Komatsu 960E-2KT Dump Truck Shop Manual CEBM028401 – PDF DOWNLOAD

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Komatsu 960E-2KT Dump Truck Shop Manual CEBM028401 – PDF DOWNLOAD

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Komatsu 960E-2KT Dump Truck Shop Manual CEBM028401 – PDF DOWNLOAD

Shop Manual, contents binder, binder label and tabs CEBM028401
00 Index and foreword
Index CEN00027-01 
Foreword, safety and general information CEN00005-11
Operating instructions CEN00026-00
01 Specification
Specification and technical data CEN01004-03
10 Structure, function and maintenance standard
Steering circuit CEN10001-06
Hoist circuit CEN10002-03
Brake circuits CEN10003-03
Suspensions CEN10004-01
Electrical system, 24 volt CEN10030-01 
Interface module (IM) CEN10027-00
Drive system CEN10023-01
Cab air conditioning CEN10008-03
Reserve engine oil system CEN10022-03
SIBAS® IGBT rack components CEN10016-06
Structure and Maintenance Standard CEN10037-01
20 Standard value table
Standard value table CEN20003-00
30 Testing and adjusting
General information CEN30001-05
Steering, brake cooling and hoist hydraulic system CEN30002-03
Brake system CEN30015-05
Accumulators and suspensions CEN30004-05
Cab air conditioning CEN30029-01
Payload meter IV CEN30070-03 
00 Index and foreword CEN00027-01
3
Interface module (IM) CEN30026-02
IGBT haul truck SIBAS® user manual, part 1 CEN30021-02
IGBT haul truck SIBAS® user manual, part 2 CEN30022-02
Installing ZR / DSP software CEN30023-02
40 Troubleshooting
Fuse and circuit breaker locations CEN40009-03
Troubleshooting by failure code, Part 1 CEN40011-05
Troubleshooting by failure code, Part 2 CEN40049-01
Troubleshooting by failure code, Part 3 CEN40115-00
Troubleshooting by failure code, Part 4 CEN40051-00
Troubleshooting by failure code, Part 5 CEN40052-01 
Drive system fault code table, Part 1 CEN40041-01
Drive system fault code table, Part 2 CEN40042-00
Drive system fault code table, Part 3 CEN40043-00
Drive system fault code table, Part 4 CEN40044-00
Drive system fault code table, Part 5 CEN40045-01
Drive system fault code table, Part 6 CEN40046-00
Drive system fault code table, Part 7 CEN40047-01
Cab air conditioning CEN40008-02
Reserve engine oil system CEN40010-00
Steering system CEN40104-05
Automatic lubrication (auto lube) system CEN40202-00 
50 Disassembly and assembly
General information CEN50001-06
Wheels, spindle and rear axle CEN50022-06 
Brake system CEN50030-01
Steering system CEN50034-04
Suspensions CEN50005-08
Hoist circuit CEN50006-04
Operator cab CEN50007-05
Body and structures CEN50024-02
Cab air conditioning CEN50028-00
Power module CEN50021-03
Auto lubrication system CEN50029-01
Three phase wheel motor CEN50026-01
Main blower CEN50031-00
Retarding grid CEN50032-01
Control cabinet CEN50033-02
90 Diagrams and drawings
Hydraulic circuit diagrams CEN90001-03 
Electrical circuit diagrams CEN90006-01 
Electrical circuit diagrams – drive system CEN90013-00
CEN00027-01 00 Index and foreword
4
Table of contents
00 Index and foreword
Index CEN00027-01
Composition of shop manual 2
Table of contents 4
Foreword, safety and general information CEN00005-11
Foreword 5
How to read the shop manual 6
General safety 8
Precautions before operating the truck 11
Precautions while operating the truck 13
Working near batteries 16
Precautions before performing service 18
While performing maintenance 20
Tires 22
Precautions for performing repairs 23
Precautions for welding on the truck 25
Handling electrical equipment and hydraulic components 26
How to Read Electric Wire Code 34
Standard torque tables 36
Conversion tables 42
Operating instructions CEN00026-00
Preparing for operation 3
Engine start-up 7
After engine start-up 8
Emergency steering system 9
Precautions during truck operation 10
Operating on a haul road 11
Starting on a grade with a loaded truck 11
Loading the dump body 12
Dumping a load 12
Trolley operating instructions 14
Using the speed control feature 19
Safe parking procedure 19
Normal engine shutdown procedure 20
Sudden loss of engine power or loss of drive system function 20
Fuel depletion 21
Towing 21
Disabled truck operation 24
Disabled truck dumping procedure 26
01 Specification
Specification and technical data CEN01004-03
Specification drawing 3
Specifications 4
00 Index and foreword CEN00027-01
5
Weight table 6
Fuel, coolant and lubricants 7
10 Structure and functions
Steering circuit CEN10001-06
Steering circuit operation 3
Steering circuit components 5
Flow amplifier operation 9
Steering/brake pump operation 19
Steering cylinder wear data 23
Hoist circuit CEN10002-03
Hoist circuit operation 3
Hoist circuit components 4
Hoist pilot valve operation 8
Hoist cylinder wear data 18
Brake circuits CEN10003-03
General information 3
Service brake circuit operation 4
Secondary braking and auto apply 4
Parking brake circuit operation 6
Wheel brake lock circuit operation 7
Brake warning circuit operation 7
Brake assembly wear data 9
Suspensions CEN10004-01
General information 3
Front suspension wear data 3
Rear suspension wear data 4
Electrical system, 24 volt CEN10030-01
Battery supply system 3
Auxiliary control cabinet components 4
Relay boards 6
Body position switches (With proximity switch and magnet) 10
Interface module (IM) CEN10027-00
General information 2
Sensors 2
Interface module inputs and outputs 3
Drive system CEN10023-01
SR rectifier module 3
ST module (auxiliary voltage inverter) 3
SD phase modules 7
SR/ST/SD module removal 7
Inverter cabinet layout 8
Inverter cabinet water flow 8
Field regulator 9
Field regulator discharge resistor 9
Gate unit power supply 10
CEN00027-01 00 Index and foreword
6
Gate unit power supply (diode) 10
Gate unit power supply (tuning resistor) 10
Control power filter 10
Filter for TCU 11
Terminal block bus bar 11
Fuses (analog sensor voltage) 12
Fuses (field regulator) 12
Fuse holder for field regulator 12
Fuses (control power and trolley box contactor) 13
Diode modules 13
Support capacitors 14
Three-phase capacitor bank (for ST module output voltage) 14
Air-cooled inductors (for ST module) 15
Three-phase transformer (for ST module) 15
Diagnostics box 16
Diagnostic and system monitoring panel 17
Current transducers 18
Current transducers (for ST module output) 19
Voltage transducers 19
Voltage transducers (for ST module output) 20
Voltage transducers (SiBAS 24V DC bus monitoring) 20
Analog inclinometer 21
DC link capacitors 21
Ground tie capacitor 22
Low-inductance bus bar assembly 22
Free-wheeling diode for low-inductance bus bars 23
Contactor (grid box and main blower motor) 23
Contactor (control power) 24
Contactor (DC contactors) 24
Contactor (crowbar bypass) 25
Temperature probes (PT100 style) 25
