Komatsu 980E-5 Dump Truck Shop Manual CEBM037302 PDF

Description

Komatsu 980E-5 Dump Truck Shop Manual CEBM037302 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 980E-5 Dump Truck Shop Manual CEBM037302 – PDF DOWNLOAD 

Language : English
Pages : 1390
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu 980E-5 Dump Truck Shop Manual CEBM037302 – PDF DOWNLOAD 

SERIAL NUMBERS 980E-5 A50150 – A50161

COVER 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword, safety and general information 23
Foreword 26
How to read the shop manual 27
Composition of shop manual 27
Revision and distribution 27
Symbols 28
General safety 29
Safety rules 29
Safety features 29
Fire extinguisher and first aid kit 29
Clothing and personal items 29
Leaving the operator seat 30
Mounting and dismounting 30
Fire prevention for fuel and oil 30
Precautions with high temperature fluids 31
Asbestos dust hazard prevention 31
Prevention of injury by work equipment 31
Unauthorized modification 31
Precautions when using ROPS 31
Precautions for attachments 32
Precautions for starting the truck 32
Precautions before operating the truck 32
Safety at the worksite 32
Fire prevention 33
Ventilation in enclosed areas 33
Preparing for operation 33
Mirrors, windows and lights 33
In operator cab (before starting the engine) 33
Seat Belts 33
Precautions while operating the truck 34
When starting the engine 34
General truck operation 34
Ensuring good visibility 34
Traveling 35
Traveling in reverse 35
Traveling on slopes 35
Operating on snow or ice 35
Avoid damage to dump body 35
Driving near high voltage cables 36
When dumping 36
When loading 36
Working on loose ground 36
Parking the truck 36
Towing 36
Working near batteries 37
Battery hazard prevention 37
Starting with jumper cables 38
Jump starting with receptacles 38
Precautions before performing service 39
Warning tag 39
Stopping the engine 39
Proper tools 39
Use of tie-off anchor duringmaintenance and repair 40
Tie-off anchor installation 40
Securing the dump body 41
Jack point locations 42
Precautions while performing service 43
Keep the truck clean 43
Attachments 43
Working under the truck 43
Rotating fan and belts 43
Adding fuel or oil 43
Use of lighting 43
Radiator coolant level 44
Precautions with the battery 44
Precautions with high pressure oil 44
Handling high pressure hoses 44
Precautions when performing maintenance near high temperature or high pressure 44
Waste materials 44
Tires 45
Inspection 45
Maintenance 45
Storage 46
Handling 47
Precautions for performing repairs 48
Engine shutdown procedure after AC drive system failure 48
Precautions for welding on the truck 49
Capacitor discharge system 50
Necessary tools 50
Warnings and cautions 51
Manual DC link capacitor discharge procedure 52
Failure of the discharge system 54
Manual discharge of capacitors 55
Short isolated capacitor terminals 57
Handling electrical equipment and hydraulic components 58
Points to remember when handling electrical equipment 58
Points to remember when handling hydraulic equipment 64
Actions taken to meet exhaust gas regulations 66
About DEF 66
Precautions for diesel exhaust fluid (DEF) 67
About DEF 67
Precautions for handling DEF 67
Precautions for storing DEF 67
Precautions for disposing of DEF 68
Crystallization management 68
Precautions for cold weather operation 68
Standard tightening torques 69
Effect of special lubricants on fasteners and standard torque values 69
Suggested sources for rust preventive grease 69
SAE grade 5 and grade 8 hex head capscrew and nut assemblies 70
SAE grade 9 capscrews 71
Class 10 9 capscrews and class 10 nuts 72
Standard tightening torques for fittings 72
Standard tightening torques for clamps 74
Conversion tables 75
Common conversion multipliers 75
01 Specification 79
Specification and technical data 79
Specification drawing 81
Specifications 82
Weight table 84
