Komatsu 980E-5 DUMP TRUCK Shop Manual CEBM033903 – PDF DOWNLOAD

Description

Komatsu 980E-5 DUMP TRUCK Shop Manual CEBM033903 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 980E-5 DUMP TRUCK Shop Manual CEBM033903 – PDF DOWNLOAD

Language : English
Pages :1059
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 980E-5 DUMP TRUCK Shop Manual CEBM033903 – PDF DOWNLOAD

SERIAL NUMBERS 980E-5 A50137 – A50140

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. 960E). 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. NOTE: Accumulations of mud, frozen material, etc, become part of the GVW and reduces the allowable payload. To maximize payload and to keep from exceeding the maximum GVW rating, these accumulations should be removed as often as practical. Exceeding the allowable payload will reduce the expected life of truck components.

TABLE OF CONTENTS:

Komatsu 980E-5 DUMP TRUCK Shop Manual CEBM033903 – PDF DOWNLOAD

SERIAL NUMBERS 980E-5 A50137 – A50140

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
Tie-off anchor installation 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
Control cabinet capacitor discharge system 46
Handling electrical equipment and hydraulic components 48
Points to remember when handling electrical equipment 48
Points to remember when handling hydraulic equipment 54
Standard tightening torques 56
Effect of special lubricants on fasteners and standard torque values 56
Suggested sources for rust preventive grease 56
SAE grade 5 and grade 8 hex head capscrew and nut assemblies 57
SAE grade 9 capscrews 58
Class 109 capscrews and class 10 nuts 58
Standard tightening torques for fittings 59
Standard tightening torques for clamps 61
Conversion tables 62
Common conversion multipliers 62
01 Specification 67
Specification and technical data 67
Specification drawing 69
Specifications 70
Weight table 72
Fuel, coolant and lubricants 73
Suspension cylinder oil and nitrogen specifications 74
10 Structure and functions 77
Steering circuit 77
Steering circuit operation 79
Steering circuit components 84
Steering control unit 84
High pressure filter 84
Steering accumulators 84
Bleeddown manifold 85
Steering accumulator bleeddown solenoid 85
Quick disconnect ports 85
Flow amplifier 85
Steering/brake pump operation 86
High altitude operation 86
Neutral position 87
Full pump volume 88
Half pump volume 89
Flow amplifier operation 90
No steer 90
Steering left 92
Steering right 94
No steer, external shock load 96
Hoist circuit 99
Hoist circuit operation 101
Hoist circuit components 102
Hydraulic tank 102
Hoist pump 102
High pressure filters 102
Hoist valve 103
Inlet sections 103
Tank ports (front) spool section 103
Work ports (rear) spool section 104
Hoist pilot valve 104
Hoist limit solenoid 105
Pilot operated check valve 105
Overcenter manifold 105
Hoist pilot valve operation 106
Float position with body down 106
Power up operation 108
Hold operation 110
Power down operation 112
Float operation 114
Brake circuits 117
General information 119
Service brake circuit operation 120
Secondary braking 123
Automatic brake application (Auto apply) 123
Parking brake circuit operation 124
Normal operation (key switch ON, engine on) 124
Wheel brake lock circuit operation 125
Brake warning circuit operation 125
Electrical system, 24 volt 129
Battery supply system 131
Batteries 131
24VDC auxiliary battery receptacles 131
Isolation box 132
Ground level shutdown switch 132
Battery disconnect switches 132
Propel lockout lever 132
System busy light 132
LED lights 132
Engine starting system with prelube 133
Prelube operation 133
Cranking operation 134
Auxiliary control cabinet components 134
24VDC to 12VDC converter 135
Circuit breakers 135
Engine service light timer 135
Ground terminals 135
24VDC power terminals 135
Relays 136
Body-up switch 137
Hoist limit switch 137
Automatic lubrication (auto lube) system 139
General information 141
System operation 142
20 Standard value table 145
Standard value table 145
Standard value table for truck 147