Coolant inlet temperature sensor 26
Coolant outlet temperature sensor (external pad style) 26
Coolant outlet temperature sensor (internal style) 27
IGBT module heat sink temperature sensor 27
Circuit breakers 28
Inner circulating blower fan 28
Coolant pump 29
Motor for coolant pump 29
Coolant pressure sensor 29
Inner radiator 30
Ground voltage monitoring resistors 30
Protection thyristor assembly (crowbar) 31
Discharge reactor 31
Main blower motor 32
Grid box 32
00 Index and foreword CEN00027-01
7
Grid box blower motor 33
Grid box blower motor grease fittings 33
Main alternator 34
IGBT – inverter/chopper phase module 37
Troubleshooting information 39
Main input rectifier module 40
Ground tie resistor, upper 42
Ground tie resistor, lower 42
Troubleshooting 43
Speed sensor, alternator 44
Speed sensors, wheel motors 45
Traction motor 46
Retarding grid 47
Cab air conditioning CEN10008-03
General information 3
Principles of refrigeration 4
Air conditioning system components 6
Air conditioning system electrical circuit 10
Reserve engine oil system CEN10022-03
General information 3
Operation 4
Remote tank fill system 5
SIBAS® IGBT rack components CEN10016-06
SiBAS®32 Traction Control Unit (TCU) 4
Overview of the SiBAS®32 systems 5
Removing and installing the SiBAS®32 cards 9
SiBAS®32 card device names 10
Structure of SiBAS®32 card part number 11
SiBAS®32 card interchangeability 12
SiBAS®32 card interactions 15
Blower subassembly 18
CPU card 21
DSP card 24
I/O card 26
TRACO card (optional) 29
Input voltage/frequency card 32
I/O analog card 34
I/O analog card 37
Output pulse amplifier card 40
Input temperature sensor card 43
UWS card 46
Digital input card 49
Power start-up unit card 52
Binary output contactor drive card 55
24V / 24V power supply 58
24V / 15V power supply 61
CEN00027-01 00 Index and foreword
8
24V / 5V power supply 64
Wheel motor transmission CEN10037-01
Structure 2
Maintenance standard 3
20 Standard value table
Standard value table CEN20003-00
Standard value table for truck 3
30 Testing and adjusting
General information CEN30001-05
Special tool list 3
Steering, brake cooling and hoist hydraulic system CEN30002-03
General information on system checkout 3
Steering system checkout procedures 3
Steering system checkout data sheet 12
Toe-in adjustment 13
Brake cooling and hoist system checkout procedures 14
Brake cooling and hoist system checkout data sheet 19
Hoist cylinder leakage test 20
Hydraulic system flushing procedure 20
Brake system CEN30015-05
General information on system checkout 3
Brake circuit checkout procedure 3
Brake system checkout data sheet 15
Brake piston leakage test 25
Brake seal pressure test 25
Wet disc brake bleeding procedure 26
Parking brake bleeding procedure 26
Service brake disc wear inspection 27
Parking brake disc wear inspection 29
Brake valve bench test and adjustment 30
Dual relay valve bench test and adjustment 33
Accumulators and suspensions CEN30004-05
Accumulator charging and storage 3
Accumulator leak testing 8
Piston accumulator 10
Checking for improper suspension charge 12
Suspension oiling and charging procedures 13
Suspension pressure test 22
Payload meter IV CEN30070-03
Payload meter IV software and tools 3
Payload meter IV system configuration 3
Payload meter IV software installation 5
Payload meter IV checkout procedure 6
PLM IV system checkout data sheet 12
00 Index and foreword CEN00027-01
9
Downloading PLM IV data and possible errors 13
Cab air conditioning CEN30029-01
General information 3
Service tools and equipment 4
Detecting leaks 7
System performance test 8
Checking system oil 9
System flushing 10
Installing the manifold gauge set 11
Recovering and recycling refrigerant 12
Evacuating the air conditioning system 14
Charging the air conditioning system 15
Interface module (IM) CEN30026-02
Interface module software 2
Interface module checkout procedures 4
IGBT haul truck SIBAS® user manual, part 1 CEN30021-02
Abbreviations 4
Installation 9
Communication with the SIBAS® 32 control unit 10
Calling up the customer monitor 11
Notes on operation of the customer monitor 13
Structure of a monitor command 13
Command buffer 15
Structure of the monitor windows 15
“Window Work open” 16
“Window Lines open” 16
“Window Tile” 16
“Window Bars open” 16
“Window Set” 16
“Window Cascade” 16
“Window Close” 16
“Window close All” 16
“Window Exit” 16
“Set Port” 17
“Set Baudrate” 17
“Set String” 18
“Set Make” 19
“Set Execute” 21
“Set Record” 21
“Set DIN-Bus” 22
“Set TCN” 22
“Set Timeout” 22
“Set Wait” 22
“Set Color” 22
“Set Info” 23
“Set comment” 23
CEN00027-01 00 Index and foreword
10
“Set CHAR Set” 23
“Set Quit” 23
“Applic Func Package” 24
“Applic Connector” 25
“Applic View” 26
“Applic Signal” 26
“Applic Observer” 27
“Applic Buffer” 31
“Applic Report” 31
“Applic Legitimation” 31
“Applic Menu” 32
“Applic Traco” 32
“Applic Environment” 32
“Hardw Flash” 34
“Hardw Clock” 35
“Hardw DSP” 36
“Hardw BCD” 36
“Hardw RESET” 36
“Hardw Info” 37
“Hardw User Flash” 38
“Hardw Sys Flash” 38
“Hardw BOOT DSP” 39
“Hardw Flash” 41
“Hardw RESET” 42
“Hardw ZR” 43
“Hardw BOOT ZR” 43
“Graphic Load” 44
“Graphic Position” 44
“Graphic Time/Div” 45
“Graphic Unit/Div” 45
“Graphic Display” 45
“Graphic Color” 46
“Graphic Format” 46
IGBT haul truck SIBAS® user manual, part 2 CEN30022-02
Traco Menu 4
HW-Traco 4
SW-Traco 6
DAC_Traco 10
Events Menu 12
STatistics 13
History 14
LEL:Last EvL 15
LES:Last EvS 17
DLL:DC,LastL 18
DLS:DC,LastS 19
DAL:DC,All L 20
00 Index and foreword CEN00027-01
11
DAS:DC,All S 21
ML:Memory L 22
MS:Memory S 23
CN:Clear Norm 24
CA:Clear All 24
Test-Code 24
DS:Diag-Strc 25
User Menu 26
DAC_IO 27
Acc test 36
Engine_Test 36
X_Test_Inx 39
STate intern 40
Pedal calib 43
Language 44
OFFline-test 44
Variables 46
IV:Vehic-ID 47
Commands 48
Settings 49
Parameters 50
Temp_prot 52
Appendix 54
Background commands 54
Monitor commands for the central processing unit 56
Monitor commands for the signal processing unit 56
Installing ZR / DSP software CEN30023-02
Monitor Program – Loading software into the SIBAS® 3
Loading software into the CPU procedure 15
Loading ZR software Prog jumpers Reset 22
Loading the proper pgm file 24
Setting the system up After loading a new pgm 24
40 Troubleshooting
Fuse and circuit breaker locations CEN40009-03
Fuse and circuit breaker locations 3
Fuse block tables 4
Prelube motor fuse 5
Circuit breaker table 6
Troubleshooting by fault code, Part 1 CEN40011-05
Fault Code A001: Left front suspension pressure sensor signal high 4
Fault Code A002: Left front suspension pressure sensor signal low 5
Fault Code A003: Right front suspension pressure sensor signal high 6
Fault Code A004: Right front suspension pressure sensor signal low 7
