Procedure to Install Truck Payload Measurement System on Certain AD55 Underground Articulated Trucks{1408, 7494} Caterpillar

Underground Articulated Truck:

AD55 (S/N: DNW613-634)

Introduction

This special instruction covers the procedure to install the truck payload measurement system. This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.

Read the entire Special Instruction. Understand the information before you perform any procedures. Understand the information before you order any parts.

Safety Section

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock between the front and rear frames before working on the machine. Before operating the machine, place the steering frame lock in the stored position. Failure to place the steering frame lock into the stored position before operating can result in loss of steering.

ReferenceDisassembly and Assembly, RENR8505, "AD55 Underground Articulated Truck Machine Systems".

ReferenceDisassembly and Assembly, KENR6708, "AD55 Underground Articulated Truck Power Train".

ReferenceService Manual, RENR4725, "Underground Articulated Trucks Truck Payload Measurement System".

ReferenceOperation and Maintenance Manual, SEBU7332, "AD55 Underground Articulated Truck".

Tools Required

Parts Required

Machine Preparation

Note: Cleanliness is an important factor. Before the removal procedure, clean the exterior of the component thoroughly. Cleaning the exterior will help to prevent dirt from entering the internal mechanism.

1. Move the machine to a hard level surface away from operating machines and away from personnel.

2. Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.

3. Stop the engine.

4. Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".

5. Turn the key start switch and the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery.

6. Release system pressure. Refer to Disassembly and Assembly, "System Pressure - Release".

Rework Procedure

Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes to prevent fluid loss and contaminants from entering the system.

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Illustration 1	g03518256

1. Remove instrument panel (1), the 212-0493 Dash Panel Assembly (not shown), cover (2), cover (3) and cover (4) .

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Illustration 2	g03501917
(1) Instrument panel (5) 3E-8766 Switch (6) 247-2041 Screw (7) 393-5400 Indicator

2. Remove and discard the 128-0315 Tray and the four screws from instrument panel (1) .

3. Install 393-5400 Indicator (7) using four 247-2041 Screws (6) to instrument panel (1) .

4. Remove the 3E-0109 Plug from the face of the instrument panel.

5. Disconnect the electrical connector from the 3E-0109 Plug . Discard the plug and connect 3E-8766 Switch (5) to the electrical connector. Install the switch in instrument panel (1) .

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Illustration 3	g03502896

6. Remove retainer (8) in order to route the 247-1633 Monitor Harness As .

Installation procedure of 247-1630 Cab Harness As , 247-1631 Panel Harness As , and 247-1633 Monitor Harness As

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Illustration 4	g03506025

1. Remove the two covers in order to gain access to the wiring harness.

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Illustration 5	g03502840
(9) 247-1634 Transmitter (10) 247-1633 Monitor Harness As (11) 247-1630 Cab Harness As (12) 119-6105 Grommet (13) 8T-9471 Grommet (14) Panel harness connectors (15) 130-5300 Clip (16) (18) (19) Main cab harness connectors (17) 247-1631 Panel Harness As

2. Remove the bolt and install 130-5300 Clip (15). Locate the two pin receptacle and (wire 707-PU) of the main cab harness. Install the receptacle to clip (15). Install 247-1631 Panel Harness As (17) and connect harness connectors (16), (18) and (19) to the main cab harness. Refer to Illustration 5.

3. Secure 247-1631 Panel Harness As (17) using 3S-2093 Cable Straps as required.

4. Install 247-1633 Monitor Harness As (10). Secure the harness using 3S-2093 Cable Straps as required.

5. Install 247-1630 Cab Harness As (11). Secure the harness to the existing harness using 3S-2093 Cable Straps as required.

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Illustration 6	g03502916

6. Install 247-1634 Transmitter (9) using two 153-8001 Bolts and 5C-8312 Nuts .

7. Connect 247-1633 Monitor Harness As (10) to transmitter (9). Secure the harness using 3S-2093 Cable Straps as required.

8. Install covers (2), (3), (4), retainer (8) and the 212-0493 Dash Panel Assembly (not shown).

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Illustration 7	g03505096
Front view (20) 247-2042 Payload Data Harness As

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Illustration 8	g03505099
Section A-A

9. Connect electrical connectors (21), (22), (23) and (24) from 393-5400 Indicator to harness electrical connectors (10), (11) and (14). Refer to Illustration 5.

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Illustration 9	g03511759

10. Install instrument panel (1) .

Payload Pivot Pins

Note: Ensure that the dump body is in the lowered position.

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Illustration 10	g03505196
Left side of the machine

1. Remove spring (2) from body position sensor (1) .

2. Remove three bolts (3). Position body position sensor (1) out of the way.

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Illustration 11	g03505977

3. Remove and discard three bolts (5) and retainer (4) .

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Illustration 12	g03505197
Right side of the machine

4. Disconnect lubrication hose assembly (8)

5. Remove plate (6) and the two bolts. Retain plate (6) and the two bolts for installation purposes.

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Illustration 13	g03505198

6. Install jacking plate (10) and three bolts (9) to pin assembly (7) .

7. Use four bolts (11) as jacking bolts to remove pin assembly (7) .

8. Remove and discard pin assembly (7) .

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Illustration 14	g03505199
Right side of the machine

9. Align the bores in the body and the rear frame.

10. Install the 393-5399 Pin .

    Note: Apply Tooling (B) to the 393-5399 Pin , the bores, and the bolts.

