Liebherr Haul Truck T284 service & repair manual

Description Liebherr Haul Truck T284 service & repair manual

Liebherr Haul Truck T284 pdf workshop service & repair manual + operator manual + maintenance manual

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

Serial numbers covered:
532-06529
532-9087
537-2085
53700013
53700011-00012,00014-00017
537-1906, 53700005-00010,00018-00020
53700022-00023
53700021,00024-00034
53700035-00040
53700041-00044
53700045-00050
53700056-00057
53700058-00059

SERVICE 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
Service Tools Operations

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
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
A/C Condenser Removal
A/C Condenser Installation
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
Batteries Removal
Batteries Installation
Battery Disconnect Box
Battery Disconnect Box
VDC Battery Isolator Switch
Starter Isolator Switch
Battery Jump Start Receptacle
Propel Inhibit Switch
Touch Screen Display Panel
Mini Programmable I/O Module
System Description and Function
CAN Temperature Module
System Function and Description

Hydraulic Power and Distribution
Drive Shaft Assembly
Drive Shaft
System Description and Function
Drive Shaft Removal
Drive Shaft Installation
Pump Drive Unit
System Description and Function
Pump Drive Unit Removal
Pump Drive Unit Installation
Hydraulic Tank
Hoist System Section of the Hydraulic Tank
Brake and Steering Section of the Hydraulic
Tank
Fuel and Hydraulic Tank
Fuel and Hydraulic Tank Removal
Fuel and Hydraulic Tank Installation
Central Service Assembly

Hoist System
System Description and Function
Hoist System Schematic
Hoist System Lockout Procedure
Proportional Valves Manifold
Hoist Pumps
Specifications
Hoist Pumps Removal
Hoist Pumps Installation
Hoist Valve
System Description and Function
Hoist Valve Removal
Hoist Valve Installation
Hoist Cylinders
System Description and Function
Hoist Cylinder Removal
Hoist Cylinder Installation
Pilot Control Valve and Float Valve Assembly
System Description and Function
Pilot Control Valve and Float Valve Removal
Pilot Control Valve and Float Valve
Installation
Dump Body Control Lever
System Description and Function
Dump Control Lever Adjustment (Factory-Set)
Dump Body Override Switch
Hoist System Pressure Filters
System Description and Function
Hoist System Pressure Filters Removal
Hoist System Pressure Filters Installation

Hydraulic Brake and Steering Systems
Brake and Steering Hydraulic System
Brake and Steering Hydraulic Schematic
Brake and Steering Pump
System Description and Function
Pump Control
At Rest (No Rotation of Prime Mover)
Start-up (Prime Mover Running)
Pump Unloading
Loading
Brake and Steering Pump Removal
Brake and Steering Pump Installation
Brake and Steering Pump Pressure Setup
Brake and Steering Pressure Filter
System Description and Function
Brake and Steering Pressure Filter Removal
Brake and Steering Pressure Filter
Brake and Steering Manifold
System Description and Function
Brake and Steering Manifold Removal
Brake and Steering Manifold Installation
Brake System
System Description and Function
Service and Park Brake Pressure Test
Front and Rear Handbrake Reducing Valve
Brake Accumulators
System Description and Function
Front Brake Accumulators Removal
Front Brake Accumulator Installation
Rear Brake Accumulator Removal
Rear Brake Accumulator Installation
Brake Accumulator Pre-Charge Pressure
Brake and Steering Accumulator Bleed
Brake Accumulator Bleed Procedure
Steering System
Steering Accumulator
System Description and Function
Steering Accumulator Removal
Steering Accumulator Installation
Steering Accumulator Pre-Charge Pressure
Steering System Verification
Flow Amplifier Valve
Flow Amplifier Valve Removal
Flow Amplifier Valve Installation
Steering Control Valve