Fuel, coolant and lubricants 85
Suspension cylinder oil and nitrogen specifications 86
Wheel motor oil specifications 86
10 Structure and functions 89
Steering circuit 89
Steering circuit operation 91
Steering circuit components 96
Steering control unit 96
High pressure filter 96
Steering accumulators 96
Bleeddown manifold 97
Steering accumulator bleeddown solenoid 97
Quick disconnect ports 97
Flow amplifier 97
Steering/brake pump operation 98
High altitude operation 98
Neutral position 99
Full pump volume 100
Half pump volume 101
Flow amplifier operation 102
No steer 102
Steering left 104
Steering right 106
No steer, external shock load 108
Hoist circuit 111
Hoist circuit operation 113
Hoist circuit components 114
Hydraulic tank 114
Hoist pump 114
High pressure filters 114
Hoist valve 115
Inlet sections 115
Tank ports (front) spool section 115
Work ports (rear) spool section 116
Hoist pilot valve 116
Hoist limit solenoid 117
Pilot operated check valve 117
Overcenter manifold 117
Hoist pilot valve operation 118
Float position with body down 118
Power up operation 120
Hold operation 122
Power down operation 124
Float operation 126
Brake circuits 129
General information 131
Service brake circuit operation 132
Secondary braking 135
Automatic brake application (Auto apply) 135
Parking brake circuit operation 136
Normal operation (key switch ON, engine on) 136
Wheel brake lock circuit operation 137
Brake warning circuit operation 137
Electrical system, 24 volt 141
Battery supply system 143
Batteries 143
24VDC auxiliary battery receptacles 143
Isolation box 144
Ground level shutdown switch 144
Battery disconnect switches 144
Propel lockout lever 144
System busy light 144
LED lights 144
Engine starting system with prelube 145
Prelube operation 145
Cranking operation 146
Auxiliary control cabinet components 147
24VDC to 12VDC converter 147
Interface module (IM) 147
VEC blocks 148
Light timers 148
Relays 148
Ground terminals 148
24VDC power terminals 148
Body-up switch 149
Hoist limit switch 150
Heating/air conditioning (HVAC) system 153
Basic air conditioning system operation 155
HVAC components 157
Control panel 157
Water valve 157
Expansion valve 157
Actuators 157
Blower 157
Heater core 157
Evaporator core 157
Cab air temperature sensor 157
ECU module 157
Air filters 159
Compressor (refrigerant pump) 159
Compressor clutch 159
Trinary™ switch 160
Receiver-drier 160
Condenser 160
Accumulator 160
Automatic lubrication (auto lube) system 163
General information 165
System operation 166
Engine emissions aftertreatment system 169
About emissions aftertreatment 173
DEF injection system 173
DEF heating system 173
Sensors 173
Exhaust system cleaning 174
Propel lockout precaution 174
Inducement strategy 174
20 Standard value table 177
Standard value table 177
Standard value table for truck 179
30 Testing and adjusting 185
Steering, hoist, brake cooling and auxiliary hydraulic system 185
Hydraulic system bleeddown procedure 187
Hydraulic system vacuum procedure 189
General information on system checkout 189
Hydraulic system checkout procedures 190
Required equipment 190
Preliminary steps 190
Hydraulic system flushing procedure 191
Flow amplifier adjustment 194
Steering pump unloader valve adjustment 195
Auxiliary accumulator pressure verification 196
System diagnostics 196
Hoist counterbalance valve adjustment 198
Final steps 199
Oil cleanliness check 200
Hydraulic system checkout data sheet 201
High altitude steering pump adjustment 204
Toe-in adjustment 205
Measuring steering pin joint wear 206
Hoist cylinder leakage test 209
Steering cylinder leakage test 209
Brake system 211
General information on system checkout 213
Brake system checkout procedures 213
Required equipment 213
Initial system setup 216
Brake lock / secondary braking checkout 216
Parking brake checkout 217
Service brake checkout 218
