197: Right rear hydraulic oil temperature is high 699
Related circuit diagram 699
Fault Code A198: Hoist pressure 1 sensor is high 700
Related circuit diagram 700
Fault Code A199: Hoist pressure 2 sensor is high 701
Related circuit diagram 701
Fault Code A200: Steering pressure sensor is high 702
Related circuit diagram 702
Fault Code A201: Brake pressure sensor is high 703
Related circuit diagram 703
Fault Code A202: Hoist pressure 1 sensor is low 704
Related circuit diagram 704
Fault Code A203: Hoist pressure 2 sensor is low 705
Related circuit diagram 705
Fault Code A204: Steering pressure sensor is low 706
Related circuit diagram 706
Fault Code A205: Brake pressure sensor is low 707
Related circuit diagram 707
Fault Code A206: Ambient temperature sensor is high 708
Related circuit diagram 708
Fault Code A207: Ambient temperature sensor is low 709
Related circuit diagram 709
Troubleshooting by fault code, Part 3 711
Fault Code A213: Parking brake should have applied but is detected as not having applied 714
Related circuit diagram 716
Fault Code A214: Parking brake should have released but is detected as not having released 718
Related circuit diagram 720
Fault Code A215: Brake auto apply valve circuit is defective 722
Related circuit diagram 724
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 726
Related circuit diagram 727
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted 728
Related circuit diagram 729
Fault Code A230: Parking brake has been requested while truck still moving 730
Related circuit diagram 731
Fault Code A231: The body is up while traveling or with selector in forward or neutral 732
Fault Code A233: Drive System Control Link is not connected 734
Related circuit diagram 735
Fault Code A235: Steering accumulator is in the process of being bled down 736
Related circuit diagram 737
Fault Code A236: The steering accumulator has not properly bled down after 90 seconds 738
Related circuit diagram 739
Fault Code A237: The CAN/RPC connection to the display is open 740
Related circuit diagram 741
Fault Code A238: Drive System and IM are reporting different park brake status 742
Related circuit diagram 743
Fault Code A239: The Drive System and IM are reporting different brake lock status 744
Related circuit diagram 745
Fault Code A240: The keyswitch input to the Interface Module is open 746
Related circuit diagram 746
Fault Code A242: Fuel gauge within the dash display panel is defective 747
Related circuit diagram 747
Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective 748
Related circuit diagram 748
Fault Code A244: Drive system temperature gauge within the dash display panel is defective 749
Related circuit diagram 749
Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective 750
Related circuit diagram 750
Fault Code A246: Payload meter reports truck overload 751
Related circuit diagram 751
Fault Code A247: Low steering pressure warning for display to operator 752
Related circuit diagram 752
Fault Code A248: Status module within the dash display panel is defective 753
Related circuit diagram 753
Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted 754
Related circuit diagram 754
Fault Code A250: Battery voltage is low with the truck parked 756
Related circuit diagram 757
Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground 758
Related circuit diagram 758
Fault Code A252: Start enable output circuit is either open or shorted to ground 759
Related circuit diagram 759
Fault Code A253: Steering bleed circuit is not open while running 760
Related circuit diagram 761
Fault Code A256: Red warning lamp in the dash display (driven by IM) is open 762
Related circuit diagram 762
Fault Code A257: Payload CAN/RPC is not connected 764
Related circuit diagram 765
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 766
Related circuit diagram 766
Troubleshooting by fault code, Part 4 769
Fault Code A260: Parking brake failure 772
Related circuit diagram 773
Fault Code A261: Low brake accumulator pressure warning for display to operator 774
Related circuit diagram 774
Fault Code A262: Steering bleed valve circuit open during shutdown 776
Related circuit diagram 777
Fault Code A264: Parking brake relay circuit is defective 778
Related circuit diagram 779
Fault Code A265: Service brake failure 780
Related circuit diagram 781
Fault Code A266: Selector switch was not in park while attempting to crank engine 782
Related circuit diagram 782
Fault Code A267: Parking brake was not set while attempting to crank engine 783
Related circuit diagram 783
Fault Code A268: Secondary engine shutdown while cranking 784
Related circuit diagram 784
Fault Code A270: Brake lock switch power supply is not on when required 786
Related circuit diagram 788
Fault Code A271: Shifter not in gear 790
Related circuit diagram 791
Fault Code A272: Brake lock switch power supply is not off when required 792
Related circuit diagram 793
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit 794
Related circuit diagram 794
Fault Code A274: A brake setting fault has been detected 796
Related circuit diagram 797
Fault Code A275: A starter has been detected as engaged without a cranking attempt 798
Related circuit diagram 799
Fault Code A277: Parking brake applied while loading 800
Related circuit diagram 801
Fault Code A278: Service brake applied while loading 802
Related circuit diagram 803
Fault Code A279: Low steering pressure switch is defective 804
Related circuit diagram 804
Fault Code A280: Steering accumulator bleeddown switch is defective 805
Related circuit diagram 805
Fault Code A281: Brake lock degrade switch is defective 806
Related circuit diagram 807
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 808
