Komatsu 980E-5 Shop Manual CEBM039202

Data Size: 58.08 MB 
File Type: PDF 
Language: English 
Manufacturer: Komatsu 
Applicable Machine: Dump Truck 
Document: Shop Manual, Error Code, Electrical Schematic, Hydraulic Schematic 
Machine Model: Komatsu 980E-5 Dump Truck 
Serial Number: A50162 and up 
Book Number: CEBM039202 
Page: 1094 Pages

List Contents:

00 CONTENTS AND FOREWORD 
Foreword 
How to Read the Shop Manual 
Safety Alert Symbol and Signal Words 
General Precautions Common to Operation and Maintenance 
Preparations for Safe Operation 
Fire and Explosion Prevention 
Precautions When Getting On or Off the Machine 
Precautions for Cab and Working Around Machine 
Precautions for Diesel Exhaust Fluid (DEF) 
Operation Precautions 
Precautions at Jobsite 
Precautions in Starting Engine 
Precautions During Operation 
Maintenance Precautions 
Precautions Before Inspection and Maintenance 
Precautions During Inspection and Maintenance 
Precautions for Electrical Equipment 
Primary Causes of Wiring Harness Failure 
Control Cabinet Capacitor Discharge 
Hydraulic Equipment Precautions 
01 SPECIFICATIONS 
Specifications 
Specifications: 980E-5 
Major component weights 
Recommended Fuel, Coolant, and Lubricant 
Suspension Cylinder Oil and Nitrogen Specifications 
Wheel Motor Oil Specifications 
10 STRUCTURE AND FUNCTION 
Steering System 
Steering System Layout 
Steering System Operation 
Steering Bleeddown Manifold 
Steering Control Unit 
Steering Accumulators (Piston Type) 
Steering/Brake Pump Operation 
Flow Amplifier Operation 
Hoist System 
Hoist System Layout 
Hoist System Operation 
Hoist Control Valve 
Hoist Pilot Valve 
Brake System 
Service Brake System Layout 
Hydraulic Brake Cabinet Layout 
Service Brake Operation 
Parking Brake Operation 
Brake Lock Operation 
Secondary Braking and Auto Apply 
Electrical System, 24V 
Battery Power Supply 
Battery Disconnect Switches 
Engine Starting System 
Auxiliary Control Cabinet Components 
Body-Up Switch 
Hoist Limit Switch 
Automatic Lubrication (Auto Lube) System 
Automatic Lubrication (Auto Lube) Grease Pump and Reservoir 
Automatic Lubrication (Auto Lube) System Operation 
Suspensions 
Engine Emissions After-Treatment System Operations 
20 STANDARD VALUE TABLE 
Standard Value Table 
30 TEST AND ADJUST 
Hydraulic Systems 
Hydraulic System Checkout Procedures 
Hydraulic System Checkout Sheet 
Steering System Leakage Check 
Toe-In Adjustment 
Hoist Cylinder Leakage Test 
Steering Cylinder Leakage Test 
Checking the Steering/Brake Pump Control Pressures 
Adjusting the Steering/Brake Pump Control Pressures 
High Altitude Steering/Brake Pump Adjustment 
Brake System 
Brake System Checkout Procedures 
Brake System Checkout Sheet: 980E-5 
Brake System Leakage Check 
Brake Piston Leakage Test 
Parking Brake Piston Leakage Test 
Brake Floating Seal Pressure Test 
Oil Separation Seal Pressure Test (Air Pressure Method) 
Oil Separation Seal Pressure Test (Oil Pressure Method) 
Wet Disc Brake Bleeding Procedure 
Parking Brake Bleeding Procedure 
Wet Disc Brake Wear Inspection 
Parking Brake Wear Inspection 
Accumulators and Suspensions 
Bladder Accumulator Charging Procedure 
Bladder Accumulator Leakage Test 
Bladder Accumulator Storage 
Piston Accumulator Charging Procedure 
Piston Accumulator Leakage Test 
Piston Accumulator Storage 
Check for Improper Suspension Charge 
Suspension Oiling and Charging Procedures 
Oiling and Charging Tools and Support Blocks 
Nitrogen Charging Kit Installation 
Nitrogen Charging Kit Removal 
Front Suspension Oiling and Charging 
Rear Suspension Oiling and Charging 
Suspension Pressure Test 
Automatic Lubrication (Auto Lube) System 
