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Komatsu 980E-4 Rigid Dump Truck Shop Manual (CEBM031608)

Format: PDF (Printable Document)

File Language: English

File Pages: 998

File Size: 58.53 MB (Speed Download Link)

Brand: Komatsu

Model: 980E-4 Rigid Dump Truck

Book No: CEBM031608

Serial No: SN A40052-UP

Type of Document: Shop Manual

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Komatsu 980E-4 Rigid Dump Truck Shop Manual (CEBM031608)

The Komatsu 980E-4 Rigid Dump Truck is a mine-haul truck used for moving large volumes of overburden and ore all day, every day. The people who usually reach for the Komatsu 980E-4 Rigid Dump Truck Shop Manual (CEBM031608) are shop mechanics, field techs, and sometimes fleet maintenance planners. They’re usually trying to chase down fault codes, plan major component swaps, or do proper tear-down and rebuild work without guessing. If you’re trying to save downtime and avoid learning the hard way, this is the type of book you lean on.

What this manual helps you do

  • Trace electrical and electronic faults using wiring information and step-by-step diagnostic routines.
  • Check engine, transmission, and braking systems using guided test procedures and expected result ranges.
  • Follow disassembly and reassembly sequences for major components like axles, suspension, and powertrain modules.
  • Diagnose hydraulic and retarder issues by following system descriptions, flow paths, and troubleshooting trees.
  • Handle adjustments and post-repair checks so the truck goes back to work safely and behaves the way Komatsu intended.

Who this is for

This shop manual is aimed at workshop-level people: field techs, dealer or independent shop mechanics, and fleet maintenance leads who sign off on big repairs. If you’re just an operator wanting basic daily checks or safety info, you’d be better off with the Operation and Maintenance Manual instead.

FAQ

Q: Is this a PDF I can download and search?

A: Yes, it’s a digital PDF you can download, search by keyword, and print specific sections for use in the shop.

Q: Is it detailed enough for full overhauls, or just light service?

A: It’s written for full repair work, from system diagnostics through major component removal and installation.

Q: How do I know if it matches my exact 980E-4 build?

A: This manual targets the Komatsu 980E-4 Rigid Dump Truck; for edge cases or special mine-spec variants, you’ll want to confirm against your machine’s plate and the CEBM031608 reference.

Bottom line: if you’re repairing or rebuilding a Komatsu 980E-4 in a workshop or field-service setting, this is the right manual; if you only need basic operation or daily service info, keep looking for the operator/maintenance book instead.

📘 Show Index

Table of Contents:

  • COVER
  • 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
    • 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-4
      • 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
      • Hoist Limit Solenoid
      • Pilot Operated Check 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
    • Electrical System, AC Drive
      • General System Operation
      • AC Drive System Components
      • DSC Software Functions
      • Alternator Field Control
      • Event Detection and Processing
      • Event Restrictions
      • Event Logging and Storage
      • Abnormal Conditions/Overriding Functions
      • Electronic Accelerator and Retard Pedals
      • Propulsion System Component Abbreviations and Locations
    • Automatic Lubrication (Auto Lube) System
      • Automatic Lubrication (Auto Lube) Grease Pump and Reservoir
      • Automatic Lubrication (Auto Lube) System Operation
    • Suspensions
  • 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-4
      • 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
      • Parking Brake Adjustment Procedure
    • 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
      • Purging Air From The Service Hoses
      • Refrigerant: Recycled vs Reclaimed
      • Refrigerant Recovery Procedure
      • Evacuate the A/C System
      • Charge the A/C System
    • Interface Module (IM)
      • Interface Module Software and Tools
      • Interface Module Checkout Procedures
        • Initial Startup
        • Checking Digital Inputs to the IM
        • Checking Analog Inputs to the IM
        • Checking Serial Communication to the IM
        • Checking Outputs from the IM
        • Interface Module 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
      • KOMTRAX Plus Software and Tools
      • KOMTRAX Plus Controller Setup Procedure
        • Preliminary Steps
        • Setup Procedure
      • Precautions When Replacing the KOMTRAX Plus Controller
      • KOMTRAX Plus Controller Checkout Procedure
        • Preliminary steps
        • Checkout Procedure
    • 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
  • 40 TROUBLESHOOTING
    • Vehicle Electrical Centers (VEC)
    • AC Drive System Fault Codes (DSC)
      • Operational Restrictions
      • DSC/PSC Event List
      • Inverter Event List
      • DID Panel Fault Codes
    • Standard Truck Fault Codes
      • A001
      • A002
      • A003
      • A004
      • A005
      • A006
      • A007
      • A008
      • A009
      • A010
      • A011
      • A013
      • A014
      • A018
      • A019
      • A022
      • A101
      • A105
      • A107
      • A108
      • A109
      • A111
      • A115
      • A117
      • A118
      • A123
      • A124
      • A125
      • A126
      • A127
      • A128
      • A139
      • A145
      • A146
      • A152
      • A153
      • A154
      • A155
      • A158
      • A166
      • A167
      • A168
      • A169
      • A170
      • A171
      • A172
      • A173
      • A184
      • A190
      • A194
      • A195
      • A196
      • A197
      • A198
      • A199
      • A200
      • A201
      • A202
      • A203
      • A204
      • A205
      • A206
      • A207
      • A212
      • A213
      • A214
      • A215
      • A216
      • A223
      • A230
      • A231
      • A233
      • A235
      • A236
      • A237
      • A240
      • A242
      • A243
      • A244
      • A245
      • A246
      • A247
      • A248
      • A249
      • A250
      • A251
      • A252
      • A253
      • A256
      • A257
      • A258
      • A260
      • A261
      • A262
      • A264
      • A265
      • A266
      • A267
      • A268
      • A270
      • A271
      • A272
      • A273
      • A274
      • A275
      • A276
      • A277
      • A278
      • A279
      • A280
      • A281
      • A282
      • A283
      • A284
      • A285
      • A286
      • A292
      • A303
      • A304
      • A305
      • A307
      • A309
      • A310
      • A311
      • A312
      • A313
      • A315
      • A316
      • A317
      • A318
      • A320
      • A321
      • A322
      • A323
      • A324
      • A325
      • A326
      • A327
      • A328
      • A329
      • A330
      • A332
      • A333
      • A334
      • A335
      • A337
      • A338
      • A341
      • A343
      • A344
      • A345
      • A346
      • A347
      • A348
      • A349
      • A350
      • A351
      • A352
      • A353
      • A354
      • A355
      • A356
      • A357
      • A358
      • A359
      • A360
      • A361
      • A362
      • A363
      • A364
      • A365
    • 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 Cab Air Conditioning
      • Preliminary Checks
      • Diagnosis of Gauge Readings and System
      • Troubleshooting by Manifold Gauge Set Readings
    • Troubleshoot the Auto Lube System
  • 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
      • Floating Seal Installation (CPS or Goetze)
      • 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 Treadle Valve Removal
      • Brake Treadle 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
      • Front Wheel Brake Assembly
      • Rear Wheel Brake Removal
      • Rear Wheel Brake Installation
      • Rear Wheel Brake Disassembly
      • Rear Wheel Brake Assembly
      • Wheel Brake Cleaning and Inspection
        • Wet Disc Brake Friction Disc Inspection
        • Wet Disc Brake Separator Plate Inspection
        • Friction Disc and Separator Plate Checkout Sheet
      • 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 Control Valve Removal
      • Hoist Control Valve Installation
      • Hoist Control Valve Service
        • Hoist Control 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
      • Grille and Hood Assembly Removal
      • Grille and Hood Assembly 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
      • Hydraulic Tank Strainers Removal
      • Hydraulic Tank Strainers Cleaning and Inspection
      • Hydraulic Tank Strainers Installation
    • Operator Cab
      • Operator Cab Removal
      • Operator Cab Installation
      • Cab Door Removal
      • Cab Door Installation
      • Door Panel Removal
      • Door Panel Installation
      • Window Regulator Removal
      • Window Regulator Installation
      • Door Glass Removal
      • Door Glass Installation
      • Door Seal Replacement
        • Replacing Door Assembly Seal and Door Hinge Seal
        • Replacing Door Opening Seal
      • Outer Door Seal Replacement
      • Interior Door Handle and Door Latch Removal
      • Interior Door Handle and Door Latch Installation
      • Door Jamb Bolt Adjustment
        • Poor Seal When Door Is Closed
        • Door Springs Back Open
      • Door Handle Plunger Adjustment
      • Side Window Glass Removal
      • Side Window Glass Installation
      • Windshield Glass Removal
      • Rear Window Glass Removal
      • Windshield Glass Installation
      • Rear Window Glass Installation
      • Windshield Wiper Motor Removal
      • Windshield Wiper Motor Installation
      • Windshield Wiper Arm Removal
      • Windshield Wiper Arm Installation
      • Windshield Wiper Linkage Removal
      • Windshield Wiper Linkage Installation
      • Cab Seat Inspection
      • Operator Seat Removal
      • Operator Seat Installation
      • Seat Compressor Replacement
      • Passenger Seat Removal
      • Passenger Seat Installation
      • Cab Seat Servicing
      • Seat Belt Removal (Standard Seat)
      • Seat Belt Installation (Standard Seat)
      • Seat Belt Service (Optional Seats)
        • Seat Belt Removal (Optional Seat)
        • Seat Belt Installation (Optional Seat)
    • Power Module
      • Power Module General Information
      • Power Module Removal
      • Power Module Installation
      • Exhaust Tube Installation
      • Exhaust Blanket Installation
      • Alternator Removal
      • Alternator Installation
        • Engine Flywheel Adapter Face Runout
        • Engine Crankshaft Endplay
        • Engine Flywheel to Flywheel Housing Adapter – Measurement “C”
        • Alternator Housing to Rotor – Measurement “A”
        • Measurements After Joining the Alternator and Engine
        • Flywheel Housing Face Runout
        • Flywheel Housing Radial Runout
        • Flywheel/Flexplate Face Runout
        • Flywheel/Flexplate Radial Runout
        • Rotor Shaft Radial Runout (Assembled)
      • Radiator Removal
      • Radiator Installation
      • Radiator Internal Inspection
      • Radiator External Cleaning
      • Radiator Disassembly
      • Radiator Cleaning and Inspection
      • Radiator Assembly
      • Engine Removal
      • Engine Service
      • Engine Installation
    • Air Conditioning System Component Replacement
      • Hoses and Fittings
      • Line
      • Expansion Valve
      • Receiver-drier
      • Thermostat
      • Compressor
      • Accumulator
      • Clutch
  • 60 MAINTENANCE STANDARD
    • Rules for Maintenance
    • Torque Specifications
    • Wheel Motor Gear Oil
    • Shutting Down the Machine
    • Hydraulic System Bleeddown Procedure
    • Hydraulic System Vacuum Procedure
    • Power Cable Inspection
    • Long Term Storage of Electric Dump Truck
    • 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-4

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