Related circuit diagram 809
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set 810
Related circuit diagram 811
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated 812
Related circuit diagram 813
Fault Code A285: The parking brake was not set when the keyswitch was turned off 814
Related circuit diagram 815
Fault Code A286: A fault was detected in the shutdown delay relay circuit 816
Related circuit diagram 817
Fault Code A292: The shutdown delay relay has remained on after the latched keyswitch circuit is off 818
Related circuit diagram 819
Troubleshooting by fault code, part 5 821
Fault Code A303: Shifter is defective 824
Related circuit diagram 825
Fault Code A304: Auto lube grease level fault 826
Related circuit diagram 826
Fault Code A305: Auto lube circuit is defective 828
Related circuit diagram 829
Fault Code A309: No brakes applied when expected 830
Related circuit diagram 831
Fault Code A310: Low fuel warning 832
Related circuit diagram 833
Fault Code A311: Brake lock switch is on when it should not be 834
Related circuit diagram 835
Fault Code A312: DCDC converter 12 volt circuit sensing is producing low readings 836
Related circuit diagram 836
Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings 837
Related circuit diagram 837
Fault Code A315: DCDC converter 12 volt circuit is low 838
Related circuit diagram 839
Fault Code A316: Starter engagement has been attempted with engine running 840
Related circuit diagram 841
Fault Code A317: Operation of brake auto apply valve without a detected response 842
Related circuit diagram 844
Fault Code A318: Unexpected power loss to Interface Module 845
Related circuit diagram 845
Fault Code A328: Drive system not powered up 846
Related circuit diagram 846
Fault Code A334: Selector switch not in park when propel was either not ready or at rest 847
Related circuit diagram 847
Fault Code A335: Manual/Auto Apply Pressure Fault 848
Fault Code A350: Overload on output 1B 849
Related circuit diagram 849
Fault Code A351: Overload on output 1E 850
Related circuit diagram 851
Fault Code A352: Overload on output 1H 852
Related circuit diagram 852
Fault Code A353: Overload on output 1J 853
Related circuit diagram 853
Fault Code A354: Overload on output 1K 854
Related circuit diagram 854
Fault Code A355: Overload on output 1L 855
Related circuit diagram 855
Fault Code A356: Overload on output 1M 856
Related circuit diagram 856
Fault Code A357: Overload on output 1N 857
Related circuit diagram 857
Fault Code A358: Overload on output 1P 858
Related circuit diagram 859
Fault Code A359: Overload on output 1R 860
Related circuit diagram 861
Fault Code A360: Overload on output 1S 862
Related circuit diagram 862
Fault Code A361: Overload on output 1T 864
Related circuit diagram 865
Fault Code A362: Overload on output 1U 866
Related circuit diagram 866
Fault Code A363: Overload on output 1X 867
Related circuit diagram 867
Fault Code A364: Overload on output 1Y 868
Related circuit diagram 868
Fault Code A365: Overload on output 1Z 869
Related circuit diagram 869
Drive system fault code table, part 1 871
Summary 874
How to use this document 874
Event code and diagnosis message 874
Description 874
Threshold 874
Detection by 874
Possible reasons 874
Action to reset 874
Action to repair 875
Operator displayed code 875
Note 875
Protection reactions 875
Event classification 876
Level 1: Warning 876
Level 2: Minor purposes 876
Level 3: Severe 876
1 L3C SYS: Time slice overflow CPU T1 877
2 L3C SYS: Time slice overflow CPU T2 877
3 L3C SYS: Time slice overflow CPU T3 877
4 L3C SYS: Time slice overflow CPU T4 877
5 L3C SYS: Time slice overflow CPU T5 877
6 L3C SYS: Time slice overflow CPU T6 877
7 L3C SYS: Time slice overflow CPU T7 877
8 L3C SYS: Time slice overflow CPU T8 877
10 L2A SYS: Pulse inhibit/asa inhibit PSU–ONLINE 878
11 L3D SYS: Pulse inhibit/asa inhibit PSU-Start-up 878
12 L1A SYS: SIBAS® blower fault 879
13 L1B SYS: Undervoltage in SIBAS® battery for BRAM 879
14 L3C SYS: SIBAS® power supply failure 24V for pulse amplifier 880
15 L3C SYS: SIBAS® power supply failure +5V 881
16 L3C SYS: SIBAS® power supply failure +15V 882
17 L3C SYS: SIBAS® power supply failure –15V 883
18 L3C SYS: SIBAS® power supply failure +24V 884
19 L3C SYS: SIBAS® power supply failure –24V 885
20 L3C SYS: SIBAS® power supply failure primary 886
21 L3C SYS: FPGA clock missing for PSU 886
22 L3C SYS: Pulse inhibit by reset in PSU from CPU 887
24 L3C SYS: General protection error (G10) 887
25 L3C SYS: Total block 888
26 L1B SYS: Permanent inhibit fault active 889
27 L1B SYS: Regular inhibit fault active 889
28 L1A SYS: GW Test stopped by A/D converter faulty 890
30 L3C DSP A: Initialization fault detected by DSP 890
31 L3C DSP A: SW-WatchdoG 891
32 L3C DSP A: Initialization fault detected by CPU 892
33 L1B DSP A: SW-Traco triggered 892
34 L1B DSP A: SW-Traco full 893
35 L3C DSP A: Time slice overflow T1 894
36 L3C DSP A: Time slice overflow T2 894
37 L3C DSP A: Time slice overflow T3 894
38 L3C DSP A: Time slice overflow T4 894
39 L1A DSP A: Communication HSCX data from DSP B missing 895
40 L1A DSP A: Communication HSCX data from DSP T missing 895
41 L3C DSP A: Current offset during pulse block 896
42 L3C DSP A: Current offset during no pulse block 896
43 L3A DSP A: Overcurrent fault 897
44 L3C DSP A: Current transducer defective phase U 898
45 L3C DSP A: Current transducer defective phase W 899
48 L1A DSP A: Modulation software fault 899
49 L3A DSP A: Active current controller at limit 900
Drive system fault code table, part 2 903
50 L3A DSP A: Active current reference at limit 906
51 L1A DSP A: Braking chopper controller at limit 906
52 L3C DSP A: Phase unbalance too large 907
53 L3A DSP A: Pulse block by DSP software 908