Low brake accumulator pressure and auto apply checkout 219
Parking brake control logic checkout 221
Brake lock control logic checkout 222
Brake system checkout data sheet 225
Brake piston leakage test 234
Brake seal pressure test 234
Oil separator seal pressure test 234
Wet disc brake bleeding procedure 235
Parking brake bleeding procedure 236
Service brake disc wear inspection 237
Parking brake disc wear inspection 238
Brake valve bench test and adjustment 239
Test setup procedure 240
Brake valve output pressure adjustment 240
Final test and adjustment 241
Dual relay valve bench test and adjustment 242
Test setup procedure 243
Relay valve output pressure adjustment 243
Accumulators and suspensions 245
Accumulator charging and storage 247
Temperature during precharge 247
Bladder accumulator charging procedure 248
Precharge maintenance 250
Bladder accumulator storage procedure 250
Bladder storage 250
Installing a bladder accumulator from storage 251
Bladder accumulator leak testing 251
Piston accumulator charging procedure 252
Piston accumulator storage 255
Piston accumulator leak testing 256
Checking for improper suspension charge on operating trucks 257
Suspension oil change recommendations 258
Suspension oiling and charging procedures 259
Required equipment 259
Installing the charging kit 260
Removing the charging kit 260
Support blocks for oiling and charging dimensions 261
Front suspensions 264
TOP FILL METHOD 265
PRESSURE FILL METHOD 265
Rear suspensions 267
TOP FILL METHOD 269
PRESSURE FILL METHOD 269
Suspension pressure test 271
Electrical systems 273
General information on system checkout 275
Truck shutdown procedure 276
Required software and tools 276
Electrical system checkout procedures 278
Visual inspection 278
Resistance checks 278
Voltage checks 278
Truck function checks 279
Interface module (IM) checks 280
KOMTRAX Plus II checks 280
Payload meter (PLM) checks 280
Drive system checks 281
Engine delayed shutdown Smart Timer check 281
Body hoist limit switch check 281
Electrical checkout sheet 282
Interface module 2 (IM2) 287
Required tools 289
Programming the IM2 289
Updating the software 289
Configuring the IM2 290
Viewing IM2 real-time data 290
Interface module checkout procedures 291
Checking for IM fault codes 291
Checking digital inputs to the IM 291
Checking analog inputs to the IM 294
Checking serial communication to the IM 294
Checking outputs from the IM 295
IM checkout sheet 296
KOMTRAX Plus II 301
Required software and tools 303
Ethernet connection to KOMTRAX Plus II controller 303
KOMTRAX Plus II configuration 305
GPS connection test 307
Iridium satellite system opening 309
Data download over ethernet connection for KOMTRAX Plus II initialization 312
Payload meter IV 315
Payload meter IV software and tools 317
Payload meter IV system configuration 317
Connecting to the payload meter IV web server 317
Configuring a static IP address 317
Payload meter IV software installation 319
Inclinometer calibration and clean truck tare 320
Payload meter IV checkout procedure 320
PLM IV system checkout data sheet 326
Downloading PLM IV data and possible errors 327
Komatsu wireless bridge (KWB) 331
General information 333
Required software and tools 333
Configuring the Bullet wireless radio 334
Installing the Bullet wireless radio 337
Configuring the NanoStation access point 338
Testing the connection 341
Changing a service computer’s IP address 342
Cab air conditioning 345
General information 347
Service tools and equipment 348
Recovery/recycle station 348
Leak detector 348
Manifold gauge set 349
Service valves 350
Vacuum pump 350
Detecting leaks 351
System performance test 352
Checking system oil 353
System flushing 354
Installing the manifold gauge set 355
Purging air from the service hoses 356
Recovering and recycling refrigerant 357
Draining oil from previous recovery cycle 358
Recovery cycle 358
