shop manual im trouble shoot section_prelimary.pdf

8/21/2019 Shop manual IM Trouble shoot section_prelimary.pdf

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960E-1 1

CEN40001-00

DUMP TRUCK1SHOPMANUAL

960E-1

Machine model Serial number

960E-1 A30001 and up

00 TroubleshootingTroubleshooting

Method of using troubleshooting charts ................................................................................................................ 3


2/226

CEN40001-00 00 Troubleshooting

2 960E-1

NOTES


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00 Troubleshooting CEN40001-00

960E-1 3

Fault Code A001: Left front suspension pressure sensor signal high

Related circui t diagram

Operator Action None

Fault Code A001

Description Left front suspension pressure sensor signal high.

Fault Conditions Sets if pressure signal is out of range high (sensor current over 22 ma).Resets if reading returns to normal.

Operator Alerting

System Response

Repair Lamp

Display Operator Action: None

Display Fault Description: PLM LF PRESS SENS HI

Display Fault Code: A001

Resulting Problem(s) Bad payload computation.

Related Information A laptop running "IM Realtime Data Monitor" software may be required to resolve this

fault.

Table

1. This fault is generated by PLM3 in response to a problem in the sensor circuit. This sensor circuit may havea related fault that can be used to resolve the problem. Refer to the Troubleshooting Instructions for the active

parameter fault(s).

2. If there are no active parameter fault codes, then based on the truck's setup while this fault is active, deter-

mine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data Monitor

program. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the unex-

pected state. Troubleshoot these items.

3. If this fault is not currently active or if no parameters are currently in the unexpected state and the malfunc-

tion is still unresolved, then check each of the parameters in the Table for proper functionality. Troubleshoot all

item(s) related to the parameter(s) which are found to be malfunctioning.

Parameter Expected State and/or Related Fault(s)

Left Front Pressure

Sensor (PLM3 36,39)

Sensor current >22 ma: failed high

Sensor current 2 ma but less than 22 ma: valid readings

Fault(s): A002

LEFT FRONTSUSPENSION

PRESSURE

LEFT DECKJUNCTION BOX

+18V

LF PRESSURE


4/226


4 960E-1

Fault Code A002: Left front suspension pressure sensor signal low



Fault Code A002

Description Left front suspension pressure sensor signal low.

Fault Conditions Sets if pressure signal is out of range low (sensor current less than 2 ma).Resets if reading returns to normal.

Operator Alerting

System Response

Repair Lamp


Display Fault Description: PLM LF PRESS SENS LO




fault.

Table


parameter fault(s).









Left Front Pressure

Sensor (PLM3 36,39)



Fault(s): A001

LEFT FRONTSUSPENSION

PRESSURE


+18V

LF PRESSURE


5/226


960E-1 5

Fault Code A003: Right front suspension pressure sensor signal high



Fault Code A003

Description Right front suspension pressure sensor signal high.


Operator Alerting

System Response

Repair Lamp


Display Fault Description: PLM RF PRESS SENS HI




fault.

Table


parameter fault(s).









Right Front Pressure

Sensor (PLM3 36,20)



Fault(s): A004

RIGHT FRONTSUSPENSION

PRESSURE

RIGHT DECKJUNCTION BOX

+18V

RF PRESSURE


6/226


6 960E-1

Fault Code A004: Right front suspension pressure sensor signal low



Fault Code A004

Description Right front suspension pressure sensor signal low.


Operator Alerting

System Response

Repair Lamp


Display Fault Description: PLM RF PRESS SENS LO




fault.

Table


parameter fault(s).










Sensor (PLM3 36,20)



Fault(s): A003

RIGHT FRONTSUSPENSION

PRESSURE


+18V

RF PRESSURE


7/226


960E-1 7

Fault Code A005: Left rear suspension pressure sensor signal high



Fault Code A005

Description Left rear suspension pressure sensor signal high.


Operator Alerting

System Response

Repair Lamp


Display Fault Description: PLM LR PRESS SENS HI




fault.

Table


parameter fault(s).









Left Rear Pressure

Sensor (PLM3 36,30)



Fault(s): A006

LEFT REARSUSPENSION

PRESSURE REAR AXLEJUNCTION BOX

+18V

LR PRESSURE

Should TB39-V be here?

Missing in newschematic.


8/226


8 960E-1

Fault Code A006: Left rear suspension pressure sensor signal low



Fault Code A006

Description Left rear suspension pressure sensor signal low.


Operator Alerting

System Response

Repair Lamp


Display Fault Description: PLM LR PRESS SENS LO




fault.

Table


parameter fault(s).









Left Rear Pressure

Sensor (PLM3 36,30)



Fault(s): A005

LEFT REARSUSPENSION


+18V

LR PRESSURE

Should TB39-V be here?

Missing in newschematic.