54 L3C DSP A: U/F Card defective 908
55 L3C DSP A: Difference in current of phase U over limit 909
56 L3C DSP A: Difference in current of phase W over limit 909
60 L3C DSP B: Initialization fault detected by DSP 910
61 L3C DSP B: SW-Watchdog 910
62 L3C DSP B: Initialization fault detected by CPU 911
63 L1B DSP B: SW-Traco triggered 911
64 L1B DSP B: SW-Traco full 912
65 L3C DSP B: Time slice overflow T1 912
69 L1A DSP B: Communication HSCX data from DSP A missing 913
70 L1A DSP B: Communication HSCX data from DSP T missing 913
71 L3C DSP B: Current offset during pulse block 914
72 L3C DSP B: Current offset during no pulse block 914
73 L3A DSP B: Overcurrent fault 915
74 L3C DSP B: Current transducer defective phase V 916
75 L3C DSP B: Current transducer defective phase W 917
78 L1A DSP B: Modulation software fault 917
79 L3A DSP B: Active current controller at limit 918
80 L3A DSP B: Active current reference at limit 918
81 L1A DSP B: Braking chopper controller at limit 918
82 L3C DSP B: Phase unbalance too large 919
83 L3A DSP B: Pulse block by DSP software 919
84 L3C DSP B: U/F Card defective 920
85 L3C DSP B: Difference in current of phase V over limit 920
86 L3C DSP B: Difference in current of phase W over limit 921
90 L3C DSP T: Initialization fault detected by DSP 921
91 L3C DSP T: SW-Watchdog 922
92 L3C DSP T: Initialization fault detected by CPU 923
93 L1B DSP T: SW-Traco triggered 923
94 L1B DSP T: SW-Traco full 924
95 L3C DSP T: Time slice overflow T1 924
96 L3C DSP T: Time slice overflow T2 924
97 L3C DSP T: Time slice overflow T3 924
98 L3C DSP T: Time slice overflow T4 924
99 L1A DSP T: Communication HSCX data from DSP A missing 925
Drive system fault code table, part 3 927
100 L1A DSP T: Communication HSCX data from DSP B missing 930
101 L3C DSP T: Current offset during pulse block 930
102 L3C DSP T: Current offset during no pulse block 931
103 L3A DSP T: Overcurrent fault 932
104 L3C DSP T: Current transducer defective phase U 933
105 L3C DSP T: Current transducer defective phase V 934
106 L3C DSP T: Current transducer defective phase W 935
107 L3C DSP T: Sum of output current not equal zero 936
108 L1A DSP T: Modulation software fault 936
109 L1A DSP T: Voltage controller at limit 937
112 L3C DSP T: Phase unbalance too large 937
113 L3A DSP T: Pulse block by DSP software 938
114 L3C DSP T: U/F Card defective 938
117 L3C DSP T: Crowbar fired by DSP T 939
119 L1C DSP T: Voltage transducer U34 not ok 940
120 L3C IO: Supervision bus clock 940
121 L3C IO: Supervision I/O clock 941
122 L3C IO: Incorrect FPGA version identifier 941
123 L3C IO: Incorrect FPGA application version identifier 942
124 L3C IO: Incorrect module version identifier 942
125 L3C/L1A IO: AD Converter faulty 943
126 L3C IO: GW Comparator faulty during start-up test 943
127 L3C IO: Test voltage not equal zero 944
128 L1A IO: SIBAS® Temperature out of range 944
129 L3C IO: Incorrect EBIN card identifier 945
130 L3C IO: Front plug monitoring 946
131 L3C IO: CPU Watchdog triggered 947
132 L3C IO: DSP A Watchdog triggered 947
133 L3C IO: DSP B Watchdog triggered 948
134 L3C IO: DSP T Watchdog triggered 948
135 L3C IO: CPU Reset triggered 949
138 L1B IO: CPU Traco triggered 949
146 L3A IO: Pulse block from I/O 950
150 L3A IO: DC link voltage A level 1 exceeded 950
151 L3A IO: DC link voltage B level 1 exceeded 951
152 L3C IO: Trolley line overvoltage 952
154 L3B IO: Trolley line overcurrent 953
155 L2B IO: Trolley line current transducer faulty 953
156 L2B IO: Trolley line voltage transducer faulty 954
160 L3A IO: Throttle pedal out of range 954
161 L3A IO: Retard pedal out of range 955
162 L1A IO: Cruise speed control module out of range 955
180 L3C UWSA1: Supervision bus clock 956
181 L3C UWSA1: Supervision module clock 956
182 L3C UWSA1: Incorrect FPGA version identifier 957
183 L3C UWSA1: Incorrect FPGA project identifier 957
184 L3C UWSA1: GW Comparator faulty during start-up test 958
185 L1A UWSA1: ADC Faulty 958
186 L3C UWSA1: Configuration failure 959
187 L1A UWSA1: Hardware failure counter / processor 959
188 L3A UWSA1: Peak current protection active 960
189 L3D UWSA1: Peak current protection pulse start 961
190 L3D UWSA1: Number of peak current protection >limit 962
191 L3D UWSA1: Supervision switching frequency 963
193 L1A UWSA1: Overvoltage level 1 exceeded 963
196 L3D UWSA1: Limit 5 overcurrent phase U 964
197 L3D UWSA1: Limit 5 overcurrent phase V 964
198 L3D UWSA1: Limit 5 overcurrent phase W 964
199 L3D UWSA1: Limit 5 overvoltage DC bus 965
Drive system fault code table, part 4 967
201 L3D UWSA1: Checkback INVA1 L1U faulty 971
202 L3D UWSA1: Checkback INVA1 L1L faulty 971
203 L3D UWSA1: Checkback INVA1 L2U faulty 971
204 L3D UWSA1: Checkback INVA1 L2L faulty 971
205 L3D UWSA1: Checkback INVA1 L3U faulty 971
206 L3D UWSA1: Checkback INVA1 L3L faulty 971
207 L3D UWSA1: Checkback chopper A faulty 971
210 L3C UWSB1: Supervision bus clock 972
211 L3C UWSB1: Supervision module clock 972
212 L3C UWSB1: Incorrect FPGA version identifier 973
213 L3C UWSB1: Incorrect FPGA project identifier 973
214 L3C UWSB1: GW Comparator faulty during start-up test 974
215 L1A UWSB1: ADC Faulty 974
216 L3C UWSB1: Configuration failure 975
217 L1A UWSB1: Hardware failure counter / processor 975
218 L3A UWSB1: Peak current protection active 976
219 L3D UWSB1: Peak current protection pulse start 977
220 L3D UWSB1: Number of peak current protection >limit 978
221 L3D UWSB1: Supervision switching frequency 979
223 L1A UWSB1: Overvoltage level 1 exceeded 979
226 L3D UWSB1: Limit 5 overcurrent phase V 980
227 L3D UWSB1: Limit 5 overcurrent phase U 980
228 L3D UWSB1: Limit 5 overcurrent phase W 980
229 L3D UWSB1: Limit 5 overvoltage DC bus 981
