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KOMATSU 960E-2K DUMP TRUCK SHOP REPAIR MANUAL SN A50011 & UP – PDF DOWNLOAD
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KOMATSU 960E-2K DUMP TRUCK SHOP REPAIR MANUAL
SERIAL NUMBERS : A50011 & UP
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Description
KOMATSU 960E-2K DUMP TRUCK SHOP REPAIR MANUAL
FILE DETAILS:
KOMATSU 960E-2K DUMP TRUCK SHOP REPAIR MANUAL
Language : English
Pages :1744
Downloadable : Yes
File Type : PDF
Size: 45.8 MB
Book Code: CEBM026301
KOMATSU 960E-2K DUMP TRUCK SHOP REPAIR MANUAL SN A50011 & UP – PDF DOWNLOAD:
DESCRIPTION:
KOMATSU 960E-2K 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-2K 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 24VDC Battery Charging Alternator......................................................................................... 173 Batteries................................................................................................................. 173 Engine Start Relays....................................................................................................... 173 24VDC Auxiliary Battery Receptacles....................................................................................... 173 Battery Disconnect Switches............................................................................................... 174 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 magnet)..................................................................... 180 Proximity switch operation................................................................................................ 180 Body-up Switch............................................................................................................ 181 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.............................................................................................................. 331 Standard value table for truck................................................................................................ 333 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 Interface module (IM)............................................................................................................. 415 Interface module software..................................................................................................... 416 Flashburn program installation............................................................................................ 416 Interface module application code installation............................................................................ 417 Interface module realtime data monitor software installation.............................................................. 417 Interface module checkout procedures.......................................................................................... 418 Necessary equipment....................................................................................................... 418 Preliminary............................................................................................................... 419 Check digital inputs to the interface module.............................................................................. 420 Check analog inputs to the interface module............................................................................... 423 Check serial interfaces to the interface module........................................................................... 424 Check outputs from the interface module................................................................................... 424 Cab air conditioning.............................................................................................................. 427 General information........................................................................................................... 428 Service tools and equipment................................................................................................... 429 Recovery/recycle station.................................................................................................. 429 Leak detector............................................................................................................. 429 Manifold gauge set........................................................................................................ 430 Service valves............................................................................................................ 431 Vacuum pump............................................................................................................... 431 Detecting leaks............................................................................................................... 432 System performance test....................................................................................................... 433 Checking system oil........................................................................................................... 434 System flushing............................................................................................................... 435 Installing the manifold gauge set............................................................................................. 436 Purging air from the service hoses........................................................................................ 436 Recovering and recycling refrigerant.......................................................................................... 437 Draining oil from previous recovery cycle................................................................................. 438 Recovery cycle............................................................................................................ 438 Recycling procedure....................................................................................................... 438 Evacuating the air conditioning system........................................................................................ 439 Charging the air conditioning system.......................................................................................... 440 IGBT haul truck SIBAS® user manual, part 1........................................................................................ 443 Abbreviations................................................................................................................. 445 Precautions................................................................................................................... 447 Qualified person.............................................................................................................. 447 Customer monitor for SIBAS® 32 control units.................................................................................. 447 Product description....................................................................................................... 447 Version management........................................................................................................ 448 Overview.................................................................................................................. 449 Requirements.............................................................................................................. 449 Installing and calling the customer monitor................................................................................... 450 Installation.................................................................................................................. 450 Environment variables..................................................................................................... 450 Communication with the SIBAS® 32 control unit................................................................................. 451 Calling up the customer monitor............................................................................................... 452 Start-up prompt........................................................................................................... 452 Monitor prompt............................................................................................................ 453 Notes on operation of the customer monitor.................................................................................... 454 Structure of a monitor command................................................................................................ 454 Step 1: Selecting the menu title.......................................................................................... 454 Step 2: Selecting a menu entry in the menu box............................................................................ 454 Step 3: Selecting a dialog box, if available.............................................................................. 455 Step 4: Entering file or connector/signal names........................................................................... 455 Command buffer................................................................................................................ 456 Structure of the monitor windows.............................................................................................. 456 Window menu................................................................................................................... 457 Commands for Opening, Altering and Closing Windows........................................................................ 457 "Window Work open"............................................................................................................ 457 "Window Lines open"........................................................................................................... 457 "Window Tile"................................................................................................................. 457 "Window Bars open"............................................................................................................ 457 Options................................................................................................................... 457 "Window Set".................................................................................................................. 457 Options................................................................................................................... 457 "Window Cascade".............................................................................................................. 457 "Window Close"................................................................................................................ 457 "Window close All"............................................................................................................ 457 "Window Exit"................................................................................................................. 457 Set Menu...................................................................................................................... 458 "Set Port".................................................................................................................... 458 Options................................................................................................................... 458 "Set Baudrate"................................................................................................................ 458 Options................................................................................................................... 458 "Set String".................................................................................................................. 459 Example................................................................................................................... 460 "Set Make".................................................................................................................... 460 Options................................................................................................................... 460 Example 1: INIT.MON start-up control of the Customer Monitor.............................................................. 461 Example 2: Any monitor batch file with freely selectable file name (incl. path)........................................... 461 "Set Execute"................................................................................................................. 462 Options................................................................................................................... 462 Example................................................................................................................... 462 "Set Record".................................................................................................................. 462 Options................................................................................................................... 462 "Set DIN-Bus"................................................................................................................. 463 "Set TCN"..................................................................................................................... 463 "Set Timeout"................................................................................................................. 463 Options................................................................................................................... 463 "Set Wait".................................................................................................................... 463 Options................................................................................................................... 463 "Set Color"................................................................................................................... 463 Options................................................................................................................... 463 "Set Info".................................................................................................................... 464 "Set comment"................................................................................................................. 464 "Set CHAR Set"................................................................................................................ 464 "Set Quit".................................................................................................................... 464 Applic. Menu.................................................................................................................. 465 "Applic. Func.Package"........................................................................................................ 465 "Applic. Connector"........................................................................................................... 466 Options................................................................................................................... 466 Example................................................................................................................... 467 "Applic. View"................................................................................................................ 467 Options................................................................................................................... 467 Example................................................................................................................... 467 "Applic. Signal".............................................................................................................. 467 "Applic. Observer"............................................................................................................ 468 Options................................................................................................................... 468 Possible time slices:..................................................................................................... 468 Options................................................................................................................... 469 Two options............................................................................................................... 