Komatsu 960E-2KT Dump Truck Shop Manual CEBM028402 PDF

Description

Komatsu 960E-2KT Dump Truck Shop Manual CEBM028402  – PDF DOWNLOAD

FILE DETAILS:

Komatsu 960E-2KT Dump Truck Shop Manual CEBM028402  – PDF DOWNLOAD

Language : English
Pages : 1735
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu 960E-2KT Dump Truck Shop Manual CEBM028402  – PDF DOWNLOAD

• SERIAL NUMBERS 960E-2KT A50028 – A50088

00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword, safety and general information 33
Foreword 37
How to read the shop manual 38
Composition of shop manual 38
Revision and distribution 38
Symbols 39
General safety 40
Safety rules 40
Safety features 40
Fire extinguisher and first aid kit 40
Clothing and personal items 40
Leaving the operator seat 41
Mounting and dismounting 41
Fire prevention for fuel and oil 41
Precautions with high temperature fluids 42
Asbestos dust hazard prevention 42
Prevention of injury by work equipment 42
Unauthorized modification 42
Precautions when using ROPS 42
Precautions for attachments 43
Precautions for starting the truck 43
Precautions before operating the truck 43
Safety at the worksite 43
Fire prevention 44
Ventilation in enclosed areas 44
Preparing for operation 44
Mirrors, windows and lights 44
In operator cab (before starting the engine) 44
Seat Belts 44
Precautions while operating the truck 45
When starting the engine 45
General truck operation 45
Ensuring good visibility 45
Traveling 46
Traveling in reverse 46
Traveling on slopes 46
Operating on snow or ice 46
Avoid damage to dump body 46
Driving near high voltage cables 47
When dumping 47
Working on loose ground 47
When loading 47
Parking the truck 47
Towing 48
Working near batteries 48
Battery hazard prevention 48
Starting with jumper cables 49
Jump starting with receptacles 49
Precautions before performing service 50
Warning tag 50
Stopping the engine 50
Proper tools 50
Use of tie-off anchor during maintenance and repair 51
The anchor must not be used for lifting Tie-off anchor installation 51
Securing the dump body 52
While performing maintenance 52
Keep the truck clean 52
Attachments 52
Working under the truck 53
Rotating fan and belts 53
Adding fuel or oil 53
Use of lighting 53
Radiator coolant level 53
Precautions with the battery 53
Precautions with high pressure oil 53
Handling high pressure hoses 54
Precautions when performing maintenance near high temperature or high pressure 54
Waste materials 54
Tires 54
Handling tires 54
Storing tires after removal 55
Precautions for performing repairs 56
Engine shutdown procedure after AC drive system failure 56
Jack point locations 57
Precautions for welding on the truck 58
Handling electrical equipment and hydraulic components 59
Points to remember when handling electrical equipment 59
Points to remember when handling hydraulic equipment 65
How to Read Electric Wire Code 67
Color Code and Harness Designation Tables 68
Standard torque tables 69
Effect of special lubricants on fasteners and standard torque values 69
Suggested sources for rust preventive grease 69
SAE grade 5 and grade 8 hex head capscrew and nut assemblies 70
SAE grade 9 capscrews 71
Class 10 9 capscrews and class 10 nuts 72
Standard tightening torques for fittings 72
Standard tightening torques for clamps 74
Conversion tables 75
Common conversion multipliers 75
Operating instructions 79
Preparing for operation 81
Walk around inspection 81
Engine start-up 85
After engine start-up 86
Emergency steering system 87
Operation 87
Pre-operation testing 87
Precautions during truck operation 88
Operating on a haul road 89
Starting on a grade with a loaded truck 89
Loading the dump body 90
Dumping a load 90
Raising the dump body 90
Lowering the dump body (on flat ground) 91
Lowering the dump body (over a berm or into a crusher) 92
Trolley operating instructions 92
Operating in trolley line mode 92
Getting on line 93
Operating on trolley 93
Getting off line 94
Line status signals 94
Trolley disconnect 95
Traffic consideration for trolley line operation 95
Approaching slow moving vehicles in a trolley assisted truck 95
Operating slow moving vehicles on trolley assist ramps 96
Truck failure while on trolley 96
Using the speed control feature 97
Safe parking procedure 97
Normal engine shutdown procedure 98
Sudden loss of engine power or loss of drive system function 98
Fuel depletion 99
Towing 99
Special Wiring Harness 100
Towing Procedure 100
Disabled truck operation 102
Components Required 102
Hookup 103
Disabled truck dumping procedure 104
Hookup 104
Raising the body 104
Lowering the body 104
01 Specification 107
Specification and technical data 107
Specification drawing 109
Specifications 110
Weight table 112
Fuel, coolant and lubricants 113
Suspension cylinder oil and nitrogen specifications 114
10 Structure and functions 117
Steering circuit 117
Steering circuit operation 119
Steering circuit components 124
Steering control unit 124
High pressure filter 124
Steering accumulators 124
Bleeddown manifold 125
Steering accumulator bleeddown solenoid 125
Quick disconnect ports 125
Hoist up limit solenoid 125
Flow amplifier 125
Steering/brake pump operation 126
High altitude operation 126
Neutral position 127
Full pump volume 128
Half pump volume 128
Flow amplifier operation 129
No steer 129
Steering left 131
Steering right 133
No steer, external shock load 135
Hoist circuit 139
Hoist circuit operation 141
Hoist circuit components 142
Hydraulic tank 142
Hoist pump 142
High pressure filters 142
Hoist valve 143
Inlet sections 143
Tank ports (front) spool section 143
Work ports (rear) spool section 144
Hoist pilot valve 144
Hoist limit solenoid 145
Pilot operated check valve 145
Overcenter manifold 145
Hoist pilot valve operation 146
Float position with body down 146
Power up operation 148
Hold operation 150
Power down operation 152
Float operation 154
Brake circuits 157
General information 159
Service brake circuit operation 160
Secondary braking and auto apply 160
Parking brake circuit operation 162
Normal operation (key switch ON, engine on) 162
Wheel brake lock circuit operation 163
Brake warning circuit operation 163
Brake assembly wear data 165
Electrical system, 24 volt 167
Battery supply system 169
24VDC Battery Charging Alternator 169
Batteries 169
Engine Start Relays 169
24VDC Auxiliary Battery Receptacles 169
Battery Disconnect Switches 170
Auxiliary control cabinet components 170
24VDC to 12VDC converter 170
Diode board – DB1 170
Power distribution terminals 170
Control power relay 171
Fuse blocks 172
Relay boards 172
Relay boards RB1, RB3, RB4, RB5 172
Relay boards RB6, RB7, RB8, RB9 174
Relay functions 174
Body position switches (With proximity switch and magnet) 176
Proximity switch operation 176
Body-up Switch 177
Hoist limit switch 178
Interface module (IM) 181
General information 182
Sensors 182
Temperature sensors 182
Pressure sensors 182
Interface module inputs and outputs 183
Drive system 189
SR rectifier module 191
ST module (auxiliary voltage inverter) 191
Technical Data 194
SD phase modules 195
SR/ST/SD module removal 195
Inverter cabinet layout 196
Inverter cabinet water flow 196
Field regulator 197
Technical Data 197
Field regulator discharge resistor 197
Technical Data 197
Gate unit power supply 198
Technical Data 198
Gate unit power supply (diode) 198
Technical Data 198
Gate unit power supply (tuning resistor) 198
Technical Data 198
Control power filter 198
Technical Data 198
Filter for TCU 199
Technical Data 199
Terminal block bus bar 199
Technical Data 199
Fuses (analog sensor voltage) 200
Technical Data 200
Fuses (field regulator) 200
Technical Data 200
Fuse holder for field regulator 200
Fuses (control power and trolley box contactor) 201
Technical Data 201
Diode modules 201
Technical Data 201
Support capacitors 202
Technical Data 202
Three-phase capacitor bank (for ST module output voltage) 202
Technical Data 202
Air-cooled inductors (for ST module) 203
Technical Data 203
Three-phase transformer (for ST module) 203
Technical Data 203
Diagnostics box 204
Diagnostic and system monitoring panel 205
Device name: DB101 205
Technical Data 205
Current transducers 206
Device names: 206
U101-U104 (Current to motor A) 206
U105-U106 (Current to chopper A-C) 206
U201-U204 (Current to motor B) 206
U205-U206 (Current to chopper B-D) 206
Technical Data 206
Current transducers (for ST module output) 207
Technical Data 207
Voltage transducers 207
Technical Data 207
Voltage transducers (for ST module output) 208
Technical Data 208
Voltage transducers (SiBAS 24V DC bus monitoring) 208
Analog inclinometer 209
Technical Data 209
DC link capacitors 209
Technical Data 209
Ground tie capacitor 210
Technical Data 210
Low-inductance bus bar assembly 210
Free-wheeling diode for low-inductance bus bars 211
Contactor (grid box and main blower motor) 211
Technical Data 211
Contactor (control power) 212
Technical Data 212
Contactor (DC contactors) 212
Technical Data 212
Contactor (crowbar bypass) 213
Technical Data 213
Temperature probes (PT100 style) 213
Technical Data 213
Coolant inlet temperature sensor 214
Technical Data 214
Coolant outlet temperature sensor (external pad style) 214
Technical Data 214
Coolant outlet temperature sensor (internal style) 215
Technical Data 215
IGBT module heat sink temperature sensor 215
Device names: 215
Circuit breakers 216
Technical Data 216
Inner circulating blower fan 216