9/226


960E-1 9

Fault Code A007: Right rear suspension pressure sensor signal high



Fault Code A007

Description Right rear suspension pressure sensor signal high.


Operator Alerting

System Response

Repair Lamp


Display Fault Description: PLM RR PRESS SENS HI




fault.

Table


parameter fault(s).









Right Rear Pressure

Sensor (PLM3 36,40)



Fault(s): A008

RIGHT REARSUSPENSION


+18V

RR PRESSURE


10/226


10 960E-1

Fault Code A008: Right rear suspension pressure sensor s ignal low



Fault Code A008

Description Right rear suspension pressure sensor signal low.


Operator Alerting

System Response

Repair Lamp


Display Fault Description: PLM RR PRESS SENS LO




fault.

Table


parameter fault(s).









Right Rear Pressure

Sensor (PLM3 36,40)



Fault(s): A007

RIGHT REARSUSPENSION


+18V

RR PRESSURE


11/226


960E-1 11

Fault Code A009: Incline sensor signal high



Fault Code A009

Description Incline sensor signal high.

Fault Conditions Sets if incline signal is out of range high (sensor voltage less than 0.565 volts).Resets if reading returns to normal.

Operator Alerting

System Response

Repair Lamp


Display Fault Description: INCLINE SENSOR HIGH




fault.

Table


parameter fault(s).









Incline Sensor (PLM3

36, 29, 19)

Sensor voltage 5.08: failed lowSensor voltage >0.565 but < 5.08: valid readings

Fault(s): A010

INCLINOMETER

INCLINE SIGNAL

INCLINE GROUND

+18V


12/226


12 960E-1

Fault Code A010: Incline sensor signal low.



Fault Code A010

Description Incline sensor signal low.

Fault Conditions Sets if incline signal is out of range low (sensor voltage greater than 5.08 volts).Resets if reading returns to normal.

Operator Alerting

System Response

Repair Lamp


Display Fault Description: INCLINE SENSOR LOW




fault.

Table


parameter fault(s).










36, 29, 19)

Sensor voltage 5.08: failed lowSensor voltage >0.565 but < 5.08: valid readings

Fault(s): A009

INCLINOMETER

INCLINE SIGNAL

INCLINE GROUND

+18V


13/226


960E-1 13

Fault Code A018: Right rear flat suspension cylinder warning


Fault Code A018

Description Right rear flat suspension cylinder warning.

Fault Conditions Sets if PLM3 detects a flat right rear suspension cylinder.Resets if conditions clears.

Operator Alerting

System Response

Repair Lamp


Display Fault Description: RR FLAT SUSP CYL FLT


Resulting Problem(s) Potential damage to suspension and frame.


fault.

Table

1. The logic that produces this fault is intended to identify flat suspension cylinders. The primary correction isto recharge / repair the cylinder. If the cylinder is not defective, use the following procedure to correct PLM3.

2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).

This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting

Instructions for the active parameter fault(s).








Parameter Expected State and/or Related Fault(s)Right Rear Pressure

Sensor (PLM3 36, 40)



Fault(s): A007, A008

Left Rear Pressure





Left Front Pressure











36, 29, 19)

Sensor voltage 5.08: failed low

Sensor voltage >0.565 but < 5.08: valid readings



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14 960E-1


LEFT FRONTSUSPENSIONPRESSURE

RIGHT FRONTSUSPENSIONPRESSURE

LEFT REAR

SUSPENSIONPRESSURE

RIGHT REARSUSPENSIONPRESSURE

INCLINOMETER

+18V

LF PRESSURE

RF PRESSURE

LR PRESSURERR PRESSURE

INCLINE SIGNAL

INCLINE GROUND

REAR AXLEJUNCTION BOX



TB38-V was in old schematic, but not in

new schematic. Should it stay?


15/226


960E-1 15

Fault Code A019: Left rear flat suspension cy linder warning


Fault Code A019

Description Left rear flat suspension cylinder warning.

Fault Conditions Sets if PLM3 detects a flat left rear suspension cylinder.Resets if conditions clears.

Operator Alerting

System Response

Repair Lamp


Display Fault Description: LR FLAT SUSP CYL FLT


Resulting Problem(s) Potential damage to suspension and frame.


fault.

Table

1. The logic that produces this fault is intended to identify flat suspension cylinders. The primary correction is torecharge / repair the cylinder. If the cylinder is not defective, use the following procedure to correct PLM3.











Parameter Expected State and/or Related Fault(s)Left Rear Pressure





Right Rear Pressure





Left Front Pressure











36, 29, 19)


Sensor voltage >0.565 but < 5.08: valid readings



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16 960E-1




LEFT REAR

SUSPENSIONPRESSURE


INCLINOMETER

+18V

LF PRESSURE

RF PRESSURE


INCLINE SIGNAL

INCLINE GROUND




TB38-V was in old schematic, but not innew schematic. Should it stay?


