860 AC 24 volt system
Page 1 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system
Isolator Switches
CRANKING
Battery Box
SYSTEM
Page 2 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Isolator box
12v Power
Eng. Start
CB61 CB62
Relay
Relay
N/A
isolator diodes
SID 1 starter
12v PS for
CB60
windows etc
Battery charge
monitor Relay
12 v Relay
- + - + 1 11
50 A
11B1A 11B2
CB60
- + 11B2
- + 1 11ST
Cranking
15 A
NC 12V 11B1
12CB
12B1 to IM3-h
CB61 C
NO
712
11
HE 515 12V MON
24v Aux Box
Page 3 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Battery Charge Alternator
Niehoff Alternator
24V 240 Amps
Page 4 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Testing
Page 5 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Testing
Page 6 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system
Page 7 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system
Page 8 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Engine Pre- Lube
Pre-Lube Motor & Pump
Items supplied with Engine
11ORS
36 wire
Page 9 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system FAN Clutch
Provides infinite slip drive
Optimizes engine cooling
Low start up torque
Prolongs belt life
Constant engine oil cooling
and lubrication supply
Solenoid regulated control
Page 10 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system FAN Clutch
H 1. Control from Engine
Management system
D
2. Fail safe N.O. operation
3. Disconnect solenoid to
lockup fan fully.
Connects to A/C drier and forces fan to lockup when A/C system
pressure is censed
Page 11 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Trouble shooting
Hot Engine; NO DRIVE
1. Check for faulty PWM, output.
2. Check for faulty or clogged
solenoid
3. Check for worn out clutch or
internal leakage
Hint; pull plug & clutch must engage
Page 12 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Body Up Switch
A Air gap 12 to 16 mm
B. +/- 25mm
C. Aluminum mount
Activates propulsion inhibit
Activates Body Up Indicator
Activates PLM zone change
Page 13 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Body hoist limit
A Air gap 12 to 16 mm
B. +/- 38 mm
Activates hoist cut out sol.
Active when hoist cylinder is
within 250 mm of full stroke
Hoist pivot spacers and
bushes must be maintained
Page 14 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Drive system feedbacks
Drive system
feedbacks
Page 15 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Auxiliary connection cubicle
RB1
RB3
RB4
RB5
DB1
Siemens Interface Connectors 1XA
thru 1XM
RB 1 RB 3 RB 4
RB 5 DB 1
Page 16 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system SiBAS connectors
Siemens connector
interlock daisy chain
1XM Main 24v in
Page 17 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system 24/12V DC/DC converter
24v / 12v DC/DC Converter
Exclusively for ICE/Radio
Key Switch
Page 18 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Automatic Lubrication
Lincoln lube Timer
Self contained logic
Engine must be running to activate
Lube system.
Auto lube fault, Interface module fb
Page 19 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Power Relays
Key Switch Relay
Control Power Relay
DC / DC 12v Converter
12v Power Relay
Windows
Aux 12v circuit plugs
24v Power Stud
12v Power Stud
DOKG, diode “or” for 712CK
Page 20 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Controllers
PLM Controller
PLM Inclinometer
Interface Module
VHMS Controller
ORBCOM Device
Page 21 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Controllers
VHMS /Orbcom
Controllers
RB 6, 7 & 8
Page 22 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system 24 volt Fuse Panels
Automotive style Fuse arrays
Page 23 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Ports
Communication ports
Panel Light Switch
(DLS)
Page 24 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Brake Cabinet
Conventional Komatsu
brake cabinet layout
Brake System control
manifold
Park Brake control
Brake pressure
monitoring
Real time data available
from Interface Module.
