Komatsu 980E-5 DUMP TRUCK Shop Manual CEBM033010 – PDF DOWNLOAD

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Komatsu 980E-5 DUMP TRUCK Shop Manual CEBM033010 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 980E-5 DUMP TRUCK Shop Manual CEBM033010 – PDF DOWNLOAD

Language : English
Pages :1111
Downloadable : Yes
File Type : PDF

DESCRIPTION:’

Komatsu 980E-5 DUMP TRUCK Shop Manual CEBM033010 – PDF DOWNLOAD

SERIAL NUMBERS 980E-5 A50003-51, A50054-136,
A50141-149

FOREWORD
HOW TO READ THE SHOP MANUAL
REMARK
• Some attachments and options given in this shop manual may not be available in some areas. If they are
required, speak to your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Komatsu shop manuals are available for the “machine part”. For detailed information on the “engine part” or
“drive system part”, see the shop manual from the original equipment manufacturer (OEM).
• Actual machine may differ from the images which are given in this manual. A typical model is shown in the
illustrations of this shop manual.
Composition of the shop manual
This manual supports quality repair through education of the product, correct repair procedures, and assistance
with repair decisions.
Understand the content of this manual and use it at every opportunity.
This shop manual contains technical information necessary to perform services in the workshops. It is organized
into chapters for ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine such as dimensions, performance, component weights,
and lubricant charts.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system.
“STRUCTURE AND FUNCTION” is helpful to understand the structure of each component and to do the
troubleshooting procedure.
20 STANDARD VALUE TABLE
This section describes the standard values for a new machine and failure criteria for testing, adjusting, and
troubleshooting. Use the “STANDARD VALUE TABLE” to check the standard values for testing and adjusting,
and troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measurement tools and methods to test and adjust each part. The standard values
and repair limit for TESTING AND ADJUSTING are given in the “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes how to troubleshoot and repair failures in the machine.
Troubleshooting steps are sorted by failure mode.
Troubleshooting steps correlate “Problems” to “Causes” in this section.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal,
installation, disassembly, and assembly of the components and parts.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.

TABLE OF CONTENTS:

