Komatsu 980E-4 Dump Truck Shop Manual CEBM031007 – PDF DOWNLOAD

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Komatsu 980E-4 Dump Truck Shop Manual CEBM031007 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 980E-4 Dump Truck Shop Manual CEBM031007 – PDF DOWNLOAD

Language : English
Pages :1130
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 980E-4 Dump Truck Shop Manual CEBM031007 – PDF DOWNLOAD

SERIAL NUMBERS 980E-4 A40003 – A40051
ENGINE 18V170

Foreword

• This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance and/or operational checks on the truck.
• All safety notices, warnings, and cautions should be understood and followed when operating the truck or performing repairs on the truck. The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually.
• For example, the disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs.
• The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck. This manual shows dimensioning of U.S. standard and metric (SI) units throughout. All references to “right,” “left,” “front,” or “rear” are made with respect to the operator’s normal seated position unless specifically stated otherwise. When assembly instructions are provided without references to specific torque values, standard torque values should be used. Standard torque values are shown in torque charts later in this section.
• Specific torques, when provided in the text, are in bold face type, such as 135 N·m (100 ft lb). All torque specifications have ±10% tolerance unless otherwise specified. A product identification plate is located on the frame in front of the right side front wheel. It designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight) rating. The KOMATSU truck model designation consists of three numbers and one letter (i.e. 730E). The three numbers represent the basic truck model. The letter “E” designates an Electrical wheel motor drive system. The Product Identification Number (vehicle serial number) contains information which identifies several characteristics of this unit. For a more detailed explanation, refer to the Operation and Maintenance Manual.
• The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the maximum GVW. GVW is total weight: empty vehicle weight + fuel & lubricants + payload. To determine the allowable payload, fill all lubricants to the proper level and fill the fuel tank of an empty truck (which includes all accessories, body liners, tailgates, etc.), and then weigh the truck. Record this value and subtract it from the GVW. The result is the allowable payload.

TABLE OF CONTENTS:

Komatsu 980E-4 Dump Truck Shop Manual CEBM031007 – PDF DOWNLOAD

SERIAL NUMBERS 980E-4 A40003 – A40051
ENGINE 18V170

Cover 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword, safety and general information 19
Foreword 22
How to read the shop manual 23
Composition of shop manual 23
Revision and distribution 23
Symbols 24
General safety 25
Safety rules 25
Safety features 25
Fire extinguisher and first aid kit 25
Clothing and personal items 25
Leaving the operator seat 26
Mounting and dismounting 26
Fire prevention for fuel and oil 26
Precautions with high temperature fluids 27
Asbestos dust hazard prevention 27
Prevention of injury by work equipment 27
Unauthorized modification 27
Precautions when using ROPS 27
Precautions for attachments 28
Precautions for starting the truck 28
Precautions before operating the truck 28
Safety at the worksite 28
Fire prevention 29
Ventilation in enclosed areas 29
Preparing for operation 29
Mirrors, windows and lights 29
In operator cab (before starting the engine) 29
Seat Belts 29
Precautions while operating the truck 30
When starting the engine 30
General truck operation 30
Ensuring good visibility 30
Traveling 31
Traveling in reverse 31
Traveling on slopes 31
Operating on snow or ice 31
Avoid damage to dump body 31
Driving near high voltage cables 32