Fault Code A005: Left rear suspension pressure sensor signal high 8
Fault Code A006: Left rear suspension pressure sensor signal low 9
CEN00027-01 00 Index and foreword
12
Fault Code A007: Right rear suspension pressure sensor signal high 10
Fault Code A008: Right rear suspension pressure sensor signal low 11
Fault Code A009: Incline sensor signal high 12
Fault Code A010: Incline sensor signal low 13
Fault Code A011: Payload meter speed sensor signal has failed 14
Fault Code A013: Body up switch has failed 15
Fault Code A014: Payload meter checksum computation has failed 16
Fault Code A016: Payload meter write to flash memory has failed 17
Fault Code A017: Payload meter flash memory read has failed 18
Fault Code A018: Right rear flat suspension cylinder warning 19
Fault Code A019: Left rear flat suspension cylinder warning 21
Fault Code A022: Carryback load excessive 23
Fault Code A100: An open circuit breaker has been detected on a relay board 25
Fault Code A101: High pressure detected across an hydraulic pump filter 26
Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level 29
Fault Code A111: Low steering pressure warning for storage by KOMTRAX Plus 31
Fault Code A115: Low steering precharge pressure detected 32
Fault Code A117: Low brake accumulator pressure warning for storage by KOMTRAX Plus 34
Fault Code A118: Brake pressure is low while in brake lock 35
Fault Code A126: Oil level in the hydraulic tank is low 37
Fault Code A127: IM-furnished +5 volt output for sensors is low 38
Fault Code A128: IM-furnished +5 volt output for sensors is high 40
Fault Code A139: Low fuel warning for storage by KOMTRAX Plus and for use by A310 42
Troubleshooting by fault code, part 2 CEN40049-01
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling
of hydraulic oil 4
Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling
of hydraulic oil 6
Fault Code A152: Starter failure 8
Fault Code A153: Battery voltage is low with the truck in operation 10
Fault Code A154: Battery charging voltage is excessive 12
Fault Code A155: Battery charging voltage is low 13
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 14
Fault Code A166: Left rear hydraulic oil temperature sensor is low 16
Fault Code A167: Right rear hydraulic oil temperature sensor is low 18
Fault Code A168: Left front hydraulic oil temperature sensor is low 20
Fault Code A169: Right front hydraulic oil temperature sensor is low 22
Fault Code A170: Left rear hydraulic oil temperature sensor is high 24
Fault Code A171: Right rear hydraulic oil temperature sensor is high 25
Fault Code A172: Left front hydraulic oil temperature sensor is high 26
Fault Code A173: Right front hydraulic oil temperature sensor is high 27
Fault Code A184: J1939 data link is not connected 28
Fault Code A190: Auto lube control has detected an incomplete lube cycle 30
Fault Code A194: Left front hydraulic oil temperature is high 32
Fault Code A195: Right front hydraulic oil temperature is high 33
Fault Code A196: Left rear hydraulic oil temperature is high 34
Fault Code A197: Right rear hydraulic oil temperature is high 35
00 Index and foreword CEN00027-01
13
Fault Code A198: Hoist pressure 1 sensor is high 36
Fault Code A199: Hoist pressure 2 sensor is high 37
Fault Code A200: Steering pressure sensor is high 38
Fault Code A201: Brake pressure sensor is high 39
Fault Code A202: Hoist pressure 1 sensor is low 40
Fault Code A203: Hoist pressure 2 sensor is low 41
Fault Code A204: Steering pressure sensor is low 42
Fault Code A205: Brake pressure sensor is low 43
Fault Code A206: Ambient temperature sensor is high 44
Fault Code A207: Ambient temperature sensor is low 45
Troubleshooting by fault code, Part 3 CEN40115-00
Fault Code A213: Parking brake should have applied but is detected as not having applied 4
Fault Code A214: Parking brake should have released but is detected as not having released8
Fault Code A215: Brake auto apply valve circuit is defective 12
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit
16
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted18
Fault Code A230: Parking brake has been requested while truck still moving 20
Fault Code A231: The body is up while traveling or with selector in forward or neutral 22
Fault Code A233: Drive System Control Link is not connected 24
Fault Code A235: Steering accumulator is in the process of being bled down 26
Fault Code A236: The steering accumulator has not properly bled down after 90 seconds 28
Fault Code A237: The CAN/RPC connection to the display is open 30
Fault Code A238: Drive System and IM are reporting different park brake status 32
Fault Code A239: The Drive System and IM are reporting different brake lock status 34
Fault Code A240: The keyswitch input to the Interface Module is open 36
Fault Code A242: Fuel gauge within the dash display panel is defective 37
Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective38
Fault Code A244: Drive system temperature gauge within the dash display panel is defective39
Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective40
Fault Code A246: Payload meter reports truck overload 41
Fault Code A247: Low steering pressure warning for display to operator 42
Fault Code A248: Status module within the dash display panel is defective 43
Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted 44
Fault Code A250: Battery voltage is low with the truck parked 46
Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground48
Fault Code A252: Start enable output circuit is either open or shorted to ground 49
Fault Code A253: Steering bleed circuit is not open while running 50
Fault Code A256: Red warning lamp in the dash display (driven by IM) is open 52
Fault Code A257: Payload CAN/RPC is not connected 54
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 56
Troubleshooting by fault code, Part 4 CEN40051-00
Fault Code A260: Parking brake failure 4
Fault Code A261: Low brake accumulator pressure warning for display to operator 6
Fault Code A262: Steering bleed valve circuit open during shutdown 8
Fault Code A264: Parking brake relay circuit is defective 10
CEN00027-01 00 Index and foreword
14
Fault Code A265: Service brake failure 12
Fault Code A266: Selector switch was not in park while attempting to crank engine 14
Fault Code A267: Parking brake was not set while attempting to crank engine 15
Fault Code A268: Secondary engine shutdown while cranking 16
Fault Code A270: Brake lock switch power supply is not on when required 18
Fault Code A271: Shifter not in gear 22
Fault Code A272: Brake lock switch power supply is not off when required 24
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit26