Komatsu 980E-5 DUMP TRUCK Shop Manual CEBM033010 – PDF DOWNLOAD

SERIAL NUMBERS 980E-5 A50003-51, A50054-136,
A50141-149

COVER 1
00 CONTENTS AND FOREWORD 3
Foreword 19
How to Read the Shop Manual 19
Safety Alert Symbol and Signal Words 20
General Precautions Common to Operation and Maintenance 21
Preparations for Safe Operation 21
Fire and Explosion Prevention 23
Precautions When Getting On or Off the Machine 25
Precautions for Cab and Working Around Machine 28
Precautions for Diesel Exhaust Fluid (DEF) 29
Operation Precautions 32
Precautions at Jobsite 32
Precautions in Starting Engine 33
Precautions During Operation 35
Maintenance Precautions 37
Precautions Before Inspection and Maintenance 37
Precautions During Inspection and Maintenance 42
Precautions for Electrical Equipment 49
Primary Causes of Wiring Harness Failure 50
Control Cabinet Capacitor Discharge 52
Hydraulic Equipment Precautions 53
01 SPECIFICATIONS 57
Specifications 58
Specifications: 980E-5 58
Weight Table: 980E-5 59
Recommended Fuel, Coolant, and Lubricant 61
Suspension Cylinder Oil and Nitrogen Specifications 61
Wheel Motor Oil Specifications 63
10 STRUCTURE AND FUNCTION 65
Steering System 66
Steering System Layout 66
Steering System Operation 66
Steering Bleeddown Manifold 68
Steering Control Unit 69
Steering Accumulators (Piston Type) 70
Steering/Brake Pump Operation 70
Flow Amplifier Operation 72
Hoist System 80
Hoist System Layout 80
Hoist System Operation 81
Hoist Control Valve 82
Hoist Pilot Valve 84
Brake System 85
Service Brake System Layout 85
Hydraulic Brake Cabinet Layout 86
Service Brake Operation 87
Parking Brake Operation 88
Brake Lock Operation 88
Secondary Braking and Auto Apply 89
Electrical System, 24V 90
Battery Power Supply 90
Battery Disconnect Switches 91
Engine Starting System 92
Auxiliary Control Cabinet Components 93
Body-Up Switch 95
Hoist Limit Switch 96
Automatic Lubrication (Auto Lube) System 97
Automatic Lubrication (Auto Lube) Grease Pump and Reservoir 97
Automatic Lubrication (Auto Lube) System Operation 98
Suspensions 100
Engine Emissions After-Treatment System Operations 101
20 STANDARD VALUE TABLE 105
Standard Value Table 106
30 TEST AND ADJUST 111
Hydraulic Systems 112
Hydraulic System Checkout Procedures 112
Hydraulic System Checkout Sheet 124
Steering System Leakage Check 127
Toe-In Adjustment 128
Hoist Cylinder Leakage Test 129
Steering Cylinder Leakage Test 129
Checking the Steering/Brake Pump Control Pressures 130
Adjusting the Steering/Brake Pump Control Pressures 131
High Altitude Steering/Brake Pump Adjustment 133
Brake System 134
Brake System Checkout Procedures 134
Brake System Checkout Sheet: 980E-5 143
Brake System Leakage Check 149
Brake Piston Leakage Test 150
Parking Brake Piston Leakage Test 151
Brake Floating Seal Pressure Test 151
Oil Separation Seal Pressure Test (Air Pressure Method) 152
Oil Separation Seal Pressure Test (Oil Pressure Method) 152
Wet Disc Brake Bleeding Procedure 153
Parking Brake Bleeding Procedure 153
Wet Disc Brake Wear Inspection 154
Parking Brake Wear Inspection 156
Accumulators and Suspensions 157
Bladder Accumulator Charging Procedure 157
Bladder Accumulator Leakage Test 158
Bladder Accumulator Storage 159
Piston Accumulator Charging Procedure 160
Piston Accumulator Leakage Test 161
Piston Accumulator Storage 162
Check for Improper Suspension Charge 163
Suspension Oiling and Charging Procedures 164
Oiling and Charging Tools and Support Blocks 165
Nitrogen Charging Kit Installation 169
Nitrogen Charging Kit Removal 169
Front Suspension Oiling and Charging 170
Rear Suspension Oiling and Charging 173
Suspension Pressure Test 176
Automatic Lubrication (Auto Lube) System 177
Prime the Auto Lube Pump 177
Prime the Auto Lube Grease Lines 177
Auto Lube System Checkout 178
Adjust the Auto Lube Cycle Timing (original IM only) 179
Adjust the Auto Lube Cycle Timing (IM2 only) 180
Cab Air Conditioning 181
Refrigerant Leak Detection 182
A/C System Performance Test 182