231 L3D UWSB1: Checkback INVB1 L1U Faulty 982
232 L3D UWSB1: Checkback INVB1 L1L Faulty 982
233 L3D UWSB1: Checkback INVB1 L2U Faulty 982
234 L3D UWSB1: Checkback INVB1 L2L Faulty 982
235 L3D UWSB1: Checkback INVB1 L3U Faulty 982
236 L3D UWSB1: Checkback INVB1 L3L Faulty 982
237 L3D UWSB1: Checkback chopper B Faulty 982
240 L3C UWSA2: Supervision bus clock 983
241 L3C UWSA2: Supervision module clock 983
242 L3C UWSA2: Incorrect FPGA version identifier 984
243 L3C UWSA2: Incorrect FPGA project identifier 984
244 L3C UWSA2: GW Comparator faulty during start-up test 985
245 L1A UWSA2: ADC Faulty 985
246 L3C UWSA2: Configuration failure 986
247 L1A UWSA2: Hardware failure counter / processor 986
248 L3A UWSA2: Peak current protection active 987
249 L3D UWSA2: Peak current protection pulse start 988
250 L3D UWSA2: Number of peak current protection >limit 989
251 L3D UWSA2: Supervision switching frequency 990
253 L1A UWSA2: Overvoltage level 1 exceeded 990
256 L3D UWSA2: Limit 5 overcurrent phase U1 991
257 L3D UWSA2: Limit 5 overcurrent phase V1 991
258 L3D UWSA2: Limit 5 overcurrent phase W1 991
259 L3D UWSA2: Limit 5 overvoltage DC bus 992
261 L3D UWSA2: Checkback INVA2 L1U faulty 993
262 L3D UWSA2: Checkback INVA2 L1L faulty 993
263 L3D UWSA2: Checkback INVA2 L2U faulty 993
264 L3D UWSA2: Checkback INVA2 L2L faulty 993
265 L3D UWSA2: Checkback INVA2 L3U faulty 993
266 L3D UWSA2: Checkback INVA2 L3L faulty 993
267 L3D UWSA2: Checkback chopper C faulty 993
270 L3C UWSB2: Supervision bus clock 994
271 L3C UWSB2: Supervision module clock 994
272 L3C UWSB2: Incorrect FPGA version identifier 995
273 L3C UWSB2: Incorrect FPGA project identifier 995
274 L3C UWSB2: GW Comparator faulty during start-up test 996
275 L1A UWSB2: ADC Faulty 996
276 L3C UWSB2: Configuration failure 997
277 L1A UWSB2: Hardware failure counter / processor 997
278 L3A UWSB2: Peak current protection active 998
279 L3D UWSB2: Peak current protection pulse start 999
280 L3D UWSB2: Number of peak current protection >limit 1000
281 L3D UWSB2: Supervision switching frequency 1001
283 L1A UWSB2: Overvoltage level 1 exceeded 1001
286 L3D UWSB2: Limit 5 overcurrent phase V1 1002
287 L3D UWSB2: Limit 5 overcurrent phase U1 1002
288 L3D UWSB2: Limit 5 overcurrent phase W1 1002
289 L3D UWSB2: Limit 5 overvoltage DC bus 1003
291 L3D UWSB2: Checkback INVB2 L1U Faulty 1004
292 L3D UWSB2: Checkback INVB2 L1L Faulty 1004
293 L3D UWSB2: Checkback INVB2 L2U Faulty 1004
294 L3D UWSB2: Checkback INVB2 L2L Faulty 1004
295 L3D UWSB2: Checkback INVB2 L3U Faulty 1004
296 L3D UWSB2: Checkback INVB2 L3L Faulty 1004
297 L3D UWSB2: Checkback chopper D Faulty 1004
Drive system fault code table, part 5 1007
300 L3C UWSST: Supervision bus clock 1011
301 L3C UWSST: Supervision module clock 1011
302 L3C UWSST: Incorrect FPGA version identifier 1012
303 L3C UWSST: Incorrect FPGA project identifieR 1012
304 L3C UWSST: GW Comparator faulty during start-up test 1013
305 L1A UWSST: ADC Faulty 1013
306 L3C UWSST: Configuration failure 1014
307 L1A UWSST: Hardware failure counter / processor 1014
308 L3A UWSST: Peak current protection active 1015
310 L3D UWSST: Number of peak current protection >limit 1016
311 L3D UWSST: Supervision switching frequency 1017
314 L3C UWSST: Crowbar is fired without command 1018
319 L3D UWSST: Limit 5 overvoltage DC bus 1020
321 L3D UWSST: Checkback INVST L1U Faulty 1021
322 L3D UWSST: Checkback INVST L1L Faulty 1021
323 L3D UWSST: Checkback INVST L2U Faulty 1021
324 L3D UWSST: Checkback INVST L2L Faulty 1021
325 L3D UWSST: Checkback INVST L3U Faulty 1021
326 L3D UWSST: Checkback INVST L3L Faulty 1021
327 L3C UWSST: Checkback crowbar faulty 1022
330 L1A BUS: CAN Communication failure 1023
331 L1A BUS: Serial link communication failure 1023
332 L1A BUS: Truck is over loaded 1023
333 L1B TR: Transient traco is triggered 1024
334 L1B TR: Transient traco is full 1024
340 L1A ETM: ADC Failure for ETM1 1024
341 L1A ETM: ADC Failure for ETM2 1025
342 L1A ETM: ADC Failure for ETM3 1025
343 L1A ETM: ADC Failure for ETM4 1025
344 L1A MEFA: ADC Failure 1026
345 L3C HL: Gate unit power supply A defective 1026
346 L3C HL: Gate unit power supply B defective 1027
351 L1A DRZ: LIMP Mode A active 1028
352 L1A DRZ: Limp mode B active 1028
353 L1A DRZ: Low battery voltage 1029
354 L1B BUS: Engine floor input increasing minimum engine speed 1029
355 L1B DM: Data store switch pressed 1030
356 L1B DM: Diagnosis memory configuration failure 1030
357 L1B DM: Diagnosis memory occupation > 75% 1030
358 L1B DM: Diagnosis memory full 1031
359 L1B DM: Test event 1031
360 L2A EXT: Main blower air flow supervision 1032
361 L2A EXT: Minimum engine speed supervision 1033
362 L1A EXT: Main blower pressure switch malfunction 1034
363 L1A EXT: Shift lever supervision 1035
364 L2A EXT: Engine derate protection active 1036
365 L1A EXT: Truck external plug monitoring 1036
367 L3A EXT: DC Power off mod request (rest switch on) 1037
369 L1A EXT: Doppler sensor defective 1039
370 L1A EXT: Auto lube control defective 1040
372 L1A EXT: Service brake pressed at high speeD 1040
373 L1A EXT: Service brake on above speed limit 1041
374 L1A EXT: Anti-roll control malfunction 1041
375 L3B BEF: CB301 Circuit breaker defective 1042
376 L3B BEF: K303/K304 Contactor defective 1043
377 L3C STP: Voltage reading incorrect between trolley line and voltage in stepdown box 1044
382 L3B BEF: K103 Feedback defective 1045
383 L3B BEF: K105 Feedback defective 1045
384 L1A BEF: K107 Feedback defective 1046
385 L1A BEF: K109 Feedback defective 1046
386 L1A BEF: K111 Feedback defective 1047
387 L1A BEF: Limp mode selector defective 1047
388 L2B BEF: CB113 Tripped 1048
390 L3D IUW: Output current supervision INV A 1048
391 L3D IUW: Output current supervision INV B 1049