17/226


960E-1 17

Fault Code A022: Carryback load excessive


Fault Code A022

Description Carryback load excessive.

Fault Conditions Sets if PLM3 detects excessive load remaining in the bed after dumping is complete.Resets if conditions clears.

Operator Alerting

System Response


Display Fault Description: None

Display Fault Code: None

Resulting Problem(s) Reduced production.


fault.

Table

1. The logic that produces this fault is intended to identify excessive carryback load. This is a VHMS recording

only. No display announces the fault. If excessive carryback does not exist, troubleshoot the payload system.2. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).











Left Rear PressureSensor (PLM3 36, 30)

Sensor current >22 ma: failed highSensor current 2 ma but less than 22 ma: valid readings


Right Rear Pressure





Left Front Pressure











36, 29, 19)


Sensor voltage >0.565 but


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18 960E-1




LEFT REAR

SUSPENSIONPRESSURE


INCLINOMETER

+18V

LF PRESSURE

RF PRESSURE


INCLINE SIGNAL

INCLINE GROUND





19/226


960E-1 19

Fault Code A100: An open circuit breaker has been detected on a relay board


Operator Action Stop: Park

Fault Code A100

Description An open circuit breaker has been detected on a relay board.

Fault Conditions Sets if any of the circuit breakers on relay boards are open for 1 second. These are alllighting and accessory electrical loads.

Operator Alerting

System Response

Sound Buzzer

Flash IM Warning indicator

Display Operator Action: STOP: PARK: PWR↓: CHKDisplay Fault Description: CIRCUIT BREAKER FLT


Resulting Problem(s) Accessory circuits (headlights, tail lights, stop lights, turn signal lights, retard lights,

engine control, service lights, or horn) may be non-functional.


fault.

Table

1. This fault is generated by parallel input to IM from the relay boards. Each relay board in turn has an LED that

indicates that one of its several breakers is open.


Circuit Breaker Tripped

(IM 2g)

0: one or more circuit breakers tripped on relay boards

1: no circuit breakers tripped on any relay boards

Relay Board 1 Turn Signal / Clearance Lights

Relay Board 3 Stop, Retard, Manual back up lights

Relay Board 4 Engine control, service lights & horn

Relay Board 5 Headlights

CIRCUIT BREAKER


20/226


20 960E-1

Fault Code A107: GE has generated a propel system caution


Operator Action Max Speed Limited

Fault Code A107

Description GE has generated a propel system caution.

Fault Conditions Sets if the GE controller generates a propel system caution event.Operator Alerting

System Response

Sound Buzzer - single burst

Display Operator Action: MAX SPEED LIMITED

Display Fault Description: PROPEL SYS CAUTION


Resulting Problem(s) Propel system may not permit the truck to remain at full performance. Shutdown of

propel system may occur if severity increases.


fault.

A laptop running GE's PTU software may be required to resolve this fault.

Table1. This fault is generated by GE driving an input pin of IM to ground.

2. It may be necessary to use GE's PTU software to determine the actual cause of the propel system distress


Propel System

Caution (IM 2t)

0: GE has generated a propel system caution

1: no propel system caution exists

GE

CONTROLPANEL

PROPEL SYSTEM CAUTION


21/226


960E-1 21

Fault Codes A111 and A247: Low steering pressure warnings


Fault Code A111 & A247

Description A111 is a low steering pressure warning for storage by VHMS. It is designed to filter

out some service and operational conditions that would otherwise produce this warn-

ing.

A247 is a low steering pressure warning for display to operator. It is designed to give

immediate information to the operator, regardless of the cause of the problem.

Fault Conditions A111 sets if low steering pressure input to IM remains after 90 seconds of engine run-

ning at 300 rpm or above and is sustained for 3 seconds at speeds of 1200 rpm or

above.

A247 sets if low steering pressure input to IM is on with engine running at 300 rpm or

above or if truck begins to move at 0.8 kph or more.

A111 resets if pressure returns or engine slows below 1200 rpm for 3 seconds.

A247 resets if pressure returns or engine stops running and truck stops moving for 1

second.

Operator Alerting

System Response

Sound Buzzer

Flash IM Warning indicator Display Operator Action: STOP: RUN WHEN CLR'D

Display Fault Description: LOW STRG PRESSURE


Resulting Problem(s) Truck may not steer properly.


fault.

Table


This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the TroubleshootingInstructions for the active parameter fault(s).









Low Steering Pressure

Sw (IM 2S)

0: steering pressure normal

1: low steering pressure

Fault(s): A279, A115, A253

Engine Speed [RPM] 0: engine is not running

Greater than 300: engine is running

Greater than 1200: engine is running fast enough to maintain steering pressure

Truck Speed [kph]

(IM1gh)

0: truck is not moving

Greater than 0.8kph: truck is moving


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22 960E-1


LOW STEERINGPRESSURE

GECONTROL

PANEL

LOW STEERINGPRESSURE

SWITCH2300 psi

TRUCK SPEED IN

TRUCK SPEED IN


23/226


960E-1 23

Fault Codes A117 and 261: Low brake accumulator pressure warnings


Fault Code A117 & A261

Description A117 is a low brake accumulator pressure warning for storage by VHMS. It is

designed to filter out some service and operational conditions that would otherwise

produce this warning.