When dumping 32
When loading 32
Working on loose ground 32
Parking the truck 32
Towing 32
Working near batteries 33
Battery hazard prevention 33
Starting with jumper cables 34
Jump starting with receptacles 34
Precautions before performing service 35
Warning tag 35
Stopping the engine 35
Proper tools 35
Use of tie-off anchor during maintenance and repair 36
Securing the dump body 37
Jack point locations 38
Precautions while performing service 39
Keep the truck clean 39
Attachments 39
Working under the truck 39
Rotating fan and belts 39
Adding fuel or oil 39
Use of lighting 39
Radiator coolant level 40
Precautions with the battery 40
Precautions with high pressure oil 40
Handling high pressure hoses 40
Precautions when performing maintenance near high temperature or high pressure 40
Waste materials 40
Tires 41
Inspection 41
Maintenance 41
Storage 42
Handling 43
Precautions for performing repairs 44
Engine shutdown procedure after AC drive system failure 44
Precautions for welding on the truck 45
Capacitor discharge system 46
Necessary tools 46
Warnings and cautions 47
Manual DC link capacitor discharge procedure 48
Failure of the discharge system 50
Manual discharge of capacitors 51
Short isolated capacitor terminals 53
Handling electrical equipment and hydraulic components 54
Points to remember when handling electrical equipment 54
Points to remember when handling hydraulic equipment 60
Standard tightening torques 62
Effect of special lubricants on fasteners and standard torque values 62
Suggested sources for rust preventive grease 62
SAE grade 5 and grade 8 hex head capscrew and nut assemblies 63
SAE grade 9 capscrews 64
Class 109 capscrews and class 10 nuts 64
Standard tightening torques for fittings 65
Standard tightening torques for clamps 67
Conversion tables 68
Common conversion multipliers 68
01 Specification 73
Specification and technical data 73
Specification drawing 75
Specifications 76
Weight table 78
Fuel, coolant and lubricants 79
Suspension cylinder oil and nitrogen specifications 80
Wheel motor oil specifications 80
10 Structure and functions 83
Steering circuit 83
Steering circuit operation 85
Steering circuit components 90
Steering control unit 90
High pressure filter 90
Steering accumulators 90
Bleeddown manifold 91
Steering accumulator bleeddown solenoid 91
Quick disconnect ports 91
Flow amplifier 91
Steering/brake pump operation 92
High altitude operation 92
Neutral position 93
Full pump volume 94
Half pump volume 95
Flow amplifier operation 96
No steer 96
Steering left 98
Steering right 100
No steer, external shock load 102
Hoist circuit 105
Hoist circuit operation 107
Hoist circuit components 108
Hydraulic tank 108
Hoist pump 108
High pressure filters 108
Hoist valve 109
Inlet sections 109
Tank ports (front) spool section 109
Work ports (rear) spool section 110
Hoist pilot valve 110
Hoist limit solenoid 111
Pilot operated check valve 111
Overcenter manifold 111
Hoist pilot valve operation 112
Float position with body down 112
Power up operation 114
Hold operation 116
Power down operation 118
Float operation 120
Brake circuits 123
General information 125
Service brake circuit operation 126
Secondary braking 129
Automatic brake application (Auto apply) 129
Parking brake circuit operation 130
Normal operation (key switch ON, engine on) 130
Wheel brake lock circuit operation 131
Brake warning circuit operation 131
Electrical system, 24 volt 135
Battery supply system 137
Batteries 137
24VDC auxiliary battery receptacles 137
Engine shutdown switch 138
Battery disconnect switches 138
Propel lockout lever 138
System busy light 138
LED lights 138
Engine starting system with prelube 139
Prelube operation 139
Cranking operation 140
Auxiliary control cabinet components 141
24VDC to 12VDC converter 141
Interface module (IM) 141
VEC blocks 142
Light timers 142
Relays 142
Ground terminals 142