392 L3B IUW: Precharge supervision 1 1050
393 L3B IUW: Precharge supervision 2 1051
394 L3A IUW: DC Link undervoltage 1052
395 L2B IUW: Trolley line undervoltage 1053
397 L3B IUW: Field regulator current setpoint supervision 1054
398 L2B IUW: Field regulator output current supervision 1055
399 L3B IUW: Alternator overcurrent protection 1056
Drive system fault code table, part 6 1059
400 L2C IUW: Alternator overload warning 1062
401 L2B IUW: Alternator overload protection 1062
402 L3C IUW: Alternator AC current sensor faulty 1063
403 L2A IUW: DC Link voltage out of range in propel 1064
404 L3A IUW: DC Link voltage out of range retard 1065
405 L3A IUW: DC Link voltage out of range for ST operation 1066
406 L3B IUW: DC Link controller supervision 1067
407 L2C IUW: Motor torque square T supervision 1068
408 L2C IUW: Motor current square T supervision 1068
409 L1A IUW: DC Link discharge time exceeded limit 1069
410 L2B IUW: Ground fault at positive DC link detected 1070
411 L2B IUW: Ground fault at negative DC link detected 1071
412 L2B IUW: Ground fault at AC side detected 1072
413 L2B IUW: Ground fault 1073
414 L3C IUW: Chopper A current supervision 1074
415 L3C IUW: Chopper B current supervision 1075
416 L3C IUW: Chopper C current supervision 1076
417 L3C IUW: Chopper D current supervision 1077
418 L3D IUW: Output current supervision INV ST 1078
419 L2A IUW: Vehicle overspeed supervisioN 1079
420 L1A IUW: DC Link voltage sensor A faulty 1080
421 L1A IUW: DC Link voltage sensor B faulty 1081
422 L3C IUW: ST Inverter failure 1082
423 L3B IUW: DC Grid fan circuit failure 1082
424 L2B IUW: Cooling water pressure out of range 1083
425 L2B IUW: Cooling water level out of range 1084
426 L1A IUW: Water pump motor overtemperature 1085
427 L1A IUW: Retard limit supervision 1085
428 L1A DRZ: Front wheel A speed sensor supervision 1086
429 L1A DRZ: Front wheel B speed sensor supervision 1087
430 L3D DRZ: Motor A speed sensor supervision 1088
431 L3D DRZ: Motor B speed sensor supervision 1089
432 L3C DRZ: Alternator speed sensor supervision 1090
433 L2A DRZ: Motor A maximum speed exceeded 1091
434 L2A DRZ: Motor B maximum speed exceeded 1091
435 L1A DRZ: Alternator maximum speed exceeded 1092
436 L3A DRZ: Motor A/B rotation inconsistency 1093
437 L3A DRZ: Motor A torque supervision 1094
438 L3A DRZ: Motor B torque supervision 1095
439 L3C SIV: Start-up sequence can’t pass due to GUPS failure 1096
440 L3C SIV: Start-up sequence can’t pass due to K103/K105 failure 1097
441 L3C SIV: Start-up sequence can’t pass due to IGBT failure 1098
442 L3C SIV: Start-up sequence can’t pass due to CB301 OR K303 failure 1099
443 L3C SIV: Start-up sequence can’t pass due to crowbar failure 1100
447 L1A SIV: Direct trolley engage sequence supervision 1101
448 L1A SIV: Direct trolley disengage sequence supervision 1102
Drive system fault code table, part 7 1105
450 L1A TMP: SIBAS® Temperature < low limit 1109
451 L1A TMP: SIBAS® Temperature > warning limit 1109
452 L3B TMP: SIBAS® Temperature > shutdown limit 1110
453 L3A TMP: IGBT Module A101 temperature < low limit 1111
454 L2C TMP: IGBT Module A101 temperature > APRS limit 1112
455 L3A TMP: IGBT Module A101 temperature > shutdown limit 1113
456 L3A TMP: IGBT Module A102 temperature < low limit 1114
457 L2C TMP: IGBT Module A102 temperature > APRS limit 1115
458 L3A TMP: IGBT Module A102 temperature > shutdown limit 1116
459 L3A TMP: IGBT ModulE A201 temperature < low limit 1117
460 L2C TMP: IGBT Module A201 temperature > APRS limit 1118
461 L3A TMP: IGBT Module A201 temperature > shutdown limit 1119
462 L3A TMP: IGBT Module A202 temperature < low limit 1120
463 L2C TMP: IGBT Module A202 temperature > APRS limit 1121
464 L3A TMP: IGBT Module A202 temperature >shutdown limit 1122
465 L3A TMP: ST Module temperature < low limit 1123
466 L2C TMP: ST Module temperature > warning limit 1124
467 L3A TMP: ST Module temperature > shutdown limit 1125
468 L2B TMP: SR Module temperature < low limit 1126
469 L2C TMP: SR Module temperature > warning limit 1127
470 L2B TMP: SR Module temperature > shutdown limit 1128
471 L2C TMP: Wheel motor A stator temperature > APRS limit 1129
472 L3A TMP: Wheel motor A stator temperature > shutdown limit 1130
473 L2C TMP: Wheel motor B Stator temperature > APRS limit 1131
474 L3A TMP: Wheel motor B stator temperature shutdown limit 1132
475 L2C TMP: Wheel motor A, DE bearing temperature > warning limit 1133
476 L3A TMP: Wheel motor A, DE bearing temperature > shutdown limit 1134
477 L2C TMP: Wheel motor A NDE bearing temperature > warning limit 1135
478 L3A TMP: Wheel motor A NDE bearing temperature > shutdown limit 1136
479 L2C TMP: Wheel motor B DE bearing temperature > warning limit 1137
480 L3A TMP: Wheel motor B DE bearing temperature > shutdown limit 1138
481 L2C TMP: Wheel motor B NDE bearing temperature > warning limit 1139
482 L3A TMP: Wheel motor B NDE bearing temperature > shutdown limit 1140
483 L2C TMP: Alternator stator temperature > APRS limit 1141
484 L2B TMP: Alternator stator temperature > shutdown limit 1142
485 L2C TMP: Alternator bearing temperature > warning limit 1143
486 L2B TMP: Alternator bearing temperature > shutdown limit 1144
487 L1A TMP: Cooling water inlet temperature < low limit 1145
488 L2C TMP: Cooling water inlet temperature > warning limit 1146
489 L2B TMP: Cooling water inlet temperature > shutdown limit 1147
490 L1A TMP: Cooling water outlet temperature < low limit 1148
491 L2C TMP: Cooling water outlet temperature > warning limit 1149
492 L2B TMP: Cooling water outlet temperature > shutdown limit 1150
493 L1A TMP: Cooling water delta T too high 1151
495 L2C TMP: Inverter cab temperature > warning limit 1152
496 L2B TMP: Inverter cab temperature > shutdown limit 1153