11. Install 246-0047 Plate (12), three 5P-2228 Bolts (13) and three 8T-4223 Hard Washers .

12. Install two bolts and plate (6) retained in Step 5.

13. Connect lubrication hose (8) and the fitting assembly.

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Illustration 15	g03505985

14. Install 5M-6214 Pipe Plug (16) (not shown) to the pin.

15. Install 203-0711 Retainer (14) and three 5P-2566 Bolts (15) and three 8T-4223 Hard Washers .

16. Repeat Step 3 through Step 15 for the other side.

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Illustration 16	g03518277
Left side of the machine

17. Position body position sensor (1) .

18. Install spacers (3) and the three bolts.

19. Install spring (2) to body position sensor (1) .

Installation Procedure of 247-1629 Cab to Hitch Harness As , 253-2736 Hitch to Payload Harness As , 253-2737 Lighting Harness As , and 247-1632 Led Lamp As .

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Illustration 17	g03505987

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Illustration 18	g03505989
Typical example

1. Install 247-1632 Led Lamp As (1) using four 9X-2046 Screws .

2. Connect the lamp harness to electrical connectors (2) .

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Illustration 19	g03505991
Right side flood lamp and crossbeam wiring

3. Remove the two bolts and 216-2699 Guard (5). Retain for installation purposes.

4. Remove the earth terminal from bolt (3) .

5. Disconnect the 216-2701 Lighting Harness As from electrical connector (6), and from electrical connector (4) .

6. Discard the 216-2701 Lighting Harness As .

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Illustration 20	g03509656
Right side lamp (3) Bolt (4) Electrical connector (5) Guard (7) 8S-0023 Clip (8) 8S-0024 Clip (9) 8T-4137 Bolt (10) 8T-4121 Hard Washer (11) 8T-4133 Nut (12) 247-1632 Led Lamp As (13) 247-1635 Plate As (14) 3S-2093 Cable Strap (15) 130-5300 Clip (16) 8T-2947 Bolt (17) 6V-7743 Locknut (18) 253-2737 Lighting Harness As

7. Assemble the lamp assembly. Refer to Illustration 20.

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Illustration 21	g03505996

8. Install the lamp assembled in Step 7 to the handrail. Refer to Illustration 21.

9. Route 253-2737 Lighting Harness As (18) and connect to electrical connector (6), and electrical connector (4). Connect the earth terminal to bolt (3). Secure the harness using three 3S-2093 Cable Straps (14). Refer to Illustrations 19 and 20.

10. Install guard (5) and the two bolts retained Step 3. Refer to Illustration 19.

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Illustration 22	g03506605
(19) 247-1629 Cab Harness As

11. Connect 247-1629 Cab Harness As (19) to the bulkhead connector of 247-1630 Cab Harness As (11). Refer to Illustration 5.

12. Route the 247-1629 Cab Harness As as shown in Illustration 22 to the hitch.

13. Secure the harness to the existing harness using 3S-2093 Cable Straps as required.

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Illustration 23	g03506025

14. Install the two covers.

15. Raise the dump body and install the body retaining pins. Refer to Operation and Maintenance Manual, "Body Retaining Pin".

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Illustration 24	g03528937

16. Connect 253-2736 Payload Harness As (20) to 247-1629 Cab Harness As (19) .

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Illustration 25	g03528938

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Illustration 26	g03528939

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Illustration 27	g03528940

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Illustration 28	g03528941

17. Route 253-2736 Payload Harness As (20) as shown in Illustrations 25, 26, 27 and 28.

    Note: Do not connect 253-2736 Payload Harness As (20) to the pivot pins or to the payload cells at this stage.

18. Secure the harness to the existing harness using 6K-0806 Cable Straps as required.

Load Cells

1. Raise the dump body and install the body retaining pins. Refer to Operation and Maintenance Manual, "Body Retaining Pin".

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Illustration 29	g03507186

2. Remove and discard four 251-8506 Truck Body Mounting Gp (1) .

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Illustration 30	g03507193
Exploded view of the payload cell (2) 8T-4183 Bolt (3) 8T-4223 Hard Washer (4) 316-2826 Pad As (5) 1D-4641 Bolt (6) 5P-8250 Washer (7) 246-0053 Shim (8) 246-0054 Shim (9) 246-0049 Plate (10) 246-0055 Shim (11) 8S-4755 Bolt (12) 5P-8250 Washer (13) 393-5395 Cell (14) 393-5396 Bearing Plate

3. Install Item (2) through Item (14) to the rear frame.

   Note: Apply Loctite Nickle Anti Sieze to the bolts.

4. Repeat the previous step for the other three payload cells.

5. Remove the body retaining pins and lower the dump body. Refer to Operation and Maintenance Manual, "Body Retaining Pin".