24VDC power terminals 142
Body-up switch 143
Hoist limit switch 143
Electrical system, AC drive 145
General system operation 147
System components 149
Drive system controller (DSC) 149
Diagnostic information display (DID) panel 150
DSC software functions 150
Input processing 150
State machine 150
DC link state 153
Engine control 154
Alternator field control 155
Desired DC link voltage 155
Self-load 155
Propel torque control 155
Retard torque control 156
Wheel slide control 156
Resistor grid control 156
Chopper voltage control 156
Event detection and processing 157
Power-on tests 157
Initiated tests 158
Periodic tests 158
Event restrictions 158
Event logging and storage 158
Data packs 159
Event reset 159
Abnormal conditions/overriding functions 160
Engine shutdown/Engine not running 160
Limp home mode 160
AC drive system component table 161
Electronic accelerator and retarder pedals 168
Cab air conditioning 171
General information 173
Environmental impact of air conditioning 173
Air conditioning for off-highway vehicles 173
Principles of refrigeration 174
Air conditioning 174
Refrigeration – the act of cooling 174
The refrigeration cycle 174
Air conditioning system components 176
Relays 176
Fan motor and speed control 176
Cab air filter 176
Heater core 176
Actuators 176
Compressor (refrigerant pump) 178
Service valves 178
Condenser 178
Receiver-drier 178
Expansion valve 179
Accumulator 179
Evaporator core 179
Air conditioning system electrical circuit 180
Thermostat 180
Compressor clutch 180
Trinary™ switch 181
Reserve engine oil system 183
General information 185
Operation 186
Pumping unit 186
LED monitor lights 187
Tank auto fill control 188
Filling procedure (remote fill feature) 188
Service 189
Every 10 hours (each shift) 189
Every 500 hours 189
Changing oil 189
Troubleshooting 190
Circuit fuses 190
Auto fill system electrical schematic 191
20 Standard value table 193
Standard value table 193
Standard value table for truck 195
30 Testing and adjusting 201
Steering, hoist, brake cooling and auxiliary hydraulic system 201
Hydraulic system bleeddown procedure 203
Hydraulic system vacuum procedure 205
General information on system checkout 205
Hydraulic system checkout procedures 206
Required equipment 206
Preliminary steps 206
Hydraulic system flushing procedure 207
Flow amplifier adjustment 210
Steering pump unloader valve adjustment 211
Auxiliary accumulator pressure verification 212
System diagnostics 212
Hoist counterbalance valve adjustment 214
Final steps 215
Oil cleanliness check 216
Hydraulic system checkout data sheet 217
High altitude steering pump adjustment 220
Toe-in adjustment 221
Measuring steering pin joint wear 222
Hoist cylinder leakage test 225
Steering cylinder leakage test 225
Brake system 227
General information on system checkout 229
Brake system checkout procedures 229
Required equipment 229
Initial system setup 232
Brake lock / secondary braking checkout 232
Parking brake checkout 233
Service brake checkout 234
Low brake accumulator pressure and auto apply checkout 235
Parking brake control logic checkout 237
Brake lock control logic checkout 238
Brake system checkout data sheet 241
Brake piston leakage test 249
Brake seal pressure test 249
Oil separator seal pressure test 249
Wet disc brake bleeding procedure 250
Parking brake bleeding procedure 251
Service brake disc wear inspection 252
Parking brake disc wear inspection 253
Brake valve bench test and adjustment 254
Test setup procedure 255
Brake valve output pressure adjustment 255
Final test and adjustment 256
Dual relay valve bench test and adjustment 257
Test setup procedure 258
Relay valve output pressure adjustment 258
Accumulators and suspensions 261
Accumulator charging and storage 263
Temperature during precharge 263
Bladder accumulator charging procedure 264
Precharge maintenance 266
Bladder accumulator storage procedure 266
Bladder storage 266