Recycling procedure 358
Evacuating the air conditioning system 359
Charging the air conditioning system 360
Automatic lubrication (auto lube) system 363
Priming the system 365
Checkout procedure 367
Adjusting the lubrication cycle timing 368
Trucks with Interface Module 1 368
Trucks with Interface Module 2 368
KomVision 371
Requirements 373
Initial setup 374
Checkout data sheet 383
Calibration sheets 388
Layout and assemblage 388
Unfolding a calibration sheet 391
Folding a calibration sheet 392
Placement of calibration sheets 393
Camera calibration procedures 395
Automatic 6 camera calibration 395
Manual 6 camera calibration 399
1 camera calibration 402
Radar setting procedure 405
Tire monitoring system 409
Tire monitoring system software and tools 411
Tire monitoring system configuration 411
Connecting to the tire monitoring system web server 411
Configuring a static IP address 411
Tire monitoring system software installation 413
Tire monitoring system checkout procedure 414
Field Troubleshooting 414
Ethernet troubleshooting 414
Tire monitoring system configuration 415
CAN RPC Troubleshooting 415
Resetting the tire monitoring system 415
Tire monitoring system checkout data sheet 416
40 Troubleshooting 419
Fuse, diode and relay locations 419
Vehicle Electrical Center (VEC-89) 421
Vehicle Electrical Center (VEC-90) 423
Vehicle Electrical Center (VEC-91) 425
Vehicle Electrical Center (VEC-92) 426
Rear Terminal Mini-fuse and Relay (RTMR3) 428
Rear Terminal Mini-fuse and Relay (RTMR4) 429
Circuit breakers 429
Troubleshooting by fault code, Part 1 431
Fault Code A001 434
Fault Code A002 435
Fault Code A003 436
Fault Code A004 437
Fault Code A005 438
Fault Code A006 439
Fault Code A007 440
Fault Code A008 441
Fault Code A009 442
Related circuit diagram 442
Fault Code A010 443
Related circuit diagram 443
Fault Code A011 444
Fault Code A013 445
Fault Code A014 446
Fault Code A016 447
Fault Code A017 448
Fault Code A018 449
Fault Code A019 450
Fault Code A022 451
Fault Code A100 452
Related circuit diagram 452
Fault Code A101 453
Fault Code A103 454
Fault Code A104 455
Fault Code A105 456
Fault Code A109 457
Fault Code A111 458
Fault Code A115 459
Fault Code A117 460
Fault Code A118 461
Fault Code A123 462
Fault Code A124 463
Fault Code A125 464
Fault Code A126 465
Fault Code A127 466
Fault Code A128 467
Fault Code A139 468
Troubleshooting by fault code, Part 2 471
Fault Code A145 474
Fault Code A146 475
Fault Code A152 476
Fault Code A153 477
Fault Code A154 478
Fault Code A155 479
Fault Code A158 480
Fault Code A166 481
Fault Code A167 482
Fault Code A168 483
Fault Code A169 484
Fault Code A170 485
Fault Code A171 486
Fault Code A172 487
Fault Code A173 488
Fault Code A184 489
Fault Code A190 490
Fault Code A193 491
Fault Code A194 492
Fault Code A195 493
Fault Code A196 494
Fault Code A197 495
Fault Code A198 496
Fault Code A199 497
Fault Code A200 498
Fault Code A201 499
Fault Code A202 500
Fault Code A203 501
Fault Code A204 502
Fault Code A205 503
Fault Code A206 504
Fault Code A207 505
Fault Code A213 506
Fault Code A214 507
Fault Code A215 508
Fault Code A216 509
Fault Code A223 510
Fault Code A230 511
Fault Code A231 512
Fault Code A233 513
Fault Code A235 514
Fault Code A236 515
Fault Code A237 516
Fault Code A238 517
Fault Code A239 519
Related circuit diagram 520
Fault Code A240 521
Fault Code A242 522
Fault Code A243 523
Fault Code A244 524
Fault Code A245 525
Fault Code A246 526
Troubleshooting by fault code, Part 3 529
Fault Code A247 532
Fault Code A248 533
Fault Code A249 534
Fault Code A250 535
Fault Code A251 536
Fault Code A252 537
Fault Code A253 538
Fault Code A256 539
Fault Code A257 540
Fault Code A258 541
Fault Code A260 542
Fault Code A261 543
Fault Code A262 544
Fault Code A264 545
Fault Code A265 546
Fault Code A266 547
Fault Code A267 548
Fault Code A268 549
Fault Code A270 550
Fault Code A271 551
