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Komatsu 980E-4 Shop Manual
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Komatsu 980E-4 Shop Manual

Dump truck
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Shop
Manual
DUMP TRUCK
SERIAL NUMBERS
ENGINE
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
October 2017
-4
980E-4 A40052
18V170
and up
Copyright 2017 Komatsu
Printed in U.S.A.
Komatsu America Corp.
CEBM031601

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Summary of Contents for Komatsu 980E-4

  • Page 1 18V170 ENGINE This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously.
  • Page 2 Find manuals at https://best-manuals.com...

  • Page 3: Machine Model

    CEN00033-01 DUMP TRUCK 1SHOP MANUAL 980E Machine model Serial number 980E-4 A40052 and up 00 Index and foreword Index Composition of shop manual ..........................2 Table of contents..............................4 Find manuals at https://best-manuals.com...
  • Page 4 Steering, brake cooling and hoist hydraulic system CEN30071-01 Brake system CEN30072-02 CEN30073-02  Accumulators and suspensions Interface module (IM) CEN30075-00 KOMTRAX Plus CEN30069-00 Payload meter IV CEN30070-01 Komatsu Wireless Bridge (KWB) CEN30074-00 CEN30053-02  Electrical system, AC Drive Cab air conditioning CEN30029-01 Find manuals at https://best-manuals.com...
  • Page 5 00 Index and foreword CEN00033-01 40 Troubleshooting Fuse, diode and relay locations CEN40161-01 AC drive system fault codes CEN40114-01 CEN40163-03  Troubleshooting by failure code, Part 1 CEN40164-01  Troubleshooting by failure code, Part 2 CEN40165-01  Troubleshooting by failure code, Part 3 CEN40166-01 ...
  • Page 6 CEN00033-01 00 Index and foreword Table of contents 00 Index and foreword Index CEN00033-01 Composition of shop manual ....................2 Table of contents ........................4 Foreword, safety and general information CEN00002-09 Foreword ...........................4 How to read the shop manual ....................5 General safety ...........................7 Precautions before operating the truck ...................10 Precautions while operating the truck ..................12 Working near batteries ......................15...
  • Page 7 00 Index and foreword CEN00033-01 Parking brake circuit operation....................7 Wheel brake lock circuit operation .................... 8 Brake warning circuit operation....................8 Brake assembly wear data ...................... 10 Electrical system, 24V CEN10070-00 Battery supply system ....................... 3 Engine starting system with prelube ..................5 Auxiliary control cabinet components..................
  • Page 8 Payload meter IV system configuration..................2 Payload meter IV software installation ..................4 Payload meter IV checkout procedure ..................5 PLM IV system checkout data sheet ..................9 Komatsu wireless bridge (KWB) CEN30074-00 General information........................2 Software download and setup ....................3 Configuring a KWB_Connect device ..................7 Configuring a TRUCK_NET device ..................10...
  • Page 9 00 Index and foreword CEN00033-01 KWB_Connect checkout data sheet ..................19 TRUCK_NET checkout data sheet ..................20 Electrical system, AC drive CEN30053-02 General information........................2 Checks prior to self load engine test (loadbox) ............... 20 Engine running tests ....................... 22 Diagnostic information display (DID) panel ................
  • Page 10 CEN00033-01 00 Index and foreword Fault Code A019: Left rear flat suspension cylinder warning ..........18 Fault Code A022: Carryback load excessive ................20 Fault Code A101: High pressure detected across an hydraulic pump filter ......22 Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level ..24 Fault Code A107: GE has generated a propel system caution ..........25 Fault Code A108: GE has generated a propel system temperature caution......26 Fault Code A109: GE has generated a propel system reduced level signal ......27...
  • Page 11 00 Index and foreword CEN00033-01 Fault Code A202: Hoist pressure 1 sensor is low ..............32 Fault Code A203: Hoist pressure 2 sensor is low ..............33 Fault Code A204: Steering pressure sensor is low ..............34 Fault Code A205: Brake pressure sensor is low ..............35 Fault Code A206: Ambient temperature sensor is high ............
