- 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.
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
Tools Required     | |||
---|---|---|---|
Tooling     | Part Number     | Part Description     | Qty     |
A     | 230-6387     | Tool-Body Pivot Pin     | 1     |
B     | -     | Loctite® Nickel Anti-Seize Compound     | 1     |
Parts Required
Parts Required     | ||
---|---|---|
Qty     | Part Number     | Description     |
1     | 119-6105     | Grommet     |
3     | 130-5300     | Clip     |
2     | 153-8001     | Bolt     |
16     | 1D-4641     | Bolt     |
2     | 203-0711     | Retainer     |
2     | 246-0047     | Plate     |
4     | 246-0049     | Plate     |
8     | 246-0053     | Shim     |
8     | 246-0054     | Shim     |
8     | 246-0055     | Shim     |
1     | 247-1625     | Antenna     |
1     | 247-1629     | Cab Harness As     |
1     | 247-1630     | Cab Harness As     |
1     | 247-1631     | Panel Harness As     |
2     | 247-1632     | Led Lamp As     |
1     | 247-1633     | Monitor Harness As     |
1     | 247-1634     | Transmitter     |
1     | 247-1635     | Plate As     |
4     | 247-2041     | Screw     |
1     | 247-2042     | Monitor Harness As     |
1     | 253-2736     | Monitor Harness As     |
1     | 253-2737     | Lighting Harness As     |
4     | 316-2826     | Pad As     |
4     | 393-5395     | Cell     |
8     | 393-5396     | Bearing Plate     |
2     | 393-5399     | Pin     |
1     | 393-5400     | Indicator     |
1     | 3E-8766     | Switch     |
25     | 3S-2093     | Cable Strap     |
2     | 4P-7429     | Clip     |
2     | 5C-8312     | Nut     |
2     | 5M-6214     | Pipe Plug     |
6     | 5P-2228     | Bolt     |
6     | 5P-2566     | Bolt     |
32     | 5P-8250     | Washer     |
25     | 6K-0806     | Cable Strap     |
4     | 6V-7743     | Locknut     |
2     | 8S-0023     | Clip     |
2     | 8S-0024     | Clip     |
16     | 8S-4755     | Bolt     |
4     | 8T-2947     | Bolt     |
2     | 8T-4121     | Hard Washer     |
2     | 8T-4133     | Nut     |
2     | 8T-4137     | Bolt     |
16     | 8T-4183     | Bolt     |
28     | 8T-4223     | Hard Washer     |
1     | 8T-9471     | Grommet     |
4     | 9X-2046     | Screw     |
4     | 9X-8256     | Washer     |
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.
- Move the machine to a hard level surface away from operating machines and away from personnel.
- Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.
- Stop the engine.
- Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".
- 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.
- 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.
- Remove instrument panel (1), the 212-0493 Dash Panel Assembly (not shown), cover (2), cover (3) and cover (4) .
Illustration 1 | g03518256 |
- Remove and discard the 128-0315 Tray and the four screws from instrument panel (1) .
Illustration 2 | g03501917 |
(1) Instrument panel (5) 3E-8766 Switch (6) 247-2041 Screw (7) 393-5400 Indicator |
- Remove the 3E-0109 Plug from the face of the instrument panel.
- 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) .
- Remove retainer (8) in order to route the 247-1633 Monitor Harness As .
Illustration 3 | g03502896 |
Installation procedure of 247-1630 Cab Harness As , 247-1631 Panel Harness As , and 247-1633 Monitor Harness As
- Remove the two covers in order to gain access to the wiring harness.
Illustration 4 | g03506025 |
- 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.
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 |
- Install 247-1633 Monitor Harness As (10). Secure the harness using 3S-2093 Cable Straps as required.
- Install 247-1630 Cab Harness As (11). Secure the harness to the existing harness using 3S-2093 Cable Straps as required.
- Install 247-1634 Transmitter (9) using two 153-8001 Bolts and 5C-8312 Nuts .
Illustration 6 | g03502916 |
- Connect 247-1633 Monitor Harness As (10) to transmitter (9). Secure the harness using 3S-2093 Cable Straps as required.
- Install covers (2), (3), (4), retainer (8) and the 212-0493 Dash Panel Assembly (not shown).
- Connect electrical connectors (21), (22), (23) and (24) from 393-5400 Indicator to harness electrical connectors (10), (11) and (14). Refer to Illustration 5.
Illustration 7 | g03505096 |
Front view (20) 247-2042 Payload Data Harness As |
Illustration 8 | g03505099 |
Section A-A |
- Install instrument panel (1) .
Illustration 9 | g03511759 |
Payload Pivot Pins
Note: Ensure that the dump body is in the lowered position.
- Remove spring (2) from body position sensor (1) .
Illustration 10 | g03505196 |
Left side of the machine |
- Remove three bolts (3). Position body position sensor (1) out of the way.
- Remove and discard three bolts (5) and retainer (4) .
Illustration 11 | g03505977 |
- Disconnect lubrication hose assembly (8)
Illustration 12 | g03505197 |
Right side of the machine |
- Remove plate (6) and the two bolts. Retain plate (6) and the two bolts for installation purposes.
