Liebherr Haul Truck T264 service & repair manual

Description Liebherr Haul Truck T264 service & repair manual

Liebherr Haul Truck T264 pdf service repair manual + operator & maintenance manual

Technical documentation, specifications, troubleshooting, maintenance, electrical diagrams, hydraulic schematics, disassembly / assembly / removal / installation instructions and other information

Serial numbers covered:
533-06561-06562
533-06567-06569, 533-06578-06579
533-06580-06582, 4280
533-06583
533-9306, 2899, 3435, 9596
53300022-00026
53300102, 53300106, 53300108-00110
53300112-00118,53300120-00122
5330123
53300047
5330128-5330133
53300103-00105, 5330107-53300111

MANUAL CONTENT:
Introduction
Technical Data
Cab Exterior Sound Power Level
Technical Data Sheets
Haul Truck Payload Policy
Service Manual Organization
Audience
Task Analysis
Manual Organization
Chapters
Procedures
Required Tools and Materials
Illustrations
Serviceable Parts
Safe Work Procedures (SWP)

Safety
Safety Critical Systems
Safety Critical Systems Definition

Useful Information
Component Weights and Dimensions
Assembled Chassis as Shipped with Power Module
Superstructure Assembly
Front Wheel Assembly
Lower Control Arm
Upper Control Arm
Front Suspension
Rear Suspension
Rim
Tire and Rim
Traction Motor
Planetary Gear Box
Planetary Gear Box Assembly
Fuel Tank Assembly
Fuel and Hydraulic Tank Assembly
Hoist Cylinder
Power Module Assembly
Traction Alternator
Air Cleaner
Cab with Air Conditioning
Additional Component Weights
Empty Vehicle Weight
Useful Information
Information Tables
Unit of Measure Conversions
Torque Chart for Unified Standard Threaded
Torque Chart for Metric Threaded Fasteners
Consumable Material
Oil Sampling Materials
Hydraulic Filter Materials
Control Box Materials
Brake Burnish Materials
Grid Blower Motor Materials
Welding Guidelines
Welding Precautions
Jacking Points Guidance
Jacking Label Location and Identification
Towing or Recovery of a Disabled Haul Truck
Towing if Engine is Inoperable
Rating for Optional Towing and Recovery
Engine Start and Stop Procedures
Engine Pre-Start Procedure
Engine Start Procedur
Engine Shutdown

Service Tools

Maintenance
Maintenance Plan
Preventive Maintenance Program
Oil and Lubricant Specifications
Preventive Maintenance Daily Inspections and Checks
Miscellaneous Checks
Dump Body Checks
Ladders, Guards, Hydraulic Tank Sight
Gauge and Radiator Checks
Control Box Inspection and Checks
Upper Deck and Platform Checks
Cab Component Checks
Daily Inspections Checklist
Preventive Maintenance Reference
Structure
500-Hour Preventive Maintenance References
Battery Maintenance
Oil Analysis - Sampling and Threshold Guidance
Control Cabinet Coolant Sample
Sample Pump Method
Drain Valve, Test Port, or Plug Method
Bottle Labeling Guidelines
Air Cleaner Filter Replacement Procedure
Inspection Guideline for Air Intake System
Guideline for Axle Box Inspection
Exterior Inspection of the Axle Box
Interior Inspection of the Axle Box
Final Drive Oil Leakage Inspection
Drag Links, Hoist Cylinders, and Rear Control Arm Wear Limit Check
Wear Measurement Check
Inspection of Critical Fasteners
Critical Fastener Locations
Inspection Procedure
Repair Guidance for Critical Locations
Critical Fastener Location
Hydraulic Hoses Inspection
Pump Drive Service Procedure
Accumulator Pre-charge Check, Drain, and Pre-Charge Procedures
Accumulator Pre-charge Check Procedure
Accumulator Drain Procedure
Accumulator Pre-Charge Procedure
Suspension Monitoring and Maintenance
Required Documents for Suspension
Assessment and Setup
Assessment Procedure
Visual Inspection
Suspension Charge
Perform Suspension Setup Procedure
Replace suspension
Suspension Assessment Flowchart
Suspension Log Example
Front Suspension Assessment Charts
Suspension Assessment Charts
Rear Suspension Assessment Charts
Suspension Assessment Charts
Service Brake Lining Check
Cyclone Filter Replacement
Check Fastener Hardware
Check the Coolant Reservoir
Check the Electrical Connections
Check the Cable Joints
Check the Seals
1000-Hour Preventive Maintenance References
Brake and Steering Filter Element Replacement
Procedure
Filter Replacement Procedure
Closeout
Hoist System Filter Replacement Procedure
Filter Replacement Procedure
Greasing the Traction Alternator Bearing
Grid Motor Inspection Guidelines
1500-Hour Preventive Maintenance References
Exhaust Bellows and Blankets Inspection
Greasing the Main Blower Bearings
Gear Oil Cooling System Filters Replacement Procedure
Rear Brake Disc Check
Inspection Procedure
Front Brake Disc Check
Inspection Procedure
Park Brake Pad and Disc Check
Inspection Procedure
2000-Hour Preventive Maintenance References
Greasing the Grid Blower Motor
2500-Hour Preventive Maintenance References
Frame and Axle Box Inspection Guideline
Inspection Procedure
Frame Inspection Locations
Axle Box Inspection Locations
Inspection Checklist
Frame Inspection Checklist
Axle Box Inspection Checklist
Idler Arm Wear Limit Check
Drag Links, Hoist Cylinders, and Rear Control Arm Wear Limit Check
Wear Measurement Check
Steering Assembly Wear Limit Check
Wear Measurement Check
Front Control Arm Wear Check
Axial Clearance Check
Radial Wear Check
Secondary Filter Replacement
3000-Hour Preventive Maintenance References
Lower Kingpin Bushing Wear Check Procedure
Additional Information
Prerequisites
Toe-In Check
Greasing the Traction Motor Bearings
10000-Hour Preventive Maintenance References
Lower Kingpin Fasteners Replacement
General Guidance for Replacing the Lower
Kingpin Bolts
Fastener Replacement Procedure
15000-Hour Preventive Maintenance References
Coolant Drain and Replace Procedure
Conditional-Hours Preventive Maintenance References
Front and Rear Control Arm and Drag Link Inspection Guideline