Coolant pump 217
Technical Data 217
Motor for coolant pump 217
Technical Data 217
Coolant pressure sensor 217
Inner radiator 218
Ground voltage monitoring resistors 218
Protection thyristor assembly (crowbar) 219
Discharge reactor 219
Main blower motor 220
Technical Data 220
Grid box 220
Technical Data 220
Grid box blower motor 221
Technical Data 221
Grid box blower motor grease fittings 221
Main alternator 222
Stator 222
Rotor 222
Bearings 222
Electrical connection 222
Cooling and ventilation 222
Rotating rectifier section 223
Technical Data 223
Main alternator circuit diagram 224
IGBT – inverter/chopper phase module 225
Device names: A101-A103 (Inverter A section) 225
A201-A203 (Inverter B section) 225
A104 (Chopper A section) 225
A204 (Chopper B section) 225
Troubleshooting information 227
Main input rectifier module 228
Device name: A1 228
Internal circuit diagram 229
Ground tie resistor, upper 230
Device Name: R11 1-R11 2 230
Technical Data 230
Ground tie resistor, lower 230
Device name: R11 3-R11 4 230
Technical Data 230
Troubleshooting 231
Fault diagnosis 231
Speed sensor, alternator 232
Technical Data 232
Speed sensors, wheel motors 233
Technical Data 233
Traction motor 234
Device name: Motor 1 (grid box side of the truck) Motor 2 (operator cab side of the truck) 234
Technical Data 234
Retarding grid 235
Device name: M04 235
Technical Data 235
Cab air conditioning 237
General information 239
Environmental impact of air conditioning 239
Air conditioning for off-highway vehicles 239
Principles of refrigeration 240
Air conditioning 240
Refrigeration – the act of cooling 240
The refrigeration cycle 240
Air conditioning system components 242
Relays 242
Fan motor and speed control 242
Cab air filter 242
Heater core 242
Actuators 242
Compressor (refrigerant pump) 244
Service valves 244
Condenser 244
Receiver-drier 244
Expansion valve 245
Accumulator 245
Evaporator core 245
Air conditioning system electrical circuit 246
Thermostat 246
Compressor clutch 246
Trinary™ switch 247
Reserve engine oil system 249
General information 251
Operation 252
LED monitor light 252
Remote tank fill system 253
SIBAS® IGBT rack components 255
SiBAS®32 Traction Control Unit (TCU) 258
Overview of the SiBAS®32 systems 259
Features 259
General technical specifications, operating conditions 259
Permissible temperature range 259
Permissible limit value for air humidity 260
Permissible power supply voltage range 260
Permissible mechanical loads 260
Protection measures against electrical hazards 260
Application 260
Removing and installing the SiBAS®32 cards 263
Removal with 24V OFF! (ESD protection required) 263
Installation with 24V OFF! (ESD protection required) 263
SiBAS®32 card device names 264
Structure of SiBAS®32 card part number 265
Development status, downward compatibility 265
SiBAS®32 card interchangeability 266
Use of service interfaces 267
Connection of the service unit 267
Maintenance 267
Cleaning 268
SiBAS®32 card interactions 269
SiBAS®32 card detailed information 272
Blower subassembly 272
Device name: N/A 272
Application 272
Battery replacement 274
Rules for handling lithium batteries 274
Replacement of the battery in the fan subassembly 274
CPU card 275
Device name: G011 275
Application 276
Front panel 276
Technical data 277
DSP card 278
Device name: G019, G027 and G35 278
Application 278
Front panel 278
Technical data 279
I/O card 280
Device name: G043 280
Application 280
Front panel 281
Technical data 282
TRACO card (optional) 283
Device name: G003 283
Application 283
Front panel 284
Technical data 285
Input voltage/frequency card 286
Device name: L055, L063 and L071 286
Application 286
Technical data 287
I/O analog card 288
Device name: L079 and L087 288
Technical data 290
I/O analog card 291
Device name: L095 and L103 291
Application 291
Technical data 293
Output pulse amplifier card 294
Device name: L115, L123, L131, L139 and L147 294
Application 294
Technical data 296
Input temperature sensor card 297
Device name: L155 and L163 297
Application 297
Technical data 299
UWS card 300
Device name: G055, G063, G071 and G079 300
Application 300
Technical data 302
Digital input card 303
Device name: G103, G111, G119, G127 and G135 303
Application 303
Technical data 305
Power start-up unit card 306
Device name: G163 306
Application 306
Technical data 308
Binary output contactor drive card 309
Device name: C019, C027 and C035 309
Application 309
Technical data 311
24V / 24V power supply 312
Device name: C045, C105, C129 312
Application 312
Testing the power supply card 313
Technical data 314
24V / 15V power supply 315
Device name: C069, C087 315
Application 315
Testing the power supply card 316
Technical data 317
24V / 5V power supply 318
Device name: C153 318
Application 318
Testing the power supply card 319
Technical data 320
Wheel motor transmission 323
Structure 324
Maintenance standard 325
20 Standard value table 329
Standard value table 329
Standard value table for truck 331
30 Testing and adjusting 337
General information 337
Special tool list 339
Steering, brake cooling and hoist hydraulic system 341
General information on system checkout 343
Steering system checkout procedures 343
Steering pump pressure control adjustments on steering pumps with a pressure compensator 344
Steering pump pressure control adjustments on steering pumps without a pressure compensator 345
Steering control valve and flow amplifier leakage test 346
Bleeddown manifold leakage test 347
Shock and suction valve pressure tests on steering pumps with a pressure compensator 348
Shock and suction valve pressure tests on steering pumps without a pressure compensator 350
Steering system checkout data sheet 352
Toe-in adjustment 353
Brake cooling and hoist system checkout procedures 354
Pressure gauge locations 354
Brake cooling circuit test 355
Power up relief pressure test 355
Power down relief pressure test 356
Counterbalance valve pressure check 357
Counterbalance valve adjustment 358
Brake cooling and hoist system checkout data sheet 359
Hoist cylinder leakage test 360
Hydraulic system flushing procedure 360
Brake system 369
General information on system checkout 371
Brake circuit checkout procedure 371
Initial system setup 373
Brake lock / secondary braking checkout 374
Brake Lock Hydraulic Circuit Trouble Shooting Guide 375
Park Brake 375
Park Brake Hydraulic Circuit Troubleshooting Guide: 376
Service brake system 376
Low Brake Pressure and Auto Apply 377
Reapplications 378
Park Brake Control Logic Check 378
Park Brake and Auto Apply sequencing: 378
Auto Apply Solenoid Hydraulic Circuit Trouble Shooting Guide: 379
Brake Lock Control Logic Check 380
Brake system checkout data sheet 383
Brake piston leakage test 393
Brake seal pressure test 393
Wet disc brake bleeding procedure 394
Parking brake bleeding procedure 394
Service brake disc wear inspection 395
Parking brake disc wear inspection 397
Brake valve bench test and adjustment 398
Test setup procedure 399
Brake valve output pressure adjustment 399
Final test and adjustment 400
Dual relay valve bench test and adjustment 401
Test setup procedure 402
Relay valve output pressure adjustment 402
Accumulators and suspensions 405
Accumulator charging and storage 407
Temperature during precharge 407
Bladder accumulator charging procedure 408
Precharge maintenance 410
Bladder accumulator storage procedure 410
Bladder storage 410
Installing a bladder accumulator from storage 411
Bladder accumulator leak testing 411
Piston accumulator charging procedure 412
Piston accumulator storage 415
Piston accumulator leak testing 416
Checking for improper suspension charge on operating trucks 417
Suspension oil change recommendations 418
Suspension oiling and charging procedures 419
Required equipment 419
Installing the charging kit 420
Removing the charging kit 420
Support blocks for oiling and charging dimensions 421
Front suspensions 424
TOP FILL METHOD 425
PRESSURE FILL METHOD 425
Rear suspensions 427
TOP FILL METHOD 429
PRESSURE FILL METHOD 429
Suspension pressure test 432
Payload meter IV 435
Payload meter IV software and tools 437
Payload meter IV system configuration 437
Connecting to the payload meter IV web server 437
Configuring a static IP address 437
Payload meter IV software installation 439
Inclinometer calibration and clean truck tare 440
Payload meter IV checkout procedure 440
PLM IV system checkout data sheet 446
Downloading PLM IV data and possible errors 447
Cab air conditioning 451
General information 453
Service tools and equipment 454
Recovery/recycle station 454
Leak detector 454
Manifold gauge set 455
Service valves 456
Vacuum pump 456
Detecting leaks 457
System performance test 458
Checking system oil 459
System flushing 460
Installing the manifold gauge set 461
Purging air from the service hoses 461
Recovering and recycling refrigerant 462
Draining oil from previous recovery cycle 463
Recovery cycle 463
Recycling procedure 463
Evacuating the air conditioning system 464
Charging the air conditioning system 465
Interface module (IM) 467
Interface module software 468
Flashburn program installation 468
Interface module application code installation 469
Interface module realtime data monitor software installation 469
Interface module checkout procedures 470
Necessary equipment 470
Preliminary 471
Check digital inputs to the interface module 472
Check analog inputs to the interface module 475
