Liebherr T264 Haul Truck Service Manual (12252446)

Format: PDF (Printable Document)

File Language: English

File Pages: 1420

File Size: 127.76 MB (Speed Download Link)

Brand: Liebherr

Model: T264 Haul Truck

Book No: 12252446

Serial No: 5330106-5330111

Type of Document: Service Manual

Category: PDF

$ 55

Liebherr T264 Haul Truck Service Manual (12252446)

Liebherr T264 Haul Truck Service Manual (12252446) (5330106-5330111)

📘 Show Index

Liebherr T264 Haul Truck Index:

Service Manual
- 01 – Introduction
  - T 264 Haul Truck Overview
  - T 264 Haul Truck Dimensions
  - Technical Data
    - Vibration Emissions
    - Technical Data Sheets
  - Haul Truck Payload Policy
  - Service Manual Organization
- 02 – Safety
  - Safety
    - Health and Safety Information
      - Voltage
      - Electrical Safety
    - Revision History
  - Safety Critical Systems
    - Revision History
- 03 – Useful Information
  - Component Weights and Dimensions
  - Useful Information
  - Torque Charts
  - Consumable Material
  - Welding Guidelines
    - Revision History
  - Jacking Points Guidance
  - Towing or Recovery of a Disabled Haul Truck
    - Rating for Towing and Recovery
    - Revision History
  - Engine Start and Stop Procedures
    - Engine Shutdown
    - Revision History
- 04 – Service Tools
  - Service Tools
  - Service Tools Operation
- 05 – Maintenance
  - Maintenance Plan
  - Oil and Lubricant Specifications
    - Revision History
  - Preventive Maintenance Daily Inspections and Checks
    - Daily Inspections Checklist
  - Preventive Maintenance Reference
    - Structure
    - Revision History
  - 500-Hour Preventive Maintenance References
  - Battery Maintenance
  - Oil Analysis — Sampling and Threshold Guidance
    - Revision History
  - Air Cleaner Filter Replacement Procedure
  - Inspection Guideline for Air Intake System
  - Hydraulic Circulation Loop Filter Replacement Procedure
    - Revision History
  - Inspection of Critical Fasteners
    - Critical Fastener Location
    - Revision History
  - Guideline for Axle Box Inspection
    - Revision History
  - Hoist Retainer Bolt Inspection
    - Revision History
  - Drag Links, Hoist Cylinders, and Rear Control Arm Wear Limit Check
    - Revision History
  - Hydraulic Hoses Inspection
  - Accumulator(s) Pre-Charge Check and Charge Procedures
    - Revision History
  - Suspension Monitoring and Maintenance
    - Suspension Assessment Charts
    - Suspension Assessment Flowchart
    - Suspension Log Example
  - Service Brake Lining Check
    - Revision History
  - Cyclone Filter Replacement
    - Revision History
  - Check Fastener Hardware
    - Revision History
  - Check the Coolant Reservoir
    - Revision History
  - Check the Electrical Connections
    - Revision History
  - Check the Cable Joints
    - Revision History
  - Check the Seals
    - Revision History
  - 1000-Hour Preventive Maintenance References
    - Revision History
  - Hydraulic System Filter Replacement Procedure
    - Revision History
  - Grid Motor Inspection Guidelines
    - Revision History
  - 1500-Hour Preventive Maintenance References
  - Exhaust Bellows and Blankets Inspection
  - Greasing the Main Blower Bearings
    - Revision History
  - Gear Oil Cooling System Filters Replacement Procedure
  - Rear Brake Disc Check
    - Revision History
  - Front Brake Disc Check
    - Revision History
  - Park Brake Pad and Disc Check
    - Revision History
  - 2000-Hour Preventive Maintenance References
  - Greasing the Grid Blower Motor
    - Revision History
  - 2500-Hour Preventive Maintenance References
  - Idler Arm Wear Limit Check
    - Revision History
  - Drag Links, Hoist Cylinders, and Rear Control Arm Wear Limit Check