Fault Code A274: A brake setting fault has been detected 28
Fault Code A275: A starter has been detected as engaged without a cranking attempt 30
Fault Code A277: Parking brake applied while loading 32
Fault Code A278: Service brake applied while loading 34
Fault Code A279: Low steering pressure switch is defective 36
Fault Code A280: Steering accumulator bleeddown switch is defective 37
Fault Code A281: Brake lock degrade switch is defective 38
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has
reached 7 40
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set42
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was
operated 44
Fault Code A285: The parking brake was not set when the keyswitch was turned off 46
Fault Code A286: A fault was detected in the shutdown delay relay circuit 48
Fault Code A292: The shutdown delay relay has remained on after the latched keyswitch circuit is off50
Troubleshooting by fault code, part 5 CEN40052-01
Fault Code A303: Shifter is defective 4
Fault Code A304: Auto lube grease level fault 6
Fault Code A305: Auto lube circuit is defective 8
Fault Code A309: No brakes applied when expected 10
Fault Code A310: Low fuel warning 12
Fault Code A311: Brake lock switch is on when it should not be 14
Fault Code A312: DCDC converter 12 volt circuit sensing is producing low readings 16
Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings 17
Fault Code A315: DCDC converter 12 volt circuit is low 18
Fault Code A316: Starter engagement has been attempted with engine running 20
Fault Code A317: Operation of brake auto apply valve without a detected response 22
Fault Code A318: Unexpected power loss to Interface Module 25
Fault Code A328: Drive system not powered up 26
Fault Code A334: Selector switch not in park when propel was either not ready or at rest 27
Fault Code A335: Manual/Auto Apply Pressure Fault 28
Fault Code A350: Overload on output 1B 29
Fault Code A351: Overload on output 1E 30
Fault Code A352: Overload on output 1H 32
Fault Code A353: Overload on output 1J 33
Fault Code A354: Overload on output 1K 34
Fault Code A355: Overload on output 1L 35
Fault Code A356: Overload on output 1M 36
Fault Code A357: Overload on output 1N 37
00 Index and foreword CEN00027-01
15
Fault Code A358: Overload on output 1P 38
Fault Code A359: Overload on output 1R 40
Fault Code A360: Overload on output 1S 42
Fault Code A361: Overload on output 1T 44
Fault Code A362: Overload on output 1U 46
Fault Code A363: Overload on output 1X 47
Fault Code A364: Overload on output 1Y 48
Fault Code A365: Overload on output 1Z 49
Drive system fault code table, part 1 CEN40041-01
Summary 4
How to use this document 4
Event classification 6
1 L3C SYS: Time slice overflow CPU T1 7
2 L3C SYS: Time slice overflow CPU T2 7
3 L3C SYS: Time slice overflow CPU T3 7
4 L3C SYS: Time slice overflow CPU T4 7
5 L3C SYS: Time slice overflow CPU T5 7
6 L3C SYS: Time slice overflow CPU T6 7
7 L3C SYS: Time slice overflow CPU T7 7
8 L3C SYS: Time slice overflow CPU T8 7
10 L2A SYS: Pulse inhibit/asa inhibit PSU–ONLINE 8
11 L3D SYS: Pulse inhibit/asa inhibit PSU-Start-up 8
12 L1A SYS: SIBAS® blower fault 9
13 L1B SYS: Undervoltage in SIBAS® battery for BRAM 9
14 L3C SYS: SIBAS® power supply failure 24V for pulse amplifier 10
15 L3C SYS: SIBAS® power supply failure +5V 11
16 L3C SYS: SIBAS® power supply failure +15V 12
17 L3C SYS: SIBAS® power supply failure –15V 13
18 L3C SYS: SIBAS® power supply failure +24V 14
19 L3C SYS: SIBAS® power supply failure –24V 15
20 L3C SYS: SIBAS® power supply failure primary 16
21 L3C SYS: FPGA clock missing for PSU 16
22 L3C SYS: Pulse inhibit by reset in PSU from CPU 17
24 L3C SYS: General protection error (G10) 17
25 L3C SYS: Total block 18
26 L1B SYS: Permanent inhibit fault active 19
27 L1B SYS: Regular inhibit fault active 19
28 L1A SYS: GW Test stopped by A/D converter faulty 20
30 L3C DSP A: Initialization fault detected by DSP 20
31 L3C DSP A: SW-WatchdoG 21
32 L3C DSP A: Initialization fault detected by CPU 22
33 L1B DSP A: SW-Traco triggered 22
34 L1B DSP A: SW-Traco full 23
35 L3C DSP A: Time slice overflow T1 24
36 L3C DSP A: Time slice overflow T2 24
37 L3C DSP A: Time slice overflow T3 24
CEN00027-01 00 Index and foreword
16
38 L3C DSP A: Time slice overflow T4 24
39 L1A DSP A: Communication HSCX data from DSP B missing 25
40 L1A DSP A: Communication HSCX data from DSP T missing 25
41 L3C DSP A: Current offset during pulse block 26
42 L3C DSP A: Current offset during no pulse block 26
43 L3A DSP A: Overcurrent fault 27
44 L3C DSP A: Current transducer defective phase U 28
45 L3C DSP A: Current transducer defective phase W 29
48 L1A DSP A: Modulation software fault 29
49 L3A DSP A: Active current controller at limit 30
Drive system fault code table, part 2 CEN40042-00
50 L3A DSP A: Active current reference at limit 4
51 L1A DSP A: Braking chopper controller at limit 4
52 L3C DSP A: Phase unbalance too large 5
53 L3A DSP A: Pulse block by DSP software 6
54 L3C DSP A: U/F Card defective 6
55 L3C DSP A: Difference in current of phase U over limit 7
56 L3C DSP A: Difference in current of phase W over limit 7
60 L3C DSP B: Initialization fault detected by DSP 8
61 L3C DSP B: SW-Watchdog 8
62 L3C DSP B: Initialization fault detected by CPU 9
63 L1B DSP B: SW-Traco triggered 9
64 L1B DSP B: SW-Traco full 10
65 L3C DSP B: Time slice overflow T1 10
69 L1A DSP B: Communication HSCX data from DSP A missing 11
70 L1A DSP B: Communication HSCX data from DSP T missing 11
71 L3C DSP B: Current offset during pulse block 12
72 L3C DSP B: Current offset during no pulse block 12
73 L3A DSP B: Overcurrent fault 13
74 L3C DSP B: Current transducer defective phase V 14
75 L3C DSP B: Current transducer defective phase W 15
78 L1A DSP B: Modulation software fault 15
79 L3A DSP B: Active current controller at limit 16
80 L3A DSP B: Active current reference at limit 16
81 L1A DSP B: Braking chopper controller at limit 16
82 L3C DSP B: Phase unbalance too large 17
83 L3A DSP B: Pulse block by DSP software 17
84 L3C DSP B: U/F Card defective 18
85 L3C DSP B: Difference in current of phase V over limit 18
86 L3C DSP B: Difference in current of phase W over limit 19
90 L3C DSP T: Initialization fault detected by DSP 19
91 L3C DSP T: SW-Watchdog 20
92 L3C DSP T: Initialization fault detected by CPU 21
93 L1B DSP T: SW-Traco triggered 21
94 L1B DSP T: SW-Traco full 22
95 L3C DSP T: Time slice overflow T1 22
00 Index and foreword CEN00027-01
17
96 L3C DSP T: Time slice overflow T2 22
97 L3C DSP T: Time slice overflow T3 22
98 L3C DSP T: Time slice overflow T4 22
99 L1A DSP T: Communication HSCX data from DSP A missing 23
Drive system fault code table, part 3 CEN40043-00