469 Notes on the display of connectors........................................................................................ 471 "Applic. Buffer".............................................................................................................. 472 Options................................................................................................................... 472 "Applic. Report".............................................................................................................. 472 "Applic. Legitimation"........................................................................................................ 472 Options................................................................................................................... 472 "Applic. Menu"................................................................................................................ 473 "Applic. Traco"............................................................................................................... 473 Options................................................................................................................... 473 "Applic. Environment"......................................................................................................... 473 Hardw. Menu................................................................................................................... 475 Hardware-Oriented Access via the Customer Monitor......................................................................... 475 "Hardw. Flash"................................................................................................................ 475 Options................................................................................................................... 475 Requirements.............................................................................................................. 475 Example................................................................................................................... 476 Deleting and loading...................................................................................................... 476 The EPROM for the communication drivers................................................................................... 476 "Hardw. Clock"................................................................................................................ 476 Options................................................................................................................... 476 "Hardw. DSP".................................................................................................................. 477 "Hardw. BCD".................................................................................................................. 477 Options................................................................................................................... 477 Example................................................................................................................... 477 "Hardw. RESET"................................................................................................................ 477 Options................................................................................................................... 477 "Hardw. Info"................................................................................................................. 478 Hardware/Operating system................................................................................................. 478 Application and tools..................................................................................................... 478 Communication module...................................................................................................... 478 Displaying the loading date............................................................................................... 478 "Hardw. User Flash"........................................................................................................... 479 Options................................................................................................................... 479 "Hardw. Sys. Flash"........................................................................................................... 479 Options................................................................................................................... 479 "Hardw. BOOT DSP"............................................................................................................. 480 Requirements.............................................................................................................. 480 DSP5600x Signal Processing Unit and TRACO................................................................................. 480 Inverter processing unit.................................................................................................. 482 Access to the Signal Processing Unit...................................................................................... 482 "Hardw. Flash"................................................................................................................ 482 Options................................................................................................................... 482 Requirements.............................................................................................................. 482 Example................................................................................................................... 482 Deleting and loading...................................................................................................... 483 The EPROM for the communication drivers................................................................................... 483 User Data Flash (UDF)..................................................................................................... 483 "Hardw. RESET"................................................................................................................ 483 Options................................................................................................................... 483 "Hardw. ZR"................................................................................................................... 484 "Hardw. BOOT ZR".............................................................................................................. 484 The following procedure is necessary:..................................................................................... 484 Graphic Menu.................................................................................................................. 485 Commands for Displaying Line Graphics..................................................................................... 485 "Graphic Load"................................................................................................................ 485 Options................................................................................................................... 485 "Graphic Position"............................................................................................................ 485 Options................................................................................................................... 485 "Graphic Time/Div"............................................................................................................ 486 Options................................................................................................................... 486 "Graphic Unit/Div"............................................................................................................ 486 Options................................................................................................................... 486 "Graphic Display"............................................................................................................. 486 Options................................................................................................................... 486 "Graphic Color"............................................................................................................... 487 Options................................................................................................................... 487 "Graphic Format".............................................................................................................. 487 Options................................................................................................................... 487 IGBT haul truck SIBAS® user manual, part 2........................................................................................ 489 Traco Menu.................................................................................................................... 491 HW-Traco...................................................................................................................... 491 Options................................................................................................................... 492 SW-Traco...................................................................................................................... 493 Options................................................................................................................... 494 ZR traco basic parameters:................................................................................................ 494 ZR traco record signal table:............................................................................................. 494 DAC_Traco..................................................................................................................... 497 Options................................................................................................................... 498 Events Menu................................................................................................................... 499 STatistics.................................................................................................................... 500 History....................................................................................................................... 501 LEL:Last EvL.................................................................................................................. 502 LES:Last EvS.................................................................................................................. 504 DLL:DC,LastL.................................................................................................................. 505 DLS:DC,LastS.................................................................................................................. 506 DAL:DC,All L.................................................................................................................. 507 DAS:DC,All S.................................................................................................................. 508 ML:Memory L................................................................................................................... 509 MS:Memory S................................................................................................................... 510 CN:Clear Norm................................................................................................................. 511 CA:Clear All.................................................................................................................. 511 Test-Code..................................................................................................................... 511 DS:Diag-Strc.................................................................................................................. 512 User Menu..................................................................................................................... 513 DAC_IO........................................................................................................................ 514 Options................................................................................................................... 514 Options................................................................................................................... 515 Operat.Data............................................................................................................... 516 Acc test...................................................................................................................... 523 Engine_Test................................................................................................................... 523 X_Test_Inx.................................................................................................................... 526 STate intern.................................................................................................................. 527 Header:................................................................................................................... 527 Vehicle Number:........................................................................................................... 527 Powering system:.......................................................................................................... 527 TCU Operation Mode:....................................................................................................... 527 Component status listings:................................................................................................ 528 Field regulator status:................................................................................................... 528 Status gate unit power supply A:.......................................................................................... 528 Status gate unit power supply B:.......................................................................................... 528 ST inverter status........................................................................................................ 529 Vehicle status............................................................................................................ 529 Drive status:............................................................................................................. 529 Operation status:......................................................................................................... 530 Pedal calib................................................................................................................... 531 Language...................................................................................................................... 532 OFFline-test.................................................................................................................. 532 Options................................................................................................................... 532 Variables..................................................................................................................... 533 Examples:................................................................................................................. 533 IV:Vehic-ID................................................................................................................... 535 Commands...................................................................................................................... 535 Discharge Dc link / Fire crowbar.......................................................................................... 536 Limp mode commands........................................................................................................ 536 Settings...................................................................................................................... 537 Parameters.................................................................................................................... 538 Temp_prot..................................................................................................................... 540 Appendix...................................................................................................................... 