Komatsu 980E-4 Dump Truck Shop Manual CEBM031606 PDF

Description

Komatsu 980E-4 Dump Truck Shop Manual CEBM031606 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 980E-4 Dump Truck Shop Manual CEBM031606 – PDF DOWNLOAD 

Language : English
Pages : 1128
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 980E-4 Dump Truck Shop Manual CEBM031606 – PDF DOWNLOAD 

SERIAL NUMBERS 980E-4 A40052 and up
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.

TABLE OF CONTENTS:

Komatsu 980E-4 Dump Truck Shop Manual CEBM031606 – PDF DOWNLOAD 

SERIAL NUMBERS 980E-4 A40052 and up
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 10 9 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 (IM) 291
Required software and tools 293
Interface module checkout procedures 294
Initial startup 294
Checking digital inputs to the IM 294
Checking analog inputs to the IM 296
Checking serial communication to the IM 296
Checking outputs from the IM 297
IM checkout sheet 298
Interface module 2 (IM2) 303
Required tools 305
Programming the IM2 305
Updating the software 305
Configuring the IM2 306
Viewing IM2 real-time data 306
Interface module checkout procedures 307
Checking for IM fault codes 307
Checking digital inputs to the IM 307
Checking analog inputs to the IM 310
Checking serial communication to the IM 310
Checking outputs from the IM 311
IM checkout sheet 312
Payload meter IV 317
Payload meter IV software and tools 319
Payload meter IV system configuration 319
Connecting to the payload meter IV web server 319
Configuring a static IP address 319
Payload meter IV software installation 321
Inclinometer calibration and clean truck tare 322
Payload meter IV checkout procedure 322
PLM IV system checkout data sheet 328
Downloading PLM IV data and possible errors 329
KOMTRAX Plus II 333
Required software and tools 335
Ethernet connection to KOMTRAX Plus II controller 335
KOMTRAX Plus II configuration 337
GPS connection test 339
Iridium satellite system opening 341
Data download over ethernet connection for KOMTRAX Plus II initialization 344
Komatsu wireless bridge (KWB) 347
General information 349
Software download and setup 350
Bullet M2 Titanium / PicoStation M2 351
Bullet M2 353
Configuring a KWB_Connect device 354
Access point configuration 354
Bullet M2 configuration 355
KOMTRAX Plus downloads 356
Configuring a TRUCK_NET device 357
Access point configuration 357
Bullet M2 configuration 358
Onboard controller access 359
Changing a service computer’s IP address 360
Connecting to a wireless network 361
KWB_Connect troubleshooting 362
Step 1 Verify communication to the access point 362
Step 2 Verify communication to the Bullet M2 362
Step 3 Verify communication to KOMTRAX Plus 363
TRUCK_NET troubleshooting 364
Step 1 Verify communication to the access point 364
Step 2 Verify communication to the Bullet M2 365
KWB_Connect checkout data sheet 366
TRUCK_NET checkout data sheet 367
Electrical system, AC drive 369
General information 371
Test equipment 371
Circuit continuity and resistance checks 371
Megger test for grounds 372
Troubleshooting for grounds 375
Low voltage power supply checks 375
Drive System Controller (DSC) card checks 376
Propulsion system software installation 377
Software installation procedure 378
DSC manual test procedures 379
Accelerator pedal, retarder pedal, and retarder lever calibration and checks 381
Set truck ID number 386
Control cabinet pressure switch check 387
Checks prior to self load engine test (loadbox) 388
Verifying DSC Software Version 388
Resetting and erasing DSC event data 389
Engine running tests 390
Battery boost circuit verification 390
Selector switch check 393
Ground detection network tests 395
Self load engine test (loadbox) procedure 400
Diagnostic information display (DID) panel 402
DID panel display selection 402
DID modes display 404
Function key F1 – DID events or faults display 405
Function key F4 – DID menu display 408
DID self load engine test (loadbox) 409
DID link capacitance test 411
DID speedometer test 412
DID view software version 413
DID view overspeed setting 414
DID view data menu 415
DID inverter cutout menu 420
DID truck configuration menu 421
Language selection 426
Viewing event and statistical data 427
Viewing the DSC event summary, trigger data, and data packs 427
Viewing the statistical data 430
Logic screens 431
Datalogger function 433
Setting up the datalogger 433
Starting the datalogger 435
Uploading data 437
Consolidated truck data save 437
USB drive 438
Cab air conditioning 441
General information 443
Service tools and equipment 444
Recovery/recycle station 444
Leak detector 444
Manifold gauge set 445
Service valves 446
Vacuum pump 446
Detecting leaks 447
System performance test 448
Checking system oil 449
System flushing 450
Installing the manifold gauge set 451
Purging air from the service hoses 452
Recovering and recycling refrigerant 453
Draining oil from previous recovery cycle 454