    - Revision History
  - Steering Assembly Wear Limit Check
    - Wear Measurement Check
    - Revision History
  - Front Control Arm Wear Check
    - Revision History
  - Secondary Filter Replacement
    - Revision History
  - Chassis Inspection Guideline
    - Revision History
  - Chassis Inspection Checklist
    - Revision History
  - 3000-Hour Preventive Maintenance References
  - Lower Kingpin Bushing Wear Check Procedure
    - Revision History
  - Greasing the Traction Alternator Bearing
    - Revision History
  - Greasing the Traction Motor Bearings
    - Revision History
  - 15000-Hour Preventive Maintenance References
  - Coolant Drain and Replace Procedure
    - Revision History
  - Conditional-Hours Preventive Maintenance References
  - Front and Rear Control Arm and Drag Link Inspection Guideline
    - Revision History
- 06 – Power Module (Drive System)
  - Power Module
    - Power Module Assembly Removal
    - Power Module Assembly Installation
  - Engine
    - Engine Removal
    - Engine Installation
    - Engine Speed Sensor Setting
    - Revision History
  - Exhaust System
    - 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
  - Traction Alternator to Engine Coupling Instructions
    - Revision History
  - Fuel Reservoir
    - Fuel Reservoir Removal
    - Fuel Reservoir Installation
    - Fuel Level Sensor
      - Fuel Level Sensor Replacement
      - How to Replace the Breather
      - Fuel Reservoir Drain
  - Engine Fuel Filter
    - Fuel Filter Element Replacement
    - Fuel Filter Element Installation
- 07 – Cooling Systems
  - Radiator
    - Radiator Coolant Drain
    - Radiator Removal
    - Radiator Cleaning
    - Radiator Tube Replacement
    - Radiator Installation
    - Radiator Coolant Fill
  - AC Drive Cooling System Assembly
    - AC Drive Cooling System Assembly Removal
      - Alternator Cooling Duct Removal
      - Axle Box Cooling Duct Removal
    - AC Drive Cooling System Assembly Installation
    - Alternator Cooling Duct Installation
    - Axle Box Cooling Duct Installation
- 08 – Heat and Air Conditioning (HVAC) Systems
  - HVAC System Overview
  - A/C Hydraulic Components
    - Hydraulic A/C Compressor Motor and Pump Schematic
    - Variable Displacement Pump
    - Hydraulic A/C System Pump Pressure Setup
    - Hydraulic A/C Compressor and Motor Assembly
      - Hydraulic A/C Compressor and Motor Specifications
      - Hydraulic A/C Compressor and Motor Removal
      - Hydraulic A/C Compressor and Motor Installation
    - Control Manifold
    - Revision History
  - Refrigerant System
  - Operator Cab Air Conditioning System
    - Air Conditioning System Error Codes, System Diagnostics, and Programming
    - Revision History
  - Heat and A/C Condenser
    - Heat and A/C Condenser Removal
    - Heat and A/C Condenser Installation
  - Operator Cab Air Conditioning System Service
    - Revision History
  - 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
- 09 – Litronic plus® Drive System
  - AC Drive System
    - Fastener Torque Requirements
      - Revision History
  - Litronic Plus® DC Bus Voltage Discharge Procedure
    - Check that the Primary DC Bus has been discharged
    - Revision History
  - Field Regulator
  - Main Rectifier
    - Main Rectifier Removal
    - Main Rectifier Installation
    - Revision History
  - Direct Current (DC) to Direct Current Converter Box
    - DC to DC Converter Box Removal
    - DC to DC Converter Box Installation
    - Revision History
  - Auxiliary Frequency Converter
    - Operator Removal
    - Frequency Converter Installation
  - IGBT Inverters (Power Stacks)
    - Inverter (Power Stack) Removal