497 L2C TMP: Inside cooler outlet temperature > warning limit 1154
498 L2B TMP: Inside cooler outlet temperature > shutdown limit 1155
499 L1A TMP: Main blower motor stator temperature > warning limit 1156
500 L1A TMP: Main blower motor stator temperature > shutdown limit 1157
505 L1A TMP: Wheel motor A rotor temperature > limit 1158
506 L1A TMP: Wheel motor B rotor temperature > limit 1159
508 L1A ETM1: Alternator PT100 open circuit 1160
509 L1A ETM1: Main blower stator PT100 open circuit 1160
510 L1A ETM1: Grid blower statoR PT100 open circuit 1160
511 L1A ETM1: Inverter CAB PT100 open circuit 1160
512 L1A ETM1: Ambient PT100 open circuit 1160
513 L1A ETM1: Heater exchanger PT100 open circuit 1160
514 L1A ETM1: Cooling water inlet PT100 open circuit 1160
515 L1A ETM1: Cooling water outlet PT100 open circuit 1160
516 L1A ETM2: Motor A NDE Bearing PT100 open circuit 1161
517 L1A ETM2: Motor A DE Bearing PT100 open circuit 1161
518 L1A ETM2: Motor B NDE Bearing PT100 open circuit 1161
519 L1A ETM2: Motor B DE Bearing PT100 open circuit 1161
520 L1A ETM2: Alternator Bearing PT100 open circuit 1161
521 L1A ETM2: Motor A stator PT100 open circuit 1161
522 L1A ETM2: Motor B stator PT100 open circuit 1161
523 L1A ETM2: Motor inlet air PT100 open circuit 1161
524 L1A ETM3: IGBT Module A101 PT100 open circuit 1162
525 L1A ETM3: IGBT Module A102 PT100 open circuit 1162
526 L1A ETM3: IGBT Module A103 PT100 open circuit 1162
527 L1A ETM3: IGBT Module A104 PT100 open circuit 1162
528 L1A ETM3: IGBT Module A201 PT100 open circuit 1162
529 L1A ETM3: IGBT Module A202 PT100 open circuit 1162
530 L1A ETM3: IGBT Module A203 PT100 open circuit 1162
531 L1A ETM3: IGBT Module A204 PT100 open circuit 1162
532 L1A ETM3: ST Module PT100 open circuit 1163
533 L1A ETM3: SR Module PT100 open circuit 1163
534 L1A ETM3: Channel 7 PT100 open circuit 1163
535 L1A ETM3: Channel 8 PT100 open circuit 1163
536 L1A ETM4: Channel 1 PT100 open circuit 1164
537 L1A ETM4: Channel 2 PT100 open circuit 1164
538 L1A ETM4: Channel 3 PT100 open circuit 1164
539 L1A ETM4: Channel 4 PT100 open circuit 1164
540 L1A ETM4: Channel 5 PT100 open circuit 1164
541 L1A ETM4: Channel 6 PT100 open circuit 1164
542 L1A ETM4: Channel 7 PT100 open circuit 1164
543 L1A ETM4: Channel 8 PT100 open circuit 1164
544 L1A ETM4: SR Module PT100 open circuit 1164
550 L3A TMP: Inverter A module temperature < low limit 1165
551 L2C TMP: Inverter A module temperature > APRS limit 1166
552 L3A TMP: Inverter A module temperature > shutdown limit 1167
553 L3A TMP: Inverter B module temperature < low limit 1168
554 L2C TMP: Inverter B module temperature > APRS limit 1169
555 L3A TMP: Inverter B module temperature > shutdown limit 1170
556 L3A TMP: Chopper A module temperature < low limit 1171
557 L2C TMP: Chopper A module temperature > APRS limit 1172
558 L3A TMP: Chopper A module temperature > shutdown limit 1173
559 L3A TMP: Chopper B module temperature < low limit 1174
560 L2C TMP: Chopper B module temperature > APRS limit 1175
561 L3A TMP: Chopper B module temperature > shutdown limit 1176
Cab air conditioning 1179
Preliminary checks 1181
Diagnosis of gauge readings and system performance 1181
Troubleshooting by manifold gauge set readings 1182
Reserve engine oil system 1189
Pumping unit LED signals 1191
Circuit fuses 1191
Steering system 1193
Steering circuit troubleshooting chart 1195
Steering circuit troubleshooting guidelines 1197
Basic hydraulic system checks 1198
System leakage check 1199
Steering pump troubleshooting guide 1201
Pump pressure control checks 1204
Pump fails to unload 1205
Pump fails to develop pressure 1205
Pump slow in developing pressure 1206
Pump control valve inspection and trouble shooting 1206
Pump case drain check 1208
Setting pump pressure controls 1208
50 Disassembly and assembly 1211
General information 1211
Special tool list 1213
Wheels, spindles and rear axle 1215
General precautions for tires and rims 1217
Rim components 1218
Wheel stud maintenance 1219
Removal and installation of front wheel 1219
Removal 1219
Installation 1220
Removal and installation of rear wheel 1221
Removal 1221
Installation 1222
Removal and installation of tires 1224
Installation 1224
Removal and installation of front wheel hub and spindle 1226
Removal 1226
Installation 1229
Disassembly and assembly of front wheel hub and spindle 1230
Disassembly 1230
Cleaning and inspection 1230
Assembly 1232
Wheel bearing adjustment 1232
Seal assembly gap check and adjustment 1233
Brake installation 1234
Speed sensor installation and adjustment 1234
Removal and installation of wheel motor 1235
Preparation 1235
Removal 1235
Cleaning and inspection 1237
Installation 1237
Removal and installation of electric motor 1241
Removal 1241
Installation 1241
Disassembly and assembly of wheel motor transmission 1242
Disassembly 1242
Cleaning and inspection 1249
Assembly 1250
Disassembly and assembly of low speed carrier 1261
Disassembly 1261
Inspection 1262
Assembly 1263
Disassembly and assembly of high speed carrier 1266
Disassembly 1266
Inspection 1267
Assembly 1268
Removal and installation of rear axle 1271
Removal 1271
Cleaning and inspection 1272
Installation 1272
Removal and installation of anti-sway bar 1273
Removal 1273
Installation 1274
Removal and installation of pivot pin 1275
Removal 1275
Installation 1275
Pivot eye and bearing service 1276
Bearing removal 1276
Bearing installation 1276
Pivot eye repair 1277
Brake system 1279
Removal and installation of brake valve 1281
Removal 1281
Installation 1282
Disassembly and assembly of brake valve/pedal assembly 1282
Disassembly 1282
Assembly 1283
Removal and installation of dual relay valve 1285
Removal 1285
Installation 1287