  • Page 12 CEN00033-01 00 Index and foreword Fault Code A264: Parking brake relay circuit is defective ............8 Fault Code A265: Service brake failure...................10 Fault Code A266: Shift lever was not in park while attempting to crank engine......12 Fault Code A267: Parking brake was not set while attempting to crank engine .....14 Fault Code A268: Secondary engine shutdown while cranking ..........16 Fault Code A270: Brake lock switch power supply is not on when required ......17 Fault Code A271: Shift lever not in gear .................19...
  • Page 13 00 Index and foreword CEN00033-01 Fault Code A322: Data link reports GE propel system reduced level fault but wired input does not ........................ 24 Fault Code A323: Data link reports GE reduced retard level fault but wired input does not ..........................25 Fault Code A324: Data link reports DC link voltage but wired input does not......
  • Page 14 CEN00033-01 00 Index and foreword 50 Disassembly and assembly Service tools CEN50046-01 Special tool group........................3 Additional service tools......................3 Locally made tools........................4 Wheels, spindles and rear axle CEN50047-01 General precautions for tires and rims ..................3 Rim components ........................4 Wheel stud maintenance......................5 Removal and installation of front wheel..................6 Removal and installation of rear wheel ..................8 Rim and tire service.........................
  • Page 15 00 Index and foreword CEN00033-01 Suspensions CEN50049-00 Removal and installation of front suspension................3 Disassembly and assembly of front suspension ..............11 Removal and installation of rear suspension ................16 Disassembly and assembly of rear suspension ..............20 Hoist circuit CEN50051-01 Removal and installation of hoist pump ..................
  • Page 16 CEN00033-01 00 Index and foreword 90 Diagrams and drawings Hydraulic circuit diagrams CEN90014-00 Steering, hoist and brake cooling hydraulic circuit diagram ......... 58B-60-21400 Brake hydraulic circuit diagram ................58B-33-00030 Auxiliary system hydraulic circuit schematic ............58E-60-01680 Electrical circuit diagrams CEN90018-00 Electrical circuit diagram ..................
  • Page 17 00 Index and foreword CEN00033-01 NOTES...
  • Page 18 CEN00033-01 00 Index and foreword 980E Dump truck Form No. CEN00033-01...
  • Page 19 Serial number 730E-8 A40003 and up 960E-1 A30003 - A30026 960E-2 A30027 and up 980E-4 A40003 and up 980E-4AT A40083 and up 00 Index and foreword Foreword, safety and general information Foreword................................4 How to read the shop manual ..........................5 General safety...............................
  • Page 20 CEN00002-09 00 Index and foreword This material is proprietary to Komatsu America Corp (KAC), and is not to be reproduced, used, or disclosed except in accordance with written autho- rization from KAC. It is the policy of the Company to improve products whenever it is possible and practical to do so.
  • Page 21 Komatsu is also aware of repair companies that will rework or modify an OEM part for reuse in critical systems. Komatsu does not generally authorize such repairs or modifications for the same reasons as noted above.
  • Page 22 Vehicle Weight) rating. and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance The KOMATSU truck model designation consists of personnel should read understand three numbers and one letter (i.e.
  • Page 23 90. Diagrams and drawings This section gives hydraulic circuit diagrams and electrical circuit diagrams. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up- to-date information before you start any work.
  • Page 24 CEN00002-09 00 Index and foreword Symbols This “ALERT” symbol is used with the signal words, “DANGER”, “WARNING”, and “CAUTION” in this manual to alert the reader to hazards arising from improper operating and maintenance practices. “DANGER” identifies a specific potential hazard WHICH WILL RESULT IN EITHER INJURY OR DEATH if proper precautions are not taken.