542 Background commands........................................................................................................... 542 Monitor commands for the central processing unit.............................................................................. 543 Monitor commands for the signal processing unit............................................................................... 543 Installing ZR / DSP software...................................................................................................... 545 Monitor Program – Loading software into the SIBAS®............................................................................ 546 Loading software into the DSP procedure....................................................................................... 546 Loading a DSP program Inverter A.............................................................................................. 551 Loading ZR software Prog. jumpers Reset....................................................................................... 565 40 Troubleshooting.................................................................................................................... 569 Fuse and circuit breaker locations................................................................................................ 569 Fuse and circuit breaker locations............................................................................................ 570 Troubleshooting by fault code, part 1............................................................................................. 575 Fault Code A001: Left front suspension pressure sensor signal high............................................................ 577 Related circuit diagram................................................................................................... 577 Fault Code A002: Left front suspension pressure sensor signal low............................................................. 578 Related circuit diagram................................................................................................... 578 Fault Code A003: Right front suspension pressure sensor signal high........................................................... 579 Related circuit diagram................................................................................................... 579 Fault Code A004: Right front suspension pressure sensor signal low............................................................ 580 Related circuit diagram................................................................................................... 580 Fault Code A005: Left rear suspension pressure sensor signal high............................................................. 581 Related circuit diagram................................................................................................... 581 Fault Code A006: Left rear suspension pressure sensor signal low.............................................................. 582 Related circuit diagram................................................................................................... 582 Fault Code A007: Right rear suspension pressure sensor signal high............................................................ 583 Related circuit diagram................................................................................................... 583 Fault Code A008: Right rear suspension pressure sensor signal low............................................................. 584 Related circuit diagram................................................................................................... 584 Fault Code A009: Incline sensor signal high................................................................................... 585 Related circuit diagram................................................................................................... 585 Fault Code A010: Incline sensor signal low.................................................................................... 586 Related circuit diagram................................................................................................... 586 Fault Code A011: Payload meter speed sensor signal has failed................................................................. 587 Related circuit diagram................................................................................................... 587 Fault Code A013: Body up switch has failed.................................................................................... 588 Related circuit diagram................................................................................................... 588 Fault Code A014: Payload meter checksum computation has failed................................................................ 589 Related circuit diagram................................................................................................... 589 Fault Code A016: Payload meter write to flash memory has failed............................................................... 590 Related circuit diagram................................................................................................... 590 Fault Code A017: Payload meter flash memory read has failed................................................................... 591 Related circuit diagram................................................................................................... 591 Fault Code A018: Right rear flat suspension cylinder warning.................................................................. 592 Related circuit diagram................................................................................................... 593 Fault Code A019: Left rear flat suspension cylinder warning................................................................... 594 Related circuit diagram................................................................................................... 595 Fault Code A022: Carryback load excessive..................................................................................... 596 Related circuit diagram................................................................................................... 597 Fault Code A100: An open circuit breaker has been detected on a relay board................................................... 599 Related circuit diagram................................................................................................... 599 Fault Code A101: High pressure detected across an hydraulic pump filter....................................................... 600 Related circuit diagram................................................................................................... 601 Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level...................................... 602 Related circuit diagram................................................................................................... 603 Fault Code A111: Low steering pressure warning for storage by KOMTRAX Plus.................................................... 604 Related circuit diagram................................................................................................... 604 Fault Code A115: Low steering precharge pressure detected..................................................................... 606 Related circuit diagram................................................................................................... 607 Fault Code A117: Low brake accumulator pressure warning for storage by KOMTRAX Plus........................................... 608 Related circuit diagram................................................................................................... 608 Fault Code A118: Brake pressure is low while in brake lock.................................................................... 610 Related circuit diagram................................................................................................... 611 Fault Code A126: Oil level in the hydraulic tank is low....................................................................... 612 Related circuit diagram................................................................................................... 612 Fault Code A127: IM-furnished +5 volt output for sensors is low............................................................... 614 Related circuit diagram................................................................................................... 615 Fault Code A128: IM-furnished +5 volt output for sensors is high.............................................................. 616 Related circuit diagram................................................................................................... 617 Fault Code A139: Low fuel warning for storage by KOMTRAX Plus and for use by A310............................................. 618 Related circuit diagram................................................................................................... 619 Troubleshooting by fault code, part 2............................................................................................. 621 Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil.... 624 Related circuit diagram................................................................................................... 625 Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil.... 626 Related circuit diagram................................................................................................... 627 Fault Code A152: Starter failure.............................................................................................. 628 Related circuit diagram................................................................................................... 629 Fault Code A153: Battery voltage is low with the truck in operation........................................................... 630 Related circuit diagram................................................................................................... 631 Fault Code A154: Battery charging voltage is excessive........................................................................ 632 Related circuit diagram................................................................................................... 632 Fault Code A155: Battery charging voltage is low.............................................................................. 633 Related circuit diagram................................................................................................... 633 Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level................................. 634 Related circuit diagram................................................................................................... 635 Fault Code A166: Left rear hydraulic oil temperature sensor is low............................................................ 636 Related circuit diagram................................................................................................... 637 Fault Code A167: Right rear hydraulic oil temperature sensor is low........................................................... 638 Related circuit diagram................................................................................................... 639 Fault Code A168: Left front hydraulic oil temperature sensor is low........................................................... 640 Related circuit diagram................................................................................................... 641 Fault Code A169: Right front hydraulic oil temperature sensor is low.......................................................... 642 Related circuit diagram................................................................................................... 643 Fault Code A170: Left rear hydraulic oil temperature sensor is high........................................................... 644 Related circuit diagram................................................................................................... 644 Fault Code A171: Right rear hydraulic oil temperature sensor is high.......................................................... 645 Related circuit diagram................................................................................................... 645 Fault Code A172: Left front hydraulic oil temperature sensor is high.......................................................... 646 Related circuit diagram................................................................................................... 646 Fault Code A173: Right front hydraulic oil temperature sensor is high......................................................... 647 Related circuit diagram................................................................................................... 647 Fault Code A184: J1939 data link is not connected............................................................................. 648 Related circuit diagram................................................................................................... 649 Fault Code A190: Auto lube control has detected an incomplete lube cycle...................................................... 650 Related circuit diagram................................................................................................... 651 Fault Code A194: Left front hydraulic oil temperature is high................................................................. 652 Related circuit diagram................................................................................................... 652 Fault Code A195: Right front hydraulic oil temperature is high................................................................ 653 Related circuit diagram................................................................................................... 653 Fault Code A196: Left rear hydraulic oil temperature is high.................................................................. 654 Related circuit diagram................................................................................................... 654 Fault Code A197: Right rear hydraulic oil temperature is high................................................................. 655 Related circuit diagram................................................................................................... 655 Fault Code A198: Hoist pressure 1 sensor is high.............................................................................. 656 Related circuit diagram................................................................................................... 656 Fault Code A199: Hoist pressure 2 sensor is high.............................................................................. 657 Related circuit diagram................................................................................................... 657 Fault Code A200: Steering pressure sensor is high............................................................................. 658 Related circuit diagram................................................................................................... 658 Fault Code A201: Brake pressure sensor is high................................................................................ 659 Related circuit diagram................................................................................................... 659 Fault Code A202: Hoist pressure 1 sensor is low............................................................................... 660 Related circuit diagram................................................................................................... 660 Fault Code A203: Hoist pressure 2 sensor is low............................................................................... 661 Related circuit diagram................................................................................................... 661 Fault Code A204: Steering pressure sensor is low.............................................................................. 662 Related circuit diagram................................................................................................... 662 Fault Code A205: Brake pressure sensor is low................................................................................. 663 Related circuit diagram................................................................................................... 