Removal and installation of brake manifold 1287
Removal 1287
Installation 1288
Disassembly and assembly of brake manifold 1288
Disassembly 1288
Assembly 1288
Removal and installation of brake accumulator 1289
Removal 1289
Installation 1290
Disassembly and assembly of brake accumulator 1290
Disassembly 1290
Cleaning and inspection 1292
Assembly 1292
Disassembly and assembly of wheel brake 1294
Disassembly 1295
Cleaning and inspection 1298
Assembly 1299
Floating ring seal assembly and installation 1302
Removal and installation of rear brake assembly 1310
Removal 1310
Installation 1310
Removal and installation of parking brake 1312
Removal 1312
Installation 1314
Disassembly and assembly of parking brake 1314
Disassembly 1314
Cleaning and inspection 1315
Assembly 1317
Cleaning and inspecting new discs 1319
Steering system 1321
Removal and installation of steering control unit 1323
Removal 1323
Installation 1324
Disassembly and assembly of steering control unit 1325
Disassembly 1325
Assembly 1327
Removal and installation of steering column 1330
Removal 1330
Inspection 1330
Installation 1331
Removal and installation of steering wheel 1331
Removal 1331
Installation 1332
Removal and installation of bleeddown manifold 1332
Removal 1333
Installation 1334
Removal and installation of flow amplifier 1335
Removal 1335
Installation 1335
Disassembly and assembly of flow amplifier 1335
Disassembly 1335
Assembly 1337
Removal and installation of steering cylinders and tie rod 1338
Removal 1338
Bearing replacement 1338
Installation 1338
Disassembly and assembly of steering cylinders 1339
Disassembly 1339
Assembly 1340
Removal and installation of steering/brake pump 1340
Removal 1340
Installation 1341
Disassembly and assembly of steering/brake pump 1343
Disassembly 1343
Inspection 1346
Assembly 1349
Driveshaft group 1349
Rotating group 1350
Removal and installation of bladder style steering accumulators 1353
Removal 1353
Installation 1353
Disassembly and assembly of bladder style steering accumulators 1354
Disassembly 1354
Cleaning and Inspection 1354
Bladder accumulator assembly 1355
Removal and installation of piston style steering accumulators 1357
Removal 1357
Installation 1358
Disassembly and assembly of piston accumulators 1359
Disassembly 1359
Cleaning and Inspection 1359
Assembly 1360
Testing 1360
Suspensions 1363
Removal and installation of front suspension 1365
Removal 1365
Installation 1366
Inspection 1369
Minor front suspension repairs (lower bearing and seals) 1372
Lower bearing retainer removal 1372
Lower bearing retainer installation 1372
Major front suspension rebuild 1373
Disassembly 1373
Assembly 1374
Removal and installation of rear suspension 1376
Removal 1377
Installation 1379
Disassembly and assembly of rear suspension 1379
Disassembly 1379
Cleaning and Inspection 1380
Assembly 1380
Hoist circuit 1383
Removal and installation of hoist pump 1385
Removal 1385
Installation 1386
Disassembly and assembly of hoist pump 1387
Disassembly 1387
Inspection 1390
Assembly 1390
Removal and installation of hoist valve 1395
Removal 1395
Installation 1396
Disassembly and assembly of hoist valve 1396
O-ring replacement 1396
Disassembly of inlet section 1397
Assembly of inlet section 1398
Disassembly of rear spool section 1398
Assembly of rear spool section 1401
Disassembly of front spool section 1402
Assembly of front spool section 1403
Overcenter valve manifold service 1403
Removal and installation of hoist pilot valve 1404
Removal 1404
Installation 1404
Disassembly and assembly of hoist pilot valve 1405
Disassembly 1405
Cleaning and inspection 1406
Assembly 1406
Removal and installation of hoist cylinders 1407
Removal 1407
Installation 1408
Disassembly and assembly of hoist cylinders 1409
Disassembly 1409
Cleaning and inspection 1411
Installation of the quill 1412
Assembly 1414
Operator cab 1417
Removal and installation of operator cab 1419
Removal 1420
Installation 1421
Removal and installation of cab door 1422
Removal 1422
Installation 1422
Disassembly and assembly of cab door 1422
Removing door panel 1422
Installing door panel 1423
Replacing the door window regulator 1423
Replacing door handle or latch assembly 1424
Replacing door assembly seal and door hinge seal 1425
Replacing door opening seal 1425
Removing door glass 1426
Installing door glass 1428
Adjustment of cab door 1429
Door jamb bolt adjustment 1429
Door handle plunger adjustment 1431
Removal and installation of side window glass 1432
Recommended tools and supplies 1432
Removal 1432
Installation 1432
Removal and installation of windshield and rear window glass 1433
Removal 1433
Installation 1433
Removal and installation of windshield wiper motor 1435
Removal 1435
Installation 1435
Removal and installation of windshield wiper arm 1436
Removal 1436
Installation 1436
Removal and installation of windshield wiper linkage 1436
Removal 1436
Installation 1437
Removal and installation of operator seat 1437
Inspection 1437
Removal 1437
Installation 1437
Replacing the Seat Compressor 1438
Removal and installation of passenger seat 1443
Removal 1443
Installation 1443
Removal and installation of seat belts (standard seats) 1444
Removal 1444
Installation 1444
Removal and installation of seat belts (optional seats) 1446
General 1446
Removal 1446
Installation 1448
Body and structures 1451
Removal and installation of dump body 1453
Removal 1453
Inspection 1454
Installation 1455
Removal and installation of body pads 1455
Removal 1455
Installation 1456
Body pad shimming procedure 1457
Removal and installation of diagonal ladder/ hood and grille assembly 1458
Removal 1458
Installation 1458
Removal and installation of right deck 1459
Removal 1459
Installation 1460
Removal and installation of left deck 1461