100 L1A DSP T: Communication HSCX data from DSP B missing 4
101 L3C DSP T: Current offset during pulse block 4
102 L3C DSP T: Current offset during no pulse block 5
103 L3A DSP T: Overcurrent fault 6
104 L3C DSP T: Current transducer defective phase U 7
105 L3C DSP T: Current transducer defective phase V 8
106 L3C DSP T: Current transducer defective phase W 9
107 L3C DSP T: Sum of output current not equal zero 10
108 L1A DSP T: Modulation software fault 10
109 L1A DSP T: Voltage controller at limit 11
112 L3C DSP T: Phase unbalance too large 11
113 L3A DSP T: Pulse block by DSP software 12
114 L3C DSP T: U/F Card defective 12
117 L3C DSP T: Crowbar fired by DSP T 13
119 L1C DSP T: Voltage transducer U34 not ok 14
120 L3C IO: Supervision bus clock 14
121 L3C IO: Supervision I/O clock 15
122 L3C IO: Incorrect FPGA version identifier 15
123 L3C IO: Incorrect FPGA application version identifier 16
124 L3C IO: Incorrect module version identifier 16
125 L3C/L1A IO: AD Converter faulty 17
126 L3C IO: GW Comparator faulty during start-up test 17
127 L3C IO: Test voltage not equal zero 18
128 L1A IO: SIBAS® Temperature out of range 18
129 L3C IO: Incorrect EBIN card identifier 19
130 L3C IO: Front plug monitoring 20
131 L3C IO: CPU Watchdog triggered 21
132 L3C IO: DSP A Watchdog triggered 21
133 L3C IO: DSP B Watchdog triggered 22
134 L3C IO: DSP T Watchdog triggered 22
135 L3C IO: CPU Reset triggered 23
138 L1B IO: CPU Traco triggered 23
146 L3A IO: Pulse block from I/O 24
150 L3A IO: DC link voltage A level 1 exceeded 24
151 L3A IO: DC link voltage B level 1 exceeded 25
152 L3C IO: Trolley line overvoltage 26
154 L3B IO: Trolley line overcurrent 27
155 L2B IO: Trolley line current transducer faulty 27
156 L2B IO: Trolley line voltage transducer faulty 28
160 L3A IO: Throttle pedal out of range 28
161 L3A IO: Retard pedal out of range 29
CEN00027-01 00 Index and foreword
18
162 L1A IO: Cruise speed control module out of range 29
180 L3C UWSA1: Supervision bus clock 30
181 L3C UWSA1: Supervision module clock 30
182 L3C UWSA1: Incorrect FPGA version identifier 31
183 L3C UWSA1: Incorrect FPGA project identifier 31
184 L3C UWSA1: GW Comparator faulty during start-up test 32
185 L1A UWSA1: ADC Faulty 32
186 L3C UWSA1: Configuration failure 33
187 L1A UWSA1: Hardware failure counter / processor 33
188 L3A UWSA1: Peak current protection active 34
189 L3D UWSA1: Peak current protection pulse start 35
190 L3D UWSA1: Number of peak current protection >limit 36
191 L3D UWSA1: Supervision switching frequency 37
193 L1A UWSA1: Overvoltage level 1 exceeded 37
196 L3D UWSA1: Limit 5 overcurrent phase U 38
197 L3D UWSA1: Limit 5 overcurrent phase V 38
198 L3D UWSA1: Limit 5 overcurrent phase W 38
199 L3D UWSA1: Limit 5 overvoltage DC bus 39
Drive system fault code table, part 4 CEN40044-00
201 L3D UWSA1: Checkback INVA1 L1U faulty 5
202 L3D UWSA1: Checkback INVA1 L1L faulty 5
203 L3D UWSA1: Checkback INVA1 L2U faulty 5
204 L3D UWSA1: Checkback INVA1 L2L faulty 5
205 L3D UWSA1: Checkback INVA1 L3U faulty 5
206 L3D UWSA1: Checkback INVA1 L3L faulty 5
207 L3D UWSA1: Checkback chopper A faulty 5
210 L3C UWSB1: Supervision bus clock 6
211 L3C UWSB1: Supervision module clock 6
212 L3C UWSB1: Incorrect FPGA version identifier 7
213 L3C UWSB1: Incorrect FPGA project identifier 7
214 L3C UWSB1: GW Comparator faulty during start-up test 8
215 L1A UWSB1: ADC Faulty 8
216 L3C UWSB1: Configuration failure 9
217 L1A UWSB1: Hardware failure counter / processor 9
218 L3A UWSB1: Peak current protection active 10
219 L3D UWSB1: Peak current protection pulse start 11
220 L3D UWSB1: Number of peak current protection >limit 12
221 L3D UWSB1: Supervision switching frequency 13
223 L1A UWSB1: Overvoltage level 1 exceeded 13
226 L3D UWSB1: Limit 5 overcurrent phase V 14
227 L3D UWSB1: Limit 5 overcurrent phase U 14
228 L3D UWSB1: Limit 5 overcurrent phase W 14
229 L3D UWSB1: Limit 5 overvoltage DC bus 15
231 L3D UWSB1: Checkback INVB1 L1U Faulty 16
232 L3D UWSB1: Checkback INVB1 L1L Faulty 16
233 L3D UWSB1: Checkback INVB1 L2U Faulty 16
00 Index and foreword CEN00027-01
19
234 L3D UWSB1: Checkback INVB1 L2L Faulty 16
235 L3D UWSB1: Checkback INVB1 L3U Faulty 16
236 L3D UWSB1: Checkback INVB1 L3L Faulty 16
237 L3D UWSB1: Checkback chopper B Faulty 16
240 L3C UWSA2: Supervision bus clock 17
241 L3C UWSA2: Supervision module clock 17
242 L3C UWSA2: Incorrect FPGA version identifier 18
243 L3C UWSA2: Incorrect FPGA project identifier 18
244 L3C UWSA2: GW Comparator faulty during start-up test 19
245 L1A UWSA2: ADC Faulty 19
246 L3C UWSA2: Configuration failure 20
247 L1A UWSA2: Hardware failure counter / processor 20
248 L3A UWSA2: Peak current protection active 21
249 L3D UWSA2: Peak current protection pulse start 22
250 L3D UWSA2: Number of peak current protection >limit 23
251 L3D UWSA2: Supervision switching frequency 24
253 L1A UWSA2: Overvoltage level 1 exceeded 24
256 L3D UWSA2: Limit 5 overcurrent phase U1 25
257 L3D UWSA2: Limit 5 overcurrent phase V1 25
258 L3D UWSA2: Limit 5 overcurrent phase W1 25
259 L3D UWSA2: Limit 5 overvoltage DC bus 26
261 L3D UWSA2: Checkback INVA2 L1U faulty 27
262 L3D UWSA2: Checkback INVA2 L1L faulty 27
263 L3D UWSA2: Checkback INVA2 L2U faulty 27
264 L3D UWSA2: Checkback INVA2 L2L faulty 27
265 L3D UWSA2: Checkback INVA2 L3U faulty 27
266 L3D UWSA2: Checkback INVA2 L3L faulty 27
267 L3D UWSA2: Checkback chopper C faulty 27
270 L3C UWSB2: Supervision bus clock 28
271 L3C UWSB2: Supervision module clock 28
272 L3C UWSB2: Incorrect FPGA version identifier 29
273 L3C UWSB2: Incorrect FPGA project identifier 29
274 L3C UWSB2: GW Comparator faulty during start-up test 30
275 L1A UWSB2: ADC Faulty 30
276 L3C UWSB2: Configuration failure 31
277 L1A UWSB2: Hardware failure counter / processor 31
278 L3A UWSB2: Peak current protection active 32
279 L3D UWSB2: Peak current protection pulse start 33
280 L3D UWSB2: Number of peak current protection >limit 34
281 L3D UWSB2: Supervision switching frequency 35
283 L1A UWSB2: Overvoltage level 1 exceeded 35
286 L3D UWSB2: Limit 5 overcurrent phase V1 36
287 L3D UWSB2: Limit 5 overcurrent phase U1 36
288 L3D UWSB2: Limit 5 overcurrent phase W1 36
289 L3D UWSB2: Limit 5 overvoltage DC bus 37
291 L3D UWSB2: Checkback INVB2 L1U Faulty 38
CEN00027-01 00 Index and foreword
20
292 L3D UWSB2: Checkback INVB2 L1L Faulty 38
293 L3D UWSB2: Checkback INVB2 L2U Faulty 38
294 L3D UWSB2: Checkback INVB2 L2L Faulty 38
295 L3D UWSB2: Checkback INVB2 L3U Faulty 38
296 L3D UWSB2: Checkback INVB2 L3L Faulty 38
297 L3D UWSB2: Checkback chopper D Faulty 38
Drive system fault code table, part 5 CEN40045-01
300 L3C UWSST: Supervision bus clock 5
301 L3C UWSST: Supervision module clock 5