A261 is a low brake accumulator pressure warning for display to operator. It is

designed to give immediate information to the operator, regardless of the cause of the

problem.

Fault Conditions A117 sets if low brake accumulator pressure input to IM remains after 90 seconds of

engine running at 300 rpm or above.

A261 sets if low brake accumulator pressure input to IM is on with engine running at

300 rpm or above or if truck begins to move at 0.8 kph or more.

A117 resets if pressure returns or engine stops running for 1 second.

A261 resets if pressure returns or engine stops running and truck stops moving for 1

second.

Operator Alerting

System Response

Sound Buzzer

Flash IM Warning indicator Display Operator Action: STOP: RUN WHEN CLR'D

Display Fault Description: LOW BRAKE PRESSURE


Resulting Problem(s) Service brake may not stop or hold the truck.


fault.

Table

1. This fault is generated by more than one parameter, but the independent parameters do not have fault codes

for situations that will affect this fault.Parameter Expected State and/or Related Fault(s)

Brake Accumulator

Pressure Sw (IM 2U)

0: brake accumulator pressure normal

1: low brake accumulator pressure



Truck Speed [kph]

(IM1gh)


Greater than 0.8kph: truck is moving


24/226


24 960E-1


LOW BRAKE ACCUMULATOR

PRESSURE

GECONTROL

PANEL

LBPSLOW BRAKE

ACCUMULATORPRESSURE SWITCH

1850 psi

TRUCK SPEED IN

TRUCK SPEED IN


25/226


960E-1 25

Fault Code A118: Brake pressure is low while in brake lock

Operator Action Set Park Brake

Fault Code A118

Description Brake pressure is low while in brake lock.

Fault Conditions Sets if brake lock is on and brake lock degrade switch closes indicating low servicebrake pressure for 3 seconds unless steering bleed has already started.

Resets if brake lock or brake lock degrade switch are off for 1 second.

Operator Alerting

System Response

Sound Buzzer


Display Operator Action: SET PARK BRAKE

Display Fault Description: SERV BRAKE DEGRADE


Resulting Problem(s) Service brake may not stop or hold the truck.


fault.

Table











Parameter Expected State and/or Related Fault(s)Brake Lock (IM 2i) 0: brake lock not on

1: brake lock is on

Fault(s): A272

Brake Lock Degrade

Sw (IM 2V)

0: brake lock degrade not on

1: brake lock degrade is on

Fault(s): A281


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26 960E-1


BDSBRAKE LOCK

DEGRADEPRESSURE

SWITCH1000 psi

BRAKE LOCKSOLENOID

BRAKE LOCK DEGRADE

BRAKE LOCK SOLENOID


27/226


960E-1 27

Fault Code A152: Starter Failure


Fault Code A152

Description Starter Failure

Fault Conditions Sets if either starter motor is not energized for 2 seconds when cranking is attempted.Resets only when steering bleed occurs.

Operator Alerting

System Response

Display: Repair Item

Display Fault Description: STARTER FAILURE


Resulting Problem(s) One good starter may be destroyed or engine may not start at all.


fault.

Table


This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the TroubleshootingInstructions for the active parameter fault(s).









Starter Motor 1

Energized (IM 3R)

0: starter motor 1 not energized

1: starter motor 1 energized

Fault(s): A275

Starter Motor 2

Energized (IM 3S)

0: starter motor 2 not energized

1: starter motor 2 energized

Fault(s): A275

Crank Sense (IM 3U) 0: no cranking in process

1: cranking in process


28/226


28 960E-1


STARTER #1

STARTER #2

START MOTOR NO. 1

START MOTOR NO. 2

CRANK SENSE

STARTERFAILURECIRCUIT

STARTERFAILURECIRCUIT


29/226


960E-1 29

Fault Code A213: Parking brake should have applied but is detected as not having applied

Operator Action Secure Vehicle

Fault Code A213

Description Parking brake should have applied but is detected as not having applied.

Fault Conditions Sets if park brake does not apply within 3 seconds if the shifter is not in the forward,neutral, or reverse positions or the engine oil pressure is below the setpoint of the

engine oil pressure switch and either the speed of the truck has been 0.8kph or less

for 1 second or the service brakes are applied, or after the engine has been off for 15

seconds with the J1939 link working, or within 2 seconds after the key switch has been

turned off, the drive system control power is off, the engine is not running, and the

truck is not moving. Park brake set is defined as closure of the park brake set pressure

switch and opening of the park brake release pressure switch.