Removal 1461
Installation 1461
Removal and installation of fuel tank 1463
Removal 1463
Cleaning and inspection 1463
Installation 1465
Removal and installation of fuel gauge sender (S/N A50003 – A50011) 1465
Removal 1465
Installation 1465
Removal and installation of fuel gauge sender (S/N A50012 & up) 1465
Removal 1465
Installation 1465
Disassembly and assembly of fuel tank breather 1466
Disassembly 1466
Assembly 1466
Removal and installation of hydraulic tank 1467
Removal 1467
Installation 1467
Cab air conditioning 1469
Replacement of air conditioning system components 1471
Hoses and fittings 1471
Lines 1471
Expansion valve 1471
Receiver-drier 1471
Thermostat 1471
Compressor 1472
Accumulator 1472
Clutch 1472
Power module 1475
Removal and installation of power module 1477
General 1477
Preparation 1477
Removal 1478
Installation 1483
Exhaust tube installation 1485
Exhaust blanket installation 1485
Removal and installation of alternator 1486
Removal 1486
Installation 1488
Removal and installation of engine 1492
Removal 1492
Service 1492
Installation 1492
Removal and installation of radiator 1493
Removal 1493
Installation 1495
Repairing the radiator 1496
Internal inspection 1496
External cleaning 1496
Disassembly 1497
Cleaning and inspection 1498
Assembly 1498
Pressure testing 1499
Automatic lubrication (autolube) system 1501
Lubrication system priming 1503
Disassembly and assembly of lubrication pump 1503
Disassembly 1503
Cleaning and Inspection 1506
Assembly 1506
Three phase wheel motor 1509
General safety information 1511
Handling the motor 1512
Transport 1513
Storage 1514
Storage of new motors 1514
Storage of used motors 1514
Motor description 1515
Maintenance 1516
Safety guidelines 1516
Maintenance intervals 1517
Maintenance work on the installed motor 1517
Checking for external damage 1517
Checking the connections 1517
Checking the interior of the motor for water 1517
Regreasing the bearings 1518
Applying grease to the bearings 1518
Checking the interior of the motor for water 1519
Disassembling the motor 1520
Removing the coupling 1521
Disassembling the rotor 1523
Removing the rubber seals and the air baffles 1527
Removing the bearing and labyrinth ring 1528
Maintenance work 1529
Cleaning 1529
Stator inspection 1529
Rotor inspection 1529
Testing the insulation 1530
High-voltage test 1530
Work on the bearings 1531
Assembling the motor 1532
Important general instructions 1532
Assembling the rubber seals and the air baffles 1533
Assembly after special repair work 1535
Bearing installation (D-end) 1536
Assembling the bearing 1536
Installing the cover 1538
Bearing installation (N-end) 1539
Assembling the bearing 1539
Installing the cover 1541
Assembling the bearing shield (N-end) at the stator frame 1542
Installing the bearing 1544
Installing the rotor 1546
Installing the labyrinth ring 1548
Installing accessories (D- and N-end) 1550
Running in the bearings 1554
Installing the gear wheel 1555
Installing the coupling 1556
Assembly conditions and instructions 1557
Repairing the motor 1558
Replacing defective connecting leads 1558
Repairing the stator winding insulation 1559
Recommended consumables 1559
Chemical cleaning agents 1559
Generally approved cleaning agents 1559
Chemical cleaning agents for outdoor use and for cleaning mechanical parts 1560
Chemical cleaning agents for flange faces 1560
Chemical cleaning agents for windings 1560
Chemical cleaning agents for windings with severe damage and for oily windings 1560
Rolling-contact bearing grease 1561
Assembly/disassembly agents for bearing seat 1561
Sealants for joining parts or gaps 1561
Locking agents for connecting elements 1561
Anti-corrosion agent 1561
Assembly paste for temperature sensors 1561
Paints for refinishing the painted parts or touching up damaged parts 1561
Special tools 1562
Mounting devices for inserting and withdrawing the rotor horizontally 1562
Press for expanding the coupling 1562
Compression devices for pressing on or for support while pressing off 1563
Pulling units with cross beam or disk 1565
Aids 1565
Extraction devices 1565
Main blower 1567
Removing the main blower motor 1569
Disassembling the main blower motor 1575
Assembling the main blower motor 1577
Installing the main blower motor 1580
Retarding grid 1587
Removing the grid blower motor 1589
Disassembling the grid blower motor 1591
Assembling the grid blower motor 1593
Installing the grid blower motor 1595
Removing a grid element 1600
Control cabinet 1603
Removing the SIBAC Inverter Module 1605
Required tools/materials 1605
Removal 1608
Installing the SIBAC Inverter Module 1612
Draining and filling the IGBT coolant system 1613
Required tools/materials 1613
Coolant mixture specification (distilled water: Antifrogen® N) 1613
Draining and filling the coolant 1615
Removing and installing the IGBT coolant pump assembly 1618
Required tools/materials 1618
Removal 1619
90 Diagrams and drawings 1623
Hydraulic circuit diagrams 1623
Steering, hoist and brake cooling hydraulic circuit 1625
Brake hydraulic circuit 1626
Electrical circuit diagrams 1629
Electrical circuit 1631
Connectors table and arrangement drawing 1647
Electrical circuit diagrams – drive system 1650
Drive system electrical circuit 1652

DESCRIPTION:

Komatsu 960E-2K Dump Truck Shop Manual CEBM026302  – PDF DOWNLOAD

• SERIAL NUMBERS 960E-2K A50011 – A50027

• 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. NOTE: Accumulations of mud, frozen material, etc, become part of the GVW and reduces the allowable payload.
• To maximize payload and to keep from exceeding the maximum GVW rating, these accumulations should be removed as often as practical. Exceeding the allowable payload will reduce the expected life of truck components

G.B 20/12/24