663 Fault Code A206: Ambient temperature sensor is high........................................................................... 664 Related circuit diagram................................................................................................... 664 Fault Code A207: Ambient temperature sensor is low............................................................................ 665 Related circuit diagram................................................................................................... 665 Troubleshooting by fault code, Part 3............................................................................................. 667 Fault Code A213: Parking brake should have applied but is detected as not having applied...................................... 669 Related circuit diagram................................................................................................... 671 Fault Code A214: Parking brake should have released but is detected as not having released.................................... 673 Related circuit diagram................................................................................................... 675 Fault Code A215: Brake auto apply valve circuit is defective.................................................................. 676 Related circuit diagram................................................................................................... 677 Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit...................... 678 Related circuit diagram................................................................................................... 679 Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted.................................... 680 Related circuit diagram................................................................................................... 681 Fault Code A230: Parking brake has been requested while truck still moving.................................................... 682 Related circuit diagram................................................................................................... 683 Fault Code A231: The body is up while traveling or with selector in forward or neutral........................................ 684 Fault Code A233: Drive System Control Link is not connected................................................................... 686 Related circuit diagram................................................................................................... 687 Fault Code A235: Steering accumulator is in the process of being bled down.................................................... 688 Related circuit diagram................................................................................................... 689 Fault Code A236: The steering accumulator has not properly bled down after 90 seconds......................................... 690 Related circuit diagram................................................................................................... 691 Fault Code A237: The CAN/RPC connection to the display is open................................................................ 692 Related circuit diagram................................................................................................... 693 Fault Code A238: Drive System and IM are reporting different park brake status................................................ 694 Related circuit diagram................................................................................................... 695 Fault Code A239: The Drive System and IM are reporting different brake lock status............................................ 696 Related circuit diagram................................................................................................... 697 Fault Code A240: The keyswitch input to the Interface Module is open.......................................................... 698 Related circuit diagram................................................................................................... 698 Fault Code A242: Fuel gauge within the dash display panel is defective........................................................ 699 Related circuit diagram................................................................................................... 699 Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective.................................. 700 Related circuit diagram................................................................................................... 700 Fault Code A244: Drive system temperature gauge within the dash display panel is defective.................................... 701 Related circuit diagram................................................................................................... 701 Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective................................... 702 Related circuit diagram................................................................................................... 702 Fault Code A246: Payload meter reports truck overload......................................................................... 703 Related circuit diagram................................................................................................... 703 Fault Code A247: Low steering pressure warning for display to operator........................................................ 705 Related circuit diagram................................................................................................... 705 Fault Code A248: Status module within the dash display panel is defective..................................................... 706 Related circuit diagram................................................................................................... 706 Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted........................................... 707 Related circuit diagram................................................................................................... 707 Fault Code A250: Battery voltage is low with the truck parked................................................................. 708 Related circuit diagram................................................................................................... 709 Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground.............................. 710 Related circuit diagram................................................................................................... 710 Fault Code A252: Start enable output circuit is either open or shorted to ground.............................................. 711 Related circuit diagram................................................................................................... 711 Fault Code A253: Steering bleed circuit is not open while running............................................................. 712 Related circuit diagram................................................................................................... 713 Fault Code A256: Red warning lamp in the dash display (driven by IM) is open.................................................. 715 Related circuit diagram................................................................................................... 715 Fault Code A257: Payload CAN/RPC is not connected............................................................................. 716 Related circuit diagram................................................................................................... 717 Fault Code A258: Steering accumulator bleed pressure switch circuit is defective.............................................. 718 Related circuit diagram................................................................................................... 718 Troubleshooting by fault code, Part 4............................................................................................. 721 Fault Code A260: Parking brake failure........................................................................................ 724 Related circuit diagram................................................................................................... 725 Fault Code A261: Low brake accumulator pressure warning for display to operator............................................... 726 Related circuit diagram................................................................................................... 726 Fault Code A262: Steering bleed valve circuit open during shutdown............................................................ 728 Related circuit diagram................................................................................................... 729 Fault Code A264: Parking brake relay circuit is defective..................................................................... 730 Related circuit diagram................................................................................................... 731 Fault Code A265: Service brake failure........................................................................................ 732 Related circuit diagram................................................................................................... 733 Fault Code A266: Selector switch was not in park while attempting to crank engine............................................. 734 Related circuit diagram................................................................................................... 734 Fault Code A267: Parking brake was not set while attempting to crank engine................................................... 735 Related circuit diagram................................................................................................... 735 Fault Code A268: Secondary engine shutdown while cranking..................................................................... 736 Related circuit diagram................................................................................................... 736 Fault Code A270: Brake lock switch power supply is not on when required....................................................... 738 Related circuit diagram................................................................................................... 739 Fault Code A271: Shifter not in gear.......................................................................................... 740 Related circuit diagram................................................................................................... 741 Fault Code A272: Brake lock switch power supply is not off when required...................................................... 742 Related circuit diagram................................................................................................... 743 Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit....................... 744 Related circuit diagram................................................................................................... 744 Fault Code A274: A brake setting fault has been detected...................................................................... 746 Related circuit diagram................................................................................................... 747 Fault Code A275: A starter has been detected as engaged without a cranking attempt............................................ 748 Related circuit diagram................................................................................................... 749 Fault Code A277: Parking brake applied while loading.......................................................................... 750 Related circuit diagram................................................................................................... 751 Fault Code A278: Service brake applied while loading.......................................................................... 752 Related circuit diagram................................................................................................... 753 Fault Code A279: Low steering pressure switch is defective.................................................................... 754 Related circuit diagram................................................................................................... 754 Fault Code A280: Steering accumulator bleeddown switch is defective........................................................... 755 Related circuit diagram................................................................................................... 755 Fault Code A281: Brake lock degrade switch is defective....................................................................... 756 Related circuit diagram................................................................................................... 757 Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7............. 758 Related circuit diagram................................................................................................... 759 Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set................................... 760 Related circuit diagram................................................................................................... 761 Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated...................... 762 Related circuit diagram................................................................................................... 763 Fault Code A285: The parking brake was not set when the keyswitch was turned off.............................................. 764 Related circuit diagram................................................................................................... 765 Fault Code A286: A fault was detected in the shutdown delay relay circuit..................................................... 766 Related circuit diagram................................................................................................... 767 Fault Code A292: The shutdown delay relay has remained on after the latched keyswitch circuit is off.......................... 768 Related circuit diagram................................................................................................... 769 Troubleshooting by fault code, part 5............................................................................................. 771 Fault Code A303: Shifter is defective......................................................................................... 774 Related circuit diagram................................................................................................... 775 Fault Code A304: Auto lube grease level fault................................................................................. 776 Related circuit diagram................................................................................................... 776 Fault Code A305: Auto lube circuit is defective............................................................................... 778 Related circuit diagram................................................................................................... 779 Fault Code A309: No brakes applied when expected.............................................................................. 780 Related circuit diagram................................................................................................... 781 Fault Code A310: Low fuel warning............................................................................................. 782 Related circuit diagram................................................................................................... 783 Fault Code A311: Brake lock switch is on when it should not be................................................................ 784 Related circuit diagram................................................................................................... 785 Fault Code A312: DCDC converter 12 volt circuit sensing is producing low readings............................................. 786 Related circuit diagram................................................................................................... 786 Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings............................................ 787 Related circuit diagram................................................................................................... 