Check serial interfaces to the interface module 476
Check outputs from the interface module 477
IGBT haul truck SIBAS® user manual, part 1 479
Abbreviations 482
Precautions 484
Qualified person 484
Customer monitor for SIBAS® 32 control units 484
Product description 484
Version management 485
Overview 486
Requirements 486
Installing and calling the customer monitor 487
Installation 487
Environment variables 487
Communication with the SIBAS® 32 control unit 488
Calling up the customer monitor 489
Start-up prompt 489
Monitor prompt 490
Notes on operation of the customer monitor 491
Structure of a monitor command 491
Step 1: Selecting the menu title 491
Step 2: Selecting a menu entry in the menu box 491
Step 3: Selecting a dialog box, if available 492
Step 4: Entering file or connector/signal names 492
Command buffer 493
Structure of the monitor windows 493
Window menu 494
Commands for Opening, Altering and Closing Windows 494
“Window Work open” 494
“Window Lines open” 494
“Window Tile” 494
“Window Bars open” 494
Options 494
“Window Set” 494
Options 494
“Window Cascade” 494
“Window Close” 494
“Window close All” 494
“Window Exit” 494
Set Menu 495
“Set Port” 495
Options 495
“Set Baudrate” 495
Options 495
“Set String” 496
Example 497
“Set Make” 497
Options 497
Example 1: INIT MON start-up control of the Customer Monitor 498
Example 2: Any monitor batch file with freely selectable file name (incl path) 498
“Set Execute” 499
Options 499
Example 499
“Set Record” 499
Options 499
“Set DIN-Bus” 500
“Set TCN” 500
“Set Timeout” 500
Options 500
“Set Wait” 500
Options 500
“Set Color” 500
Options 500
“Set Info” 501
“Set comment” 501
“Set CHAR Set” 501
“Set Quit” 501
Applic Menu 502
“Applic Func Package” 502
“Applic Connector” 503
Options 503
Example 504
“Applic View” 504
Options 504
Example 504
“Applic Signal” 504
“Applic Observer” 505
Options 505
Possible time slices: 505
Options 506
Two options 506
Notes on the display of connectors 508
“Applic Buffer” 509
Options 509
“Applic Report” 509
“Applic Legitimation” 509
Options 509
“Applic Menu” 510
“Applic Traco” 510
Options 510
“Applic Environment” 510
Hardw Menu 512
Hardware-Oriented Access via the Customer Monitor 512
“Hardw Flash” 512
Options 512
Requirements 512
Example 513
Deleting and loading 513
The EPROM for the communication drivers 513
“Hardw Clock” 513
Options 513
“Hardw DSP” 514
“Hardw BCD” 514
Options 514
Example 514
“Hardw RESET” 514
Options 514
“Hardw Info” 515
Hardware/Operating system 515
Application and tools 515
Communication module 515
Displaying the loading date 515
“Hardw User Flash” 516
Options 516
“Hardw Sys Flash” 516
Options 516
“Hardw BOOT DSP” 517
Requirements 517
DSP5600x Signal Processing Unit and TRACO 517
Inverter processing unit 519
Access to the Signal Processing Unit 519
“Hardw Flash” 519
Options 519
Requirements 519
Example 519
Deleting and loading 520
The EPROM for the communication drivers 520
User Data Flash (UDF) 520
“Hardw RESET” 520
Options 520
“Hardw ZR” 521
“Hardw BOOT ZR” 521
The following procedure is necessary: 521
Graphic Menu 522
Commands for Displaying Line Graphics 522
“Graphic Load” 522
Options 522
“Graphic Position” 522
Options 522
“Graphic Time/Div” 523
Options 523
“Graphic Unit/Div” 523
Options 523
“Graphic Display” 523
Options 523
“Graphic Color” 524
Options 524
“Graphic Format” 524
Options 524
IGBT haul truck SIBAS® user manual, part 2 527
Traco Menu 530
HW-Traco 530
Options 531
SW-Traco 532
Options 533
ZR traco basic parameters: 533
ZR traco record signal table: 533
DAC_Traco 536
Options 537
Events Menu 538
STatistics 539
History 540
LEL:Last EvL 541
LES:Last EvS 543
DLL:DC,LastL 544
DLS:DC,LastS 545
DAL:DC,All L 546
DAS:DC,All S 547
ML:Memory L 548
MS:Memory S 549
CN:Clear Norm 550
CA:Clear All 550
Test-Code 550
DS:Diag-Strc 551
User Menu 552
DAC_IO 553
Options 553
Options 554
Operat Data 555
Acc test 562
Engine_Test 562
X_Test_Inx 565
STate intern 566
Header: 566
Vehicle Number: 566
Powering system: 566
TCU Operation Mode: 566
Component status listings: 567
Field regulator status: 567
Status gate unit power supply A: 567
Status gate unit power supply B: 567
ST inverter status 567
Vehicle status 568
Drive status: 568
Operation status: 568
Pedal calib 569
Language 570
OFFline-test 570
Options 570
Variables 572
Examples: 572
IV:Vehic-ID 573
Commands 574
Discharge Dc link / Fire crowbar 574
Limp mode commands 574
Settings 575
Parameters 576
Temp_prot 578
Appendix 580
Background commands 580
Monitor commands for the central processing unit 582
Monitor commands for the signal processing unit 582
Installing ZR / DSP software 585
Monitor Program – Loading software into the SIBAS® 587
Loading software into the DSP procedure 587
Loading a DSP program Inverter A 592
Loading software into the CPU procedure 599
Loading ZR software Prog jumpers Reset 606
Loading the proper pgm file 608
Setting the system up After loading a new pgm 608
40 Troubleshooting 611
Fuse and circuit breaker locations 611
Fuse and circuit breaker locations 613
Fuse block tables 614
Prelube motor fuse 615
Circuit breaker table 616
Troubleshooting by fault code, Part 1 619
Fault Code A001: Left front suspension pressure sensor signal high 622
Related circuit diagram 622
Fault Code A002: Left front suspension pressure sensor signal low 623
Related circuit diagram 623
Fault Code A003: Right front suspension pressure sensor signal high 624
Related circuit diagram 624
Fault Code A004: Right front suspension pressure sensor signal low 625
Related circuit diagram 625
Fault Code A005: Left rear suspension pressure sensor signal high 626
Related circuit diagram 626
Fault Code A006: Left rear suspension pressure sensor signal low 627
Related circuit diagram 627
Fault Code A007: Right rear suspension pressure sensor signal high 628
Related circuit diagram 628
Fault Code A008: Right rear suspension pressure sensor signal low 629
Related circuit diagram 629
Fault Code A009: Incline sensor signal high 630
Related circuit diagram 630
Fault Code A010: Incline sensor signal low 631
Related circuit diagram 631
Fault Code A011: Payload meter speed sensor signal has failed 632
Related circuit diagram 632
Fault Code A013: Body up switch has failed 633
Related circuit diagram 633
Fault Code A014: Payload meter checksum computation has failed 634
Related circuit diagram 634
Fault Code A016: Payload meter write to flash memory has failed 635
Related circuit diagram 635
Fault Code A017: Payload meter flash memory read has failed 636
Related circuit diagram 636
Fault Code A018: Right rear flat suspension cylinder warning 637
Related circuit diagram 638
Fault Code A019: Left rear flat suspension cylinder warning 639
Related circuit diagram 640
Fault Code A022: Carryback load excessive 641
Related circuit diagram 642
Fault Code A100: An open circuit breaker has been detected on a relay board 643
Related circuit diagram 643
Fault Code A101: High pressure detected across an hydraulic pump filter 644
Related circuit diagram 646
Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level 647
Related circuit diagram 648
Fault Code A111: Low steering pressure warning for storage by KOMTRAX Plus 649
Related circuit diagram 649
Fault Code A115: Low steering precharge pressure detected 650
Related circuit diagram 651
Fault Code A117: Low brake accumulator pressure warning for storage by KOMTRAX Plus 652
Related circuit diagram 652
Fault Code A118: Brake pressure is low while in brake lock 653
Related circuit diagram 654
Fault Code A126: Oil level in the hydraulic tank is low 655
Related circuit diagram 655
Fault Code A127: IM-furnished +5 volt output for sensors is low 656
Related circuit diagram 657
Fault Code A128: IM-furnished +5 volt output for sensors is high 658
Related circuit diagram 659
Fault Code A139: Low fuel warning for storage by KOMTRAX Plus and for use by A310 660
Related circuit diagram 661
Troubleshooting by fault code, part 2 663
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil 666
Related circuit diagram 667
Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil 668
Related circuit diagram 669
Fault Code A152: Starter failure 670
Related circuit diagram 671
Fault Code A153: Battery voltage is low with the truck in operation 672
Related circuit diagram 673
Fault Code A154: Battery charging voltage is excessive 674
Related circuit diagram 674
Fault Code A155: Battery charging voltage is low 675
Related circuit diagram 675
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 676
Related circuit diagram 677
Fault Code A166: Left rear hydraulic oil temperature sensor is low 678
Related circuit diagram 679
Fault Code A167: Right rear hydraulic oil temperature sensor is low 680
Related circuit diagram 681
Fault Code A168: Left front hydraulic oil temperature sensor is low 682
Related circuit diagram 683
Fault Code A169: Right front hydraulic oil temperature sensor is low 684
Related circuit diagram 685
Fault Code A170: Left rear hydraulic oil temperature sensor is high 686
Related circuit diagram 686
Fault Code A171: Right rear hydraulic oil temperature sensor is high 687
Related circuit diagram 687
Fault Code A172: Left front hydraulic oil temperature sensor is high 688
Related circuit diagram 688
Fault Code A173: Right front hydraulic oil temperature sensor is high 689
Related circuit diagram 689
Fault Code A184: J1939 data link is not connected 690
Related circuit diagram 691