  • Page 25: General Safety

    00 Index and foreword CEN00002-09 General safety Fire extinguisher and first aid kit Safety records from most organizations will show that • Make sure that fire extinguishers are accessible and proper usage techniques are known. the greatest percentage of accidents are caused by unsafe acts performed by people.
  • Page 26 CEN00002-09 00 Index and foreword Fire prevention for fuel and oil Leaving the operator seat When preparing to leave the operator's seat, do not • Fuel, oil, and antifreeze can be ignited by a flame. Fuel is extremely flammable and can be touch any control lever that is not locked.
  • Page 27 If before removing the cap. it is modified or repaired without authorization from Komatsu, or if it is damaged when the truck rolls over, the strength of the structure will be compromised and will not be able to fulfill its Asbestos dust hazard prevention intended purpose.
  • Page 28 In addition, know the proper use and care of all the safety equipment on the truck. Only • Do not use attachments that are not authorized by Komatsu America Corp. or the authorized qualified operators or technicians should attempt to regional Komatsu distributor. Use of unauthorized operate or maintain a Komatsu machine.
  • Page 29 00 Index and foreword CEN00002-09 Fire prevention Mirrors, windows and lights • Remove wood chips, leaves, paper, and other • Remove any dirt from the surface of the flammable items that have accumulated in the windshield, cab windows, mirrors and lights. engine compartment.
  • Page 30 CEN00002-09 00 Index and foreword Precautions while operating the truck When starting the engine • Never attempt to start the engine by shorting across cranking motor terminals. This may cause The tire and rim assembly may explode if a fire, or serious injury or death to anyone in subjected to excessive heat.
  • Page 31 00 Index and foreword CEN00002-09 Traveling on slopes Traveling • When traveling on rough ground, travel at low • Traveling on slopes could result in the truck tipping over or slipping. speeds. When changing direction, avoid turning suddenly. • Do not change direction on slopes. To ensure •...
  • Page 32 CEN00002-09 00 Index and foreword Driving near high voltage cables Working on loose ground Driving near high voltage cables can cause electric • Avoid operating the truck near cliffs, overhangs and deep ditches. If these areas collapse, the shock. Always maintain safe distances between the truck could fall or tip over and result in serious truck and the high voltage cable as listed below.
  • Page 33 00 Index and foreword CEN00002-09 • Batteries generate hydrogen gas. Hydrogen gas Working near batteries is very explosive and can easily be ignited with a Battery hazard prevention small spark or flame. • Before working with batteries, stop the engine •...
  • Page 34 CEN00002-09 00 Index and foreword • If any tool touches between the positive (+) Starting with jumper cables terminal and the chassis, it will cause sparks. • Always wear safety glasses or goggles when Always use caution when using tools near the starting the machine with jumper cables.
  • Page 35 Attach additional warning tags around the truck as necessary. These tags are available from your Komatsu distributor. Warning tag part number: 09963-A1640 Use of Tie-Off Anchor During Maintenance and...
  • Page 36 The Komatsu body-up safety sling can only be used with a Komatsu body. Non-OEM body may not accommodate the Komatsu body-up safety sling. The end user must ensure that a proper cable/sling is used.
  • Page 37 00 Index and foreword CEN00002-09 Jack point locations Proper jack point locations must be used. The jacks at locations (3, Figure 00-2) must be located on the When a truck is being stored for any period of time or frame rails. being secured for maintenance work, portable jack stands or permanent jack stands may be used.
  • Page 38 CEN00002-09 00 Index and foreword Precautions while performing service Working under the truck NOTE: Only authorized personnel should service and • Always lower all movable work equipment to the ground or to their lowest position before repair the truck. performing service or repairs under the truck. Keep the truck clean •...
  • Page 39 00 Index and foreword CEN00002-09 Radiator coolant level Handling high pressure hoses If it is necessary to add coolant to the radiator, stop • Do not bend high pressure hoses or hit them with hard objects. Do not use any bent or cracked the engine and allow the engine and radiator to cool piping, tubes or hoses.
  • Page 40 CEN00002-09 00 Index and foreword Tires Inspection The truck tires must be inspected and tire pressure must be checked with an accurate pressure gauge When inflating and deflating tires, always use a before each work shift and during tire rotations. Tire safety cage.
  • Page 41 00 Index and foreword CEN00002-09 Storage Tires must be stored indoors, if possible, in a cool, dry, dark, draft-free location. If stored outdoors, cover tires with a tarpaulin to keep out dirt, water and other foreign materials. Erect a fence around the tires and DO NOT weld or apply heat on the rim assembly put up “No Entry”...
  • Page 42 CEN00002-09 00 Index and foreword Handling Ensure that the tire handling equipment is capa- ble of lifting and maneuvering the load. Due to the size and weight of the tire and rim assem- blies, special handling equipment, such as a modified fork lift called a “tire handler”, as shown in Figure 00- 6, is desirable.
  • Page 43 AC drive system. • Many components on the Komatsu truck are large and heavy. Ensure that lifting equipment 1. Before shutting down the engine, verify the (hoists, slings, chains, and lifting eyes) are of status of all the drive system warning lights.
  • Page 44 The metal panels on the back of the cabinet are NOTE: Before welding or repairing an AC drive truck, part of capacitors and cannot be heated. notify a Komatsu service representative. Only • Do not weld on the retarding grid exhaust qualified personnel, specifically trained for servicing louvers! They are made of stainless steel.
  • Page 45 00 Index and foreword CEN00002-09 Capacitor discharge system The control cabinets are equipped with two capacitor charge lights, one on the exterior of the cabinet and one in the interior. The capacitor charge lights, when off, indicate to service personnel that the drive sys- tem is safe to work on.
  • Page 46 CEN00002-09 00 Index and foreword Warnings and cautions All applicable local mine, government, and industry rules for working with high voltage must be followed. Required personal protective equipment, including but not limited to safety shoes, high voltage gloves, Hazardous voltages are present in this equip- and safety glasses must be worn.
  • Page 47 00 Index and foreword CEN00002-09 Manual DC link capacitor discharge procedure Follow any and all local and site specific procedures and requirements for working on off-highway mining equipment. 1. Verify that the engine is off and the parking brake is on. 2.
  • Page 48 CEN00002-09 00 Index and foreword 4. Observe both capacitor charge lights (CCL1, CCL2). CCL1 is on the outside of the contactor box. CCL2 is on the switch panel inside the low voltage area. The lights will stay illuminated as long as the voltage on the DC link is greater than 50 VDC.
  • Page 49 00 Index and foreword CEN00002-09 Failure of the discharge system 1. Open the high voltage area doors. 2. Use a suitable high voltage meter (rated for at If the capacitor charge lights remain illuminated, a least 2000 VDC) and suitable protective equip- failure of the normal (fast) capacitor discharge sys- ment that are included in 2000VDC meter kit tem (RP discharge path) has likely occurred.
  • Page 50 CEN00002-09 00 Index and foreword Manual discharge of capacitors If the voltage is greater than 1V on any of the capaci- tors, the capacitor must be manually discharged. Use a suitable capacitor discharge device, such as the Hazardous voltages are present in this equip- grounding sticks included in 2000VDC meter kit ment.
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A40052