Description
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Model List:
- 980E-4 Dump Truck
- 1. FOREWORD
- 2. TABLE OF CONTENTS
- 3. SAFETY RULES, TOOLS EQUIPMENT
- 3.1. SAFETY RULES
- 3.2. BODYUP RETENTION SLING
- 3.3. HIGH VOLTAGE TOOLS
- 3.4. VDC CUSTOM METER KIT (58B0600800)
- 4. MAJOR COMPONENTS AND SPECIFICATIONS
- 4.1. SPECIFICATIONS
- 4.2. REAR AXLE COMPONENTS
- 5. FIELD WELDING FOR ASSEMBLY OR REPAIR
- 5.1. WELDER QUALIFICATION AND TRAINING
- 5.2. WELD PROCEDURES
- 5.3. APPROVED CONSUMABLES
- 5.4. WELD QUALITY REQUIREMENTS
- 5.5. MATERIALS, CONTROLS, AND PRECAUTIONS
- 5.6. WELD INSPECTION
- 5.7. RECORDS
- 5.8. ANNEX A
- 5.9. ANNEX B
- 5.10. BIBLIOGRAPHY
- 5.11. SPECIAL PRECAUTIONS WHEN SERVICING AN AC DRIVE SYSTEM TRUCK
- 6. RECEIVING ASSEMBLY PREPARATION
- 6.1. Preparation
- 6.2. ASSEMBLY LAYOUT
- 7. CHASSIS ASSEMBLY
- 7.1. RECOMMENDED ASSEMBLY DATA
- 7.2. BASIC ASSEMBLY PROCEDURE
- 7.3. ORDER OF ASSEMBLY
- 7.4. CHASSIS ASSEMBLY
- 7.5. HARDWARE TIGHTENING METHOD
- 7.6. GENERAL PRECAUTIONS AND INSTRUCTION
- 7.6.1. Before Starting the Engine
- 8. DUMP BODY ASSEMBLY
- 8.1. GENERAL INFORMATION
- 8.2. BODY WELDING INFORMATION
- 8.3. BODY ASSEMBLY
- 9. FINAL ASSEMBLY
- 10. APPENDIX
- 10.1. LUBRICATION CHART
- 10.2. TORQUE TABLES AND CONVERSION CHARTS
- 10.2.1. EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values
- 10.2.2. STANDARD TIGHTENING TORQUES For Class 10.9 Capscrews Class 10 Nuts
- 10.2.3. STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Capscrews
- 10.2.4. STANDARD TIGHTENING TORQUES For SAE Grade 9 Capscrews
- 10.3. SUSPENSION OILING AND CHARGING PROCEDURE
- 10.3.1. GENERAL
- 10.3.2. Front Suspension
- 10.3.3. Rear Suspension
- 10.4. OIL AND NITROGEN SPECIFICATIONS CHART
- 10.5. TOEIN ADJUSTMENT PROCEDURE
- 10.6. AUTOMATIC LUBRICATION SYSTEM PRIMING
- 10.6.1. PUMP PRIMING PROCEDURE
- 10.6.2. SYSTEM PRIMING PROCEDURE
- 10.7. BRAKE TEST CHECKOUT PROCEDURE
- 10.8. PARKING BRAKE BLEEDING/FLUSHING PROCEDURE
- 10.9. ALTERNATOR TO ENGINE ASSEMBLY CHECKOUT PROCEDURE
- 10.9.1. Cummins Crankshaft End Play (See Figure 12)
- 10.9.2. Engine Flywheel to Flywheel Adaptor Plate Measurement C (See Figure 13)
- 10.9.3. Alternator Housing to Rotor Measurement Measurement A (See Figures 1416)
- 10.9.4. Measurements after Joining the Alternator and Engine
- 10.9.5. Additional Engine Measurements (For Reference Only Not Required For Production Assembly)
- 10.9.6. References
- 10.9.7. Appendix 1
- 10.9.8. Appendix 2
- 10.9.9. Flywheel Housing Radial Runout
- 10.9.10. Appendix 3
- 10.9.11. Flywheel Housing Radial Runout
- 10.9.12. Appendix 4
- 10.9.13. Flywheel/Flexplate Face Runout
- 10.9.14. Appendix 5
- 10.9.15. Flywheel/Flexplate Radial Runout
- 10.9.16. Appendix 6