Related circuit diagram 552
Fault Code A272 553
Fault Code A273 554
Fault Code A274 555
Fault Code A275 556
Fault Code A277 557
Fault Code A278 558
Fault Code A279 559
Fault Code A280 560
Fault Code A281 561
Fault Code A282 562
Fault Code A283 563
Fault Code A284 564
Fault Code A285 565
Fault Code A286 566
Fault Code A292 567
Troubleshooting by fault code, Part 4 569
Fault Code A303 572
Fault Code A304 573
Fault Code A305 574
Fault Code A307 575
Fault Code A309 576
Fault Code A310 577
Fault Code A311 578
Fault Code A312 579
Fault Code A313 580
Fault Code A315 581
Fault Code A316 582
Fault Code A317 583
Fault Code A318 584
Fault Code A328 585
Fault Code A332 586
Fault Code A333 587
Fault Code A334 588
Fault Code A335 589
Fault Code A337 590
Fault Code A338 591
Fault Code A339 592
Fault Code A340 593
Fault Code A341 594
Fault Code A342 595
Fault Code A343 596
Fault Code A344 597
Fault Code A345 598
Fault Code A346 599
Fault Code A347 600
Fault Code A348 601
Fault Code A349 602
Fault Code A350 603
Fault Code A351 604
Fault Code A352 605
Fault Code A353 606
Fault Code A354 607
Fault Code A355 608
Fault Code A356 609
Fault Code A357 610
Fault Code A358 611
Fault Code A359 612
Fault Code A360 613
Fault Code A361 614
Fault Code A362 615
Fault Code A363 616
Fault Code A364 617
Fault Code A365 618
Fault Code A366 619
Troubleshooting by fault code, Part 5 621
Fault Code A400 624
Fault Code A401 625
Fault Code A402 626
Fault Code A403 627
Fault Code A404 628
Fault Code A405 629
Fault Code A406 630
Fault Code A407 631
Fault Code A408 632
Fault Code A409 633
Fault Code A410 634
Fault Code A411 635
Fault Code A412 636
Fault Code A413 637
Fault Code A414 638
Fault Code A415 639
Fault Code A416 640
Fault Code A417 641
Fault Code A418 642
Fault Code A419 643
Fault Code A420 644
Fault Code A421 645
Fault Code A422 646
Fault Code A423 647
Fault Code A424 648
Fault Code A425 649
Fault Code A426 650
Fault Code A427 651
Fault Code A428 652
Fault Code A429 653
Fault Code A430 654
Fault Code A431 655
Fault Code A432 656
Fault Code A433 657
Fault Code A434 658
Fault Code A435 659
Fault Code A436 660
Fault Code A437 661
Fault Code A438 662
Fault Code A439 663
Fault Code A440 664
Fault Code A441 665
Fault Code A442 666
Fault Code A443 667
Fault Code A444 668
Fault Code A445 669
Fault Code A446 670
Fault Code A447 671
Aftertreatment system fault codes 673
Fault Code CA256 677
Fault Code CA1677 679
Fault Code CA1678 681
Fault Code CA1682 684
Fault Code CA1683 691
Fault Code CA1684 693
Fault Code CA1685 695
Fault Code CA1686 697
Fault Code CA1712 699
Fault Code CA1713 701
Fault Code CA1714 703
Fault Code CA1715 704
Fault Code CA1887 706
Fault Code CA2771 707
Fault Code CA3142 711
Fault Code CA3143 713
Fault Code CA3146 715
Fault Code CA3147 717
Fault Code CA3232 719
Fault Code CA3497 722
Fault Code CA3498 723
Fault Code CA3547 724
Fault Code CA3558 725
Fault Code CA3559 727
Fault Code CA3562 729
Fault Code CA3563 731
Fault Code CA3567 733
Fault Code CA3571 735
Fault Code CA3572 737
Fault Code CA3573 740
Fault Code CA3574 742
Fault Code CA3575 744
Fault Code CA3712 746
Fault Code CA3713 747
Fault Code CA3714 750
Fault Code CA3867 751
Fault Code CA3868 753
Fault Code CA3878 756
Fault Code CA3988 757
Fault Code CA3995 761
Fault Code CA4113 763
Fault Code CA4114 765
Fault Code CA4119 767
Fault Code CA4121 769
Fault Code CA4152 771
Fault Code CA4164 775
Fault Code CA4165 777
Fault Code CA4166 780
Fault Code CA4168 782
Fault Code CA4169 784
Fault Code CA4174 786
Fault Code CA4175 788
Fault Code CA4233 791
Fault Code CA4234 792
Fault Code CA4243 793
Fault Code CA4277 794
Fault Code CA4457 796
Fault Code CA4458 798
Fault Code CA4459 801
Fault Code CA4461 803
Fault Code CA4462 805
Fault Code CA4464 807
Fault Code CA4465 809
Fault Code CA4466 812
Fault Code CA4467 819
Fault Code CA4474 821
Fault Code CA4475 823
Fault Code CA4572 826