Recovery cycle 454
Recycling procedure 454
Evacuating the air conditioning system 455
Charging the air conditioning system 456
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
To verify pump unload pressure 726
To verify pump reloading 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 729
Pump case drain check 731
Adjustment 732
Automatic lubrication (auto lube) system 735
Autolube troubleshooting chart 737
50 Disassembly and assembly 741
Service tools 741
Special tool group 743
Heated body tool group 743
Additional service tools 744
KomVision calibration tools 744
Locally made tools 744
Wheels, spindles and rear axle 747
General precautions for tires and rims 749
Wheel stud maintenance 750
Rear outer wheel stud installation 751
Removal and installation of front wheel 752
Removal 752
Installation 753
Removal and installation of rear wheel 754
Removal 754
Installation 755
Rim components 757
Smart rim component layout 757
Rim and tire service 758
Lubricants 758
Tire inflation 758
Lock ring retainer installation 758
Removing the lock ring 759
Installing the lock ring 760
Removing the tire from the front rim (5-piece rim) 761
Removing the tire from the rear outer dual rim (7-piece Smart rim) 764
Removing the tire from the rear inner dual rim (5-piece rim) 766
Preparation before assembly 767
Installing the tire on the front rim (5-piece rim) 768
Installing the tire on the rear inner dual rim (5-piece rim) 770
Installing the tire on the rear outer dual rim (7-piece Smart rim) 771
Removal and installation of front wheel hub and spindle 772
Removal 772
Spindle removal (off the truck) 776
Installation 778
Disassembly and assembly of front wheel hub and spindle 779
Cross Section View 779
Disassembly 780
Cleaning and inspection 786
Wheel bearing adjustment 788
Seal assembly gap adjustment 789
Seal installation 790
Brake installation 793
Wheel hub and brake assembly installation 794
Speed sensor installation and adjustment 796
Floating seal assembly and installation 798
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 798
Removal and installation of rear axle 808
Removal 808
Cleaning and inspection 809
Installation 810
Removal and installation of anti-sway bar 811
Removal 811
Installation 813
Removal and installation of pivot pin 814
Removal 814
Installation 815
Pivot eye and bearing service 816
Bearing inspection 816
Bearing replacement 818
Pivot eye repair 819
Removal of wheel motor 820
Preparation 820
Installation of wheel motor 823
Cleaning and inspection 823
Installation 824
Removal and installation of rear brake assembly 827
Wheel motor flushing procedure 827
Flushing procedure 829
Brake system 833
Removal and installation of brake valve 835
Removal 835
Installation 836
Disassembly and assembly of brake valve/pedal assembly 838
Disassembly 838
Assembly 839
Removal and installation of dual relay valve 841
Removal 841
Installation 842
Removal and installation of brake manifold 843
Removal 843
Installation 843
Disassembly and assembly of brake manifold 844
Disassembly 844
Assembly 844
Removal and installation of piston brake accumulator 845
Removal 845
Installation 848
Disassembly and assembly of piston brake accumulator 848
Disassembly 848
Cleaning and inspection 850
Piston seal replacement 851
Assembly 851
Disassembly and assembly of front wheel brake 852
Disassembly 852
Cleaning and inspection 856
Assembly 856
Disassembly and assembly of rear wheel brake 858
Disassembly 858
Cleaning and inspection 861
Assembly 862
Brake floating ring seal assembly and installation 865
Brake disc wear measurement and rebuild criteria 871
Inspection of friction discs 871
Inspection of separator plates 875
Brake disc inspection checklist 877
Removal and installation of parking brake 880
Removal 880
Installation 882
Disassembly and assembly of parking brake 882
Disassembly 882
Cleaning and inspection 884
Cleaning and inspecting new discs 886
Assembly 887
Steering system 889
Removal and installation of steering control unit 891
Removal 891
Installation 892
Disassembly and assembly of steering control unit 893
Disassembly 893
Assembly 895
Removal and installation of steering column 898
Removal 898
Inspection 899
Installation 900
Removal and installation of steering wheel 901
Removal 901
Installation 901
Removal and installation of bleeddown manifold 902
Removal 902
Installation 903
Removal and installation of flow amplifier 904
Removal 904
Installation 904
Removal and installation of steering cylinders and tie rod 905
Removal 905
Installation 905
Disassembly and assembly of steering cylinders 907
Disassembly 907
Cleaning and inspection 909
Assembly 910
Removal and installation of steering/brake pump 911
Removal 911
Installation 912
Removal and installation of piston steering accumulator 913
Removal 913
Installation 915
Disassembly and assembly of piston steering accumulator 915
Disassembly 915
Cleaning and inspection 917
Piston seal replacement 918