Resets after 3 seconds if the park brake applies, or if the park brake request is can-

celled and the shifter is not in the park position and the shifter is in the forward, neutral,

or reverse positions and the engine is running.

Operator Alerting

System Response

Sound Buzzer


Display Operator Action: SECURE VEHICLEDisplay Fault Description: NO PARK BRAKE


Resulting Problem(s) The parking brake may be non-functional.

Engine cranking may be prevented.

Smart Timed Engine Shutdown may be prevented.


fault.

Table

1. This fault's logic contains more than one parameter, each of which may have its own related fault code(s).This fault may be resolved by resolving the parameter(s) active fault code(s). Refer to the Troubleshooting










Selector Switch (FNR)

(IM 2N)

0: shifter is not in forward, neutral, or reverse

1: shifter is in forward, neutral, or reverse


Park Brake Set (IM 2f) 0: parking brake pressure switch indicating low pressure and an applied parking brake

1: parking brake pressure switch indicating higher pressure and an unapplied parking

brake

Park Brake Released

(IM 2M)

0: parking brake pressure switch indicating high pressure and a released parking

brake

1: parking brake pressure switch indicating low pressure and an applied parking brake


30/226


30 960E-1

Selector Switch (Park)

(IM 3T)

0: shifter is not in park

1: shifter is in park


Park Brake Request

(IM 3V)

0: shifter is not in the forward, neutral, or reverse positions or the engine oil pressure is

below the setpoint of the engine oil pressure switch

1: shifter is in the forward, neutral, or reverse positions and the engine oil pressure isabove the setpoint of the engine oil pressure switch

Fault(s): A264



Truck Speed [kph]

(IM1gh)


Greater than 0: truck is moving

Fault(s): A212

CAN J1939 connec-

tion (IM1qrs)

Fault(s): A184

Keyswitch (IM 3G) 0: keyswitch is off and the truck is not moving and the engine is not running

1: keyswitch is on or the truck is moving or the engine is running

Fault(s): A240

Park Brake Solenoid

(IM 1E)

Status - Open Load: Unexpected. Troubleshoot.

Status - Normal: Expected. No Problem.

Status - Shorted to Ground: Expected if shifter is in the forward, neutral, or reverse

positions and the engine oil pressure is above the setpoint of the engine oil pressure

switch. Otherwise unexpected and must troubleshoot.

Status - Overload: Unexpected. Troubleshoot.


below the setpoint of the engine oil pressure switch and either the speed of the truck

has been 0.8kph or less for 1 second or the service brakes are applied.

1: shifter is in the forward, neutral, or reverse positions and the engine oil pressure is

above the setpoint of the engine oil pressure switch.

Fault(s): A216,


31/226


960E-1 31


E N G I N E R U N

O I L P R E S S U R E S W I T C H

D I R S E L E C T

S W I T C H

S H O W N I N

F O R W A R D

P O S I T I O N )

P B S

P A R K B R A K E

S O L E N O I D

G E

C O N T R O L

P A N E L

P A R K B R A K E

O F F R E L A Y

P B R P S

P A R K B R A K E

R E L E A S E

P

R E S S . S W I T C H

1 2 5 0 p s i

P B A P

S

P A R K B R

A K E

A P P L

Y

P R E S S . S W I T C H

7 5 p s i

P A R K B R A K E

R E L E A S E D

T R U C K S P E E D I N

F O R W

A R D

R E V E R S E

P A R K B R A K E

N E U T R A L

P A R K B R A K E S E T


K E Y S W I T C H

S E L E C T O R

S W I T C H P A R K

P A R K B R A K E

R E Q U E S T

P A R K B R A K E

S O L E N O I D

J 1 9 3 9 - H I G H

J 1 9 3 9 - L O W

J 1 9 3 9 - S H L D

S E L E C T O R

S W I T C H F N R


32/226


32 960E-1

Fault Code A214: Parking brake should have released but is detected as not havingreleased


Fault Code A214

Description Parking brake should have released but is detected as not having released.

Fault Conditions Sets if the engine has been running 90 seconds or more with the keyswitch on and the

park brake does not release in response to the selector switch being moved out of

park or in response to truck speeds over 0.8 kph for 3 seconds. Park brake release is

defined as the closure of the park brake release pressure switch and the opening of

the park brake set pressure switch.

Resets after 3 seconds if the park brake releases, or engine stops running, or key-

switch and propel control power are both turned off, or selector switch is moved to park

position.

Operator Alerting

System Response


Park Brake Status Lamp stays on

Display Operator Action: STOP: PRK: PWR↓: CHKDisplay Fault Description: PARK BRAKE ON


Resulting Problem(s) Operation of the truck may be prevented or the parking brake may be damaged.


fault.