Installing a bladder accumulator from storage 267
Bladder accumulator leak testing 267
Piston accumulator charging procedure 268
Piston accumulator storage 271
Piston accumulator leak testing 272
Checking for improper suspension charge on operating trucks 273
Suspension oil change recommendations 274
Suspension oiling and charging procedures 275
Required equipment 275
Installing the charging kit 276
Removing the charging kit 276
Support blocks for oiling and charging dimensions 277
Front suspensions 280
TOP FILL METHOD 281
PRESSURE FILL METHOD 281
Rear suspensions 283
TOP FILL METHOD 285
PRESSURE FILL METHOD 285
Suspension pressure test 288
Interface module 1 (IM1) 291
Interface module software 293
Flashburn program installation 293
Interface module application code installation 294
Interface module realtime data monitor software installation 294
Interface module checkout procedures 295
Necessary equipment 295
Preliminary 296
Check digital inputs to the interface module 297
Check analog inputs to the interface module 299
Check serial interfaces to the interface module 299
Check outputs from the interface module 300
Checkout procedure 301
Interface module 2 (IM2) 305
Required tools 307
Programming the IM2 307
Updating the software 307
Configuring the IM2 308
Viewing IM2 real-time data 308
Interface module checkout procedures 309
Checking for IM fault codes 309
Checking digital inputs to the IM 309
Checking analog inputs to the IM 312
Checking serial communication to the IM 312
Checking outputs from the IM 313
IM checkout sheet 314
KOMTRAX Plus II 319
Required software and tools 321
Ethernet connection to KOMTRAX Plus II controller 321
KOMTRAX Plus II configuration 323
GPS connection test 325
Iridium satellite system opening 327
Data download over ethernet connection for KOMTRAX Plus II initialization 330
Payload meter IV 333
Payload meter IV software and tools 335
Payload meter IV system configuration 335
Connecting to the payload meter IV web server 335
Configuring a static IP address 335
Payload meter IV software installation 337
Inclinometer calibration and clean truck tare 338
Payload meter IV checkout procedure 338
PLM IV system checkout data sheet 344
Downloading PLM IV data and possible errors 345
Komatsu wireless bridge (KWB) 349
General information 351
Software download and setup 352
Bullet M2 Titanium / PicoStation M2 353
Bullet M2 355
Configuring a KWB_Connect device 356
Access point configuration 356
Bullet M2 configuration 357
KOMTRAX Plus downloads 358
Configuring a TRUCK_NET device 359
Access point configuration 359
Bullet M2 configuration 360
Onboard controller access 361
Changing a service computer’s IP address 362
Connecting to a wireless network 363
KWB_Connect troubleshooting 364
Step 1 Verify communication to the access point 364
Step 2 Verify communication to the Bullet M2 364
Step 3 Verify communication to KOMTRAX Plus 365
TRUCK_NET troubleshooting 366
Step 1 Verify communication to the access point 366
Step 2 Verify communication to the Bullet M2 367
KWB_Connect checkout data sheet 368
TRUCK_NET checkout data sheet 369
Electrical system, AC drive 371
General information 373
Test equipment 373
Circuit continuity and resistance checks 373
Megger test for grounds 374
Preparation for meggers test 374
Megger test procedure 376
Troubleshooting for grounds 377
Low voltage power supply checks 377
Preparation for power supply checks 377
Power supply check procedure 378
Drive System Controller (DSC) card checks 378
Propulsion system software installation 379
Software installation procedure 380
DSC manual test procedures 381
Accelerator pedal, retarder pedal, and retarder lever calibration and checks 383
Set truck ID number 388
Control cabinet pressure switch check 389
Checks prior to self load engine test (loadbox) 390
Verifying DSC Software Version 390
Resetting and erasing DSC event data 391
Engine running tests 392