Power Module (Drive System)
Power Module
System Description and Function
Power Module Assembly Removal
Engine
Power Module Assembly Installation
Traction Alternator to Engine Coupling Instructions
Exhaust System
System Description and Function
Exhaust System Removal
Exhaust System Installation
Engine Air Cleaner
Engine Air Cleaner Ducts Removal
Engine Air Cleaner Ducts Installation
Traction Alternator
Traction Alternator Removal
Traction Alternator Installation
Air Cleaner Restriction Check
Fuel and Hydraulic Tank
Fuel Tank Drain
Fuel Tank Repair
Fuel Level Sensor
Engine Fuel Filter

Cooling Systems
Radiator
System Description and Function
Cleaning
Radiator Coolant Drain
Radiator Removal
Radiator Installation
Radiator Tube Replacement
Radiator Coolant Fill
AC Drive Cooling System
Main Blower Assembly
AC Drive Cooling System Motor Removal
AC Drive Cooling System Motor Installation
Alternator Cooling Duct
Alternator Cooling Duct Removal
Alternator Cooling Duct Installation
Axle Box Cooling Duct
Axle Box Cooling Duct Removal
Axle Box Cooling Duct Installation

Heat and Air Conditioning (HVAC) Systems
HVAC System Overview
Air Conditioning System Freon and Lubricating Oil
A/C Hydraulic Components
Hydraulic A/C Compressor Motor and Pump
Schematic
Variable Displacement Pump
Hydraulic A/C System Pump Pressure Setup
Variable Displacement Pump Removal
Variable Displacement Pump Installation
Hydraulic A/C Compressor and Motor
Assembly
Control Manifold
Refrigerant System
System Description and Function
A/C Condenser
Receiver-Dryer
Thermostatic Expansion Valve
Evaporator Coil and Blower Assembly
Hydraulic, Heat and A/C Hose Routing
Operator Cab Air Conditioning System
System Description and Function
Heater Water Valve
Air Conditioning System Control and Display Panel
Air Conditioning System Error Codes, System Diagnostics, and Programming
Heat and A/C Condenser
A/C Condenser
Heat and A/C Condenser Removal
Heat and A/C Condenser Installation
Operator Cab Air Conditioning System Service
System Description and Function
A/C Annual System Check
A/C Refrigeration Charge
A/C System Evacuation
A/C Hydraulic Compressor Oil Amount
A/C Troubleshooting
A/C Ambient to Cab Air Discharge Check
Variable Displacement Pump Troubleshooting
Excessive Noise and/or Vibration
Actuator Response is Slow
System Operating Hot
Low Pump Output Flow
Pressure or Flow not Stable
System Pressure Not Reaching PC Setting
High Inlet Vacuum
Air Conditioning System Troubleshooting
Resistance Chart
Air Conditioning System Electrical Diagrams