Fault Code A190: Auto lube control has detected an incomplete lube cycle 692
Related circuit diagram 693
Fault Code A194: Left front hydraulic oil temperature is high 694
Related circuit diagram 694
Fault Code A195: Right front hydraulic oil temperature is high 695
Related circuit diagram 695
Fault Code A196: Left rear hydraulic oil temperature is high 696
Related circuit diagram 696
Fault Code A197: Right rear hydraulic oil temperature is high 697
Related circuit diagram 697
Fault Code A198: Hoist pressure 1 sensor is high 698
Related circuit diagram 698
Fault Code A199: Hoist pressure 2 sensor is high 699
Related circuit diagram 699
Fault Code A200: Steering pressure sensor is high 700
Related circuit diagram 700
Fault Code A201: Brake pressure sensor is high 701
Related circuit diagram 701
Fault Code A202: Hoist pressure 1 sensor is low 702
Related circuit diagram 702
Fault Code A203: Hoist pressure 2 sensor is low 703
Related circuit diagram 703
Fault Code A204: Steering pressure sensor is low 704
Related circuit diagram 704
Fault Code A205: Brake pressure sensor is low 705
Related circuit diagram 705
Fault Code A206: Ambient temperature sensor is high 706
Related circuit diagram 706
Fault Code A207: Ambient temperature sensor is low 707
Related circuit diagram 707
Troubleshooting by fault code, Part 3 709
Fault Code A213: Parking brake should have applied but is detected as not having applied 712
Related circuit diagram 715
Fault Code A214: Parking brake should have released but is detected as not having released 716
Related circuit diagram 718
Fault Code A215: Brake auto apply valve circuit is defective 720
Related circuit diagram 722
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 724
Related circuit diagram 725
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted 726
Related circuit diagram 727
Fault Code A230: Parking brake has been requested while truck still moving 728
Related circuit diagram 729
Fault Code A231: The body is up while traveling or with selector in forward or neutral 730
Fault Code A233: Drive System Control Link is not connected 732
Related circuit diagram 733
Fault Code A235: Steering accumulator is in the process of being bled down 734
Related circuit diagram 735
Fault Code A236: The steering accumulator has not properly bled down after 90 seconds 736
Related circuit diagram 737
Fault Code A237: The CAN/RPC connection to the display is open 738
Related circuit diagram 739
Fault Code A238: Drive System and IM are reporting different park brake status 740
Related circuit diagram 741
Fault Code A239: The Drive System and IM are reporting different brake lock status 742
Related circuit diagram 743
Fault Code A240: The keyswitch input to the Interface Module is open 744
Related circuit diagram 744
Fault Code A242: Fuel gauge within the dash display panel is defective 745
Related circuit diagram 745
Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective 746
Related circuit diagram 746
Fault Code A244: Drive system temperature gauge within the dash display panel is defective 747
Related circuit diagram 747
Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective 748
Related circuit diagram 748
Fault Code A246: Payload meter reports truck overload 749
Related circuit diagram 749
Fault Code A247: Low steering pressure warning for display to operator 750
Related circuit diagram 750
Fault Code A248: Status module within the dash display panel is defective 751
Related circuit diagram 751
Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted 752
Related circuit diagram 752
Fault Code A250: Battery voltage is low with the truck parked 754
Related circuit diagram 755
Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground 756
Related circuit diagram 756
Fault Code A252: Start enable output circuit is either open or shorted to ground 757
Related circuit diagram 757
Fault Code A253: Steering bleed circuit is not open while running 758
Related circuit diagram 759
Fault Code A256: Red warning lamp in the dash display (driven by IM) is open 760
Related circuit diagram 760
Fault Code A257: Payload CAN/RPC is not connected 762
Related circuit diagram 763
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 764
Related circuit diagram 764
Troubleshooting by fault code, Part 4 767
Fault Code A260: Parking brake failure 770
Related circuit diagram 771
Fault Code A261: Low brake accumulator pressure warning for display to operator 772
Related circuit diagram 772
Fault Code A262: Steering bleed valve circuit open during shutdown 774
Related circuit diagram 775
Fault Code A264: Parking brake relay circuit is defective 776
Related circuit diagram 777
Fault Code A265: Service brake failure 778
Related circuit diagram 779
Fault Code A266: Selector switch was not in park while attempting to crank engine 780
Related circuit diagram 780
Fault Code A267: Parking brake was not set while attempting to crank engine 781
Related circuit diagram 781
Fault Code A268: Secondary engine shutdown while cranking 782
Related circuit diagram 782
Fault Code A270: Brake lock switch power supply is not on when required 784
Related circuit diagram 786
Fault Code A271: Shifter not in gear 788
Related circuit diagram 789
Fault Code A272: Brake lock switch power supply is not off when required 790
Related circuit diagram 791
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit 792
Related circuit diagram 792
Fault Code A274: A brake setting fault has been detected 794
Related circuit diagram 795
Fault Code A275: A starter has been detected as engaged without a cranking attempt 796
Related circuit diagram 797
Fault Code A277: Parking brake applied while loading 798
Related circuit diagram 799
Fault Code A278: Service brake applied while loading 800
Related circuit diagram 801
Fault Code A279: Low steering pressure switch is defective 802
Related circuit diagram 802
Fault Code A280: Steering accumulator bleeddown switch is defective 803
Related circuit diagram 803
Fault Code A281: Brake lock degrade switch is defective 804
Related circuit diagram 805
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 806
Related circuit diagram 807
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set 808
Related circuit diagram 809
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated 810
Related circuit diagram 811
Fault Code A285: The parking brake was not set when the keyswitch was turned off 812
Related circuit diagram 813
Fault Code A286: A fault was detected in the shutdown delay relay circuit 814
Related circuit diagram 815
Fault Code A292: The shutdown delay relay has remained on after the latched keyswitch circuit is off 816
Related circuit diagram 817
Troubleshooting by fault code, part 5 819
Fault Code A303: Shifter is defective 822
Related circuit diagram 823
Fault Code A304: Auto lube grease level fault 824
Related circuit diagram 824
Fault Code A305: Auto lube circuit is defective 826
Related circuit diagram 827
Fault Code A309: No brakes applied when expected 828
Related circuit diagram 829
Fault Code A310: Low fuel warning 830
Related circuit diagram 831
Fault Code A311: Brake lock switch is on when it should not be 832
Related circuit diagram 833
Fault Code A312: DCDC converter 12 volt circuit sensing is producing low readings 834
Related circuit diagram 834
Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings 835
Related circuit diagram 835
Fault Code A315: DCDC converter 12 volt circuit is low 836
Related circuit diagram 837
Fault Code A316: Starter engagement has been attempted with engine running 838
Related circuit diagram 839
Fault Code A317: Operation of brake auto apply valve without a detected response 840
Related circuit diagram 842
Fault Code A318: Unexpected power loss to Interface Module 843
Related circuit diagram 843
Fault Code A328: Drive system not powered up 844
Related circuit diagram 844
Fault Code A334: Selector switch not in park when propel was either not ready or at rest 845
Related circuit diagram 845
Fault Code A335: Manual/Auto Apply Pressure Fault 846
Fault Code A350: Overload on output 1B 847
Related circuit diagram 847
Fault Code A351: Overload on output 1E 848
Related circuit diagram 849
Fault Code A352: Overload on output 1H 850
Related circuit diagram 850
Fault Code A353: Overload on output 1J 851
Related circuit diagram 851
Fault Code A354: Overload on output 1K 852
Related circuit diagram 852
Fault Code A355: Overload on output 1L 853
Related circuit diagram 853
Fault Code A356: Overload on output 1M 854
Related circuit diagram 854
Fault Code A357: Overload on output 1N 855
Related circuit diagram 855
Fault Code A358: Overload on output 1P 856
Related circuit diagram 857
Fault Code A359: Overload on output 1R 858
Related circuit diagram 859
Fault Code A360: Overload on output 1S 860
Related circuit diagram 860
Fault Code A361: Overload on output 1T 862
Related circuit diagram 863
Fault Code A362: Overload on output 1U 864
Related circuit diagram 864
Fault Code A363: Overload on output 1X 865
Related circuit diagram 865
Fault Code A364: Overload on output 1Y 866
Related circuit diagram 866
Fault Code A365: Overload on output 1Z 867
Related circuit diagram 867
Drive system fault code table, part 1 869
Summary 872
How to use this document 872
Event code and diagnosis message 872
Description 872
Threshold 872
Detection by 872
Possible reasons 872
Action to reset 872
Action to repair 873