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Illustration 31	g03507194
Typical example

6. Ensure that the dump body sits evenly on the body support pad assemblies. Add or remove shims as required.

   Note: If raising the dump body again is necessary, install the body retaining pins prior to commencing work. Refer to Operation and Maintenance Manual, "Body Retaining Pin".

   Note: Proper installation of the body support pad assemblies will effectively balance the load weight reducing the risk of possible damage to the rear frame.

7. Calibrate the payload measurement system. Refer to ""Calibrating Procedure for the Truck Payload Measurement System" ".

Calibrating Procedure for the Truck Payload Measurement System

Note: Use two people for the following procedure.

1. Raise the dump body. Install the body retaining pins. Refer to Operation and Maintenance Manual, "Body Retaining Pin".

2. Stop the engine. Turn the key start switch to the ON position.
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   Table 3

   First Attempt
   Payload Cell	Body Up	Body Down	Difference	Action
   Front Right
   Front Left
   Rear Right
   Rear Left

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Illustration 32	g03528879
Indicator

Note: Ensure that the display units are "Kg". In order to change the display units, refer to Service Manual, RENR4725, "Truck Payload Measurement System, Underground Articulated Truck", "System Setup".

3. Connect the harness to the front right payload cell. Record the reading from the indicator in Table 3. Disconnect the harness from the payload cell.

4. Connect the harness to the front left payload cell. Record the reading from the indicator in Table 3. Disconnect the harness from the payload cell.

5. Connect the harness to the rear right payload cell. Record the reading from the indicator in Table 3. Disconnect the harness from the payload cell.

6. Connect the harness to the rear left payload cell. Record the reading from the indicator in Table 3. Disconnect the harness from the payload cell.

7. Remove the body retaining pins and lower the dump body. Refer to Operation and Maintenance Manual, "Body Retaining Pin".

8. Stop the engine. Turn the key start switch to the ON position.

   Note: Ensure that the hoist control is in the FLOAT position.

9. Repeat Step 3 through Step 8.

10. Calculate the difference by subtracting the "Body Down" reading from the "Body Up" reading for the four payload cells.

    Note: If the "Difference" readings were not within 5000 kg (11000 lb)of each other, remove or add shims.

    Note: If three of the four readings are within 5000 kg (11000 lb), but one reading is more than 5000 kg (11000 lb) higher than the lowest reading, remove shims from under the payload cell with the higher reading. Refer to the example below in Table 4.

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    Table 4

    Payload Cell	Body Up	Body Down	Difference	Action
    Front Right	-12930	-1160	11770	Remove shim
    Front Left	-9780	-2900	6880
    Rear Right	-13120	-8110	5010
    Rear Left	-15120	-9040	6080

    Note: If three of the four readings are within 5000 kg (11000 lb) but one reading is more than 5000 kg (11000 lb) higher than the lowest reading, remove shims from under the payload cell with the higher reading. Refer to the example below in Table 5.

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    Table 5

    Payload Cell	Body Up	Body Down	Difference	Action
    Front Right	-13000	-5000	8000
    Front Left	-11000	-1000	10000
    Rear Right	-5000	-4500	500	Add shim
    Rear Left	-12000	-1000	11000

    Note: If two have to change, and both are on the same side, add shim to both on that side to get all four readings within 5000 kg (11000 lb) of each other. Refer to the example below in Table 6.

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    Table 6

    Payload Cell	Body Up	Body Down	Difference	Action
    Front Right	-13000	-5000	8000
    Front Left	-10000	-8000	2000	Add shim
    Rear Right	-11000	-1000	10000
    Rear Left	-12000	-9000	3000	Add shim

    Note: If two have to change and the two in the front are the low values, add shim to the two front load cells.

    Note: If two have to change and the two in the rear are the low values, add shim to the rear two.

    Note: For any other scenarios, try to optimize based on the shims available in order to get the closest four readings possible.

11. This process may need repeating several times. Use the following tables to record the readings:
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    Table 7

    Second Attempt
    Payload Cell Pad	Body Up	Body Down	Difference	Action
    Front Right
    Front Left
    Rear Right
    Rear Left

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    Table 8

    Third Attempt
    Payload Cell Pad	Body Up	Body Down	Difference	Action
    Front Right
    Front Left
    Rear Right
    Rear Left

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    Table 9

    Fourth Attempt
    Payload Cell Pad	Body Up	Body Down	Difference	Action
    Front Right
    Front Left
    Rear Right
    Rear Left

12. Raise the dump body. Install the body retaining pins. Refer to Operation and Maintenance Manual, "Body Retaining Pin".

13. Connect the harness to the four payload cells and the two pivot pins. Secure the harness using 3S-2093 Cable Straps as required. Refer to Illustrations 25, 26, 27 and 28.

14. Remove the body retaining pins and lower the dump body. Refer to Operation and Maintenance Manual, "Body Retaining Pin".

15. Carry out the tare calibration. Refer to Underground Articulated Trucks Truck Payload Measurement System, RENR4725, "Calibration".

16. Carry out the span calibration. Refer to Underground Articulated Trucks Truck Payload Measurement System, RENR4725, "Calibration".