Table





mine which of the parameters in the Table is not shown in its expected state on the IM Realtime Data Monitorprogram. Refer to the schematic to identify which item(s) may be causing the parameter(s) to be in the unex-






Selector Switch (Park)

(IM 3T)

0: shifter is not in park

1: shifter is in park


Park Brake Released

(IM 2M)

0: parking brake pressure switch indicating high pressure and a released parking

brake

1: parking brake pressure switch indicating lower pressure and an applied parkingbrake

Park Brake Set (IM 2f) 0: parking brake pressure switch indicating low pressure and an applied parking brake

1: parking brake pressure switch indicating higher pressure and a released parking

brake


33/226


960E-1 33

Park Brake Request

(IM 3V)




above the setpoint of the engine oil pressure switch

Fault(s): A264

Engine Speed [RPM] Less than 300 RPM: engine is not runningGreater than 300 RPM for 4 seconds: engine is running

Truck Speed [kph]

(IM1gh)

Less than 0.8kph : park brake can be applied

Greater than 0.8kph: park brake cannot be applied

Fault(s): A212

CAN J1939 connec-

tion (IM1qrs)

Fault(s): A184


1: keyswitch is on or the truck is moving (GE power not yet off)

Fault(s): A240

Park Brake Solenoid

(IM 1E)

Status - Open Load: Unexpected. Troubleshoot.

Status - Normal: Expected. No Problem.

Status - Shorted to Ground: Expected if shifter is in the forward, neutral, or reverse

positions and the engine oil pressure is above the setpoint of the engine oil pressure

switch. Otherwise unexpected and must troubleshoot.



below the setpoint of the engine oil pressure switch and either the speed of the truck

has been 0.8kph or less for 1 second or the service brakes are applied





34/226


34 960E-1


E N G I N E R U N

O I L P R E S S U R E S W I T C H

D I R S E L E C T

S W I T C H

S H O W

N I N

F O R W

A R D

P O S I T

I O N )

P B S

P A R K B R A K E

S O L E N O I D

G E

C O N T R O L

P A N E L

P A R K

B R A K E

O F F

R E L A Y

P B R P S

P A R K B R A K E

R E L E A S E


1 2 5 0 p s i

P B A P S

P A R K B R A K E

A P P L Y


7 5 p s i

P A R K B R A K E

R E L E A S E D


F O R W A R D

R E V E R S E

P A R K B R A K E

N E U T R A L

P A R K B R A K E S E T


K E Y S W I T C H

S E L E C T O R

S W I T C H P A R K

P A R K B R A K E

R E Q U E S T

P A R K B R A K E

S O L E N O I D

J 1 9 3 9 - H I G H

J 1 9 3 9 - L O W

J 1 9 3 9 - S H L D


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960E-1 35

Fault Code A215: Brake auto apply valve circuit is defective

Operator Action Go To Shop

Fault Code A215

Description Brake auto apply valve circuit is defective.

Fault Conditions Sets if the output driver circuit detects an open circuit or short to ground when the key-switch is on and the park brake is requested, or sets if the output driver circuit does not

detect an open circuit with the key switch on and the park brake not requested.

Resets only at power down.

Operator Alerting

System Response

Sound Buzzer

Flash IM Warning Indicator

Display Operator Action: GO TO SHOP NOW

Display Fault Description: BRK AUTO APPLY FLT


Resulting Problem(s) Park brake may not be protected in an application while rolling, or service brake may

not release and permit movement.


fault.

Table









tion is still unresolved, then check each of the parameters in the Table for proper functionality. Troubleshoot allitem(s) related to the parameter(s) which are found to be malfunctioning.


Park Brake Request

(IM 3V)







1: keyswitch is on or the truck is moving (GE power not yet off)

Fault(s): A240


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36 960E-1


Auto Brake Apply

Solenoid (IM 1R)

Status - Open Load: Unexpected if park brake request and keyswitch are on. But

expected if park brake request is off or keyswitch is off. Troubleshoot if inconsistent.

Status - Normal: Expected if park brake request and keyswitch are on. Troubleshoot if

status is normal with park brake request off or keyswitch off.

Status - Shorted to ground: Unexpected. Troubleshoot


0: normal operation with park brake either on or off. This valve operates only tran-

siently when the park brake is turned on.

1: brake auto apply valve operates for 1.5 seconds after the park brake is turned on if

the truck is stopped. If moving, it will not operate until truck speed has dropped to 0.8

kph.

Fault(s): A359

ABA AUTO BRAKE

APPLY SOLENOID

KEY SWITCH

PARK BRAKE REQUEST

BRAKE AUTO APPLY


37/226


960E-1 37

Fault Code A242: Fuel gauge within the Actia display panel is defective



Fault Code A242

Description Fuel gauge within the Actia display panel is defective.

Fault Conditions Sets if Actia reports a fuel gauge fault.Resets if Actia clears the fault.

