Komatsu Dump Truck 980E-4 service & repair manual

Description Komatsu Dump Truck 980E-4 service & repair manual

Komatsu Dump Truck 980E-4 pdf workshop service manual + operation & maintenance manual

Serial numbers:
A40003 - A40051
A40052 and up

Specifications, testing, adjusting, troubleshooting, technical documentation, electrical wiring diagrams, hydraulic schematics, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and foreword
Index
Foreword, safety and general information

Specification
Specification and technical data
Specification drawing
Weight table
Fuel, coolant and lubricants

Structure and functions
Steering circuit
Hoist circuit
Brake circuits
Electrical system, 24 volt
Electrical system, AC drive
Cab air conditioning
Reserve engine oil system

Standard value table
Standard value table for truck

Testing and adjusting
Steering, hoist, brake cooling and auxiliary hydraulic system
Brake system
Accumulators and suspensions
Interface module (IM)
Interface module 2 (IM2)
Payload meter IV
KOMTRAX Plus II
Komatsu wireless bridge (KWB)
Electrical system, AC drive
Cab air conditioning

Troubleshooting
Fuse, diode and relay locations
AC drive system fault codes (DSC)
Troubleshooting by fault code
Orbcomm
Cab air conditioning
Steering system
Automatic lubrication (auto lube) system

Disassembly and assembly
Service tools
Special tool group
Heated body tool group
Additional service tools
KomVision calibration tools
Locally made tools
Wheels, spindles and rear axle
General precautions for tires and rims
Wheel stud maintenance
Rear outer wheel stud installation
Removal and installation of front wheel
Removal and installation of rear wheel
Rim components
Rim and tire service
Removal and installation of front wheel hub and spindle
Disassembly and assembly of front wheel hub and spindle
Floating seal assembly and installation
Removal and installation of rear axle
Removal and installation of anti-sway bar
Removal and installation of pivot pin
Pivot eye and bearing service
Removal of wheel motor
Installation of wheel motor
Removal and installation of rear brake assembly
Wheel motor flushing procedure
Brake system
Removal and installation of brake valve
Disassembly and assembly of brake valve/pedal assembly
Removal and installation of dual relay valve
Removal and installation of brake manifold
Disassembly and assembly of brake manifold
Removal and installation of piston brake accumulator
Disassembly and assembly of piston brake accumulator
Disassembly and assembly of front wheel brake
Disassembly and assembly of rear wheel brake
Brake floating ring seal assembly and installation
Brake disc wear measurement and rebuild criteria
Removal and installation of parking brake
Disassembly and assembly of parking brake
Steering system
Removal and installation of steering control unit
Disassembly and assembly of steering control unit
Removal and installation of steering column
Removal and installation of steering wheel
Removal and installation of bleeddown manifold
Removal and installation of flow amplifier
Removal and installation of steering cylinders and tie rod
Disassembly and assembly of steering cylinders
Removal and installation of steering/brake pump
Removal and installation of piston steering accumulator
Disassembly and assembly of piston steering accumulator
Suspensions
General information
Removal and installation of front suspension
Disassembly and assembly of front suspension
Removal and installation of rear suspension
Disassembly and assembly of rear suspension
Hoist circuit
Removal and installation of hoist pump
Disassembly and assembly of hoist pump
Removal and installation of hoist valve
Disassembly and assembly of hoist valve
Overcenter manifold service
Removal and installation of hoist pilot valve
Disassembly and assembly of hoist pilot valve
Removal and installation of hoist cylinders
Disassembly and assembly of hoist cylinders
Body and structures
Removal and installation of dump body
Removal and installation of body pads
Removal and installation of diagonal ladder/ hood and grille assembly
Removal and installation of RH deck
Removal and installation of LH deck
Installing and adjusting egress gates
Removal and installation of fuel tank
Removal and installation of fuel gauge sender
Removal and installation of hydraulic tank
Removal and installation of hydraulic tank strainers
Operator cab
Removal and installation of operator cab
Removal and installation of cab door
Disassembly and assembly of cab door
Adjustment of cab door
Removal and installation of side window glass
Removal and installation of windshield and rear window glass
Removal and installation of windshield wiper motor
Removal and installation of windshield wiper arm
Removal and installation of windshield wiper linkage
Removal and installation of optional seats
Removal and installation of seat belts (optional seats)
Removal and installation of electronic accelerator and retard pedals
Cab air conditioning
Replacement of air conditioning system components
Power module
Removal and installation of power module
Exhaust tube installation
Exhaust blanket installation
Removal and installation of alternator
Removal and installation of radiator
Repairing the radiator
Removal and installation of engine

Diagrams and drawings
Hydraulic circuit diagrams
Electrical circuit diagrams