Prime the Auto Lube Pump 
Prime the Auto Lube Grease Lines 
Auto Lube System Checkout 
Adjust the Auto Lube Cycle Timing 
Cab Air Conditioning 
Refrigerant Leak Detection 
A/C System Performance Test 
Check the A/C System Oil 
A/C System Flushing Procedure 
Manifold Gauge Set Installation 
Refrigerant: Recycled vs Reclaimed 
Refrigerant Recovery Procedure 
Evacuate the A/C System 
Charge the A/C System 
Electrical Systems 
Shutdown Procedure for Drive System Service 
Electrical System Checkout Procedures 
Visual Checks 
Resistance Checks 
Voltage Checks 
Truck Function Checks 
Interface Module (IM) Checks 
KOMTRAX Plus II Checks 
Payload Meter (PLM) Checks 
Drive System Checks 
Engine Delayed Shutdown Smart Timer Check 
Hoist Limit Switch Check 
Electrical System Checkout Sheet 
Interface Module 2 (IM2) 
Interface Module 2 Software and Tools 
Program the IM2 Controller 
Interface Module 2 Checkout Procedures 
Check for IM Fault Codes 
Checking Digital Inputs to the IM2 
Checking Analog Inputs to the IM2 
Checking Serial Communication to the IM 
Checking Outputs from the IM2 
Interface Module 2 Checkout Sheet 
Payload Meter IV 
Payload Meter IV Software and Tools 
Payload Meter IV System Configuration 
Configuring a Static IP Address 
Payload Meter IV Software Installation 
Payload Meter IV Data Downloading 
Payload Meter IV Checkout Procedure 
Payload Meter IV Checkout Sheet 
KOMTRAX Plus II 
KOMTRAX Plus II Software and Tools 
Komtrax Plus II Controller Ethernet Connection 
KOMTRAX Plus II Configuration 
GPS Connection Test 
Satellite Connection Test 
Komtrax Plus II System Initialization 
KomVision 
KomVision Setup and Calibration Requirements 
KomVision Initial Setup and Checkout Procedure 
KomVision Checkout Sheet 
KomVision Calibration Sheets 
Calibration Sheet Layout 
Unfold and Fold Calibration Sheet 
Calibration Sheet Placement 
KomVision Camera Calibration Procedures 
Automatic 6 Camera Calibration 
Manual 6 Camera Calibration 
1 Camera Calibration 
KomVision Radar Setting Procedure 
Komatsu Wireless Bridge (KWB) 
Komatsu Wireless Bridge Software and Tools 
Bullet Wireless Radio Configuration 
Bullet Wireless Radio Installation 
NanoStation Access Point Configuration 
NanoStation Access Point Connection Test 
Tire Monitoring System 
Tire Monitoring System Software and Tools 
Tire Monitoring System Software Installation 
Tire Monitoring System Configuration 
Connecting to the Tire Monitoring System Web Server 
Configuring a Static IP Address 
Tire Monitoring System Reset 
Tire Monitoring System Checkout Procedure 
Tire Monitoring System Checkout Sheet 
40 TROUBLESHOOTING 
Fuses, Diodes and Relays 
Standard Truck Fault Codes 
A001 
A002 
A003 
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A441 
A442 
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A444 
A445 
A446 
A447 
Aftertreatment System Fault Codes 
CA256 
CA1677 
CA1678 
CA1682 
CA1683 
CA1684 
CA1685 
CA1686 
CA1712 
CA1713 
CA1714 
CA1715 
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CA4863 
CA5115 
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CA5768 
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CA5892 
CA5893 
CA6692 
CA6693 
CA6694 
CA6695 
CA6696 
CA6697 
CA6855 
CA6856 
KomVision Fault Codes 
Troubleshoot the Steering System 
Steering System Troubleshooting Guide 
Basic Hydraulic System Checks 
Steering/Brake Pump Troubleshooting Guide 
Steering/Brake Pump Troubleshooting Checks 
Steering/Brake Pump Fails to Unload 
Steering/Brake Pump Fails to Develop Pressure 
Steering/Brake Pump Slow to Develop Pressure 
Steering/Brake Pump Control Valve Inspection 
Steering/Brake Pump Case Drain Check 