Operator displayed code 873
Note 873
Protection reactions 873
Event classification 874
Level 1: Warning 874
Level 2: Minor purposes 874
Level 3: Severe 874
1 L3C SYS: Time slice overflow CPU T1 875
2 L3C SYS: Time slice overflow CPU T2 875
3 L3C SYS: Time slice overflow CPU T3 875
4 L3C SYS: Time slice overflow CPU T4 875
5 L3C SYS: Time slice overflow CPU T5 875
6 L3C SYS: Time slice overflow CPU T6 875
7 L3C SYS: Time slice overflow CPU T7 875
8 L3C SYS: Time slice overflow CPU T8 875
10 L2A SYS: Pulse inhibit/asa inhibit PSU–ONLINE 876
11 L3D SYS: Pulse inhibit/asa inhibit PSU-Start-up 876
12 L1A SYS: SIBAS® blower fault 877
13 L1B SYS: Undervoltage in SIBAS® battery for BRAM 877
14 L3C SYS: SIBAS® power supply failure 24V for pulse amplifier 878
15 L3C SYS: SIBAS® power supply failure +5V 879
16 L3C SYS: SIBAS® power supply failure +15V 880
17 L3C SYS: SIBAS® power supply failure –15V 881
18 L3C SYS: SIBAS® power supply failure +24V 882
19 L3C SYS: SIBAS® power supply failure –24V 883
20 L3C SYS: SIBAS® power supply failure primary 884
21 L3C SYS: FPGA clock missing for PSU 884
22 L3C SYS: Pulse inhibit by reset in PSU from CPU 885
24 L3C SYS: General protection error (G10) 885
25 L3C SYS: Total block 886
26 L1B SYS: Permanent inhibit fault active 887
27 L1B SYS: Regular inhibit fault active 887
28 L1A SYS: GW Test stopped by A/D converter faulty 888
30 L3C DSP A: Initialization fault detected by DSP 888
31 L3C DSP A: SW-WatchdoG 889
32 L3C DSP A: Initialization fault detected by CPU 890
33 L1B DSP A: SW-Traco triggered 890
34 L1B DSP A: SW-Traco full 891
35 L3C DSP A: Time slice overflow T1 892
36 L3C DSP A: Time slice overflow T2 892
37 L3C DSP A: Time slice overflow T3 892
38 L3C DSP A: Time slice overflow T4 892
39 L1A DSP A: Communication HSCX data from DSP B missing 893
40 L1A DSP A: Communication HSCX data from DSP T missing 893
41 L3C DSP A: Current offset during pulse block 894
42 L3C DSP A: Current offset during no pulse block 894
43 L3A DSP A: Overcurrent fault 895
44 L3C DSP A: Current transducer defective phase U 896
45 L3C DSP A: Current transducer defective phase W 897
48 L1A DSP A: Modulation software fault 897
49 L3A DSP A: Active current controller at limit 898
Drive system fault code table, part 2 901
50 L3A DSP A: Active current reference at limit 904
51 L1A DSP A: Braking chopper controller at limit 904
52 L3C DSP A: Phase unbalance too large 905
53 L3A DSP A: Pulse block by DSP software 906
54 L3C DSP A: U/F Card defective 906
55 L3C DSP A: Difference in current of phase U over limit 907
56 L3C DSP A: Difference in current of phase W over limit 907
60 L3C DSP B: Initialization fault detected by DSP 908
61 L3C DSP B: SW-Watchdog 908
62 L3C DSP B: Initialization fault detected by CPU 909
63 L1B DSP B: SW-Traco triggered 909
64 L1B DSP B: SW-Traco full 910
65 L3C DSP B: Time slice overflow T1 910
69 L1A DSP B: Communication HSCX data from DSP A missing 911
70 L1A DSP B: Communication HSCX data from DSP T missing 911
71 L3C DSP B: Current offset during pulse block 912
72 L3C DSP B: Current offset during no pulse block 912
73 L3A DSP B: Overcurrent fault 913
74 L3C DSP B: Current transducer defective phase V 914
75 L3C DSP B: Current transducer defective phase W 915
78 L1A DSP B: Modulation software fault 915
79 L3A DSP B: Active current controller at limit 916
80 L3A DSP B: Active current reference at limit 916
81 L1A DSP B: Braking chopper controller at limit 916
82 L3C DSP B: Phase unbalance too large 917
83 L3A DSP B: Pulse block by DSP software 917
84 L3C DSP B: U/F Card defective 918
85 L3C DSP B: Difference in current of phase V over limit 918
86 L3C DSP B: Difference in current of phase W over limit 919
90 L3C DSP T: Initialization fault detected by DSP 919
91 L3C DSP T: SW-Watchdog 920
92 L3C DSP T: Initialization fault detected by CPU 921
93 L1B DSP T: SW-Traco triggered 921
94 L1B DSP T: SW-Traco full 922
95 L3C DSP T: Time slice overflow T1 922
96 L3C DSP T: Time slice overflow T2 922
97 L3C DSP T: Time slice overflow T3 922
98 L3C DSP T: Time slice overflow T4 922
99 L1A DSP T: Communication HSCX data from DSP A missing 923
Drive system fault code table, part 3 925
100 L1A DSP T: Communication HSCX data from DSP B missing 928
101 L3C DSP T: Current offset during pulse block 928
102 L3C DSP T: Current offset during no pulse block 929
103 L3A DSP T: Overcurrent fault 930
104 L3C DSP T: Current transducer defective phase U 931
105 L3C DSP T: Current transducer defective phase V 932
106 L3C DSP T: Current transducer defective phase W 933
107 L3C DSP T: Sum of output current not equal zero 934
108 L1A DSP T: Modulation software fault 934
109 L1A DSP T: Voltage controller at limit 935
112 L3C DSP T: Phase unbalance too large 935
113 L3A DSP T: Pulse block by DSP software 936
114 L3C DSP T: U/F Card defective 936
117 L3C DSP T: Crowbar fired by DSP T 937
119 L1C DSP T: Voltage transducer U34 not ok 938
120 L3C IO: Supervision bus clock 938
121 L3C IO: Supervision I/O clock 939
122 L3C IO: Incorrect FPGA version identifier 939
123 L3C IO: Incorrect FPGA application version identifier 940
124 L3C IO: Incorrect module version identifier 940
125 L3C/L1A IO: AD Converter faulty 941
126 L3C IO: GW Comparator faulty during start-up test 941
127 L3C IO: Test voltage not equal zero 942
128 L1A IO: SIBAS® Temperature out of range 942
129 L3C IO: Incorrect EBIN card identifier 943
130 L3C IO: Front plug monitoring 944
131 L3C IO: CPU Watchdog triggered 945
132 L3C IO: DSP A Watchdog triggered 945
133 L3C IO: DSP B Watchdog triggered 946
134 L3C IO: DSP T Watchdog triggered 946
135 L3C IO: CPU Reset triggered 947
138 L1B IO: CPU Traco triggered 947
146 L3A IO: Pulse block from I/O 948
150 L3A IO: DC link voltage A level 1 exceeded 948
151 L3A IO: DC link voltage B level 1 exceeded 949
152 L3C IO: Trolley line overvoltage 950
154 L3B IO: Trolley line overcurrent 951
155 L2B IO: Trolley line current transducer faulty 951
156 L2B IO: Trolley line voltage transducer faulty 952
160 L3A IO: Throttle pedal out of range 952
161 L3A IO: Retard pedal out of range 953
162 L1A IO: Cruise speed control module out of range 953
180 L3C UWSA1: Supervision bus clock 954
181 L3C UWSA1: Supervision module clock 954
182 L3C UWSA1: Incorrect FPGA version identifier 955
183 L3C UWSA1: Incorrect FPGA project identifier 955
184 L3C UWSA1: GW Comparator faulty during start-up test 956
185 L1A UWSA1: ADC Faulty 956
186 L3C UWSA1: Configuration failure 957
187 L1A UWSA1: Hardware failure counter / processor 957
188 L3A UWSA1: Peak current protection active 958
189 L3D UWSA1: Peak current protection pulse start 959
190 L3D UWSA1: Number of peak current protection >limit 960
191 L3D UWSA1: Supervision switching frequency 961
193 L1A UWSA1: Overvoltage level 1 exceeded 961
196 L3D UWSA1: Limit 5 overcurrent phase U 962
197 L3D UWSA1: Limit 5 overcurrent phase V 962
198 L3D UWSA1: Limit 5 overcurrent phase W 962
199 L3D UWSA1: Limit 5 overvoltage DC bus 963
Drive system fault code table, part 4 965
201 L3D UWSA1: Checkback INVA1 L1U faulty 969
202 L3D UWSA1: Checkback INVA1 L1L faulty 969
203 L3D UWSA1: Checkback INVA1 L2U faulty 969
204 L3D UWSA1: Checkback INVA1 L2L faulty 969
205 L3D UWSA1: Checkback INVA1 L3U faulty 969
206 L3D UWSA1: Checkback INVA1 L3L faulty 969
207 L3D UWSA1: Checkback chopper A faulty 969
210 L3C UWSB1: Supervision bus clock 970
211 L3C UWSB1: Supervision module clock 970
212 L3C UWSB1: Incorrect FPGA version identifier 971
213 L3C UWSB1: Incorrect FPGA project identifier 971
214 L3C UWSB1: GW Comparator faulty during start-up test 972
215 L1A UWSB1: ADC Faulty 972
216 L3C UWSB1: Configuration failure 973
217 L1A UWSB1: Hardware failure counter / processor 973
218 L3A UWSB1: Peak current protection active 974
219 L3D UWSB1: Peak current protection pulse start 975
220 L3D UWSB1: Number of peak current protection >limit 976
221 L3D UWSB1: Supervision switching frequency 977
223 L1A UWSB1: Overvoltage level 1 exceeded 977
226 L3D UWSB1: Limit 5 overcurrent phase V 978
227 L3D UWSB1: Limit 5 overcurrent phase U 978
228 L3D UWSB1: Limit 5 overcurrent phase W 978
229 L3D UWSB1: Limit 5 overvoltage DC bus 979
231 L3D UWSB1: Checkback INVB1 L1U Faulty 980
232 L3D UWSB1: Checkback INVB1 L1L Faulty 980
233 L3D UWSB1: Checkback INVB1 L2U Faulty 980
234 L3D UWSB1: Checkback INVB1 L2L Faulty 980
235 L3D UWSB1: Checkback INVB1 L3U Faulty 980
236 L3D UWSB1: Checkback INVB1 L3L Faulty 980
237 L3D UWSB1: Checkback chopper B Faulty 980
240 L3C UWSA2: Supervision bus clock 981
241 L3C UWSA2: Supervision module clock 981
242 L3C UWSA2: Incorrect FPGA version identifier 982
243 L3C UWSA2: Incorrect FPGA project identifier 982
244 L3C UWSA2: GW Comparator faulty during start-up test 983
245 L1A UWSA2: ADC Faulty 983
246 L3C UWSA2: Configuration failure 984
247 L1A UWSA2: Hardware failure counter / processor 984
248 L3A UWSA2: Peak current protection active 985
249 L3D UWSA2: Peak current protection pulse start 986
250 L3D UWSA2: Number of peak current protection >limit 987
251 L3D UWSA2: Supervision switching frequency 988
253 L1A UWSA2: Overvoltage level 1 exceeded 988
256 L3D UWSA2: Limit 5 overcurrent phase U1 989
257 L3D UWSA2: Limit 5 overcurrent phase V1 989
258 L3D UWSA2: Limit 5 overcurrent phase W1 989
259 L3D UWSA2: Limit 5 overvoltage DC bus 990
261 L3D UWSA2: Checkback INVA2 L1U faulty 991
262 L3D UWSA2: Checkback INVA2 L1L faulty 991