Litronic plus Drive System
AC Drive System
Fastener Torque Requirements
Litronic Plus DC Bus Voltage Discharge Procedure
Check that the Primary DC Bus has been discharged
Field Regulator
System Description and Function
Main Rectifier
System Description and Function
Main Rectifier Removal
Main Rectifier Installation
Direct Current (DC) to Direct Current Converter Box
System Description and Function
DC to DC Converter Box Schematic
DC to DC Converter Box Removal
DC to DC Converter Box Installation
Auxiliary Frequency Converter
System Description and Function
Frequency Converter Schematics
Operator Removal 508
Frequency Converter Installation
9.7 IGBT Inverters (Power Stacks)
System Description and Function
Inverter (Power Stack) Removal
Inverter (Power Stack) Installation
Inverter (Brake Chopper)
System Description and Function
Inverter (Brake Chopper) Removal
Inverter (Brake Chopper) Installation
DC Link Capacitor
System Description and Function
DC Link Capacitor Removal
DC Link Capacitors Installation
Traction Motors
Grid Box
System Description and Function
Grid Blower Control
Cooling Pump
System Description and Function
Main Programmable I/O Module
System Description and Function
Inverter Controller (Frequency Converter Controllers)
System Description and Function
Ground Fault Monitoring
System Description and Function
Independent Power Control
System Description and Function
Schematic

24V Electronic Systems
24 VDC Battery Bank
System Description and Function
Battery Disconnect Box
Mini Programmable I/O Module
CAN Temperature Module
Touch Screen Display Panel

Hydraulic Power and Distribution
Main Hydraulic Pumps Assembly
Hydraulic System Filters
Hydraulic Reservoir
Hydraulic Reservoir Fill Procedures
Hydraulic Reservoir Drain Procedure
Central Service Assembly

Hoist System
Hoist System Operator Cab Components
Hoist Manifold Assembly
Hoist Cylinders

Hydraulic Brake and Steering Systems
Brake and Steering Hydraulic System
Brake System Components
Brake Accumulators
Brake and Steering Manifold
Remote Valves
Brake and Steering Pressure Filter
Brake and Steering Accumulator Bleed
Steering System
Steering Accumulator
Flow Amplifier Valve
Steering Control Valve
Steering Cylinders
Pump Control Accumulator
Buddy Brake and Steering Components
Hydraulic Oil Cleanliness

Hydraulic Gear Oil Cooling Systems
Auto Lube System
Auto Lube Troubleshooting
Gear Oil Cooling System
Hydraulic Schematic
Gear Oil Cooling System Filters
Gear Oil Cooling System Manifold Valve
Gear Oil Coolers
Hydraulic Oil Cooling System
Gear Oil Cooling Axle Box Assembly
Gear Oil Cooling System Flow Control Valve

Suspensions
Front Suspensions
Rear Suspensions

Wheel Assemblies
Front Wheel Assembly
Tire and Rim Assembly
Tire Stud Inspection and Replacement
Front Wheel Oil Drain and Fill Procedure
Front Brake System
Front and Rear Brake Burnish Procedure
Front Brake Bleed
Front Brake Calipers
Front Brake Disc
Kingpins and Spindle
Toe-In Check
Toe-In Adjustment
Idler Arm Assembly
Steering Arm
Steering Stop Pads
Upper and Lower Front Control Arms
Rear Wheel Drive Assembly
Rear Wheel Drive Oil Drain and Fill Procedure
Rear Tire and Rim Assembly
Rear Brake System
Rear Brake Bleed
Park Brake Calipers
Rear Brake Disc
Mechanical Release of the Park Brake

Chassis, Dump Body and Structures
Chassis
Chassis Mudguards Removal
Dump Body
Dump Body Lift or Lower for Service (Hydraulically)
Dump Body Pivot Pins
Dump Body Pads
Dump Body Proximity Switch
Dump Body Lighting Installation
Rock Knocker
Superstructure
Control Box
Grid Box
Battery Boxes
Axle Box
Axle Box Electrical Connections
Drag Links
Rear Control A-Arm
Ladders and Handrails
Liebherr Hydraulic Stair Assembly
Steps and Engine Access Ladder Assemblies
Driver Side Exterior Mirror
Fire Suppression System

Operator Cab

Computers and Auxiliary Systems

Safe Work Procedures

AND OTHER INFORMATION