- Install jacking plate (10) and three bolts (9) to pin assembly (7) .
Illustration 13 | g03505198 |
- Use four bolts (11) as jacking bolts to remove pin assembly (7) .
- Remove and discard pin assembly (7) .
- Align the bores in the body and the rear frame.
Illustration 14 | g03505199 |
Right side of the machine |
- Install two bolts and plate (6) retained in Step 5.
- Connect lubrication hose (8) and the fitting assembly.
- Install 5M-6214 Pipe Plug (16) (not shown) to the pin.
Illustration 15 | g03505985 |
- Repeat Step 3 through Step 15 for the other side.
- Position body position sensor (1) .
Illustration 16 | g03518277 |
Left side of the machine |
- Install spacers (3) and the three bolts.
- 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 .
- Install 247-1632 Led Lamp As (1) using four 9X-2046 Screws .
Illustration 17 | g03505987 |
Illustration 18 | g03505989 |
Typical example |
- Connect the lamp harness to electrical connectors (2) .
- Remove the two bolts and 216-2699 Guard (5). Retain for installation purposes.
Illustration 19 | g03505991 |
Right side flood lamp and crossbeam wiring |
- Remove the earth terminal from bolt (3) .
- Disconnect the 216-2701 Lighting Harness As from electrical connector (6), and from electrical connector (4) .
- Discard the 216-2701 Lighting Harness As .
- Assemble the lamp assembly. Refer to Illustration 20.
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 |
- Install the lamp assembled in Step 7 to the handrail. Refer to Illustration 21.
Illustration 21 | g03505996 |
- 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.
- Install guard (5) and the two bolts retained Step 3. Refer to Illustration 19.
- Connect 247-1629 Cab Harness As (19) to the bulkhead connector of 247-1630 Cab Harness As (11). Refer to Illustration 5.
Illustration 22 | g03506605 |
(19) 247-1629 Cab Harness As |
- Route the 247-1629 Cab Harness As as shown in Illustration 22 to the hitch.
- Secure the harness to the existing harness using 3S-2093 Cable Straps as required.
- Install the two covers.
Illustration 23 | g03506025 |
- Raise the dump body and install the body retaining pins. Refer to Operation and Maintenance Manual, "Body Retaining Pin".
- Connect 253-2736 Payload Harness As (20) to 247-1629 Cab Harness As (19) .
Illustration 24 | g03528937 |
- 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.
Illustration 25 | g03528938 |
Illustration 26 | g03528939 |
Illustration 27 | g03528940 |
Illustration 28 | g03528941 |
- Secure the harness to the existing harness using 6K-0806 Cable Straps as required.
Load Cells
- Raise the dump body and install the body retaining pins. Refer to Operation and Maintenance Manual, "Body Retaining Pin".
- Remove and discard four 251-8506 Truck Body Mounting Gp (1) .
Illustration 29 | g03507186 |
- Install Item (2) through Item (14) to the rear frame.
Note: Apply Loctite Nickle Anti Sieze to the bolts.
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 |
- Repeat the previous step for the other three payload cells.
- Remove the body retaining pins and lower the dump body. Refer to Operation and Maintenance Manual, "Body Retaining Pin".
- 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.
Illustration 31 | g03507194 |
Typical example |
- 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.
- Raise the dump body. Install the body retaining pins. Refer to Operation and Maintenance Manual, "Body Retaining Pin".
- Stop the engine. Turn the key start switch to the ON position.
Show/hide table
Table 3 First Attempt     Payload Cell     Body Up     Body Down     Difference     Action     Front Right                     Front Left                     Rear Right                     Rear Left                    
- 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.
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".
- 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.
- 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.
- 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.
- Remove the body retaining pins and lower the dump body. Refer to Operation and Maintenance Manual, "Body Retaining Pin".
- Stop the engine. Turn the key start switch to the ON position.
Note: Ensure that the hoist control is in the FLOAT position.
- Repeat Step 3 through Step 8.
- 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.
Show/hide tableTable 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.
Show/hide tableTable 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.
Show/hide tableTable 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.
- This process may need repeating several times. Use the following tables to record the readings:
Show/hide table
Table 7 Second Attempt     Payload Cell Pad     Body Up     Body Down     Difference     Action     Front Right                     Front Left                     Rear Right                     Rear Left                     Show/hide tableTable 8 Third Attempt     Payload Cell Pad     Body Up     Body Down     Difference     Action     Front Right                     Front Left                     Rear Right                     Rear Left                     Show/hide tableTable 9 Fourth Attempt     Payload Cell Pad     Body Up     Body Down     Difference     Action     Front Right                     Front Left                     Rear Right                     Rear Left                    
- Raise the dump body. Install the body retaining pins. Refer to Operation and Maintenance Manual, "Body Retaining Pin".
- 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.
- Remove the body retaining pins and lower the dump body. Refer to Operation and Maintenance Manual, "Body Retaining Pin".
- Carry out the tare calibration. Refer to Underground Articulated Trucks Truck Payload Measurement System, RENR4725, "Calibration".
- Carry out the span calibration. Refer to Underground Articulated Trucks Truck Payload Measurement System, RENR4725, "Calibration".