Page 25 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system
Page 26 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system
Page 27 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Interface Module
KAC Interface Controller
Controls timing & logic
functions
Drives Text Display
Drives Monitor Panel
Provides real time & data
logging @ 4 frames/sec
[Link]/interfacemodule Web page
IM platform software
Checkout Procedure
I M platform Input Data
Table Log
A235
Page 28 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system
5 volt temp sensor PS IM3-j
IM1-A 24volt supply
5 volt temp sensor PS IM3-c
IM1-C Ground
18volt transducer PS IM3-b
IM1-F Batt ON 11 wire
OUTPUT
24v IM controlled devices IM1-W
IM2-a Right Front PB SET
Auto Brk Apply Sol. IM1-R
IM2-D Left Rear PB released
Page 29 (12/07)
Steering Bleed Solenoid IM1-P
IM2-d Left Front PB SET
Prop Inhibit Relay "on" IM1-N
IM2-f Right Rear PB SET
Sonalert Buzzer IM1-M
IM2-g CB Tripped, RB1,3, 4 & 5
IM on signal to display IM1-K
IM2-h 5 min Shut Down OFF
5 min timer relay IM1-H
IM2-i Brake Lock Request
Red Trangle power IM1-G
IM2-j Crank Request
Park Brk Sol. IM1-E
IM2-k Lo Hyd level monitor
Crank Lock out IM1-B
IM2-L Snapshot in progress
IM2-m Left Rear PB SET
INTERFACE MODULE
Interface Module INPUTS
RS232
IM2-N SS not in PARK remote connector IM2-C
IM2-q Dash rocker mode #4
860E-2 Siemens Electric Drive Truck
remote connector IM2-B
IM2-S Low Strg Pressure remote connector IM2-A
IM2-T Right Rear PB released
IM2-U Brake Acc Pressure, LAP
IM2-V Brk Press degradation CAN-LO IM1-s
Monitoring & Warning Systems
IM2-W Strg Acc pre-charge monitor
CAN
CAN-HI IM1-r
IM2-X Left Front PB released CAN-LO IM1-k
IM2-Y Hydraulic Filter Bypass CAN-HI IM1-j
IM2-Z Strg Bleed Pressure Shield IM1-q
IM3-C D.O.S./Reset active Shield IM1-i
IM3-d Steering Pressure (analog)
IM3-E Engine Run power
Start 5 min Timer IM3-Z
IM3-e Amibient temperature (analog)
Auto Lube Fault IM3-Y
IM3-F Crank Inhibit
Dash rocker mode #5 IM3-X
IM3-G wire 712CK = 24volt
IM3-W Dash rocker mode #6
IM3-g Fuel Level
Park Brake release request IM3-V
IM3-H Dash rocker mode #1 "LEFT"
INPUTS
Crank Request IM3-U
IM3-h 12 volt monitor (12B1)
Left Frt Brk temp IM3-t
IM3-i Left Rear Brk temp
Selector in PARK IM3-T
IM3-J Dash rocker mode #2 "OK"
Hoist #1 Pressure (analog) IM3-s
IM3-K Dash rocker mode #3 "DOWN""
Cranking Motor #2 defect IM3-S
IM3-L Brake Lock Power
Right Frt Brk temp IM3-r
IM3-M wire 71 = 24volt
Cranking Motor #1 defect IM3R
IM3-m Right Rear Brk temp
HE 510
Hoist #2 Pressure (analog) IM3-q
IM3-P Right Front PB released
Brake Pressure (analog) IM3-p
860 AC 24 volt system CAN System Network
CAN network
RCP/CAN
120 Ω
120 Ω
ELECTRONIC
DISPLAY
VHMS INTERFACE
and Overloaded statement
MODULE
ne Speed (Hot Hyd Oil)
MONITOR
Service Brake applied
PLM III
plied,
PLM III, GVW a
Park Brake app
Dump Body UP P
Increase Engin
Truck Speed
CAN
Eng. Speed
WIRE
CM850
120 Ω
120 Ω
CENSE
J1939
CN1XC
CUMMINS QUANTUM
QSK-60
SiBAS
engine de-rate (fault active)
CN1XD Tier 2
rpm command + eng running ECM’s
CN1XC
CM850
rpm feedback Siemens
CN1XB
GTA HE 509
Page 30 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system
Page 31 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Speed Cruise Control
Automotive style stalk control
Can be engaged at speeds >5 kph
Minimum Speed set point must be >8 kph
SC set to “ON”
Page 32 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Speed Cruise Control
Can be set to operate in one of two modes or can be disabled entirely;
( by using Service Computer)
Propel and Retard mode (Full)
Retard only mode
Full Cruise Control
System will automatically maintain the vehicle at a set speed without input from
the Throttle or Retard pedals.
• Use of the throttle pedal will apply additional Propel Torque.