302 L3C UWSST: Incorrect FPGA version identifier 6
303 L3C UWSST: Incorrect FPGA project identifieR 6
304 L3C UWSST: GW Comparator faulty during start-up test 7
305 L1A UWSST: ADC Faulty 7
306 L3C UWSST: Configuration failure 8
307 L1A UWSST: Hardware failure counter / processor 8
308 L3A UWSST: Peak current protection active 9
310 L3D UWSST: Number of peak current protection >limit 10
311 L3D UWSST: Supervision switching frequency 11
314 L3C UWSST: Crowbar is fired without command 12
319 L3D UWSST: Limit 5 overvoltage DC bus 14
321 L3D UWSST: Checkback INVST L1U Faulty 15
322 L3D UWSST: Checkback INVST L1L Faulty 15
323 L3D UWSST: Checkback INVST L2U Faulty 15
324 L3D UWSST: Checkback INVST L2L Faulty 15
325 L3D UWSST: Checkback INVST L3U Faulty 15
326 L3D UWSST: Checkback INVST L3L Faulty 15
327 L3C UWSST: Checkback crowbar faulty 16
330 L1A BUS: CAN Communication failure 17
331 L1A BUS: Serial link communication failure 17
332 L1A BUS: Truck is over loaded 17
333 L1B TR: Transient traco is triggered 18
334 L1B TR: Transient traco is full 18
340 L1A ETM: ADC Failure for ETM1 18
341 L1A ETM: ADC Failure for ETM2 19
342 L1A ETM: ADC Failure for ETM3 19
343 L1A ETM: ADC Failure for ETM4 19
344 L1A MEFA: ADC Failure 20
345 L3C HL: Gate unit power supply A defective 20
346 L3C HL: Gate unit power supply B defective 21
351 L1A DRZ: LIMP Mode A active 22
352 L1A DRZ: Limp mode B active 22
353 L1A DRZ: Low battery voltage 23
354 L1B BUS: Engine floor input increasing minimum engine speed 23
355 L1B DM: Data store switch pressed 24
356 L1B DM: Diagnosis memory configuration failure 24
357 L1B DM: Diagnosis memory occupation > 75% 24
00 Index and foreword CEN00027-01
21
358 L1B DM: Diagnosis memory full 25
359 L1B DM: Test event 25
360 L2A EXT: Main blower air flow supervision 26
361 L2A EXT: Minimum engine speed supervision 27
362 L1A EXT: Main blower pressure switch malfunction 28
363 L1A EXT: Shift lever supervision 29
364 L2A EXT: Engine derate protection active 30
365 L1A EXT: Truck external plug monitoring 30
367 L3A EXT: DC Power off mod request (rest switch on) 31
369 L1A EXT: Doppler sensor defective 33
370 L1A EXT: Auto lube control defective 34
372 L1A EXT: Service brake pressed at high speeD 34
373 L1A EXT: Service brake on above speed limit 35
374 L1A EXT: Anti-roll control malfunction 35
375 L3B BEF: CB301 Circuit breaker defective 36
376 L3B BEF: K303/K304 Contactor defective 37
377 L3C STP: Voltage reading incorrect between trolley line and voltage in stepdown box 38
382 L3B BEF: K103 Feedback defective 39
383 L3B BEF: K105 Feedback defective 39
384 L1A BEF: K107 Feedback defective 40
385 L1A BEF: K109 Feedback defective 40
386 L1A BEF: K111 Feedback defective 41
387 L1A BEF: Limp mode selector defective 41
388 L2B BEF: CB113 Tripped 42
390 L3D IUW: Output current supervision INV A 42
391 L3D IUW: Output current supervision INV B 43
392 L3B IUW: Precharge supervision 1 44
393 L3B IUW: Precharge supervision 2 45
394 L3A IUW: DC Link undervoltage 46
395 L2B IUW: Trolley line undervoltage 47
397 L3B IUW: Field regulator current setpoint supervision 48
398 L2B IUW: Field regulator output current supervision 49
399 L3B IUW: Alternator overcurrent protection 50
Drive system fault code table, part 6 CEN40046-00
400 L2C IUW: Alternator overload warning 4
401 L2B IUW: Alternator overload protection 4
402 L3C IUW: Alternator AC current sensor faulty 5
403 L2A IUW: DC Link voltage out of range in propel 6
404 L3A IUW: DC Link voltage out of range retard 7
405 L3A IUW: DC Link voltage out of range for ST operation 8
406 L3B IUW: DC Link controller supervision 9
407 L2C IUW: Motor torque square T supervision 10
408 L2C IUW: Motor current square T supervision 10
409 L1A IUW: DC Link discharge time exceeded limit 11
410 L2B IUW: Ground fault at positive DC link detected 12
411 L2B IUW: Ground fault at negative DC link detected 13
CEN00027-01 00 Index and foreword
22
412 L2B IUW: Ground fault at AC side detected 14
413 L2B IUW: Ground fault 15
414 L3C IUW: Chopper A current supervision 16
415 L3C IUW: Chopper B current supervision 17
416 L3C IUW: Chopper C current supervision 18
417 L3C IUW: Chopper D current supervision 19
418 L3D IUW: Output current supervision INV ST 20
419 L2A IUW: Vehicle overspeed supervisioN 21
420 L1A IUW: DC Link voltage sensor A faulty 22
421 L1A IUW: DC Link voltage sensor B faulty 23
422 L3C IUW: ST Inverter failure 24
423 L3B IUW: DC Grid fan circuit failure 24
424 L2B IUW: Cooling water pressure out of range 25
425 L2B IUW: Cooling water level out of range 26
426 L1A IUW: Water pump motor overtemperature 27
427 L1A IUW: Retard limit supervision 27
428 L1A DRZ: Front wheel A speed sensor supervision 28
429 L1A DRZ: Front wheel B speed sensor supervision 29
430 L3D DRZ: Motor A speed sensor supervision 30
431 L3D DRZ: Motor B speed sensor supervision 31
432 L3C DRZ: Alternator speed sensor supervision 32
433 L2A DRZ: Motor A maximum speed exceeded 33
434 L2A DRZ: Motor B maximum speed exceeded 33
435 L1A DRZ: Alternator maximum speed exceeded 34
436 L3A DRZ: Motor A/B rotation inconsistency 35
437 L3A DRZ: Motor A torque supervision 36
438 L3A DRZ: Motor B torque supervision 37
439 L3C SIV: Start-up sequence can’t pass due to GUPS failure 38
440 L3C SIV: Start-up sequence can’t pass due to K103/K105 failure 39
441 L3C SIV: Start-up sequence can’t pass due to IGBT failure 40
442 L3C SIV: Start-up sequence can’t pass due to CB301 OR K303 failure 41
443 L3C SIV: Start-up sequence can’t pass due to crowbar failure 42
447 L1A SIV: Direct trolley engage sequence supervision 43
448 L1A SIV: Direct trolley disengage sequence supervision 44
Drive system fault code table, part 7 CEN40047-01
450 L1A TMP: SIBAS® Temperature < low limit 5
451 L1A TMP: SIBAS® Temperature > warning limit 5
452 L3B TMP: SIBAS® Temperature > shutdown limit 6
453 L3A TMP: IGBT Module A101 temperature < low limit 7
454 L2C TMP: IGBT Module A101 temperature > APRS limit 8
455 L3A TMP: IGBT Module A101 temperature > shutdown limit 9
456 L3A TMP: IGBT Module A102 temperature < low limit 10
457 L2C TMP: IGBT Module A102 temperature > APRS limit 11
458 L3A TMP: IGBT Module A102 temperature > shutdown limit 12
459 L3A TMP: IGBT ModulE A201 temperature < low limit 13
460 L2C TMP: IGBT Module A201 temperature > APRS limit 14
00 Index and foreword CEN00027-01
23
461 L3A TMP: IGBT Module A201 temperature > shutdown limit 15
462 L3A TMP: IGBT Module A202 temperature < low limit 16
463 L2C TMP: IGBT Module A202 temperature > APRS limit 17
464 L3A TMP: IGBT Module A202 temperature >shutdown limit 18
465 L3A TMP: ST Module temperature < low limit 19
466 L2C TMP: ST Module temperature > warning limit 20