787 Fault Code A315: DCDC converter 12 volt circuit is low........................................................................ 788 Related circuit diagram................................................................................................... 789 Fault Code A316: Starter engagement has been attempted with engine running.................................................... 790 Related circuit diagram................................................................................................... 791 Fault Code A317: Operation of brake auto apply valve without a detected response.............................................. 792 Related circuit diagram................................................................................................... 793 Fault Code A318: Unexpected power loss to Interface Module.................................................................... 794 Related circuit diagram................................................................................................... 794 Fault Code A328: Drive system not powered up.................................................................................. 795 Related circuit diagram................................................................................................... 795 Fault Code A350: Overload on output 1B........................................................................................ 796 Related circuit diagram................................................................................................... 796 Fault Code A351: Overload on output 1E........................................................................................ 798 Related circuit diagram................................................................................................... 799 Fault Code A352: Overload on output 1H........................................................................................ 800 Related circuit diagram................................................................................................... 800 Fault Code A353: Overload on output 1J........................................................................................ 801 Related circuit diagram................................................................................................... 801 Fault Code A354: Overload on output 1K........................................................................................ 802 Related circuit diagram................................................................................................... 802 Fault Code A355: Overload on output 1L........................................................................................ 803 Related circuit diagram................................................................................................... 803 Fault Code A356: Overload on output 1M........................................................................................ 804 Related circuit diagram................................................................................................... 804 Fault Code A357: Overload on output 1N........................................................................................ 805 Related circuit diagram................................................................................................... 805 Fault Code A358: Overload on output 1P........................................................................................ 806 Related circuit diagram................................................................................................... 806 Fault Code A359: Overload on output 1R........................................................................................ 807 Related circuit diagram................................................................................................... 807 Fault Code A360: Overload on output 1S........................................................................................ 808 Related circuit diagram................................................................................................... 808 Fault Code A361: Overload on output 1T........................................................................................ 810 Related circuit diagram................................................................................................... 811 Fault Code A362: Overload on output 1U........................................................................................ 812 Related circuit diagram................................................................................................... 812 Fault Code A363: Overload on output 1X........................................................................................ 813 Related circuit diagram................................................................................................... 813 Fault Code A364: Overload on output 1Y........................................................................................ 814 Related circuit diagram................................................................................................... 814 Fault Code A365: Overload on output 1Z........................................................................................ 815 Related circuit diagram................................................................................................... 815 Drive system fault code table, Part 1............................................................................................. 817 Summary....................................................................................................................... 819 How to use this document...................................................................................................... 819 Event code and diagnosis message.............................................................................................. 819 Description................................................................................................................... 819 Threshold..................................................................................................................... 819 Detection by.................................................................................................................. 819 Possible reasons.............................................................................................................. 819 Action to reset............................................................................................................... 819 Action to repair.............................................................................................................. 820 Operator displayed code....................................................................................................... 820 Note.......................................................................................................................... 820 Protection reactions.......................................................................................................... 820 EVENT CLASSIFICATION.......................................................................................................... 820 Level 1: Warning.............................................................................................................. 821 Level 2: Minor purposes....................................................................................................... 821 Level 3: Severe............................................................................................................... 821 Drive system fault code table, Part 2............................................................................................. 857 Drive system fault code table, Part 3............................................................................................. 897 Drive system fault code table, Part 4............................................................................................. 957 Drive system fault code table, Part 5.............................................................................................1011 Drive system fault code table, Part 6.............................................................................................1085 Drive system fault code table, Part 7.............................................................................................1135 Cab air conditioning..............................................................................................................1209 Preliminary checks............................................................................................................1211 Diagnosis of gauge readings and system performance............................................................................1211 Troubleshooting by manifold gauge set readings................................................................................1212 Reserve engine oil system.........................................................................................................1219 Pumping unit LED signals......................................................................................................1221 Circuit fuses.............................................................................................................1221 Steering system...................................................................................................................1223 Steering circuit..............................................................................................................1224 Steering pump.................................................................................................................1226 Basic Hydraulic System Checks.............................................................................................1227 System Leakage Check......................................................................................................1228 Steering Pump Troubleshooting Guide.......................................................................................1229 Pump Pressure Control Checks..............................................................................................1233 Pump fails to unload......................................................................................................1233 Pump fails to develop pressure............................................................................................1234 Pump slow in developing pressure..........................................................................................1234 Pump control valve inspection and trouble shooting........................................................................1235 Pump case drain check.....................................................................................................1236 Setting pump pressure controls............................................................................................1238 Definitions:..............................................................................................................1238 Adjustment................................................................................................................1239 50 Disassembly and assembly...........................................................................................................1241 General information...............................................................................................................1241 Special tool list.............................................................................................................1243 Wheels, spindles and rear axle....................................................................................................1249 General information for tires and rims........................................................................................1251 Storage and handling......................................................................................................1251 Wheel stud maintenance....................................................................................................1252 Removal and installation of front wheel.......................................................................................1252 Removal...................................................................................................................1252 Installation..............................................................................................................1253 Removal and installation of rear wheel........................................................................................1254 Removal...................................................................................................................1254 Installation..............................................................................................................1255 Removal and installation of tires.............................................................................................1256 Removal...................................................................................................................1257 Installation..............................................................................................................1257 Removal and installation of front wheel hub and spindle.......................................................................1259 Removal...................................................................................................................1259 Installation..............................................................................................................1262 Disassembly and assembly of front wheel hub and spindle.......................................................................1263 Disassembly...............................................................................................................1263 Cleaning and inspection...................................................................................................1263 Assembly..................................................................................................................1265 Wheel bearing adjustment..................................................................................................1265 Seal assembly gap check and adjustment....................................................................................1266 Brake installation........................................................................................................1267 Speed sensor installation and adjustment..................................................................................1267 Removal and installation of wheel motor.......................................................................................1268 Preparation...............................................................................................................1268 Removal...................................................................................................................1268 Cleaning and inspection...................................................................................................1270 Installation..............................................................................................................1270 Removal and installation of electric motor....................................................................................1274 Removal...................................................................................................................1274 Installation..............................................................................................................1274 Disassembly and assembly of wheel motor transmission..........................................................................1274 Disassembly...............................................................................................................1274 Cleaning and inspection...................................................................................................1282 Assembly..................................................................................................................1282 Disassembly and assembly of low speed carrier.................................................................................1294 