Fault Code CA4677 830
Fault Code CA4679 834
Fault Code CA4682 835
Fault Code CA4731 836
Fault Code CA4732 837
Fault Code CA4736 838
Fault Code CA4737 839
Fault Code CA4738 840
Fault Code CA4739 841
Fault Code CA4745 842
Fault Code CA4768 843
Fault Code CA4769 845
Fault Code CA4842 847
Fault Code CA4863 848
Fault Code CA4947 849
Fault Code CA5115 850
Fault Code CA5116 853
Fault Code CA5117 856
Fault Code CA5247 859
Fault Code CA5653 861
Fault Code CA5654 864
Fault Code CA5725 866
Fault Code CA5727 871
Fault Code CA5728 874
Fault Code CA5729 877
Fault Code CA5748 879
Fault Code CA5749 881
Fault Code CA5751 883
Fault Code CA5753 885
Fault Code CA5755 888
Fault Code CA5756 893
Fault Code CA5758 895
Fault Code CA5768 897
Fault Code CA5769 899
Fault Code CA5771 902
Fault Code CA5772 904
Fault Code CA5773 907
Fault Code CA5774 910
Fault Code CA5775 912
Fault Code CA5776 917
Fault Code CA5778 919
Fault Code CA5779 921
Fault Code CA5887 923
Fault Code CA5888 924
Fault Code CA5889 925
Fault Code CA5891 926
Fault Code CA5892 927
Fault Code CA5893 928
Fault Code CA6692 929
Fault Code CA6693 931
Fault Code CA6694 933
Fault Code CA6695 935
Fault Code CA6696 937
Fault Code CA6697 939
Fault Code CA6855 941
Fault Code CA6856 944
Steering system 947
Steering circuit troubleshooting chart 949
Steering circuit troubleshooting guidelines 951
Basic hydraulic system checks 952
System leakage check 953
Steering pump troubleshooting guide 955
Pump pressure control checks 958
To verify pump unload pressure 958
To verify pump reloading 958
Pump fails to unload 959
Pump fails to develop pressure 959
Pump slow in developing pressure 960
Pump control valve inspection and trouble shooting 961
Pump case drain check 963
Definitions: 964
Adjustment 964
KomVision 967
KomVision fault codes 969
Automatic lubrication (auto lube) system 979
Autolube troubleshooting chart 981
Heating/air conditioning (HVAC) system 985
Control panel configurations 987
Diagnostics mode 988
Error codes 988
Advanced diagnostics 988
Firmware version 989
Additional HVAC troubleshooting chart 989
Voltage levels 991
Electronic fan clutch 993
Electronic fan clutch troubleshooting 995
Electronic fan clutch fault codes 997
50 Disassembly and assembly 999
Service tools 999
Special tool group 1001
Heated body tool group 1001
Additional service tools 1002
KomVision calibration tools 1002
Locally made tools 1002
Wheels, spindles and rear axle 1005
General precautions for tires and rims 1007
Wheel stud maintenance 1008
Rear outer wheel stud installation 1009
Removal and installation of front wheel 1010
Removal 1010
Installation 1011
Removal and installation of rear wheel 1012
Removal 1012
Installation 1013
Rim components 1015
Smart rim component layout 1015
Rim and tire service 1016
Lubricants 1016
Tire inflation 1016
Lock ring retainer installation 1016
Removing the lock ring 1017
Installing the lock ring 1018
Removing the tire from the front rim (5-piece rim) 1019
Removing the tire from the rear outer dual rim (7-piece Smart rim) 1022
Removing the tire from the rear inner dual rim (5-piece rim) 1024
Preparation before assembly 1025
Installing the tire on the front rim (5-piece rim) 1026
Installing the tire on the rear inner dual rim (5-piece rim) 1028
Installing the tire on the rear outer dual rim (7-piece Smart rim) 1029
Removal and installation of front wheel hub and spindle 1030
Removal 1030
Spindle removal (off the truck) 1034
Installation 1036
Disassembly and assembly of front wheel hub and spindle 1037
Cross Section View 1037
Disassembly 1038
Cleaning and inspection 1044
Wheel bearing adjustment 1046
Seal assembly gap adjustment 1047
Seal installation 1048
Brake installation 1051
Wheel hub and brake assembly installation 1052
Speed sensor installation and adjustment 1054
Floating seal assembly and installation 1056
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 1056