30 Testing and adjusting 153
Steering, hoist, brake cooling and auxiliary hydraulic system 153
Hydraulic system bleeddown procedure 155
Hydraulic system vacuum procedure 157
General information on system checkout 157
Hydraulic system checkout procedures 158
Required equipment 158
Preliminary steps 158
Hydraulic system flushing procedure 159
Flow amplifier adjustment 162
Steering pump unloader valve adjustment 163
Auxiliary accumulator pressure verification 164
System diagnostics 164
Hoist counterbalance valve adjustment 166
Final steps 167
Oil cleanliness check 168
Hydraulic system checkout data sheet 169
High altitude steering pump adjustment 172
Toe-in adjustment 173
Measuring steering pin joint wear 174
Hoist cylinder leakage test 177
Steering cylinder leakage test 177
Brake system 179
General information on system checkout 181
Brake system checkout procedures 181
Required equipment 181
Initial system setup 184
Brake lock / secondary braking checkout 184
Parking brake checkout 185
Service brake checkout 186
Low brake accumulator pressure and auto apply checkout 187
Parking brake control logic checkout 189
Brake lock control logic checkout 190
Brake system checkout data sheet 193
Brake piston leakage test 202
Brake seal pressure test 202
Oil separator seal pressure test 202
Wet disc brake bleeding procedure 203
Parking brake bleeding procedure 204
Service brake disc wear inspection 205
Parking brake disc wear inspection 206
Brake valve bench test and adjustment 207
Test setup procedure 208
Brake valve output pressure adjustment 208
Final test and adjustment 209
Dual relay valve bench test and adjustment 210
Test setup procedure 211
Relay valve output pressure adjustment 211
Accumulators and suspensions 213
Accumulator charging and storage 215
Temperature during precharge 215
Bladder accumulator charging procedure 216
Precharge maintenance 218
Bladder accumulator storage procedure 218
Bladder storage 218
Installing a bladder accumulator from storage 219
Bladder accumulator leak testing 219
Piston accumulator charging procedure 220
Piston accumulator storage 223
Piston accumulator leak testing 224
Checking for improper suspension charge on operating trucks 225
Suspension oil change recommendations 226
Suspension oiling and charging procedures 227
Required equipment 227
Installing the charging kit 228
Removing the charging kit 228
Support blocks for oiling and charging dimensions 229
Front suspensions 232
TOP FILL METHOD 233
PRESSURE FILL METHOD 233
Rear suspensions 235
TOP FILL METHOD 237
PRESSURE FILL METHOD 237
Suspension pressure test 239
Electrical systems 241
General information on system checkout 243
Loadbox test information 243
Truck shutdown procedure 244
Required software and tools 244
Electrical system checkout procedures 246
Visual inspection 246
Resistance checks 246
Voltage checks 247
Truck function checks 249
Interface module (IM) checks 250
KOMTRAX Plus II checks 250
Payload meter (PLM) checks 250
Drive system checks 250
Engine delayed shutdown Smart Timer check 251
Body hoist limit switch check 251
Electrical checkout sheet 252
Interface module 2 (IM2) 257
Required tools 259
Programming the IM2 259
Updating the software 259
Configuring the IM2 260
Viewing IM2 real-time data 260
Interface module checkout procedures 261
Checking for IM fault codes 261
Checking digital inputs to the IM 261
Checking analog inputs to the IM 264
Checking serial communication to the IM 264
Checking outputs from the IM 265
IM checkout sheet 266
KOMTRAX Plus II 271
Required software and tools 273
Ethernet connection to KOMTRAX Plus II controller 273
KOMTRAX Plus II configuration 275
GPS connection test 277
Iridium satellite system opening 279
Data download over ethernet connection for KOMTRAX Plus II initialization 282
Payload meter IV 285
Payload meter IV software and tools 287
Payload meter IV system configuration 287
Connecting to the payload meter IV web server 287
Configuring a static IP address 287
Payload meter IV software installation 289
Inclinometer calibration and clean truck tare 290