Operator Alerting

System Response


Display Fault Description: FUEL GAUGE FAULT


Resulting Problem(s) Truck could run out of fuel.


fault.

Table

1. This fault is entirely contained within the ACTIA display panel. The panel and communication to it must be

working in order for IM to be aware of the fault. Therefore the only diagnostic effort is to check the gauge andwiring within the panel and replace if necessary.


POWER 7.5V

GND

LIN

Actia LIN connector, from MasterGauge to all other gauges and lightpanel by a daisy chain connection.

TO SLAVE DEVICES

MASTER GAUGE


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38 960E-1

Fault Code A243: Engine coolant temp gauge within the Actia display panel is defective


Operator Action Go to Shop

Fault Code A243

Description Engine coolant temp gauge within the Actia display panel is defective.

Fault Conditions Sets if Actia reports an engine coolant temp gauge fault.Resets if Actia clears the fault or steering bleed comes on.

Operator Alerting

System Response

Sound Buzzer



Display Fault Description: ENG COOL TEMP GAUGE


Resulting Problem(s) Engine could overheat without warning.


fault.

Table1. Except for being masked by the steering bleed process, this fault is entirely contained within the ACTIA dis-

play panel. The panel and communication to it must be working in order for IM to be aware of the fault. There-

fore the only diagnostic effort is to check the gauge and wiring within the panel and replace if necessary.


Steering Bleed Valve 0: steering bleed valve is off

1: steering bleed valve is on

POWER 7.5VGND

LIN


TO SLAVE DEVICES

MASTER GAUGE


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960E-1 39

Fault Code A244: Drive system temp gauge with in the Actia display panel is defective



Fault Code A244

Description Drive system temp gauge within the Actia display panel is defective.

Fault Conditions Sets if Actia reports a drive system temperature gauge fault.Resets if Actia clears the fault or steering bleed comes on.

Operator Alerting

System Response

Sound Buzzer



Display Fault Description: DRIVE SYS TEMP GAUGE


Resulting Problem(s) Drive system could overheat without warning.


fault.







POWER 7.5VGND

LIN


TO SLAVE DEVICES

MASTER GAUGE


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40 960E-1

Fault Code A245: Hydraulic o il temp gauge wi thin the Actia display panel is defective



Fault Code A245

Description Hydraulic oil temp gauge within the Actia display panel is defective.

Fault Conditions Sets if Actia reports an hydraulic oil temperature gauge fault.Resets if Actia clears the fault or steering bleed comes on.

Operator Alerting

System Response

Sound Buzzer



Display Fault Description: HYD OIL TEMP GAUGE


Resulting Problem(s) Hydraulic oil could overheat without warning.


fault.







POWER 7.5VGND

LIN


TO SLAVE DEVICES

MASTER GAUGE


41/226


960E-1 41

Fault Code A246: PLM3 reports truck overload


None.

Operator Action Speed Limit

Fault Code A246

Description PLM3 reports truck overload.

Fault Conditions Sets if PLM3 reports an overloaded truck.Resets if PLM3 clears the overloaded truck report.

Operator Alerting

System Response


Display Operator Action: MAX SPEED LIMIT

Display Fault Description: LOAD EXCEEDS LIMIT


Resulting Problem(s) Truck could be damaged by operating in overload condition.


fault.

Table

1. This fault is entirely contained within PLM3 (payload meter). The panel and communication to it must beworking in order for IM to be aware of the fault. Normal corrective measures would be to correct the loading

process.

2. Any faults within the payload meter system that might affect its accuracy are developed and reported by

PLM3.



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42 960E-1

Fault Code A248: Status module with in the Actia display panel is defective



Fault Code A248

Description Status module within the Actia display panel is defective.

Fault Conditions Sets if Actia reports a status module fault.Resets if Actia clears the fault or steering bleed comes on.

Operator Alerting

System Response

Sound Buzzer



Display Fault Description: STATUS MODULE FLT


Resulting Problem(s) Proper operation will be difficult without status information.


fault.



fore the only diagnostic effort is to check the status module and wiring within the panel and replace if

necessary.




POWER 7.5V

GND

LIN


POWER 7.5V

GND

LIN

LIGHT MODULEMASTER GAUGE

TO SLAVE DEVICES TO SLAVE DEVICES


43/226


960E-1 43

Fault Code A249: Red warning lamp within the ACTIA disp lay (driven by IM) is shorted



Fault Code A249

Description Red warning lamp within the ACTIA display (driven by IM) is shorted.

Fault Conditions Sets if the red warning lamp feedback voltage is high for 400 ms with the red warninglamp on.

Resets at power down.

Operator Alerting

System Response

Sound Buzzer



Display Fault Description: RED WARN LAMP FLT


Resulting Problem(s) Warnings will be audible only.


fault.

Table

1. This fault's logic contains no additional external parameters. The red warning lamp feedback connection is

made internally.