Check the A/C System Oil 183
A/C System Flushing Procedure 184
Manifold Gauge Set Installation 185
Refrigerant: Recycled vs Reclaimed 186
Refrigerant Recovery Procedure 186
Evacuate the A/C System 186
Charge the A/C System 187
Electrical Systems 189
Shutdown Procedure for Drive System Service 189
Electrical System Checkout Procedures 190
Visual Checks 190
Resistance Checks 190
Voltage Checks 191
Truck Function Checks 192
Interface Module (IM) Checks 193
KOMTRAX Plus II Checks 193
Payload Meter (PLM) Checks 194
Drive System Checks 194
Engine Delayed Shutdown Smart Timer Check 195
Hoist Limit Switch Check 195
Electrical System Checkout Sheet 195
Interface Module (IM) 198
Interface Module Software and Tools 198
Interface Module Checkout Procedures 198
Setup for IM Realtime Monitor Software 198
Checking Digital Inputs to the IM 199
Checking Analog Inputs to the IM 200
Checking Serial Communication to the IM 201
Checking Outputs from the IM 201
Interface Module Checkout Sheet 202
Interface Module 2 (IM2) 205
Interface Module 2 Software and Tools 205
Program the IM2 Controller 205
Interface Module 2 Checkout Procedures 207
Check for IM Fault Codes 207
Checking Digital Inputs to the IM2 208
Checking Analog Inputs to the IM2 209
Checking Serial Communication to the IM 210
Checking Outputs from the IM2 210
Interface Module 2 Checkout Sheet 211
Payload Meter IV 214
Payload Meter IV Software and Tools 214
Payload Meter IV System Configuration 214
Configuring a Static IP Address 214
Payload Meter IV Software Installation 217
Payload Meter IV Data Downloading 217
Payload Meter IV Checkout Procedure 218
Payload Meter IV Checkout Sheet 224
KOMTRAX Plus II 225
KOMTRAX Plus II Software and Tools 225
Komtrax Plus II Controller Ethernet Connection 225
KOMTRAX Plus II Configuration 226
GPS Connection Test 229
Satellite Connection Test 231
Komtrax Plus II System Initialization 234
KomVision 236
KomVision Setup and Calibration Requirements 236
KomVision Initial Setup and Checkout Procedure 236
KomVision Checkout Sheet 242
KomVision Calibration Sheets 244
Calibration Sheet Layout 244
Unfold and Fold Calibration Sheet 247
Calibration Sheet Placement 249
KomVision Camera Calibration Procedures 250
Automatic 6 Camera Calibration 250
Manual 6 Camera Calibration 253
1 Camera Calibration 255
KomVision Radar Setting Procedure 258
Komatsu Wireless Bridge (KWB) 261
Komatsu Wireless Bridge Software and Tools 261
Bullet Wireless Radio Configuration 261
Bullet Wireless Radio Installation 264
NanoStation Access Point Configuration 265
NanoStation Access Point Connection Test 267
Tire Monitoring System 269
Tire Monitoring System Software and Tools 269
Tire Monitoring System Software Installation 269
Tire Monitoring System Configuration 269
Connecting to the Tire Monitoring System Web Server 269
Configuring a Static IP Address 270
Tire Monitoring System Reset 272
Tire Monitoring System Checkout Procedure 272
Tire Monitoring System Checkout Sheet 274
40 TROUBLESHOOTING 275
Fuses, Diodes and Relays 276
Standard Truck Fault Codes 285
A001 285
KomVision Fault Codes 632
Troubleshoot the Steering System 643
Steering System Troubleshooting Guide 643
Basic Hydraulic System Checks 644
Steering/Brake Pump Troubleshooting Guide 645
Steering/Brake Pump Troubleshooting Checks 648
Steering/Brake Pump Fails to Unload 648
Steering/Brake Pump Fails to Develop Pressure 648
Steering/Brake Pump Slow to Develop Pressure 649
Steering/Brake Pump Control Valve Inspection 650
Steering/Brake Pump Case Drain Check 651
Troubleshoot the Auto Lube System 652
Troubleshoot the HVAC System 656
Control Panel Configurations 656
Diagnostics Mode 657
Error Codes 657
Advanced Diagnostics 657
Firmware Version 658
Additional HVAC Troubleshooting Chart 658
Voltage Levels 660
50 DISASSEMBLY AND ASSEMBLY 663
Special Tools List 664
Wheels, Spindles and Rear Axle 666
General Precautions for Tires and Rims 666
Lubricants for Tire and Rim Service 666
Tire Inflation 667
Rim Components 667