Payload meter IV checkout procedure 290
PLM IV system checkout data sheet 296
Downloading PLM IV data and possible errors 297
Komatsu wireless bridge (KWB) 301
General information 303
Required software and tools 303
Configuring the Bullet wireless radio 304
Installing the Bullet wireless radio 307
Configuring the NanoStation access point 308
Testing the connection 311
Changing a service computer’s IP address 312
KomVision 315
Requirements 317
Initial setup 318
Checkout data sheet 327
Calibration sheets 332
Layout and assemblage 332
Unfolding a calibration sheet 335
Folding a calibration sheet 336
Placement of calibration sheets 337
Camera calibration procedures 339
Automatic 6 camera calibration 339
Manual 6 camera calibration 343
1 camera calibration 346
Radar setting procedure 349
Cab air conditioning 353
General information 355
Service tools and equipment 356
Recovery/recycle station 356
Leak detector 356
Manifold gauge set 357
Service valves 358
Vacuum pump 358
Detecting leaks 359
System performance test 360
Checking system oil 361
System flushing 362
Installing the manifold gauge set 363
Purging air from the service hoses 364
Recovering and recycling refrigerant 365
Draining oil from previous recovery cycle 366
Recovery cycle 366
Recycling procedure 366
Evacuating the air conditioning system 367
Charging the air conditioning system 368
Automatic lubrication (auto lube) system 371
Priming the system 373
Checkout procedure 374
Adjusting the lubrication cycle timing 375
Trucks with Interface Module 1 375
Trucks with Interface Module 2 375
40 Troubleshooting 377
Fuse, diode and relay locations 377
Vehicle Electrical Center (VEC-89) 379
Vehicle Electrical Center (VEC-90) 381
Vehicle Electrical Center (VEC-91) 383
Vehicle Electrical Center (VEC-92) 384
Rear Terminal Mini-fuse and Relay (RTMR3) 386
Rear Terminal Mini-fuse and Relay (RTMR4) 387
Circuit breakers 387
Troubleshooting by fault code, Part 1 389
Fault Code A001 392
Fault Code A002 393
Fault Code A003 394
Fault Code A004 395
Fault Code A005 396
Fault Code A006 397
Fault Code A007 398
Fault Code A008 399
Fault Code A009 400
Related circuit diagram 400
Fault Code A010 401
Related circuit diagram 401
Fault Code A011 402
Fault Code A013 403
Fault Code A014 404
Fault Code A016 405
Fault Code A017 406
Fault Code A018 407
Fault Code A019 408
Fault Code A022 409
Fault Code A100 410
Related circuit diagram 410
Fault Code A101 411
Fault Code A103 412
Fault Code A104 413
Fault Code A105 414
Fault Code A109 415
Fault Code A111 416
Fault Code A115 417
Fault Code A117 418
Fault Code A118 419
Fault Code A123 420
Fault Code A124 421
Fault Code A125 422
Fault Code A126 423
Fault Code A127 424
Fault Code A128 425
Fault Code A139 426
Troubleshooting by fault code, Part 2 429
Fault Code A145 432
Fault Code A146 433
Fault Code A152 434
Fault Code A153 435
Fault Code A154 436
Fault Code A155 437
Fault Code A158 438
Fault Code A166 439
Fault Code A167 440
Fault Code A168 441
Fault Code A169 442
Fault Code A170 443
Fault Code A171 444
Fault Code A172 445
Fault Code A173 446
Fault Code A184 447
Fault Code A190 448
Fault Code A193 449
Fault Code A194 450
Fault Code A195 451
Fault Code A196 452
Fault Code A197 453
Fault Code A198 454
Fault Code A199 455
Fault Code A200 456
Fault Code A201 457
Fault Code A202 458
Fault Code A203 459
Fault Code A204 460
Fault Code A205 461
Fault Code A206 462
Fault Code A207 463
Fault Code A213 464
Fault Code A214 465
Fault Code A215 466
Fault Code A216 467
Fault Code A223 468
Fault Code A230 469
Fault Code A231 470
Fault Code A233 471
Fault Code A235 472
Fault Code A236 473
Fault Code A237 474
Fault Code A238 475
Fault Code A239 477
Related circuit diagram 478
Fault Code A240 479
Fault Code A242 480
Fault Code A243 481
Fault Code A244 482
Fault Code A245 483
Fault Code A246 484
Troubleshooting by fault code, Part 3 487
Fault Code A247 490
Fault Code A248 491
Fault Code A249 492
Fault Code A250 493
Fault Code A251 494
Fault Code A252 495
Fault Code A253 496
Fault Code A256 497
Fault Code A257 498