Battery boost circuit verification 392
Selector switch check 395
Ground detection network tests 397
Self load engine test (loadbox) procedure 402
Diagnostic information display (DID) panel 404
DID panel display selection 404
DID modes display 406
Function key F1 – DID events or faults display 407
Function key F4 – DID menu display 410
DID self load engine test (loadbox) 411
DID link capacitance test 413
DID speedometer test 414
DID view software version 415
DID view overspeed setting 416
DID view data menu 417
DID inverter cutout menu 422
DID truck configuration menu 423
Language selection 428
Viewing event and statistical data 429
Viewing the DSC event summary, trigger data, and data packs 429
Viewing the statistical data 432
Logic screens 433
Datalogger function 435
Setting up the datalogger 435
Starting the datalogger 437
Uploading data 439
Consolidated truck data save 439
USB drive 440
Cab air conditioning 443
General information 445
Service tools and equipment 446
Recovery/recycle station 446
Leak detector 446
Manifold gauge set 447
Service valves 448
Vacuum pump 448
Detecting leaks 449
System performance test 450
Checking system oil 451
System flushing 452
Installing the manifold gauge set 453
Purging air from the service hoses 453
Recovering and recycling refrigerant 454
Draining oil from previous recovery cycle 455
Recovery cycle 455
Recycling procedure 455
Evacuating the air conditioning system 456
Charging the air conditioning system 457
40 Troubleshooting 459
Fuse, diode and relay locations 459
Vehicle Electrical Center (VEC-89) 461
Vehicle Electrical Center (VEC-90) 463
Vehicle Electrical Center (VEC-91) 465
Vehicle Electrical Center (RTMR1) 467
AC drive system fault codes (DSC) 469
Fault code tables 471
Troubleshooting by fault code, Part 1 499
Fault Code A001 502
Fault Code A002 503
Fault Code A003 504
Fault Code A004 505
Fault Code A005 506
Fault Code A006 507
Fault Code A007 508
Fault Code A008 509
Fault Code A009 510
Fault Code A010 511
Fault Code A011 512
Fault Code A013 513
Fault Code A014 514
Fault Code A018 515
Fault Code A019 516
Fault Code A022 517
Fault Code A101 518
Fault Code A105 519
Fault Code A107 520
Fault Code A108 521
Fault Code A109 522
Fault Code A111 523
Fault Code A115 524
Fault Code A117 525
Fault Code A118 526
Fault Code A123 527
Fault Code A124 528
Fault Code A125 529
Fault Code A126 530
Fault Code A127 531
Fault Code A128 532
Fault Code A139 533
Troubleshooting by fault code, Part 2 535
Fault Code A145 538
Fault Code A146 539
Fault Code A152 540
Fault Code A153 541
Fault Code A154 542
Fault Code A155 543
Fault Code A158 544
Fault Code A166 545
Fault Code A167 546
Fault Code A168 547
Fault Code A169 548
Fault Code A170 549
Fault Code A171 550
Fault Code A172 551
Fault Code A173 552
Fault Code A184 553
Fault Code A190 554
Fault Code A194 555
Fault Code A195 556
Fault Code A196 557
Fault Code A197 558
Fault Code A198 559
Fault Code A199 560
Fault Code A200 561
Fault Code A201 562
Fault Code A202 563
Fault Code A203 564
Fault Code A204 565
Fault Code A205 566
Fault Code A206 567
Fault Code A207 568
Troubleshooting by fault code, Part 3 571
Fault Code A212 574
Fault Code A213 575
Fault Code A214 576
Fault Code A215 577
Fault Code A216 578
Fault Code A223 579
Fault Code A230 580
Fault Code A231 581
Fault Code A233 582
Fault Code A235 583
Fault Code A236 584
Fault Code A237 585
Fault Code A240 586
Fault Code A242 587
Fault Code A243 588
Fault Code A244 589
Fault Code A245 590
Fault Code A246 591
Fault Code A247 592
Fault Code A248 593
Fault Code A249 594
Fault Code A250 595
Fault Code A251 596
Fault Code A252 597
Fault Code A253 598
Fault Code A256 599
Fault Code A257 600
Fault Code A258 601
Troubleshooting by fault code, Part 4 603
Fault Code A260 606
Fault Code A261 607
Fault Code A262 608
Fault Code A264 609
Fault Code A265 610
Fault Code A266 611
Fault Code A267 612