Wheel Stud Maintenance 668
Rear Outer Wheel Stud Installation 669
Front Wheel Removal 670
Front Wheel Installation 672
Rear Wheel Removal 673
Rear Wheel Installation 676
Lock Ring Retainer Installation 679
Lock Ring Removal 679
Lock Ring Installation 680
Tire Removal (Front 5-Piece Rim) 681
Tire Removal (Rear Outer 7-Piece Rim) 684
Tire Removal (Rear Inner 5-Piece Rim) 686
Tire and Rim Preparation 687
Tire Installation (Front 5-Piece Rim) 688
Tire Installation (Rear Inner 5-Piece Rim) 689
Tire Installation (Rear Outer 7-Piece Rim) 690
Front Wheel Hub and Spindle Removal 691
Spindle Removal While Off the Truck 695
Front Wheel Hub and Spindle Installation 696
Spindle, Hub and Brake Assembly Cross-Section View 700
Front Wheel Hub and Spindle Disassembly 700
Front Wheel Hub and Spindle Cleaning and Inspection 707
Front Wheel Hub and Spindle Assembly 708
Hub Floating Seal Installation 717
Rear Axle Removal 721
Rear Axle Cleaning and Inspection 722
Rear Axle Installation 722
Anti-Sway Bar Removal 724
Anti-Sway Bar Installation 726
Pivot Pin Removal 728
Pivot Pin Installation 730
Pivot Eye Bearing Wear Inspection 731
Pivot Eye Bearing Replacement 732
Pivot Eye Removal 733
Pivot Eye Installation 733
Wheel Motor Removal 734
Wheel Motor Cleaning and Inspection 736
Wheel Motor Installation 737
Steering System 741
Steering Control Unit Removal 741
Steering Control Unit Installation 741
Steering Control Unit Disassembly 743
Steering Control Unit Assembly 745
Steering Column Removal 748
Steering Column Installation 750
Steering Wheel Removal 752
Steering Wheel Installation 752
Bleeddown Manifold Removal 753
Bleeddown Manifold Installation 754
Flow Amplifier Removal 755
Flow Amplifier Installation 756
Steering Pin Joint Wear Inspection 757
Tie Rod Removal 759
Tie Rod Installation 760
Steering Cylinder Removal 761
Steering Cylinder Installation 762
Steering Cylinder Disassembly 763
Steering Cylinder Cleaning and Inspection 765
Steering Cylinder Assembly 766
Steering/Brake Pump Removal 768
Steering/Brake Pump Installation 769
Piston Steering Accumulator Removal 771
Piston Steering Accumulator Installation 773
Piston Steering Accumulator Disassembly 775
Piston Accumulator Cleaning and Inspection 777
Piston Seal Replacement 777
Piston Steering Accumulator Assembly 778
Brake System 780
Brake Valve Removal 780
Brake Valve Installation 781
Brake Valve/Pedal Disassembly 783
Brake Valve/Pedal Assembly 784
Front Brake Dual Relay Valve Removal 788
Front Brake Dual Relay Valve Installation 788
Rear Brake Dual Relay Valve Removal 790
Rear Brake Dual Relay Valve Installation 791
Brake Manifold Removal 792
Brake Manifold Installation 794
Brake Manifold Component Replacement 795
Piston Brake Accumulator Removal 796
Piston Brake Accumulator Installation 797
Piston Brake Accumulator Disassembly 799
Piston Accumulator Cleaning and Inspection 801
Piston Seal Replacement 801
Piston Brake Accumulator Assembly 802
Front Wheel Brake Disassembly 803
Wheel Brake Cleaning and Inspection 807
Front Wheel Brake Assembly 808
Rear Wheel Brake Disassembly 811
Wheel Brake Cleaning and Inspection 814
Rear Wheel Brake Assembly 815
Brake Floating Seal Installation 820
Parking Brake Removal 825
Parking Brake Installation 826
Parking Brake Disassembly 827
Parking Brake Cleaning and Inspection 830
New Parking Brake Disc Cleaning and Inspection 831
Parking Brake Assembly 832
Hoist System 835
Hoist Pump Removal 835
Hoist Pump Installation 839
Hoist Pump Disassembly 842
Hoist Pump Inspection 847
Hoist Pump Assembly 847
Hoist Valve Removal 852
Hoist Valve Installation 855
Hoist Valve Service 856
Hoist Valve O-Ring Replacement 856
Inlet Section Disassembly 857
Inlet Section Assembly 858
Rear Spool Section Disassembly 860
Rear Spool Section Assembly 862
Front Spool Section Disassembly 864
Front Spool Section Assembly 866
Overcenter Manifold Service 867
Hoist Pilot Valve Removal 868
Hoist Pilot Valve Installation 869
Hoist Pilot Valve Disassembly 869
Hoist Pilot Valve Cleaning and Inspection 871