Disassembly...............................................................................................................1294 Inspection................................................................................................................1295 Assembly..................................................................................................................1296 Disassembly and assembly of high speed carrier................................................................................1299 Disassembly...............................................................................................................1299 Inspection................................................................................................................1300 Assembly..................................................................................................................1301 Removal and installation of rear axle.........................................................................................1303 Removal...................................................................................................................1303 Cleaning and inspection...................................................................................................1304 Installation..............................................................................................................1305 Removal and installation of anti-sway bar.....................................................................................1305 Removal...................................................................................................................1305 Installation..............................................................................................................1306 Removal and installation of pivot pin.........................................................................................1307 Removal...................................................................................................................1307 Installation..............................................................................................................1307 Pivot eye and bearing service.................................................................................................1308 Bearing removal...........................................................................................................1308 Bearing installation......................................................................................................1308 Pivot eye repair..........................................................................................................1309 Brake system......................................................................................................................1311 Removal and installation of brake valve.......................................................................................1313 Removal...................................................................................................................1313 Installation..............................................................................................................1314 Disassembly and assembly of brake valve.......................................................................................1314 Disassembly...............................................................................................................1314 Cleaning and inspection...................................................................................................1318 Assembly..................................................................................................................1318 Removal and installation of dual relay valve..................................................................................1321 Removal...................................................................................................................1321 Installation..............................................................................................................1322 Disassembly and assembly of dual relay valve..................................................................................1323 Disassembly...............................................................................................................1323 Cleaning and inspection...................................................................................................1324 Assembly..................................................................................................................1324 Removal and installation of brake manifold....................................................................................1325 Removal...................................................................................................................1325 Installation..............................................................................................................1325 Disassembly and assembly of brake manifold....................................................................................1326 Disassembly...............................................................................................................1326 Assembly..................................................................................................................1326 Removal and installation of brake accumulator.................................................................................1327 Removal...................................................................................................................1327 Installation..............................................................................................................1327 Disassembly and assembly of brake accumulator.................................................................................1328 Disassembly...............................................................................................................1328 Cleaning and inspection...................................................................................................1329 Assembly..................................................................................................................1330 Disassembly and assembly of wheel brake.......................................................................................1331 Disassembly...............................................................................................................1332 Cleaning and inspection...................................................................................................1335 Assembly..................................................................................................................1336 Floating ring seal assembly and installation..............................................................................1339 Removal and installation of rear brake assembly...............................................................................1347 Removal...................................................................................................................1347 Installation..............................................................................................................1347 Removal and installation of parking brake.....................................................................................1349 Removal...................................................................................................................1349 Installation..............................................................................................................1351 Disassembly and assembly of parking brake.....................................................................................1351 Disassembly...............................................................................................................1351 Cleaning and inspection...................................................................................................1352 Assembly..................................................................................................................1354 Cleaning and inspecting new discs.........................................................................................1356 Steering system...................................................................................................................1359 Removal and installation of steering control unit.............................................................................1361 Removal...................................................................................................................1361 Installation..............................................................................................................1362 Disassembly and assembly of steering control unit.............................................................................1363 Disassembly...............................................................................................................1363 Assembly..................................................................................................................1365 Removal and installation of steering column...................................................................................1368 Removal...................................................................................................................1368 Inspection................................................................................................................1368 Installation..............................................................................................................1369 Removal and installation of steering wheel....................................................................................1369 Removal...................................................................................................................1369 Installation..............................................................................................................1370 Removal and installation of bleeddown manifold................................................................................1371 Removal...................................................................................................................1371 Installation..............................................................................................................1372 Removal and installation of flow amplifier....................................................................................1373 Removal...................................................................................................................1373 Installation..............................................................................................................1373 Disassembly and assembly of flow amplifier....................................................................................1373 Disassembly...............................................................................................................1373 Assembly..................................................................................................................1375 Removal and installation of steering cylinders and tie rod....................................................................1376 Removal...................................................................................................................1376 Bearing replacement.......................................................................................................1376 Installation..............................................................................................................1376 Disassembly and assembly of steering cylinders................................................................................1377 Disassembly...............................................................................................................1377 Assembly..................................................................................................................1378 Removal and installation of steering/brake pump...............................................................................1378 Removal...................................................................................................................1378 Installation..............................................................................................................1379 Disassembly and assembly of steering/brake pump...............................................................................1381 Disassembly...............................................................................................................1381 Inspection................................................................................................................1384 Assembly..................................................................................................................1387 Driveshaft group..........................................................................................................1387 Rotating group............................................................................................................1388 Removal and installation of steering accumulators.............................................................................1391 Removal...................................................................................................................1391 Installation..............................................................................................................1392 Disassembly and assembly of steering accumulators.............................................................................1392 Disassembly...............................................................................................................1392 Cleaning and Inspection...................................................................................................1393 Assembly..................................................................................................................1394 Suspensions.......................................................................................................................1397 Removal and installation of front suspension..................................................................................1399 Removal...................................................................................................................1399 Installation..............................................................................................................1400 Inspection................................................................................................................1403 Minor front suspension repairs (lower bearing and seals)......................................................................1406 Lower bearing retainer removal............................................................................................1406 Lower bearing retainer installation.......................................................................................1406 Major front suspension rebuild................................................................................................1407 Disassembly...............................................................................................................1407 Assembly..................................................................................................................1408 Removal and installation of rear suspension...................................................................................1410 Removal...................................................................................................................1411 Installation..............................................................................................................1413 Disassembly and assembly of rear suspension...................................................................................1413 Disassembly...............................................................................................................1413 Cleaning and Inspection...................................................................................................1414 