- 10.9.17. Attachment Shaft Radial Runout Measurement (See Figure 112)
- 10.10. INTERFACE MODULE CHECKOUT PROCEDURE
- 10.10.1. Purpose
- 10.10.2. Necessary Equipment
- 10.10.3. Install the Application Code
- 10.10.4. How to Use the IM Realtime Data Monitor Software
- 10.10.5. Check for Fault Codes Associated With the Interface Module
- 10.10.6. Interface Module I/O
- 10.10.7. S/N ___________________ IM Installation Checkout Checklist
- 10.11. AUTOMATIC LUBRICATION SYSTEM CHECKOUT PROCEDURE
- 10.11.1. Lincoln Flow Master Phase 1 Auto Lube System With Fixed Hydraulic Controls
- 10.11.2. Lube Pump Startup / Purging Procedure
- 10.11.3. Truck Lube System Purging Procedure
- 10.11.4. Adjust Injector Settings
- 10.11.5. Timer
- 10.11.6. Warning System
- 10.12. RESERVE OIL SYSTEM CHECKOUT PROCEDURE
- 10.13. AIR CONDITIONING SYSTEM CHECKOUT PROCEDURE
- 10.14. HYDRAULIC SYSTEM CHECKOUT PROCEDURE
- 10.14.1. General information on system checkout
- 10.14.2. Hydraulic system checkout procedures
- 10.14.3. Hydraulic system checkout data sheet
- 10.14.4. Date shift completed
- 10.15. BRAKE SYSTEM CHECKOUT PROCEDURE
- 10.15.1. General information on system checkout
- 10.15.2. Brake system checkout procedures
- 10.15.3. Brake system checkout data sheet
- 10.16. KOMTRAX PLUS SETUP PROCEDURE
- 10.16.1. Purpose
- 10.16.2. Preliminary Procedures
- 10.16.3. Necessary Equipment
- 10.16.4. Check for KOMTRAX Plus System Faults
- 10.16.5. KOMTRAX Plus Setup
- 10.16.6. Begin KOMTRAX Plus Setup
- 10.17. KOMTRAX PLUS CHECKOUT PROCEDURE
- 10.17.1. Purpose
- 10.17.2. Preliminary Procedures
- 10.17.3. Necessary Equipment
- 10.17.4. Check for KOMTRAX Plus System Faults
- 10.17.5. Checkout Procedure
- 10.18. PAYLOAD METER IV CHECKOUT PROCEDURE
- 10.18.1. Appendix A
- 10.18.2. Appendix B
- 10.18.3. Payload Meter IV Checkout Procedure Confirmation
- 10.19. ELECTRICAL SYSTEM CHECKOUT PROCEDURE
- 10.19.1. General Description
- 10.19.2. General Precautions
- 10.19.3. AC Drive System Description
- 10.19.4. Visual Inspection
- 10.19.5. Resistance Checks
- 10.19.6. Voltage Check
- 10.19.7. Interface Module (IM) System Checkout
- 10.19.8. Checkout Completion Report
- 10.20. KOMVISION CHECKOUT PROCEDURE
- 10.20.1. STEP 1 Settings
- 10.21. WIRELESS BRIDGE CHECKOUT PROCEDURE
- 10.22. RETRACTABLE LADDER SYSTEM CHECKOUT PROCEDURE
- 10.22.1. Scope of Checkout Procedure
- 10.22.2. Required Software
- 10.22.3. Data to Record
- 10.22.4. Precheckout Items
- 10.22.5. Procedure Steps
- 10.22.6. Retractable Ladder System Checkout Data Sheet
- 10.23. SEAT BELTS AND TETHERS CHECKOUT PROCEDURE
- 10.23.1. GENERAL DESCRIPTION
- 10.24. FIELD ASSEMBLY INSPECTION REPORT
- 10.25. HOUR POSTCOMMISSIONING CHECKSHEET
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