2. Check wiring and connections between IM and the ACTIA display and wiring within the display to the red

warning lamp as well as the lamp itself.


Red Warning Lamp (IM

1G)

0: red lamp is not on

1: red lamp is on

Fault(s): A256

Red Warning Lamp

Feedback (IM 1G)

Above 3.75 volts for 400 ms with the lamp on: shorted

Less than 3.75 volts for 400 ms with the lamp on: normal

ELECTRONIC DASH PANEL(PC1927) AND (PC1929)

RED WARNING LAMP


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44 960E-1

Fault Code A251: Sonalert used with the ACTIA display but driven by IM, is open orshorted to ground


Fault Code A251

Description Sonalert used with the ACTIA display but driven by IM, is open or shorted to ground.

Fault Conditions Sets if the sonalert circuit is open or short to ground for 400 ms and steering bleed not

on.

Resets if circuit is normal for 400 ms or if steering bleed comes on.

Operator Alerting

System Response

Sound Buzzer



Display Fault Description: SONALERT IM FAULT


Resulting Problem(s) Warnings will be visual only.


fault.

Table












Sonalert (IM 1M) Status - Open Load: Unexpected. Troubleshoot.

Status - Normal: Expected. No problem.

Status - Shorted to Ground: Unexpected. Troubleshoot.


0: No faults are active that require buzzer operation.

1. One or more faults are active that require buzzer action.

Fault(s): A356




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960E-1 45


SONALERT

SONALERT #2(IM FAULTS)

+24V OUT


46/226


46 960E-1

Fault Code A252: Start enable output circuit is either open or shorted to ground


Fault Code A252

Description Start enable output circuit is either open or shorted to ground.

Fault Conditions Sets if the start enable relay circuit is open or short to ground for 2 seconds.Resets only at power down.

Operator Alerting

System Response

Repair Status Light On


Display Fault Description: STRT ENABLE CKT FLT


Resulting Problem(s) Starting will either not be possible, or will lack the protections that IM provides for the

start enable circuit (excessive cranking, selector switch position, J1939 ok, and engine

speed 0 to start and not above 400rpm at finish).


fault.

Table











Parameter Expected State and/or Related Fault(s)Start Enable (IM 1B) Status - Open Load: Unexpected. Troubleshoot

Status - Normal: Expected. No problem.



0: One of several interlocking situations exist to prevent cranking (excessive cranking

history, selector switch in wrong position, engine red light, J1939 not ok, engine speed

either not 0 to begin cranking or over 400 rpm while cranking).

1. No interlocking situations exist to prevent cranking.

Fault(s): A350




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960E-1 47


START CIRCUIT

RELAY

START ENABLE

+24V OUT


48/226


48 960E-1

Fault Code A253: Steering bleed circuit is not open while running


Fault Code A253

Description Steering bleed circuit is not open while running,

Fault Conditions Sets if the steering bleed circuit is not open for 2 seconds, beginning 11 seconds afterthe keyswitch is turned on.

Resets only at power down.

Operator Alerting

System Response

Repair Status Light On


Display Fault Description: STG BLD CKT NOT OPN


Resulting Problem(s) Steering bleed will be possible during normal running, if IM or some of its inputs should

also malfunction.


fault.

Table











Parameter Expected State and/or Related Fault(s)Steering Bleed Valve

(IM 1P)

Status - Open Load: Expected with key switch on. No problem. Otherwise, unex-

pected. Must troubleshoot.

Status - Normal: Expected only with key off and steering bleed in process. Trouble

shoot if found with key on.


Status - Overload: Unexpected.Troubleshoot.

0: steering bleed valve is off. This is expected in normal running operation.

1: steering bleed valve is on. This is expected after key off initiates steering bleed

operation.

Fault(s): A262, A263, A358


1: keyswitch is on or the truck is moving or the engine is runningFault(s): A240


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960E-1 49


STEERING ACCUMULATOR

BLEEDDOWN SOLENOID

BLEEDDOWN POWERSUPPLY RELAY

KEY SWITCH

STEERINGBLEEDDOWNSOLENOID


50/226


50 960E-1

Fault Code A256: Red warning lamp in the ACTIA display but dr iven by IM, is open



Fault Code A256

Description Red warning lamp in the ACTIA display but driven by IM, is open.

Fault Conditions Sets if red lamp stays open for 1 second with steering bleed off. (The red lamp is openif feedback voltage stays low for 400 ms with red lamp off.)

Resets if red lamp returns to normal or steering bleed operates for 1 sec. (The red

lamp is normal if feedback voltage goes high for 400 ms with red lamp off.)

Operator Alerting

System Response

Sound Buzzer



Display Fault Description: RED WARN LAMP FLT


Resulting Problem(s) Warnings will be audible only.

Related Information A laptop running "IM Realtime Data Monit

shop manual im trouble shoot section_prelimary.pdf

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