263 L3D UWSA2: Checkback INVA2 L2U faulty 991
264 L3D UWSA2: Checkback INVA2 L2L faulty 991
265 L3D UWSA2: Checkback INVA2 L3U faulty 991
266 L3D UWSA2: Checkback INVA2 L3L faulty 991
267 L3D UWSA2: Checkback chopper C faulty 991
270 L3C UWSB2: Supervision bus clock 992
271 L3C UWSB2: Supervision module clock 992
272 L3C UWSB2: Incorrect FPGA version identifier 993
273 L3C UWSB2: Incorrect FPGA project identifier 993
274 L3C UWSB2: GW Comparator faulty during start-up test 994
275 L1A UWSB2: ADC Faulty 994
276 L3C UWSB2: Configuration failure 995
277 L1A UWSB2: Hardware failure counter / processor 995
278 L3A UWSB2: Peak current protection active 996
279 L3D UWSB2: Peak current protection pulse start 997
280 L3D UWSB2: Number of peak current protection >limit 998
281 L3D UWSB2: Supervision switching frequency 999
283 L1A UWSB2: Overvoltage level 1 exceeded 999
286 L3D UWSB2: Limit 5 overcurrent phase V1 1000
287 L3D UWSB2: Limit 5 overcurrent phase U1 1000
288 L3D UWSB2: Limit 5 overcurrent phase W1 1000
289 L3D UWSB2: Limit 5 overvoltage DC bus 1001
291 L3D UWSB2: Checkback INVB2 L1U Faulty 1002
292 L3D UWSB2: Checkback INVB2 L1L Faulty 1002
293 L3D UWSB2: Checkback INVB2 L2U Faulty 1002
294 L3D UWSB2: Checkback INVB2 L2L Faulty 1002
295 L3D UWSB2: Checkback INVB2 L3U Faulty 1002
296 L3D UWSB2: Checkback INVB2 L3L Faulty 1002
297 L3D UWSB2: Checkback chopper D Faulty 1002
Drive system fault code table, part 5 1005
300 L3C UWSST: Supervision bus clock 1009
301 L3C UWSST: Supervision module clock 1009
302 L3C UWSST: Incorrect FPGA version identifier 1010
303 L3C UWSST: Incorrect FPGA project identifieR 1010
304 L3C UWSST: GW Comparator faulty during start-up test 1011
305 L1A UWSST: ADC Faulty 1011
306 L3C UWSST: Configuration failure 1012
307 L1A UWSST: Hardware failure counter / processor 1012
308 L3A UWSST: Peak current protection active 1013
310 L3D UWSST: Number of peak current protection >limit 1014
311 L3D UWSST: Supervision switching frequency 1015
314 L3C UWSST: Crowbar is fired without command 1016
319 L3D UWSST: Limit 5 overvoltage DC bus 1018
321 L3D UWSST: Checkback INVST L1U Faulty 1019
322 L3D UWSST: Checkback INVST L1L Faulty 1019
323 L3D UWSST: Checkback INVST L2U Faulty 1019
324 L3D UWSST: Checkback INVST L2L Faulty 1019
325 L3D UWSST: Checkback INVST L3U Faulty 1019
326 L3D UWSST: Checkback INVST L3L Faulty 1019
327 L3C UWSST: Checkback crowbar faulty 1020
330 L1A BUS: CAN Communication failure 1021
331 L1A BUS: Serial link communication failure 1021
332 L1A BUS: Truck is over loaded 1021
333 L1B TR: Transient traco is triggered 1022
334 L1B TR: Transient traco is full 1022
340 L1A ETM: ADC Failure for ETM1 1022
341 L1A ETM: ADC Failure for ETM2 1023
342 L1A ETM: ADC Failure for ETM3 1023
343 L1A ETM: ADC Failure for ETM4 1023
344 L1A MEFA: ADC Failure 1024
345 L3C HL: Gate unit power supply A defective 1024
346 L3C HL: Gate unit power supply B defective 1025
351 L1A DRZ: LIMP Mode A active 1026
352 L1A DRZ: Limp mode B active 1026
353 L1A DRZ: Low battery voltage 1027
354 L1B BUS: Engine floor input increasing minimum engine speed 1027
355 L1B DM: Data store switch pressed 1028
356 L1B DM: Diagnosis memory configuration failure 1028
357 L1B DM: Diagnosis memory occupation > 75% 1028
358 L1B DM: Diagnosis memory full 1029
359 L1B DM: Test event 1029
360 L2A EXT: Main blower air flow supervision 1030
361 L2A EXT: Minimum engine speed supervision 1031
362 L1A EXT: Main blower pressure switch malfunction 1032
363 L1A EXT: Shift lever supervision 1033
364 L2A EXT: Engine derate protection active 1034
365 L1A EXT: Truck external plug monitoring 1034
367 L3A EXT: DC Power off mod request (rest switch on) 1035
369 L1A EXT: Doppler sensor defective 1037
370 L1A EXT: Auto lube control defective 1038
372 L1A EXT: Service brake pressed at high speeD 1038
373 L1A EXT: Service brake on above speed limit 1039
374 L1A EXT: Anti-roll control malfunction 1039
375 L3B BEF: CB301 Circuit breaker defective 1040
376 L3B BEF: K303/K304 Contactor defective 1041
377 L3C STP: Voltage reading incorrect between trolley line and voltage in stepdown box 1042
382 L3B BEF: K103 Feedback defective 1043
383 L3B BEF: K105 Feedback defective 1043
384 L1A BEF: K107 Feedback defective 1044
385 L1A BEF: K109 Feedback defective 1044
386 L1A BEF: K111 Feedback defective 1045
387 L1A BEF: Limp mode selector defective 1045
388 L2B BEF: CB113 Tripped 1046
390 L3D IUW: Output current supervision INV A 1046
391 L3D IUW: Output current supervision INV B 1047
392 L3B IUW: Precharge supervision 1 1048
393 L3B IUW: Precharge supervision 2 1049
394 L3A IUW: DC Link undervoltage 1050
395 L2B IUW: Trolley line undervoltage 1051
397 L3B IUW: Field regulator current setpoint supervision 1052
398 L2B IUW: Field regulator output current supervision 1053
399 L3B IUW: Alternator overcurrent protection 1054
Drive system fault code table, part 6 1057
400 L2C IUW: Alternator overload warning 1060
401 L2B IUW: Alternator overload protection 1060
402 L3C IUW: Alternator AC current sensor faulty 1061
403 L2A IUW: DC Link voltage out of range in propel 1062
404 L3A IUW: DC Link voltage out of range retard 1063
405 L3A IUW: DC Link voltage out of range for ST operation 1064
406 L3B IUW: DC Link controller supervision 1065
407 L2C IUW: Motor torque square T supervision 1066
408 L2C IUW: Motor current square T supervision 1066
409 L1A IUW: DC Link discharge time exceeded limit 1067
410 L2B IUW: Ground fault at positive DC link detected 1068
411 L2B IUW: Ground fault at negative DC link detected 1069
412 L2B IUW: Ground fault at AC side detected 1070
413 L2B IUW: Ground fault 1071
414 L3C IUW: Chopper A current supervision 1072
415 L3C IUW: Chopper B current supervision 1073
416 L3C IUW: Chopper C current supervision 1074
417 L3C IUW: Chopper D current supervision 1075
418 L3D IUW: Output current supervision INV ST 1076
419 L2A IUW: Vehicle overspeed supervisioN 1077
420 L1A IUW: DC Link voltage sensor A faulty 1078
421 L1A IUW: DC Link voltage sensor B faulty 1079
422 L3C IUW: ST Inverter failure 1080
423 L3B IUW: DC Grid fan circuit failure 1080
424 L2B IUW: Cooling water pressure out of range 1081
425 L2B IUW: Cooling water level out of range 1082
426 L1A IUW: Water pump motor overtemperature 1083
427 L1A IUW: Retard limit supervision 1083
428 L1A DRZ: Front wheel A speed sensor supervision 1084
429 L1A DRZ: Front wheel B speed sensor supervision 1085
430 L3D DRZ: Motor A speed sensor supervision 1086
431 L3D DRZ: Motor B speed sensor supervision 1087
432 L3C DRZ: Alternator speed sensor supervision 1088
433 L2A DRZ: Motor A maximum speed exceeded 1089
434 L2A DRZ: Motor B maximum speed exceeded 1089
435 L1A DRZ: Alternator maximum speed exceeded 1090
436 L3A DRZ: Motor A/B rotation inconsistency 1091
437 L3A DRZ: Motor A torque supervision 1092
438 L3A DRZ: Motor B torque supervision 1093
439 L3C SIV: Start-up sequence can’t pass due to GUPS failure 1094
440 L3C SIV: Start-up sequence can’t pass due to K103/K105 failure 1095
441 L3C SIV: Start-up sequence can’t pass due to IGBT failure 1096
442 L3C SIV: Start-up sequence can’t pass due to CB301 OR K303 failure 1097
443 L3C SIV: Start-up sequence can’t pass due to crowbar failure 1098
447 L1A SIV: Direct trolley engage sequence supervision 1099
448 L1A SIV: Direct trolley disengage sequence supervision 1100
Drive system fault code table, part 7 1103
450 L1A TMP: SIBAS® Temperature < low limit 1107
451 L1A TMP: SIBAS® Temperature > warning limit 1107
452 L3B TMP: SIBAS® Temperature > shutdown limit 1108
453 L3A TMP: IGBT Module A101 temperature < low limit 1109
454 L2C TMP: IGBT Module A101 temperature > APRS limit 1110
455 L3A TMP: IGBT Module A101 temperature > shutdown limit 1111
456 L3A TMP: IGBT Module A102 temperature < low limit 1112
457 L2C TMP: IGBT Module A102 temperature > APRS limit 1113
458 L3A TMP: IGBT Module A102 temperature > shutdown limit 1114
459 L3A TMP: IGBT ModulE A201 temperature < low limit 1115
460 L2C TMP: IGBT Module A201 temperature > APRS limit 1116
461 L3A TMP: IGBT Module A201 temperature > shutdown limit 1117
462 L3A TMP: IGBT Module A202 temperature < low limit 1118
463 L2C TMP: IGBT Module A202 temperature > APRS limit 1119
464 L3A TMP: IGBT Module A202 temperature >shutdown limit 1120
465 L3A TMP: ST Module temperature < low limit 1121
466 L2C TMP: ST Module temperature > warning limit 1122
467 L3A TMP: ST Module temperature > shutdown limit 1123
468 L2B TMP: SR Module temperature < low limit 1124
469 L2C TMP: SR Module temperature > warning limit 1125
470 L2B TMP: SR Module temperature > shutdown limit 1126
471 L2C TMP: Wheel motor A stator temperature > APRS limit 1127
472 L3A TMP: Wheel motor A stator temperature > shutdown limit 1128
473 L2C TMP: Wheel motor B Stator temperature > APRS limit 1129
474 L3A TMP: Wheel motor B stator temperature shutdown limit 1130
475 L2C TMP: Wheel motor A, DE bearing temperature > warning limit 1131
476 L3A TMP: Wheel motor A, DE bearing temperature > shutdown limit 1132
477 L2C TMP: Wheel motor A NDE bearing temperature > warning limit 1133
478 L3A TMP: Wheel motor A NDE bearing temperature > shutdown limit 1134
479 L2C TMP: Wheel motor B DE bearing temperature > warning limit 1135
480 L3A TMP: Wheel motor B DE bearing temperature > shutdown limit 1136
481 L2C TMP: Wheel motor B NDE bearing temperature > warning limit 1137