Fault Code A268 613
Fault Code A270 614
Fault Code A271 615
Fault Code A272 616
Fault Code A273 617
Fault Code A274 618
Fault Code A275 619
Fault Code A276 620
Fault Code A277 621
Fault Code A278 622
Fault Code A279 623
Fault Code A280 624
Fault Code A281 625
Fault Code A282 626
Fault Code A283 627
Fault Code A284 628
Fault Code A285 629
Fault Code A286 630
Fault Code A292 631
Troubleshooting by fault code, Part 5 633
Fault Code A303 636
Fault Code A304 637
Fault Code A305 638
Fault Code A307 639
Fault Code A309 640
Fault Code A310 641
Fault Code A311 642
Fault Code A312 643
Fault Code A313 644
Fault Code A315 645
Fault Code A316 646
Fault Code A317 647
Fault Code A318 648
Fault Code A320 649
Fault Code A321 650
Fault Code A322 651
Fault Code A323 652
Fault Code A324 653
Fault Code A325 654
Fault Code A326 655
Fault Code A327 656
Fault Code A328 657
Fault Code A329 658
Fault Code A330 659
Fault Code A332 660
Fault Code A333 661
Fault Code A334 662
Fault Code A335 663
Fault Code A337 664
Fault Code A338 665
Fault Code A341 666
Fault Code A343 667
Fault Code A344 668
Fault Code A345 669
Fault Code A346 670
Fault Code A347 671
Fault Code A348 672
Fault Code A349 673
Troubleshooting by fault code, Part 6 675
Fault Code A350 677
Fault Code A351 678
Fault Code A352 679
Fault Code A353 680
Fault Code A354 681
Fault Code A355 682
Fault Code A356 683
Fault Code A357 684
Fault Code A358 685
Fault Code A359 686
Fault Code A360 687
Fault Code A361 688
Fault Code A362 689
Fault Code A363 690
Fault Code A364 691
Fault Code A365 692
Orbcomm 695
Orbcomm satellite connection 697
Required equipment 697
Truck has never communicated with Orbcomm 697
Poor connection or no connection to WebCARE 698
Confirmed satellite communication but not reporting correctly to WebCARE 702
Cab air conditioning 705
Preliminary checks 707
Diagnosis of gauge readings and system performance 707
Troubleshooting by manifold gauge set readings 708
Steering system 715
Steering circuit troubleshooting chart 717
Steering circuit troubleshooting guidelines 719
Basic hydraulic system checks 720
System leakage check 721
Steering pump troubleshooting guide 723
Pump pressure control checks 726
Pump fails to unload 727
Pump fails to develop pressure 727
Pump slow in developing pressure 728
Pump control valve inspection and trouble shooting 728
Pump case drain check 730
Setting pump pressure controls 730
Automatic lubrication (auto lube) system 733
Autolube troubleshooting chart 735
50 Disassembly and assembly 739
Service tools 739
Special tool group 741
Heated body tool group 741
Additional service tools 742
KomVision calibration tools 742
Locally made tools 742
Wheels, spindles and rear axle 745
General precautions for tires and rims 747
Wheel stud maintenance 748
Rear outer wheel stud installation 749
Removal and installation of front wheel 750
Removal 750
Installation 751
Removal and installation of rear wheel 752
Removal 752
Installation 753
Rim components 755
Smart rim component layout 755
Rim and tire service 756
Lubricants 756
Tire inflation 756
Lock ring retainer installation 756
Removing the lock ring 757
Installing the lock ring 758
Removing the tire from the front rim (5-piece rim) 759
Removing the tire from the rear outer dual rim (7-piece Smart rim) 762
Removing the tire from the rear inner dual rim (5-piece rim) 764
Preparation before assembly 765
Installing the tire on the front rim (5-piece rim) 766
Installing the tire on the rear inner dual rim (5-piece rim) 768
Installing the tire on the rear outer dual rim (7-piece Smart rim) 769
Removal and installation of front wheel hub and spindle 770
Removal 770
Spindle removal (off the truck) 774
Installation 776
Disassembly and assembly of front wheel hub and spindle 777
Cross Section View 777
Disassembly 778
Cleaning and inspection 784
Wheel bearing adjustment 786
Seal assembly gap adjustment 787
Seal installation 788