    - Inverter (Power Stack) Installation
    - Revision History
  - Inverter (Brake Chopper)
    - Inverter (Brake Chopper) Removal
    - Inverter (Brake Chopper) Installation
  - DC Link Capacitor
    - DC Link Capacitor Removal
    - DC Link Capacitors Installation
  - Cooling Pump
  - Main Programmable I/O Module
  - Inverter Controller (Frequency Converter Controllers)
  - Ground Fault Monitoring
  - Independent Power Control
  - Traction Motors
  - Grid Box
- 10 – 24V Electronic Systems
  - 24 VDC Battery Bank
    - Batteries Removal
    - Batteries Installation
  - Battery Disconnect Box
  - Mini Programmable I/O Module
  - CAN Temperature Module
  - Touch Screen Display Panel
- 11 – Hydraulic Power and Distribution
  - Main Hydraulic Pumps Assembly
    - Main Hydraulic Pumps Assembly Schematics
    - Main Pump
    - Main Hydraulic Pumps Assembly Removal
    - Main Hydraulic Pumps Assembly Installation
  - Hydraulic System Filters
    - Circulation Loop Filter Assembly Removal
    - Circulation Loop Filter Assembly Installation
  - Hydraulic Reservoir
    - Hydraulic Reservoir Removal
    - Hydraulic Reservoir Installation
  - Hydraulic Reservoir Fill Procedures
  - Hydraulic Reservoir Drain Procedure
  - Central Service Assembly
- 12 – Hoist System
  - Hoist System
    - Hoist System Lockout Procedure
  - Hoist System Operator Cab Components
  - Hoist Manifold Assembly
    - Hoist Manifold Schematics
    - Hoist Manifold Assembly Removal
    - Hoist Manifold Assembly Installation
  - Hoist Cylinders
    - Hoist Cylinder Removal
    - Hoist Cylinder Installation
- 13 – Hydraulic Brake and Steering Systems
  - Brake and Steering Hydraulic System
    - Brake and Steering System Schematics
  - Brake System Components
  - Brake Accumulators
    - Front Brake Supply and Pilot Accumulator Removal
      - Front Brake Supply Accumulator Removal
      - Front Brake Pilot Accumulator Removal
    - Front Brake Supply and Pilot Accumulator Installation
      - Front Brake Supply Accumulator Installation
      - Front Brake Pilot Accumulator Installation
    - Rear Brake Supply and Pilot Accumulator Removal
      - Rear Brake Supply Accumulator Removal
      - Rear Brake Pilot Accumulator Removal
    - Rear Brake Supply and Pilot Accumulator Installation
      - Rear Brake Supply Accumulator Installation
      - Rear Brake Pilot Accumulator Installation
    - Brake Accumulator Pre-Charge Pressure Check
  - Brake and Steering Manifold
    - Brake and Steering Manifold Test Ports
    - Brake and Steering Manifold Removal
    - Brake and Steering Manifold Installation
  - Remote Valves
  - Brake and Steering Pressure Filter
    - Brake and Steering Pressure Filter Removal
    - Brake and Steering Pressure Filter Installation
  - Brake and Steering Accumulator Bleed
    - Brake Accumulator Bleed Procedure
    - Steering Accumulator Bleed Procedure
  - Steering System
  - Steering Accumulator
    - Steering Accumulator Removal
    - Steering Accumulator Installation
    - Steering Accumulator Pre-Charge Pressure Check
  - Flow Amplifier Valve
    - Flow Amplifier Valve Removal
      - Flow Amplifier Valve Installation
      - Pilot Pressure Relief Valve Adjustment
  - Steering Control Valve
    - Steering Control Valve Removal
    - Steering Control Valve Installation
  - Steering Cylinders
    - Steering Cylinder Removal
    - Steering Cylinders Installation
  - Pump Control Accumulator
    - Pump Control Accumulator Removal
    - Pump Control Accumulator Installation
    - Pump Control Accumulator Pressure Check
  - Buddy Brake and Steering Components
- 14 – Hydraulic Gear Oil Cooling Systems
  - Auto Lube System
    - Auto Lube Components
      - Hydraulic Pump