482 L3A TMP: Wheel motor B NDE bearing temperature > shutdown limit 1138
483 L2C TMP: Alternator stator temperature > APRS limit 1139
484 L2B TMP: Alternator stator temperature > shutdown limit 1140
485 L2C TMP: Alternator bearing temperature > warning limit 1141
486 L2B TMP: Alternator bearing temperature > shutdown limit 1142
487 L1A TMP: Cooling water inlet temperature < low limit 1143
488 L2C TMP: Cooling water inlet temperature > warning limit 1144
489 L2B TMP: Cooling water inlet temperature > shutdown limit 1145
490 L1A TMP: Cooling water outlet temperature < low limit 1146
491 L2C TMP: Cooling water outlet temperature > warning limit 1147
492 L2B TMP: Cooling water outlet temperature > shutdown limit 1148
493 L1A TMP: Cooling water delta T too high 1149
495 L2C TMP: Inverter cab temperature > warning limit 1150
496 L2B TMP: Inverter cab temperature > shutdown limit 1151
497 L2C TMP: Inside cooler outlet temperature > warning limit 1152
498 L2B TMP: Inside cooler outlet temperature > shutdown limit 1153
499 L1A TMP: Main blower motor stator temperature > warning limit 1154
500 L1A TMP: Main blower motor stator temperature > shutdown limit 1155
505 L1A TMP: Wheel motor A rotor temperature > limit 1156
506 L1A TMP: Wheel motor B rotor temperature > limit 1157
508 L1A ETM1: Alternator PT100 open circuit 1158
509 L1A ETM1: Main blower stator PT100 open circuit 1158
510 L1A ETM1: Grid blower statoR PT100 open circuit 1158
511 L1A ETM1: Inverter CAB PT100 open circuit 1158
512 L1A ETM1: Ambient PT100 open circuit 1158
513 L1A ETM1: Heater exchanger PT100 open circuit 1158
514 L1A ETM1: Cooling water inlet PT100 open circuit 1158
515 L1A ETM1: Cooling water outlet PT100 open circuit 1158
516 L1A ETM2: Motor A NDE Bearing PT100 open circuit 1159
517 L1A ETM2: Motor A DE Bearing PT100 open circuit 1159
518 L1A ETM2: Motor B NDE Bearing PT100 open circuit 1159
519 L1A ETM2: Motor B DE Bearing PT100 open circuit 1159
520 L1A ETM2: Alternator Bearing PT100 open circuit 1159
521 L1A ETM2: Motor A stator PT100 open circuit 1159
522 L1A ETM2: Motor B stator PT100 open circuit 1159
523 L1A ETM2: Motor inlet air PT100 open circuit 1159
524 L1A ETM3: IGBT Module A101 PT100 open circuit 1160
525 L1A ETM3: IGBT Module A102 PT100 open circuit 1160
526 L1A ETM3: IGBT Module A103 PT100 open circuit 1160
527 L1A ETM3: IGBT Module A104 PT100 open circuit 1160
528 L1A ETM3: IGBT Module A201 PT100 open circuit 1160
529 L1A ETM3: IGBT Module A202 PT100 open circuit 1160
530 L1A ETM3: IGBT Module A203 PT100 open circuit 1160
531 L1A ETM3: IGBT Module A204 PT100 open circuit 1160
532 L1A ETM3: ST Module PT100 open circuit 1161
533 L1A ETM3: SR Module PT100 open circuit 1161
534 L1A ETM3: Channel 7 PT100 open circuit 1161
535 L1A ETM3: Channel 8 PT100 open circuit 1161
536 L1A ETM4: Channel 1 PT100 open circuit 1162
537 L1A ETM4: Channel 2 PT100 open circuit 1162
538 L1A ETM4: Channel 3 PT100 open circuit 1162
539 L1A ETM4: Channel 4 PT100 open circuit 1162
540 L1A ETM4: Channel 5 PT100 open circuit 1162
541 L1A ETM4: Channel 6 PT100 open circuit 1162
542 L1A ETM4: Channel 7 PT100 open circuit 1162
543 L1A ETM4: Channel 8 PT100 open circuit 1162
544 L1A ETM4: SR Module PT100 open circuit 1162
550 L3A TMP: Inverter A module temperature < low limit 1163
551 L2C TMP: Inverter A module temperature > APRS limit 1164
552 L3A TMP: Inverter A module temperature > shutdown limit 1165
553 L3A TMP: Inverter B module temperature < low limit 1166
554 L2C TMP: Inverter B module temperature > APRS limit 1167
555 L3A TMP: Inverter B module temperature > shutdown limit 1168
556 L3A TMP: Chopper A module temperature < low limit 1169
557 L2C TMP: Chopper A module temperature > APRS limit 1170
558 L3A TMP: Chopper A module temperature > shutdown limit 1171
559 L3A TMP: Chopper B module temperature < low limit 1172
560 L2C TMP: Chopper B module temperature > APRS limit 1173
561 L3A TMP: Chopper B module temperature > shutdown limit 1174
Cab air conditioning 1177
Preliminary checks 1179
Diagnosis of gauge readings and system performance 1179
Troubleshooting by manifold gauge set readings 1180
Reserve engine oil system 1187
Pumping unit LED signals 1189
Circuit fuses 1189
Steering system 1191
Steering circuit troubleshooting chart 1193
Steering circuit troubleshooting guidelines 1195
Basic hydraulic system checks 1196
System leakage check 1197
Steering pump troubleshooting guide 1199
Pump pressure control checks 1202
Pump fails to unload 1203
Pump fails to develop pressure 1203
Pump slow in developing pressure 1204
Pump control valve inspection and trouble shooting 1204
Pump case drain check 1206
Setting pump pressure controls 1206
Automatic lubrication (auto lube) system 1209
Autolube troubleshooting chart 1211
50 Disassembly and assembly 1215
General information 1215
Special tool list 1217
Wheels, spindles and rear axle 1219
General precautions for tires and rims 1221
Rim components 1222
Wheel stud maintenance 1223
Removal and installation of front wheel 1223
Removal 1223
Installation 1224
Removal and installation of rear wheel 1225
Removal 1225
Installation 1226
Removal and installation of tires 1228
Installation 1228
Removal and installation of front wheel hub and spindle 1230
Removal 1230
Installation 1233
Disassembly and assembly of front wheel hub and spindle 1234
Disassembly 1234
Cleaning and inspection 1234
Assembly 1236
Wheel bearing adjustment 1236
Seal assembly gap check and adjustment 1237
Brake installation 1238
Speed sensor installation and adjustment 1238
Removal and installation of wheel motor 1239
Preparation 1239
Removal 1239
Cleaning and inspection 1241
Installation 1241
Removal and installation of electric motor 1245
Removal 1245
Installation 1245
Disassembly and assembly of wheel motor transmission 1246
Disassembly 1246
Cleaning and inspection 1253
Assembly 1254
Disassembly and assembly of low speed carrier 1265
Disassembly 1265
Inspection 1266
Assembly 1267
Disassembly and assembly of high speed carrier 1270
Disassembly 1270
Inspection 1271
Assembly 1272
Removal and installation of rear axle 1275
Removal 1275
Cleaning and inspection 1276
Installation 1276
Removal and installation of anti-sway bar 1277
Removal 1277
Installation 1278
Removal and installation of pivot pin 1279
Removal 1279
Installation 1279
Pivot eye and bearing service 1280
Bearing removal 1280
Bearing installation 1280
Pivot eye repair 1281
Brake system 1283
Removal and installation of brake valve 1285
Removal 1285
Installation 1286
Disassembly and assembly of brake valve/pedal assembly 1286
Disassembly 1286
Assembly 1287
Removal and installation of dual relay valve 1289
Removal 1289
Installation 1291
Removal and installation of brake manifold 1291
Removal 1291
Installation 1292
Disassembly and assembly of brake manifold 1292
Disassembly 1292
Assembly 1292
Removal and installation of brake accumulator 1293
Removal 1293
Installation 1294
Disassembly and assembly of brake accumulator 1294
Disassembly 1294
Cleaning and inspection 1296
Assembly 1296
Disassembly and assembly of wheel brake 1298
Disassembly 1299
Cleaning and inspection 1302
Assembly 1303
Floating ring seal assembly and installation 1306
Removal and installation of rear brake assembly 1314
Removal 1314
Installation 1314
Removal and installation of parking brake 1317
Removal 1317
Installation 1319
Disassembly and assembly of parking brake 1319
Disassembly 1319
Cleaning and inspection 1320
Assembly 1322
Cleaning and inspecting new discs 1324
Steering system 1327
Removal and installation of steering control unit 1329
Removal 1329
Installation 1330
Disassembly and assembly of steering control unit 1331
Disassembly 1331
Assembly 1333
Removal and installation of steering column 1336
Removal 1336
Inspection 1336
Installation 1337
Removal and installation of steering wheel 1337
Removal 1337
Installation 1338
Removal and installation of bleeddown manifold 1339
Removal 1339
Installation 1340
Removal and installation of flow amplifier 1341
Removal 1341
Installation 1341
Disassembly and assembly of flow amplifier 1341
Disassembly 1341
Assembly 1343
Removal and installation of steering cylinders and tie rod 1344
Removal 1344
Bearing replacement 1344
Installation 1344
Disassembly and assembly of steering cylinders 1345
Disassembly 1345
Assembly 1346
Removal and installation of steering/brake pump 1346
Removal 1346
Installation 1347
Disassembly and assembly of steering/brake pump 1349
Disassembly 1349
Inspection 1352
Assembly 1355
Driveshaft group 1356
Rotating group 1356
Removal and installation of bladder style steering accumulators 1359
Removal 1359
Installation 1359
Disassembly and assembly of bladder style steering accumulators 1360
Disassembly 1360
Cleaning and Inspection 1360
Bladder accumulator assembly 1361
Removal and installation of piston style steering accumulators 1363
Removal 1363
Installation 1364
Disassembly and assembly of piston accumulators 1365
Disassembly 1365
Cleaning and Inspection 1365
Assembly 1366
Testing 1366
Suspensions 1369
Removal and installation of front suspension 1371
Removal 1371
Installation 1372
Inspection 1375
Minor front suspension repairs (lower bearing and seals) 1378
Lower bearing retainer removal 1378
Lower bearing retainer installation 1378
Major front suspension rebuild 1379
Disassembly 1379
Assembly 1380
Removal and installation of rear suspension 1382
Removal 1383
Installation 1385