467 L3A TMP: ST Module temperature > shutdown limit 21
468 L2B TMP: SR Module temperature < low limit 22
469 L2C TMP: SR Module temperature > warning limit 23
470 L2B TMP: SR Module temperature > shutdown limit 24
471 L2C TMP: Wheel motor A stator temperature > APRS limit 25
472 L3A TMP: Wheel motor A stator temperature > shutdown limit 26
473 L2C TMP: Wheel motor B Stator temperature > APRS limit 27
474 L3A TMP: Wheel motor B stator temperature shutdown limit 28
475 L2C TMP: Wheel motor A, DE bearing temperature > warning limit 29
476 L3A TMP: Wheel motor A, DE bearing temperature > shutdown limit 30
477 L2C TMP: Wheel motor A NDE bearing temperature > warning limit 31
478 L3A TMP: Wheel motor A NDE bearing temperature > shutdown limit 32
479 L2C TMP: Wheel motor B DE bearing temperature > warning limit 33
480 L3A TMP: Wheel motor B DE bearing temperature > shutdown limit 34
481 L2C TMP: Wheel motor B NDE bearing temperature > warning limit 35
482 L3A TMP: Wheel motor B NDE bearing temperature > shutdown limit 36
483 L2C TMP: Alternator stator temperature > APRS limit 37
484 L2B TMP: Alternator stator temperature > shutdown limit 38
485 L2C TMP: Alternator bearing temperature > warning limit 39
486 L2B TMP: Alternator bearing temperature > shutdown limit 40
487 L1A TMP: Cooling water inlet temperature < low limit 41
488 L2C TMP: Cooling water inlet temperature > warning limit 42
489 L2B TMP: Cooling water inlet temperature > shutdown limit 43
490 L1A TMP: Cooling water outlet temperature < low limit 44
491 L2C TMP: Cooling water outlet temperature > warning limit 45
492 L2B TMP: Cooling water outlet temperature > shutdown limit 46
493 L1A TMP: Cooling water delta T too high 47
495 L2C TMP: Inverter cab temperature > warning limit 48
496 L2B TMP: Inverter cab temperature > shutdown limit 49
497 L2C TMP: Inside cooler outlet temperature > warning limit 50
498 L2B TMP: Inside cooler outlet temperature > shutdown limit 51
499 L1A TMP: Main blower motor stator temperature > warning limit 52
500 L1A TMP: Main blower motor stator temperature > shutdown limit 53
505 L1A TMP: Wheel motor A rotor temperature > limit 54
506 L1A TMP: Wheel motor B rotor temperature > limit 55
508 L1A ETM1: Alternator PT100 open circuit 56
509 L1A ETM1: Main blower stator PT100 open circuit 56
510 L1A ETM1: Grid blower statoR PT100 open circuit 56
511 L1A ETM1: Inverter CAB PT100 open circuit 56
512 L1A ETM1: Ambient PT100 open circuit 56
CEN00027-01 00 Index and foreword
24
513 L1A ETM1: Heater exchanger PT100 open circuit 56
514 L1A ETM1: Cooling water inlet PT100 open circuit 56
515 L1A ETM1: Cooling water outlet PT100 open circuit 56
516 L1A ETM2: Motor A NDE Bearing PT100 open circuit 57
517 L1A ETM2: Motor A DE Bearing PT100 open circuit 57
518 L1A ETM2: Motor B NDE Bearing PT100 open circuit 57
519 L1A ETM2: Motor B DE Bearing PT100 open circuit 57
520 L1A ETM2: Alternator Bearing PT100 open circuit 57
521 L1A ETM2: Motor A stator PT100 open circuit 57
522 L1A ETM2: Motor B stator PT100 open circuit 57
523 L1A ETM2: Motor inlet air PT100 open circuit 57
524 L1A ETM3: IGBT Module A101 PT100 open circuit 58
525 L1A ETM3: IGBT Module A102 PT100 open circuit 58
526 L1A ETM3: IGBT Module A103 PT100 open circuit 58
527 L1A ETM3: IGBT Module A104 PT100 open circuit 58
528 L1A ETM3: IGBT Module A201 PT100 open circuit 58
529 L1A ETM3: IGBT Module A202 PT100 open circuit 58
530 L1A ETM3: IGBT Module A203 PT100 open circuit 58
531 L1A ETM3: IGBT Module A204 PT100 open circuit 58
532 L1A ETM3: ST Module PT100 open circuit 59
533 L1A ETM3: SR Module PT100 open circuit 59
534 L1A ETM3: Channel 7 PT100 open circuit 59
535 L1A ETM3: Channel 8 PT100 open circuit 59
536 L1A ETM4: Channel 1 PT100 open circuit 60
537 L1A ETM4: Channel 2 PT100 open circuit 60
538 L1A ETM4: Channel 3 PT100 open circuit 60
539 L1A ETM4: Channel 4 PT100 open circuit 60
540 L1A ETM4: Channel 5 PT100 open circuit 60
541 L1A ETM4: Channel 6 PT100 open circuit 60
542 L1A ETM4: Channel 7 PT100 open circuit 60
543 L1A ETM4: Channel 8 PT100 open circuit 60
544 L1A ETM4: SR Module PT100 open circuit 60
550 L3A TMP: Inverter A module temperature < low limit 61
551 L2C TMP: Inverter A module temperature > APRS limit 62
552 L3A TMP: Inverter A module temperature > shutdown limit 63
553 L3A TMP: Inverter B module temperature < low limit 64
554 L2C TMP: Inverter B module temperature > APRS limit 65
555 L3A TMP: Inverter B module temperature > shutdown limit 66
556 L3A TMP: Chopper A module temperature < low limit 67
557 L2C TMP: Chopper A module temperature > APRS limit 68
558 L3A TMP: Chopper A module temperature > shutdown limit 69
559 L3A TMP: Chopper B module temperature < low limit 70
560 L2C TMP: Chopper B module temperature > APRS limit 71
561 L3A TMP: Chopper B module temperature > shutdown limit 72
Cab air conditioning CEN40008-02
Preliminary checks 3
00 Index and foreword CEN00027-01
25
Diagnosis of gauge readings and system performance 3
Troubleshooting by manifold gauge set readings 4
Reserve engine oil system CEN40010-00
Pumping unit LED signals 3
Circuit fuses 3
Steering system CEN40104-05
Steering circuit troubleshooting chart 3
Steering circuit troubleshooting guidelines 5
Basic hydraulic system checks 6
System leakage check 7
Steering pump troubleshooting guide 9
Pump pressure control checks 12
Automatic lubrication (auto lube) system CEN40202-00
Autolube troubleshooting chart 3
50 Disassembly and assembly
General information CEN50001-06
Special tool list 3
Wheels, spindles and rear axle CEN50022-06
General precautions for tires and rims 3
Rim components 4
Removal and installation of front wheel 5
Removal and installation of rear wheel 7
Removal and installation of tires 10
Removal and installation of front wheel hub and spindle 12
Disassembly and assembly of front wheel hub and spindle 16
Removal and installation of wheel motor 21
Removal and installation of electric motor 27
Disassembly and assembly of wheel motor transmission 28
Disassembly and assembly of low speed carrier 47
Disassembly and assembly of high speed carrier 52
Removal and installation of rear axle 57
Removal and installation of anti-sway bar 59
Removal and installation of pivot pin 61
Pivot eye and bearing service 62
Brake system CEN50030-01
Removal and installation of brake valve 3
Disassembly and assembly of brake valve/pedal assembly 4
Removal and installation of dual relay valve 7
Removal and installation of brake manifold 9
Disassembly and assembly of brake manifold 10
Removal and installation of brake accumulator 11
Disassembly and assembly of brake accumulator 12
Disassembly and assembly of wheel brake 16
Removal and installation of rear brake assembly 32