Troubleshoot the Auto Lube System 
Troubleshoot the HVAC System 
Control Panel Configurations 
Diagnostics Mode 
Error Codes 
Advanced Diagnostics 
Firmware Version 
Additional HVAC Troubleshooting Chart 
Voltage Levels 
50 DISASSEMBLY AND ASSEMBLY 
Special Tools List 
Wheels, Spindles and Rear Axle 
General Precautions for Tires and Rims 
Lubricants for Tire and Rim Service 
Tire Inflation 
Rim Components 
Wheel Stud Maintenance 
Rear Outer Wheel Stud Installation 
Front Wheel Removal 
Front Wheel Installation 
Rear Wheel Removal 
Rear Wheel Installation 
Lock Ring Removal 
Lock Ring Installation 
Tire Removal (Front 5-Piece Rim) 
Tire Removal (Rear Outer 7-Piece Rim) 
Tire Removal (Rear Inner 5-Piece Rim) 
Tire and Rim Preparation 
Tire Installation (Front 5-Piece Rim) 
Tire Installation (Rear Inner 5-Piece Rim) 
Tire Installation (Rear Outer 7-Piece Rim) 
Front Wheel Hub and Spindle Removal 
Spindle Removal While Off the Truck 
Front Wheel Hub and Spindle Installation 
Spindle, Hub and Brake Assembly Cross-Section View 
Front Wheel Hub and Spindle Disassembly 
Front Wheel Hub and Spindle Cleaning and Inspection 
Front Wheel Hub and Spindle Assembly 
Hub Floating Seal Installation 
Rear Axle Removal 
Rear Axle Cleaning and Inspection 
Rear Axle Installation 
Anti-Sway Bar Removal 
Anti-Sway Bar Installation 
Pivot Pin Removal 
Pivot Pin Installation 
Pivot Eye Bearing Wear Inspection 
Pivot Eye Bearing Replacement 
Pivot Eye Removal 
Pivot Eye Installation 
Wheel Motor Removal 
Wheel Motor Cleaning and Inspection 
Wheel Motor Installation 
Steering System 
Steering Control Unit Removal 
Steering Control Unit Installation 
Steering Control Unit Disassembly 
Steering Control Unit Assembly 
Steering Column Removal 
Steering Column Installation 
Steering Wheel Removal 
Steering Wheel Installation 
Bleeddown Manifold Removal 
Bleeddown Manifold Installation 
Flow Amplifier Removal 
Flow Amplifier Installation 
Steering Pin Joint Wear Inspection 
Tie Rod Removal 
Tie Rod Installation 
Steering Cylinder Removal 
Steering Cylinder Installation 
Steering Cylinder Disassembly 
Steering Cylinder Cleaning and Inspection 
Steering Cylinder Assembly 
Steering/Brake Pump Removal 
Steering/Brake Pump Installation 
Piston Steering Accumulator Removal 
Piston Steering Accumulator Installation 
Piston Steering Accumulator Disassembly 
Piston Accumulator Cleaning and Inspection 
Piston Seal Replacement 
Piston Steering Accumulator Assembly 
Brake System 
Brake Valve Removal 
Brake Valve Installation 
Brake Valve/Pedal Disassembly 
Brake Valve/Pedal Assembly 
Front Brake Dual Relay Valve Removal 
Front Brake Dual Relay Valve Installation 
Rear Brake Dual Relay Valve Removal 
Rear Brake Dual Relay Valve Installation 
Brake Manifold Removal 
Brake Manifold Installation 
Brake Manifold Component Replacement 
Piston Brake Accumulator Removal 
Piston Brake Accumulator Installation 
Piston Brake Accumulator Disassembly 
Piston Accumulator Cleaning and Inspection 
Piston Seal Replacement 
Piston Brake Accumulator Assembly 
Front Wheel Brake Disassembly 
Wheel Brake Cleaning and Inspection 
Front Wheel Brake Assembly 
Rear Wheel Brake Removal 
Rear Wheel Brake Installation 
Rear Wheel Brake Disassembly 
Wheel Brake Cleaning and Inspection 
Rear Wheel Brake Assembly 
Brake Floating Seal Installation 
Parking Brake Removal 
Parking Brake Installation 
Parking Brake Disassembly 
Parking Brake Cleaning and Inspection 
New Parking Brake Disc Cleaning and Inspection 
Parking Brake Assembly 
Hoist System 
Hoist Pump Removal 
Hoist Pump Installation 
Hoist Pump Disassembly 
Hoist Pump Inspection 
Hoist Pump Assembly 
Hoist Valve Removal 
Hoist Valve Installation 
