Dynamic Braking System - Retard

Troubleshooting and Maintenance

FEB 2018
CONTENTS

Contactors K191 - K181

Transducer U171
Grid motor
Resistors bank A - B
Motor Control Resistor RG1, RG2, RG3
Capacitor CG2
Chopper Modules
Transducers U104 / U204
Connectors

Dynamic Braking System - Retard

$IBTGZA Chopper current A
$IBTGZB Chopper current B
$BENK181 Close K181
$YAMMET Grid fan circuit current
Possible Events

Contronic SIBAS Code Description Possible cause

• fault of grid blower motor.
• fault of RG1, RG2, RG3.
GRID FAN CONTROL CIRCUIT FAILED • fault card L095.
43 2124 • fault of contactor K181 or 191.
• Wiring
• Software settings for RG1, RG2, RG3, and Motor resistance.
• Grid blower current transducer (U171)
•Poor insulation of power cables
• poor insulation of grid blower motor.
121, 123 1470 GROUND FAULT DETECTED • Grounded grid resistors,
• Faulty choppers.
• Grounded RG1, RG2, RG3.
• power module fault
• Gate Unit fault
626 GTO SWITCHING FAILURE A104 • wiring fault (GTO commands and feedback signals)
• pulse-amplifier-card fault (L111, L095)
• UWS-card fault (G071)
• power module fault
• Gate Unit fault
726 GTO SWITCHING FAILURE A204 • wiring fault (GTO commands and feedback signals)
• pulse-amplifier-card fault (L119, L103)
• UWS-card fault (G079)
Contactors K191 / K181

• K191 starts/stop grid blower motor.

• Auxiliary contactor K181 is needed to

apply power on K191 coil.

• K181 is engaged by the TCU

• K191 and K181 don’t send feedback signal

to TCU.
 Contactors K191 / K181

Archute tip Archute static tip Isolation sheet

Static power tip

Mobile power tip

IMPORTANT :Maintenance Tip K191

To remove archute, press clip To install , seat base , press clip,

and pull archute as shown by push archute until clip engages.
the arrow
Solid Sate Relay K181

K181 Receives command from Sibas and

energizes K191 coil
Note : There is not close / open feedback
from this contactor to SIBAS.
Transducer U171

• U171 Monitors grid blower motor circuit current, for protection.

• U171 is rated for 15VDC which are supplied by card L095
Grid Blower Motor

• Provides cooling for grid resistor box.

• Looking from the deck of the truck, the motor turns
counter clockwise
• This motor starts when:
• Grid dry mode is active
• Retard mode. When grid power exceeds
certain limit.
• Load test active

Tip: If the dump body is not seated or if

the body up sensor is not working
the Grid Blower motor will not start.
 Grid Blower Motor

Bus DC-
K191
Maintenance tip: After a connection is
revised on the grid blower motor, make
sure the connection box is closed
Bus DC+
properly.

Terminal connections (motor box)

Rg1 A1 A2 S1 S2 Rg3
Grid motor maintenance

• Periodically, verify the length of brushes, and

amount of carbon dust inside the motor.

• Blow grid blower motor with dry air every

500Hrs

Inspection windows
 Grid Resistor Bank

• Dissipate excess energy produced by wheel

motors during retard.
• Burns power during the Engine Load Test
• Connected between DC bus positive side
Chopper A and Chopper Modules.

Chopper B
• There are 2 groups of grid resistors. One for
each inverter.

Bus DC +

7 resistors per bank (Hitachi trucks)

Motor Control Resistors RG1, RG2, RG3

• Located in the same compartment as grid resistors

• RG1 & RG3: resistance value is 5Ω , in series with

the grid motor.

• RG2: This resistor is connected in parallel with the

grid motor. Resistance value is 5.5 Ω
 Grid box assembly

Grid resistors bank

A and B

Resistor RG2

Grid motor
Grid motor capacitor

• Helps to smooth the voltage on grid motor

terminals.
• The capacitor is connected in parallel to the
grid motor
Chopper Modules

• Connect and disconnect the grid resistors to

dissipate excess energy on the DC bus bar.
• Discharge DC bus bars after system is OFF.
• Engine load test requires choppers modulation,
to drive engine/alternator power to the grid box.
How to test a Chopper Module
Note: Connections must be removed from module before test

You need a DMM in diode mode:

Diode V4
• Connect red lead to terminal 3
• Connect black lead to terminal 2
• Measured value should be 0,25 – 0,45
• Interchange leads 2 and 3.Measured value should be OL or
very high value
How to test a Chopper Module

Diode V3
• Connect red lead to Terminal 4
• Connect black lead to terminal 3
• Measured value 0,25 – 0,45
• Interchange leads 4 and 3. Measure value should be
OL or very high value
How to test a Chopper module

Gate Cathode V2

• Connect red lead to Terminal 9

• Connect black lead to Terminal 10
• Measured value 0.40 – 0.70
• Change terminal 9 and 10, measured value OL or
very high number
How to test a Chopper Module

Gate Cathode V1

• Connect red lead to Terminal 11

• Connect black lead to Terminal 12
• Measured Value 0.40 – 0.70
• Change leads 11 and 12. Measured value should be
OL or very high number
Chopper Transducers U104 and U204

Measure current through the grid box bank

U104 for inverter A
U204 for inverter B
Retard System Faults

Ground Faults
Typical Root Cause:
 Moisture, water
 Short circuit
- Power cables insulation
- Grid resistors grounded
- DC bus voltage transducers damage
- RG2 grounded
 Grid motor grounded
 Retard System Faults
Code 2124 Grid fan Control Circuit Failed
2124 Fault Detection : Motor current evaluation
POSITIVE BUS
$BENK181 DELAY

MCR
$YAGBFA & 2S DELAY 2124

88 > $YAGBFA > 115%

$YGBVOLT
+
$YAMMET
RG2 =MOTOR V $YGBCURR = $YAGBFA 
$YGBVOLT
(CALCULATED) MOTOR CURRENT  $YGBCURR
- (CALCULATED) $YRG 2OHM

2124 Fault Detection : K191 command close evaluation

MCR
$BENK181
K181 & 2S DELAY 2124
K191
$BENK181
$YAMMET

U171=$YAMMET
NEGATIVE MORE THAN 20A?
(MEASURED)
Questions?

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