      - Hydraulic Pump Schematic
  - Auto Lube Troubleshooting
    - Divider Valve Troubleshooting
  - Gear Oil Cooling System
    - Gear Oil Cooling Schematic
  - Hydraulic Schematic
  - Gear Oil Cooling System Filters
    - Gear Oil Filter Assembly Removal
    - Gear Oil Filter Assembly Installation
  - Gear Oil Cooling System Manifold Valve
    - Manifold Valve Removal
    - Manifold Valve Installation
  - Gear Oil Coolers
    - Gear Oil Cooler Removal
    - Gear Oil Cooler Installation
  - Hydraulic Oil Cooling System
    - Hydraulic Cooling System Schematic
    - Hydraulic Oil Cooling Exchanger Removal
    - Hydraulic Oil Cooling Exchanger Installation
  - Gear Oil Cooling Axle Box Assembly
    - Gear Oil Cooling Pump Removal
    - Gear Oil Cooling Pump Installation
  - Gear Oil Cooling System Flow Control Valve
    - Setting the Flow Control Valve
- 15 – Suspensions
  - Front Suspensions
    - Front Suspension Removal
    - Front Suspension Installation
    - Front Suspension Setup
    - Oil Level Check
    - Adding Oil to a Front Suspension
    - Front Suspension Discharge
      - Gas Charge Check
  - Rear Suspensions
    - Rear Suspensions Removal
    - Rear Suspension Installation
    - Rear Suspension Setup
    - Oil Level Check
    - Adding Oil to a Rear Suspension
    - Rear Suspension Discharge Procedure
    - Gas Charge Check
- 16 – Wheel Assemblies
  - Front Wheel Assembly
    - Front Wheel Assembly Removal
    - Front Wheel Assembly Installation
  - Front Tire and Rim Assembly
    - Front Tire and Rim Assembly Removal
    - Front Tire and Rim Assembly Installation
  - Tire Stud Inspection and Replacement
    - Tire and Stud Inspection
    - Front Wheel Stud Replacement
    - Rear Wheel Stud Replacement
  - Front Wheel Oil Drain and Fill Procedure
  - Front Brake System
  - Front and Rear Brake Burnish Procedure
    - Revision History
  - Front Brake Bleed
    - Revision History
  - Front Brake Calipers
    - Front Brake Caliper Removal
    - Front Brake Caliper Installation
      - Revision History
  - Front Brake Disc
  - Kingpins and Spindle
    - Kingpin Removal
    - Kingpin Installation
  - Toe-In Check
  - Toe-In Adjustment
  - Tie Rods
    - Tie Rod Removal
    - Tie Rod Installation
  - Idler Arm Assembly
    - Idler Arm Assembly Removal
    - Idler Arm Assembly Installation
    - Revision History
  - Steering Arm
    - Steering Arm Removal
    - Steering Arm Installation
  - Steering Stop Pads
    - Steering Stop Pads Removal
    - Steering Stop Shim Procedure
    - Steering Stop Pads Installation
  - Upper and Lower Front Control Arms
    - Front Control Arm Removal
    - Front Control Arm Installation
    - Revision History
  - Rear Wheel Drive Assembly
    - Rear Wheel Drive Assembly Removal
    - Rear Wheel Drive Assembly Installation
    - Traction Motor Removal
    - Traction Motor Installation
  - Rear Wheel Drive Oil Drain and Fill Procedure
  - Rear Tire and Rim Assembly
    - Rear Tire and Rim Removal
    - Rear Tire and Rim Installation
    - Revision History
  - Rear Brake System
    - Rear Brake Caliper Removal
    - Rear Brake Caliper Installation
  - Rear Brake Bleed
  - Park Brake Calipers
    - Park Brake Removal
    - Park Brake Installation
  - Rear Brake Disc
    - Rear Brake Disc Removal (from inside the Axle Box)
    - Rear Brake Disc Installation
    - Revision History
  - Mechanical Release of the Park Brake
- 17 – Chassis, Dump Body and Structures
  - Chassis
    - Chassis Welding and Repairs
  - Chassis Mudguards Removal
    - Chassis Mudguards Installation
  - Dump Body
    - Dump Body Welding and Repairs
    - Dump Body Removal
    - Dump Body Installation
