Komatsu 980E-5 Dump Truck Field Assembly Manual CEAW009700 – PDF Download

Description

Komatsu 980E-5 Dump Truck Field Assembly Manual – CEAW009700

This Komatsu 980E-5 Dump Truck Field Assembly Manual is a practical PDF reference for assembling the 980E-5 dump truck from shipped components through chassis build-up, dump body assembly, final assembly and final checkout. It applies to 980E-5 trucks from serial number A50003 and up with the 18V170 engine, and the specifications section identifies the engine as the Komatsu SSDA18V170. The manual is written around field assembly work, so it focuses on the sequence of tasks, lifting and support, hardware tightening, welding requirements, component installation and the checks needed before the truck is released for operation.

Because this is a field assembly manual rather than a general operator booklet, it is built for assembly technicians, field service crews and maintenance planners who need the assembly order and the related procedures in one document. It includes safety rules, tool and equipment lists, major component weights, field welding guidance, receiving and preparation steps, detailed chassis and body installation procedures, final assembly steps and an appendix of checkout procedures and reference tables.

File Details

• Manual type: Field Assembly Manual
• Brand/model: Komatsu 980E-5 Dump Truck
• Language: English
• Page count: 376 pages
• File format: PDF
• Document number: CEAW009700

Chapters Covered

• Foreword
• Safety Rules, Tools & Equipment
• Truck Components and Specifications
• Major Component Weights
• Field Welding for Assembly or Repair
• Receiving and Assembly Preparation
• Chassis Assembly
• Dump Body Assembly
• Final Assembly
• Final Check-Out
• Appendix

Foreword, Safety Rules, Tools & Equipment

The opening sections explain how the manual is organized and set the safety expectations for field assembly. The safety rules cover personnel training, protective equipment, inspection of lifting devices, fire control equipment, welding precautions, battery disconnect requirements and fall protection. The tools and equipment chapter lists cranes, forklifts, welding units, air tools, torque tools, lifting slings, jacks, cribbing, ladders and special service tools, along with part numbers and illustrations for several of the special tools. This section is useful before work starts because it helps crews confirm lifting capacity, tooling and site readiness.

Truck Components and Specifications

This chapter introduces the 980E-5 dump truck as an off-highway rear dump truck with AC electric drive, then describes the engine, traction alternator, main control cabinet, AC induction traction motorized wheels, suspension, operator cab, power steering, dynamic retarding grid, brake system and selective catalytic reduction system. The specifications portion gives engine ratings, electric drive data, battery system details, service capacities, hydraulic system data, service brake data, steering data, tire size and standard dump body capacities and dimensions. It also includes weight distribution for empty and loaded vehicle conditions.

Major Component Weights

The major component weights chapter provides dry weights for chassis items, deck and deck support components, power module components, hydraulic components, front axle components and rear axle components. Weights are shown in kilograms and pounds for items such as the main frame, wheel rim and tire, cab, decks, air cleaner assemblies, control cabinet, engine, radiator, hydraulic tank, steering accumulator, hoist cylinder, front suspension cylinder, rear suspension cylinder and rear axle housing. These values support lift planning and cribbing decisions during assembly.

Field Welding for Assembly or Repair

The field welding chapter covers welder qualification and training, approved welding processes and consumables, weld quality requirements, materials control, preheating and post heating, weld inspection methods and records. It also includes repair procedures for load-carrying members, toe hammer peening, toe grinding with a rotary burr, and special precautions for welding on an AC drive system truck. The chapter lists GMAW, FCAW and SMAW consumables, discusses protection from wind and moisture, and explains inspection methods such as visual, dye penetrant, fluorescent penetrant, magnetic particle, ultrasonic and X-ray inspection.

Receiving and Assembly Preparation

This section begins with inspection for shipping damage, organizing parts by unit number, checking for missing parts, verifying the cab and decks belong to the correct chassis, installing support blocks and cleaning mounting surfaces. It explains coded boxes and how assembly parts are packed in chronological order. A site layout diagram shows where to place the body, cranes, small parts, jigs, tools, decks, tires, welder, forklift and major components. The preparation steps are important because the manual relies on correct staging and identification of components before assembly begins.

Chassis Assembly

The chassis assembly chapter is the largest assembly portion. It covers lifting the chassis from the transport trailer, placing it on support blocks, installing ladders and handrails, mounting uprights and air cleaners, installing diagonal beams, installing and welding deck supports, mounting the cab, installing the hydraulic tank, fuel tank and DEF tank, installing rear suspension cylinders, hoist cylinders, front suspensions, spindles, tie rod and steering cylinders, installing wheel motors, air intake tubes, decks, retarding grid, control cabinet, transformer, cooling blowers and ducting, battery box, diagonal ladder, bumper extensions, reserve oil system, lubrication system, isolation station, tires and rear wheels. It also includes hardware tightening methods, torque values, welding instructions, wheel motor mounting sequences and checks before dump body installation.

Dump Body Assembly

The dump body assembly chapter explains how to organize body sections, position them upside down, remove paint from weld areas, align the body halves, install the pivot, install canopy and floor hardware, tighten capscrews, install filler plates and backer strips, tack weld joints and complete body welding. It includes welding sequence guidance for the front sheet and floor, procedures for turning the body over with two cranes, installation of gussets, body guides and body pad mounts, and installation of optional equipment such as body liners and side boards.

Final Assembly and Final Check-Out

The final assembly chapter covers installing the dump body onto the chassis, installing body pivot pins, hoist cylinder upper mounts, shimming body pads, installing rock ejectors, mud flaps, body guide brackets, the body up limit switch, grease lines, exhaust tubing blankets, lubrication system, isolation box, scoreboard, engine bay lights, KomVision cameras and radar, painting, decals and fire suppression system. The final checkout chapter covers delivery and warranty forms, fluid levels, hydraulic shut-off valves, purging air from pumps and suction lines, final system checks, brake tests and the Field Assembly Inspection Report.

Appendix and Checkout Procedures

The appendix brings together reference material and separate checkout procedures used after assembly. It includes lubrication charts, torque tables and conversion charts, suspension oiling and charging procedures, toe-in adjustment, automatic lubrication system priming and checkout, brake test checkout, parking brake bleeding and flushing, alternator-to-engine assembly checkout, alternator lock checkout, interface module checkout, automatic lubrication system description and troubleshooting, reserve oil system checkout, air conditioning checkout, hydraulic system checkout, brake system checkout, KOMTRAX Plus setup and checkout, Payload Meter IV checkout, electrical system checkout, KomVision checkout, wireless bridge checkout, retractable ladder system checkout, seat belts and tethers checkout, the Field Assembly Inspection Report and the 50 Hour Post-Commissioning Checksheet.

Why This Komatsu 980E-5 Field Assembly Manual Matters

Assembling a 980E-5 dump truck is not a generic mechanical job. The manual ties the work to specific component weights, lifting points, tightening methods, weld requirements and installation sequences. It gives the assembly crew a single reference for the order of operations and the checks that must be completed before the truck moves to final checkout. For field service teams, having the assembly procedure and the related appendix checkouts together helps reduce guesswork, supports safer lift planning and provides a clear path from receiving to release.

This PDF is delivered electronically after payment, so there is no shipping delay and no physical book to wait for. You can open it on a laptop, tablet or phone, print the pages needed for the shop floor and keep the file on hand for assembly planning and future reference.

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