Brake installation 791
Wheel hub and brake assembly installation 792
Speed sensor installation and adjustment 794
Floating seal assembly and installation 796
Use isopropyl alcohol in a spray bottle to clean the parts prior to assembly Use clean, lint-free material such as Micro-Wipes # 05310 for cleaning and wiping Do not use Stanosol or any other liquid that leaves an oily film or does not evaporate qu 796
Removal and installation of rear axle 806
Removal 806
Cleaning and inspection 807
Installation 808
Removal and installation of anti-sway bar 809
Removal 809
Installation 811
Removal and installation of pivot pin 812
Removal 812
Installation 813
Pivot eye and bearing service 814
Bearing inspection 814
Bearing replacement 816
Pivot eye repair 817
Removal of wheel motor 818
Preparation 818
Installation of wheel motor 821
Cleaning and inspection 821
Installation 822
Removal and installation of rear brake assembly 825
Wheel motor flushing procedure 825
Flushing procedure 827
Brake system 831
Removal and installation of brake valve 833
Removal 833
Installation 834
Disassembly and assembly of brake valve/pedal assembly 836
Disassembly 836
Assembly 837
Removal and installation of dual relay valve 839
Removal 839
Installation 840
Removal and installation of brake manifold 841
Removal 841
Installation 841
Disassembly and assembly of brake manifold 842
Disassembly 842
Assembly 842
Removal and installation of piston brake accumulator 843
Removal 843
Installation 846
Disassembly and assembly of piston brake accumulator 846
Disassembly 846
Cleaning and inspection 848
Piston seal replacement 849
Assembly 849
Disassembly and assembly of front wheel brake 850
Disassembly 850
Cleaning and inspection 854
Assembly 854
Disassembly and assembly of rear wheel brake 856
Disassembly 856
Cleaning and inspection 859
Assembly 860
Brake floating ring seal assembly and installation 863
Brake disc wear measurement and rebuild criteria 869
Inspection of friction discs 869
Inspection of separator plates 873
Brake disc inspection checklist 875
Removal and installation of parking brake 878
Removal 878
Installation 880
Disassembly and assembly of parking brake 880
Disassembly 880
Cleaning and inspection 882
Cleaning and inspecting new discs 884
Assembly 885
Steering system 887
Removal and installation of steering control unit 889
Removal 889
Installation 890
Disassembly and assembly of steering control unit 891
Disassembly 891
Assembly 893
Removal and installation of steering column 896
Removal 896
Inspection 897
Installation 898
Removal and installation of steering wheel 899
Removal 899
Installation 899
Removal and installation of bleeddown manifold 900
Removal 900
Installation 901
Removal and installation of flow amplifier 902
Removal 902
Installation 902
Removal and installation of steering cylinders and tie rod 903
Removal 903
Installation 903
Disassembly and assembly of steering cylinders 905
Disassembly 905
Cleaning and inspection 907
Assembly 907
Removal and installation of steering/brake pump 908
Removal 908
Installation 909
Removal and installation of piston steering accumulator 910
Removal 910
Installation 912
Disassembly and assembly of piston steering accumulator 912
Disassembly 912
Cleaning and inspection 914
Piston seal replacement 915
Assembly 915
Suspensions 919
General information 921
Removal and installation of front suspension 921
Preparation 921
Removal 921
Cleaning and Inspection 923
Installation 924
Disassembly and assembly of front suspension 930
Disassembly 930
Cleaning and inspection 933
Assembly 933
Removal and installation of rear suspension 935
Removal 935
Installation 938
Disassembly and assembly of rear suspension 941
Disassembly 941
Cleaning and inspection 943
Assembly 944
Hoist circuit 947
Removal and installation of hoist pump 949
Removal 949
Installation 953
Disassembly and assembly of hoist pump 954
Disassembly 954