• Use of retard / service brake will disengage Cruise Control temporally, setting the
SC switch to “off” will Cancel set speed.
Retard Mode only
drive system applies retard torque to maintain the truck speed at the set point.
The drive system will apply up to full rated retard torque to keep the truck at the
selected speed.
• Use of throttle will override retarding
• Use of retarder/brake will add to the retarding effect and will not cancel settings, but
end of stalk must be pushed to resume set speed.
Page 33 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Hill Start systems and controls
Using Dump Over-ride Switch
Brake Stall Torque is limited to 30% of maximum available torque
Reverse propel torque is 100% (High Torque Option, DOS pressed)
Anti-Roll system
Activates if movement opposite to selected direction of travel
Automatically applies Brake lock (Rear Brakes) < 8kph.
Automatically releases Brakes when operator applies throttle and
sufficient pull away torque is developed (based on GVW and angle
of slope)
Retard and Brake blending
When truck speed in retard slows to 0.3kph with retard pedal
pressed 75% or more will cause Brake Lock to automatically apply
Page 34 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system
Page 35 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Engine, Cranking
21INS CUMMINS
IM3-F E
Interface
21PT ECM
Module
IM3-U
CN805
24VIM
IM1-W
IF ENG SPEED IS
>400 RPM OR
21SL RED ENG LIGHT
Start Lockout IM1-B FAIL TO HIGH
NC 21PS
30 sec crank 21S
IM2- j 5 psi
C
IM3-R
NO
IM3-S
RB6-K7
Start Lockout
C
NC
NO
Pre-Lube
Relay
25A
21PL
M1
21
R
S
1PT
PRE-LUBE __
B
Mag Switch + 11SOL
SID1
KEY SWITCH
21PTI
11SM1
11KS
11PF 11PL
300 AMP
25B
Start Relay
11ST
M2
Pre-Lube
Motor
11SM2
HE 513_2
Page 36 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Park Brake Application
Park Brake Solenoid
Interface Module 52CS 71BC
IM 1E
Park Brake will not apply
Park Brake Request sequence above 0.8 kph
{PB req. & <0.8 kph} NC Park Brake will not release
speed to zero C unless the engine is running
NO
Automatic blending of
IM 1E
Park Brake Service and Park Brakes
release relay
IM 1R RB6-K4 KAC Interface Controller will
time trig ½ 1 1½ sec
apply the service brakes
prior to every Park Brake
0.8 kph}
IM 3V 52C NO
C
PB Release request providing that truck
{PB req. & <0
Request Auto Brake 52PBO
speed is less than 0.8 kph.
NC
Apply Solenoid 72FNR
52ABA 36
IM 1R
Park Brake
Park Brake status reported
engine oil
Relay 1
RB6-K8
to Drive system over CAN
pressure
Selector NOT in PARK IM 2N Drawn in
PARK
R
Selector Switch PARK REQUEST IM 3T F
72P
1425 psi 71SS
PARK BRAKE RELEASED
PARK BRAKE VERIFICTION
TYPICAL FOUR (4) PLACES
PARK BRAKE SET
CAN network
Park Brake SET
P
Park Brake RELEASED
Park Brake UN-KNOWN 75 psi HE 508-2
SiBAS control oil
Page 37 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system
Page 38 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system
Page 39 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system
Page 40 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Engine Electronics
Cummins CM850 (3)
ECM (fuel control)
Modular Common Rail fuel System
Coupled to J1939 CAN network
for VHMS interface
Cummins Cense software
Diagnostic and trending tool
coupled to J1939 Network
for personnel running INSITE
Page 41 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system DOKG
Page 42 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system
Input
Table
Page 43 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system
Input Table
Page 44 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system
Alarm Public
Page 45 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Interface Input Chart
Page 46 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Interface Module platform
Page 47 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system
Page 48 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system
Page 49 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system
Page 50 (12/07) 860E-2 Siemens Electric Drive Truck
860 AC 24 volt system Solid State Lube Timer
Off & On time settings
Alarm mode settings
Timer memory mode
Set timer according to the demands of
the application.
Set each Injector to suit the demands of
the each greased item in terms of SIZE
and FEQUENCY of movement
(on time)
Page 51 (12/07) 860E-2 Siemens Electric Drive Truck