Fault Code A258 499
Fault Code A260 500
Fault Code A261 501
Fault Code A262 502
Fault Code A264 503
Fault Code A265 504
Fault Code A266 505
Fault Code A267 506
Fault Code A268 507
Fault Code A270 508
Fault Code A271 509
Related circuit diagram 510
Fault Code A272 511
Fault Code A273 512
Fault Code A274 513
Fault Code A275 514
Fault Code A277 515
Fault Code A278 516
Fault Code A279 517
Fault Code A280 518
Fault Code A281 519
Fault Code A282 520
Fault Code A283 521
Fault Code A284 522
Fault Code A285 523
Fault Code A286 524
Fault Code A292 525
Troubleshooting by fault code, Part 4 527
Fault Code A303 530
Fault Code A304 531
Fault Code A305 532
Fault Code A307 533
Fault Code A309 534
Fault Code A310 535
Fault Code A311 536
Fault Code A312 537
Fault Code A313 538
Fault Code A315 539
Fault Code A316 540
Fault Code A317 541
Fault Code A318 542
Fault Code A328 543
Fault Code A332 544
Fault Code A333 545
Fault Code A334 546
Fault Code A335 547
Fault Code A337 548
Fault Code A338 549
Fault Code A339 550
Fault Code A340 551
Fault Code A341 552
Fault Code A342 553
Fault Code A343 554
Fault Code A344 555
Fault Code A345 556
Fault Code A346 557
Fault Code A347 558
Fault Code A348 559
Fault Code A349 560
Fault Code A350 561
Fault Code A351 562
Fault Code A352 563
Fault Code A353 564
Fault Code A354 565
Fault Code A355 566
Fault Code A356 567
Fault Code A357 568
Fault Code A358 569
Fault Code A359 570
Fault Code A360 571
Fault Code A361 572
Fault Code A362 573
Fault Code A363 574
Fault Code A364 575
Fault Code A365 576
Fault Code A366 577
Troubleshooting by fault code, Part 5 579
Fault Code A400 582
Fault Code A401 583
Fault Code A402 584
Fault Code A403 585
Fault Code A404 586
Fault Code A405 587
Fault Code A406 588
Fault Code A407 589
Fault Code A408 590
Fault Code A409 591
Fault Code A410 592
Fault Code A411 593
Fault Code A412 594
Fault Code A413 595
Fault Code A414 596
Fault Code A415 597
Fault Code A416 598
Fault Code A417 599
Fault Code A418 600
Fault Code A419 601
Fault Code A420 602
Fault Code A421 603
Fault Code A422 604
Fault Code A423 605
Fault Code A424 606
Fault Code A425 607
Fault Code A426 608
Fault Code A427 609
Fault Code A428 610
Fault Code A429 611
Fault Code A430 612
Fault Code A431 613
Fault Code A432 614
Fault Code A433 615
Fault Code A434 616
Fault Code A435 617
Fault Code A436 618
Fault Code A437 619
Fault Code A438 620
Fault Code A439 621
Fault Code A440 622
Fault Code A441 623
Fault Code A442 624
Fault Code A443 625
Fault Code A444 626
Fault Code A445 627
Fault Code A446 628
Fault Code A447 629
Steering system 631
Steering circuit troubleshooting chart 633
Steering circuit troubleshooting guidelines 635
Basic hydraulic system checks 636
System leakage check 637
Steering pump troubleshooting guide 639
Pump pressure control checks 642
To verify pump unload pressure 642
To verify pump reloading 642
Pump fails to unload 643
Pump fails to develop pressure 643
Pump slow in developing pressure 644
Pump control valve inspection and trouble shooting 645
Pump case drain check 647
Definitions: 648
Adjustment 648
KomVision 651
KomVision fault codes 653
Automatic lubrication (auto lube) system 663
Autolube troubleshooting chart 665
Electronic fan clutch 669
Electronic fan clutch troubleshooting 671
Electronic fan clutch fault codes 673
50 Disassembly and assembly 675
Service tools 675
Special tool group 677
Heated body tool group 677
Additional service tools 678
KomVision calibration tools 678
Locally made tools 678
Wheels, spindles and rear axle 681
General precautions for tires and rims 683
Wheel stud maintenance 684
Rear outer wheel stud installation 685
Removal and installation of front wheel 686
Removal 686
Installation 687
Removal and installation of rear wheel 688
Removal 688
Installation 689
Rim and tire service 691
Rim components 691
Smart rim component layout 691
Lubricants 692
Tire inflation 692
Lock ring retainer installation 692
Removing the lock ring 693
Installing the lock ring 694
Removing the tire from the front rim (5-piece rim) 695