System Description and Function
Steering Control Valve Assembly Removal
Steering Control Valve Assembly Installation
Steering Cylinders
Steering Cylinders Removal
Steering Cylinders Installation
Buddy Brake and Steering Components
System Description and Function
Towing with a Disabled Steering System
Brake and Steering Pumps Unloader Valve Accumulator
System Description and Function
Brake and Steering Pumps Unloader Valve
Accumulator Removal
Brake and Steering Pump Unloader Valve
Accumulator Installation
Brake and Steering Pump Unloader Valve
Accumulator Pressure Check
Hydraulic Oil Cleanliness
Removing Contamination from Tank
Drain and Replace Brake Steering Tank
Hydraulic Oil
Use Truck to Filter Brake and Steering
Hydraulic Oil
Use External Filter Cart to Filter Brake and
Steering Hydraulic Oil
For Tank Filtration Only
For Tank and Brake and Steering Manifold
Filtration
Removing Contamination from Steering
Circuit
Removing Contamination from Brake Circuit

Hydraulic Auxiliary Systems
Auto Lube System
System Description and Function
Auto Lube Components
Auto Lube Troubleshooting
Pump does not operate
Pump runs too much
Pump speeds up or operates irregularly
Pump runs, but output is low
Lubricant leaking from safety unloader valve
Lubricant leaking from weep hole in vent
Divider Valve Troubleshooting
Gear Oil Cooling System
System Description and Function
Gear Oil Cooling System Filters
Gear Oil Cooling System Manifold Valves
Gear Oil System Coolers
Gear Oil Cooling Pump with Hydraulic Motor
Gear Oil System Coolers Removal
Gear Oil System Coolers Installation
Gear Oil Cooling Pump Removal
Hydraulic Gear Oil Cooling System Schematic
Hoist Oil Cooling System
System Description and Function

Suspension
Front Suspensions
System Description and Function
Front Suspension Removal
Front Suspension Installation
Front Suspension Setup
Oil Level Check
Gas Charge Check
Adding Oil to a Front Suspension
Front Suspension Discharge
Rear Suspensions
System Description and Function
Rear Suspension Removal
Rear Suspension Installation
Rear Suspension Setup
Rear Suspension Oil Fill and Pressure
Testing Procedure

Wheel Assemblies
Front Wheel Assembly
Steering Arm
Front Brakes
Front Brake Bleed
Front Brake Calipers
Front Brake Disc
Front and Rear Brake Burnish Procedure
Kingpins and Spindle
Front Tire and Rim Assembly
Front Wheel Oil Drain and Fill Procedures
Idler Arm Assembly
Tie Rods
Toe-In Check
Toe-In Adjustment
Steering Encoder
Steering Stop Pads
Upper and Lower Front Control Arms
Rear Gear Assembly
Tightening Procedure Axle Box/Planetary Gear Set
Connection Using 1.5" Fasteners
Rear Tire and Rim Assembly
Rear Wheel Oil Level Check, Drain, and Fill
Rear Brake Assembly
Rear Brake Bleed
Traction Motor and Coupling Removal
Park Brake
Mechanical Release of the Park Brake

Chassis, Dump Body and Structures
Chassis
Belly Pans
Dump Body
Dump Body Lift or Lower for Service (Hydraulically)
Dump Body Lift or Lower for Service (Manually)
Dump Body Pivot Pins
Dump Body Pads
Rock Knocker
Superstructure
Hood and Grill
Diagonal Ladder and Handrails
Litronic plus Control Box
Grid Box
Battery Boxes
Axle Box
Drag Links
Rear Control A-Arm (Rear Control Arm Axle Box)
Liebherr Hydraulic Driver-Side (DS) Stair Assembly

Operator Cab
Operator Cab Glass Replacement
Windshield Wiper Assembly
Foot Pedal Controls
Accelerator Pedal
Service Brake Pedal
Dynamic Brake Pedal
Steering Column and Controls
Operator Cab Seat Removal
Dash Panel and Components

Computers and Auxiliary Systems

Safe Work Procedures