Removal and installation of rear axle 1067
Removal 1067
Cleaning and inspection 1068
Installation 1069
Removal and installation of anti-sway bar 1070
Removal 1070
Installation 1072
Removal and installation of pivot pin 1073
Removal 1073
Installation 1074
Pivot eye and bearing service 1075
Bearing inspection 1075
Bearing replacement 1077
Pivot eye repair 1078
Removal of wheel motor 1079
Preparation 1079
Installation of wheel motor 1082
Cleaning and inspection 1082
Installation 1083
Removal and installation of rear brake assembly 1086
Wheel motor flushing procedure 1086
Flushing procedure 1088
Brake system 1091
Removal and installation of brake valve 1093
Removal 1093
Installation 1094
Disassembly and assembly of brake valve/pedal assembly 1095
Disassembly 1095
Assembly 1096
Removal and installation of dual relay valve 1098
Removal 1098
Installation 1100
Removal and installation of brake manifold 1101
Removal 1101
Installation 1101
Disassembly and assembly of brake manifold 1102
Disassembly 1102
Assembly 1102
Removal and installation of piston brake accumulator 1103
Removal 1103
Installation 1105
Disassembly and assembly of piston brake accumulator 1107
Disassembly 1107
Cleaning and inspection 1109
Piston seal replacement 1109
Assembly 1110
Disassembly and assembly of front wheel brake 1111
Disassembly 1111
Cleaning and inspection 1114
Assembly 1115
Disassembly and assembly of rear wheel brake 1117
Disassembly 1117
Cleaning and inspection 1120
Assembly 1121
Brake floating ring seal assembly and installation 1125
Removal and installation of parking brake 1132
Removal 1132
Installation 1134
Disassembly and assembly of parking brake 1134
Disassembly 1134
Cleaning and inspection 1136
Cleaning and inspecting new discs 1138
Assembly 1139
Steering system 1141
Removal and installation of steering control unit 1143
Removal 1143
Installation 1145
Disassembly and assembly of steering control unit 1146
Disassembly 1146
Assembly 1148
Removal and installation of steering column 1151
Removal 1151
Installation 1152
Removal and installation of steering wheel 1153
Removal 1153
Installation 1153
Removal and installation of bleeddown manifold 1154
Removal 1154
Installation 1155
Removal and installation of flow amplifier 1156
Removal 1156
Installation 1156
Removal and installation of steering cylinders and tie rod 1157
Removal 1157
Installation 1157
Disassembly and assembly of steering cylinders 1159
Disassembly 1159
Cleaning and inspection 1161
Assembly 1161
Removal and installation of steering/brake pump 1162
Removal 1162
Installation 1164
Removal and installation of piston steering accumulator 1165
Removal 1165
Installation 1167
Disassembly and assembly of piston steering accumulator 1170
Disassembly 1170
Cleaning and inspection 1172
Piston seal replacement 1172
Assembly 1173
Suspensions 1175
Removal and installation of front suspension 1177
Preparation 1177
Removal 1177
Cleaning and Inspection 1179
Installation 1180
Disassembly and assembly of front suspension 1186
Disassembly 1186
Cleaning and inspection 1189
Assembly 1189
Removal and installation of rear suspension 1191
Removal 1191
Installation 1194
Disassembly and assembly of rear suspension 1197
Disassembly 1197
Cleaning and inspection 1199
Assembly 1200
Hoist circuit 1203
Removal and installation of hoist pump 1205
Removal 1205
Installation 1209
Disassembly and assembly of hoist pump 1210
Disassembly 1210
Inspection 1215
Assembly 1216
Removal and installation of hoist valve 1219
Removal 1219
Installation 1221
Disassembly and assembly of hoist valve 1221
O-ring replacement 1221
Disassembly of inlet section 1223
Assembly of inlet section 1224
Disassembly of rear spool section 1225
Assembly of rear spool section 1227
Disassembly of front spool section 1228
Assembly of front spool section 1229
Overcenter manifold service 1229
Removal and installation of hoist pilot valve 1230