Hoist Valve Service 
Hoist Valve O-Ring Replacement 
Inlet Section Disassembly 
Inlet Section Assembly 
Rear Spool Section Disassembly 
Rear Spool Section Assembly 
Front Spool Section Disassembly 
Front Spool Section Assembly 
Overcenter Manifold Service 
Hoist Pilot Valve Removal 
Hoist Pilot Valve Installation 
Hoist Pilot Valve Disassembly 
Hoist Pilot Valve Cleaning and Inspection 
Hoist Pilot Valve Assembly 
Hoist Cylinder Removal 
Hoist Cylinder Installation 
Hoist Cylinder Disassembly 
Hoist Cylinder Cleaning and Inspection 
Quill Installation 
Quill Check Ball and Plug Installation 
Hoist Cylinder Assembly 
Suspensions 
Front Suspension Removal 
Front Suspension Cleaning and Inspection 
Front Suspension Installation 
Front Suspension Bolted Joint Inspection 
Front Suspension Charging Valve Replacement 
Front Suspension Disassembly 
Front Suspension Assembly 
Rear Suspension Removal 
Rear Suspension Installation 
Rear Suspension Charging Valve Replacement 
Rear Suspension Disassembly 
Rear Suspension Cleaning and Inspection 
Rear Suspension Assembly 
Dump Body and Structures 
Dump Body Removal 
Dump Body Inspection 
Dump Body Installation 
Body Pads Removal 
Body Pads Installation 
Body Pad Shimming Procedure 
Diagonal Ladder Removal 
Diagonal Ladder Installation 
Egress Gate Adjustment 
RH Deck Removal 
RH Deck Installation 
LH Deck Removal 
LH Deck Installation 
Fuel Tank Removal 
Fuel Tank Cleaning and Inspection 
Fuel Tank Installation 
Fuel Gauge Sender Removal 
Fuel Gauge Sender Installation 
Hydraulic Tank Removal 
Hydraulic Tank Installation 
Hoist Valve Service 
Hoist Valve O-Ring Replacement 
Inlet Section Disassembly 
Inlet Section Assembly 
Rear Spool Section Disassembly 
Rear Spool Section Assembly 
Front Spool Section Disassembly 
Front Spool Section Assembly 
Overcenter Manifold Service 
Hoist Pilot Valve Removal 
Hoist Pilot Valve Installation 
Hoist Pilot Valve Disassembly 
Hoist Pilot Valve Cleaning and Inspection 
Hoist Pilot Valve Assembly 
Hoist Cylinder Removal 
Hoist Cylinder Installation 
Hoist Cylinder Disassembly 
Hoist Cylinder Cleaning and Inspection 
Quill Installation 
Quill Check Ball and Plug Installation 
Hoist Cylinder Assembly 
Suspensions 
Front Suspension Removal 
Front Suspension Cleaning and Inspection 
Front Suspension Installation 
Front Suspension Bolted Joint Inspection 
Front Suspension Charging Valve Replacement 
Front Suspension Disassembly 
Front Suspension Assembly 
Rear Suspension Removal 
Rear Suspension Installation 
Rear Suspension Charging Valve Replacement 
Rear Suspension Disassembly 
Rear Suspension Cleaning and Inspection 
Rear Suspension Assembly 
Dump Body and Structures 
Dump Body Removal 
Dump Body Inspection 
Dump Body Installation 
Body Pads Removal 
Body Pads Installation 
Body Pad Shimming Procedure 
Diagonal Ladder Removal 
Diagonal Ladder Installation 
Egress Gate Adjustment 
RH Deck Removal 
RH Deck Installation 
LH Deck Removal 
LH Deck Installation 
Fuel Tank Removal 
Fuel Tank Cleaning and Inspection 
Fuel Tank Installation 
Fuel Gauge Sender Removal 
Fuel Gauge Sender Installation 
Hydraulic Tank Removal 
Hydraulic Tank Installation 
Radiator External Cleaning 
Radiator Disassembly 
Radiator Cleaning and Inspection 
Radiator Assembly 
Engine Removal 
Engine Service 
Engine Installation 
60 MAINTENANCE STANDARD 
Rules for Maintenance 
Torque Specifications 
Hydraulic System Bleeddown Procedure 
Hydraulic System Vacuum Procedure 
Hydraulic Pumps 
Steering/Brake Pump 
Hoist Pump 
Wet Disc Brakes 
Service Brake 
Parking Brake 
Tie Rod 
Tail Lights, Clearance Lights and Turn Signals 
90 CIRCUIT DIAGRAMS 
CONTENTS: 980E-5 
Index