      - Revision History
  - Dump Body Lift or Lower for Service (Hydraulically)
  - Dump Body Pivot Pins
    - Dump Body Pivot Pins and Bearing Removal
    - Dump Body Pivot Pins and Bearing Installation
  - Dump Body Pads
    - Dump Body Pads Removal
    - Dump Body Pads Installation
    - Dump Body Pad Shimming Procedure
    - Dump Body Guide Shimming Procedure
  - Dump Body Proximity Switch
    - Dump Body Proximity Switch Removal
    - Dump Body Proximity Switch Installation
      - Dump Body Proximity Switch Test
  - Dump Body Lighting Installation
  - Rock Knocker
    - Rock Knocker Removal
    - Rock Knocker Installation
  - Superstructure
  - Control Box
    - Control Box Removal
    - Control Box Installation
  - Grid Box
    - Grid Box Removal
    - Grid Box Installation
  - Battery Boxes
    - Battery Boxes Removal
    - Battery Boxes Installation
  - Axle Box
    - Axle Box: Access Door Removal
    - Axle Box: Access Door Installation
    - Axle Box: Vent Removal
    - Axle Box: Vent Installation
  - Drag Links
    - Drag Link Removal
    - Drag Link Installation
  - Rear Control A-Arm
    - Rear Control A-Arm Removal
      - Rear Control A-Arm Installation
    - Rear Control A-Arm Shim Procedure
    - Revision History
  - Ladders and Handrails
    - Diagonal Ladder Removal
    - Diagonal Ladder Installation
    - Vertical Ladder Removal
    - Vertical Ladder Installation
    - Handrail Removal
    - Handrail Installation
  - Liebherr Hydraulic Stair Assembly
    - Hydraulic Stair Installation
    - Hydraulic Stair Removal
    - Hydraulic Stair Control Box Assembly
    - Hydraulic Stair Control Box Manifold Removal
    - Hydraulic Stair Control Box Manifold Installation
    - Accumulator Removal
    - Accumulator Installation
    - Actuator Removal
    - Actuator Installation
    - CAM Removal
    - CAM Installation
    - CAM Periodic Adjustment
    - Flange Bearing Removal
    - Flange Bearing Installation
    - Revision History
  - Steps and Engine Access Ladder Assemblies
    - Steps and Engine Access Ladder Removal
    - Steps and Engine Access Ladder Installation
  - Driver Side Exterior Mirror
    - Driver Side Mirror Removal
    - Driver Side Mirror Installation
  - Fire Suppression System
- 18 – Operator Cab
  - Operator Cab
    - Operator Cab Removal
    - Operator Cab Installation
    - Operator Cab Component Removal
    - Operator Cab Component Installation
  - Operator Cab Glass Replacement
  - Windshield Wiper Assembly
    - Windshield Wiper Reservoir Fill
    - Replace Wiper Blade and Arm
    - Replace Wiper Motor
  - Foot Pedal Controls
    - Revision History
  - Accelerator Pedal
  - Service Brake Pedal
    - Service Brake Pedal Removal
    - Service Brake Pedal Installation
  - Dynamic Brake Pedal
    - Dynamic Brake Pedal Removal
    - Dynamic Brake Pedal Installation
  - Steering Column and Controls
    - Trough Cover Removal and Installation
    - Steering Column Removal and Installation
    - Steering Column Turn Signal Switch Removal and Installation
    - Steering Column Knob Kit
    - Steering Column Gap Hider Cover
    - Steering Column Tilt Stop Kit
    - Revision History
  - Operator Cab Seat Removal
    - Operator Cab Seat Installation
  - Dash Panel and Components
    - Dash Panel and Component Removal
    - Dash Panel and Component Installation
    - Circuit Breaker Panel Removal
    - Circuit Breaker Panel Installation
- 19 – Computers and Auxiliary Systems
  - Payload Weigh System Display Panel Unit
    - Display Panel Unit
    - Display Panel Unit — CAN-Bus Controller Unit
      - Installation of the CAN-Bus Controller Unit
    - Display Panel Unit — LED-Array Module
      - Removal of the LED-Array Module