Inspection 959
Assembly 960
Removal and installation of hoist valve 963
Removal 963
Installation 965
Disassembly and assembly of hoist valve 965
O-ring replacement 965
Disassembly of inlet section 967
Assembly of inlet section 968
Disassembly of rear spool section 969
Assembly of rear spool section 971
Disassembly of front spool section 972
Assembly of front spool section 973
Overcenter manifold service 973
Removal and installation of hoist pilot valve 974
Removal 974
Installation 974
Disassembly and assembly of hoist pilot valve 977
Disassembly 977
Cleaning and inspection 978
Assembly 978
Removal and installation of hoist cylinders 979
Removal 979
Installation 981
Disassembly and assembly of hoist cylinders 982
Disassembly 982
Cleaning and inspection 986
Installation of the quill 987
Assembly 989
Body and structures 995
Removal and installation of dump body 997
Removal 997
Inspection 998
Installation 999
Removal and installation of body pads1000
Removal1000
Installation1000
Body pad shimming procedure1001
Removal and installation of diagonal ladder/ hood and grille assembly1002
Removal1002
Installation1002
Removal and installation of RH deck1004
Removal1004
Installation1004
Removal and installation of LH deck1006
Removal1006
Installation1006
Installing and adjusting egress gates1008
Removal and installation of fuel tank1010
Removal1010
Cleaning and inspection1010
Installation1012
Removal and installation of fuel gauge sender1012
Removal1012
Installation1012
Removal and installation of hydraulic tank1013
Removal1013
Installation1014
Removal and installation of hydraulic tank strainers1015
Removal1015
Cleaning and inspection1016
Installation1016
Operator cab1019
Removal and installation of operator cab1021
Removal1021
Installation1024
Removal and installation of cab door1024
Removal1024
Installation1025
Disassembly and assembly of cab door1026
Removing inner door panel1026
Installing inner door panel1027
Replacing the door window regulator1027
Replacing door handle or latch assembly1028
Replacing door assembly seal and door hinge seal1029
Replacing door opening seal1029
Removing door glass1030
Installing door glass1031
Adjustment of cab door1033
Door jamb bolt adjustment1033
Door handle plunger adjustment1035
Removal and installation of side window glass1036
Recommended tools and supplies1036
Removal1036
Installation1036
Removal and installation of windshield and rear window glass1037
Removal1037
Installation1038
Removal and installation of windshield wiper motor1039
Removal1039
Installation1039
Removal and installation of windshield wiper arm1040
Removal1040
Installation1040
Removal and installation of windshield wiper linkage1040
Removal1040
Installation1041
Removal and installation of optional seats1041
Removal1041
Installation1041
Removal and installation of seat belts (optional seats)1042
General1042
Removal1042
Installation1044
Removal and installation of electronic accelerator and retard pedals1046
Removal1046
Installation1046
Disassembly1046
Assembly1047
Cab air conditioning1049
Replacement of air conditioning system components1051
Hoses and fittings1051
Lines1051
Expansion valve1051
Receiver-drier1051
Thermostat1051
Compressor1052
Accumulator1052
Clutch1052
Power module1055
Removal and installation of power module1057
General1057
Removal1058
Installation1066
Exhaust tube installation1069
Exhaust blanket installation1069
Removal and installation of alternator1070
Removal1070
Installation1073
Removal and installation of radiator1085
Removal1085
Installation1090
Repairing the radiator1091
Internal inspection1091
External cleaning1091
Disassembly1091
Cleaning and inspection1092
Assembly1093
Pressure testing1094
Removal and installation of engine1094
Removal1094
Service1094
Installation1095
90 Diagrams and drawings1097
Hydraulic circuit diagrams1097
Electrical circuit diagrams1103

IMAGES PREVIEW OF THE MANUAL:

S.M 22/12/24