Disassembly and assembly of rear suspension 1385
Disassembly 1385
Cleaning and Inspection 1386
Assembly 1386
Hoist circuit 1389
Removal and installation of hoist pump 1391
Removal 1391
Installation 1392
Disassembly and assembly of hoist pump 1393
Disassembly 1393
Inspection 1396
Assembly 1396
Removal and installation of hoist valve 1401
Removal 1401
Installation 1402
Disassembly and assembly of hoist valve 1402
O-ring replacement 1402
Disassembly of inlet section 1403
Assembly of inlet section 1404
Disassembly of rear spool section 1404
Assembly of rear spool section 1407
Disassembly of front spool section 1408
Assembly of front spool section 1409
Overcenter valve manifold service 1409
Removal and installation of hoist pilot valve 1410
Removal 1410
Installation 1410
Disassembly and assembly of hoist pilot valve 1411
Disassembly 1411
Cleaning and inspection 1412
Assembly 1412
Removal and installation of hoist cylinders 1413
Removal 1413
Installation 1414
Disassembly and assembly of hoist cylinders 1415
Disassembly 1415
Cleaning and inspection 1417
Installation of the quill 1418
Assembly 1420
Operator cab 1423
Removal and installation of operator cab 1425
Removal 1426
Installation 1427
Removal and installation of cab door 1428
Removal 1428
Installation 1428
Disassembly and assembly of cab door 1428
Removing door panel 1428
Installing door panel 1429
Replacing the door window regulator 1429
Replacing door handle or latch assembly 1430
Replacing door assembly seal and door hinge seal 1431
Replacing door opening seal 1431
Removing door glass 1432
Installing door glass 1434
Adjustment of cab door 1435
Door jamb bolt adjustment 1435
Door handle plunger adjustment 1437
Removal and installation of side window glass 1438
Recommended tools and supplies 1438
Removal 1438
Installation 1438
Removal and installation of windshield and rear window glass 1439
Removal 1439
Installation 1439
Removal and installation of windshield wiper motor 1441
Removal 1441
Installation 1441
Removal and installation of windshield wiper arm 1442
Removal 1442
Installation 1442
Removal and installation of windshield wiper linkage 1442
Removal 1442
Installation 1443
Removal and installation of operator seat 1443
Inspection 1443
Removal 1443
Installation 1443
Replacing the Seat Compressor 1444
Removal and installation of passenger seat 1449
Removal 1449
Installation 1449
Removal and installation of seat belts (standard seats) 1450
Removal 1450
Installation 1450
Removal and installation of seat belts (optional seats) 1452
General 1452
Removal 1452
Installation 1454
Body and structures 1457
Removal and installation of dump body 1459
Removal 1459
Inspection 1460
Installation 1461
Removal and installation of body pads 1461
Removal 1461
Installation 1462
Body pad shimming procedure 1463
Removal and installation of diagonal ladder/ hood and grille assembly 1464
Removal 1464
Installation 1464
Removal and installation of right deck 1465
Removal 1465
Installation 1466
Removal and installation of left deck 1467
Removal 1467
Installation 1467
Removal and installation of fuel tank 1469
Removal 1469
Cleaning and inspection 1469
Installation 1471
Removal and installation of fuel gauge sender (S/N A50003 – A50011) 1471
Removal 1471
Installation 1471
Removal and installation of fuel gauge sender (S/N A50012 & up) 1471
Removal 1471
Installation 1471
Disassembly and assembly of fuel tank breather 1472
Disassembly 1472
Assembly 1472
Removal and installation of hydraulic tank 1473
Removal 1473
Installation 1473
Cab air conditioning 1475
Replacement of air conditioning system components 1477
Hoses and fittings 1477
Lines 1477
Expansion valve 1477
Receiver-drier 1477
Thermostat 1477
Compressor 1478
Accumulator 1478
Clutch 1478
Power module 1481
Removal and installation of power module 1483
General 1483
Preparation 1483
Removal 1484
Installation 1490
Exhaust tube installation 1492
Exhaust blanket installation 1492
Removal and installation of alternator 1493
Removal 1493
Installation 1495
Engine flywheel housing face runout 1495
Engine Crankshaft Endplay 1496
Measurements after joining the alternator and engine 1502
Flywheel housing face runout 1503
Flywheel housing radial runout measurement 1503
Flywheel/flexplate face runout measurement 1504
Removal and installation of engine 1505
Removal 1505
Service 1505
Installation 1505
Removal and installation of radiator 1506
Removal 1506
Installation 1508
Repairing the radiator 1509
Internal inspection 1509
External cleaning 1509
Disassembly 1510
Cleaning and inspection 1511
Assembly 1511
Pressure testing 1512
Automatic lubrication (autolube) system 1515
Lubrication system priming 1517
Disassembly and assembly of lubrication pump 1517
Disassembly 1517
Cleaning and Inspection 1520
Assembly 1520
Three phase wheel motor 1523
General safety information 1525
Handling the motor 1526
Transport 1527
Storage 1528
Storage of new motors 1528
Storage of used motors 1528
Motor description 1529
Maintenance 1530
Safety guidelines 1530
Maintenance intervals 1531
Maintenance work on the installed motor 1531
Checking for external damage 1531
Checking the connections 1531
Checking the interior of the motor for water 1531
Regreasing the bearings 1532
Applying grease to the bearings 1532
Checking the interior of the motor for water 1533
Disassembling the motor 1534
Removing the coupling 1535
Disassembling the rotor 1537
Removing the rubber seals and the air baffles 1541
Removing the bearing and labyrinth ring 1542
Maintenance work 1543
Cleaning 1543
Stator inspection 1543
Rotor inspection 1543
Testing the insulation 1544
High-voltage test 1544
Work on the bearings 1545
Assembling the motor 1546
Important general instructions 1546
Assembling the rubber seals and the air baffles 1547
Assembly after special repair work 1549
Bearing installation (D-end) 1550
Assembling the bearing 1550
Installing the cover 1552
Bearing installation (N-end) 1553
Assembling the bearing 1553
Installing the cover 1555
Assembling the bearing shield (N-end) at the stator frame 1556
Installing the bearing 1558
Installing the rotor 1560
Installing the labyrinth ring 1562
Installing accessories (D- and N-end) 1564
Running in the bearings 1568
Installing the gear wheel 1569
Installing the coupling 1570
Assembly conditions and instructions 1571
Repairing the motor 1572
Replacing defective connecting leads 1572
Repairing the stator winding insulation 1573
Recommended consumables 1573
Chemical cleaning agents 1573
Generally approved cleaning agents 1573
Chemical cleaning agents for outdoor use and for cleaning mechanical parts 1574
Chemical cleaning agents for flange faces 1574
Chemical cleaning agents for windings 1574
Chemical cleaning agents for windings with severe damage and for oily windings 1574
Rolling-contact bearing grease 1575
Assembly/disassembly agents for bearing seat 1575
Sealants for joining parts or gaps 1575
Locking agents for connecting elements 1575
Anti-corrosion agent 1575
Assembly paste for temperature sensors 1575
Paints for refinishing the painted parts or touching up damaged parts 1575
Special tools 1576
Mounting devices for inserting and withdrawing the rotor horizontally 1576
Press for expanding the coupling 1576
Compression devices for pressing on or for support while pressing off 1577
Pulling units with cross beam or disk 1579
Aids 1579
Extraction devices 1579
Main blower 1581
Removing the main blower motor 1583
Disassembling the main blower motor 1589
Assembling the main blower motor 1591
Installing the main blower motor 1594
Retarding grid 1601
Removing the grid blower motor 1603
Disassembling the grid blower motor 1605
Assembling the grid blower motor 1607
Installing the grid blower motor 1609
Removing a grid element 1614
Control cabinet 1617
Removing the SIBAC Inverter Module 1619
Required tools/materials 1619
Removal 1622
Installing the SIBAC Inverter Module 1626
Draining and filling the IGBT coolant system 1627
Required tools/materials 1627
Coolant mixture specification (distilled water: Antifrogen® N) 1627
Draining and filling the coolant 1629
Removing and installing the IGBT coolant pump assembly 1632
Required tools/materials 1632
Removal 1633
90 Diagrams and drawings 1637
Hydraulic circuit diagrams 1637
Electrical circuit diagrams 1643
Electrical circuit diagrams – drive system 1667
Blank Page

DESCRIPTION:

Komatsu 960E-2KT Dump Truck Shop Manual CEBM028402  – PDF DOWNLOAD

• SERIAL NUMBERS 960E-2KT A50028 – A50088

Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The
structure and function sub-section explains the structure and function of each component. It serves not
only to give an understanding of the structure, but also serves as reference material for troubleshooting.
The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgment criteria for testing, adjusting,
and troubleshooting. This standard value table is used to check the standard values in testing and adjusting
and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgment criteria for testing and adjusting are
explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by
failure modes.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and weight of
components are also explained.
90. Diagrams and drawings
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Revision and distribution
Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most update
information before you start any work.

G.B 20/12/24