      - Installation of the LED-Array Module
    - Display Panel Unit — Backing Plate with Heating Element
      - Removal of the Backing Plate with Heating Element
      - Installation of the Backing Plate with Heating Element
    - Revision History
- 20 – Safe Work Procedures
  - Safe Work Procedures
  - Erection Site Setup
    - Erection Site Setup Safety
  - Jacking Plates and Erection Stands
    - Jacking Plates and Erection Stands Safety
  - Off-loading Chassis from Transport Vehicle to Stands
    - Off-loading Chassis from Transport Vehicle Safety
  - Off-loading Superstructure from Transport Vehicle
    - Off-loading Superstructure from Transport Vehicle Safety
  - Removing the Containers from Transport Vehicles
    - Removing the Containers from Transport Vehicles Safety
  - Fitting the Main Blower Motor
    - Fitting the Main Blower Motor
  - Fitting Superstructure to Chassis
    - Fitting Superstructure to Chassis Safety
  - Fitting the Left or Right Traction Motor
    - Fitting the Left or Right Traction Motor Safety
  - Fitting Hydraulic Tank
    - Fitting Hydraulic Tank Safety
  - Fitting Fuel Tank
    - Fitting Fuel Tank Safety
  - Fitting Front Control Arms
    - Fitting Front Control Arms Safety
  - Fitting Front Wheel, Kingpin, Spindle, Tie Rod and Idler Arm
    - Fitting Front Wheel, Kingpin, Spindle, Tie Rod and Idler Arm Safety
  - Fitting Suspensions (Shock Absorber)
    - Fitting Suspensions Safety
  - Fitting the Hood and Grill
    - Fitting the Hood and Grill Safety
  - Fitting Front Access Systems
    - Fitting Front Access System Safety
  - Fitting Rollover Protective Structure (ROPS)
    - Fitting Rollover Protective Structure (ROPS) Safety
  - Fit Dump Body
    - Fitting Dump Body Safety
  - Fitting Air Cleaner Boxes
    - Fitting Air Cleaner Boxes
  - Fitting Operator Cab and Setup
    - Fitting Operator Cab and Setup Safety
  - Fitting Rear Wheel Assembly
    - Fitting Rear Wheel Assembly
  - Exhaust System Assembly
    - Exhaust System Assembly Safety
  - Fitting Battery Boxes and Batteries
    - Fitting Battery Boxes and Batteries
  - Filling and Topping Off Oils, Coolants, and Fuels
    - Filling and Topping Off Machine Oils and Fuels
  - Suspensions Setup
    - Suspensions Setup Safety
  - Bleeding Pumps and Setting Pressure
    - Bleeding Pumps and Setting Pressure Safety
  - Haul Truck Commissioning
    - Haul Truck Commissioning Safety
  - Welding on the Haul Truck
    - Welding on the Haul Truck
  - Ladder, Platform, and Rails
    - Ladder, Platform, and Ladder — Wiring Safety
  - Battery Disconnect Switch Box
    - Battery Disconnect Switch Box Safety
  - Fit Belly Pans
    - Fit Belly Pans Installation Safety
  - Moving Haul Truck from Erection Pad
    - Moving Haul Truck from Erection Pad Safety
  - Painting Touch Up Work
    - Paint Touch Up Work Safety
  - Live Testing
    - Live Testing Safety
  - Lights Check
    - Lights Check Safety
  - General Haul Truck Electrical Commission Checks
    - General Haul Truck Electrical Commission Checks Safety
  - Harnessing for Reversing Camera
    - Run Camera Harness for Reversing Camera Safety
  - Steering Accumulator
    - Fit Steering Accumulator Safety
  - Main Blower Motor
    - Main Blower Motor Safety
  - Radiator
    - Radiator Safety
  - Accumulators
    - Accumulators Safety
  - Control Arms
    - Front Control Arms Safety
  - Toe-In Adjustment and Check
    - Toe-In Adjustment and Check Safety
  - Traction Motor
    - Traction Motor Safety
  - Traction Motor Wiring
    - Traction Motor Wiring Safety
  - Burnishing the Brakes
    - Burnishing the Brakes Safety
- List of Acronyms
- Glossary
- Index
- Illustration Index