Assembly..................................................................................................................1414 Hoist circuit.....................................................................................................................1417 Removal and installation of hoist pump........................................................................................1419 Removal...................................................................................................................1419 Installation..............................................................................................................1420 Disassembly and assembly of hoist pump........................................................................................1421 Disassembly...............................................................................................................1421 Inspection................................................................................................................1424 Assembly..................................................................................................................1424 Removal and installation of hoist valve.......................................................................................1429 Removal...................................................................................................................1429 Installation..............................................................................................................1430 Disassembly and assembly of hoist valve.......................................................................................1430 O-ring replacement........................................................................................................1430 Disassembly of inlet section..............................................................................................1431 Assembly of inlet section.................................................................................................1432 Disassembly of rear spool section.........................................................................................1432 Assembly of rear spool section............................................................................................1435 Disassembly of front spool section........................................................................................1436 Assembly of front spool section...........................................................................................1437 Overcenter valve manifold service.............................................................................................1437 Removal and installation of hoist pilot valve.................................................................................1438 Removal...................................................................................................................1438 Installation..............................................................................................................1438 Disassembly and assembly of hoist pilot valve.................................................................................1439 Disassembly...............................................................................................................1439 Cleaning and inspection...................................................................................................1440 Assembly..................................................................................................................1440 Removal and installation of hoist cylinders...................................................................................1441 Removal...................................................................................................................1441 Installation..............................................................................................................1442 Disassembly and assembly of hoist cylinders...................................................................................1443 Disassembly...............................................................................................................1443 Cleaning and inspection...................................................................................................1445 Installation of the quill.................................................................................................1446 Assembly..................................................................................................................1448 Operator cab......................................................................................................................1451 Removal and installation of operator cab......................................................................................1453 Removal...................................................................................................................1454 Installation..............................................................................................................1455 Removal and installation of cab door..........................................................................................1456 Removal...................................................................................................................1456 Installation..............................................................................................................1456 Disassembly and assembly of cab door..........................................................................................1456 Removing door panel.......................................................................................................1456 Installing door panel.....................................................................................................1457 Replacing the door window regulator.......................................................................................1457 Replacing door handle or latch assembly...................................................................................1458 Replacing door assembly seal and door hinge seal..........................................................................1459 Replacing door opening seal...............................................................................................1459 Removing door glass.......................................................................................................1460 Installing door glass.....................................................................................................1462 Adjustment of cab door........................................................................................................1463 Door jamb bolt adjustment.................................................................................................1463 Door handle plunger adjustment............................................................................................1465 Removal and installation of side window glass.................................................................................1466 Recommended tools and supplies............................................................................................1466 Removal...................................................................................................................1466 Installation..............................................................................................................1466 Removal and installation of windshield and rear window glass..................................................................1467 Removal...................................................................................................................1467 Installation..............................................................................................................1467 Removal and installation of windshield wiper motor............................................................................1469 Removal...................................................................................................................1469 Installation..............................................................................................................1469 Removal and installation of windshield wiper arm..............................................................................1470 Removal...................................................................................................................1470 Installation..............................................................................................................1470 Removal and installation of windshield wiper linkage..........................................................................1470 Removal...................................................................................................................1470 Installation..............................................................................................................1471 Removal and installation of operator seat.....................................................................................1471 Inspection................................................................................................................1471 Removal...................................................................................................................1471 Installation..............................................................................................................1471 Replacing the Seat Compressor.............................................................................................1472 Removal and installation of passenger seat....................................................................................1477 Removal...................................................................................................................1477 Installation..............................................................................................................1477 Removal and installation of seat belts (standard seats).......................................................................1478 Removal...................................................................................................................1478 Installation..............................................................................................................1478 Removal and installation of seat belts (optional seats).......................................................................1480 General...................................................................................................................1480 Removal...................................................................................................................1480 Installation..............................................................................................................1482 Body and structures...............................................................................................................1485 Removal and installation of dump body.........................................................................................1487 Removal...................................................................................................................1487 Inspection................................................................................................................1488 Installation..............................................................................................................1489 Removal and installation of body pads.........................................................................................1489 Removal...................................................................................................................1489 Installation..............................................................................................................1490 Body pad shimming procedure...............................................................................................1491 Removal and installation of diagonal ladder/hood and grille assembly..........................................................1492 Removal...................................................................................................................1492 Installation..............................................................................................................1492 Removal and installation of right deck........................................................................................1493 Removal...................................................................................................................1493 Installation..............................................................................................................1494 Removal and installation of left deck.........................................................................................1495 Removal...................................................................................................................1495 Installation..............................................................................................................1495 Removal and installation of fuel tank.........................................................................................1497 Removal...................................................................................................................1497 Cleaning and inspection...................................................................................................1497 Installation..............................................................................................................1499 Removal and installation of fuel gauge sender (S/N A50003 - A50011)...........................................................1499 Removal...................................................................................................................1499 Installation..............................................................................................................1499 Removal and installation of fuel gauge sender (S/N A50012 & up)...............................................................1499 Removal...................................................................................................................1499 Installation..............................................................................................................1499 Disassembly and assembly of fuel tank breather................................................................................1500 Disassembly...............................................................................................................1500 Assembly..................................................................................................................1500 Removal and installation of hydraulic tank....................................................................................1501 Removal...................................................................................................................1501 Installation..............................................................................................................1501 Cab air conditioning..............................................................................................................1503 Replacement of air conditioning system components.............................................................................1505 Hoses and fittings........................................................................................................1505 Lines.....................................................................................................................1505 Expansion valve...........................................................................................................1505 Receiver-drier............................................................................................................1505 Thermostat................................................................................................................1505 Compressor................................................................................................................1506 Accumulator...............................................................................................................1506 