Removal 1230
Installation 1230
Disassembly and assembly of hoist pilot valve 1233
Disassembly 1233
Cleaning and inspection 1234
Assembly 1234
Removal and installation of hoist cylinders 1235
Removal 1235
Installation 1238
Disassembly and assembly of hoist cylinders 1241
Disassembly 1241
Cleaning and inspection 1245
Installation of the quill 1246
Assembly 1248
Body and structures 1253
Removal and installation of dump body 1255
Removal 1255
Inspection 1256
Installation 1257
Removal and installation of body pads 1258
Removal 1258
Installation 1258
Body pad shimming procedure 1259
Removal and installation of diagonal ladder/ hood and grille assembly 1260
Removal 1260
Installation 1260
Removal and installation of RH deck 1262
Removal 1262
Installation 1262
Removal and installation of LH deck 1264
Removal 1264
Installation 1264
Removal and installation of fuel tank (with DEF tank) 1266
Removal 1266
Cleaning and inspection 1266
Installation 1268
Removal and installation of fuel gauge sender 1268
Removal 1268
Installation 1268
Removal and installation of hydraulic tank 1269
Removal 1269
Installation 1270
Removal and installation of hydraulic tank strainers 1271
Removal 1271
Cleaning and inspection 1272
Installation 1272
Operator cab 1275
Removal and installation of operator cab 1277
Removal 1277
Installation 1280
Removal and installation of cab door 1280
Removal 1280
Installation 1281
Disassembly and assembly of cab door 1282
Removing the window regulator 1282
Installing the window regulator 1283
Removing the door glass 1284
Installing the door glass 1285
Replacing the inner door seal 1286
Replacing the outer door seal 1286
Removing the interior door handle and door latch (earlier models) 1287
Installation and removal of interior door handle and door latch (later models) 1290
Adjustment of cab door 1292
Door jamb bolt adjustment 1292
Exterior door handle release button adjustment 1294
Removal and installation of side window glass 1295
Recommended tools and supplies 1295
Removal 1295
Installation 1296
Removal and installation of windshield and rear window glass 1297
Removal 1297
Installation 1297
Removal and installation of windshield wiper components 1298
Removing the windshield wiper motor 1298
Installing the windshield wiper motor 1298
Removing the windshield wiper arm and linkage 1299
Installing the windshield wiper arm and linkage 1300
Removal and installation of cab seats 1300
Removal 1300
Servicing the seat 1301
Installation 1301
Removal and installation of seat belts 1302
Removal 1302
Installation 1303
Power module 1305
Removal and installation of power module 1307
General 1307
Removal 1308
Installation 1317
Exhaust tube installation 1327
Exhaust blanket installation 1327
Removal and installation of alternator 1328
Removal 1328
Installation 1331
Removal and installation of radiator 1342
Removal 1342
Installation 1347
Repairing the radiator 1348
Internal inspection 1348
External cleaning 1348
Disassembly 1348
Cleaning and inspection 1349
Assembly 1350
Pressure testing 1351
Removal and installation of engine 1351
Removal 1351
Service 1351
Installation 1352
Removal and installation of electronic fan clutch 1353
Removal 1353
Installation 1354
Removal and installation of electronic fan clutch speed sensor 1354
Removal 1354
Installation 1354
90 Diagrams and drawings 1357
Hydraulic circuit diagrams 1357
Steering, hoist and brake cooling hydraulic circuit schematic – 58B-60-21400 1359
Brake hydraulic circuit schematic – 58F-60-00841 1360
Auxiliary system hydraulic circuit schematic – 58E-60-01680 1361
Electrical circuit diagrams 1364
Electrical circuit diagram – 58B-06-02396 1366
HVAC circuit diagram – 58B-06-06830 1388

DESCRIPTION:

Komatsu 980E-5 Dump Truck Shop Manual CEBM037302 – PDF DOWNLOAD 

SERIAL NUMBERS 980E-5 A50150 – A50161

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.

S.V 28/12/24