Assembly 918
Suspensions 921
General information 923
Removal and installation of front suspension 923
Preparation 923
Removal 923
Cleaning and Inspection 925
Installation 926
Disassembly and assembly of front suspension 932
Disassembly 932
Cleaning and inspection 935
Assembly 935
Removal and installation of rear suspension 937
Removal 937
Installation 940
Disassembly and assembly of rear suspension 943
Disassembly 943
Cleaning and inspection 945
Assembly 946
Hoist circuit 949
Removal and installation of hoist pump 951
Removal 951
Installation 955
Disassembly and assembly of hoist pump 956
Disassembly 956
Inspection 961
Assembly 962
Removal and installation of hoist valve 965
Removal 965
Installation 967
Disassembly and assembly of hoist valve 967
O-ring replacement 967
Disassembly of inlet section 969
Assembly of inlet section 970
Disassembly of rear spool section 971
Assembly of rear spool section 973
Disassembly of front spool section 974
Assembly of front spool section 975
Overcenter manifold service 975
Removal and installation of hoist pilot valve 976
Removal 976
Installation 976
Disassembly and assembly of hoist pilot valve 979
Disassembly 979
Cleaning and inspection 980
Assembly 980
Removal and installation of hoist cylinders 981
Removal 981
Installation 983
Disassembly and assembly of hoist cylinders 984
Disassembly 984
Cleaning and inspection 988
Installation of the quill 989
Assembly 991
Body and structures 997
Removal and installation of dump body 999
Removal 999
Inspection 1000
Installation 1001
Removal and installation of body pads 1002
Removal 1002
Installation 1002
Body pad shimming procedure 1003
Removal and installation of diagonal ladder/ hood and grille assembly 1004
Removal 1004
Installation 1004
Removal and installation of RH deck 1006
Removal 1006
Installation 1006
Removal and installation of LH deck 1008
Removal 1008
Installation 1008
Installing and adjusting egress gates 1010
Removal and installation of fuel tank 1012
Removal 1012
Cleaning and inspection 1012
Installation 1014
Removal and installation of fuel gauge sender 1014
Removal 1014
Installation 1014
Removal and installation of hydraulic tank 1015
Removal 1015
Installation 1016
Removal and installation of hydraulic tank strainers 1017
Removal 1017
Cleaning and inspection 1018
Installation 1018
Operator cab 1021
Removal and installation of operator cab 1023
Removal 1023
Installation 1026
Removal and installation of cab door 1026
Removal 1026
Installation 1027
Disassembly and assembly of cab door 1028
Removing inner door panel 1028
Installing inner door panel 1029
Replacing the door window regulator 1029
Replacing door handle or latch assembly 1030
Replacing door assembly seal and door hinge seal 1031
Replacing door opening seal 1031
Removing door glass 1032
Installing door glass 1033
Adjustment of cab door 1035
Door jamb bolt adjustment 1035
Door handle plunger adjustment 1037
Removal and installation of side window glass 1038
Recommended tools and supplies 1038
Removal 1038
Installation 1038
Removal and installation of windshield and rear window glass 1039
Removal 1039
Installation 1040
Removal and installation of windshield wiper motor 1041
Removal 1041
Installation 1041
Removal and installation of windshield wiper arm 1042
Removal 1042
Installation 1042
Removal and installation of windshield wiper linkage 1042
Removal 1042
Installation 1043
Removal and installation of optional seats 1043
Removal 1043
Installation 1043
Removal and installation of seat belts (optional seats) 1044
General 1044
Removal 1044
Installation 1046
Removal and installation of electronic accelerator and retard pedals 1048
Removal 1048
Installation 1048
Disassembly 1048
Assembly 1049
Cab air conditioning 1051
Replacement of air conditioning system components 1053
Hoses and fittings 1053
Lines 1053
Expansion valve 1053
Receiver-drier 1053
Thermostat 1053
Compressor 1054
Accumulator 1054
Clutch 1054
Power module 1057
Removal and installation of power module 1059
General 1059
Removal 1060
Installation 1068
Exhaust tube installation 1071
Exhaust blanket installation 1071
Removal and installation of alternator 1072
Removal 1072
Installation 1075
Removal and installation of radiator 1087
Removal 1087
Installation 1092
Repairing the radiator 1093
Internal inspection 1093
External cleaning 1093
Disassembly 1093
Cleaning and inspection 1094
Assembly 1095
Pressure testing 1096
Removal and installation of engine 1096
Removal 1096
Service 1096
Installation 1097
90 Diagrams and drawings 1099
Hydraulic circuit diagrams 1099
Steering, hoist and brake cooling hydraulic circuit schematic – 58B-60-21400 1101
Brake hydraulic circuit schemati – 58F-60-00841 1102
Auxiliary system hydraulic circuit schematic – 58E-60-01680 1103
Electrical circuit diagrams 1105
Electrical circuit diagram – 58B-06-02262 1107
IM2 jumper wiring diagram – 58B-06-09501 1127

IMAGES PREVIEW OF THE MANUAL:

S.V 27/12/24