Removing the tire from the rear outer dual rim (7-piece Smart rim) 698
Removing the tire from the rear inner dual rim (5-piece rim) 700
Preparation before assembly 701
Installing the tire on the front rim (5-piece rim) 702
Installing the tire on the rear inner dual rim (5-piece rim) 704
Installing the tire on the rear outer dual rim (7-piece Smart rim) 705
Removal and installation of front wheel hub and spindle 706
Removal 706
Spindle removal (off the truck) 710
Installation 712
Disassembly and assembly of front wheel hub and spindle 713
Cross Section View 713
Disassembly 714
Cleaning and inspection 720
Wheel bearing adjustment 722
Seal assembly gap adjustment 723
Seal installation 724
Brake installation 727
Wheel hub and brake assembly installation 728
Speed sensor installation and adjustment 730
Floating seal assembly and installation 732
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 732
Removal and installation of rear axle 742
Removal 742
Cleaning and inspection 744
Installation 744
Removal and installation of anti-sway bar 745
Removal 745
Installation 747
Removal and installation of pivot pin 748
Removal 748
Installation 749
Pivot eye and bearing service 750
Bearing replacement 750
Pivot eye repair 751
Removal and installation of wheel motor 752
Preparation 752
Installation of wheel motor 755
Cleaning and inspection 755
Installation 756
Removal and installation of rear brake assembly 759
Brake system 761
Removal and installation of brake valve 763
Removal 763
Installation 764
Disassembly and assembly of brake valve/pedal assembly 765
Disassembly 765
Assembly 766
Removal and installation of dual relay valve 768
Removal 768
Installation 770
Removal and installation of brake manifold 771
Removal 771
Installation 771
Disassembly and assembly of brake manifold 772
Disassembly 772
Assembly 772
Removal and installation of piston brake accumulator 773
Removal 773
Installation 775
Disassembly and assembly of piston brake accumulator 777
Disassembly 777
Cleaning and inspection 779
Piston seal replacement 779
Assembly 780
Disassembly and assembly of front wheel brake 781
Disassembly 781
Cleaning and inspection 784
Assembly 785
Disassembly and assembly of rear wheel brake 787
Disassembly 787
Cleaning and inspection 790
Assembly 791
Brake floating ring seal assembly and installation 795
Removal and installation of parking brake 802
Removal 802
Installation 804
Disassembly and assembly of parking brake 804
Disassembly 804
Cleaning and inspection 806
Cleaning and inspecting new discs 808
Assembly 809
Steering system 811
Removal and installation of steering control unit 813
Removal 813
Installation 815
Disassembly and assembly of steering control unit 816
Disassembly 816
Assembly 818
Removal and installation of steering column 821
Removal 821
Installation 822
Removal and installation of steering wheel 823
Removal 823
Installation 823
Removal and installation of bleeddown manifold 824
Removal 824
Installation 825
Removal and installation of flow amplifier 826
Removal 826
Installation 826
Removal and installation of steering cylinders and tie rod 827
Removal 827
Installation 827
Disassembly and assembly of steering cylinders 829
Disassembly 829
Cleaning and inspection 831
Assembly 831
Removal and installation of steering/brake pump 832
Removal 832
Installation 834
Removal and installation of piston steering accumulator 835
Removal 835
Installation 837
Disassembly and assembly of piston steering accumulator 840
Disassembly 840
Cleaning and inspection 842
Piston seal replacement 842
Assembly 843
Suspensions 845
Removal and installation of front suspension 847
Preparation 847
Removal 847
Cleaning and Inspection 849
Installation 850
Disassembly and assembly of front suspension 856
Disassembly 856
Cleaning and inspection 859
Assembly 859
Removal and installation of rear suspension 861
Removal 861
Installation 864
Disassembly and assembly of rear suspension 867
Disassembly 867
Cleaning and inspection 869
Assembly 870
Hoist circuit 873
Removal and installation of hoist pump 875
Removal 875