Hoist Pilot Valve Assembly 871
Hoist Cylinder Removal 873
Hoist Cylinder Installation 877
Hoist Cylinder Disassembly 879
Hoist Cylinder Cleaning and Inspection 888
Quill Installation 889
Quill Check Ball and Plug Installation 891
Hoist Cylinder Assembly 892
Suspensions 904
Front Suspension Removal 904
Front Suspension Cleaning and Inspection 905
Front Suspension Installation 906
Front Suspension Bolted Joint Inspection 911
Front Suspension Charging Valve Replacement 911
Front Suspension Disassembly 912
Front Suspension Assembly 917
Rear Suspension Removal 922
Rear Suspension Installation 925
Rear Suspension Charging Valve Replacement 929
Rear Suspension Disassembly 930
Rear Suspension Cleaning and Inspection 933
Rear Suspension Assembly 934
Dump Body and Structures 937
Dump Body Removal 937
Dump Body Inspection 938
Dump Body Installation 939
Body Pads Removal 940
Body Pads Installation 941
Body Pad Shimming Procedure 941
Diagonal Ladder Removal 942
Diagonal Ladder Installation 943
RH Deck Removal 945
RH Deck Installation 946
LH Deck Removal 948
LH Deck Installation 949
Fuel Tank Removal 951
Fuel Tank Cleaning and Inspection 953
Fuel Tank Installation 954
Fuel Gauge Sender Removal 955
Fuel Gauge Sender Installation 955
Hydraulic Tank Removal 956
Hydraulic Tank Installation 957
Hydraulic Tank Strainers Removal 958
Hydraulic Tank Strainers Cleaning and Inspection 959
Hydraulic Tank Strainers Installation 960
Operator Cab 961
Operator Cab Removal 961
Operator Cab Installation 964
Cab Door Removal 967
Cab Door Installation 968
Window Regulator Removal 969
Window Regulator Installation 970
Door Glass Removal 972
Door Glass Installation 974
Inner Door Seal Replacement 976
Outer Door Seal Replacement 977
Interior Door Handle and Door Latch Removal 978
Interior Door Handle and Door Latch Installation 981
Interior Door Handle and Door Latch Removal 983
Interior Door Handle and Door Latch Installation 985
Door Jamb Bolt Adjustment 987
Poor Seal When Door Is Closed 987
Door Springs Back Open 988
Exterior Door Handle Release Button Adjustment 988
Side Window Glass Removal 989
Side Window Glass Installation 989
Windshield and Rear Window Glass Removal 991
Windshield and Rear Window Glass Installation 991
Windshield Wiper Motor Removal 992
Windshield Wiper Motor Installation 994
Windshield Wiper Arm and Linkage Removal 995
Windshield Wiper Arm and Linkage Installation 996
Cab Seat Removal 996
Cab Seat Servicing 997
Cab Seat Installation 997
Seat Belt Removal 998
Seat Belt Installation 999
Power Module1001
Power Module General Information1001
Power Module Removal1001
Power Module Installation1008
Exhaust Tube Installation1017
Exhaust Blanket Installation1018
Alternator Removal1018
Alternator Removal1022
Alternator Installation1026
Engine Flywheel Adapter Face Runout1027
Engine Crankshaft Endplay1027
Engine Flywheel to Flywheel Housing Adapter – Measurement “C”1028
Alternator Housing to Rotor – Measurement “A”1029
Measurements After Joining the Alternator and Engine1034
Flywheel Housing Face Runout1034
Flywheel Housing Radial Runout1035
Flywheel/Flexplate Face Runout1035
Flywheel/Flexplate Radial Runout1036
Rotor Shaft Radial Runout (Assembled)1036
Radiator Removal1037
Radiator Installation1041
Radiator Internal Inspection1045
Radiator External Cleaning1045
Radiator Disassembly1046
Radiator Cleaning and Inspection1046
Radiator Assembly1047
Engine Removal1048
Engine Removal1049
Engine Service1050
Engine Installation1050
Engine Installation1052
60 MAINTENANCE STANDARD1053
Rules for Maintenance1054
Torque Specifications1055
Hydraulic System Bleeddown Procedure1062
Hydraulic System Vacuum Procedure1065
Hydraulic Pumps1066
Steering/Brake Pump1066
Hoist Pump1067
Wet Disc Brakes1068
Service Brake1068
Parking Brake1069
Tie Rod1071
Tail Lights, Clearance Lights and Turn Signals1072
90 CIRCUIT DIAGRAMS1073
CONTENTS: 980E-51074
Index1102

IMAGES PREVIEW OF THE MANUAL:

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