Clutch....................................................................................................................1506 Power module......................................................................................................................1509 Removal and installation of power module......................................................................................1511 General...................................................................................................................1511 Preparation...............................................................................................................1511 Removal...................................................................................................................1512 Installation..............................................................................................................1517 Removal and installation of alternator........................................................................................1519 Removal...................................................................................................................1519 Installation..............................................................................................................1521 Removal and installation of engine............................................................................................1524 Removal...................................................................................................................1524 Service...................................................................................................................1525 Installation..............................................................................................................1525 Removal and installation of radiator..........................................................................................1525 Removal...................................................................................................................1525 Installation..............................................................................................................1527 Repairing the radiator........................................................................................................1529 Internal inspection.......................................................................................................1529 External cleaning.........................................................................................................1529 Disassembly...............................................................................................................1529 Cleaning and inspection...................................................................................................1530 Assembly..................................................................................................................1531 Pressure testing..........................................................................................................1532 Auto lubrication system...........................................................................................................1535 Lubrication system priming....................................................................................................1536 Disassembly and assembly of lubrication pump..................................................................................1536 Disassembly...............................................................................................................1536 Cleaning and Inspection...................................................................................................1538 Assembly..................................................................................................................1538 Three phase wheel motor...........................................................................................................1541 General safety information....................................................................................................1542 Handling the motor............................................................................................................1543 Transport.....................................................................................................................1544 Storage.......................................................................................................................1545 Storage of new motors.....................................................................................................1545 Storage of used motors....................................................................................................1545 Motor description.............................................................................................................1546 Maintenance...................................................................................................................1547 Safety guidelines.............................................................................................................1547 Maintenance intervals.........................................................................................................1548 Maintenance work on the installed motor.......................................................................................1548 Checking for external damage..............................................................................................1548 Checking the connections..................................................................................................1548 Checking the interior of the motor for water..............................................................................1548 Regreasing the bearings.......................................................................................................1549 Applying grease to the bearings...............................................................................................1549 Checking the interior of the motor for water..................................................................................1550 Disassembling the motor.......................................................................................................1551 Removing the coupling.........................................................................................................1552 Disassembling the rotor.......................................................................................................1554 Removing the rubber seals and the air baffles.................................................................................1559 Removing the bearing and labyrinth ring.......................................................................................1560 Maintenance work..............................................................................................................1561 Cleaning......................................................................................................................1561 Stator inspection.............................................................................................................1561 Rotor inspection..............................................................................................................1561 Testing the insulation........................................................................................................1562 High-voltage test.........................................................................................................1562 Work on the bearings..........................................................................................................1563 Assembling the motor..........................................................................................................1564 Important general instructions................................................................................................1564 Assembling the rubber seals and the air baffles...............................................................................1565 Assembly after special repair work............................................................................................1567 Bearing installation (D-end)..................................................................................................1568 Assembling the bearing....................................................................................................1568 Installing the cover......................................................................................................1570 Bearing installation (N-end)..................................................................................................1571 Assembling the bearing....................................................................................................1571 Installing the cover......................................................................................................1573 Assembling the bearing shield (N-end) at the stator frame.....................................................................1574 Installing the bearing........................................................................................................1576 Installing the rotor..........................................................................................................1578 Installing the labyrinth ring.................................................................................................1580 Installing accessories (D- and N-end).........................................................................................1582 Running in the bearings.......................................................................................................1586 Installing the gear wheel.....................................................................................................1587 Installing the coupling.......................................................................................................1588 Assembly conditions and instructions..........................................................................................1589 Repairing the motor...........................................................................................................1590 Replacing defective connecting leads..........................................................................................1590 Repairing the stator winding insulation.......................................................................................1591 Recommended consumables.......................................................................................................1591 Chemical cleaning agents......................................................................................................1591 Generally approved cleaning agents........................................................................................1591 Chemical cleaning agents for outdoor use and for cleaning mechanical parts................................................1592 Chemical cleaning agents for flange faces.................................................................................1592 Chemical cleaning agents for windings.....................................................................................1592 Chemical cleaning agents for windings with severe damage and for oily windings............................................1592 Rolling-contact bearing grease................................................................................................1593 Assembly/disassembly agents for bearing seat..................................................................................1593 Sealants for joining parts or gaps............................................................................................1593 Locking agents for connecting elements........................................................................................1593 Anti-corrosion agent..........................................................................................................1593 Assembly paste for temperature sensors........................................................................................1593 Paints for refinishing the painted parts or touching up damaged parts.........................................................1593 Special tools.................................................................................................................1594 Mounting devices for inserting and withdrawing the rotor horizontally.........................................................1594 Press for expanding the coupling..............................................................................................1594 Compression devices for pressing on or for support while pressing off.........................................................1595 Pulling units with cross beam or disk.........................................................................................1597 Aids..........................................................................................................................1597 Extraction devices............................................................................................................1597 Main blower.......................................................................................................................1599 Removing the main blower motor................................................................................................1600 Disassembling the main blower motor...........................................................................................1606 Assembling the main blower motor..............................................................................................1608 Installing the main blower motor..............................................................................................1611 Retarding grid....................................................................................................................1619 Removing the grid blower motor................................................................................................1620 Disassembling the grid blower motor...........................................................................................1622 Assembling the grid blower motor..............................................................................................1624 Installing the grid blower motor..............................................................................................1626 Removing a grid element.......................................................................................................1629 Control cabinet...................................................................................................................1633 Draining and filling the IGBT coolant system..................................................................................1635 Required tools/materials..................................................................................................1635 Coolant mixture specification (distilled water : Antifrogen N)............................................................1635 Draining and filling the coolant..........................................................................................1636 Removing and installing the IGBT coolant pump assembly........................................................................1639 Required tools/materials..................................................................................................1639 Removal...................................................................................................................1640 90 Diagrams and drawings..............................................................................................................1643 Hydraulic circuit diagrams........................................................................................................1643 Electrical circuit diagrams.......................................................................................................1649 Electrical circuit diagrams - drive system........................................................................................1690
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]