Installation 879
Disassembly and assembly of hoist pump 880
Disassembly 880
Inspection 885
Assembly 886
Removal and installation of hoist valve 889
Removal 889
Installation 891
Disassembly and assembly of hoist valve 891
O-ring replacement 891
Disassembly of inlet section 893
Assembly of inlet section 894
Disassembly of rear spool section 895
Assembly of rear spool section 897
Disassembly of front spool section 898
Assembly of front spool section 899
Overcenter manifold service 899
Removal and installation of hoist pilot valve 900
Removal 900
Installation 900
Disassembly and assembly of hoist pilot valve 903
Disassembly 903
Cleaning and inspection 904
Assembly 904
Removal and installation of hoist cylinders 905
Removal 905
Installation 908
Disassembly and assembly of hoist cylinders 911
Disassembly 911
Cleaning and inspection 915
Installation of the quill 916
Assembly 918
Body and structures 923
Removal and installation of dump body 925
Removal 925
Inspection 926
Installation 927
Removal and installation of body pads 928
Removal 928
Installation 928
Body pad shimming procedure 929
Removal and installation of diagonal ladder/ hood and grille assembly 930
Removal 930
Installation 930
Removal and installation of RH deck 932
Removal 932
Installation 932
Removal and installation of LH deck 934
Removal 934
Installation 934
Removal and installation of fuel tank 936
Removal 936
Cleaning and inspection 937
Installation 939
Removal and installation of fuel gauge sender 939
Removal 939
Installation 939
Removal and installation of hydraulic tank 940
Removal 940
Installation 941
Removal and installation of hydraulic tank strainers 942
Removal 942
Cleaning and inspection 943
Installation 943
Operator cab 945
Removal and installation of operator cab 947
Removal 947
Installation 950
Removal and installation of cab door 950
Removal 950
Installation 951
Disassembly and assembly of cab door 952
Removing the window regulator 952
Installing the window regulator 953
Removing the door glass 954
Installing the door glass 955
Replacing the inner door seal 956
Replacing the outer door seal 956
Installation and removal of the interior door handle and door latch (earlier models) 957
Installation and removal of interior door handle and door latch (later models) 960
Adjustment of cab door 962
Door jamb bolt adjustment 962
Exterior door handle release button adjustment 964
Removal and installation of side window glass 965
Recommended tools and supplies 965
Removal 965
Installation 966
Removal and installation of windshield and rear window glass 968
Removal 968
Installation 968
Removal and installation of windshield wiper components 969
Removing the windshield wiper motor 969
Installing the windshield wiper motor 969
Removing the windshield wiper arm and linkage 970
Installing the windshield wiper arm and linkage 971
Removal and installation of cab seats 971
Removal 971
Servicing the seat 972
Installation 972
Removal and installation of seat belts 973
Removal 973
Installation 974
Power module 977
Removal and installation of power module 979
General 979
Removal 980
Installation 991
Removal and installation of alternator 994
Removal 994
Installation 997
Engine / alternator attachment checkout data sheet1005
Additional engine measurements1007
Flywheel Housing Face Runout1007
Flywheel Housing Radial Runout1008
Flywheel/Flexplate Face Runout1009
Flywheel/Flexplate Radial Runout1010
Removal and installation of the cooling module1011
Removal1011
Installation1015
Repairing the radiator1016
Internal inspection1016
External cleaning1016
Disassembly1016
Cleaning and inspection1017
Assembly1018
Pressure testing1019
Removal and installation of engine1019
Removal1019
Service1019
Installation1020
Removal and installation of electronic fan clutch1023
Removal1023
Installation1024
Removal and installation of electronic fan clutch speed sensor1024
Removal1024
Installation1024
90 Diagrams and drawings1027
Hydraulic circuit diagrams1027
Electrical circuit diagrams1034

IMAGES PREVIEW OF THE MANUAL:

S.M 15/12/24