Removal and installation of parking brake 34
CEN00027-01 00 Index and foreword
26
Disassembly and assembly of parking brake 36
Steering system CEN50034-04
Removal and installation of steering control unit 3
Disassembly and assembly of steering control unit 5
Removal and installation of steering column 10
Removal and installation of steering wheel 11
Removal and installation of bleeddown manifold 12
Removal and installation of flow amplifier 15
Disassembly and assembly of flow amplifier 15
Removal and installation of steering cylinders and tie rod 18
Disassembly and assembly of steering cylinders 19
Removal and installation of steering/brake pump 20
Disassembly and assembly of steering/brake pump 23
Removal and installation of bladder style steering accumulators 33
Disassembly and assembly of bladder style steering accumulators 34
Removal and installation of piston style steering accumulators 37
Disassembly and assembly of piston accumulators 39
Suspensions CEN50005-08
Removal and installation of front suspension 3
Minor front suspension repairs (lower bearing and seals) 10
Major front suspension rebuild 11
Removal and installation of rear suspension 14
Disassembly and assembly of rear suspension 17
Hoist circuit CEN50006-04
Removal and installation of hoist pump 3
Disassembly and assembly of hoist pump 5
Removal and installation of hoist valve 13
Disassembly and assembly of hoist valve 14
Overcenter valve manifold service 21
Removal and installation of hoist pilot valve 22
Disassembly and assembly of hoist pilot valve 23
Removal and installation of hoist cylinders 25
Disassembly and assembly of hoist cylinders 27
Operator cab CEN50007-05
Removal and installation of operator cab 3
Removal and installation of cab door 6
Disassembly and assembly of cab door 6
Adjustment of cab door 13
Removal and installation of side window glass 16
Removal and installation of windshield and rear window glass 17
Removal and installation of windshield wiper motor 19
Removal and installation of windshield wiper arm 20
Removal and installation of windshield wiper linkage 20
Removal and installation of operator seat 21
Removal and installation of passenger seat 27
Removal and installation of seat belts (standard seats) 28
00 Index and foreword CEN00027-01
27
Removal and installation of seat belts (optional seats) 30
Body and structures CEN50024-02
Removal and installation of dump body 3
Removal and installation of body pads 5
Removal and installation of diagonal ladder/hood and grille assembly 8
Removal and installation of right deck 9
Removal and installation of left deck 11
Removal and installation of fuel tank 13
Removal and installation of fuel gauge sender (S/N A50003 – A50011) 15
Removal and installation of fuel gauge sender (S/N A50012 & up) 15
Disassembly and assembly of fuel tank breather 16
Removal and installation of hydraulic tank 17
Cab air conditioning CEN50028-03
Replacement of air conditioning system components 3
Power module CEN50021-04
Removal and installation of power module 3
Exhaust tube installation 11
Exhaust blanket installation 11
Removal and installation of alternator 12
Removal and installation of engine 18
Removal and installation of radiator 19
Repairing the radiator 22
Automatic lubrication (autolube) system CEN50029-01
Lubrication system priming 3
Disassembly and assembly of lubrication pump 3
Three phase wheel motor CEN50026-01
Transport 5
Storage 6
Safety guidelines 8
Maintenance intervals 9
Maintenance work on the installed motor 9
Regreasing the bearings 10
Applying grease to the bearings 10
Checking the interior of the motor for water 11
Removing the coupling 13
Disassembling the rotor 15
Removing the rubber seals and the air baffles 19
Removing the bearing and labyrinth ring 20
Cleaning 21
Stator inspection 21
Rotor inspection 21
Testing the insulation 22
Work on the bearings 23
Important general instructions 24
Assembling the rubber seals and the air baffles 25
Assembly after special repair work 27
CEN00027-01 00 Index and foreword
28
Bearing installation (D-end) 28
Bearing installation (N-end) 31
Assembling the bearing shield (N-end) at the stator frame 34
Installing the bearing 36
Installing the rotor 38
Installing the labyrinth ring 40
Installing accessories (D- and N-end) 42
Running in the bearings 46
Installing the gear wheel 47
Installing the coupling 48
Assembly conditions and instructions 49
Replacing defective connecting leads 50
Repairing the stator winding insulation 51
Chemical cleaning agents 51
Rolling-contact bearing grease 53
Assembly/disassembly agents for bearing seat 53
Sealants for joining parts or gaps 53
Locking agents for connecting elements 53
Anti-corrosion agent 53
Assembly paste for temperature sensors 53
Paints for refinishing the painted parts or touching up damaged parts 53
Mounting devices for inserting and withdrawing the rotor horizontally 54
Press for expanding the coupling 54
Compression devices for pressing on or for support while pressing off 55
Pulling units with cross beam or disk 57
Aids 57
Extraction devices 57
Main blower CEN50031-00
Removing the main blower motor 3
Disassembling the main blower motor 9
Assembling the main blower motor 11
Installing the main blower motor 14
Retarding grid CEN50032-01
Removing the grid blower motor 3
Disassembling the grid blower motor 5
Assembling the grid blower motor 7
Installing the grid blower motor 9
Removing a grid element 14
Control cabinet CEN50033-02
Removing the SIBAC Inverter Module 3
Installing the SIBAC Inverter Module 10
Draining and filling the IGBT coolant system 11
Removing and installing the IGBT coolant pump assembly 16
00 Index and foreword CEN00027-01
29
90 Diagrams and drawings
Hydraulic circuit diagrams CEN90001-03
Steering, hoist and brake cooling hydraulic circuit diagram 58B-60-20100
Brake hydraulic circuit diagram 58B-33-00030
Electrical circuit diagrams CEN90006-01
Electrical circuit diagram – 960E-2K 58B-06-01782
Connectors table and arrangement drawing HE487
Electrical circuit diagrams – drive system CEN90013-00
Electrical circuit diagram – AC drive system 58B-06-02050
AC trolley drive system 58B-06-02060

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DESCRIPTION:

Komatsu 960E-2KT Dump Truck Shop Manual CEBM028401 – PDF DOWNLOAD

SERIAL NUMBERS 960E-2KT A50028 – A50088
ENGINE 18V170

Composition of shop manual:

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
: New module (to be filed additionally) : Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tab No. with No. indicated next
to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accordingly.

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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